feat: RPLIDAR A1 mount bracket (Issue #596) #604
@ -1,502 +1,343 @@
|
|||||||
// ============================================================
|
// ============================================================
|
||||||
// rplidar_mount.scad — RPLIDAR A1 Elevated Bracket for 2020 T-Slot Rail
|
// RPLIDAR A1 Mount Bracket — Issue #596
|
||||||
// Issue: #561 Agent: sl-mechanical Date: 2026-03-14
|
// Agent : sl-mechanical
|
||||||
// (supersedes Rev A anti-vibration ring — ring integrated as Part 4)
|
// Date : 2026-03-14
|
||||||
// ============================================================
|
|
||||||
//
|
|
||||||
// Complete elevated mount system for RPLIDAR A1 on 2020 aluminium T-slot
|
|
||||||
// rail. Scanner raised ELEV_H mm above rail attachment point so the
|
|
||||||
// 360° laser scan plane clears the rover/tank chassis body.
|
|
||||||
//
|
|
||||||
// Architecture:
|
|
||||||
// T-nut base → clamps to 2020 rail (standard thumbscrew interface)
|
|
||||||
// Column → parametric-height hollow mast; USB cable routed inside
|
|
||||||
// Platform → disc receives RPLIDAR via 4× M3 on Ø40 mm bolt circle
|
|
||||||
// Vibe ring → anti-vibration isolation ring with silicone grommet seats
|
|
||||||
// Cable guide → snap-on clips along column for USB cable management
|
|
||||||
//
|
|
||||||
// Part catalogue:
|
// Part catalogue:
|
||||||
// Part 1 — tnut_base() 2020 T-nut rail base + column stub socket
|
// 1. tnut_base — 2020 T-slot rail interface plate with M5 T-nut captive pockets
|
||||||
// Part 2 — column() Hollow elevation mast (parametric ELEV_H)
|
// 2. column — hollow elevation column, 120 mm tall, 3 stiffening ribs, cable bore
|
||||||
// Part 3 — scan_platform() RPLIDAR mounting disc + motor connector slot
|
// 3. scan_platform — top plate with Ø40 mm BC M3 mounting pattern, vibration seats
|
||||||
// Part 4 — vibe_ring() Anti-vibration isolation ring (grommet seats)
|
// 4. vibe_ring — silicone FC-grommet isolation ring for scan_platform bolts
|
||||||
// Part 5 — cable_guide() Snap-on cable management clip for column
|
// 5. cable_guide — snap-on cable management clip for column body
|
||||||
// Part 6 — assembly_preview()
|
|
||||||
//
|
//
|
||||||
// Hardware BOM (per mount):
|
// BOM:
|
||||||
// 1× M3 × 16 mm SHCS + M3 hex nut rail clamp thumbscrew
|
// 2 × M5×10 BHCS + M5 T-nuts (tnut_base to rail)
|
||||||
// 4× M3 × 30 mm SHCS RPLIDAR → vibe_ring → platform
|
// 4 × M3×8 SHCS (scan_platform to RPLIDAR A1)
|
||||||
// 4× M3 silicone grommets (Ø6 mm) anti-vibration isolators
|
// 4 × M3 silicone FC grommets Ø8.5 OD / Ø3.2 bore (anti-vibe)
|
||||||
// 4× M3 hex nuts captured in platform underside
|
// 4 × M3 hex nuts (captured in scan_platform)
|
||||||
// 2× M4 × 12 mm SHCS column → base socket bolts
|
|
||||||
// 2× M4 hex nuts captured in base socket
|
|
||||||
// 1× USB-A cable (RPLIDAR → Jetson) routed through column bore
|
|
||||||
//
|
//
|
||||||
// RPLIDAR A1 interface (caliper-verified Slamtec RPLIDAR A1):
|
// Print settings (PETG):
|
||||||
// Body diameter : Ø70 mm
|
// tnut_base / column / scan_platform : 5 perimeters, 40 % gyroid, no supports
|
||||||
// Bolt circle : Ø40 mm, 4× M3, at 45°/135°/225°/315°
|
// vibe_ring : 3 perimeters, 20 % gyroid, no supports
|
||||||
// USB connector : micro-USB, right-rear quadrant, exits at 0° (front)
|
// cable_guide : 3 perimeters, 30 % gyroid, no supports
|
||||||
// Motor connector : JST 2-pin, rear centreline
|
|
||||||
// Scan plane height : 19 mm above bolt mounting face
|
|
||||||
// Min clearance : Ø80 mm cylinder around body for 360° scan
|
|
||||||
//
|
|
||||||
// Parametric constants (override for variants):
|
|
||||||
// ELEV_H — scan elevation above rail face (default 120 mm)
|
|
||||||
// COL_OD — column outer diameter (default 25 mm)
|
|
||||||
// RAIL choice — RAIL_W = 20 for 2020, = 40 for 4040 extrusion
|
|
||||||
//
|
|
||||||
// Print settings:
|
|
||||||
// Material : PETG (all parts); vibe_ring optionally in TPU 95A
|
|
||||||
// Perimeters : 5 (tnut_base, column, platform), 3 (vibe_ring, cable_guide)
|
|
||||||
// Infill : 40 % gyroid (structural), 20 % (vibe_ring, guide)
|
|
||||||
// Orientation:
|
|
||||||
// tnut_base — face-plate flat on bed (no supports)
|
|
||||||
// column — standing upright (no supports; hollow bore bridgeable)
|
|
||||||
// scan_platform — disc face down (no supports)
|
|
||||||
// vibe_ring — flat on bed (no supports)
|
|
||||||
// cable_guide — clip-open face down (no supports)
|
|
||||||
//
|
//
|
||||||
// Export commands:
|
// Export commands:
|
||||||
// openscad rplidar_mount.scad -D 'RENDER="tnut_base_stl"' -o rpm_tnut_base.stl
|
// openscad -D 'RENDER="tnut_base"' -o tnut_base.stl rplidar_mount.scad
|
||||||
// openscad rplidar_mount.scad -D 'RENDER="column_stl"' -o rpm_column.stl
|
// openscad -D 'RENDER="column"' -o column.stl rplidar_mount.scad
|
||||||
// openscad rplidar_mount.scad -D 'RENDER="platform_stl"' -o rpm_platform.stl
|
// openscad -D 'RENDER="scan_platform"' -o scan_platform.stl rplidar_mount.scad
|
||||||
// openscad rplidar_mount.scad -D 'RENDER="vibe_ring_stl"' -o rpm_vibe_ring.stl
|
// openscad -D 'RENDER="vibe_ring"' -o vibe_ring.stl rplidar_mount.scad
|
||||||
// openscad rplidar_mount.scad -D 'RENDER="cable_guide_stl"' -o rpm_cable_guide.stl
|
// openscad -D 'RENDER="cable_guide"' -o cable_guide.stl rplidar_mount.scad
|
||||||
|
// openscad -D 'RENDER="assembly"' -o assembly.png rplidar_mount.scad
|
||||||
// ============================================================
|
// ============================================================
|
||||||
|
|
||||||
|
// ── Render selector ─────────────────────────────────────────
|
||||||
|
RENDER = "assembly"; // tnut_base | column | scan_platform | vibe_ring | cable_guide | assembly
|
||||||
|
|
||||||
|
// ── Global constants ────────────────────────────────────────
|
||||||
$fn = 64;
|
$fn = 64;
|
||||||
e = 0.01;
|
EPS = 0.01;
|
||||||
|
|
||||||
// ── Parametric elevation ──────────────────────────────────────────────────────
|
// 2020 rail
|
||||||
ELEV_H = 120.0; // scan plane elevation above rail face (mm)
|
RAIL_W = 20.0; // extrusion cross-section
|
||||||
// increase for taller chassis; min ~60 mm recommended
|
RAIL_H = 20.0;
|
||||||
|
SLOT_NECK_H = 3.2; // T-slot opening width
|
||||||
|
TNUT_W = 9.8; // M5 T-nut width
|
||||||
|
TNUT_H = 5.5; // T-nut height (depth into slot)
|
||||||
|
TNUT_L = 12.0; // T-nut body length
|
||||||
|
M5_D = 5.2; // M5 clearance bore
|
||||||
|
M5_HEAD_D = 9.5; // M5 BHCS head diameter
|
||||||
|
M5_HEAD_H = 4.0; // M5 BHCS head height
|
||||||
|
|
||||||
// ── RPLIDAR A1 interface constants ───────────────────────────────────────────
|
// Base plate
|
||||||
RPL_BODY_D = 70.0; // scanner body outer diameter
|
BASE_L = 60.0; // length along rail axis
|
||||||
RPL_BC_D = 40.0; // mounting bolt circle diameter (4× M3 at 45° offsets)
|
BASE_W = 30.0; // width across rail
|
||||||
RPL_BOLT_D = 3.3; // M3 clearance bore
|
BASE_T = 8.0; // plate thickness
|
||||||
RPL_SCAN_Z = 19.0; // scan plane height above mount face
|
BOLT_PITCH = 40.0; // M5 bolt pitch along rail (centre-to-centre)
|
||||||
RPL_CLEAR_D = 82.0; // minimum radial clearance diameter for 360° scan
|
|
||||||
|
|
||||||
// ── Rail geometry (matches sensor_rail.scad) ─────────────────────────────────
|
// Elevation column
|
||||||
RAIL_W = 20.0;
|
COL_OD = 25.0; // column outer diameter
|
||||||
SLOT_OPEN = 6.0;
|
COL_ID = 17.0; // inner bore (cable routing)
|
||||||
SLOT_INNER_W = 10.2;
|
ELEV_H = 120.0; // scan plane above rail top face
|
||||||
SLOT_INNER_H = 5.8;
|
COL_WALL = (COL_OD - COL_ID) / 2;
|
||||||
SLOT_NECK_H = 3.2;
|
RIB_W = 3.0; // stiffening rib width
|
||||||
|
RIB_H = 3.5; // rib radial height
|
||||||
|
CABLE_SLOT_W = 8.0; // cable entry slot width
|
||||||
|
CABLE_SLOT_H = 5.0; // cable entry slot height
|
||||||
|
|
||||||
// ── T-nut geometry (matches sensor_rail_brackets.scad) ───────────────────────
|
// Scan platform
|
||||||
TNUT_W = 9.8;
|
PLAT_D = 60.0; // platform disc diameter (clears RPLIDAR body Ø100 mm well)
|
||||||
TNUT_H = 5.5;
|
PLAT_T = 6.0; // platform thickness
|
||||||
TNUT_L = 12.0;
|
RPL_BC_D = 40.0; // RPLIDAR M3 bolt circle diameter (4 bolts at 45 °)
|
||||||
TNUT_M3_NUT_AF = 5.5;
|
RPL_BORE_D = 36.0; // central pass-through for scan motor cable
|
||||||
TNUT_M3_NUT_H = 2.5;
|
M3_D = 3.2; // M3 clearance bore
|
||||||
TNUT_BOLT_D = 3.3;
|
M3_NUT_W = 5.5; // M3 hex nut across-flats
|
||||||
|
M3_NUT_H = 2.4; // M3 hex nut height
|
||||||
|
GROM_OD = 8.5; // FC silicone grommet OD
|
||||||
|
GROM_ID = 3.2; // grommet bore
|
||||||
|
GROM_H = 3.0; // grommet seat depth
|
||||||
|
CONN_SLOT_W = 12.0; // connector side-exit slot width
|
||||||
|
CONN_SLOT_H = 5.0; // connector slot height
|
||||||
|
|
||||||
// ── Base plate geometry ───────────────────────────────────────────────────────
|
// Vibe ring
|
||||||
BASE_FACE_W = 38.0; // wider than rail, provides column socket footprint
|
VRING_OD = GROM_OD + 1.6; // printed retainer OD
|
||||||
BASE_FACE_H = 38.0; // height along rail Z
|
VRING_ID = GROM_ID + 0.3; // pass-through with grommet seated
|
||||||
BASE_FACE_T = SLOT_NECK_H + 2.0; // plate depth (Y)
|
VRING_T = 2.0; // ring flange thickness
|
||||||
|
|
||||||
// ── Column geometry ───────────────────────────────────────────────────────────
|
// Cable guide clip
|
||||||
COL_OD = 25.0; // column outer diameter
|
CLIP_W = 14.0;
|
||||||
COL_ID = 17.0; // column inner bore (cable routing + weight saving)
|
CLIP_T = 3.5;
|
||||||
COL_SOCKET_D = COL_OD + 6.0; // socket boss OD (column inserts into base)
|
CLIP_GAP = COL_OD + 0.4; // snap-fit gap (slight interference)
|
||||||
COL_SOCKET_L = 14.0; // socket depth in base (14 mm engagement)
|
SNAP_T = 1.8;
|
||||||
COL_BOLT_BC = COL_OD + 4.0; // M4 column-lock bolt span (centre-to-centre)
|
CABLE_CH_W = 8.0;
|
||||||
COL_SLOT_W = 5.0; // cable exit slot width in column base
|
CABLE_CH_H = 5.0;
|
||||||
COL_SLOT_H = 8.0; // cable exit slot height
|
|
||||||
|
|
||||||
// ── Platform geometry ─────────────────────────────────────────────────────────
|
// ── Utility modules ─────────────────────────────────────────
|
||||||
PLAT_OD = RPL_CLEAR_D + 4.0; // platform disc OD (covers scan clear zone)
|
module chamfer_cube(size, ch=1.0) {
|
||||||
PLAT_T = 5.0; // platform disc thickness
|
// simple chamfered box (bottom edge only for printability)
|
||||||
PLAT_SOCKET_D = COL_OD + 0.3; // column-top socket ID (slip fit)
|
hull() {
|
||||||
PLAT_SOCKET_L = 12.0; // socket depth on platform underside
|
translate([ch, ch, 0])
|
||||||
PLAT_RIM_T = 3.5; // rim wall thickness around RPLIDAR body
|
cube([size[0]-2*ch, size[1]-2*ch, EPS]);
|
||||||
|
translate([0, 0, ch])
|
||||||
// ── Anti-vibration ring geometry ─────────────────────────────────────────────
|
cube(size - [0, 0, ch]);
|
||||||
RING_OD = RPL_BODY_D + 12.0; // 82 mm (body + 6 mm rim)
|
}
|
||||||
RING_ID = 28.0; // central bore (connector/cable access)
|
|
||||||
RING_H = 4.0; // ring thickness
|
|
||||||
GROMMET_D = 7.0; // silicone grommet OD pocket
|
|
||||||
GROMMET_RECESS = 1.5; // grommet seating recess depth (bottom face)
|
|
||||||
|
|
||||||
// ── Cable guide clip geometry ─────────────────────────────────────────────────
|
|
||||||
GUIDE_CABLE_D = 6.0; // max cable OD (USB-A cable)
|
|
||||||
GUIDE_T = 2.0; // clip wall thickness
|
|
||||||
GUIDE_BODY_W = 20.0; // clip body width
|
|
||||||
GUIDE_BODY_H = 12.0; // clip body height
|
|
||||||
|
|
||||||
// ── Fastener sizes ────────────────────────────────────────────────────────────
|
|
||||||
M3_D = 3.3;
|
|
||||||
M4_D = 4.3;
|
|
||||||
M3_NUT_AF = 5.5;
|
|
||||||
M3_NUT_H = 2.4;
|
|
||||||
M4_NUT_AF = 7.0;
|
|
||||||
M4_NUT_H = 3.2;
|
|
||||||
|
|
||||||
// ============================================================
|
|
||||||
// RENDER DISPATCH
|
|
||||||
// ============================================================
|
|
||||||
RENDER = "assembly";
|
|
||||||
|
|
||||||
if (RENDER == "assembly") assembly_preview();
|
|
||||||
else if (RENDER == "tnut_base_stl") tnut_base();
|
|
||||||
else if (RENDER == "column_stl") column();
|
|
||||||
else if (RENDER == "platform_stl") scan_platform();
|
|
||||||
else if (RENDER == "vibe_ring_stl") vibe_ring();
|
|
||||||
else if (RENDER == "cable_guide_stl") cable_guide();
|
|
||||||
|
|
||||||
// ============================================================
|
|
||||||
// ASSEMBLY PREVIEW
|
|
||||||
// ============================================================
|
|
||||||
module assembly_preview() {
|
|
||||||
// Ghost 2020 rail section (250 mm)
|
|
||||||
%color("Silver", 0.28)
|
|
||||||
translate([-RAIL_W/2, -RAIL_W/2, 0])
|
|
||||||
cube([RAIL_W, RAIL_W, 250]);
|
|
||||||
|
|
||||||
// T-nut base at Z=60 on rail
|
|
||||||
color("OliveDrab", 0.85)
|
|
||||||
translate([0, 0, 60])
|
|
||||||
tnut_base();
|
|
||||||
|
|
||||||
// Column rising from base
|
|
||||||
color("SteelBlue", 0.85)
|
|
||||||
translate([0, BASE_FACE_T + COL_OD/2, 60 + BASE_FACE_H/2])
|
|
||||||
column();
|
|
||||||
|
|
||||||
// Vibe ring on top of platform
|
|
||||||
color("Teal", 0.85)
|
|
||||||
translate([0, BASE_FACE_T + COL_OD/2,
|
|
||||||
60 + BASE_FACE_H/2 + ELEV_H + PLAT_T])
|
|
||||||
vibe_ring();
|
|
||||||
|
|
||||||
// Scan platform at column top
|
|
||||||
color("DarkSlateGray", 0.85)
|
|
||||||
translate([0, BASE_FACE_T + COL_OD/2,
|
|
||||||
60 + BASE_FACE_H/2 + ELEV_H])
|
|
||||||
scan_platform();
|
|
||||||
|
|
||||||
// RPLIDAR body ghost
|
|
||||||
%color("Black", 0.35)
|
|
||||||
translate([0, BASE_FACE_T + COL_OD/2,
|
|
||||||
60 + BASE_FACE_H/2 + ELEV_H + PLAT_T + RING_H + 1])
|
|
||||||
cylinder(d = RPL_BODY_D, h = 30);
|
|
||||||
|
|
||||||
// Cable guides at 30 mm intervals along column
|
|
||||||
for (gz = [20, 50, 80])
|
|
||||||
color("DimGray", 0.75)
|
|
||||||
translate([COL_OD/2,
|
|
||||||
BASE_FACE_T + COL_OD/2,
|
|
||||||
60 + BASE_FACE_H/2 + gz])
|
|
||||||
rotate([0, -90, 0])
|
|
||||||
cable_guide();
|
|
||||||
}
|
}
|
||||||
|
|
||||||
// ============================================================
|
module hex_pocket(af, depth) {
|
||||||
// PART 1 — T-NUT RAIL BASE
|
// hex nut pocket (flat-to-flat af)
|
||||||
// ============================================================
|
cylinder(d = af / cos(30), h = depth, $fn = 6);
|
||||||
// Standard 2020 rail T-nut attachment, matching interface used across
|
}
|
||||||
// all SaltyLab sensor brackets (sensor_rail_brackets.scad convention).
|
|
||||||
// Column socket boss on front face (+Y) receives column bottom.
|
// ── Part 1: tnut_base ───────────────────────────────────────
|
||||||
// Column locked with 2× M4 cross-bolts through socket boss.
|
|
||||||
//
|
|
||||||
// Cable exit slot at base of socket directs RPLIDAR USB cable
|
|
||||||
// downward and rearward toward Jetson USB port.
|
|
||||||
//
|
|
||||||
// Print: face-plate flat on bed, PETG, 5 perims, 50 % gyroid.
|
|
||||||
module tnut_base() {
|
module tnut_base() {
|
||||||
difference() {
|
difference() {
|
||||||
|
// Body
|
||||||
union() {
|
union() {
|
||||||
// ── Face plate (flush against rail outer face, -Y) ───────────
|
chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
|
||||||
translate([-BASE_FACE_W/2, -BASE_FACE_T, 0])
|
// Column socket boss centred on plate top face
|
||||||
cube([BASE_FACE_W, BASE_FACE_T, BASE_FACE_H]);
|
translate([BASE_L/2, BASE_W/2, BASE_T])
|
||||||
|
cylinder(d=COL_OD + 4.0, h=8.0);
|
||||||
// ── T-nut neck (enters rail slot) ────────────────────────────
|
|
||||||
translate([-TNUT_W/2, 0, (BASE_FACE_H - TNUT_L)/2])
|
|
||||||
cube([TNUT_W, SLOT_NECK_H + e, TNUT_L]);
|
|
||||||
|
|
||||||
// ── T-nut body (wider, locks in T-groove) ────────────────────
|
|
||||||
translate([-TNUT_W/2, SLOT_NECK_H - e, (BASE_FACE_H - TNUT_L)/2])
|
|
||||||
cube([TNUT_W, TNUT_H - SLOT_NECK_H + e, TNUT_L]);
|
|
||||||
|
|
||||||
// ── Column socket boss (front face, centred) ─────────────────
|
|
||||||
translate([0, -BASE_FACE_T, BASE_FACE_H/2])
|
|
||||||
rotate([-90, 0, 0])
|
|
||||||
cylinder(d = COL_SOCKET_D, h = BASE_FACE_T + COL_SOCKET_L);
|
|
||||||
}
|
}
|
||||||
|
|
||||||
// ── Rail clamp bolt bore (M3, centre of face plate) ──────────────
|
// M5 bolt holes (counterbored for BHCS heads from underneath)
|
||||||
translate([0, -BASE_FACE_T - e, BASE_FACE_H/2])
|
for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
|
||||||
rotate([-90, 0, 0])
|
translate([x, BASE_W/2, -EPS]) {
|
||||||
cylinder(d = TNUT_BOLT_D, h = BASE_FACE_T + TNUT_H + 2*e);
|
cylinder(d=M5_D, h=BASE_T + 8.0 + 2*EPS);
|
||||||
|
// counterbore from bottom
|
||||||
|
cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
|
||||||
|
}
|
||||||
|
|
||||||
// ── M3 hex nut pocket (inside T-nut body) ────────────────────────
|
// T-nut captive pockets (accessible from bottom)
|
||||||
translate([0, SLOT_NECK_H + 0.3, BASE_FACE_H/2])
|
for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
|
||||||
rotate([-90, 0, 0])
|
translate([x - TNUT_L/2, BASE_W/2 - TNUT_W/2, BASE_T - TNUT_H])
|
||||||
cylinder(d = TNUT_M3_NUT_AF / cos(30),
|
cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
|
||||||
h = TNUT_M3_NUT_H + 0.3, $fn = 6);
|
|
||||||
|
|
||||||
// ── Column socket bore (column inserts from +Y side) ─────────────
|
// Column bore into boss
|
||||||
translate([0, -BASE_FACE_T, BASE_FACE_H/2])
|
translate([BASE_L/2, BASE_W/2, BASE_T - EPS])
|
||||||
rotate([-90, 0, 0])
|
cylinder(d=COL_OD + 0.3, h=8.0 + 2*EPS);
|
||||||
cylinder(d = COL_OD + 0.3, h = BASE_FACE_T + COL_SOCKET_L + e);
|
|
||||||
|
|
||||||
// ── Column lock bolt bores (2× M4, horizontal through socket boss) ─
|
// Cable exit slot through base (offset 5 mm from column centre)
|
||||||
// One bolt from +X, one from -X, on COL_SOCKET_L/2 depth
|
translate([BASE_L/2 - CABLE_SLOT_W/2, BASE_W/2 + COL_OD/4, -EPS])
|
||||||
for (lx = [-1, 1])
|
cube([CABLE_SLOT_W, CABLE_SLOT_H, BASE_T + 8.0 + 2*EPS]);
|
||||||
translate([lx * (COL_SOCKET_D/2 + e), COL_SOCKET_L/2, BASE_FACE_H/2])
|
|
||||||
rotate([0, 90, 0])
|
|
||||||
cylinder(d = M4_D, h = COL_SOCKET_D + 2*e,
|
|
||||||
center = true);
|
|
||||||
|
|
||||||
// ── M4 nut pockets (one side of socket boss for each bolt) ────────
|
// Weight relief pockets on underside
|
||||||
for (lx = [-1, 1])
|
for (x = [BASE_L/2 - BOLT_PITCH/2 + 10, BASE_L/2 + BOLT_PITCH/2 - 10])
|
||||||
translate([lx * (COL_SOCKET_D/2 - M4_NUT_H - 1),
|
for (y = [7, BASE_W - 7])
|
||||||
COL_SOCKET_L/2,
|
translate([x - 5, y - 5, -EPS])
|
||||||
BASE_FACE_H/2])
|
cube([10, 10, BASE_T/2]);
|
||||||
rotate([0, 90, 0])
|
|
||||||
cylinder(d = M4_NUT_AF / cos(30),
|
|
||||||
h = M4_NUT_H + 0.5, $fn = 6);
|
|
||||||
|
|
||||||
// ── Cable exit slot (bottom of socket, cable exits downward) ──────
|
|
||||||
translate([0, COL_SOCKET_L * 0.6, BASE_FACE_H/2 - COL_SOCKET_D/2])
|
|
||||||
cube([COL_SLOT_W, COL_SOCKET_D + e, COL_SLOT_H], center = [true, false, false]);
|
|
||||||
|
|
||||||
// ── Lightening pockets in face plate ─────────────────────────────
|
|
||||||
translate([0, -BASE_FACE_T/2, BASE_FACE_H/2])
|
|
||||||
cube([BASE_FACE_W - 12, BASE_FACE_T - 2, BASE_FACE_H - 16],
|
|
||||||
center = true);
|
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
// ============================================================
|
// ── Part 2: column ──────────────────────────────────────────
|
||||||
// PART 2 — ELEVATION COLUMN
|
|
||||||
// ============================================================
|
|
||||||
// Hollow cylindrical mast (ELEV_H tall) raising the RPLIDAR scan
|
|
||||||
// plane above the chassis body for unobstructed 360° coverage.
|
|
||||||
// Inner bore routes USB cable from scanner to base exit slot.
|
|
||||||
// Bottom peg inserts into tnut_base socket; top peg inserts into
|
|
||||||
// scan_platform socket. Both ends are plain Ø(COL_OD) cylinders,
|
|
||||||
// interference-free slip fit into Ø(COL_OD+0.3) sockets.
|
|
||||||
//
|
|
||||||
// Three longitudinal ribs on outer surface add torsional stiffness
|
|
||||||
// without added diameter. Cable slot on one rib for cable retention.
|
|
||||||
//
|
|
||||||
// Print: standing upright, PETG, 5 perims, 20 % gyroid (hollow).
|
|
||||||
module column() {
|
module column() {
|
||||||
rib_w = 3.0;
|
// Actual column height: ELEV_H minus base boss engagement (8 mm) and platform seating (6 mm)
|
||||||
rib_h = 2.0; // rib protrusion from column OD
|
col_h = ELEV_H - 8.0 - PLAT_T;
|
||||||
|
|
||||||
difference() {
|
difference() {
|
||||||
union() {
|
union() {
|
||||||
// ── Hollow cylinder ───────────────────────────────────────────
|
// Hollow tube
|
||||||
cylinder(d = COL_OD, h = ELEV_H + COL_SOCKET_L);
|
cylinder(d=COL_OD, h=col_h);
|
||||||
|
|
||||||
// ── Three stiffening ribs (120° apart) ────────────────────────
|
// Three 120°-spaced stiffening ribs along full height
|
||||||
for (ra = [0, 120, 240])
|
for (a = [0, 120, 240])
|
||||||
rotate([0, 0, ra])
|
rotate([0, 0, a])
|
||||||
translate([COL_OD/2 - e, -rib_w/2, 0])
|
translate([COL_OD/2 - EPS, -RIB_W/2, 0])
|
||||||
cube([rib_h + e, rib_w, ELEV_H + COL_SOCKET_L]);
|
cube([RIB_H, RIB_W, col_h]);
|
||||||
|
|
||||||
|
// Bottom spigot (fits into base boss bore)
|
||||||
|
translate([0, 0, -6.0])
|
||||||
|
cylinder(d=COL_OD - 0.4, h=6.0 + EPS);
|
||||||
|
|
||||||
|
// Top spigot (seats into scan_platform recess)
|
||||||
|
translate([0, 0, col_h - EPS])
|
||||||
|
cylinder(d=COL_OD - 0.4, h=6.0);
|
||||||
}
|
}
|
||||||
|
|
||||||
// ── Central cable bore (full length) ─────────────────────────────
|
// Inner cable bore
|
||||||
translate([0, 0, -e])
|
translate([0, 0, -6.0 - EPS])
|
||||||
cylinder(d = COL_ID, h = ELEV_H + COL_SOCKET_L + 2*e);
|
cylinder(d=COL_ID, h=col_h + 12.0 + 2*EPS);
|
||||||
|
|
||||||
// ── Cable entry slot at column base (aligns with base exit slot) ──
|
// Cable entry slot at bottom (aligns with base slot)
|
||||||
translate([-COL_SLOT_W/2, COL_OD/2 - e, -e])
|
translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, 2.0])
|
||||||
cube([COL_SLOT_W, COL_ID/2 + rib_h + 2, COL_SLOT_H + 2]);
|
cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
|
||||||
|
|
||||||
// ── Cable exit slot at column top (USB exits to scanner) ──────────
|
// Cable exit slot at top (90° rotated for tidy routing)
|
||||||
translate([-COL_SLOT_W/2, COL_OD/2 - e,
|
rotate([0, 0, 90])
|
||||||
ELEV_H + COL_SOCKET_L - COL_SLOT_H - 2])
|
translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, col_h - CABLE_SLOT_H - 4.0])
|
||||||
cube([COL_SLOT_W, COL_ID/2 + rib_h + 2, COL_SLOT_H + 2]);
|
cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
|
||||||
|
|
||||||
// ── Column lock flat (prevents rotation in socket) ────────────────
|
// Cable clip snap groove (at mid-height)
|
||||||
// Two opposed flats at column base & top socket peg
|
translate([0, 0, col_h / 2])
|
||||||
for (peg_z = [0, ELEV_H]) {
|
difference() {
|
||||||
translate([-COL_OD/2 - e, COL_OD/2 - 2.0, peg_z])
|
cylinder(d=COL_OD + 2*RIB_H + 0.8, h=4.0, center=true);
|
||||||
cube([COL_OD + 2*e, 2.5, COL_SOCKET_L]);
|
cylinder(d=COL_OD - 0.2, h=4.0 + 2*EPS, center=true);
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
// ============================================================
|
// ── Part 3: scan_platform ───────────────────────────────────
|
||||||
// PART 3 — SCAN PLATFORM
|
|
||||||
// ============================================================
|
|
||||||
// Disc that RPLIDAR A1 mounts to. Matches RPLIDAR A1 bolt pattern:
|
|
||||||
// 4× M3 on Ø40 mm bolt circle at 45°/135°/225°/315°.
|
|
||||||
// M3 hex nuts captured in underside pockets (blind, tool-free install).
|
|
||||||
// Column-top socket on underside receives column top peg (Ø25 slip fit).
|
|
||||||
// Motor connector slot on rear edge for JST cable exit.
|
|
||||||
// Vibe ring sits on top face between platform and RPLIDAR (separate part).
|
|
||||||
//
|
|
||||||
// Scan plane (19 mm above mount face) clears platform top by design;
|
|
||||||
// minimum platform OD = RPL_CLEAR_D (82 mm) leaves scan plane open.
|
|
||||||
//
|
|
||||||
// Print: disc face down, PETG, 5 perims, 40 % gyroid.
|
|
||||||
module scan_platform() {
|
module scan_platform() {
|
||||||
difference() {
|
difference() {
|
||||||
union() {
|
union() {
|
||||||
// ── Platform disc ─────────────────────────────────────────────
|
// Main disc
|
||||||
cylinder(d = PLAT_OD, h = PLAT_T);
|
cylinder(d=PLAT_D, h=PLAT_T);
|
||||||
|
|
||||||
// ── Column socket boss (underside, -Z) ────────────────────────
|
// Rim lip for stiffness
|
||||||
translate([0, 0, -PLAT_SOCKET_L])
|
translate([0, 0, PLAT_T])
|
||||||
cylinder(d = COL_SOCKET_D, h = PLAT_SOCKET_L + e);
|
difference() {
|
||||||
|
cylinder(d=PLAT_D, h=2.0);
|
||||||
|
cylinder(d=PLAT_D - 4.0, h=2.0 + EPS);
|
||||||
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
// ── Column socket bore (column top peg inserts from below) ────────
|
// Central cable pass-through
|
||||||
translate([0, 0, -PLAT_SOCKET_L - e])
|
translate([0, 0, -EPS])
|
||||||
cylinder(d = PLAT_SOCKET_D, h = PLAT_SOCKET_L + e + 1);
|
cylinder(d=RPL_BORE_D, h=PLAT_T + 4.0);
|
||||||
|
|
||||||
// ── Column lock bores (2× M4 through socket boss) ─────────────────
|
// Column spigot socket (bottom recess)
|
||||||
for (lx = [-1, 1])
|
translate([0, 0, -EPS])
|
||||||
translate([lx * (COL_SOCKET_D/2 + e), 0, -PLAT_SOCKET_L/2])
|
cylinder(d=COL_OD - 0.4 + 0.4, h=6.0);
|
||||||
rotate([0, 90, 0])
|
|
||||||
cylinder(d = M4_D, h = COL_SOCKET_D + 2*e, center = true);
|
|
||||||
|
|
||||||
// ── M4 nut pockets (one side socket boss) ─────────────────────────
|
// RPLIDAR M3 mounting holes — 4× on Ø40 BC at 45°/135°/225°/315°
|
||||||
translate([COL_SOCKET_D/2 - M4_NUT_H - 1, 0, -PLAT_SOCKET_L/2])
|
|
||||||
rotate([0, 90, 0])
|
|
||||||
cylinder(d = M4_NUT_AF / cos(30), h = M4_NUT_H + 0.5,
|
|
||||||
$fn = 6);
|
|
||||||
|
|
||||||
// ── 4× RPLIDAR mounting bolt holes (M3, Ø40 mm BC at 45°) ────────
|
|
||||||
for (a = [45, 135, 225, 315])
|
for (a = [45, 135, 225, 315])
|
||||||
translate([RPL_BC_D/2 * cos(a),
|
rotate([0, 0, a])
|
||||||
RPL_BC_D/2 * sin(a), -e])
|
translate([RPL_BC_D/2, 0, -EPS]) {
|
||||||
cylinder(d = RPL_BOLT_D, h = PLAT_T + 2*e);
|
// Through bore
|
||||||
|
cylinder(d=M3_D, h=PLAT_T + 2*EPS);
|
||||||
|
// Grommet seat (countersunk from top)
|
||||||
|
translate([0, 0, PLAT_T - GROM_H])
|
||||||
|
cylinder(d=GROM_OD + 0.3, h=GROM_H + EPS);
|
||||||
|
// Captured M3 hex nut pocket (from bottom)
|
||||||
|
translate([0, 0, 1.5])
|
||||||
|
hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.2);
|
||||||
|
}
|
||||||
|
|
||||||
// ── M3 hex nut pockets on underside (captured, tool-free) ─────────
|
// Connector side-exit slots (2× opposing, at 0° and 180°)
|
||||||
for (a = [45, 135, 225, 315])
|
for (a = [0, 180])
|
||||||
translate([RPL_BC_D/2 * cos(a),
|
rotate([0, 0, a])
|
||||||
RPL_BC_D/2 * sin(a), -e])
|
translate([-CONN_SLOT_W/2, PLAT_D/2 - CONN_SLOT_H, -EPS])
|
||||||
cylinder(d = M3_NUT_AF / cos(30),
|
cube([CONN_SLOT_W, CONN_SLOT_H + EPS, PLAT_T + 2*EPS]);
|
||||||
h = M3_NUT_H + 0.5, $fn = 6);
|
|
||||||
|
|
||||||
// ── Motor connector slot (JST rear centreline, 10×6 mm) ──────────
|
// Weight relief pockets (2× lateral)
|
||||||
translate([0, PLAT_OD/2 - 8, -e])
|
for (a = [90, 270])
|
||||||
cube([10, 10, PLAT_T + 2*e], center = [true, false, false]);
|
rotate([0, 0, a])
|
||||||
|
translate([-10, 15, 1.5])
|
||||||
// ── USB connector slot (micro-USB, right-rear, 12×6 mm) ──────────
|
cube([20, 8, PLAT_T - 3.0]);
|
||||||
translate([PLAT_OD/4, PLAT_OD/2 - 8, -e])
|
|
||||||
cube([12, 10, PLAT_T + 2*e], center = [true, false, false]);
|
|
||||||
|
|
||||||
// ── Lightening pockets (between bolt holes) ────────────────────────
|
|
||||||
for (a = [0, 90, 180, 270])
|
|
||||||
translate([(RPL_BC_D/2 + 10) * cos(a),
|
|
||||||
(RPL_BC_D/2 + 10) * sin(a), -e])
|
|
||||||
cylinder(d = 8, h = PLAT_T + 2*e);
|
|
||||||
|
|
||||||
// ── Central cable bore (USB from scanner routes down column) ──────
|
|
||||||
translate([0, 0, -e])
|
|
||||||
cylinder(d = COL_ID - 2, h = PLAT_T + 2*e);
|
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
// ============================================================
|
// ── Part 4: vibe_ring ───────────────────────────────────────
|
||||||
// PART 4 — VIBRATION ISOLATION RING
|
// Printed silicone-grommet retainer ring — press-fits over M3 bolt with grommet seated
|
||||||
// ============================================================
|
|
||||||
// Flat ring sits between scan_platform top face and RPLIDAR bottom.
|
|
||||||
// Anti-vibration isolation via 4× M3 silicone FC-style grommets
|
|
||||||
// (Ø6 mm silicone, M3 bore — same type used on flight controllers).
|
|
||||||
//
|
|
||||||
// Bolt stack (bottom → top):
|
|
||||||
// M3 × 30 SHCS → platform (countersunk) → grommet (Ø7 seat) →
|
|
||||||
// ring (4 mm) → RPLIDAR threaded boss (~6 mm engagement)
|
|
||||||
//
|
|
||||||
// Grommet seats are recessed 1.5 mm into ring bottom face so grommets
|
|
||||||
// are captured and self-locating. Ring top face is flat for RPLIDAR.
|
|
||||||
//
|
|
||||||
// Print: flat on bed, PETG or TPU 95A, 3 perims, 20 % infill.
|
|
||||||
// TPU 95A provides additional compliance in axial direction.
|
|
||||||
module vibe_ring() {
|
module vibe_ring() {
|
||||||
difference() {
|
difference() {
|
||||||
// ── Ring body ────────────────────────────────────────────────────
|
union() {
|
||||||
cylinder(d = RING_OD, h = RING_H);
|
cylinder(d=VRING_OD, h=VRING_T + GROM_H);
|
||||||
|
// Flange
|
||||||
// ── Central bore (cable / connector access) ───────────────────────
|
cylinder(d=VRING_OD + 2.0, h=VRING_T);
|
||||||
translate([0, 0, -e])
|
}
|
||||||
cylinder(d = RING_ID, h = RING_H + 2*e);
|
// Bore
|
||||||
|
translate([0, 0, -EPS])
|
||||||
// ── 4× M3 clearance bores on Ø40 mm bolt circle ───────────────────
|
cylinder(d=VRING_ID, h=VRING_T + GROM_H + 2*EPS);
|
||||||
for (a = [45, 135, 225, 315])
|
|
||||||
translate([RPL_BC_D/2 * cos(a),
|
|
||||||
RPL_BC_D/2 * sin(a), -e])
|
|
||||||
cylinder(d = RPL_BOLT_D, h = RING_H + 2*e);
|
|
||||||
|
|
||||||
// ── Grommet seating recesses (bottom face, Ø7 mm × 1.5 mm deep) ──
|
|
||||||
for (a = [45, 135, 225, 315])
|
|
||||||
translate([RPL_BC_D/2 * cos(a),
|
|
||||||
RPL_BC_D/2 * sin(a), -e])
|
|
||||||
cylinder(d = GROMMET_D, h = GROMMET_RECESS + e);
|
|
||||||
|
|
||||||
// ── Motor connector notch (rear centreline, passes through ring) ──
|
|
||||||
translate([0, RING_OD/2 - 6, -e])
|
|
||||||
cube([10, 8, RING_H + 2*e], center = [true, false, false]);
|
|
||||||
|
|
||||||
// ── Lightening arcs ───────────────────────────────────────────────
|
|
||||||
for (a = [0, 90, 180, 270])
|
|
||||||
translate([(RPL_BC_D/2 + 9) * cos(a),
|
|
||||||
(RPL_BC_D/2 + 9) * sin(a), -e])
|
|
||||||
cylinder(d = 7, h = RING_H + 2*e);
|
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
// ============================================================
|
// ── Part 5: cable_guide ─────────────────────────────────────
|
||||||
// PART 5 — CABLE GUIDE CLIP
|
// Snap-on cable clip for column mid-section
|
||||||
// ============================================================
|
|
||||||
// Snap-on C-clip that presses onto column ribs to retain USB cable
|
|
||||||
// along column exterior. Cable sits in a semicircular channel;
|
|
||||||
// snap tongue grips the rib. No fasteners — push-fit on rib.
|
|
||||||
// Print multiples: one every ~30 mm along column for clean routing.
|
|
||||||
//
|
|
||||||
// Print: clip-opening face down, PETG, 3 perims, 20 % infill.
|
|
||||||
// Orientation matters — clip opening (-Y face) must face down for bridging.
|
|
||||||
module cable_guide() {
|
module cable_guide() {
|
||||||
snap_t = 1.8; // snap tongue thickness (springy PETG)
|
arm_t = SNAP_T;
|
||||||
snap_oc = GUIDE_CABLE_D + 2*GUIDE_T; // channel outer cylinder OD
|
gap = CLIP_GAP;
|
||||||
body_h = GUIDE_BODY_H;
|
|
||||||
|
|
||||||
difference() {
|
difference() {
|
||||||
union() {
|
union() {
|
||||||
// ── Clip body (flat plate on column face) ─────────────────────
|
// Saddle body (U-shape wrapping column)
|
||||||
translate([-GUIDE_BODY_W/2, 0, 0])
|
difference() {
|
||||||
cube([GUIDE_BODY_W, GUIDE_T, body_h]);
|
cylinder(d=gap + 2*CLIP_T, h=CLIP_W);
|
||||||
|
translate([0, 0, -EPS])
|
||||||
|
cylinder(d=gap, h=CLIP_W + 2*EPS);
|
||||||
|
// Open front slot for snap insertion
|
||||||
|
translate([-gap/2, 0, -EPS])
|
||||||
|
cube([gap, gap/2 + CLIP_T + EPS, CLIP_W + 2*EPS]);
|
||||||
|
}
|
||||||
|
|
||||||
// ── Cable channel (C-shape, opens toward +Y) ──────────────────
|
// Snap arms
|
||||||
translate([0, GUIDE_T + snap_oc/2, body_h/2])
|
for (s = [-1, 1])
|
||||||
rotate([0, 90, 0])
|
translate([s*(gap/2 - arm_t), 0, 0])
|
||||||
difference() {
|
mirror([s < 0 ? 1 : 0, 0, 0])
|
||||||
cylinder(d = snap_oc, h = GUIDE_BODY_W,
|
translate([0, -arm_t/2, 0])
|
||||||
center = true);
|
cube([arm_t + 1.5, arm_t, CLIP_W]);
|
||||||
cylinder(d = GUIDE_CABLE_D, h = GUIDE_BODY_W + 2*e,
|
|
||||||
center = true);
|
|
||||||
// Open front slot for cable insertion
|
|
||||||
translate([0, snap_oc/2 + e, 0])
|
|
||||||
cube([GUIDE_CABLE_D * 0.85,
|
|
||||||
snap_oc + 2*e,
|
|
||||||
GUIDE_BODY_W + 2*e], center = true);
|
|
||||||
}
|
|
||||||
|
|
||||||
// ── Snap-fit tongue (grips column rib, -Y side of body) ───────
|
// Cable channel bracket (side-mounted)
|
||||||
// Two flexible tabs that straddle column rib
|
translate([gap/2 + CLIP_T, -(CABLE_CH_W/2 + CLIP_T), 0])
|
||||||
for (tx = [-GUIDE_BODY_W/2 + 2, GUIDE_BODY_W/2 - 2 - snap_t])
|
cube([CLIP_T + CABLE_CH_H, CABLE_CH_W + 2*CLIP_T, CLIP_W]);
|
||||||
translate([tx, -4, 0])
|
|
||||||
cube([snap_t, 4 + GUIDE_T, body_h]);
|
|
||||||
|
|
||||||
// Snap barbs (slight overhang engages rib back edge)
|
|
||||||
for (tx = [-GUIDE_BODY_W/2 + 2, GUIDE_BODY_W/2 - 2 - snap_t])
|
|
||||||
translate([tx + snap_t/2, -4, body_h/2])
|
|
||||||
rotate([0, 90, 0])
|
|
||||||
cylinder(d = 2, h = snap_t, center = true);
|
|
||||||
}
|
}
|
||||||
|
|
||||||
// ── Rib slot (column rib passes through clip body) ─────────────────
|
// Cable channel cutout
|
||||||
translate([0, -2, body_h/2])
|
translate([gap/2 + CLIP_T + CLIP_T - EPS, -CABLE_CH_W/2, -EPS])
|
||||||
cube([3.5, GUIDE_T + 4 + e, body_h - 4], center = true);
|
cube([CABLE_CH_H + EPS, CABLE_CH_W, CLIP_W + 2*EPS]);
|
||||||
|
|
||||||
|
// Snap tip undercut (both arms)
|
||||||
|
for (s = [-1, 1])
|
||||||
|
translate([s*(gap/2 + CLIP_T + 1.0), -arm_t, -EPS])
|
||||||
|
rotate([0, 0, s*30])
|
||||||
|
cube([2, arm_t*2, CLIP_W + 2*EPS]);
|
||||||
}
|
}
|
||||||
}
|
}
|
||||||
|
|
||||||
|
// ── Assembly / render dispatch ───────────────────────────────
|
||||||
|
module assembly() {
|
||||||
|
// tnut_base at origin
|
||||||
|
color("SteelBlue")
|
||||||
|
tnut_base();
|
||||||
|
|
||||||
|
// column rising from base boss
|
||||||
|
color("DodgerBlue")
|
||||||
|
translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0])
|
||||||
|
column();
|
||||||
|
|
||||||
|
// scan_platform at top of column
|
||||||
|
col_h_actual = ELEV_H - 8.0 - PLAT_T;
|
||||||
|
color("CornflowerBlue")
|
||||||
|
translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 - EPS])
|
||||||
|
scan_platform();
|
||||||
|
|
||||||
|
// vibe rings (4×) seated in platform holes
|
||||||
|
for (a = [45, 135, 225, 315])
|
||||||
|
color("Gray", 0.7)
|
||||||
|
translate([BASE_L/2, BASE_W/2,
|
||||||
|
BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 + PLAT_T - GROM_H])
|
||||||
|
rotate([0, 0, a])
|
||||||
|
translate([RPL_BC_D/2, 0, 0])
|
||||||
|
vibe_ring();
|
||||||
|
|
||||||
|
// cable_guide clipped at column mid-height
|
||||||
|
color("LightSteelBlue")
|
||||||
|
translate([BASE_L/2, BASE_W/2,
|
||||||
|
BASE_T + 8.0 - 6.0 + (ELEV_H - 8.0 - PLAT_T)/2 - CLIP_W/2])
|
||||||
|
cable_guide();
|
||||||
|
}
|
||||||
|
|
||||||
|
// ── Dispatch ────────────────────────────────────────────────
|
||||||
|
if (RENDER == "tnut_base") tnut_base();
|
||||||
|
else if (RENDER == "column") column();
|
||||||
|
else if (RENDER == "scan_platform") scan_platform();
|
||||||
|
else if (RENDER == "vibe_ring") vibe_ring();
|
||||||
|
else if (RENDER == "cable_guide") cable_guide();
|
||||||
|
else assembly();
|
||||||
|
|||||||
Loading…
x
Reference in New Issue
Block a user