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feat: SIM7600X mount + LTE/GNSS antenna brackets #70

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seb merged 1 commits from sl-mechanical/cellular-mount into main 2026-03-01 01:00:50 -05:00
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// ============================================================
// antenna_mount.scad — LTE + GNSS Antenna Brackets Rev A
// 2026-03-01 sl-mechanical
// ============================================================
// Stem-mounted brackets for the SIM7600X cellular/GPS system.
//
// lte_bracket() 25 mm stem clamp + arm with 2× SMA
// bulkhead holes (LTE main + diversity).
// Antennas point skyward.
//
// gnss_platform() 25 mm stem clamp + upward-facing tray
// for active GNSS patch antenna (≤40×40 mm).
//
// Recommended stem positions (above base plate):
// LTE bracket 500–600 mm (above battery carousel)
// GNSS platform 750–800 mm (below sensor head, clear sky)
//
// Both use the same split-collar design:
// M4 clamping bolts + M4 set screw (height lock).
// Cable-tie slot on rear half for u.FL pigtail management.
//
// u.FL → SMA pigtail cables route down stem to SIM7600X HAT.
//
// ⚠ VERIFY: MAWB_HOLE_X / MAWB_HOLE_Y for any M2.5 pattern
// SMA_D for your SMA bulkhead thread OD
//
// RENDER options:
// "lte_assembly" LTE bracket view (default)
// "lte_front" LTE collar front half for slicing
// "lte_rear" LTE collar rear half
// "lte_arm" LTE SMA arm for slicing (print flat)
// "gnss_assembly" GNSS platform view
// "gnss_front" GNSS collar front half
// "gnss_rear" GNSS collar rear half
// "gnss_tray" GNSS patch-antenna tray for slicing
// "full_stem" both brackets on 400 mm stem stub
// ============================================================
RENDER = "lte_assembly";
// ── Stem ─────────────────────────────────────────────────────
STEM_OD = 25.0;
STEM_BORE = 25.4; // +0.4 clearance
// ── Collar (shared) ──────────────────────────────────────────
COL_OD = 52.0;
COL_H = 28.0;
COL_BOLT_X = 19.0; // M4 clamping bolt CL from stem axis
COL_BOLT_D = 4.5; // M4 clearance hole
COL_NUT_W = 7.0; // M4 hex nut A/F
COL_NUT_H = 3.4;
// Cable-tie slot on rear half outer face (for pigtail routing)
TIE_W = 5.0;
TIE_D = 3.0;
TIE_Z1 = COL_H * 0.35;
TIE_Z2 = COL_H * 0.70;
// ── LTE SMA arm ──────────────────────────────────────────────
// 2× SMA bulkhead connectors pointing skyward
SMA_D = 6.6; // SMA bulkhead clearance hole (6.35 mm thread)
SMA_NUT_AF = 10.2; // SMA hex-nut capture across-flats
SMA_NUT_H = 4.5; // hex-nut pocket depth (bottom of arm)
SMA_SPACING = 22.0; // centre-to-centre between 2 SMA positions
LTE_ARM_L = 40.0; // arm length (from collar OD to SMA CL)
LTE_ARM_W = SMA_SPACING + 18.0; // arm width
LTE_ARM_H = 9.0; // arm thickness
LTE_SMA_Y = LTE_ARM_L * 0.65; // SMA position along arm
// Pigtail cable relief (semi-circular groove on arm underside)
PIGTAIL_D = 4.5;
// M3 attachment bolts (arm → collar boss)
M3_D = 3.3;
// ── GNSS patch-antenna tray ───────────────────────────────────
GNSS_PATCH = 40.0; // maximum patch antenna side (fits 25, 35, 40 mm)
GNSS_LIP_T = 2.2; // lip wall thickness
GNSS_LIP_H = 3.0; // lip height above tray surface
GNSS_TRAY_T = 3.0; // tray base thickness
// Optional M2 bolt-down pattern for larger patch antennas
GNSS_M2_SP = 30.0; // M2 spacing (verify with your patch antenna)
M2_D = 2.2;
// Coax cable slot (centre of tray, through base)
GNSS_COAX_W = 5.5;
// Arm connecting tray to collar
GNSS_ARM_L = 28.0;
GNSS_ARM_W = 22.0;
GNSS_ARM_H = 7.0;
// Spacing between LTE and GNSS collars on stem
STEM_SPACING = 80.0;
$fn = 64;
e = 0.01;
// ─────────────────────────────────────────────────────────────
// collar_half(side, arm_type)
// arm_type: "lte" | "gnss" | "none"
// Print flat-face-down.
// ─────────────────────────────────────────────────────────────
module collar_half(side="front", arm_type="lte") {
y_front = (side == "front");
has_arm = y_front && (arm_type != "none");
arm_w = (arm_type == "lte") ? LTE_ARM_W : GNSS_ARM_W;
arm_l = (arm_type == "lte") ? LTE_ARM_L : GNSS_ARM_L;
arm_h = (arm_type == "lte") ? LTE_ARM_H : GNSS_ARM_H;
arm_z = COL_H/2 - arm_h/2;
difference() {
union() {
// D-shaped collar half
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]);
}
// Arm boss integrated into front half
if (has_arm)
translate([-arm_w/2, COL_OD/2, arm_z])
cube([arm_w, arm_l, arm_h]);
}
// 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);
// M4 hex nut pockets (rear half only)
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);
// M4 set screw (height lock, front half outer face)
if (y_front)
translate([0, COL_OD/2, COL_H * 0.75])
rotate([90,0,0])
cylinder(d=COL_BOLT_D,
h=COL_OD/2 - STEM_BORE/2 + e);
// Cable-tie grooves on rear half outer surface (2×)
if (!y_front)
for (tz=[TIE_Z1, TIE_Z2])
translate([-COL_OD/2 - e, -TIE_W/2, tz])
cube([TIE_D + e, TIE_W, TIE_W]);
// M3 attachment holes through arm boss (2×)
if (has_arm)
for (dx=[-arm_w/4, arm_w/4])
translate([dx, COL_OD/2 + arm_l * 0.45, arm_z - e])
cylinder(d=M3_D, h=arm_h + 2*e);
}
}
// ─────────────────────────────────────────────────────────────
// lte_sma_arm()
// Separate arm piece bolts to collar front boss.
// 2× SMA bulkheads point upward. Pigtail grooves on underside.
// Print: lay flat on bottom face.
// ─────────────────────────────────────────────────────────────
module lte_sma_arm() {
difference() {
translate([-LTE_ARM_W/2, 0, 0])
cube([LTE_ARM_W, LTE_ARM_L, LTE_ARM_H]);
// 2× SMA bulkhead through-holes (vertical)
for (dx=[-SMA_SPACING/2, SMA_SPACING/2]) {
translate([dx, LTE_SMA_Y, -e])
cylinder(d=SMA_D, h=LTE_ARM_H + 2*e);
// Hex-nut pocket from bottom face
translate([dx, LTE_SMA_Y, -e])
cylinder(d=SMA_NUT_AF/cos(30), h=SMA_NUT_H + e,
$fn=6);
}
// u.FL pigtail relief grooves on underside
for (dx=[-SMA_SPACING/2, SMA_SPACING/2])
translate([dx, 0, -e])
rotate([0, 0, 0])
linear_extrude(PIGTAIL_D/2 + e)
translate([0, LTE_ARM_L/2])
circle(d=PIGTAIL_D);
// M3 attachment holes (collar boss)
for (dx=[-LTE_ARM_W/4, LTE_ARM_W/4])
translate([dx, LTE_ARM_L * 0.45, -e])
cylinder(d=M3_D, h=LTE_ARM_H + 2*e);
}
}
// ─────────────────────────────────────────────────────────────
// gnss_tray()
// Horizontal tray faces skyward. Retention lip on all 4 sides.
// Central coax slot + optional M2 bolt holes.
// Print: top face on bed (tray upside-down → no supports needed).
// ─────────────────────────────────────────────────────────────
module gnss_tray() {
outer = GNSS_PATCH + 2 * GNSS_LIP_T;
difference() {
union() {
// Base plate
translate([-outer/2, 0, 0])
cube([outer, outer, GNSS_TRAY_T]);
// Retention lip (4 walls)
translate([-outer/2, 0, GNSS_TRAY_T])
difference() {
cube([outer, outer, GNSS_LIP_H]);
translate([GNSS_LIP_T, GNSS_LIP_T, -e])
cube([GNSS_PATCH, GNSS_PATCH, GNSS_LIP_H + 2*e]);
}
// Arm connecting to collar
translate([-GNSS_ARM_W/2, -GNSS_ARM_L, 0])
cube([GNSS_ARM_W, GNSS_ARM_L, GNSS_ARM_H]);
}
// GNSS coax cable slot (centre, through base)
translate([-GNSS_COAX_W/2, outer/2 - GNSS_COAX_W/2, -e])
cube([GNSS_COAX_W, GNSS_COAX_W, GNSS_TRAY_T + 2*e]);
// M2 bolt-down holes (30×30 mm pattern, centred in tray)
tray_cx = 0;
tray_cy = outer/2;
for (dx=[-GNSS_M2_SP/2, GNSS_M2_SP/2])
for (dy=[-GNSS_M2_SP/2, GNSS_M2_SP/2])
translate([tray_cx + dx, tray_cy + dy, -e])
cylinder(d=M2_D, h=GNSS_TRAY_T + 2*e);
// M3 bolt holes (arm → collar)
for (dx=[-GNSS_ARM_W/4, GNSS_ARM_W/4])
translate([dx, -GNSS_ARM_L * 0.45, -e])
cylinder(d=M3_D, h=GNSS_ARM_H + 2*e);
}
}
// ─────────────────────────────────────────────────────────────
// lte_bracket_assembly() / gnss_bracket_assembly()
// ─────────────────────────────────────────────────────────────
module lte_bracket_assembly() {
color("SteelBlue", 0.9) collar_half("front", "lte");
color("CornflowerBlue", 0.9) mirror([0,1,0]) collar_half("rear", "none");
color("LightSteelBlue", 0.85)
translate([0, COL_OD/2, COL_H/2 - LTE_ARM_H/2])
lte_sma_arm();
// Phantom SMA stub antennas
for (dx=[-SMA_SPACING/2, SMA_SPACING/2])
color("DimGray", 0.5)
translate([dx, COL_OD/2 + LTE_SMA_Y,
COL_H/2 + LTE_ARM_H/2])
cylinder(d=7, h=60);
}
module gnss_bracket_assembly() {
color("Teal", 0.9) collar_half("front", "gnss");
color("DarkCyan", 0.9) mirror([0,1,0]) collar_half("rear", "none");
// Tray: arm at Y−, tray faces +Z
color("LightCyan", 0.85)
translate([0, COL_OD/2 + GNSS_ARM_L,
COL_H/2 - GNSS_ARM_H/2])
rotate([90, 0, 0])
gnss_tray();
// Phantom GNSS patch
color("Gold", 0.35)
translate([-GNSS_PATCH/2,
COL_OD/2 + GNSS_ARM_L + GNSS_LIP_T,
COL_H/2 + GNSS_ARM_H/2 + GNSS_TRAY_T])
cube([GNSS_PATCH, GNSS_PATCH, 8]);
}
// ─────────────────────────────────────────────────────────────
// Render selector
// ─────────────────────────────────────────────────────────────
if (RENDER == "lte_assembly") {
lte_bracket_assembly();
} else if (RENDER == "lte_front") {
collar_half("front", "lte");
} else if (RENDER == "lte_rear") {
collar_half("rear", "none");
} else if (RENDER == "lte_arm") {
translate([0, 0, LTE_ARM_H]) rotate([180,0,0]) lte_sma_arm();
} else if (RENDER == "gnss_assembly") {
gnss_bracket_assembly();
} else if (RENDER == "gnss_front") {
collar_half("front", "gnss");
} else if (RENDER == "gnss_rear") {
collar_half("rear", "none");
} else if (RENDER == "gnss_tray") {
gnss_tray();
} else if (RENDER == "full_stem") {
color("Silver", 0.2)
translate([0,0,-40])
cylinder(d=STEM_OD, h=STEM_SPACING + COL_H + 80);
lte_bracket_assembly();
translate([0, 0, STEM_SPACING])
gnss_bracket_assembly();
}

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// ============================================================
// sim7600x_mount.scad — Waveshare SIM7600X 4G HAT Bracket
// Rev A 2026-03-01 sl-mechanical
// ============================================================
// Mounts the SIM7600X HAT near the Jetson Orin on the base plate.
//
// PCB: 65 × 56 mm, 4× M2.5 mounting holes (RPi HAT std pattern).
//
// SIM card access without disassembly:
// The Y− edge of the bracket platform is fully open — a notch
// in the floor plate is wider than the SIM tray so the card
// inserts / ejects with the board fully installed.
//
// Base plate attachment: 4× M3 flat-head countersunk holes at
// bracket corners. Drill M3 clearance holes in base plate and
// use M3 nyloc nuts underneath, or use captured M3 T-nuts.
//
// ⚠ VERIFY WITH CALIPERS BEFORE PRINTING:
// HAT_L, HAT_W PCB dimensions
// HAT_HOLE_X, HAT_HOLE_Y M2.5 hole spacing
// HAT_HOLE_OX, HAT_HOLE_OY hole inset from PCB corners
// SIM_X, SIM_W SIM slot centre & width on Y− edge
// USB_X, USB_W, USB_H USB port on Y− edge
//
// RENDER options:
// "assembly" bracket + phantom PCB (default)
// "bracket" print-ready bracket
// "bracket_2d" floor projection → DXF for base-plate layout
// ============================================================
RENDER = "assembly";
// ── ⚠ Verify before printing ─────────────────────────────────
// Waveshare SIM7600X-H 4G HAT
HAT_L = 65.0; // PCB length (X)
HAT_W = 56.0; // PCB width (Y) — SIM slot on Y=0 edge
HAT_H_BELOW = 3.0; // tallest component on PCB underside (verify)
// RPi HAT standard M2.5 hole pattern
HAT_HOLE_X = 58.0; // X span between hole pairs
HAT_HOLE_Y = 49.0; // Y span between hole pairs
HAT_HOLE_OX = 3.5; // hole inset from X− edge of PCB
HAT_HOLE_OY = 3.5; // hole inset from Y− edge of PCB
M25_D = 2.7; // M2.5 clearance (loose, for alignment)
M25_OD = 5.0; // standoff post outer diameter
// SIM card slot (Y− edge, verify position from left/X− corner)
SIM_X = 42.0; // SIM slot centre from PCB X− edge
SIM_W = 17.0; // SIM slot width
SIM_H_NOTCH = 4.5; // notch height for tray travel + eject pin
// USB Micro-B port (Y− edge, verify — may differ by HAT version)
USB_X = 11.0; // USB port centre from PCB X− edge
USB_W = 10.5; // USB port width
USB_H = 7.0; // USB port height
// u.FL pigtail exit slot (Y+ wall)
UFL_SLOT_W = 12.0;
UFL_SLOT_H = 5.0;
// ── Bracket geometry ─────────────────────────────────────────
STNDFF_H = HAT_H_BELOW + 4.0; // standoff height (clears underside)
PLAT_T = 3.5; // floor plate thickness
WALL_T = 2.5; // side wall thickness
PAD_X = 5.0; // platform extends PAD_X beyond PCB on X± sides
PAD_Y_PLUS = 8.0; // platform extends PAD_Y_PLUS beyond PCB on Y+ side
// Y− side: open (no wall, no floor overhang) — SIM/USB access
PLAT_L = HAT_L + 2 * PAD_X;
PLAT_W = HAT_W + PAD_Y_PLUS; // Y− edge flush with PCB Y=0
// PCB sits with Y=0 edge flush with bracket Y=0 face
PCB_X0 = PAD_X; // X offset of PCB within bracket
// M3 base-plate mounting holes
M3_D = 3.4;
M3_CS_D = 6.2; // flat-head countersink diameter
M3_CS_H = 3.0; // countersink depth (from bottom face)
M3_INSET = 5.0; // hole inset from bracket corner
// Side wall height (for cable containment)
WALL_H = STNDFF_H + 4.0;
$fn = 48;
e = 0.01;
// ─────────────────────────────────────────────────────────────
module sim7600x_bracket() {
difference() {
union() {
// ── Floor plate ──────────────────────────────────
cube([PLAT_L, PLAT_W, PLAT_T]);
// ── Side walls: X−, X+, Y+ only (Y− open) ───────
translate([0, 0, 0])
cube([WALL_T, PLAT_W, WALL_H]);
translate([PLAT_L - WALL_T, 0, 0])
cube([WALL_T, PLAT_W, WALL_H]);
translate([0, PLAT_W - WALL_T, 0])
cube([PLAT_L, WALL_T, WALL_H]);
// ── M2.5 standoff posts (×4) ─────────────────────
for (hx=[0, HAT_HOLE_X], hy=[0, HAT_HOLE_Y])
translate([PCB_X0 + HAT_HOLE_OX + hx,
HAT_HOLE_OY + hy,
PLAT_T])
cylinder(d=M25_OD, h=STNDFF_H);
}
// ── M2.5 clearance bores through standoffs ───────────
for (hx=[0, HAT_HOLE_X], hy=[0, HAT_HOLE_Y])
translate([PCB_X0 + HAT_HOLE_OX + hx,
HAT_HOLE_OY + hy, -e])
cylinder(d=M25_D, h=PLAT_T + STNDFF_H + e);
// ── SIM card access notch (Y− face of floor) ─────────
// Notch 4 mm wider than SIM slot each side
translate([PCB_X0 + SIM_X - SIM_W/2 - 4, -e, -e])
cube([SIM_W + 8, WALL_T + e, PLAT_T + SIM_H_NOTCH + e]);
// ── USB port access notch (Y− face of X− wall) ───────
translate([PCB_X0 + USB_X - USB_W/2, -e,
PLAT_T + STNDFF_H/2 - USB_H/2])
cube([USB_W, WALL_T + 2*e, USB_H]);
// ── u.FL pigtail exit slot (Y+ wall, upper zone) ─────
translate([PLAT_L/2 - UFL_SLOT_W/2,
PLAT_W - WALL_T - e,
PLAT_T + STNDFF_H - UFL_SLOT_H])
cube([UFL_SLOT_W, WALL_T + 2*e, UFL_SLOT_H + e]);
// ── M3 base-plate mounting holes (×4, countersunk) ───
for (cx=[M3_INSET, PLAT_L - M3_INSET])
for (cy=[M3_INSET, PLAT_W - M3_INSET]) {
translate([cx, cy, -e])
cylinder(d=M3_D, h=PLAT_T + 2*e);
// Countersink from bottom face
translate([cx, cy, -e])
cylinder(d1=M3_CS_D, d2=M3_D,
h=M3_CS_H + e);
}
// ── Cable relief notch in X+ wall ────────────────────
translate([PLAT_L - WALL_T - e, PLAT_W * 0.35, PLAT_T + 2])
cube([WALL_T + 2*e, 9, 5]);
}
}
// ─────────────────────────────────────────────────────────────
if (RENDER == "assembly") {
color("DimGray", 0.92) sim7600x_bracket();
// Phantom PCB
color("ForestGreen", 0.3)
translate([PCB_X0, 0, PLAT_T + STNDFF_H])
cube([HAT_L, HAT_W, 1.6]);
// SIM access marker (yellow arrow zone)
color("Gold", 0.7)
translate([PCB_X0 + SIM_X - 10, -8, 0])
cube([20, 8, 2]);
} else if (RENDER == "bracket") {
sim7600x_bracket();
} else if (RENDER == "bracket_2d") {
projection(cut=true)
translate([0, 0, -PLAT_T/2])
sim7600x_bracket();
}