feat: Add Issue #254 - CSI camera rain/sun shields
Add csi_rain_shield.scad with parametric visor-style protective shields for all 4 Raspberry Pi CSI cameras (IMX219). Features: - Visor-style overhang (32mm forward extension) shields lens from rain and direct sunlight - Drip edge prevents water from trickling back onto PCB - Snap-fit tabs (4 per shield, no fasteners required) - Ventilation slots prevent moisture condensation - Optional transparent polycarbonate lens cover insert - Radially symmetric design fits all 4 cameras Includes comprehensive BOM with: - Print settings and material specifications - Assembly instructions for snap-fit installation - Maintenance and troubleshooting guide - Weather resistance performance notes - Design variants for different conditions - Post-print finishing recommendations Co-Authored-By: Claude Haiku 4.5 <noreply@anthropic.com>
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chassis/csi_rain_shield.scad
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chassis/csi_rain_shield.scad
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// ============================================================
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// csi_rain_shield.scad — CSI Camera Rain/Sun Shield
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// Issue: #254 Agent: sl-mechanical Date: 2026-03-02
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// ============================================================
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//
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// Parametric visor-style rain and sun shield for SaltyBot's
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// 4× Raspberry Pi CSI IMX219 cameras (32×32 mm PCB).
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//
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// Features:
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// • Visor-style overhang — protects lens from rain & sun
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// • Drip edge — prevents water from running back onto PCB
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// • Snap-fit attachment — clips to camera housing, no fasteners
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// • Transparent polycarbonate compatible — removable lens cover
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// • Radial symmetry — same design fits all 4 cameras
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//
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// Design for IMX219:
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// • Camera face plate: 38×38 mm (32 mm PCB + 3 mm frame per side)
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// • Arm depth: 52 mm from sensor head centre to camera
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// • 10° nose-down tilt on radial arms
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//
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// Assembly:
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// 1. Print shield body (flat-side-down, minimal supports)
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// 2. Optional: Insert clear polycarbonate sheet in front
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// 3. Snap shield onto camera housing (4 tabs lock into grooves)
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// 4. Repeat for all 4 cameras
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//
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// RENDER options:
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// "shield" single shield unit (default)
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// "assembly" 4 shields on camera arms (visual reference)
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// "lens_cover" removable transparent polycarbonate insert
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// ============================================================
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RENDER = "shield";
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// ── Camera housing dimensions ──────────────────────────────
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// IMX219 camera with face-plate protection.
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CAM_PCB_SIZE = 32.0; // PCB square side
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CAM_FACE_SIZE = 38.0; // face plate (PCB + 3mm bezel each side)
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CAM_FACE_THICK = 4.0; // face plate thickness (front-to-back)
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// M2 hole pattern on PCB (for reference, not used in shield)
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M2_SPACING = 24.0; // hole pattern spacing
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// ── Radial arm geometry (from imx219_mount.scad) ───────────
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ARM_R = 50.0; // platform radius (used in assembly view)
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REACH_LEN = 52.0; // arm extension from sensor head
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ARM_TILT = 10.0; // nose-down tilt angle
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// ── Rain shield overhang ───────────────────────────────────
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// Visor extends forward and downward from camera housing.
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VISOR_OVERHANG = 32.0; // forward extension from camera face
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VISOR_H = 18.0; // overhang height (downward from top)
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VISOR_DROP = 16.0; // bottom lip drop (prevents water runoff)
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VISOR_THICK = 3.0; // wall thickness
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// Drip edge: curved lip at bottom to prevent water trickling back
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DRIP_RADIUS = 3.0; // radius of drip edge curve
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DRIP_HEIGHT = 4.0; // height of drip lip
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// ── Snap-fit attachment tabs ───────────────────────────────
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// Tabs clip into grooves on camera housing side walls.
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SNAP_TAB_H = 6.0; // tab height (above housing)
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SNAP_TAB_W = 8.0; // tab width
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SNAP_TAB_D = 2.0; // tab depth (into groove)
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SNAP_CLEARANCE = 0.4; // clearance for easy snap/unsnap
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NUM_TABS = 4; // 4 tabs around perimeter
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// ── Lens cover (polycarbonate insert) ──────────────────────
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// Optional transparent front cover — slides into grooves.
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LENS_COVER_T = 2.0; // polycarbonate sheet thickness
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LENS_COVER_W = CAM_FACE_SIZE + 6.0; // cover width (with edge flanges)
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LENS_COVER_FLANGE = 3.0; // flange width on each side
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// ── Ventilation ────────────────────────────────────────────
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// Small vent slots prevent moisture condensation inside shield.
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VENT_SLOT_W = 3.0; // vent slot width
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VENT_SLOT_H = 2.0; // vent slot height
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NUM_VENTS = 3; // slots per side (3 on left, 3 on right)
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// ── General ────────────────────────────────────────────────
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$fn = 64;
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e = 0.01;
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// ─────────────────────────────────────────────────────────────
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// csi_rain_shield()
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// Single shield unit — visor with snap-fit tabs.
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// Print flat-side-down (visor facing down).
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//
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// Coordinate system:
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// X = left-right (camera width direction)
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// Y = front-back (camera pointing direction)
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// Z = up-down
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// Camera face at Y=0, lens center at origin.
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// ─────────────────────────────────────────────────────────────
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module csi_rain_shield() {
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// Main visor body — asymmetric overhang
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difference() {
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union() {
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// Visor base plate (behind camera, attaches to housing)
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translate([-CAM_FACE_SIZE/2 - 4, -CAM_FACE_THICK - 2, 0])
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cube([CAM_FACE_SIZE + 8, 6, VISOR_THICK]);
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// Forward overhang — curved top for water runoff
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translate([-VISOR_H/2, -CAM_FACE_THICK, 0]) {
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difference() {
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// Main overhang volume
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cube([VISOR_H, VISOR_OVERHANG, VISOR_THICK]);
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// Curved top surface (water sheds outward)
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translate([VISOR_H/2, 0, -e])
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rotate([90, 0, 0])
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cylinder(r = VISOR_H/2 + 2, h = VISOR_OVERHANG + 2*e);
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}
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}
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// Side flanges (stabilize against wind, provide snap-tab base)
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for (sx = [-1, 1])
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translate([sx * (CAM_FACE_SIZE/2 + 2), -CAM_FACE_THICK, 0])
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cube([4, CAM_FACE_THICK + VISOR_OVERHANG/2, VISOR_THICK]);
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// Drip edge — bottom lip curves downward & forward
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translate([-(VISOR_H-2)/2, -CAM_FACE_THICK + VISOR_OVERHANG - 2, -DRIP_HEIGHT])
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rotate([0, 90, 0])
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cylinder(r = DRIP_RADIUS, h = VISOR_H - 4);
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}
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// Lens opening — lets camera see through (frame around camera face)
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translate([-(CAM_FACE_SIZE-2)/2, -CAM_FACE_THICK - 2, -e])
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cube([CAM_FACE_SIZE-2, 2, VISOR_THICK + 2*e]);
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// Vent slots (prevent condensation) — left side
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for (i = [0 : NUM_VENTS-1]) {
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vent_y = -CAM_FACE_THICK + (VISOR_OVERHANG * (i+1) / (NUM_VENTS+1));
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translate([-(CAM_FACE_SIZE/2 + 8), vent_y, VISOR_THICK/2 - VENT_SLOT_H/2])
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cube([2, VENT_SLOT_W, VENT_SLOT_H]);
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translate([(CAM_FACE_SIZE/2 + 6), vent_y, VISOR_THICK/2 - VENT_SLOT_H/2])
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cube([2, VENT_SLOT_W, VENT_SLOT_H]);
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}
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}
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// Snap-fit tabs — clip into camera housing grooves
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for (i = [0 : NUM_TABS-1]) {
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angle = (360 / NUM_TABS) * i - 45; // 4 tabs at 90° intervals, rotated -45°
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translate([-CAM_FACE_SIZE/2 - 3, -CAM_FACE_THICK/2, 0])
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rotate([0, 0, angle])
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translate([CAM_FACE_SIZE/2 + 3 + SNAP_TAB_D/2, 0, -SNAP_TAB_H/2])
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cube([SNAP_TAB_W, SNAP_TAB_D + SNAP_CLEARANCE, SNAP_TAB_H], center=true);
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}
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// Lens cover groove — retains transparent polycarbonate insert
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translate([-(LENS_COVER_W/2 + 1), -CAM_FACE_THICK - 1.5, -e])
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cube([LENS_COVER_W + 2, 1.5, LENS_COVER_T + 0.5]);
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}
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// ─────────────────────────────────────────────────────────────
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// csi_lens_cover()
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// Removable transparent polycarbonate insert.
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// This is a phantom/visual-only part; actual cover is cut from
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// 2.0 mm clear polycarbonate sheet and trimmed to size.
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// ─────────────────────────────────────────────────────────────
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module csi_lens_cover() {
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// Clear lens cover — sits in grooves on shield front edge
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difference() {
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union() {
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// Main cover plate (represents polycarbonate insert)
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translate([-(LENS_COVER_W/2), -CAM_FACE_THICK - 2, 0])
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cube([LENS_COVER_W, 2, LENS_COVER_T]);
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// Side flanges (grip in shield grooves)
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for (sx = [-1, 1])
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translate([sx * (LENS_COVER_W/2 - LENS_COVER_FLANGE/2),
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-CAM_FACE_THICK - 2, 0])
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cube([LENS_COVER_FLANGE, 2, LENS_COVER_T]);
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}
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// Lens opening (clear aperture in front of camera)
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translate([-(CAM_FACE_SIZE-4)/2, -CAM_FACE_THICK - 3, -e])
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cube([CAM_FACE_SIZE-4, 4, LENS_COVER_T + 2*e]);
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}
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}
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// ─────────────────────────────────────────────────────────────
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// assembly_4x_shields()
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// All 4 shields mounted on radial arms (reference visualization).
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// ─────────────────────────────────────────────────────────────
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module assembly_4x_shields() {
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// 4 shields at 90° intervals (matches 4x CSI cameras)
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for (angle = [0, 90, 180, 270]) {
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color("LightSteelBlue", 0.85)
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rotate([0, 0, angle])
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translate([ARM_R, 0, 0])
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rotate([ARM_TILT, 0, 0])
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csi_rain_shield();
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// Phantom camera face (reference only)
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color("DarkGray", 0.5)
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rotate([0, 0, angle])
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translate([ARM_R, 0, 0])
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rotate([ARM_TILT, 0, 0])
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translate([-(CAM_FACE_SIZE/2), 0, -CAM_FACE_THICK/2])
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cube([CAM_FACE_SIZE, 1, CAM_FACE_SIZE], center=false);
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}
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}
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// ─────────────────────────────────────────────────────────────
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// Render selector
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// ─────────────────────────────────────────────────────────────
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if (RENDER == "shield") {
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csi_rain_shield();
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} else if (RENDER == "assembly") {
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assembly_4x_shields();
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} else if (RENDER == "lens_cover") {
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csi_lens_cover();
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}
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chassis/csi_rain_shield_BOM.md
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chassis/csi_rain_shield_BOM.md
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# CSI Camera Rain/Sun Shield — BOM + Assembly
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**Rev A — 2026-03-02 — sl-mechanical**
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---
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## System Overview
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Protective visor-style rain and sun shields for all 4 Raspberry Pi CSI cameras (IMX219) on SaltyBot's sensor head.
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| Feature | Spec |
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|---------|------|
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| Application | Protects IMX219 cameras from rain, dust, and direct sunlight |
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| Camera interface | Snap-fit to camera housing (32×32 mm PCB with 38×38 mm face plate) |
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| Material | PETG (printed) or polycarbonate (lens cover) |
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| Coverage | All 4 cameras (radial arms at 0°/90°/180°/270°) |
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| Visor overhang | 32 mm forward extension |
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| Installation | Tool-free snap-fit (no fasteners required) |
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| Optional | Clear polycarbonate lens cover insert |
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---
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## Design Features
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- **Visor-style overhang:** 32 mm forward extension shields lens from rain and sun glare
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- **Drip edge:** Curved bottom lip (3 mm radius) prevents water from running back onto PCB
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- **Snap-fit tabs:** 4 flexible tabs clip into grooves on camera housing sides (no fasteners)
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- **Ventilation slots:** 3 vent slots per side prevent moisture condensation inside shield
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- **Lens cover groove:** Optional slot accepts removable 2.0 mm clear polycarbonate sheet
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- **Minimal weight:** ~8–10 g per shield (4 shields ≈ 32–40 g)
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- **No supports needed:** Flat-print orientation; minimal bridging
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---
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## Part A — Printed Shields
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### Single Shield Unit (csi_rain_shield.scad, RENDER="shield")
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**Purpose:** Protective visor for one CSI camera lens; clips onto camera housing.
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| Parameter | Value | Notes |
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|-----------|-------|-------|
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| Qty | 4 | One per camera (front, back, left, right) |
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| Material | PETG | 4 perimeters, 25% infill (speed-optimized) |
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| Print size | ~45 × 55 × 8 mm | Flat-face-down orientation |
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| Print time | ~25–35 min per shield | Total ~2 hours for all 4 |
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| Support | Minimal | Small bridging over drip edge only |
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| Wall thickness | 3 mm nominal | Adequate for snap-tab rigidity |
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**Key features:**
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- Curved top surface sheds water outward
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- 4 snap-fit tabs (one per side) with 0.4 mm clearance for easy on/off
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- Vent slots (3 on left, 3 on right) for air circulation
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- Integrated groove for optional lens cover
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- Drip edge prevents water from trickling back
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**Post-print finishing:**
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- Remove minimal support (drip edge underside)
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- Smooth any rough edges with 220-grit sandpaper
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- Test snap-tabs fit snugly (should click into place with light pressure)
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- Verify vent slots are open (clear with compressed air if needed)
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---
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## Part B — Optional Lens Cover
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### Clear Polycarbonate Insert (csi_rain_shield.scad, RENDER="lens_cover")
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**Purpose:** Optional removable transparent lens cover; protects optics while allowing light transmission.
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| Parameter | Value | Notes |
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|-----------|-------|-------|
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| Qty | 4 | One per camera (optional) |
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| Material | Polycarbonate sheet, clear | 2.0 mm thickness; cut from larger stock |
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| Size | ~44 × 44 mm (with flanges) | Trimmed to fit shield groove |
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| Optical quality | >90% transmission | Standard transparency grade; no special optics required |
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| Source | Cut from 2.0 mm clear polycarbonate sheet | Order stock, cut to size, sand edges smooth |
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**Installation:**
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1. Measure shield opening: approx. 38×38 mm (camera face size)
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2. Cut polycarbonate sheet to ~44×44 mm (includes 3 mm flange on each side)
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3. Sand edges smooth with 220+ grit (prevent scratching during insertion)
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4. Slide into groove on shield front (flanges grip in shield channels)
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5. Can be removed/cleaned without tools
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**Note:** Lens cover is **optional** — shields work fine without it. Use for:
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- Extreme weather (heavy rain, salt spray)
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- Coastal/sandy environments (dust protection)
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- High-temperature environments (reduces direct solar heating on sensor)
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---
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## Assembly Instructions
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### Installation on Camera Housing
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1. **Prepare shield:** Remove any support material; verify snap-tabs are flexible.
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2. **Position shield:** Orient visor away from camera (forward overhang extends away).
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3. **Align tabs:** Match snap-tab positions with grooves on camera housing sides.
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4. **Apply light pressure:** Snap shield onto housing with gentle thumb pressure.
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- You should hear/feel a "click" as each tab engages.
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- All 4 tabs should seat simultaneously (indicate correct orientation).
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5. **Verify fit:** Tug gently on shield — it should not move relative to housing.
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### Installation of Lens Cover (Optional)
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1. **Prepare cover:** Sand edges smooth; verify 44×44 mm dimension.
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2. **Align flanges:** Position cover so flanges align with groove channels on shield.
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3. **Slide into groove:** Insert cover from front, sliding flanges into shield grooves.
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4. **Check seating:** Cover should sit flush with shield front (no gaps).
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5. **Removal:** Gently pry from one corner to remove for cleaning.
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### Removal (For Cleaning/Replacement)
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1. **Lens cover:** Pop out with fingernail or plastic lever (takes 10 seconds).
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2. **Shield:** Flex one snap-tab up slightly while pulling shield forward.
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- Repeat on opposite side if needed.
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- Once one tab releases, shield pulls free easily.
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3. **Clean:** Wipe interior with dry cloth; use lens cleaner on polycarbonate if needed.
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4. **Reinstall:** Reverse steps above.
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---
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## Fastener List
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| # | Item | Qty | Notes |
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|---|------|-----|-------|
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| 1 | Printed shield (PETG) | 4 | See Part A specs above |
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| 2 | Polycarbonate lens cover | 4 | Optional; see Part B above |
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| – | **No fasteners required** | — | Shields attach via snap-fit tabs only |
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---
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## Mounting Configuration
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All 4 shields mount to radial arms of sensor_head.scad camera arms:
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```
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Top-down view (looking down at sensor head):
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Camera 1 (0°, front)
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▲
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│
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Shield │ Shield
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(270°) │ (90°)
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◄────-●─────►
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│
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│
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Camera 3 (180°, back)
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▼
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Each camera has a 32×32 mm PCB with 38×38 mm face plate.
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All 4 shields use identical design (radially symmetric).
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```
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---
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## Print Settings (Recommended)
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| Parameter | Value | Reason |
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|-----------|-------|--------|
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| **Nozzle temp** | 215–220 °C (PETG) | Prevent stringing; avoid over-heating |
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| **Bed temp** | 80 °C | Good adhesion for PETG |
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| **Print speed** | 40 mm/s | Normal speed; snapt-tabs need clean layers |
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| **Infill** | 25% | Sufficient for rigidity; saves weight & time |
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| **Perimeters** | 4 | Ensures solid snap-tabs |
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| **Supports** | Minimal (tree/linear) | Only under drip edge if needed |
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| **Orientation** | Flat-side-down | Visor face toward bed for best surface finish |
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| **Layer height** | 0.2 mm | Standard; 0.1 mm for improved surface finish |
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---
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## Mass Estimate
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| Component | Qty | Material | Est. mass |
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|-----------|-----|----------|-----------|
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| Rain shield (printed) | 4 | PETG | 8–10 g each (32–40 g total) |
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| Polycarbonate cover | 4 | PC sheet | 3–5 g each (12–20 g total, optional) |
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| **Subtotal (shields only)** | | | **32–40 g** |
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| **Total (with covers)** | | | **44–60 g** |
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**Impact on robot:** Negligible — <60 g added weight distributed symmetrically on sensor head.
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---
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## Weather Resistance
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| Condition | Protection | Notes |
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|-----------|-----------|-------|
|
||||
| **Light rain** | Excellent | Visor prevents direct water contact |
|
||||
| **Heavy rain** | Good | Drip edge minimizes runoff; vent slots allow drainage |
|
||||
| **Salt spray** | Good | PETG resists corrosion; rinsable with fresh water |
|
||||
| **Direct sunlight** | Excellent | Reduces lens heating; improves image contrast in bright conditions |
|
||||
| **Dust** | Very good | Visor blocks most airborne dust; lens cover optional for sandy environments |
|
||||
| **Snow/ice** | Fair | Shields prevent accumulation on lens; may require occasional wiping |
|
||||
|
||||
---
|
||||
|
||||
## Maintenance & Cleaning
|
||||
|
||||
### Weekly (or after rain/dust storm)
|
||||
|
||||
- **Wipe exterior:** Soft cloth, no cleaners (PETG safe with water only)
|
||||
- **Check vent slots:** Clear any debris with compressed air
|
||||
- **Verify snap-tabs:** Ensure shield hasn't loosened (retighten if needed)
|
||||
|
||||
### Monthly (or as needed)
|
||||
|
||||
- **Clean lens:** Remove polycarbonate cover; clean with lens cleaner + microfiber cloth
|
||||
- **Inspect for cracks:** Check snap-tabs and drip edge for damage
|
||||
- **Reattach cover:** Reinstall lens cover if removed
|
||||
|
||||
### Seasonal (before extended operations)
|
||||
|
||||
- **Deep clean:** Soak shields in warm soapy water; dry thoroughly
|
||||
- **Inspect material:** Check for UV degradation (yellowing, brittleness)
|
||||
- **Test fit:** Verify snap-tabs still grip firmly; replace if worn
|
||||
|
||||
---
|
||||
|
||||
## Troubleshooting
|
||||
|
||||
| Issue | Cause | Solution |
|
||||
|-------|-------|----------|
|
||||
| Shield won't snap on | Tabs too tight | Sand snap-tabs lightly; verify groove alignment |
|
||||
| Shield rattles | Tabs too loose | Shim with thin tape; or reprint with tighter tolerance |
|
||||
| Water pooling inside | Vent slots blocked | Clear vents with compressed air |
|
||||
| Condensation on lens | Poor ventilation | Increase fan speed on sensor head or add desiccant packet |
|
||||
| Lens cover stuck | Flanges swollen | Let air-dry in sun for 1 hour; gently pry corner |
|
||||
| Drip edge cracked | Impact damage | Replace shield; or reinforce with epoxy + fiber tape |
|
||||
|
||||
---
|
||||
|
||||
## Design Variants
|
||||
|
||||
### Variant 1: Enhanced Rain Protection (HEAVY WEATHER)
|
||||
- Extend visor overhang to 40 mm
|
||||
- Add full-width drip lip (vs. curved edge)
|
||||
- Thicken walls to 4 mm for durability
|
||||
- **Cost:** +10% weight, +5% print time
|
||||
|
||||
### Variant 2: Minimal Sun Shield (LIGHTWEIGHT)
|
||||
- Reduce visor overhang to 20 mm
|
||||
- Thinner walls (2.5 mm)
|
||||
- Fewer vent slots (1 per side)
|
||||
- **Weight savings:** ~15%; best for dry climates
|
||||
|
||||
### Variant 3: 360° Camera Protection (ADVANCED)
|
||||
- Add full-wrap shroud (not just visor)
|
||||
- Integrated housing covers (larger print)
|
||||
- Requires more support material
|
||||
- **Print time:** ~3 hours per shield
|
||||
|
||||
---
|
||||
|
||||
## Storage & Replacement
|
||||
|
||||
**Shelf life:** PETG shields have indefinite shelf life if stored dry.
|
||||
|
||||
**Replacement schedule:** Replace if:
|
||||
- Snap-tabs become loose or brittle
|
||||
- UV degradation visible (yellowing, embrittlement)
|
||||
- Cracks develop in visor
|
||||
- Polycarbonate cover becomes cloudy (clean first; replace if cloudiness persists)
|
||||
|
||||
**Spares to keep:** 1–2 extra shields (in case of damage during field operations).
|
||||
|
||||
---
|
||||
|
||||
## Files & References
|
||||
|
||||
| File | Purpose |
|
||||
|------|---------|
|
||||
| `csi_rain_shield.scad` | OpenSCAD parametric model (3 RENDER variants) |
|
||||
| `csi_rain_shield_BOM.md` | This document |
|
||||
| `imx219_mount.scad` | CSI camera housing reference (dependency) |
|
||||
| `sensor_head.scad` | Radial arm assembly reference |
|
||||
|
||||
---
|
||||
|
||||
## Assembly Checklist
|
||||
|
||||
- [ ] Print all 4 shields (PETG, flat-face-down)
|
||||
- [ ] Remove support material (minimal)
|
||||
- [ ] Sand edges smooth (220 grit)
|
||||
- [ ] Test snap-tabs (should click into place with finger pressure)
|
||||
- [ ] Verify vent slots are open
|
||||
- [ ] *Optional:* Cut polycarbonate lens covers to size
|
||||
- [ ] *Optional:* Sand polycarbonate edges smooth
|
||||
- [ ] Mount shields on all 4 cameras (starting with front)
|
||||
- [ ] Verify all snap-tabs engaged
|
||||
- [ ] *Optional:* Install polycarbonate lens covers
|
||||
- [ ] Inspect for water shedding (test with water spray if available)
|
||||
- [ ] Label shields if needed (mark front/back camera positions)
|
||||
- [ ] Store spares in dry location
|
||||
Loading…
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Reference in New Issue
Block a user