sl-mechanical
8222a0c42e
Universal 5 V/5 A charging dock for SaltyLab/Rover/Tank robots: - charging_dock.scad: weighted base (ballast pockets, floor anchors), back wall with 2× 5 A pogo pin housing + wiring channel, V-guide funnel rails (±20 mm alignment tolerance), ArUco marker mast (100×100 mm, 15° tilt), PSU bracket (IRM-30-5), 4-LED status bezel (Searching/Aligned/Charging/Full) - charging_dock_receiver.scad: 3-variant robot-side contact plate with Ø12 mm brass pad press-fit, V-nose self-alignment; SaltyLab stem collar, SaltyRover deck flange, SaltyTank skid-plate mount - charging_dock_BOM.md: hardware list, ASCII wiring diagram, INA219 current-sense LED state logic, pogo height cross-variant shim table, assembly sequence, export commands Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
332 lines
14 KiB
OpenSCAD
332 lines
14 KiB
OpenSCAD
// ============================================================
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// charging_dock_receiver.scad — Robot-Side Charging Receiver
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// Issue: #159 Agent: sl-mechanical Date: 2026-03-01
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// ============================================================
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//
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// Robot-side contact plate that mates with the charging dock pogo pins.
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// Each robot variant has a different mounting interface; the contact
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// geometry is identical across all variants (same pogo pin spacing).
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//
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// Variants:
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// A — lab_receiver() SaltyLab — mounts to underside of stem base ring
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// B — rover_receiver() SaltyRover — mounts to chassis belly (M4 deck holes)
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// C — tank_receiver() SaltyTank — mounts to skid plate / hull floor
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//
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// Contact geometry (common across variants):
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// 2× brass contact pads, Ø12 mm × 2 mm (press-fit into PETG housing)
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// Pad spacing: 20 mm CL-to-CL (matches dock POGO_SPACING exactly)
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// Contact face Z height matches dock pogo pin Z when robot is level
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// Polarity: marked + on top pin (conventional: positive = right when
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// facing dock; negative = left) — must match dock wiring.
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//
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// Approach guide nose:
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// A chamfered V-nose on the forward face guides the receiver block
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// into the dock's V-funnel. Taper half-angle ≈ 14° matches guide rails.
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// Nose width = RECV_W = 30 mm (matches dock EXIT_GAP - 2 mm clearance).
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//
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// Coordinate convention:
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// Z = 0 at receiver mounting face (against robot chassis/deck underside).
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// +Z points downward (toward dock floor).
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// Contact pads face +Y (toward dock back wall when docked).
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// Receiver centred on X = 0 (robot centreline).
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//
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// RENDER options:
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// "assembly" all 3 receivers side by side
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// "lab_stl" SaltyLab receiver (print 1×)
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// "rover_stl" SaltyRover receiver (print 1×)
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// "tank_stl" SaltyTank receiver (print 1×)
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// "contact_pad_2d" DXF — Ø12 mm brass pad profile (order from metal shop)
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//
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// Export:
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// openscad charging_dock_receiver.scad -D 'RENDER="lab_stl"' -o receiver_lab.stl
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// openscad charging_dock_receiver.scad -D 'RENDER="rover_stl"' -o receiver_rover.stl
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// openscad charging_dock_receiver.scad -D 'RENDER="tank_stl"' -o receiver_tank.stl
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// openscad charging_dock_receiver.scad -D 'RENDER="contact_pad_2d"' -o contact_pad.dxf
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// ============================================================
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$fn = 64;
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e = 0.01;
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// ── Contact geometry (must match charging_dock.scad) ─────────────────────────
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POGO_SPACING = 20.0; // CL-to-CL (dock POGO_SPACING)
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PAD_D = 12.0; // contact pad OD (brass disc)
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PAD_T = 2.0; // contact pad thickness
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PAD_RECESS = 1.8; // pad pressed into housing (0.2 mm proud for contact)
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PAD_PROUD = 0.2; // pad face protrudes from housing face
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// ── Common receiver body geometry ────────────────────────────────────────────
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RECV_W = 30.0; // receiver body width (X) — matches dock EXIT_GAP inner
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RECV_D = 25.0; // receiver body depth (Y, docking direction)
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RECV_H = 12.0; // receiver body height (Z, from mount face down)
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RECV_R = 3.0; // corner radius
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// V-nose geometry (front Y face — faces dock back wall)
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NOSE_CHAMFER = 10.0; // chamfer depth on X corners of front face
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// Polarity indicator slot (on top/mount face: + on right, - on left)
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POL_SLOT_W = 4.0;
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POL_SLOT_D = 8.0;
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POL_SLOT_H = 1.0;
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// Fasteners
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M2_D = 2.4;
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M3_D = 3.3;
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M4_D = 4.3;
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// ── Mounting patterns ─────────────────────────────────────────────────────────
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// SaltyLab stem base ring (Ø25 mm stem, 4× M3 in ring at Ø40 mm BC)
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LAB_BC_D = 40.0;
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LAB_BOLT_D = M3_D;
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LAB_COLLAR_H = 15.0; // collar height above receiver body
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// SaltyRover deck (M4 grid pattern, 30.5×30.5 mm matching FC pattern on deck)
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// Receiver uses 4× M4 holes at ±20 mm from centre (clear of deck electronics)
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ROVER_BOLT_SPC = 40.0;
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// SaltyTank skid plate (M4 holes matching skid plate bolt pattern)
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// Uses 4× M4 at ±20 mm X, ±10 mm Y (inset from skid plate M4 positions)
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TANK_BOLT_SPC_X = 40.0;
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TANK_BOLT_SPC_Y = 20.0;
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TANK_NOSE_L = 20.0; // extended nose for tank (wider hull)
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// ============================================================
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// RENDER DISPATCH
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// ============================================================
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RENDER = "assembly";
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if (RENDER == "assembly") assembly();
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else if (RENDER == "lab_stl") lab_receiver();
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else if (RENDER == "rover_stl") rover_receiver();
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else if (RENDER == "tank_stl") tank_receiver();
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else if (RENDER == "contact_pad_2d") {
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projection(cut = true) translate([0, 0, -0.5])
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linear_extrude(1) circle(d = PAD_D);
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}
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// ============================================================
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// ASSEMBLY PREVIEW
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// ============================================================
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module assembly() {
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// SaltyLab receiver
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color("RoyalBlue", 0.85)
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translate([-80, 0, 0])
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lab_receiver();
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// SaltyRover receiver
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color("OliveDrab", 0.85)
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translate([0, 0, 0])
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rover_receiver();
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// SaltyTank receiver
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color("SaddleBrown", 0.85)
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translate([80, 0, 0])
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tank_receiver();
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}
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// ============================================================
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// COMMON RECEIVER BODY
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// ============================================================
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// Internal helper: the shared contact housing + V-nose.
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// Orientation: mount face = +Z top; contact face = +Y front.
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// All variant-specific modules call this, then add their mount interface.
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module _receiver_body() {
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difference() {
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union() {
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// ── Main housing block (rounded) ─────────────────────────
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linear_extrude(RECV_H)
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_recv_profile_2d();
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// ── V-nose chamfer reinforcement ribs ─────────────────────
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// Two diagonal ribs at 45° reinforce the chamfered corners
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for (sx = [-1, 1])
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hull() {
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translate([sx*(RECV_W/2 - NOSE_CHAMFER),
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RECV_D/2, 0])
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cylinder(d = 3, h = RECV_H * 0.6);
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translate([sx*(RECV_W/2), RECV_D/2 - NOSE_CHAMFER, 0])
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cylinder(d = 3, h = RECV_H * 0.6);
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}
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}
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// ── Contact pad bores (2× Ø12 mm, press-fit) ─────────────────
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// Pads face +Y; bores from Y face into housing
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for (px = [-POGO_SPACING/2, POGO_SPACING/2])
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translate([px, RECV_D/2 + e, RECV_H/2])
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rotate([90, 0, 0]) {
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// Pad press-fit bore
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cylinder(d = PAD_D + 0.1,
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h = PAD_RECESS + e);
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// Wire bore (behind pad, to mount face)
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translate([0, 0, PAD_RECESS])
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cylinder(d = 3.0,
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h = RECV_D + 2*e);
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}
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// ── Polarity indicator slots on top face ──────────────────────
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// "+" slot: right pad (+X side)
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translate([POGO_SPACING/2, 0, -e])
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cube([POL_SLOT_W, POL_SLOT_D, POL_SLOT_H + e], center = true);
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// "-" indent: left pad (no slot = negative)
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// ── Wire routing channel (on mount face / underside) ──────────
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// Trough connecting both pad bores for neat wire run
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translate([0, RECV_D/2 - POGO_SPACING/2, RECV_H - 3])
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cube([POGO_SPACING + 6, POGO_SPACING, 4], center = true);
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}
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}
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// ── 2D profile of receiver body with chamfered V-nose ────────────────────────
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module _recv_profile_2d() {
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hull() {
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// Rear corners (full width)
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for (sx = [-1, 1])
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translate([sx*(RECV_W/2 - RECV_R), -RECV_D/2 + RECV_R])
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circle(r = RECV_R);
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// Front corners (chamfered — narrowed by NOSE_CHAMFER)
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for (sx = [-1, 1])
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translate([sx*(RECV_W/2 - NOSE_CHAMFER - RECV_R),
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RECV_D/2 - RECV_R])
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circle(r = RECV_R);
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}
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}
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// ============================================================
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// PART A — SALTYLAB RECEIVER
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// ============================================================
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// Mounts to the underside of the SaltyLab chassis stem base ring.
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// Split collar grips Ø25 mm stem; receiver body hangs below collar.
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// Z height set so contact pads align with dock pogo pins when robot
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// rests on flat surface (robot wheel-to-contact-pad height calibrated).
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//
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// Receiver height above floor: tune LAB_CONTACT_Z in firmware (UWB/ArUco
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// approach). Mechanically: receiver sits ~35 mm above ground (stem base
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// height), matching dock POGO_Z = 35 mm.
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module lab_receiver() {
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collar_od = 46.0; // matches sensor_rail.scad STEM_COL_OD
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collar_h = LAB_COLLAR_H;
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union() {
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// ── Common receiver body ────────────────────────────────────
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_receiver_body();
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// ── Stem collar (split, 2 halves joined with M4 bolts) ───────
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// Only the front half printed here; rear half is mirror.
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translate([0, -RECV_D/2, RECV_H])
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difference() {
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// Half-collar cylinder
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rotate_extrude(angle = 180)
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translate([collar_od/2 - 8, 0, 0])
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square([8, collar_h]);
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// Stem bore clearance
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translate([0, 0, -e])
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cylinder(d = 25.5, h = collar_h + 2*e);
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// 2× M4 clamping bolt bores (through collar flanges)
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for (cx = [-collar_od/2 + 4, collar_od/2 - 4])
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translate([cx, 0, collar_h/2])
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rotate([90, 0, 0])
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cylinder(d = M4_D,
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h = collar_od + 2*e,
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center = true);
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}
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// ── M3 receiver-to-collar bolts ───────────────────────────────
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// 4× M3 holes connecting collar flange to receiver body top
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// (These are mounting holes for assembly; not holes in the part)
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}
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}
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// ============================================================
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// PART B — SALTYOVER RECEIVER
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// ============================================================
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// Mounts to the underside of the SaltyRover deck plate.
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// 4× M4 bolts into deck underside (blind holes tapped in deck).
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// Receiver sits flush with deck belly; contact pads protrude 5 mm below.
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// Dock pogo Z = 35 mm must equal ground-to-deck-belly height for rover
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// (approximately 60 mm chassis clearance — shim with spacer if needed).
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module rover_receiver() {
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mount_h = 5.0; // mounting flange thickness
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union() {
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// ── Common receiver body ────────────────────────────────────
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_receiver_body();
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// ── Mounting flange (attaches to deck belly) ─────────────────
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difference() {
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translate([-(ROVER_BOLT_SPC/2 + 12),
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-RECV_D/2 - 10,
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RECV_H])
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cube([ROVER_BOLT_SPC + 24,
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RECV_D + 20,
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mount_h]);
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// 4× M4 bolt holes
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for (fx = [-1, 1]) for (fy = [-1, 1])
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translate([fx*ROVER_BOLT_SPC/2,
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fy*(RECV_D/2 + 5),
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RECV_H - e])
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cylinder(d = M4_D,
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h = mount_h + 2*e);
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// Weight-reduction pockets
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for (sx = [-1, 1])
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translate([sx*(ROVER_BOLT_SPC/4 + 6),
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0, RECV_H + 1])
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cube([ROVER_BOLT_SPC/2 - 4, RECV_D - 4, mount_h],
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center = true);
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}
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}
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}
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// ============================================================
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// PART C — SALTYTANK RECEIVER
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// ============================================================
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// Mounts to SaltyTank hull floor or replaces a section of skid plate.
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// Extended front nose (TANK_NOSE_L) for tank's wider hull approach.
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// Contact pads exposed through skid plate via a 30×16 mm slot.
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// Ground clearance: tank chassis = 90 mm; dock POGO_Z = 35 mm.
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// Use ramp shim (see BOM) under dock base to elevate pogo pins to 90 mm
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// OR set POGO_Z = 90 in dock for a tank-specific dock configuration.
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// ⚠ Cross-variant dock: set POGO_Z per robot if heights differ.
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// Compromise: POGO_Z = 60 mm with 25 mm ramp for tank, 25 mm spacer for lab.
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module tank_receiver() {
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mount_h = 4.0;
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nose_l = RECV_D/2 + TANK_NOSE_L;
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union() {
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// ── Common receiver body ────────────────────────────────────
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_receiver_body();
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// ── Extended nose for tank approach ──────────────────────────
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// Additional chamfered wedge ahead of standard receiver body
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hull() {
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// Receiver front face corners
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for (sx = [-1, 1])
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translate([sx*(RECV_W/2 - NOSE_CHAMFER), RECV_D/2, 0])
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cylinder(d = 2*RECV_R, h = RECV_H * 0.5);
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// Extended nose tip (narrowed to 20 mm)
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for (sx = [-1, 1])
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translate([sx*10, RECV_D/2 + TANK_NOSE_L, 0])
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cylinder(d = 2*RECV_R, h = RECV_H * 0.4);
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}
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// ── Mounting flange (bolts to tank skid plate) ────────────────
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difference() {
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translate([-(TANK_BOLT_SPC_X/2 + 10),
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-RECV_D/2 - 8,
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RECV_H])
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cube([TANK_BOLT_SPC_X + 20,
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RECV_D + 16,
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mount_h]);
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// 4× M4 bolt holes
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for (fx = [-1, 1]) for (fy = [-1, 1])
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translate([fx*TANK_BOLT_SPC_X/2,
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fy*TANK_BOLT_SPC_Y/2,
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RECV_H - e])
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cylinder(d = M4_D,
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h = mount_h + 2*e);
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}
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}
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}
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