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feat: ROS2 sensor health monitor (Issue #566) #572

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sl-jetson merged 2 commits from sl-jetson/issue-566-health-monitor into main 2026-03-14 11:49:56 -04:00
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chassis/uwb_anchor_mount.scad
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// ============================================================
// uwb_anchor_mount.scad — Stem-Mounted UWB Anchor Rev A
// Agent: sl-mechanical 2026-03-01
// Closes issues #57, #62
// 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)
// ============================================================
// Clamp-on bracket for 2× MaUWB ESP32-S3 anchor modules on
// SaltyBot 25 mm OD vertical stem.
// Anchors spaced ANCHOR_SPACING = 250 mm apart.
//
// Features:
// • Split D-collar with M4 clamping bolts + M4 set screw
// • Anti-rotation flat tab that keys against a small pin
// OR printed key tab that registers on the stem flat (if stem
// has a ground flat) — see ANTI_ROT_MODE parameter
// • Module bracket: faces outward, tilted 10° from vertical
// so antenna clears stem and faces horizon
// • USB cable channel (power from Orin via USB-A) on collar
// • Tool-free capture: M4 thumbscrews (slot-head, hand-tighten)
// • UWB antenna area: NO material within 10 mm of PCB top face
// 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.
//
// Components per mount:
// 2× collar_half print in PLA/PETG, flat-face-down
// 1× module_bracket print in PLA/PETG, flat-face-down
// Architecture:
// Wall base → flat backplate with 2× screw holes (wall or ceiling)
// Tilt knuckle → single-axis articulating joint; 15° detent steps
// locked with M3 nyloc bolt; range 0–90°
// 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:
// 2× M4 × 30 mm wood screws (or #6 drywall screws) wall fasteners
// 1× M3 × 20 mm SHCS + M3 nyloc nut tilt pivot bolt
// 4× M2.5 × 8 mm SHCS PCB-to-cradle
// 4× M2.5 hex nuts captured in standoffs
// 1× USB-C cable anchor power
//
// ESP32 UWB Pro interface (verify with calipers):
// PCB size : UWB_L × UWB_W × UWB_H (55 × 28 × 10 mm default)
// Mounting holes : M2.5, 4× corners on UWB_HOLE_X × UWB_HOLE_Y pattern
// USB-C port : centred on short edge, UWB_USBC_W × UWB_USBC_H
// Antenna area : top face rear half — 10 mm keep-out of bracket material
//
// Tilt angles (15° detent steps, set TILT_DEG before export):
// 0° → horizontal face-up (ceiling, antenna faces down)
// 30° → 30° downward (wall near ceiling) [default]
// 45° → diagonal (wall mid-height)
// 90° → vertical face-out (wall, antenna faces forward)
//
// RENDER options:
// "assembly" single mount assembled (default)
// "collar_front" front collar half for slicing (×2 per mount × 2 mounts = 4)
// "collar_rear" rear collar half
// "bracket" module bracket (×2 mounts)
// "pair" both mounts on 350 mm stem section
// "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, 0–90°, 15° steps) ───────────────────────
TILT_DEG = 30;
// ── ESP32 UWB Pro PCB dimensions (verify with calipers) ──────────────────────
UWB_L = 55.0; // PCB length
UWB_W = 28.0; // PCB width
UWB_H = 10.0; // PCB + components height
UWB_HOLE_X = 47.5; // M2.5 hole X span
UWB_HOLE_Y = 21.0; // M2.5 hole Y span
UWB_USBC_W = 9.5; // USB-C receptacle width
UWB_USBC_H = 4.0; // USB-C receptacle height
UWB_ANTENNA_L = 20.0; // antenna area at PCB rear (keep-out)
// ── Wall base geometry ────────────────────────────────────────────────────────
BASE_W = 60.0;
BASE_H = 50.0;
BASE_T = 5.0;
BASE_SCREW_D = 4.5; // M4 clearance
BASE_SCREW_HD = 8.5; // countersink OD
BASE_SCREW_HH = 3.5; // countersink depth
BASE_SCREW_SPC = 35.0; // Z span between screw holes
KNUCKLE_T = BASE_T + 4.0; // pivot ear depth (Y)
// ── Tilt arm geometry ─────────────────────────────────────────────────────────
ARM_W = 12.0;
ARM_T = 5.0;
ARM_L = 35.0;
PIVOT_D = 3.3; // M3 clearance
PIVOT_NUT_AF = 5.5;
PIVOT_NUT_H = 2.4;
DETENT_D = 3.2; // detent notch diameter
DETENT_R = 8.0; // detent notch radius from pivot
// ── 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; // label card thickness
// ── USB-C cable 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";
// ── ⚠ Verify with calipers ───────────────────────────────────
MAWB_L = 50.0; // PCB length
MAWB_W = 25.0; // PCB width
MAWB_H = 10.0; // PCB + components
MAWB_HOLE_X = 43.0; // M2 mounting hole X span
MAWB_HOLE_Y = 20.0; // M2 mounting hole Y span
M2_D = 2.2; // M2 clearance
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();
// ── Stem ─────────────────────────────────────────────────────
STEM_OD = 25.0;
STEM_BORE = 25.4; // +0.4 clearance
WALL = 2.0; // wall thickness (used in thumbscrew recess)
// ============================================================
// ASSEMBLY PREVIEW
// ============================================================
module assembly_preview() {
// Ghost wall surface
%color("Wheat", 0.22)
translate([-BASE_W/2, -10, -BASE_H/2])
cube([BASE_W, 10, BASE_H + 40]);
// ── Collar ───────────────────────────────────────────────────
COL_OD = 52.0;
COL_H = 30.0; // taller than sensor-head collar for rigidity
COL_BOLT_X = 19.0; // M4 bolt CL from stem axis
COL_BOLT_D = 4.5; // M4 clearance
THUMB_HEAD_D= 8.0; // M4 thumbscrew head OD (slot for access)
COL_NUT_W = 7.0; // M4 hex nut A/F
COL_NUT_H = 3.4;
// Wall base
color("OliveDrab", 0.85)
wall_base();
// Anti-rotation flat tab: a 3 mm wall tab that protrudes radially
// and bears against the bracket arm, preventing axial rotation
// without needing a stem flat.
ANTI_ROT_T = 3.0; // tab thickness (radial)
ANTI_ROT_W = 8.0; // tab width (tangential)
ANTI_ROT_Z = 4.0; // distance from collar base
// Tilt arm at TILT_DEG, pivoting at knuckle
color("SteelBlue", 0.85)
translate([0, KNUCKLE_T, 0])
rotate([TILT_DEG, 0, 0])
tilt_arm();
// USB cable channel: groove on collar outer surface, runs Z direction
// Cable routes from anchor module down to base
USB_CHAN_W = 9.0; // channel width (fits USB-A cable Ø6 mm)
USB_CHAN_D = 5.0; // channel depth
// Anchor cradle at arm end
color("DarkSlateGray", 0.85)
translate([0, KNUCKLE_T, 0])
rotate([TILT_DEG, 0, 0])
translate([0, ARM_T, ARM_L])
anchor_cradle();
// ── Module bracket ───────────────────────────────────────────
ARM_L = 20.0; // arm length from collar OD to bracket face
ARM_W = MAWB_W + 6.0; // bracket width (Y, includes side walls)
ARM_H = 6.0; // arm thickness (Z)
BRKT_TILT = 10.0; // tilt outward from vertical (antenna faces horizon)
// PCB ghost
%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]);
BRKT_BACK_T = 3.0; // bracket back wall (module sits against this)
BRKT_SIDE_T = 2.0; // bracket side walls
// Cable clip at arm mid-point
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();
}
M2_STNDFF = 3.0; // M2 standoff height
M2_STNDFF_OD= 4.5;
// USB port access notch in bracket side wall (8×5 mm)
USB_NOTCH_W = 10.0;
USB_NOTCH_H = 7.0;
// ── Spacing ───────────────────────────────────────────────────
ANCHOR_SPACING = 250.0; // centre-to-centre Z separation
$fn = 64;
e = 0.01;
// ─────────────────────────────────────────────────────────────
// collar_half(side)
// split at Y=0 plane. Bracket arm on front (+Y) half.
// Print flat-face-down.
// ─────────────────────────────────────────────────────────────
module collar_half(side = "front") {
y_front = (side == "front");
// ============================================================
// PART 1 — WALL BASE
// ============================================================
// Flat backplate screws to wall or ceiling with 2× countersunk
// M4/#6 wood screws on BASE_SCREW_SPC (35 mm) centres.
// Two pivot ears straddle the tilt arm; M3 pivot bolt passes through
// both ears and arm knuckle.
// Detent arc on inner face of +X ear: 7 notches at 15° steps (0–90°)
// so tilt can be set without a protractor.
// Shallow rear recess accepts a printed installation-zone label.
//
// Dual-use: flat face to wall (vertical screw axis) or flat face
// to ceiling (horizontal screw axis) — same part either way.
//
// 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() {
// D-shaped body
intersection() {
cylinder(d=COL_OD, h=COL_H);
translate([-COL_OD/2, y_front ? 0 : -COL_OD/2, 0])
cube([COL_OD, COL_OD/2, COL_H]);
}
// ── Backplate ────────────────────────────────────────────────
translate([-BASE_W/2, -BASE_T, -BASE_H/2])
cube([BASE_W, BASE_T, BASE_H]);
// Anti-rotation tab (front half only, at +X side)
if (y_front) {
translate([COL_OD/2, -ANTI_ROT_W/2, ANTI_ROT_Z])
cube([ANTI_ROT_T, ANTI_ROT_W,
COL_H - ANTI_ROT_Z - 4]);
}
// ── Two pivot ears ────────────────────────────────────────────
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]);
// Bracket arm attachment boss (front half only, top centre)
if (y_front) {
translate([-ARM_W/2, COL_OD/2, COL_H * 0.3])
cube([ARM_W, ARM_L, COL_H * 0.4]);
}
// ── Stiffening gussets ────────────────────────────────────────
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*0.6 : 0),
-BASE_T, -ear_h/6])
cube([ear_t * 0.4, 1, ear_h/3]);
}
}
// ── Stem bore ─────────────────────────────────────────
translate([0,0,-e])
cylinder(d=STEM_BORE, h=COL_H + 2*e);
// ── M4 clamping bolt holes (Y direction) ──────────────
for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
translate([bx, y_front ? COL_OD/2 : 0, COL_H/2])
rotate([90,0,0])
cylinder(d=COL_BOLT_D, h=COL_OD/2 + e);
// Thumbscrew head recess on outer face (front only — access side)
if (y_front) {
translate([bx, COL_OD/2 - WALL, COL_H/2])
rotate([90,0,0])
cylinder(d=THUMB_HEAD_D, h=8 + e);
}
// ── 2× countersunk wall screws ────────────────────────────────────
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);
}
// ── M4 hex nut pockets (rear half) ────────────────────
if (!y_front) {
for (bx=[-COL_BOLT_X, COL_BOLT_X]) {
translate([bx, -(COL_OD/4 + e), COL_H/2])
rotate([90,0,0])
cylinder(d=COL_NUT_W/cos(30), h=COL_NUT_H + e,
$fn=6);
}
}
// ── Pivot bolt bore (M3, through both ears) ───────────────────────
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);
// ── Set screw (height lock, front half) ───────────────
if (y_front) {
translate([0, COL_OD/2, COL_H * 0.8])
rotate([90,0,0])
cylinder(d=COL_BOLT_D,
h=COL_OD/2 - STEM_BORE/2 + e);
}
// ── M3 nyloc nut pocket (outer face of one ear) ───────────────────
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);
// ── USB cable routing channel (rear half, −X side) ────
if (!y_front) {
translate([-COL_OD/2, -USB_CHAN_W/2, -e])
cube([USB_CHAN_D, USB_CHAN_W, COL_H + 2*e]);
}
// ── Detent arc — 7 notches at 15° steps on +X ear inner face ─────
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);
// ── M4 hole through arm boss (Z direction, for bracket bolt) ─
if (y_front) {
for (dx=[-ARM_W/4, ARM_W/4])
translate([dx, COL_OD/2 + ARM_L/2, COL_H * 0.35])
cylinder(d=COL_BOLT_D, h=COL_H * 0.35 + e);
}
// ── Installation label recess (rear face of backplate) ────────────
translate([0, -BASE_T - e, 0])
rotate([-90, 0, 0])
cube([BASE_W - 12, BASE_H - 16, 1.6], center = true);
// ── Lightening pocket ─────────────────────────────────────────────
translate([0, -BASE_T + 1.5, 0])
cube([BASE_W - 14, BASE_T - 3, BASE_H - 20], center = true);
}
}
// ─────────────────────────────────────────────────────────────
// module_bracket()
// Bolts to collar arm boss. Holds MaUWB PCB facing outward.
// Tilted BRKT_TILT° from vertical — antenna clears stem.
// Print flat-face-down (back wall on bed).
// ─────────────────────────────────────────────────────────────
module module_bracket() {
bk = BRKT_BACK_T;
sd = BRKT_SIDE_T;
// ============================================================
// PART 2 — TILT ARM
// ============================================================
// Pivoting arm linking wall_base pivot ears to anchor_cradle.
// Knuckle end (Z=0): M3 pivot bore + spring-plunger detent pocket
// that indexes into the base ear detent arc notches.
// Cradle end (Z=ARM_L): 2× M3 bolt attachment to cradle back wall.
// USB-C cable channel runs along 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() {
// ── Back wall (mounts to collar arm boss) ─────────
cube([ARM_W, bk, MAWB_H + M2_STNDFF + 6]);
// ── Arm body ─────────────────────────────────────────────────
translate([-ARM_W/2, 0, 0])
cube([ARM_W, ARM_T, total_h]);
// ── Side walls ────────────────────────────────────
for (sx=[0, ARM_W - sd])
translate([sx, bk, 0])
cube([sd, MAWB_L + 2, MAWB_H + M2_STNDFF + 6]);
// ── Knuckle boss (rounded pivot end) ─────────────────────────
translate([0, ARM_T/2, 0])
rotate([90, 0, 0])
cylinder(d = ARM_W, h = ARM_T, center = true);
// ── M2 standoff posts (PCB mounts to these) ───────
for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
0])
cylinder(d=M2_STNDFF_OD, h=M2_STNDFF);
// ── Cradle attach stub (Z = ARM_L) ────────────────────────────
translate([-ARM_W/2, 0, ARM_L])
cube([ARM_W, ARM_T + CRADLE_BACK_T, ARM_T]);
}
// ── M2 bores through standoffs ────────────────────────
for (hx=[0, MAWB_HOLE_X], hy=[0, MAWB_HOLE_Y])
translate([(ARM_W - MAWB_HOLE_X)/2 + hx,
bk + (MAWB_L - MAWB_HOLE_Y)/2 + hy,
-e])
cylinder(d=M2_D, h=M2_STNDFF + e);
// ── M3 pivot bore ─────────────────────────────────────────────────
translate([-ARM_W/2 - e, ARM_T/2, 0])
rotate([0, 90, 0])
cylinder(d = PIVOT_D, h = ARM_W + 2*e);
// ── Antenna clearance cutout in back wall ─────────────
// Open slot near top of back wall so antenna is unobstructed
translate([sd, -e, M2_STNDFF + 2])
cube([ARM_W - 2*sd, bk + 2*e, MAWB_H]);
// ── Detent plunger pocket (3 mm spring-ball, outer +Y face) ──────
translate([0, ARM_T + e, 0])
rotate([90, 0, 0])
cylinder(d = 3.2, h = 4 + e);
// ── USB port access notch on one side wall ────────────
translate([-e, bk + 2, M2_STNDFF - 1])
cube([sd + 2*e, USB_NOTCH_W, USB_NOTCH_H]);
// ── USB-C cable channel (outer +Y face, mid-arm length) ───────────
translate([-USBC_CHAN_W/2, ARM_T - e, ARM_T + 4])
cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L - ARM_T - 8]);
// ── Mounting holes to collar arm boss (×2) ────────────
for (dx=[-ARM_W/4, ARM_W/4])
translate([ARM_W/2 + dx, bk + ARM_L/2, -e])
cylinder(d=COL_BOLT_D, h=6 + e);
// ── Cradle attach bolt holes (2× M3 at cradle stub) ───────────────
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);
// ── M3 nut pockets (front of cradle stub) ─────────────────────────
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);
// ── Lightening pocket ─────────────────────────────────────────────
translate([0, ARM_T/2, ARM_L/2])
cube([ARM_W - 4, ARM_T - 2, ARM_L - 18], center = true);
}
}
// ─────────────────────────────────────────────────────────────
// single_anchor_assembly()
// ─────────────────────────────────────────────────────────────
module single_anchor_assembly(show_phantom=false) {
// Collar
color("SteelBlue", 0.9) collar_half("front");
color("CornflowerBlue", 0.9) mirror([0,1,0]) collar_half("rear");
// ============================================================
// PART 3 — ANCHOR CRADLE
// ============================================================
// Open-front U-cradle for ESP32 UWB Pro PCB.
// PCB retained on 4× M2.5 standoffs matching UWB_HOLE_X × UWB_HOLE_Y.
// Back wall features:
// • USB-C exit slot — aligns with PCB USB-C port
// • USB-C groove — cable routes from slot toward arm channel
// • Label card slot — insert printed strip for anchor ID
// • Antenna keep-out — back wall material removed above antenna area
// Front lip prevents PCB from sliding forward.
// Two attachment tabs bolt to tilt_arm cradle stub.
//
// 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;
// Bracket tilted BRKT_TILT° outward from top of arm boss
color("LightSteelBlue", 0.85)
translate([0, COL_OD/2 + ARM_L, COL_H * 0.3])
rotate([BRKT_TILT, 0, 0])
translate([-ARM_W/2, 0, 0])
module_bracket();
difference() {
union() {
// ── Cradle body ───────────────────────────────────────────────
translate([-outer_l/2, 0, 0])
cube([outer_l, outer_w, total_z]);
// Phantom UWB PCB
if (show_phantom)
color("ForestGreen", 0.4)
translate([-MAWB_L/2,
COL_OD/2 + ARM_L + BRKT_BACK_T,
COL_H * 0.3 + M2_STNDFF])
cube([MAWB_L, MAWB_W, MAWB_H]);
// ── Front retaining lip ───────────────────────────────────────
translate([-outer_l/2, outer_w - CRADLE_LIP_T, 0])
cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
// ── Arm attachment tabs (behind back wall) ─────────────────────
for (tx = [-ARM_W/4, ARM_W/4])
translate([tx - 4, -CRADLE_BACK_T, 0])
cube([8, CRADLE_BACK_T + 1, total_z]);
}
// ── PCB pocket ────────────────────────────────────────────────────
translate([-UWB_L/2, 0, pcb_z])
cube([UWB_L, UWB_W + 1, UWB_H + 4]);
// ── USB-C exit slot (through back wall, aligned to PCB port) ─────
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]);
// ── USB-C cable routing groove (outer back wall face) ─────────────
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]);
// ── Label card slot (insert from below, rear face upper half) ─────
// Paper/laminate card strip identifying this anchor instance
translate([0, -CRADLE_BACK_T - e, pcb_z + UWB_H/2])
cube([LABEL_W, LABEL_T + 0.3, LABEL_H],
center = [true, false, false]);
// ── Antenna keep-out: remove back wall above antenna area ─────────
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]);
// ── Arm bolt holes through attachment tabs ────────────────────────
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);
// ── Lightening slots in side walls ────────────────────────────────
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]);
}
// ── M2.5 standoff bosses (positive, inside cradle floor) ──────────────
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);
}
}
// ─────────────────────────────────────────────────────────────
// Render selector
// ─────────────────────────────────────────────────────────────
if (RENDER == "assembly") {
single_anchor_assembly(show_phantom=true);
// ============================================================
// PART 4 — CABLE CLIP
// ============================================================
// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
// Presses onto ARM_T-wide arm with PETG snap tongues.
// Open-front cable channel for push-in cable insertion.
// Print ×2–3 per anchor, spaced 25 mm 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;
} else if (RENDER == "collar_front") {
collar_half("front");
difference() {
union() {
// ── Body plate ────────────────────────────────────────────────
translate([-CLIP_BODY_W/2, 0, 0])
cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
} else if (RENDER == "collar_rear") {
collar_half("rear");
// ── Cable channel (C-shape, opens toward +Y) ─────────────────
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);
// open insertion slot
translate([0, ch_r + e, 0])
cube([CLIP_CABLE_D * 0.85,
ch_r * 2 + 2*e,
CLIP_BODY_W + 2*e], center = true);
}
} else if (RENDER == "bracket") {
module_bracket();
// ── Snap tongues (straddle arm, -Y side of body) ─────────────
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]);
} else if (RENDER == "pair") {
// Both anchors at 250 mm spacing on a stem stub
color("Silver", 0.2)
translate([0, 0, -50])
cylinder(d=STEM_OD, h=ANCHOR_SPACING + COL_H + 100);
// ── Snap barbs ────────────────────────────────────────────────
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);
}
// Lower anchor (Z = 0)
single_anchor_assembly(show_phantom=true);
// Upper anchor (Z = ANCHOR_SPACING)
translate([0, 0, ANCHOR_SPACING])
single_anchor_assembly(show_phantom=true);
// ── Arm slot (arm body passes between tongues) ─────────────────────
translate([0, -ARM_T - 1 - e, CLIP_BODY_H/2])
cube([CLIP_BODY_W - 6, ARM_T + 2, CLIP_BODY_H - 4], center = true);
}
}