Add blink test firmware, docs and new schematic iterations

2 files changed, 123 insertions, 58 deletions

diff --git a/model/.gitignore b/model/.gitignore
new file mode 100644
index 0000000..1567411
--- /dev/null
+++ b/model/.gitignore
@@ -0,0 +1 @@
+*.stl
diff --git a/model/main.py b/model/main.py
index a172a27..ca1e437 100644
--- a/model/main.py
+++ b/model/main.py
@@ -1,6 +1,11 @@
 from types import SimpleNamespace
-from cadquery import ParallelDirSelector, Workplane, Solid
+from cadquery import Workplane
 
+if "show_object" not in globals():
+    show_object = lambda v: ()
+
+nothing = 0.0001
+origin = (0, 0, 0)
 XY = Workplane("XY")
 center_xy = (True, True, False)
 
@@ -33,25 +38,108 @@ def V3(x, y, z):
 def V21(v):
     return V3(2 * v, 2 * v, v)
 
+def box(*args):
+    return XY.box(*args, centered=center_xy)
+
+def cylinder(r, h):
+    return XY.circle(r).extrude(h)
+
+def build_usbc(width, height, depth, tol):
+    def shape(width, height, depth):
+        radius = (height + 2 * tol) / 2
+        offset = width / 2 - radius
+        part = box(width - radius * 2, height, depth)
+        part = part.union(cylinder(radius, depth).translate((-offset, 0, 0)))
+        part = part.union(cylinder(radius, depth).translate((offset, 0, 0)))
+        return part
+    def gen(tol):
+        dims = (width + 2 * tol, height + 2 * tol, depth + 2 * tol)
+        part = shape(*dims).translate((0, 0, -tol))
+        if tol != 0:
+            part = part.union(shape(*dims[:2], 20).translate((0, 0, -20)))
+        return part
+    part = gen(0).translate((0, -height / 2, 0)).rotate(origin, (1, 0, 0), -90)
+    bounds = gen(tol).translate((0, -height / 2, 0)).rotate(origin, (1, 0, 0), -90)
+    return Ext(part, bounds)
+
 def build_bolt(bolt, shaft, tol):
     height = shaft + bolt.head_height
 
-    part = XY.circle(bolt.head_radius).extrude(bolt.head_height)
-    part = part.union(XY.circle(bolt.radius).extrude(height))
-
-    bounds = XY.circle(bolt.head_radius + 2 * tol).extrude(bolt.head_height + 2 * tol).translate((0, 0, -tol))
-    bounds = bounds.union(XY.circle(bolt.radius - 0.1 + tol).extrude(height + 10 + 2 * tol).translate((0, 0, - 10 -tol)))
+    def gen(tol):
+        part = cylinder(bolt.head_radius + tol, bolt.head_height + 2 * tol)\
+            .translate((0, 0, height + 2 * tol - bolt.head_height - 2 * tol))
+        if tol != 0:
+            part = part.union(cylinder(bolt.cut_radius + tol, height + 2 * tol))
+            part = part.translate((0, 0, -tol))
+        else:
+            part = part.union(cylinder(bolt.radius, height))
+        return part
 
-    transform = lambda p, h: p.rotate((0, 0, 0), (1, 0, 0), 180).translate((0, 0, h))
-    return Ext(transform(part, height), transform(bounds, height + tol))
+    return Ext(gen(0), gen(tol))
 
 def build_rod(rod, tol):
     part = XY.circle(rod.outer).circle(rod.inner).extrude(rod.len)
 
-    bounds = XY.circle(rod.outer + tol).extrude(rod.len + 2 * tol).translate((0, 0, -tol))
+    bounds = cylinder(rod.outer + tol, rod.len + 2 * tol).translate((0, 0, -tol))
 
     return Ext(part, bounds)
 
+def build_base(base, rod, rod_shaft, usbc, bolt, wall, tol, lid):
+    outer = base
+    inner = outer - V3(2 * wall.x, 2 * wall.y, wall.z) + V21(tol) 
+
+    floor = wall.z - tol
+    part = box(*base.xyz())
+    part = part.cut(box(*inner.xyz()).translate((0, 0, floor)))
+
+    tower_radius = bolt.radius + wall.x + 1
+    tower_height = inner.z
+    for y in range(-1, 2, 2):
+        for x in range(-1, 2, 2):
+            pos = V3(x * lid.hole_spacing.x / 2, y * lid.hole_spacing.y / 2, floor)
+            offset_x = (inner.x - lid.hole_spacing.x) / 2
+            offset_y = (inner.y - lid.hole_spacing.y) / 2
+            part = part.union(box(offset_x, offset_y + tower_radius, tower_height) \
+                              .translate((pos + V3(offset_x*x/2, y*(offset_y-(offset_y+tower_radius)/2), 0)).xyz()))
+            part = part.union(box(offset_x + tower_radius, offset_y, tower_height) \
+                                  .translate((pos + V3(x*(offset_x-(offset_x+tower_radius)/2), offset_y*y/2, 0)).xyz()))
+            part = part.union(cylinder(tower_radius, tower_height).translate(pos.xyz()))
+
+    part = part.union(box(wall.x, inner.y, tower_height).translate((-20, 0, floor)))
+    part = part.union(box(wall.x, inner.y, tower_height).translate((20, 0, floor)))
+
+    # rod cut-out
+    rod_pos = (rod_shaft.pos + V3(0, 0, floor)).xyz()
+    base_rod_outer = rod.outer + 6
+    part = part.union(cylinder(base_rod_outer, tower_height).translate(rod_pos))
+    fill_y = inner.y / 2 - rod_shaft.pos.y
+    part = part.union(box(40, fill_y, tower_height).translate(rod_pos)\
+                      .translate((0, -rod_shaft.pos.y+inner.y/2-fill_y/2, 0)))
+    part = part.cut(cylinder(rod.outer + tol, tower_height).translate(rod_pos))
+    part = part.union(box(40, fill_y, 3).translate(rod_pos)\
+                      .translate((0, -rod_shaft.pos.y+inner.y/2-fill_y/2, 0)))
+    part = part.cut(box(20, 25, 8).translate(rod_pos).translate((0, -rod.outer - wall.x/2)))
+
+    part = part.cut(build_lid(**lid.__dict__).bounds.translate((0, 0, base.z - lid.base.z)))
+
+    board_hole = V(outer = 3, inner = 2.9 / 2 + tol, height = 2)
+    board_space = V3(40 - wall.x, 60, 0)
+    print("Board Space", board_space)
+    board_space_inner = board_space - V3(2 * board_hole.outer, 2 * board_hole.outer, 0)
+    board_center = V3(0, -inner.y / 2 + board_space.y / 2, floor)
+    for y in (-1, 1):
+        for x in (-1, 1):
+            pos = board_center + V3(x * board_space_inner.x / 2, y * board_space_inner.y / 2, 0)
+            part = part.union(cylinder(board_hole.outer, board_hole.height).translate(pos.xyz()))
+            pos2 = pos + V3(x * board_hole.outer / 2, y * board_hole.outer / 2, 0)
+            part = part.union(box(board_hole.outer, board_hole.outer, board_hole.height-nothing).translate(pos2.xyz()))
+            part = part.cut(cylinder(board_hole.inner, board_hole.height).translate(pos.xyz()))
+
+    part_usbc = build_usbc(**usbc.__dict__, tol=tol)
+    part = part.cut(part_usbc.bounds.translate((board_center + V3(0, -board_space.y / 2 - 1.5, 4)).xyz()))
+
+    return part
+
 def build_lid(base, rod, rod_shaft, wall, bolt, bolt_depth, tol, hole_spacing):
     outer = base
     inner = base - V21(wall + tol)
@@ -62,8 +150,8 @@ def build_lid(base, rod, rod_shaft, wall, bolt, bolt_depth, tol, hole_spacing):
     def gen(tol):
         outer_padded = outer + V3(tol, tol, tol) * 2
         inner_padded = inner - V3(tol, tol, tol) * 2
-        part = XY.box(*outer_padded.xyz(), centered=center_xy).translate((0, 0, -tol))
-        part = part.cut(XY.box(*inner_padded.xyz(), centered=center_xy).translate((0, 0, -tol)))
+        part = box(*outer_padded.xyz()).translate((0, 0, -tol))
+        part = part.cut(box(*inner_padded.xyz()).translate((0, 0, -tol)))
         for y in range(-1, 2, 2):
             for x in range(-1, 2, 2):
                 pos = V3(x * hole_spacing.x / 2, y * hole_spacing.y / 2, outer.z)
@@ -71,11 +159,11 @@ def build_lid(base, rod, rod_shaft, wall, bolt, bolt_depth, tol, hole_spacing):
                 head_height = bolt.head_height + wall + tol
                 offset_x = (outer.x - 2 * wall - hole_spacing.x) / 2 + tol
                 offset_y = (outer.y - 2 * wall - hole_spacing.y) / 2 + tol
-                part = part.union(XY.circle(head_radius).extrude(head_height) \
+                part = part.union(cylinder(head_radius, head_height) \
                                   .translate((pos + V3(0, 0, -head_height)).xyz()))
-                part = part.union(XY.box(offset_x, offset_y + head_radius, head_height, centered=center_xy) \
+                part = part.union(box(offset_x, offset_y + head_radius, head_height) \
                                   .translate((pos + V3(offset_x*x/2, y*(offset_y-(offset_y+head_radius)/2), -head_height)).xyz()))
-                part = part.union(XY.box(offset_x + head_radius, offset_y, head_height, centered=center_xy) \
+                part = part.union(box(offset_x + head_radius, offset_y, head_height) \
                                   .translate((pos + V3(x*(offset_x-(offset_x+head_radius)/2), offset_y*y/2, -head_height)).xyz()))
                 if tol != 0:
                     part = part.union(part_bolt.bounds.translate((pos + V3(0, 0, -bolt_depth - bolt.head_height)).xyz()))
@@ -84,50 +172,19 @@ def build_lid(base, rod, rod_shaft, wall, bolt, bolt_depth, tol, hole_spacing):
         return part
 
     part = gen(0)
-    part_rod_wall = XY.circle(rod_wall.outer).extrude(rod_wall.z)
-    part = part.union(part_rod_wall.translate((rod_shaft.pos + V3(0, 0, inner.z)).xyz()))
+    part_rod_wall = cylinder(rod_wall.outer + 5 + tol, 10)
+    part = part.cut(part_rod_wall.translate((rod_shaft.pos + V3(0, 0, outer.z - 1)).xyz()))
     part = part.cut(build_rod(rod, tol).bounds.translate(rod_shaft.pos.xyz()))
 
     part_bounds = gen(tol)
 
     return Ext(part, part_bounds)
 
-def build_base(base, rod, rod_shaft, insert, bolt, wall, tol, lid):
-    outer = base
-    inner = outer - V3(2 * wall.x, 2 * wall.y, wall.z) + V21(tol) 
-
-    floor = wall.z - tol
-    part = XY.box(*base.xyz(), centered=center_xy)
-    part = part.cut(XY.box(*inner.xyz(), centered=center_xy).translate((0, 0, floor)))
-
-    tower_radius = bolt.radius + wall.x + 1
-    tower_height = inner.z
-    for y in range(-1, 2, 2):
-        for x in range(-1, 2, 2):
-            pos = V3(x * lid.hole_spacing.x / 2, y * lid.hole_spacing.y / 2, floor)
-            offset_x = (inner.x - lid.hole_spacing.x) / 2
-            offset_y = (inner.y - lid.hole_spacing.y) / 2
-            part = part.union(XY.box(offset_x, offset_y + tower_radius, tower_height, centered=center_xy) \
-                              .translate((pos + V3(offset_x*x/2, y*(offset_y-(offset_y+tower_radius)/2), 0)).xyz()))
-            part = part.union(XY.box(offset_x + tower_radius, offset_y, tower_height, centered=center_xy) \
-                                  .translate((pos + V3(x*(offset_x-(offset_x+tower_radius)/2), offset_y*y/2, 0)).xyz()))
-            part = part.union(XY.circle(tower_radius).extrude(tower_height).translate(pos.xyz()))
-
-    part = part.union(XY.box(wall.x, inner.y, tower_height, centered=center_xy).translate((-20, 0, floor)))
-    part = part.union(XY.box(wall.x, inner.y, tower_height, centered=center_xy).translate((20, 0, floor)))
-
-    rod_pos = (rod_shaft.pos + V3(0, 0, floor)).xyz()
-    part = part.union(XY.circle(rod.outer + wall.x + 2).extrude(tower_height).translate(rod_pos))
-    fill_y = inner.y / 2 - rod_shaft.pos.y
-    part = part.union(XY.box(40, fill_y, tower_height, centered=center_xy).translate(rod_pos)\
-                      .translate((0, -rod_shaft.pos.y+inner.y/2-fill_y/2, 0)))
-    part = part.cut(XY.circle(rod.outer + tol).extrude(tower_height).translate(rod_pos))
-    part = part.union(XY.box(40, fill_y, 3, centered=center_xy).translate(rod_pos)\
-                      .translate((0, -rod_shaft.pos.y+inner.y/2-fill_y/2, 0)))
-    part = part.cut(XY.box(20, 25, 8, centered=center_xy).translate(rod_pos).translate((0, -rod.outer - wall.x/2)))
-
-    part = part.cut(build_lid(**lid.__dict__).bounds.translate((0, 0, base.z - lid.base.z)))
-
+def build_sheath(rod, rod_shaft, tol, wall):
+    rod_wall = V(outer = rod.outer + tol + wall, inner = rod.outer + tol, z = rod_shaft.height)
+    part = cylinder(rod_wall.outer + 5, 2)
+    part = part.union(cylinder(rod_wall.outer, rod_wall.z))
+    part = part.cut(build_rod(rod, tol).bounds)
     return part
 
 def main():
@@ -135,28 +192,35 @@ def main():
     base = V3(80, 80, 15)
     rod_shaft = V(pos = V3(0, 0, 0), height = 20)
 
+    base = V3(120, 120, 30)
+    rod_shaft = V(pos = V3(0, 30, 0), height = 35)
     tol = 0.05
-    rod = V(outer = 25 / 2, inner = 21 / 2, len = 500)
-    #base = V3(120, 120, 30)
-    #rod_shaft = V(pos = V3(0, 30, 0), height = 35)
+    rod = V(outer = 25.3 / 2, inner = 21 / 2, len = 500)
     thin_wall = 2.4
     thick_wall = 4
-    bolt = V(radius = 3 / 2, head_radius = 5.4 / 2, head_height = 3)
-    bolt_depth = 10 + 1
+    bolt = V(radius = 3 / 2, head_radius = 5.4 / 2, head_height = 3, cut_radius = 2.9 / 2)
 
     lid = V3(base.x, base.y, 10)
     lid_hole_spacing = V3(lid.x - 15, lid.y - 15, 0)
     insert = V(radius=5 / 2, height=5)
     base_wall = V3(thick_wall, thick_wall, thin_wall)
 
+    bolt_depth = base.z - bolt.head_height # - base_wall.z # let bolt go through
+
+    usbc = V(width = 9, height = 3, depth = 7.3)
+
     #show_object(build_rod(rod).translate((0, 0, 10)))
 
+    sheath_ctx = V(rod=rod, rod_shaft=rod_shaft, tol=tol, wall=thin_wall)
+    show_object(build_sheath(**sheath_ctx.__dict__).translate((-100, 0, 0)))
+
     lid_ctx = V(base=lid, rod=rod, rod_shaft=rod_shaft,
                 wall=thin_wall, bolt=bolt, bolt_depth=bolt_depth, tol=tol,
                 hole_spacing=lid_hole_spacing)
     show_object(build_lid(**lid_ctx.__dict__).translate((150, 0, 0)))
 
-    base_ctx = V(base=base, rod=rod, rod_shaft=rod_shaft, bolt=bolt, wall=base_wall, tol=tol, insert=insert)
+    base_ctx = V(base=base, rod=rod, rod_shaft=rod_shaft, bolt=bolt,
+                 wall=base_wall, tol=tol, usbc=usbc)
     show_object(build_base(**base_ctx.__dict__, lid=lid_ctx))
 
 main()