sl-mechanical
796e343b78
Dovetail rail + tool-free swappable payload modules for all variants: - payload_bay_rail.scad: 50×12 mm 60° dovetail rail (DXF for CNC Al bar), spring ball detent (Ø6 mm, 50 mm pitch), continuous safety-lock groove (M4 thumbscrew), 4-pin pogo connector housing (GND/5V/12V/UART), lab/rover/tank deck adapter plates - payload_bay_modules.scad: universal _module_base() (male tongue, detent bore, 4× Ø4 mm target pads, lock bore) + 3 example modules: cargo tray (200×100 mm, Velcro slots, bungee cord slots), camera boom (120 mm mast + 80 mm arm, 2020-rail-compatible head, 3-position tilt), cup holder (Ø80 mm tapered, 8-slot flex grip). Includes copy-paste module template. - payload_bay_BOM.md: hardware list, CNC spec (dovetail dimensions, surface finish, connector pocket), load analysis (2 kg rated with Al rail + lock), module developer guide with constraints table Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
463 lines
22 KiB
OpenSCAD
463 lines
22 KiB
OpenSCAD
// ============================================================
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// payload_bay_modules.scad — Payload Bay Module Template + Examples
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// Issue: #170 Agent: sl-mechanical Date: 2026-03-01
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// ============================================================
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//
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// ── HOW TO CREATE A NEW MODULE ──────────────────────────────────────────────
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//
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// 1. Copy the "MODULE TEMPLATE" section at the bottom of this file.
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// 2. Set MODULE_L to your module's Y length (min 60 mm).
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// 3. Add your payload geometry on top of the _module_base() call.
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// 4. The _module_base() provides:
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// • Male dovetail tongue (slides into rail slot)
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// • Spring detent bore(s) (for Ø6 mm ball + spring plunger)
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// • Connector target pads (4× Ø4 mm brass, matching rail pogo pins)
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// • Safety-lock M4 thumbscrew bore (side of tongue)
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// • Bottom-face flush with rail top (Z = 0 at rail top / module base)
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// 5. Your payload geometry sits at Z ≥ 0 (above the rail top face).
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// 6. Add a RENDER dispatch entry and export command.
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//
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// ── DOVETAIL TONGUE GEOMETRY ────────────────────────────────────────────────
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//
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// TONGUE_BOT = DOVE_SLOT_BOT - 2*DOVE_CLEAR = 28.0 - 0.6 = 27.4 mm
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// TONGUE_TOP = DOVE_SLOT_TOP + 2*DOVE_CLEAR = 37.2 + 0.6 = 37.8 mm
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// TONGUE_H = DOVE_H + 0.2 (slight extra depth, no binding at corners)
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//
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// Tongue runs full module length (-Y to +Y in module coords).
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// Module body sits on top of tongue at Z = 0.
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//
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// ── CONNECTOR PADS ──────────────────────────────────────────────────────────
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// 4× Ø4 mm brass discs press-fit into tongue bottom face.
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// Pad positions: must align with rail connector at CONN_Y when module
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// is slid to its intended position (any detent step).
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// Default: pads centred in module length → module must be placed so its
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// centre aligns with CONN_Y on rail. Or: set MODULE_CONN_OFFSET to shift.
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//
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// ── PAYLOAD RATING ──────────────────────────────────────────────────────────
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// 2 kg rated payload when safety-lock thumbscrew is tightened.
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// Detent-only (no thumbscrew): ~0.5 kg (impact / vibration condition).
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//
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// ── RENDERED EXAMPLES ────────────────────────────────────────────────────────
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// Part 1 — cargo_tray() 200×100 mm cargo tray, 30 mm walls
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// Part 2 — camera_boom() L-arm with sensor_rail-compatible head
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// Part 3 — cup_holder() Ø80 mm tapered cup cradle
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//
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// RENDER options:
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// "assembly" all 3 modules on ghost rail
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// "base_stl" module base / tongue only (universal)
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// "cargo_tray_stl" cargo tray module
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// "camera_boom_stl" camera boom module
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// "cup_holder_stl" cup holder module
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// "target_pad_2d" DXF — Ø4 mm brass target pad profile
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//
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// Export:
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// openscad payload_bay_modules.scad -D 'RENDER="base_stl"' -o payload_base.stl
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// openscad payload_bay_modules.scad -D 'RENDER="cargo_tray_stl"' -o payload_cargo_tray.stl
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// openscad payload_bay_modules.scad -D 'RENDER="camera_boom_stl"' -o payload_camera_boom.stl
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// openscad payload_bay_modules.scad -D 'RENDER="cup_holder_stl"' -o payload_cup_holder.stl
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// ============================================================
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$fn = 64;
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e = 0.01;
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// ── Rail geometry constants (must match payload_bay_rail.scad) ────────────────
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RAIL_W = 50.0;
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RAIL_T = 12.0;
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DOVE_ANGLE = 30.0;
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DOVE_H = 8.0;
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DOVE_SLOT_BOT = 28.0;
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DOVE_SLOT_TOP = DOVE_SLOT_BOT + 2 * DOVE_H * tan(DOVE_ANGLE);
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DOVE_CLEAR = 0.3;
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DETENT_PITCH = 50.0;
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DETENT_BALL_D = 6.0;
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DETENT_SPG_OD = 6.2;
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DETENT_SPG_L = 16.0;
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CONN_PIN_SPC = 5.0;
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CONN_N_PINS = 4;
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CONN_HOUSING_D = 8.0;
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// ── Module tongue (male dovetail) geometry ────────────────────────────────────
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TONGUE_BOT = DOVE_SLOT_BOT - 2*DOVE_CLEAR; // 27.4 mm
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TONGUE_TOP = DOVE_SLOT_TOP + 2*DOVE_CLEAR; // 37.8 mm
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TONGUE_H = DOVE_H + 0.2; // 8.2 mm (slight extra depth)
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// ── Connector target pad ──────────────────────────────────────────────────────
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TARGET_PAD_D = 4.0; // brass pad OD (slightly larger than pogo Ø2 mm)
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TARGET_PAD_T = 1.5; // brass pad thickness
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TARGET_PAD_RECESS = 1.3; // press-fit recess depth (pad is 0.2 mm proud)
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// 4 pads at CONN_PIN_SPC pitch, centred in module tongue
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CONN_SPAN = (CONN_N_PINS - 1) * CONN_PIN_SPC; // 15 mm
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// ── Module safety lock ────────────────────────────────────────────────────────
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LOCK_BOLT_D = 4.3; // M4 thumbscrew bore through tongue side
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LOCK_BOLT_Z = TONGUE_H/2; // Z of thumbscrew CL from tongue bottom
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// Thumbscrew tightens against continuous groove in rail side.
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// Fasteners
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M3_D = 3.3;
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M4_D = 4.3;
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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 == "base_stl") _module_base(80);
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else if (RENDER == "cargo_tray_stl") cargo_tray();
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else if (RENDER == "camera_boom_stl") camera_boom();
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else if (RENDER == "cup_holder_stl") cup_holder();
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else if (RENDER == "target_pad_2d") {
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projection(cut = true) translate([0, 0, -0.5])
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linear_extrude(1) circle(d = TARGET_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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// Ghost rail
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%color("Silver", 0.25)
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translate([0, 0, -RAIL_T])
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cube([RAIL_W, 600, RAIL_T], center = true);
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// Cargo tray at Y=50 (first detent position)
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color("OliveDrab", 0.85)
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translate([0, 50, 0])
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cargo_tray();
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// Cup holder at Y=300
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color("RoyalBlue", 0.85)
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translate([0, 300, 0])
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cup_holder();
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// Camera boom at Y=500
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color("DarkSlateGray", 0.85)
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translate([0, 500, 0])
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camera_boom();
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}
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// ============================================================
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// UNIVERSAL MODULE BASE (_module_base)
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// ============================================================
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// All modules use this as their foundation.
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// Provides: male dovetail tongue, detent bore, connector pads, lock bore.
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//
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// module_len : module length in Y (≥ 60 mm)
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// n_detents : how many ball detent bores to include (1 or 2)
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// conn_offset: Y offset of connector pads from module centre (default 0)
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//
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// After calling _module_base(), add payload geometry at Z = 0 and above.
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// The tongue occupies Z = -(TONGUE_H) to Z = 0.
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// Rail top face is at Z = 0.
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module _module_base(module_len, n_detents = 1, conn_offset = 0) {
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ml = module_len;
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difference() {
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// ── Dovetail tongue (male) ────────────────────────────────────
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translate([0, ml/2, -TONGUE_H/2])
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linear_extrude(TONGUE_H, center = true, twist = 0,
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convexity = 2)
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_tongue_profile_2d();
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// ── Spring detent bore(s) (up through tongue top face) ────────
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// 1 detent: at module centre; 2 detents: at ±25 mm from centre
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for (i = [0 : n_detents - 1]) {
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dy = (n_detents == 1)
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? ml/2
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: ml/2 + (i - (n_detents-1)/2) * DETENT_PITCH;
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translate([0, dy, -(TONGUE_H/2) - DETENT_SPG_L/2])
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cylinder(d = DETENT_SPG_OD,
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h = DETENT_SPG_L + TONGUE_H/2 + e);
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}
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// ── Connector target pad recesses (tongue bottom face) ────────
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for (i = [0 : CONN_N_PINS - 1]) {
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px = (i - (CONN_N_PINS-1)/2) * CONN_PIN_SPC;
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translate([px,
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ml/2 + conn_offset,
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-TONGUE_H + e])
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cylinder(d = TARGET_PAD_D + 0.1,
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h = TARGET_PAD_RECESS + e);
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}
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// ── Safety-lock M4 thumbscrew bore (right side of tongue) ─────
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// Bore exits tongue right face, tip bears on rail side groove
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translate([TONGUE_TOP/2 + e, ml/2, LOCK_BOLT_Z - TONGUE_H])
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rotate([0, 90, 0])
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cylinder(d = LOCK_BOLT_D,
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h = (TONGUE_TOP - TONGUE_BOT)/2 + 6 + e);
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// ── Lead-in chamfer on entry end of tongue ────────────────────
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// 2 mm chamfer on bottom corners of tongue at Y=0 end
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translate([0, 0, -TONGUE_H])
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rotate([45, 0, 0])
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cube([TONGUE_TOP + 2*e, 4, 4], center = true);
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}
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}
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// ── Tongue 2D cross-section (male dovetail, trapezoid wider at bottom) ────────
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// Module tongue: narrower at top (entering slot), wider at bottom (interlocking).
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// Note orientation: tongue points DOWN (-Z), so wider face is at bottom (-Z).
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module _tongue_profile_2d() {
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polygon([
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[-TONGUE_TOP/2, 0], // top-left (at Z = 0, flush with rail top)
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[ TONGUE_TOP/2, 0], // top-right
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[ TONGUE_BOT/2, -TONGUE_H], // bottom-right (interlocking face)
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[-TONGUE_BOT/2, -TONGUE_H], // bottom-left
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]);
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}
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// ============================================================
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// PART 1 — CARGO TRAY
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// ============================================================
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// 200×100 mm open tray for transporting small items.
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// 30 mm walls, chamfered rim, 4× drainage holes.
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// Two Velcro strip slots on tray floor for cargo retention.
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// Module length: 200 mm (4 detent positions).
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// Weight budget: tray printed ~180 g; payload up to 2 kg.
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TRAY_L = 200.0; // module Y length
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TRAY_W = 100.0; // tray interior width (X)
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TRAY_WALL = 3.0; // tray wall thickness
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TRAY_H = 30.0; // tray wall height above module base
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TRAY_FLOOR_T = 3.0; // tray floor thickness
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module cargo_tray() {
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// Mount base on rail (2 detents at ±50 mm from module centre)
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_module_base(TRAY_L, n_detents = 2);
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difference() {
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union() {
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// ── Tray body on top of base ────────────────────────────
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translate([-TRAY_W/2 - TRAY_WALL, 0,
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0])
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cube([TRAY_W + 2*TRAY_WALL,
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TRAY_L,
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TRAY_FLOOR_T + TRAY_H]);
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// ── Corner gussets (stiffening for 2 kg load) ───────────
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for (cx = [-1, 1]) for (cy = [0, 1])
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hull() {
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translate([cx * TRAY_W/2,
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cy * (TRAY_L - TRAY_WALL),
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0])
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cube([TRAY_WALL + e, TRAY_WALL + e,
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TRAY_FLOOR_T + TRAY_H * 0.6], center = true);
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translate([cx * (TRAY_W/2 - 10),
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cy * (TRAY_L - TRAY_WALL),
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0])
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cylinder(d = TRAY_WALL * 2, h = e);
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}
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}
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// ── Tray interior cavity ─────────────────────────────────────
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translate([-TRAY_W/2, TRAY_WALL,
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TRAY_FLOOR_T])
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cube([TRAY_W, TRAY_L - 2*TRAY_WALL,
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TRAY_H + e]);
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// ── Drainage holes (4× Ø8 mm in floor) ──────────────────────
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for (dx = [-TRAY_W/4, TRAY_W/4])
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for (dy = [TRAY_L/4, 3*TRAY_L/4])
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translate([dx, dy, -e])
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cylinder(d = 8, h = TRAY_FLOOR_T + 2*e);
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// ── Velcro slot × 2 (25 mm wide grooves in floor) ────────────
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for (dy = [TRAY_L/3, 2*TRAY_L/3])
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translate([0, dy, TRAY_FLOOR_T - 1.5])
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cube([TRAY_W - 10, 25, 2 + e], center = true);
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// ── Rim chamfer (top inner edge, ergonomic) ───────────────────
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translate([0, TRAY_L/2, TRAY_FLOOR_T + TRAY_H + e])
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cube([TRAY_W + 2*TRAY_WALL + 2*e,
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TRAY_L + 2*e, 4], center = true);
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// ── Side slots for bungee cord retention (3× each long side) ─
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for (sx = [-1, 1])
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for (sy = [TRAY_L/4, TRAY_L/2, 3*TRAY_L/4])
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translate([sx * (TRAY_W/2 + TRAY_WALL/2),
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sy, TRAY_FLOOR_T + TRAY_H/2])
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cube([TRAY_WALL + 2*e, 8, 6], center = true);
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}
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}
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// ============================================================
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// PART 2 — CAMERA BOOM
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// ============================================================
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// L-shaped arm: vertical mast + horizontal boom.
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// Boom head accepts sensor_rail 2020 T-slot (RAIL_W/2 bolt pattern).
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// Sensor head can be rotated 0/90/180° and locked with M4 bolt.
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// Module length: 80 mm; arm rises 120 mm, boom extends 80 mm forward.
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BOOM_MODULE_L = 80.0;
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BOOM_MAST_H = 120.0; // mast height above rail top (Z)
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BOOM_ARM_L = 80.0; // horizontal boom length (+Y forward)
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BOOM_ARM_W = 20.0; // arm cross-section width
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BOOM_ARM_T = 20.0; // arm cross-section height
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BOOM_HEAD_W = 50.0; // sensor head width (matches 2020 rail flange)
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BOOM_HEAD_H = 20.0; // sensor head plate height
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BOOM_HEAD_T = 5.0; // sensor head plate thickness
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module camera_boom() {
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_module_base(BOOM_MODULE_L, n_detents = 1);
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difference() {
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union() {
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// ── Mast (vertical column from module body) ──────────────
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translate([-BOOM_ARM_W/2, BOOM_MODULE_L/2 - BOOM_ARM_T/2, 0])
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cube([BOOM_ARM_W, BOOM_ARM_T, BOOM_MAST_H]);
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// ── Horizontal boom (from mast top, extends +Y) ──────────
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translate([-BOOM_ARM_W/2,
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BOOM_MODULE_L/2 - BOOM_ARM_T/2,
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BOOM_MAST_H - BOOM_ARM_W])
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cube([BOOM_ARM_W, BOOM_ARM_L, BOOM_ARM_W]);
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// ── Sensor head plate (at boom tip) ──────────────────────
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translate([-BOOM_HEAD_W/2,
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BOOM_MODULE_L/2 - BOOM_ARM_T/2 + BOOM_ARM_L,
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BOOM_MAST_H - BOOM_ARM_W - BOOM_HEAD_H/2 + BOOM_ARM_W/2])
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cube([BOOM_HEAD_W, BOOM_HEAD_T, BOOM_HEAD_H]);
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// ── Junction gussets (mast + horizontal boom) ────────────
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translate([-BOOM_ARM_W/2,
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BOOM_MODULE_L/2 - BOOM_ARM_T/2,
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BOOM_MAST_H - BOOM_ARM_W])
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rotate([45, 0, 0])
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cube([BOOM_ARM_W, BOOM_ARM_W * 0.7, BOOM_ARM_W * 0.7]);
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}
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// ── 2020 sensor-rail bolt pattern in head plate ───────────────
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// 2× M5 slots (matches sensor_rail.scad tank_clamp slot geometry)
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for (sz = [-BOOM_HEAD_H/4, BOOM_HEAD_H/4])
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translate([0,
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BOOM_MODULE_L/2 - BOOM_ARM_T/2 + BOOM_ARM_L + BOOM_HEAD_T + e,
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BOOM_MAST_H - BOOM_ARM_W/2 + sz])
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rotate([90, 0, 0])
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hull() {
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translate([-6, 0, 0])
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cylinder(d = 5.3, h = BOOM_HEAD_T + 2*e);
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translate([+6, 0, 0])
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cylinder(d = 5.3, h = BOOM_HEAD_T + 2*e);
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}
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// ── Tilt angle slots (3 positions: 0°, ±15°) ─────────────────
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for (ta = [-15, 0, 15]) {
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translate([0,
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BOOM_MODULE_L/2 - BOOM_ARM_T/2 + BOOM_ARM_L/2,
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BOOM_MAST_H - BOOM_ARM_W/2])
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rotate([ta, 0, 0])
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translate([0, BOOM_ARM_L/2, 0])
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cylinder(d = 4.3, h = BOOM_ARM_W + 2*e,
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center = true);
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}
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// ── Cable tie slots in mast ───────────────────────────────────
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for (cz = [BOOM_MAST_H * 0.3, BOOM_MAST_H * 0.6])
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translate([0, BOOM_MODULE_L/2, cz])
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cube([BOOM_ARM_W + 2*e, 4, 4], center = true);
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// ── Lightening pockets in mast ────────────────────────────────
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translate([0, BOOM_MODULE_L/2, BOOM_MAST_H * 0.4])
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cube([BOOM_ARM_W - 6, BOOM_ARM_T - 6,
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BOOM_MAST_H * 0.4], center = true);
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}
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}
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// ============================================================
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// PART 3 — CUP HOLDER
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// ============================================================
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// Tapered cup cradle for standard travel mugs / water bottles.
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// Inner diameter: 80 mm at top, 68 mm at bottom (matches Ø70 mm typical mug).
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// Flexible gripper ribs (cut slots) provide spring retention.
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// Drain hole at bottom for condensation.
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// Module length: 80 mm.
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CUP_MODULE_L = 80.0;
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CUP_INNER_TOP = 80.0; // inner bore OD at top
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CUP_INNER_BOT = 68.0; // inner bore OD at bottom (taper for grip)
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CUP_OUTER_T = 4.0; // wall thickness
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CUP_H = 80.0; // cup holder height
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CUP_GRIP_SLOTS = 8; // number of flex slots (spring grip)
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CUP_SLOT_W = 2.5; // flex slot width
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CUP_SLOT_H = 40.0; // flex slot height (from top)
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module cup_holder() {
|
||
_module_base(CUP_MODULE_L, n_detents = 1);
|
||
|
||
difference() {
|
||
union() {
|
||
// ── Outer shell (tapered cylinder) ───────────────────────
|
||
cylinder(d1 = CUP_INNER_BOT + 2*CUP_OUTER_T,
|
||
d2 = CUP_INNER_TOP + 2*CUP_OUTER_T,
|
||
h = CUP_H);
|
||
|
||
// ── Base flange (connects to module body footprint) ───────
|
||
hull() {
|
||
cylinder(d = CUP_INNER_BOT + 2*CUP_OUTER_T + 4,
|
||
h = 4);
|
||
translate([0, CUP_MODULE_L/2, 0])
|
||
cube([RAIL_W, CUP_MODULE_L, 4], center = true);
|
||
}
|
||
}
|
||
|
||
// ── Inner bore (tapered cup cavity) ──────────────────────────
|
||
translate([0, 0, CUP_OUTER_T])
|
||
cylinder(d1 = CUP_INNER_BOT, d2 = CUP_INNER_TOP,
|
||
h = CUP_H + e);
|
||
|
||
// ── Base drain hole ──────────────────────────────────────────
|
||
translate([0, 0, -e])
|
||
cylinder(d = 12, h = CUP_OUTER_T + 2*e);
|
||
|
||
// ── Flex grip slots (from top down) ──────────────────────────
|
||
// Slots allow upper rim to flex inward and grip cup body
|
||
for (i = [0 : CUP_GRIP_SLOTS - 1]) {
|
||
angle = i * 360 / CUP_GRIP_SLOTS;
|
||
rotate([0, 0, angle])
|
||
translate([CUP_INNER_TOP/2 + CUP_OUTER_T/2, 0, CUP_H - CUP_SLOT_H])
|
||
cube([CUP_OUTER_T + 2*e, CUP_SLOT_W, CUP_SLOT_H + e],
|
||
center = true);
|
||
}
|
||
|
||
// ── Exterior branding recess (optional label area) ────────────
|
||
translate([CUP_INNER_BOT/2 + CUP_OUTER_T/2 - 0.5, 0, CUP_H/2])
|
||
rotate([0, 90, 0])
|
||
cube([25, 40, 1 + e], center = true);
|
||
}
|
||
}
|
||
|
||
// ============================================================
|
||
// ══ MODULE TEMPLATE ═══════════════════════════════════════════
|
||
// ══ Copy this block to create a new payload module ════════════
|
||
// ============================================================
|
||
//
|
||
// module my_new_module() {
|
||
// MY_LEN = 120.0; // module length — must be multiple of DETENT_PITCH (50 mm)
|
||
//
|
||
// // Always start with the base (provides tongue, pads, detent bore)
|
||
// _module_base(MY_LEN, n_detents = 2);
|
||
//
|
||
// // Add your payload geometry here.
|
||
// // Z = 0 is the rail top face / module mounting face.
|
||
// // Build upward from Z = 0.
|
||
//
|
||
// difference() {
|
||
// union() {
|
||
// // Example: a simple platform
|
||
// translate([-(RAIL_W + 10)/2, 0, 0])
|
||
// cube([RAIL_W + 10, MY_LEN, 10]);
|
||
//
|
||
// // Add your geometry...
|
||
// }
|
||
//
|
||
// // Add your cutouts...
|
||
// }
|
||
// }
|
||
//
|
||
// ── Don't forget to: ──────────────────────────────────────────
|
||
// 1. Add else if (RENDER == "my_module_stl") my_new_module();
|
||
// in the RENDER DISPATCH block above.
|
||
// 2. Add export command in BOM / README.
|
||
// 3. Test: verify tongue fits rail slot (should slide with 0.3 mm clearance).
|
||
// 4. Verify connector pad positions align with CONN_Y on rail.
|
||
// ============================================================
|