Enclosure with recessed plug for strain relief.

3 files changed, 338 insertions, 17 deletions

diff --git a/box/box.scad b/box/box.scad
index 585668e..5c53432 100644
--- a/box/box.scad
+++ b/box/box.scad
@@ -58,12 +58,12 @@ pcbThickness        = 1.6;
 
 //-- How much the PCB needs to be raised from the base
 //-- to leave room for solderings and whatnot
-standoffHeight      = 3.4;
+standoffHeight      = 3.9; //4.3;
 pinDiameter         = 2.7;
 standoffDiameter    = 6;
                             
 //-- padding between pcb and inside wall
-paddingFront        = 0.1;
+paddingFront        = 49.4;
 paddingBack         = 0.1;
 paddingRight        = 0.1;
 paddingLeft         = 0.1;
@@ -101,7 +101,7 @@ cutoutsLid  =   [
 // (5) = { yappRectangle | yappCircle }
 // (6) = { yappCenter }
 cutoutsFront =  [
-    [-3.67 * IN + origin_y - 9/2, 0, 9, 3.3, 0, yappRectangle]
+    //[-3.67 * IN + origin_y - 9/2, 0, 9, 3.3, 0, yappRectangle]
 ];
 
 //-- back plane  -- origin is pcb[0,0,0]
@@ -123,7 +123,7 @@ cutoutsBack =   [
 // (2..5) = yappLeft / yappRight / yappFront / yappBack (one or more)
 // (n) = { yappSymmetric }
 snapJoins   =     [
-    [2, 5, yappLeft, yappRight, yappSymmetric]
+    [20, 5, yappLeft, yappRight, yappSymmetric]
 ];
 
 //-- origin of labels is box [0,0,0]
@@ -135,9 +135,8 @@ snapJoins   =     [
 // (5) = size
 // (6) = "label text"
 labelsPlane =   [
-    [12, 35, 0, "lid", "Liberation Mono:style=bold", 4, "Square Dishy"],
-    [15, 30, 0, "lid", "Liberation Mono:style=bold", 4, "150W PoE++" ],
-    [15, 25, 0, "lid", "Liberation Mono:style=bold", 4, "50V DC" ],
+    [12, 35, 0, "lid", "Liberation Mono:style=bold", 4, "Square Dishy 150W PoE++"],
+    [35, 28, 0, "lid", "Liberation Mono:style=bold", 4, "50V DC" ],
 ];
                 
 // Reference board model
@@ -149,31 +148,135 @@ translate([pcbX - origin_x, pcbY + origin_y, pcbZ - pcbThickness / 2])
 onLidGap = 0;
 
 module lid_diagrams() {
-    translate([15, 18, -lidLabelDepth])
+    translate([12, 27.5, -lidLabelDepth])
         linear_extrude(basePlaneThickness)
             scale([0.15, 0.15, 1])
                 import("Polarity_marking_center_positive.svg");
+}
+
+module sl_plug() {
+    h1 = 36;
+    h2 = 3.5;
+    h3 = 11;
+    h4 = 55.5 - h3;
+    d1 = 12;
+    d2 = 10;
+    d3 = 3.3;
+    hull() {
+        cylinder(h=h1, d1=d1, d2=d2);
+        translate([0, 0, h1])
+            cylinder(h=h2, d1=d2, d2=d3);
+        translate([0, 5, 0]) {
+            cylinder(h=h1, d1=d1, d2=d2);
+            translate([0, 0, h1])
+                cylinder(h=h2, d1=d2, d2=d3);
+        }
+    }
+    hull() {
+        cylinder(h=h4, d=d3);
+        translate([0, 5, 0])
+            cylinder(h=h4, d=d3);
+    }
+    translate([13, 15, -h3])
+        rotate([0, 0, 90])
+            linear_extrude(h3)
+                mirror([1, 0, 0])
+                    offset(0.2)
+                        import("outline.svg");
+}
 
-    translate([shellLength - frontLabelDepth, 23.5, -12])
-        rotate([90, 0, 90])
-            linear_extrude(basePlaneThickness)
-                scale([0.075, 0.075, 1])
-                    import("plug.svg");
+module sl_shell() {
+    difference() {
+        hull() {
+            minkowski() {
+                sl_plug();
+                sphere(r=2);
+            }
+            translate([15, 0, 0])
+            minkowski() {
+                sl_plug();
+                sphere(r=2);
+            }
+        }
+        sl_plug();
+        translate([-25, -25, -60])
+            cube(50);
+        translate([-25, -25, 39.8])
+            cube(50);
+        hull() {
+            $fn=16;
+            translate([0, -0.35, 0])
+                cylinder(h=50, d=3.5);
+            translate([0, 5.35, 0])
+                cylinder(h=50, d=3.5);
+        }
+        hull() {
+            translate([7, -15, -4.5])
+                rotate([90, 0, 45])
+                    cylinder(h=10, d=7);
+            translate([7, -15, -13])
+                rotate([90, 0, 45])
+                    cylinder(h=10, d=7);
+        }
+    }
 }
 
+module solidMinkowskiBox(L, W, H, rad, plane, wall)
+{
+    minkowski() {
+        cube([L+(wall*2)-(rad*2), 
+            W+(wall*2)-(rad*2), 
+            (H*2)+(plane*2)-(rad*2)], 
+            center=true);
+        sphere(rad);
+    }
+}
+
+
 difference() {
-    YAPPgenerate();
+    union() {
+        YAPPgenerate();
+        difference() {
+            translate([pcbX + 101, pcbY + origin_y - 3.67 * IN + 5/2, pcbZ + 3.3/2])
+                rotate([180, 90, 0])
+                    sl_shell();
+            difference() {
+                cube(400, center=true);
+                translate([(shellLength/2), shellWidth/2, (baseWallHeight) + basePlaneThickness]) {
+                    $fn=25;
+                    solidMinkowskiBox(shellInsideLength, shellInsideWidth, baseWallHeight, 
+                     roundRadius, basePlaneThickness, wallThickness);
+                }
+            }
+            translate([0, 0, (baseWallHeight+basePlaneThickness+
+                            lidWallHeight+lidPlaneThickness)])
+                lidShell();
+        }
+    }
+    
+    translate([pcbX + 101, pcbY + origin_y - 3.67 * IN + 5/2, pcbZ + 3.3/2])
+        rotate([180, 90, 0])
+            sl_plug();
 
     if (printLidShell) {
         if (showSideBySide) {
             mirror([0,0,1])
             mirror([0,1,0])
-            translate([0, (5 + shellWidth+(shiftLid/2))*-2, 0])
-            lid_diagrams();
+            translate([0, (5 + shellWidth+(shiftLid/2))*-2, 0]) {
+                lid_diagrams();
+                translate([0, 0, -(baseWallHeight+basePlaneThickness+
+                                lidWallHeight+lidPlaneThickness+onLidGap)])
+                translate([pcbX + 101, pcbY + origin_y - 3.67 * IN + 5/2, pcbZ + 3.3/2])
+        rotate([180, 90, 0])
+            sl_plug();
+            }
         } else {
             translate([0, 0, (baseWallHeight+basePlaneThickness+
                                 lidWallHeight+lidPlaneThickness+onLidGap)])
-            lid_diagrams();
+                lid_diagrams();
+            translate([pcbX + 101, pcbY + origin_y - 3.67 * IN + 5/2, pcbZ + 3.3/2])
+        rotate([180, 90, 0])
+            sl_plug();
         }
     }
 }
\ No newline at end of file
diff --git a/box/outline.svg b/box/outline.svg
new file mode 100644
index 0000000..d92b86c
--- /dev/null
+++ b/box/outline.svg
@@ -0,0 +1,39 @@
+<?xml version="1.0" encoding="UTF-8" standalone="no"?>
+<svg
+   xmlns:dc="http://purl.org/dc/elements/1.1/"
+   xmlns:cc="http://creativecommons.org/ns#"
+   xmlns:rdf="http://www.w3.org/1999/02/22-rdf-syntax-ns#"
+   xmlns:svg="http://www.w3.org/2000/svg"
+   xmlns="http://www.w3.org/2000/svg"
+   width="36.329704mm"
+   height="19.66452mm"
+   viewBox="0 0 36.329704 19.66452"
+   version="1.1"
+   id="svg8">
+  <defs
+     id="defs2" />
+  <metadata
+     id="metadata5">
+    <rdf:RDF>
+      <cc:Work
+         rdf:about="">
+        <dc:format>image/svg+xml</dc:format>
+        <dc:type
+           rdf:resource="http://purl.org/dc/dcmitype/StillImage" />
+        <dc:title></dc:title>
+      </cc:Work>
+    </rdf:RDF>
+  </metadata>
+  <g
+     id="layer1"
+     transform="translate(-2.2700427,-1.168005)">
+    <g
+       id="g885"
+       transform="rotate(0.88356372,20.772726,11.169722)">
+      <path
+         style="opacity:1;fill:none;fill-rule:evenodd;stroke:#000000;stroke-width:0.065;stroke-linecap:butt;stroke-linejoin:miter;stroke-miterlimit:4;stroke-dasharray:none;stroke-opacity:1"
+         d="m 29.550904,1.0646023 -26.1830573,0.403141 -0.8716825,0.5715728 -0.315346,1.224312 6.5985523,11.1795929 0.502963,0.472039 0.5603807,0.153863 12.7091728,-0.13996 1.049498,0.236467 7.563396,5.466011 7.437659,-6.70687 L 31.070618,1.8789656 30.443793,1.3524909 Z"
+         id="path881" />
+    </g>
+  </g>
+</svg>
diff --git a/box/simple_box.scad b/box/simple_box.scad
new file mode 100644
index 0000000..585668e
--- /dev/null
+++ b/box/simple_box.scad
@@ -0,0 +1,179 @@
+
+
+module RoundBox(length, width, height, radius)
+{
+    translate([0, radius, radius])
+    {
+        minkowski()
+        {
+            cube([length / 2, width - 2 * radius, height - 2 * radius]);
+            rotate([0, 90, 0])
+                cylinder(r=radius, h=length / 2, center=false);
+        }
+    }
+}
+
+IN = 25.4;
+origin_x = 3.85 * IN;
+origin_y = 4.85 * IN;
+
+include <YAPPgenerator_v14.scad>
+
+// Overrides
+
+//-- which half do you want to print?
+printBaseShell      = true;
+printLidShell       = true;
+
+//-- Edit these parameters for your own board dimensions
+wallThickness       = 1.6;
+basePlaneThickness  = 1.6;
+lidPlaneThickness   = 1.6;
+
+//-- Label depths
+baseLabelDepth      = 0.4;
+lidLabelDepth       = 0.4;
+leftLabelDepth      = 0.4;
+rightLabelDepth     = 0.4;
+frontLabelDepth     = 0.4;
+backLabelDepth      = 0.4;
+
+//-- Total height of box = basePlaneThickness + lidPlaneThickness 
+//--                     + baseWallHeight + lidWallHeight
+//-- space between pcb and lidPlane :=
+//--      (bottonWallHeight+lidWallHeight) - (standoffHeight+pcbThickness)
+baseWallHeight      = 8;
+lidWallHeight       = 14.4;
+
+//-- ridge where base and lid off box can overlap
+//-- Make sure this isn't less than lidWallHeight
+ridgeHeight         = 3.0;
+ridgeSlack          = 0.2;
+roundRadius         = 3.0;
+
+//-- pcb dimensions
+pcbLength           = 2.4 * IN;
+pcbWidth            = 1.8 * IN;
+pcbThickness        = 1.6;
+
+//-- How much the PCB needs to be raised from the base
+//-- to leave room for solderings and whatnot
+standoffHeight      = 3.4;
+pinDiameter         = 2.7;
+standoffDiameter    = 6;
+                            
+//-- padding between pcb and inside wall
+paddingFront        = 0.1;
+paddingBack         = 0.1;
+paddingRight        = 0.1;
+paddingLeft         = 0.1;
+
+//-- pcb_standoffs  -- origin is pcb[0,0,0]
+// (0) = posx
+// (1) = posy
+// (2) = { yappBoth | yappLidOnly | yappBaseOnly }
+// (3) = { yappHole, YappPin }
+pcbStands =    [
+    [ 4 * IN - origin_x, -4.7 * IN + origin_y, yappBoth, yappPin ],
+    [ 4 * IN - origin_x, -3.2 * IN + origin_y, yappBoth, yappPin ],
+    [ 6.1 * IN - origin_x, -3.2 * IN + origin_y, yappBoth, yappPin ],
+    [ 6.1 * IN - origin_x, -4.7 * IN + origin_y, yappBoth, yappPin ]
+];
+
+//-- Lid plane    -- origin is pcb[0,0,0]
+// (0) = posx
+// (1) = posy
+// (2) = width
+// (3) = length
+// (4) = angle
+// (5) = { yappRectangle | yappCircle }
+// (6) = { yappCenter }
+cutoutsLid  =   [
+    [4.8 * IN - origin_x + 1.27, -4.5 * IN + origin_y, 5, 5, 0, yappCircle]
+];
+
+//-- front plane  -- origin is pcb[0,0,0]
+// (0) = posy
+// (1) = posz
+// (2) = width
+// (3) = height
+// (4) = angle
+// (5) = { yappRectangle | yappCircle }
+// (6) = { yappCenter }
+cutoutsFront =  [
+    [-3.67 * IN + origin_y - 9/2, 0, 9, 3.3, 0, yappRectangle]
+];
+
+//-- back plane  -- origin is pcb[0,0,0]
+// (0) = posy
+// (1) = posz
+// (2) = width
+// (3) = height
+// (4) = angle
+// (5) = { yappRectangle | yappCircle }
+// (6) = { yappCenter }
+cutoutsBack =   [
+    [21.96, 0, 15.6, 12.7, 0, yappRectangle],
+    [9.3, 0, 9, 11, 0, yappRectangle]
+];
+
+//-- snap Joins -- origen = box[x0,y0]
+// (0) = posx | posy
+// (1) = width
+// (2..5) = yappLeft / yappRight / yappFront / yappBack (one or more)
+// (n) = { yappSymmetric }
+snapJoins   =     [
+    [2, 5, yappLeft, yappRight, yappSymmetric]
+];
+
+//-- origin of labels is box [0,0,0]
+// (0) = posx
+// (1) = posy/z
+// (2) = orientation
+// (3) = plane {lid | base | left | right | front | back }
+// (4) = font
+// (5) = size
+// (6) = "label text"
+labelsPlane =   [
+    [12, 35, 0, "lid", "Liberation Mono:style=bold", 4, "Square Dishy"],
+    [15, 30, 0, "lid", "Liberation Mono:style=bold", 4, "150W PoE++" ],
+    [15, 25, 0, "lid", "Liberation Mono:style=bold", 4, "50V DC" ],
+];
+                
+// Reference board model
+translate([pcbX - origin_x, pcbY + origin_y, pcbZ - pcbThickness / 2])
+    %import("poe.stl");
+
+// DEBUG    
+//showSideBySide      = false;
+onLidGap = 0;
+
+module lid_diagrams() {
+    translate([15, 18, -lidLabelDepth])
+        linear_extrude(basePlaneThickness)
+            scale([0.15, 0.15, 1])
+                import("Polarity_marking_center_positive.svg");
+
+    translate([shellLength - frontLabelDepth, 23.5, -12])
+        rotate([90, 0, 90])
+            linear_extrude(basePlaneThickness)
+                scale([0.075, 0.075, 1])
+                    import("plug.svg");
+}
+
+difference() {
+    YAPPgenerate();
+
+    if (printLidShell) {
+        if (showSideBySide) {
+            mirror([0,0,1])
+            mirror([0,1,0])
+            translate([0, (5 + shellWidth+(shiftLid/2))*-2, 0])
+            lid_diagrams();
+        } else {
+            translate([0, 0, (baseWallHeight+basePlaneThickness+
+                                lidWallHeight+lidPlaneThickness+onLidGap)])
+            lid_diagrams();
+        }
+    }
+}
\ No newline at end of file