feat: VESC dual ESC mount bracket for T-slot (Issue #699) #704
296
chassis/vesc_mount.scad
Normal file
296
chassis/vesc_mount.scad
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// ============================================================
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// vesc_mount.scad — FSESC 6.7 Pro Mini Dual ESC Mount Cradle
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// Issue #699 / sl-mechanical 2026-03-17
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// ============================================================
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// Open-top tray for Flipsky FSESC 6.7 Pro Mini Dual (~100 × 68 × 28 mm).
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// Attaches to 2020 aluminium T-slot rail via 4× M5 T-nuts
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// (2× per rail, two parallel rails, 60 mm bolt spacing in X,
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// 20 mm bolt spacing in Y matching 2020 slot pitch).
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//
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// Connector access:
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// XT60 battery inputs — X− end wall cutouts (2 connectors, side-by-side)
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// XT30 motor outputs — Y+ and Y− side wall cutouts (2 per side wall)
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// CAN/UART terminal — X+ end wall cutout (screw terminal, wire exit)
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//
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// Ventilation:
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// Open top face — heatsink fins fully exposed
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// Floor grille slots — under-board airflow
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// Side vent louvres — 4 slots on each Y± wall at heatsink height
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//
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// Retention: 4× M3 heat-set insert boss in floor — board screws down through
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// ESC mounting holes via M3×8 FHCS. Board sits on 4 mm raised posts for
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// under-board airflow.
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//
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// ⚠ VERIFY WITH CALIPERS BEFORE PRINTING:
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// PCB_L, PCB_W board outline
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// XT60_W, XT60_H XT60 shell at X− edge
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// XT30_W, XT30_H XT30 shells at Y± edges
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// TERM_W, TERM_H CAN screw terminal at X+ edge
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// MOUNT_X1/X2, MOUNT_Y1/Y2 ESC board mounting hole pattern
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//
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// Print settings (PETG):
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// 3 perimeters, 40 % gyroid infill, no supports, 0.2 mm layer
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// Print orientation: open face UP (as modelled)
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//
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// BOM:
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// 4 × M5×10 BHCS + 4 × M5 slide-in T-nut (2020 rail)
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// 4 × M3 heat-set insert (Voron-style, OD 4.5 mm × 4 mm deep)
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// 4 × M3×8 FHCS (board retention)
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//
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// Export commands:
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// openscad -D 'RENDER="mount"' -o vesc_mount.stl vesc_mount.scad
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// openscad -D 'RENDER="assembly"' -o vesc_assembly.png vesc_mount.scad
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// ============================================================
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RENDER = "assembly"; // mount | assembly
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$fn = 48;
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EPS = 0.01;
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// ── ⚠ Verify before printing ─────────────────────────────────
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// FSESC 6.7 Pro Mini Dual PCB
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PCB_L = 100.0; // board length (X: XT60 end → CAN terminal end)
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PCB_W = 68.0; // board width (Y)
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PCB_T = 2.0; // board thickness (incl. bottom-side components)
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COMP_H = 26.0; // tallest component above board top face (heatsink ~26 mm)
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// XT60 battery connectors at X− end (2 connectors, side-by-side)
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XT60_W = 16.0; // each XT60 shell width (Y)
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XT60_H = 16.0; // each XT60 shell height (Z) above board surface
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XT60_Z0 = 0.0; // connector bottom offset above board surface
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// Y centres of each XT60 measured from PCB Y− edge
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XT60_Y1 = 16.0;
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XT60_Y2 = 52.0;
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// XT30 motor output connectors at Y± sides (2 per side)
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XT30_W = 10.5; // each XT30 shell width (X span)
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XT30_H = 12.0; // each XT30 shell height (Z) above board surface
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XT30_Z0 = 0.5; // connector bottom offset above board surface
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// X centres measured from PCB X− edge (same layout both Y− and Y+ sides)
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XT30_X1 = 22.0;
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XT30_X2 = 78.0;
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// CAN / UART screw terminal block at X+ end (3-pos 3.5 mm pitch)
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TERM_W = 14.0; // terminal block Y span
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TERM_H = 10.0; // terminal block height above board surface
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TERM_Z0 = 0.5; // terminal bottom offset above board surface
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TERM_Y_CTR = PCB_W / 2;
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// ── ESC board mounting hole pattern ──────────────────────────
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// 4 corner holes, 4 mm inset from each PCB edge
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MOUNT_INSET = 4.0;
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MOUNT_X1 = MOUNT_INSET;
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MOUNT_X2 = PCB_L - MOUNT_INSET;
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MOUNT_Y1 = MOUNT_INSET;
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MOUNT_Y2 = PCB_W - MOUNT_INSET;
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M3_INSERT_OD = 4.6; // Voron M3 heat-set insert press-fit OD
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M3_INSERT_H = 4.0; // insert depth
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M3_CLEAR_D = 3.4; // M3 clearance bore below insert
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// ── Cradle geometry ──────────────────────────────────────────
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WALL_T = 2.8; // side / end wall thickness
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FLOOR_T = 4.5; // floor plate thickness (fits M5 BHCS head pocket)
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POST_H = 4.0; // standoff post height (board lifts off floor for airflow)
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CL_SIDE = 0.35; // Y clearance per side
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CL_END = 0.40; // X clearance per end
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INN_W = PCB_W + 2*CL_SIDE;
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INN_L = PCB_L + 2*CL_END;
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INN_H = POST_H + PCB_T + COMP_H + 1.5;
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OTR_W = INN_W + 2*WALL_T;
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OTR_L = INN_L + 2*WALL_T;
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OTR_H = FLOOR_T + INN_H;
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PCB_X0 = WALL_T + CL_END;
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PCB_Y0 = WALL_T + CL_SIDE;
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PCB_Z0 = FLOOR_T + POST_H;
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// ── M5 T-nut mount (2020 rail) ────────────────────────────────
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// 4 bolts: 2 columns (X) × 2 rows (Y), centred on body
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M5_D = 5.3;
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M5_HEAD_D = 9.5;
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M5_HEAD_H = 3.0;
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M5_SPAC_X = 60.0; // X bolt spacing
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M5_SPAC_Y = 20.0; // Y bolt spacing (2020 T-slot pitch)
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// ── Floor ventilation grille ──────────────────────────────────
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GRILLE_SLOT_W = 4.0;
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GRILLE_SLOT_T = FLOOR_T - 1.5;
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GRILLE_PITCH = 10.0;
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GRILLE_X0 = WALL_T + 14;
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GRILLE_X_LEN = OTR_L - 2*WALL_T - 28;
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GRILLE_N = floor((INN_W - 10) / GRILLE_PITCH);
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// ── Side vent louvres on Y± walls ────────────────────────────
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LOUV_H = 5.0;
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LOUV_W = 12.0;
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LOUV_Z = FLOOR_T + POST_H + PCB_T + 4.0; // mid-heatsink height
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LOUV_N = 4;
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LOUV_PITCH = (OTR_L - 2*WALL_T - 20) / max(LOUV_N - 1, 1);
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// ── CAN wire strain relief bosses (X+ end) ───────────────────
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SR_BOSS_OD = 7.0;
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SR_BOSS_H = 6.0;
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SR_SLOT_W = 3.5;
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SR_SLOT_T = 2.2;
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SR_Y1 = WALL_T + INN_W * 0.25;
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SR_Y2 = WALL_T + INN_W * 0.75;
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SR_X = OTR_L - WALL_T - SR_BOSS_OD/2 - 2.5;
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// ─────────────────────────────────────────────────────────────
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module m3_insert_boss() {
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// Solid post with heat-set insert bore from top
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post_h = FLOOR_T + POST_H;
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difference() {
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cylinder(d = M3_INSERT_OD + 3.2, h = post_h);
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// Insert bore from top
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translate([0, 0, post_h - M3_INSERT_H])
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cylinder(d = M3_INSERT_OD, h = M3_INSERT_H + EPS);
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// Clearance bore from bottom
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translate([0, 0, -EPS])
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cylinder(d = M3_CLEAR_D, h = post_h - M3_INSERT_H + EPS);
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}
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}
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module vesc_mount() {
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difference() {
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union() {
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// Main body
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cube([OTR_L, OTR_W, OTR_H]);
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// M3 insert bosses at board mounting corners
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for (mx = [MOUNT_X1, MOUNT_X2])
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for (my = [MOUNT_Y1, MOUNT_Y2])
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translate([PCB_X0 + mx, PCB_Y0 + my, 0])
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m3_insert_boss();
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// CAN strain relief bosses on X+ end
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for (sy = [SR_Y1, SR_Y2])
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translate([SR_X, sy, 0])
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cylinder(d = SR_BOSS_OD, h = SR_BOSS_H);
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}
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// ── Interior cavity (open top) ─────────────────────────
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translate([WALL_T, WALL_T, FLOOR_T])
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cube([INN_L, INN_W, INN_H + EPS]);
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// ── XT60 cutouts at X− end (2 connectors) ──────────────
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for (yc = [XT60_Y1, XT60_Y2])
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translate([-EPS,
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PCB_Y0 + yc - (XT60_W + 2.0)/2,
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PCB_Z0 + XT60_Z0 - 0.5])
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cube([WALL_T + 2*EPS, XT60_W + 2.0, XT60_H + 3.0]);
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// ── XT30 cutouts at Y− side (2 connectors) ─────────────
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for (xc = [XT30_X1, XT30_X2])
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translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
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-EPS,
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PCB_Z0 + XT30_Z0 - 0.5])
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cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
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// ── XT30 cutouts at Y+ side (2 connectors) ─────────────
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for (xc = [XT30_X1, XT30_X2])
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translate([PCB_X0 + xc - (XT30_W + 2.0)/2,
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OTR_W - WALL_T - EPS,
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PCB_Z0 + XT30_Z0 - 0.5])
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cube([XT30_W + 2.0, WALL_T + 2*EPS, XT30_H + 3.0]);
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// ── CAN terminal cutout at X+ end ──────────────────────
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translate([OTR_L - WALL_T - EPS,
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PCB_Y0 + TERM_Y_CTR - (TERM_W + 3.0)/2,
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PCB_Z0 + TERM_Z0 - 0.5])
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cube([WALL_T + 2*EPS, TERM_W + 3.0, TERM_H + 5.0]);
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// ── Floor ventilation grille ───────────────────────────
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for (i = [0 : GRILLE_N - 1]) {
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sy = WALL_T + 5 + i * GRILLE_PITCH;
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translate([GRILLE_X0, sy, -EPS])
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cube([GRILLE_X_LEN, GRILLE_SLOT_W, GRILLE_SLOT_T + EPS]);
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}
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// ── Side vent louvres — Y− wall ────────────────────────
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for (i = [0 : LOUV_N - 1]) {
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lx = WALL_T + 10 + i * LOUV_PITCH;
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translate([lx, -EPS, LOUV_Z])
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cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
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}
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// ── Side vent louvres — Y+ wall ────────────────────────
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for (i = [0 : LOUV_N - 1]) {
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lx = WALL_T + 10 + i * LOUV_PITCH;
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translate([lx, OTR_W - WALL_T - EPS, LOUV_Z])
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cube([LOUV_W, WALL_T + 2*EPS, LOUV_H]);
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}
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// ── M5 BHCS head pockets (4 bolts, bottom face) ────────
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for (mx = [OTR_L/2 - M5_SPAC_X/2, OTR_L/2 + M5_SPAC_X/2])
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for (my = [OTR_W/2 - M5_SPAC_Y/2, OTR_W/2 + M5_SPAC_Y/2])
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translate([mx, my, -EPS]) {
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cylinder(d = M5_D, h = FLOOR_T + 2*EPS);
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cylinder(d = M5_HEAD_D, h = M5_HEAD_H + EPS);
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}
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// ── Zip-tie slots through CAN strain relief bosses ─────
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for (sy = [SR_Y1, SR_Y2])
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translate([SR_X, sy, SR_BOSS_H/2 - SR_SLOT_T/2])
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rotate([0, 90, 0])
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cube([SR_SLOT_T, SR_SLOT_W, SR_BOSS_OD + 2*EPS],
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center = true);
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// ── Weight-relief pocket in floor underside ─────────────
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translate([WALL_T + 16, WALL_T + 6, -EPS])
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cube([OTR_L - 2*WALL_T - 32, OTR_W - 2*WALL_T - 12,
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FLOOR_T - 2.0 + EPS]);
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}
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}
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// ── Assembly preview ─────────────────────────────────────────
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if (RENDER == "assembly") {
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color("DimGray", 0.93) vesc_mount();
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// Phantom PCB
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color("ForestGreen", 0.30)
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translate([PCB_X0, PCB_Y0, PCB_Z0])
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cube([PCB_L, PCB_W, PCB_T]);
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// Phantom heatsink / component block
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color("SlateGray", 0.22)
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translate([PCB_X0, PCB_Y0, PCB_Z0 + PCB_T])
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cube([PCB_L, PCB_W, COMP_H]);
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// XT60 connector highlights (X− end)
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for (yc = [XT60_Y1, XT60_Y2])
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color("Gold", 0.85)
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translate([-2,
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PCB_Y0 + yc - XT60_W/2,
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PCB_Z0 + XT60_Z0])
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cube([WALL_T + 3, XT60_W, XT60_H]);
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// XT30 connector highlights — Y− side
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for (xc = [XT30_X1, XT30_X2])
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color("OrangeRed", 0.80)
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translate([PCB_X0 + xc - XT30_W/2,
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-2,
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PCB_Z0 + XT30_Z0])
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cube([XT30_W, WALL_T + 3, XT30_H]);
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// XT30 connector highlights — Y+ side
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for (xc = [XT30_X1, XT30_X2])
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color("OrangeRed", 0.80)
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translate([PCB_X0 + xc - XT30_W/2,
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OTR_W - WALL_T - 1,
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PCB_Z0 + XT30_Z0])
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cube([XT30_W, WALL_T + 3, XT30_H]);
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// CAN terminal highlight
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color("Tomato", 0.75)
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translate([OTR_L - WALL_T - 1,
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PCB_Y0 + TERM_Y_CTR - TERM_W/2,
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PCB_Z0 + TERM_Z0])
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cube([WALL_T + 3, TERM_W, TERM_H]);
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} else {
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vesc_mount();
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}
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