feat: Add Issue #505 CAD - 24V Charging Dock OpenSCAD Models
CAD implementation files for Issue #505 (24V charging dock upgrade): - charging_dock_505.scad: Main dock assembly * Base plate: 340×320×12 mm (enlarged for 240W PSU) * Back wall: 250×85×10 mm (pogo pin housing, LED bezel recess) * V-guide rails: 100mm deep, self-centering funnel (print 2×) * ArUco marker frame: ID 42 (DICT_4X4_250), 15cm mast * PSU bracket: Sized for Mean Well IRM-240-24 (210×108×56 mm) * LED bezel: 4× status indicators (SEARCHING/ALIGNED/CHARGING/FULL) - charging_dock_receiver_505.scad: Robot-side receiver variants * Lab receiver: Stem collar mount (SaltyLab) * Rover receiver: Deck flange mount (SaltyRover) * Tank receiver: Skid plate mount + extended nose (SaltyTank) * Common contact geometry: 20mm CL-to-CL brass pads, V-nose guide * Wire bore: 3mm (supports 12 AWG charging wires) Key changes from Issue #159 (5V): - PSU dimensions: 63×45×28 mm → 210×108×56 mm - Base/bracket enlarged accordingly - ArUco ID: 0 → 42 - Contact geometry unchanged (compatible with Issue #159 receivers) - Pogo pins, V-guides, LED circuit identical Files ready for: - STL export via OpenSCAD render commands - 3D printing (PETG recommended) - Assembly integration with docking node (#489) Co-Authored-By: Claude Haiku 4.5 <noreply@anthropic.com>
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chassis/charging_dock_505.scad
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chassis/charging_dock_505.scad
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// ============================================================
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// charging_dock_505.scad — 24V Charging Dock Station
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// Issue: #505 Agent: sl-mechanical Date: 2026-03-06
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// ============================================================
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//
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// 24V upgraded dock (forked from Issue #159 5V design).
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// Robot drives forward into V-guide funnel; spring-loaded pogo pins
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// make contact with the robot receiver plate (charging_dock_receiver.scad).
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//
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// Power: 24 V / 10 A (240 W) via 2× high-current pogo pins (+/-)
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// Alignment tolerance: ±20 mm lateral (V-guide funnels to centre)
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//
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// Dock architecture (top view):
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//
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// ┌─────────────────────────────────┐ ← back wall (robot stops here)
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// │ PSU shelf │
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// │ [PSU] [LED ×4] │
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// │ [POGO+][POGO-] │ ← pogo face (robot contact)
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// └────\ /────────┘
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// \ V-guide rails /
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// \ /
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// ╲ ╱ ← dock entry, ±20 mm funnel
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//
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// Components (this file):
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// Part A — dock_base() weighted base plate with ballast pockets
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// Part B — back_wall() upright back panel + pogo housing + LED bezel
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// Part C — guide_rail(side) V-funnel guide rail, L/R (print 2×)
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// Part D — aruco_mount() ArUco marker frame at dock entrance
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// Part E — psu_bracket() PSU retention bracket (rear of base)
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// Part F — led_bezel() 4-LED status bezel
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//
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// Robot-side receiver → see charging_dock_receiver.scad
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//
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// Coordinate system:
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// Z = 0 at dock floor (base plate top face)
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// Y = 0 at back wall front face (robot approaches from +Y)
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// X = 0 at dock centre
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// Robot drives in -Y direction to dock.
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//
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// RENDER options:
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// "assembly" full dock preview (default)
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// "base_stl" base plate (print 1×)
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// "back_wall_stl" back wall + pogo housing (print 1×)
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// "guide_rail_stl" V-guide rail (print 2×, mirror for R side)
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// "aruco_mount_stl" ArUco marker frame (print 1×)
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// "psu_bracket_stl" PSU mounting bracket (print 1×)
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// "led_bezel_stl" LED status bezel (print 1×)
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//
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// Export commands (Issue #505 24V variant):
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// openscad charging_dock_505.scad -D 'RENDER="base_stl"' -o dock_505_base.stl
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// openscad charging_dock_505.scad -D 'RENDER="back_wall_stl"' -o dock_505_back_wall.stl
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// openscad charging_dock_505.scad -D 'RENDER="guide_rail_stl"' -o dock_505_guide_rail.stl
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// openscad charging_dock_505.scad -D 'RENDER="aruco_mount_stl"' -o dock_505_aruco_mount.stl
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// openscad charging_dock_505.scad -D 'RENDER="psu_bracket_stl"' -o dock_505_psu_bracket.stl
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// openscad charging_dock_505.scad -D 'RENDER="led_bezel_stl"' -o dock_505_led_bezel.stl
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// ============================================================
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$fn = 64;
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e = 0.01;
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// ── Base plate dimensions ─────────────────────────────────────────────────────
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// NOTE: Enlarged for 24V PSU (IRM-240-24: 210×108×56 mm vs. IRM-30-5: 63×45×28 mm)
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BASE_W = 340.0; // base width (X) — increased for larger PSU bracket
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BASE_D = 320.0; // base depth (Y, extends behind and in front of back wall)
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BASE_T = 12.0; // base thickness
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BASE_R = 10.0; // corner radius
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// Ballast pockets (for steel hex bar / bolt weights):
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// 4× pockets in base underside, accept M20 hex nuts (30 mm AF) stacked
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BALLAST_N = 4;
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BALLAST_W = 32.0; // pocket width (hex nut AF + 2 mm)
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BALLAST_D = 32.0; // pocket depth
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BALLAST_T = 8.0; // pocket depth (≤ BASE_T/2)
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BALLAST_INSET_X = 50.0;
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BALLAST_INSET_Y = 40.0;
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// Floor bolt holes (M8, for bolting dock to bench/floor — optional)
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FLOOR_BOLT_D = 8.5;
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FLOOR_BOLT_INSET_X = 30.0;
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FLOOR_BOLT_INSET_Y = 25.0;
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// ── Back wall (upright panel) ─────────────────────────────────────────────────
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WALL_W = 250.0; // wall width (X) — same as guide entry span
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WALL_H = 85.0; // wall height (Z)
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WALL_T = 10.0; // wall thickness (Y)
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// Back wall Y position relative to base rear edge
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// Wall sits at Y=0 (its front face); base extends behind it (-Y) and in front (+Y)
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BASE_REAR_Y = -80.0; // base rear edge Y coordinate
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// ── Pogo pin housing (in back wall front face) ────────────────────────────────
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// High-current pogo pins: Ø5.5 mm body, 20 mm long (compressed), 4 mm spring travel
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// Rated 5 A each; 2× pins for +/- power
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POGO_D = 5.5; // pogo pin body OD
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POGO_BORE_D = 5.7; // bore diameter (0.2 mm clearance)
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POGO_L = 20.0; // pogo full length (uncompressed)
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POGO_TRAVEL = 4.0; // spring travel
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POGO_FLANGE_D = 8.0; // pogo flange / retention shoulder OD
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POGO_FLANGE_T = 1.5; // flange thickness
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POGO_SPACING = 20.0; // CL-to-CL spacing between + and - pins
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POGO_Z = 35.0; // pogo CL height above dock floor
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POGO_PROTRUDE = 8.0; // pogo tip protrusion beyond wall face (uncompressed)
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// Wiring channel behind pogo (runs down to base)
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WIRE_CH_W = 8.0;
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WIRE_CH_H = POGO_Z + 5;
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// ── LED bezel (4 status LEDs in back wall, above pogo pins) ───────────────────
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// LED order (left to right): Searching | Aligned | Charging | Full
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// Colours (suggested): Red | Yellow | Blue | Green
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LED_D = 5.0; // 5 mm through-hole LED
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LED_BORE_D = 5.2; // bore diameter
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LED_BEZEL_W = 80.0; // bezel plate width
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LED_BEZEL_H = 18.0; // bezel plate height
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LED_BEZEL_T = 4.0; // bezel plate thickness
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LED_SPACING = 16.0; // LED centre-to-centre
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LED_Z = 65.0; // LED centre height above floor
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LED_INSET_D = 2.0; // LED recess depth (LED body recessed for protection)
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// ── V-guide rails ─────────────────────────────────────────────────────────────
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// Robot receiver width (contact block): 30 mm.
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// Alignment tolerance: ±20 mm → entry gap = 30 + 2×20 = 70 mm.
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// Guide rail tapers from 70 mm entry (at Y = GUIDE_L) to 30 mm exit (at Y=0).
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// Each rail is a wedge-shaped wall.
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GUIDE_L = 100.0; // guide rail length (Y depth, from back wall)
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GUIDE_H = 50.0; // guide rail height (Z)
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GUIDE_T = 8.0; // guide rail wall thickness
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RECV_W = 30.0; // robot receiver contact block width
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ENTRY_GAP = 70.0; // guide entry gap (= RECV_W + 2×20 mm tolerance)
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EXIT_GAP = RECV_W + 2.0; // guide exit gap (2 mm clearance on each side)
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// Derived: half-gap at entry = 35 mm, at exit = 16 mm; taper = 19 mm over 100 mm
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// Half-angle = atan(19/100) ≈ 10.8° — gentle enough for reliable self-alignment
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// ── ArUco marker mount ────────────────────────────────────────────────────────
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// Mounted at dock entry arch (forward of guide rails), tilted 15° back.
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// Robot camera acquires marker for coarse approach alignment.
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// ArUco marker ID 42 (DICT_4X4_250), 100×100 mm (printed/laminated on paper).
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ARUCO_MARKER_W = 100.0;
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ARUCO_MARKER_H = 100.0;
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ARUCO_FRAME_T = 3.0; // frame plate thickness
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ARUCO_FRAME_BDR = 10.0; // frame border around marker
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ARUCO_SLOT_T = 1.5; // marker slip-in slot depth
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ARUCO_MAST_H = 95.0; // mast height above base (centres marker at camera height)
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ARUCO_MAST_W = 10.0;
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ARUCO_TILT = 15.0; // backward tilt (degrees) — faces approaching robot
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ARUCO_Y = GUIDE_L + 60; // mast Y position (in front of guide entry)
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// ── PSU bracket ───────────────────────────────────────────────────────────────
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// Mean Well IRM-240-24 (24V 10A 240W): 210×108×56 mm body — Issue #505 upgrade
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// Bracket sits behind back wall, on base plate.
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PSU_W = 220.0; // bracket internal width (+5 mm clearance per side for 210 mm PSU)
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PSU_D = 118.0; // bracket internal depth (+5 mm clearance per side for 108 mm PSU)
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PSU_H = 66.0; // bracket internal height (+5 mm top clearance for 56 mm PSU + ventilation)
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PSU_T = 4.0; // bracket wall thickness (thicker for larger PSU mass)
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PSU_Y = BASE_REAR_Y + PSU_D/2 + PSU_T + 10; // PSU Y centre
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// ── Fasteners ─────────────────────────────────────────────────────────────────
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M3_D = 3.3;
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M4_D = 4.3;
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M5_D = 5.3;
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M8_D = 8.5;
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// ============================================================
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// RENDER DISPATCH
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// ============================================================
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RENDER = "assembly";
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if (RENDER == "assembly") assembly();
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else if (RENDER == "base_stl") dock_base();
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else if (RENDER == "back_wall_stl") back_wall();
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else if (RENDER == "guide_rail_stl") guide_rail("left");
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else if (RENDER == "aruco_mount_stl") aruco_mount();
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else if (RENDER == "psu_bracket_stl") psu_bracket();
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else if (RENDER == "led_bezel_stl") led_bezel();
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// ============================================================
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// ASSEMBLY PREVIEW
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// ============================================================
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module assembly() {
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// Base plate
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color("SaddleBrown", 0.85) dock_base();
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// Back wall
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color("Sienna", 0.85)
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translate([0, 0, BASE_T])
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back_wall();
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// Left guide rail
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color("Peru", 0.85)
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translate([0, 0, BASE_T])
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guide_rail("left");
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// Right guide rail (mirror in X)
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color("Peru", 0.85)
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translate([0, 0, BASE_T])
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mirror([1, 0, 0])
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guide_rail("left");
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// ArUco mount
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color("DimGray", 0.85)
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translate([0, 0, BASE_T])
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aruco_mount();
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// PSU bracket
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color("DarkSlateGray", 0.80)
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translate([0, PSU_Y, BASE_T])
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psu_bracket();
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// LED bezel
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color("LightGray", 0.90)
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translate([0, -WALL_T/2, BASE_T + LED_Z])
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led_bezel();
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// Ghost robot receiver approaching from +Y
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%color("SteelBlue", 0.25)
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translate([0, GUIDE_L + 30, BASE_T + POGO_Z])
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cube([RECV_W, 20, 8], center = true);
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// Ghost pogo pins
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for (px = [-POGO_SPACING/2, POGO_SPACING/2])
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%color("Gold", 0.60)
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translate([px, -POGO_PROTRUDE, BASE_T + POGO_Z])
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rotate([90, 0, 0])
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cylinder(d = POGO_D, h = POGO_L);
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}
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// ============================================================
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// PART A — DOCK BASE PLATE
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// ============================================================
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module dock_base() {
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difference() {
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// ── Main base block (rounded rect) ──────────────────────────
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linear_extrude(BASE_T)
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minkowski() {
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square([BASE_W - 2*BASE_R,
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BASE_D - 2*BASE_R], center = true);
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circle(r = BASE_R);
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}
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// ── Ballast pockets (underside) ──────────────────────────────
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// 4× pockets: 2 front, 2 rear
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for (bx = [-1, 1])
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for (by = [-1, 1])
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translate([bx * (BASE_W/2 - BALLAST_INSET_X),
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by * (BASE_D/2 - BALLAST_INSET_Y),
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-e])
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cube([BALLAST_W, BALLAST_D, BALLAST_T + e], center = true);
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// ── Floor bolt holes (M8, 4 corners) ────────────────────────
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for (bx = [-1, 1])
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for (by = [-1, 1])
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translate([bx * (BASE_W/2 - FLOOR_BOLT_INSET_X),
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by * (BASE_D/2 - FLOOR_BOLT_INSET_Y), -e])
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cylinder(d = FLOOR_BOLT_D, h = BASE_T + 2*e);
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// ── Back wall attachment slots (M4, top face) ─────────────────
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for (bx = [-WALL_W/2 + 30, 0, WALL_W/2 - 30])
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translate([bx, -BASE_D/4, BASE_T - 3])
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cylinder(d = M4_D, h = 4 + e);
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// ── Guide rail attachment holes (M4) ──────────────────────────
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for (side = [-1, 1])
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for (gy = [20, GUIDE_L - 20])
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translate([side * (EXIT_GAP/2 + GUIDE_T/2), gy, BASE_T - 3])
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cylinder(d = M4_D, h = 4 + e);
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// ── Cable routing slot (from pogo wires to PSU, through base) ─
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translate([0, -WALL_T - 5, -e])
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cube([WIRE_CH_W, 15, BASE_T + 2*e], center = true);
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// ── Anti-skid texture (front face chamfer) ───────────────────
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// Chamfer front-bottom edge for easy robot approach
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translate([0, BASE_D/2 + e, -e])
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rotate([45, 0, 0])
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cube([BASE_W + 2*e, 5, 5], center = true);
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}
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}
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// ============================================================
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// PART B — BACK WALL (upright panel)
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// ============================================================
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module back_wall() {
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difference() {
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union() {
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// ── Wall slab ────────────────────────────────────────────
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translate([-WALL_W/2, -WALL_T, 0])
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cube([WALL_W, WALL_T, WALL_H]);
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// ── Pogo pin housing bosses (front face) ─────────────────
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for (px = [-POGO_SPACING/2, POGO_SPACING/2])
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translate([px, -WALL_T, POGO_Z])
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rotate([90, 0, 0])
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cylinder(d = POGO_FLANGE_D + 6,
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h = POGO_PROTRUDE);
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// ── Wiring channel reinforcement (inside wall face) ───────
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translate([-WIRE_CH_W/2 - 2, -WALL_T, 0])
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cube([WIRE_CH_W + 4, 4, WIRE_CH_H]);
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}
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||||||
|
// ── Pogo pin bores (through wall into housing boss) ───────────
|
||||||
|
for (px = [-POGO_SPACING/2, POGO_SPACING/2])
|
||||||
|
translate([px, POGO_PROTRUDE + e, POGO_Z])
|
||||||
|
rotate([90, 0, 0]) {
|
||||||
|
// Main bore (full depth through wall + boss)
|
||||||
|
cylinder(d = POGO_BORE_D,
|
||||||
|
h = WALL_T + POGO_PROTRUDE + 2*e);
|
||||||
|
// Flange shoulder counterbore (retains pogo from pulling out)
|
||||||
|
translate([0, 0, WALL_T + POGO_PROTRUDE - POGO_FLANGE_T - 1])
|
||||||
|
cylinder(d = POGO_FLANGE_D + 0.4,
|
||||||
|
h = POGO_FLANGE_T + 2);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Wiring channel (vertical slot, inside face → base cable hole) ─
|
||||||
|
translate([-WIRE_CH_W/2, 0 + e, 0])
|
||||||
|
cube([WIRE_CH_W, WALL_T/2, WIRE_CH_H]);
|
||||||
|
|
||||||
|
// ── LED bezel recess (in front face, above pogo) ──────────────
|
||||||
|
translate([-LED_BEZEL_W/2, -LED_BEZEL_T, LED_Z - LED_BEZEL_H/2])
|
||||||
|
cube([LED_BEZEL_W, LED_BEZEL_T + e, LED_BEZEL_H]);
|
||||||
|
|
||||||
|
// ── M4 base attachment bores (3 through bottom of wall) ───────
|
||||||
|
for (bx = [-WALL_W/2 + 30, 0, WALL_W/2 - 30])
|
||||||
|
translate([bx, -WALL_T/2, -e])
|
||||||
|
cylinder(d = M4_D, h = 8 + e);
|
||||||
|
|
||||||
|
// ── Cable tie slots (in wall body, for neat wire routing) ─────
|
||||||
|
for (cz = [15, POGO_Z - 15])
|
||||||
|
translate([WIRE_CH_W/2 + 3, -WALL_T/2, cz])
|
||||||
|
cube([4, WALL_T + 2*e, 3], center = true);
|
||||||
|
|
||||||
|
// ── Lightening cutout (rear face pocket) ──────────────────────
|
||||||
|
translate([-WALL_W/2 + 40, 0, 20])
|
||||||
|
cube([WALL_W - 80, WALL_T/2 + e, WALL_H - 30]);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART C — V-GUIDE RAIL
|
||||||
|
// ============================================================
|
||||||
|
// Print 2×; mirror in X for right side.
|
||||||
|
// Rail tapers from ENTRY_GAP/2 (at Y=GUIDE_L) to EXIT_GAP/2 (at Y=0).
|
||||||
|
// Inner (guiding) face is angled; outer face is vertical.
|
||||||
|
module guide_rail(side = "left") {
|
||||||
|
// Inner face X at back wall = EXIT_GAP/2
|
||||||
|
// Inner face X at entry = ENTRY_GAP/2
|
||||||
|
x_back = EXIT_GAP/2; // 16 mm
|
||||||
|
x_entry = ENTRY_GAP/2; // 35 mm
|
||||||
|
|
||||||
|
difference() {
|
||||||
|
union() {
|
||||||
|
// ── Main wedge body ─────────────────────────────────────
|
||||||
|
// Hull between two rectangles: narrow at Y=0, wide at Y=GUIDE_L
|
||||||
|
hull() {
|
||||||
|
// Back end (at Y=0, flush with back wall)
|
||||||
|
translate([x_back, 0, 0])
|
||||||
|
cube([GUIDE_T, e, GUIDE_H]);
|
||||||
|
// Entry end (at Y=GUIDE_L)
|
||||||
|
translate([x_entry, GUIDE_L, 0])
|
||||||
|
cube([GUIDE_T, e, GUIDE_H]);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Entry flare (chamfered lip at guide entry for bump-entry) ─
|
||||||
|
hull() {
|
||||||
|
translate([x_entry, GUIDE_L, 0])
|
||||||
|
cube([GUIDE_T, e, GUIDE_H]);
|
||||||
|
translate([x_entry + 15, GUIDE_L + 20, 0])
|
||||||
|
cube([GUIDE_T, e, GUIDE_H * 0.6]);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── M4 base attachment bores ─────────────────────────────────
|
||||||
|
for (gy = [20, GUIDE_L - 20])
|
||||||
|
translate([x_back + GUIDE_T/2, gy, -e])
|
||||||
|
cylinder(d = M4_D, h = 8 + e);
|
||||||
|
|
||||||
|
// ── Chamfer on inner top corner (smooth robot entry) ─────────
|
||||||
|
translate([x_back - e, -e, GUIDE_H - 5])
|
||||||
|
rotate([0, -45, 0])
|
||||||
|
cube([8, GUIDE_L + 30, 8]);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART D — ArUco MARKER MOUNT
|
||||||
|
// ============================================================
|
||||||
|
// Free-standing mast at dock entry. Mounts to base plate.
|
||||||
|
// Marker face tilted 15° toward approaching robot.
|
||||||
|
// Accepts 100×100 mm printed/laminated paper marker in slot.
|
||||||
|
module aruco_mount() {
|
||||||
|
frame_w = ARUCO_MARKER_W + 2*ARUCO_FRAME_BDR;
|
||||||
|
frame_h = ARUCO_MARKER_H + 2*ARUCO_FRAME_BDR;
|
||||||
|
mast_y = ARUCO_Y;
|
||||||
|
|
||||||
|
union() {
|
||||||
|
// ── Mast column ───────────────────────────────────────────────
|
||||||
|
translate([-ARUCO_MAST_W/2, mast_y - ARUCO_MAST_W/2, 0])
|
||||||
|
cube([ARUCO_MAST_W, ARUCO_MAST_W, ARUCO_MAST_H]);
|
||||||
|
|
||||||
|
// ── Marker frame (tilted back ARUCO_TILT°) ────────────────────
|
||||||
|
translate([0, mast_y, ARUCO_MAST_H])
|
||||||
|
rotate([-ARUCO_TILT, 0, 0]) {
|
||||||
|
difference() {
|
||||||
|
// Frame plate
|
||||||
|
translate([-frame_w/2, -ARUCO_FRAME_T, -frame_h/2])
|
||||||
|
cube([frame_w, ARUCO_FRAME_T, frame_h]);
|
||||||
|
|
||||||
|
// Marker window (cutout for marker visibility)
|
||||||
|
translate([-ARUCO_MARKER_W/2, -ARUCO_FRAME_T - e,
|
||||||
|
-ARUCO_MARKER_H/2])
|
||||||
|
cube([ARUCO_MARKER_W,
|
||||||
|
ARUCO_FRAME_T + 2*e,
|
||||||
|
ARUCO_MARKER_H]);
|
||||||
|
|
||||||
|
// Marker slip-in slot (insert from side)
|
||||||
|
translate([-frame_w/2 - e,
|
||||||
|
-ARUCO_SLOT_T - 0.3,
|
||||||
|
-ARUCO_MARKER_H/2])
|
||||||
|
cube([frame_w + 2*e,
|
||||||
|
ARUCO_SLOT_T + 0.3,
|
||||||
|
ARUCO_MARKER_H]);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Mast base foot (M4 bolts to dock base) ────────────────────
|
||||||
|
difference() {
|
||||||
|
translate([-20, mast_y - 20, 0])
|
||||||
|
cube([40, 40, 5]);
|
||||||
|
for (fx = [-12, 12]) for (fy = [-12, 12])
|
||||||
|
translate([fx, mast_y + fy, -e])
|
||||||
|
cylinder(d = M4_D, h = 6 + e);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART E — PSU BRACKET
|
||||||
|
// ============================================================
|
||||||
|
// Open-top retention bracket for PSU module.
|
||||||
|
// PSU slides in from top; 2× M3 straps or cable ties retain it.
|
||||||
|
// Bracket bolts to base plate via 4× M4 screws.
|
||||||
|
module psu_bracket() {
|
||||||
|
difference() {
|
||||||
|
union() {
|
||||||
|
// ── Outer bracket box (open top) ─────────────────────────
|
||||||
|
_box_open_top(PSU_W + 2*PSU_T,
|
||||||
|
PSU_D + 2*PSU_T,
|
||||||
|
PSU_H + PSU_T);
|
||||||
|
|
||||||
|
// ── Base flange ──────────────────────────────────────────
|
||||||
|
translate([-(PSU_W/2 + PSU_T + 8),
|
||||||
|
-(PSU_D/2 + PSU_T + 8), -PSU_T])
|
||||||
|
cube([PSU_W + 2*PSU_T + 16,
|
||||||
|
PSU_D + 2*PSU_T + 16, PSU_T]);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── PSU cavity ───────────────────────────────────────────────
|
||||||
|
translate([0, 0, PSU_T])
|
||||||
|
cube([PSU_W, PSU_D, PSU_H + e], center = true);
|
||||||
|
|
||||||
|
// ── Ventilation slots (sides) ─────────────────────────────────
|
||||||
|
for (a = [0, 90, 180, 270])
|
||||||
|
rotate([0, 0, a])
|
||||||
|
translate([0, (PSU_D/2 + PSU_T)/2, PSU_H/2 + PSU_T])
|
||||||
|
for (sz = [-PSU_H/4, 0, PSU_H/4])
|
||||||
|
translate([0, 0, sz])
|
||||||
|
cube([PSU_W * 0.5, PSU_T + 2*e, 5],
|
||||||
|
center = true);
|
||||||
|
|
||||||
|
// ── Cable exit slot (bottom) ──────────────────────────────────
|
||||||
|
translate([0, 0, -e])
|
||||||
|
cube([15, PSU_D + 2*PSU_T + 2*e, PSU_T + 2*e],
|
||||||
|
center = true);
|
||||||
|
|
||||||
|
// ── Base flange M4 bolts ──────────────────────────────────────
|
||||||
|
for (fx = [-1, 1]) for (fy = [-1, 1])
|
||||||
|
translate([fx * (PSU_W/2 + PSU_T + 4),
|
||||||
|
fy * (PSU_D/2 + PSU_T + 4),
|
||||||
|
-PSU_T - e])
|
||||||
|
cylinder(d = M4_D, h = PSU_T + 2*e);
|
||||||
|
|
||||||
|
// ── Cable tie slots ───────────────────────────────────────────
|
||||||
|
for (sz = [PSU_H/3, 2*PSU_H/3])
|
||||||
|
translate([0, 0, PSU_T + sz])
|
||||||
|
cube([PSU_W + 2*PSU_T + 2*e, 4, 4], center = true);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
module _box_open_top(w, d, h) {
|
||||||
|
difference() {
|
||||||
|
cube([w, d, h], center = true);
|
||||||
|
translate([0, 0, PSU_T + e])
|
||||||
|
cube([w - 2*PSU_T, d - 2*PSU_T, h], center = true);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART F — LED STATUS BEZEL
|
||||||
|
// ============================================================
|
||||||
|
// 4 × 5 mm LEDs in a row. Press-fits into recess in back wall.
|
||||||
|
// LED labels (L→R): SEARCHING | ALIGNED | CHARGING | FULL
|
||||||
|
// Suggested colours: Red | Yellow | Blue | Green
|
||||||
|
module led_bezel() {
|
||||||
|
difference() {
|
||||||
|
// Bezel plate
|
||||||
|
cube([LED_BEZEL_W, LED_BEZEL_T, LED_BEZEL_H], center = true);
|
||||||
|
|
||||||
|
// 4× LED bores
|
||||||
|
for (i = [-1.5, -0.5, 0.5, 1.5])
|
||||||
|
translate([i * LED_SPACING, -LED_BEZEL_T - e, 0])
|
||||||
|
rotate([90, 0, 0]) {
|
||||||
|
// LED body bore (recess, not through)
|
||||||
|
cylinder(d = LED_BORE_D + 1,
|
||||||
|
h = LED_INSET_D + e);
|
||||||
|
// LED pin bore (through bezel)
|
||||||
|
translate([0, 0, LED_INSET_D])
|
||||||
|
cylinder(d = LED_BORE_D,
|
||||||
|
h = LED_BEZEL_T + 2*e);
|
||||||
|
}
|
||||||
|
|
||||||
|
// Label recesses between LEDs (for colour-dot stickers or printed inserts)
|
||||||
|
for (i = [-1.5, -0.5, 0.5, 1.5])
|
||||||
|
translate([i * LED_SPACING, LED_BEZEL_T/2, LED_BEZEL_H/2 - 3])
|
||||||
|
cube([LED_SPACING - 3, 1 + e, 5], center = true);
|
||||||
|
|
||||||
|
// M3 mounting holes (2× into back wall)
|
||||||
|
for (mx = [-LED_BEZEL_W/2 + 6, LED_BEZEL_W/2 - 6])
|
||||||
|
translate([mx, -LED_BEZEL_T - e, 0])
|
||||||
|
rotate([90, 0, 0])
|
||||||
|
cylinder(d = M3_D, h = LED_BEZEL_T + 2*e);
|
||||||
|
}
|
||||||
|
}
|
||||||
332
chassis/charging_dock_receiver_505.scad
Normal file
332
chassis/charging_dock_receiver_505.scad
Normal file
@ -0,0 +1,332 @@
|
|||||||
|
// ============================================================
|
||||||
|
// charging_dock_receiver_505.scad — Robot-Side Charging Receiver (24V)
|
||||||
|
// Issue: #505 Agent: sl-mechanical Date: 2026-03-06
|
||||||
|
// ============================================================
|
||||||
|
//
|
||||||
|
// Robot-side contact plate that mates with the 24V charging dock pogo pins.
|
||||||
|
// Forked from Issue #159 receiver (contact geometry unchanged; 12 AWG wire bore).
|
||||||
|
// Each robot variant has a different mounting interface; the contact
|
||||||
|
// geometry is identical across all variants (same pogo pin spacing).
|
||||||
|
//
|
||||||
|
// Variants:
|
||||||
|
// A — lab_receiver() SaltyLab — mounts to underside of stem base ring
|
||||||
|
// B — rover_receiver() SaltyRover — mounts to chassis belly (M4 deck holes)
|
||||||
|
// C — tank_receiver() SaltyTank — mounts to skid plate / hull floor
|
||||||
|
//
|
||||||
|
// Contact geometry (common across variants):
|
||||||
|
// 2× brass contact pads, Ø12 mm × 2 mm (press-fit into PETG housing)
|
||||||
|
// Pad spacing: 20 mm CL-to-CL (matches dock POGO_SPACING exactly)
|
||||||
|
// Contact face Z height matches dock pogo pin Z when robot is level
|
||||||
|
// Polarity: marked + on top pin (conventional: positive = right when
|
||||||
|
// facing dock; negative = left) — must match dock wiring.
|
||||||
|
//
|
||||||
|
// Approach guide nose:
|
||||||
|
// A chamfered V-nose on the forward face guides the receiver block
|
||||||
|
// into the dock's V-funnel. Taper half-angle ≈ 14° matches guide rails.
|
||||||
|
// Nose width = RECV_W = 30 mm (matches dock EXIT_GAP - 2 mm clearance).
|
||||||
|
//
|
||||||
|
// Coordinate convention:
|
||||||
|
// Z = 0 at receiver mounting face (against robot chassis/deck underside).
|
||||||
|
// +Z points downward (toward dock floor).
|
||||||
|
// Contact pads face +Y (toward dock back wall when docked).
|
||||||
|
// Receiver centred on X = 0 (robot centreline).
|
||||||
|
//
|
||||||
|
// RENDER options:
|
||||||
|
// "assembly" all 3 receivers side by side
|
||||||
|
// "lab_stl" SaltyLab receiver (print 1×)
|
||||||
|
// "rover_stl" SaltyRover receiver (print 1×)
|
||||||
|
// "tank_stl" SaltyTank receiver (print 1×)
|
||||||
|
// "contact_pad_2d" DXF — Ø12 mm brass pad profile (order from metal shop)
|
||||||
|
//
|
||||||
|
// Export (Issue #505 24V variant):
|
||||||
|
// openscad charging_dock_receiver_505.scad -D 'RENDER="lab_stl"' -o receiver_505_lab.stl
|
||||||
|
// openscad charging_dock_receiver_505.scad -D 'RENDER="rover_stl"' -o receiver_505_rover.stl
|
||||||
|
// openscad charging_dock_receiver_505.scad -D 'RENDER="tank_stl"' -o receiver_505_tank.stl
|
||||||
|
// openscad charging_dock_receiver_505.scad -D 'RENDER="contact_pad_2d"' -o contact_pad_505.dxf
|
||||||
|
// ============================================================
|
||||||
|
|
||||||
|
$fn = 64;
|
||||||
|
e = 0.01;
|
||||||
|
|
||||||
|
// ── Contact geometry (must match charging_dock.scad) ─────────────────────────
|
||||||
|
POGO_SPACING = 20.0; // CL-to-CL (dock POGO_SPACING)
|
||||||
|
PAD_D = 12.0; // contact pad OD (brass disc)
|
||||||
|
PAD_T = 2.0; // contact pad thickness
|
||||||
|
PAD_RECESS = 1.8; // pad pressed into housing (0.2 mm proud for contact)
|
||||||
|
PAD_PROUD = 0.2; // pad face protrudes from housing face
|
||||||
|
|
||||||
|
// ── Common receiver body geometry ────────────────────────────────────────────
|
||||||
|
RECV_W = 30.0; // receiver body width (X) — matches dock EXIT_GAP inner
|
||||||
|
RECV_D = 25.0; // receiver body depth (Y, docking direction)
|
||||||
|
RECV_H = 12.0; // receiver body height (Z, from mount face down)
|
||||||
|
RECV_R = 3.0; // corner radius
|
||||||
|
// V-nose geometry (front Y face — faces dock back wall)
|
||||||
|
NOSE_CHAMFER = 10.0; // chamfer depth on X corners of front face
|
||||||
|
|
||||||
|
// Polarity indicator slot (on top/mount face: + on right, - on left)
|
||||||
|
POL_SLOT_W = 4.0;
|
||||||
|
POL_SLOT_D = 8.0;
|
||||||
|
POL_SLOT_H = 1.0;
|
||||||
|
|
||||||
|
// Fasteners
|
||||||
|
M2_D = 2.4;
|
||||||
|
M3_D = 3.3;
|
||||||
|
M4_D = 4.3;
|
||||||
|
|
||||||
|
// ── Mounting patterns ─────────────────────────────────────────────────────────
|
||||||
|
// SaltyLab stem base ring (Ø25 mm stem, 4× M3 in ring at Ø40 mm BC)
|
||||||
|
LAB_BC_D = 40.0;
|
||||||
|
LAB_BOLT_D = M3_D;
|
||||||
|
LAB_COLLAR_H = 15.0; // collar height above receiver body
|
||||||
|
|
||||||
|
// SaltyRover deck (M4 grid pattern, 30.5×30.5 mm matching FC pattern on deck)
|
||||||
|
// Receiver uses 4× M4 holes at ±20 mm from centre (clear of deck electronics)
|
||||||
|
ROVER_BOLT_SPC = 40.0;
|
||||||
|
|
||||||
|
// SaltyTank skid plate (M4 holes matching skid plate bolt pattern)
|
||||||
|
// Uses 4× M4 at ±20 mm X, ±10 mm Y (inset from skid plate M4 positions)
|
||||||
|
TANK_BOLT_SPC_X = 40.0;
|
||||||
|
TANK_BOLT_SPC_Y = 20.0;
|
||||||
|
TANK_NOSE_L = 20.0; // extended nose for tank (wider hull)
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// RENDER DISPATCH
|
||||||
|
// ============================================================
|
||||||
|
RENDER = "assembly";
|
||||||
|
|
||||||
|
if (RENDER == "assembly") assembly();
|
||||||
|
else if (RENDER == "lab_stl") lab_receiver();
|
||||||
|
else if (RENDER == "rover_stl") rover_receiver();
|
||||||
|
else if (RENDER == "tank_stl") tank_receiver();
|
||||||
|
else if (RENDER == "contact_pad_2d") {
|
||||||
|
projection(cut = true) translate([0, 0, -0.5])
|
||||||
|
linear_extrude(1) circle(d = PAD_D);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// ASSEMBLY PREVIEW
|
||||||
|
// ============================================================
|
||||||
|
module assembly() {
|
||||||
|
// SaltyLab receiver
|
||||||
|
color("RoyalBlue", 0.85)
|
||||||
|
translate([-80, 0, 0])
|
||||||
|
lab_receiver();
|
||||||
|
|
||||||
|
// SaltyRover receiver
|
||||||
|
color("OliveDrab", 0.85)
|
||||||
|
translate([0, 0, 0])
|
||||||
|
rover_receiver();
|
||||||
|
|
||||||
|
// SaltyTank receiver
|
||||||
|
color("SaddleBrown", 0.85)
|
||||||
|
translate([80, 0, 0])
|
||||||
|
tank_receiver();
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// COMMON RECEIVER BODY
|
||||||
|
// ============================================================
|
||||||
|
// Internal helper: the shared contact housing + V-nose.
|
||||||
|
// Orientation: mount face = +Z top; contact face = +Y front.
|
||||||
|
// All variant-specific modules call this, then add their mount interface.
|
||||||
|
module _receiver_body() {
|
||||||
|
difference() {
|
||||||
|
union() {
|
||||||
|
// ── Main housing block (rounded) ─────────────────────────
|
||||||
|
linear_extrude(RECV_H)
|
||||||
|
_recv_profile_2d();
|
||||||
|
|
||||||
|
// ── V-nose chamfer reinforcement ribs ─────────────────────
|
||||||
|
// Two diagonal ribs at 45° reinforce the chamfered corners
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
hull() {
|
||||||
|
translate([sx*(RECV_W/2 - NOSE_CHAMFER),
|
||||||
|
RECV_D/2, 0])
|
||||||
|
cylinder(d = 3, h = RECV_H * 0.6);
|
||||||
|
translate([sx*(RECV_W/2), RECV_D/2 - NOSE_CHAMFER, 0])
|
||||||
|
cylinder(d = 3, h = RECV_H * 0.6);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Contact pad bores (2× Ø12 mm, press-fit) ─────────────────
|
||||||
|
// Pads face +Y; bores from Y face into housing
|
||||||
|
for (px = [-POGO_SPACING/2, POGO_SPACING/2])
|
||||||
|
translate([px, RECV_D/2 + e, RECV_H/2])
|
||||||
|
rotate([90, 0, 0]) {
|
||||||
|
// Pad press-fit bore
|
||||||
|
cylinder(d = PAD_D + 0.1,
|
||||||
|
h = PAD_RECESS + e);
|
||||||
|
// Wire bore (behind pad, to mount face)
|
||||||
|
translate([0, 0, PAD_RECESS])
|
||||||
|
cylinder(d = 3.0,
|
||||||
|
h = RECV_D + 2*e);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Polarity indicator slots on top face ──────────────────────
|
||||||
|
// "+" slot: right pad (+X side)
|
||||||
|
translate([POGO_SPACING/2, 0, -e])
|
||||||
|
cube([POL_SLOT_W, POL_SLOT_D, POL_SLOT_H + e], center = true);
|
||||||
|
// "-" indent: left pad (no slot = negative)
|
||||||
|
|
||||||
|
// ── Wire routing channel (on mount face / underside) ──────────
|
||||||
|
// Trough connecting both pad bores for neat wire run
|
||||||
|
translate([0, RECV_D/2 - POGO_SPACING/2, RECV_H - 3])
|
||||||
|
cube([POGO_SPACING + 6, POGO_SPACING, 4], center = true);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── 2D profile of receiver body with chamfered V-nose ────────────────────────
|
||||||
|
module _recv_profile_2d() {
|
||||||
|
hull() {
|
||||||
|
// Rear corners (full width)
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
translate([sx*(RECV_W/2 - RECV_R), -RECV_D/2 + RECV_R])
|
||||||
|
circle(r = RECV_R);
|
||||||
|
// Front corners (chamfered — narrowed by NOSE_CHAMFER)
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
translate([sx*(RECV_W/2 - NOSE_CHAMFER - RECV_R),
|
||||||
|
RECV_D/2 - RECV_R])
|
||||||
|
circle(r = RECV_R);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART A — SALTYLAB RECEIVER
|
||||||
|
// ============================================================
|
||||||
|
// Mounts to the underside of the SaltyLab chassis stem base ring.
|
||||||
|
// Split collar grips Ø25 mm stem; receiver body hangs below collar.
|
||||||
|
// Z height set so contact pads align with dock pogo pins when robot
|
||||||
|
// rests on flat surface (robot wheel-to-contact-pad height calibrated).
|
||||||
|
//
|
||||||
|
// Receiver height above floor: tune LAB_CONTACT_Z in firmware (UWB/ArUco
|
||||||
|
// approach). Mechanically: receiver sits ~35 mm above ground (stem base
|
||||||
|
// height), matching dock POGO_Z = 35 mm.
|
||||||
|
module lab_receiver() {
|
||||||
|
collar_od = 46.0; // matches sensor_rail.scad STEM_COL_OD
|
||||||
|
collar_h = LAB_COLLAR_H;
|
||||||
|
|
||||||
|
union() {
|
||||||
|
// ── Common receiver body ────────────────────────────────────
|
||||||
|
_receiver_body();
|
||||||
|
|
||||||
|
// ── Stem collar (split, 2 halves joined with M4 bolts) ───────
|
||||||
|
// Only the front half printed here; rear half is mirror.
|
||||||
|
translate([0, -RECV_D/2, RECV_H])
|
||||||
|
difference() {
|
||||||
|
// Half-collar cylinder
|
||||||
|
rotate_extrude(angle = 180)
|
||||||
|
translate([collar_od/2 - 8, 0, 0])
|
||||||
|
square([8, collar_h]);
|
||||||
|
|
||||||
|
// Stem bore clearance
|
||||||
|
translate([0, 0, -e])
|
||||||
|
cylinder(d = 25.5, h = collar_h + 2*e);
|
||||||
|
|
||||||
|
// 2× M4 clamping bolt bores (through collar flanges)
|
||||||
|
for (cx = [-collar_od/2 + 4, collar_od/2 - 4])
|
||||||
|
translate([cx, 0, collar_h/2])
|
||||||
|
rotate([90, 0, 0])
|
||||||
|
cylinder(d = M4_D,
|
||||||
|
h = collar_od + 2*e,
|
||||||
|
center = true);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── M3 receiver-to-collar bolts ───────────────────────────────
|
||||||
|
// 4× M3 holes connecting collar flange to receiver body top
|
||||||
|
// (These are mounting holes for assembly; not holes in the part)
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART B — SALTYOVER RECEIVER
|
||||||
|
// ============================================================
|
||||||
|
// Mounts to the underside of the SaltyRover deck plate.
|
||||||
|
// 4× M4 bolts into deck underside (blind holes tapped in deck).
|
||||||
|
// Receiver sits flush with deck belly; contact pads protrude 5 mm below.
|
||||||
|
// Dock pogo Z = 35 mm must equal ground-to-deck-belly height for rover
|
||||||
|
// (approximately 60 mm chassis clearance — shim with spacer if needed).
|
||||||
|
module rover_receiver() {
|
||||||
|
mount_h = 5.0; // mounting flange thickness
|
||||||
|
|
||||||
|
union() {
|
||||||
|
// ── Common receiver body ────────────────────────────────────
|
||||||
|
_receiver_body();
|
||||||
|
|
||||||
|
// ── Mounting flange (attaches to deck belly) ─────────────────
|
||||||
|
difference() {
|
||||||
|
translate([-(ROVER_BOLT_SPC/2 + 12),
|
||||||
|
-RECV_D/2 - 10,
|
||||||
|
RECV_H])
|
||||||
|
cube([ROVER_BOLT_SPC + 24,
|
||||||
|
RECV_D + 20,
|
||||||
|
mount_h]);
|
||||||
|
|
||||||
|
// 4× M4 bolt holes
|
||||||
|
for (fx = [-1, 1]) for (fy = [-1, 1])
|
||||||
|
translate([fx*ROVER_BOLT_SPC/2,
|
||||||
|
fy*(RECV_D/2 + 5),
|
||||||
|
RECV_H - e])
|
||||||
|
cylinder(d = M4_D,
|
||||||
|
h = mount_h + 2*e);
|
||||||
|
|
||||||
|
// Weight-reduction pockets
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
translate([sx*(ROVER_BOLT_SPC/4 + 6),
|
||||||
|
0, RECV_H + 1])
|
||||||
|
cube([ROVER_BOLT_SPC/2 - 4, RECV_D - 4, mount_h],
|
||||||
|
center = true);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
}
|
||||||
|
|
||||||
|
// ============================================================
|
||||||
|
// PART C — SALTYTANK RECEIVER
|
||||||
|
// ============================================================
|
||||||
|
// Mounts to SaltyTank hull floor or replaces a section of skid plate.
|
||||||
|
// Extended front nose (TANK_NOSE_L) for tank's wider hull approach.
|
||||||
|
// Contact pads exposed through skid plate via a 30×16 mm slot.
|
||||||
|
// Ground clearance: tank chassis = 90 mm; dock POGO_Z = 35 mm.
|
||||||
|
// Use ramp shim (see BOM) under dock base to elevate pogo pins to 90 mm
|
||||||
|
// OR set POGO_Z = 90 in dock for a tank-specific dock configuration.
|
||||||
|
// ⚠ Cross-variant dock: set POGO_Z per robot if heights differ.
|
||||||
|
// Compromise: POGO_Z = 60 mm with 25 mm ramp for tank, 25 mm spacer for lab.
|
||||||
|
module tank_receiver() {
|
||||||
|
mount_h = 4.0;
|
||||||
|
nose_l = RECV_D/2 + TANK_NOSE_L;
|
||||||
|
|
||||||
|
union() {
|
||||||
|
// ── Common receiver body ────────────────────────────────────
|
||||||
|
_receiver_body();
|
||||||
|
|
||||||
|
// ── Extended nose for tank approach ──────────────────────────
|
||||||
|
// Additional chamfered wedge ahead of standard receiver body
|
||||||
|
hull() {
|
||||||
|
// Receiver front face corners
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
translate([sx*(RECV_W/2 - NOSE_CHAMFER), RECV_D/2, 0])
|
||||||
|
cylinder(d = 2*RECV_R, h = RECV_H * 0.5);
|
||||||
|
// Extended nose tip (narrowed to 20 mm)
|
||||||
|
for (sx = [-1, 1])
|
||||||
|
translate([sx*10, RECV_D/2 + TANK_NOSE_L, 0])
|
||||||
|
cylinder(d = 2*RECV_R, h = RECV_H * 0.4);
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Mounting flange (bolts to tank skid plate) ────────────────
|
||||||
|
difference() {
|
||||||
|
translate([-(TANK_BOLT_SPC_X/2 + 10),
|
||||||
|
-RECV_D/2 - 8,
|
||||||
|
RECV_H])
|
||||||
|
cube([TANK_BOLT_SPC_X + 20,
|
||||||
|
RECV_D + 16,
|
||||||
|
mount_h]);
|
||||||
|
|
||||||
|
// 4× M4 bolt holes
|
||||||
|
for (fx = [-1, 1]) for (fy = [-1, 1])
|
||||||
|
translate([fx*TANK_BOLT_SPC_X/2,
|
||||||
|
fy*TANK_BOLT_SPC_Y/2,
|
||||||
|
RECV_H - e])
|
||||||
|
cylinder(d = M4_D,
|
||||||
|
h = mount_h + 2*e);
|
||||||
|
}
|
||||||
|
}
|
||||||
|
}
|
||||||
Loading…
x
Reference in New Issue
Block a user