// ============================================================
// uwb_anchor_mount.scad — Wall/Ceiling UWB Anchor Mount Bracket
// Issue: #564  Agent: sl-mechanical  Date: 2026-03-14
// (supersedes Rev A stem-collar mount — see git history)
// ============================================================
//
// Parametric wall or ceiling mount bracket for ESP32 UWB Pro anchor.
// Designed for fixed-infrastructure deployment: anchors screw into
// wall or ceiling drywall/timber with standard M4 or #6 wood screws,
// at a user-defined tilt angle so the UWB antenna faces the desired
// coverage zone.
//
// Architecture:
//   Wall base    -> flat backplate with 2x screw holes (wall or ceiling)
//   Tilt knuckle -> single-axis articulating joint; 15deg detent steps
//                   locked with M3 nyloc bolt; range 0-90deg
//   Anchor cradle-> U-cradle holding ESP32 UWB Pro PCB on M2.5 standoffs
//   USB-C channel-> routed groove on tilt arm + exit slot in cradle back wall
//   Label slot   -> rear window slot for printed anchor-ID card strip
//
// Part catalogue:
//   Part 1 -- wall_base()       Backplate + 2-ear pivot block + detent arc
//   Part 2 -- tilt_arm()        Pivoting arm with knuckle + cradle stub
//   Part 3 -- anchor_cradle()   PCB cradle, standoffs, USB-C slot, label window
//   Part 4 -- cable_clip()      Snap-on USB-C cable guide for tilt arm
//   Part 5 -- assembly_preview()
//
// Hardware BOM:
//   2x M4 x 30mm wood screws (or #6 drywall screws)  wall fasteners
//   1x M3 x 20mm SHCS + M3 nyloc nut                 tilt pivot bolt
//   4x M2.5 x 8mm SHCS                               PCB-to-cradle
//   4x M2.5 hex nuts                                  captured in standoffs
//   1x USB-C cable                                    anchor power
//
// ESP32 UWB Pro interface (verify with calipers):
//   PCB size       : UWB_L x UWB_W x UWB_H  (55 x 28 x 10 mm default)
//   Mounting holes : M2.5, 4x corners on UWB_HOLE_X x UWB_HOLE_Y pattern
//   USB-C port     : centred on short edge, UWB_USBC_W x UWB_USBC_H
//   Antenna area   : top face rear half -- 10mm keep-out of bracket material
//
// Tilt angles (15deg detent steps, set TILT_DEG before export):
//   0deg  -> horizontal face-up   (ceiling, antenna faces down)
//   30deg -> 30deg downward tilt  (wall near ceiling)  [default]
//   45deg -> diagonal             (wall mid-height)
//   90deg -> vertical face-out    (wall, antenna faces forward)
//
// RENDER options:
//   "assembly"           full assembly at TILT_DEG (default)
//   "wall_base_stl"      Part 1
//   "tilt_arm_stl"       Part 2
//   "anchor_cradle_stl"  Part 3
//   "cable_clip_stl"     Part 4
//
// Export commands:
//   openscad uwb_anchor_mount.scad -D 'RENDER="wall_base_stl"'     -o uwb_wall_base.stl
//   openscad uwb_anchor_mount.scad -D 'RENDER="tilt_arm_stl"'      -o uwb_tilt_arm.stl
//   openscad uwb_anchor_mount.scad -D 'RENDER="anchor_cradle_stl"' -o uwb_anchor_cradle.stl
//   openscad uwb_anchor_mount.scad -D 'RENDER="cable_clip_stl"'    -o uwb_cable_clip.stl
// ============================================================

$fn  = 64;
e    = 0.01;

// -- Tilt angle (override per anchor, 0-90deg, 15deg steps) ------------------
TILT_DEG = 30;

// -- ESP32 UWB Pro PCB dimensions (verify with calipers) ---------------------
UWB_L         = 55.0;
UWB_W         = 28.0;
UWB_H         = 10.0;
UWB_HOLE_X    = 47.5;
UWB_HOLE_Y    = 21.0;
UWB_USBC_W    =  9.5;
UWB_USBC_H    =  4.0;
UWB_ANTENNA_L = 20.0;

// -- Wall base geometry -------------------------------------------------------
BASE_W         = 60.0;
BASE_H         = 50.0;
BASE_T         =  5.0;
BASE_SCREW_D   =  4.5;
BASE_SCREW_HD  =  8.5;
BASE_SCREW_HH  =  3.5;
BASE_SCREW_SPC = 35.0;
KNUCKLE_T      = BASE_T + 4.0;

// -- Tilt arm geometry --------------------------------------------------------
ARM_W         = 12.0;
ARM_T         =  5.0;
ARM_L         = 35.0;
PIVOT_D       =  3.3;
PIVOT_NUT_AF  =  5.5;
PIVOT_NUT_H   =  2.4;
DETENT_D      =  3.2;
DETENT_R      =  8.0;

// -- Anchor cradle geometry ---------------------------------------------------
CRADLE_WALL_T  =  3.5;
CRADLE_BACK_T  =  4.0;
CRADLE_FLOOR_T =  3.0;
CRADLE_LIP_H   =  4.0;
CRADLE_LIP_T   =  2.5;
STANDOFF_H     =  3.0;
STANDOFF_OD    =  5.5;
LABEL_W        = UWB_L - 4.0;
LABEL_H        = UWB_W * 0.55;
LABEL_T        =  1.2;

// -- USB-C routing ------------------------------------------------------------
USBC_CHAN_W   = 11.0;
USBC_CHAN_H   =  7.0;

// -- Cable clip ---------------------------------------------------------------
CLIP_CABLE_D  =  4.5;
CLIP_T        =  2.0;
CLIP_BODY_W   = 16.0;
CLIP_BODY_H   = 10.0;

// -- Fasteners ----------------------------------------------------------------
M2P5_D    = 2.7;
M3_D      = 3.3;
M3_NUT_AF = 5.5;
M3_NUT_H  = 2.4;

// ============================================================
// RENDER DISPATCH
// ============================================================
RENDER = "assembly";

if      (RENDER == "assembly")           assembly_preview();
else if (RENDER == "wall_base_stl")      wall_base();
else if (RENDER == "tilt_arm_stl")       tilt_arm();
else if (RENDER == "anchor_cradle_stl")  anchor_cradle();
else if (RENDER == "cable_clip_stl")     cable_clip();

// ============================================================
// ASSEMBLY PREVIEW
// ============================================================
module assembly_preview() {
    %color("Wheat", 0.22)
        translate([-BASE_W/2, -10, -BASE_H/2])
            cube([BASE_W, 10, BASE_H + 40]);
    color("OliveDrab", 0.85)  wall_base();
    color("SteelBlue", 0.85)
        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0]) tilt_arm();
    color("DarkSlateGray", 0.85)
        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
            translate([0, ARM_T, ARM_L]) anchor_cradle();
    %color("ForestGreen", 0.38)
        translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
            translate([-UWB_L/2, ARM_T+CRADLE_BACK_T,
                       ARM_L+CRADLE_FLOOR_T+STANDOFF_H])
                cube([UWB_L, UWB_W, UWB_H]);
    color("DimGray", 0.70)
        translate([ARM_W/2, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
            translate([0, ARM_T+e, ARM_L/2]) rotate([0,-90,90]) cable_clip();
}

// ============================================================
// PART 1 -- WALL BASE
// ============================================================
// Flat backplate, 2x countersunk M4/#6 wood screws on 35mm centres.
// Two pivot ears straddle the tilt arm; M3 pivot bolt through both.
// Detent arc on +X ear inner face: 7 notches at 15deg steps (0-90deg).
// Shallow rear recess for installation-zone label strip.
// Same part for wall mount and ceiling mount.
//
// Print: backplate flat on bed, PETG, 5 perims, 40% gyroid.
module wall_base() {
    ear_h   = ARM_W + 3.0;
    ear_t   = 6.0;
    ear_sep = ARM_W + 1.0;

    difference() {
        union() {
            translate([-BASE_W/2, -BASE_T, -BASE_H/2])
                cube([BASE_W, BASE_T, BASE_H]);
            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
                translate([ex, -BASE_T+e, -ear_h/2])
                    cube([ear_t, KNUCKLE_T+e, ear_h]);
            for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
                hull() {
                    translate([ex, -BASE_T, -ear_h/4])
                        cube([ear_t, BASE_T-1, ear_h/2]);
                    translate([ex + (ex<0 ? ear_t*0.5 : 0), -BASE_T, -ear_h/6])
                        cube([ear_t*0.5, 1, ear_h/3]);
                }
        }
        for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
                cylinder(d=BASE_SCREW_D, h=BASE_T+2*e);
            translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
                cylinder(d1=BASE_SCREW_HD, d2=BASE_SCREW_D, h=BASE_SCREW_HH+e);
        }
        translate([-(ear_sep/2+ear_t+e), KNUCKLE_T*0.55, 0])
            rotate([0,90,0]) cylinder(d=PIVOT_D, h=ear_sep+2*ear_t+2*e);
        translate([ear_sep/2+ear_t-PIVOT_NUT_H-0.4, KNUCKLE_T*0.55, 0])
            rotate([0,90,0])
                cylinder(d=PIVOT_NUT_AF/cos(30), h=PIVOT_NUT_H+0.5, $fn=6);
        for (da = [0 : 15 : 90])
            translate([ear_sep/2-e,
                       KNUCKLE_T*0.55 + DETENT_R*sin(da),
                       DETENT_R*cos(da)])
                rotate([0,90,0]) cylinder(d=DETENT_D, h=ear_t*0.45+e);
        translate([0, -BASE_T-e, 0]) rotate([-90,0,0])
            cube([BASE_W-12, BASE_H-16, 1.6], center=true);
        translate([0, -BASE_T+1.5, 0])
            cube([BASE_W-14, BASE_T-3, BASE_H-20], center=true);
    }
}

// ============================================================
// PART 2 -- TILT ARM
// ============================================================
// Pivoting arm linking wall_base ears to anchor_cradle.
// Knuckle (Z=0): M3 pivot bore + spring-plunger detent pocket (3mm).
// Cradle end (Z=ARM_L): 2x M3 bolt attachment stub.
// USB-C cable channel groove on outer +Y face, full arm length.
//
// Print: knuckle face flat on bed, PETG, 5 perims, 40% gyroid.
module tilt_arm() {
    total_h = ARM_L + 10;
    difference() {
        union() {
            translate([-ARM_W/2, 0, 0]) cube([ARM_W, ARM_T, total_h]);
            translate([0, ARM_T/2, 0]) rotate([90,0,0])
                cylinder(d=ARM_W, h=ARM_T, center=true);
            translate([-ARM_W/2, 0, ARM_L])
                cube([ARM_W, ARM_T+CRADLE_BACK_T, ARM_T]);
        }
        translate([-ARM_W/2-e, ARM_T/2, 0]) rotate([0,90,0])
            cylinder(d=PIVOT_D, h=ARM_W+2*e);
        translate([0, ARM_T+e, 0]) rotate([90,0,0])
            cylinder(d=3.2, h=4+e);
        translate([-USBC_CHAN_W/2, ARM_T-e, ARM_T+4])
            cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L-ARM_T-8]);
        for (bx = [-ARM_W/4, ARM_W/4])
            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([90,0,0])
                cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
        for (bx = [-ARM_W/4, ARM_W/4])
            translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([-90,0,0])
                cylinder(d=M3_NUT_AF/cos(30), h=M3_NUT_H+0.5, $fn=6);
        translate([0, ARM_T/2, ARM_L/2])
            cube([ARM_W-4, ARM_T-2, ARM_L-18], center=true);
    }
}

// ============================================================
// PART 3 -- ANCHOR CRADLE
// ============================================================
// Open-front U-cradle for ESP32 UWB Pro PCB.
// 4x M2.5 standoffs on UWB_HOLE_X x UWB_HOLE_Y pattern.
// Back wall: USB-C exit slot + routing groove, label card slot,
//            antenna keep-out cutout (material removed above antenna area).
// Front retaining lip prevents PCB sliding out.
// Two attachment tabs bolt to tilt_arm cradle stub via M3.
//
// Label card slot: insert paper/laminate strip to ID this anchor
// (e.g. "UWB-A3 NE-CORNER"), accessible from open cradle end.
//
// Print: back wall flat on bed, PETG, 5 perims, 40% gyroid.
module anchor_cradle() {
    outer_l  = UWB_L + 2*CRADLE_WALL_T;
    outer_w  = UWB_W + CRADLE_FLOOR_T;
    pcb_z    = CRADLE_FLOOR_T + STANDOFF_H;
    total_z  = pcb_z + UWB_H + 2;

    difference() {
        union() {
            translate([-outer_l/2, 0, 0]) cube([outer_l, outer_w, total_z]);
            translate([-outer_l/2, outer_w-CRADLE_LIP_T, 0])
                cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
            for (tx = [-ARM_W/4, ARM_W/4])
                translate([tx-4, -CRADLE_BACK_T, 0])
                    cube([8, CRADLE_BACK_T+1, total_z]);
        }
        translate([-UWB_L/2, 0, pcb_z]) cube([UWB_L, UWB_W+1, UWB_H+4]);
        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2-UWB_USBC_H/2])
            cube([UWB_USBC_W+2, CRADLE_BACK_T+2*e, UWB_USBC_H+2],
                 center=[true,false,false]);
        translate([0, -CRADLE_BACK_T-e, -e])
            cube([USBC_CHAN_W, USBC_CHAN_H, pcb_z+UWB_H/2+USBC_CHAN_H],
                 center=[true,false,false]);
        translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2])
            cube([LABEL_W, LABEL_T+0.3, LABEL_H], center=[true,false,false]);
        translate([0, -e, pcb_z+UWB_H-UWB_ANTENNA_L])
            cube([UWB_L-4, CRADLE_BACK_T+2*e, UWB_ANTENNA_L+4],
                 center=[true,false,false]);
        for (tx = [-ARM_W/4, ARM_W/4])
            translate([tx, ARM_T/2-CRADLE_BACK_T, total_z/2])
                rotate([-90,0,0])
                    cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
        for (side_x = [-outer_l/2-e, outer_l/2-CRADLE_WALL_T-e])
            translate([side_x, 2, pcb_z+2])
                cube([CRADLE_WALL_T+2*e, UWB_W-4, UWB_H-4]);
    }
    for (hx = [-UWB_HOLE_X/2, UWB_HOLE_X/2])
    for (hy = [(outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2,
               (outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2 + UWB_HOLE_Y])
        difference() {
            translate([hx, hy, CRADLE_FLOOR_T-e])
                cylinder(d=STANDOFF_OD, h=STANDOFF_H+e);
            translate([hx, hy, CRADLE_FLOOR_T-2*e])
                cylinder(d=M2P5_D, h=STANDOFF_H+4);
        }
}

// ============================================================
// PART 4 -- CABLE CLIP
// ============================================================
// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
// Presses onto ARM_T-wide arm with flexible PETG snap tongues.
// Print x2-3 per anchor, spaced 25mm along arm.
//
// Print: clip-opening face down, PETG, 3 perims, 20% infill.
module cable_clip() {
    ch_r   = CLIP_CABLE_D/2 + CLIP_T;
    snap_t = 1.6;
    difference() {
        union() {
            translate([-CLIP_BODY_W/2, 0, 0])
                cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
            translate([0, CLIP_T+ch_r, CLIP_BODY_H/2]) rotate([0,90,0])
                difference() {
                    cylinder(r=ch_r, h=CLIP_BODY_W, center=true);
                    cylinder(r=CLIP_CABLE_D/2, h=CLIP_BODY_W+2*e, center=true);
                    translate([0, ch_r+e, 0])
                        cube([CLIP_CABLE_D*0.85, ch_r*2+2*e, CLIP_BODY_W+2*e],
                             center=true);
                }
            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
                translate([tx, -ARM_T-1, 0])
                    cube([snap_t, ARM_T+1+CLIP_T, CLIP_BODY_H]);
            for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
                translate([tx+snap_t/2, -ARM_T-1, CLIP_BODY_H/2])
                    rotate([0,90,0]) cylinder(d=2, h=snap_t, center=true);
        }
        translate([0, -ARM_T-1-e, CLIP_BODY_H/2])
            cube([CLIP_BODY_W-6, ARM_T+2, CLIP_BODY_H-4], center=true);
    }
}
