Fix front panel height. Add screw hole for debug panel (on top chassi…

…s). Rework of screws connecting bottom and top chassis. Add PCB mounting screw. Add PCB support bars. Refactor by splitting models to separate files and submodules. Related to #50.

Mechanic/MechanicOverview/ChassisBottom.scad

@@ -0,0 +1,93 @@
+// This is model of bottom chassis.
+
+module ChassisBottom_FrontPanel(Height)
+{
+    translate([-PCB_X/2 - CHASSIS_THICKNESS-COMPONENT_TOLERANCE,
+                -PCB_Y/2,
+                Height])
+    {
+        GenericFrontPanel();
+    }
+}
+
+module ChassisBottom_SupportAroundPCB()
+{
+    linear_extrude(height = 2*CHASSIS_THICKNESS+PCB_Z_OFFSET, convexity = 10, twist = 0)
+    {
+        square([PCB_X+2*COMPONENT_TOLERANCE, CHASSIS_THICKNESS]);
+    }
+}
+
+module ChassisBottom_SupportsAroundPCB()
+{
+    translate([-PCB_X/2 -COMPONENT_TOLERANCE,
+                -PCB_Y/2-CHASSIS_THICKNESS-COMPONENT_TOLERANCE,
+                0])
+    {
+        ChassisBottom_SupportAroundPCB();
+    }
+
+    translate([-PCB_X/2 - COMPONENT_TOLERANCE,
+                PCB_Y/2+COMPONENT_TOLERANCE,
+                0])
+    {
+        ChassisBottom_SupportAroundPCB();
+    }
+}
+
+module ChassisBottom_PCBMountingHole()
+{
+    translate([0,
+                0,
+                CHASSIS_THICKNESS])
+    {
+        GenericChassis_InsertNutSocket(PCB_Z_OFFSET, false);
+    }
+}
+
+module ChassisBottom_PCBBottomHolder()
+{
+    PCBBottomHolderThickness = 2;
+
+    linear_extrude(height = PCB_Z_OFFSET, convexity = 10, twist = 0)
+    {
+        square([PCBBottomHolderThickness, PCB_Y]);
+    }
+}
+
+module ChassisBottom_PCBBottomHolders()
+{
+    translate([-PCB_X/2,
+                -PCB_Y/2,
+                CHASSIS_THICKNESS])
+    {
+        ChassisBottom_PCBBottomHolder();
+    }
+
+    translate([PCB_X/2-1,
+                -PCB_Y/2,
+                CHASSIS_THICKNESS])
+    {
+        ChassisBottom_PCBBottomHolder();
+    }
+}
+
+module ChassisBottom(Height)
+{
+    difference()
+    {
+        union()
+        {
+            GenericChassis(Height);
+            ChassisBottom_FrontPanel(Height);
+            ChassisBottom_SupportsAroundPCB();
+            ChassisBottom_PCBMountingHole();
+            ChassisBottom_PCBBottomHolders();
+
+            InsertNutSockets(Height, false);
+        }
+
+        // add mounting for top and bottom chassis
+        InsertNutSockets(Height, true);
+    }
+}

Mechanic/MechanicOverview/ChassisTop.scad

@@ -0,0 +1,125 @@
+// This is model of top chassis.
+
+// below values are taken from KiCad model
+
+SCREW_CONNECTOR_DX = 10 + COMPONENT_TOLERANCE;
+SCREW_CONNECTOR_Y = 1 - COMPONENT_TOLERANCE;
+SCREW_CONNECTOR_DY = 20.668 + 2*COMPONENT_TOLERANCE;
+
+AdcPowerSupplyYOffset = PCB_X/2
+                        - SCREW_CONNECTOR_DX
+                        + CHASSIS_THICKNESS
+                        - COMPONENT_TOLERANCE;
+
+module ChassisTop_WallsAroundADCAndPowerSupplySocket(Height)
+{
+    linear_extrude(height = Height, convexity = 10, twist = 0)
+    {
+        translate([AdcPowerSupplyYOffset,
+                    -SCREW_CONNECTOR_DY - SCREW_CONNECTOR_Y - CHASSIS_THICKNESS,
+                    0])
+        {
+            square([SCREW_CONNECTOR_DX + COMPONENT_TOLERANCE, CHASSIS_THICKNESS]);
+        }
+
+        translate([AdcPowerSupplyYOffset,
+                    -SCREW_CONNECTOR_DY - SCREW_CONNECTOR_Y + SCREW_CONNECTOR_DY,
+                    0])
+        {
+            square([SCREW_CONNECTOR_DX + COMPONENT_TOLERANCE, CHASSIS_THICKNESS]);
+        }
+
+        translate([AdcPowerSupplyYOffset,
+                    -SCREW_CONNECTOR_DY - SCREW_CONNECTOR_Y,
+                    0])
+        {
+            square([CHASSIS_THICKNESS, SCREW_CONNECTOR_DY + CHASSIS_THICKNESS]);
+        }
+    }
+}
+
+module ChassisTop_SupportFrontPanel()
+{
+    translate([-PCB_X/2 -COMPONENT_TOLERANCE,
+               -PCB_Y/2,
+                CHASSIS_THICKNESS])
+    {
+        linear_extrude(height = CHASSIS_THICKNESS, convexity = 10, twist = 0)
+        {
+            square([CHASSIS_THICKNESS, PCB_Y]);
+        }
+    }
+
+}
+
+module ChassisTop_DebugPanelMountingScrewSupport()
+{
+
+    DebugPanelSupportSize = 10;
+
+    translate([-PCB_X/2+DEBUG_CONNECTOR_X+DEBUG_CONNECTOR_DX/2,
+            -PCB_Y/2+DEBUG_CONNECTOR_DY/2+COMPONENT_TOLERANCE,
+            0])
+    {
+        difference()
+        {
+            union()
+            {
+                translate([0,DebugPanelSupportSize/2,0])
+                {
+                    linear_extrude(height = CHASSIS_THICKNESS+INSERT_NUT_LENGTH, convexity = 10, twist = 0)
+                    {
+                        square([INSERT_NUT_HOLDER_DIAMETER, DebugPanelSupportSize], center=true);
+                    }
+                }
+                GenericChassis_InsertNutSocket(CHASSIS_THICKNESS+INSERT_NUT_LENGTH, false);
+            }
+
+            // add hole for debug socket screw
+            linear_extrude(height = CHASSIS_THICKNESS+INSERT_NUT_LENGTH, convexity = 10, twist = 0)
+            {
+                circle(r=INSERT_NUT_RADIUS);
+            }
+        }
+    }
+}
+
+module Chassis3DTop(Height)
+{
+    difference()
+    {
+        union()
+        {
+            GenericChassis(Height);
+            ChassisTop_DebugPanelMountingScrewSupport();
+        }
+
+        // add hole for ADC and power supply socket
+        translate([AdcPowerSupplyYOffset,
+                    -SCREW_CONNECTOR_DY - SCREW_CONNECTOR_Y,
+                    0])
+        {
+            linear_extrude(height = Height, convexity = 10, twist = 0)
+            {
+                square([SCREW_CONNECTOR_DX + CHASSIS_THICKNESS, SCREW_CONNECTOR_DY]);
+            }
+        }
+
+        // add hole for flashing and UART sockets
+        DebugPanel(Height);
+
+        // add hole for front pannel
+        translate([-PCB_X/2 - CHASSIS_THICKNESS-COMPONENT_TOLERANCE,
+                   -PCB_Y/2,
+                    CHASSIS_THICKNESS])
+        {
+            GenericFrontPanel();
+        }
+    }
+
+    ChassisTop_WallsAroundADCAndPowerSupplySocket(Height);
+    ChassisTop_SupportFrontPanel();
+
+    // add nounting screws
+    InsertNutSockets(Height, false);
+}

Mechanic/MechanicOverview/GenericChassis.scad

@@ -0,0 +1,112 @@
+module Chassis2DQuarter(Thickness)
+{
+    CHASSIS_X = PCB_X/2 + COMPONENT_TOLERANCE + Thickness;
+    CHASSIS_Y = PCB_Y/2 + COMPONENT_TOLERANCE + Thickness;
+
+    polygon(points=[
+        [0, 0],
+        [CHASSIS_X, 0],
+        [CHASSIS_X, CHASSIS_Y + CHASSIS_CORNER_DIAMETER/2 - Thickness/2],
+        [CHASSIS_X - CHASSIS_CORNER_RADIUS - CHASSIS_THICKNESS/2, CHASSIS_Y + CHASSIS_CORNER_DIAMETER],
+        [0, CHASSIS_Y + CHASSIS_CORNER_DIAMETER],
+    ]);
+
+    translate([CHASSIS_X - CHASSIS_THICKNESS - INSERT_NUT_RADIUS,
+            CHASSIS_Y + INSERT_NUT_RADIUS,
+            0])
+    {
+        circle(r=INSERT_NUT_RADIUS + CHASSIS_THICKNESS);
+    }
+}
+
+module Chassis2DHalf(Thickness)
+{
+    Chassis2DQuarter(Thickness);
+
+    rotate([180, 0, 0])
+    {
+        Chassis2DQuarter(Thickness);
+    }
+}
+
+module GenericChassis2D(Thickness)
+{
+    Chassis2DHalf(Thickness);
+
+    rotate([0, 180, 0])
+    {
+        Chassis2DHalf(Thickness);
+    }
+}
+
+
+
+module GenericChassis_InsertNutSocket(Height, isFull)
+{
+    linear_extrude(height = Height, convexity = 10, twist = 0)
+    {
+        difference()
+        {
+            if(!isFull)
+            {
+                circle(r=INSERT_NUT_RADIUS + CHASSIS_THICKNESS);
+            }
+
+            circle(r=INSERT_NUT_RADIUS);
+        }
+    }
+}
+
+module InsertNutSockets(Height, isFull)
+{
+    Thickness = CHASSIS_THICKNESS;
+    CHASSIS_X = PCB_X/2 + COMPONENT_TOLERANCE + Thickness;
+    CHASSIS_Y = PCB_Y/2 + COMPONENT_TOLERANCE + Thickness;
+
+    translate([CHASSIS_X - Thickness - INSERT_NUT_RADIUS,
+            CHASSIS_Y + INSERT_NUT_RADIUS,
+            0])
+    {
+        GenericChassis_InsertNutSocket(Height, isFull);
+    }
+
+    translate([CHASSIS_X - Thickness - INSERT_NUT_RADIUS,
+            -CHASSIS_Y - INSERT_NUT_RADIUS,
+            0])
+    {
+        GenericChassis_InsertNutSocket(Height, isFull);
+    }
+
+    translate([-CHASSIS_X + Thickness + INSERT_NUT_RADIUS,
+            CHASSIS_Y + INSERT_NUT_RADIUS,
+            0])
+    {
+        GenericChassis_InsertNutSocket(Height, isFull);
+    }
+
+    translate([-CHASSIS_X + Thickness + INSERT_NUT_RADIUS,
+            -CHASSIS_Y - INSERT_NUT_RADIUS,
+            0])
+    {
+        GenericChassis_InsertNutSocket(Height, isFull);
+    }
+}
+
+module GenericChassis(Height)
+{
+    difference()
+    {
+        linear_extrude(height = Height, convexity = 10, twist = 0)
+        {
+            GenericChassis2D(CHASSIS_THICKNESS);
+        }
+
+        translate([0, 0, CHASSIS_THICKNESS])
+        {
+            linear_extrude(height = Height - CHASSIS_THICKNESS, convexity = 10, twist = 0)
+            {
+                GenericChassis2D(0);
+            }
+        }
+    }
+}

Mechanic/MechanicOverview/GenericFrontPanel.scad

@@ -0,0 +1,9 @@
+// This is model of panel where BNC, LCD and encoder are.
+
+module GenericFrontPanel()
+{
+    linear_extrude(height = TOP_CHASSIS_HEIGHT-CHASSIS_THICKNESS, convexity = 10, twist = 0)
+    {
+        square([CHASSIS_THICKNESS, PCB_Y]);
+    }
+}