sl-mechanical
914afbc1ca
ARCHITECTURE CHANGE: batteries no longer sit flat on the base plate. They mount VERTICALLY on a central mast via a height-adjustable carousel. CG is tuned by sliding the carousel up/down the stem. Part A — prototype_baseplate.scad (Rev C): - PLATE_DEPTH: 210mm → 130mm (no battery footprint constraint) - Removed all battery tray geometry (holes, strap slots, expansion mounts) - Added central stem socket: Ø38.6mm bore + 4x M5 flange bolt holes on Ø66mm BC - Added stem_flange() module: laser-cut ring (qty 2, one each side of plate) - Wiring pass-through slots flanking stem centre - FC mount relocated to FC_X_OFFSET = -40mm (front of plate, clear of stem) - New RENDER="stem_flange_2d" DXF export option Part B — stem_battery_clamp.scad (new): - Collar: two 3D-printed D-shaped halves, split at Y=0 - Ø38.6mm bore (1.5" EMT / 6061-T6 tube) - 4x M6 clamping bolts + hex nut pockets - 1x M6 set screw per half for height/rotation lock - Arm attachment pads with M4 through-holes + nut pockets - Arms: flat bars, laser-cut or printed, ARM_REACH=55mm - Battery cradles: U-channel, open top, Velcro strap slots at 30% + 65% height - BATT_COUNT param: 2 (180°), 3 (120°), or 4 (90°) radial batteries - ARM_START_ANGLE chosen per BATT_COUNT to keep all arms clear of Y=0 split - Battery ghosts in assembly for visualisation - Full RENDER control: assembly / collar_half / arm / arm_2d / cradle - Assembly sequence + CG tuning notes in file footer BOM.md → Rev C: - Part A table updated (5 laser-cut parts + stem tube) - Part B table added (collar halves, arms, cradles, fasteners) - Battery section: flat-deck layout replaced with vertical stem guide - Fastener table updated to match new architecture Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
349 lines
14 KiB
OpenSCAD
349 lines
14 KiB
OpenSCAD
// =============================================================================
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// SaltyBot — Prototype Base Plate (Rev C — compact, stem-mount)
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// Agent: sl-mechanical | 2026-02-28
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//
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// Laser-cut or CNC-routed flat plate (6 mm Al / 8 mm acrylic).
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// Uses CALIPER-VERIFIED hub motor axle measurements (see PR #7 / #11).
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//
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// ARCHITECTURE CHANGE (Rev C):
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// Batteries are NO LONGER on the base plate.
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// They stand vertically on a central stem via stem_battery_clamp.scad.
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// The base plate is now compact — only axle dropouts + stem socket + FC mount.
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//
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// ── AXLE PROFILE (stepped D-cut, caliper-verified) ───────────────────────────
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// Zone │ Feature │ Ø / Width │ Length
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// ───────┼──────────────────┼────────────────────┼──────────
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// Base │ Round (near hub) │ Ø 16.11 mm │ 15.00 mm
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// D-cut │ Round OD │ Ø 15.95 mm │ 43.35 mm
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// │ Flat chord │ 13.00 mm │
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// Tip │ Shoulder/end │ — │ 3.00 mm
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// Total │ Hub face → tip │ — │ 65.50 mm
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// Bearing seat collar: Ø 37.8 mm
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// Tire: 10 × 2.125" pneumatic (Ø 254 mm, 35 PSI)
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// =============================================================================
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$fn = 128;
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// =============================================================================
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// AXLE PARAMETERS — caliper-verified
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// =============================================================================
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AXLE_BASE_DIA = 16.11;
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AXLE_BASE_LEN = 15.00;
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AXLE_DCUT_DIA = 15.95;
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AXLE_DCUT_FLAT = 13.00;
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AXLE_DCUT_LEN = 43.35;
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AXLE_TIP_LEN = 3.00;
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AXLE_TOTAL = 65.50;
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BEARING_SEAT_OD = 37.80;
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TIRE_OD = 254.0;
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AXLE_CL_HEIGHT = TIRE_OD / 2; // 127 mm above ground
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// =============================================================================
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// PLATE PARAMETERS
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// =============================================================================
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WHEELBASE = 600.0; // mm axle C/L to axle C/L
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// Plate depth now driven only by structural + FC needs (no battery footprint).
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PLATE_DEPTH = 130.0; // mm front-to-rear
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PLATE_OVERHANG = 40.0; // mm plate past axle C/L each side
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PLATE_THICK = 6.0; // mm
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// Fork slot
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FORK_W = AXLE_BASE_DIA + 0.4; // 16.51 mm
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FORK_DEPTH = 50.0;
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// Dropout clamp (two-piece sandwich)
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CLAMP_L = 80.0;
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CLAMP_H = 60.0;
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CLAMP_THICK = 8.0;
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CLAMP_BOLT_D = 5.3; // M5
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CLAMP_BOLT_DX = 22.0;
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CLAMP_BOLT_DY = 22.0;
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CLAMP_ALIGN_D = 4.1; // Ø4 pin
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// D-cut bore clearance
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DCUT_CL = 0.3;
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// FC mount — MAMBA F722S 30.5 × 30.5 mm M3
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FC_PITCH = 30.5;
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FC_HOLE_D = 3.2;
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// FC is offset toward front of plate (away from stem)
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FC_X_OFFSET = -40.0; // mm from plate centre (negative = front/motor side)
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// =============================================================================
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// STEM SOCKET PARAMETERS
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// =============================================================================
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STEM_OD = 38.1; // mm 1.5" EMT conduit OD
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STEM_BORE = STEM_OD + 0.5; // 38.6 mm with clearance
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// Flange ring (laser-cut, bolts above + below plate to grip tube):
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STEM_FLANGE_OD = 82.0; // mm flange outer diameter
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STEM_FLANGE_BC = 66.0; // mm bolt circle diameter (4× M5 at 90°)
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STEM_FLANGE_T = 6.0; // mm = PLATE_THICK (flush-mount)
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// Stem position: at plate centre (X=0, Y=0)
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// =============================================================================
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// UTILITIES
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// =============================================================================
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M3 = 3.2; M4 = 4.3; M5 = 5.3;
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PLATE_X_HALF = WHEELBASE/2 + PLATE_OVERHANG; // ± 340 mm
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DCUT_R = (AXLE_DCUT_DIA + 2*DCUT_CL) / 2;
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DCUT_FC = AXLE_DCUT_FLAT + 2*DCUT_CL;
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// =============================================================================
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// RENDER CONTROL
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// =============================================================================
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//
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// "assembly" full 3-D preview
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// "plate_2d" DXF — base plate
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// "clamp_lower_2d" DXF — lower dropout clamp (× 2)
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// "clamp_upper_2d" DXF — upper dropout clamp (× 2)
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// "stem_flange_2d" DXF — stem flange ring (× 2, one above + one below plate)
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RENDER = "assembly";
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if (RENDER == "assembly") {
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assembly();
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} else if (RENDER == "plate_2d") {
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projection(cut=true) translate([0,0,-PLATE_THICK/2]) base_plate();
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} else if (RENDER == "clamp_lower_2d") {
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projection(cut=true) translate([0,0,-CLAMP_THICK/2]) clamp_lower();
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} else if (RENDER == "clamp_upper_2d") {
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projection(cut=true) translate([0,0,-CLAMP_THICK/2]) clamp_upper();
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} else if (RENDER == "stem_flange_2d") {
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projection(cut=true) translate([0,0,-STEM_FLANGE_T/2]) stem_flange();
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}
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// =============================================================================
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// ASSEMBLY
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// =============================================================================
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module assembly() {
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color("Silver", 0.85) base_plate();
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for (side = [-1, 1]) {
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color("SteelBlue", 0.80)
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translate([side * WHEELBASE/2, 0, PLATE_THICK])
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clamp_lower();
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color("CornflowerBlue", 0.80)
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translate([side * WHEELBASE/2, 0, PLATE_THICK + CLAMP_THICK])
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clamp_upper();
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}
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// Stem flange rings (above and below plate)
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color("DimGray", 0.70)
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translate([0, 0, -STEM_FLANGE_T])
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stem_flange();
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color("DimGray", 0.70)
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translate([0, 0, PLATE_THICK])
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stem_flange();
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// Reference ghosts
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%color("Orange", 0.25)
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translate([0, 0, PLATE_THICK + STEM_FLANGE_T])
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cylinder(d=STEM_OD, h=800); // vertical stem
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%for (side = [-1, 1])
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color("Tomato", 0.2)
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translate([side * WHEELBASE/2, 0, 0])
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rotate([0, side*90, 0])
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axle_ghost();
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}
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// =============================================================================
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// BASE PLATE (Part A — compact)
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// =============================================================================
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module base_plate() {
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R = 12; // corner radius
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difference() {
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// ── Outer profile ──
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linear_extrude(PLATE_THICK)
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minkowski() {
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square([2*(PLATE_X_HALF - R), PLATE_DEPTH - 2*R], center=true);
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circle(r=R);
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}
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// ── Fork slots (open at ±X edges, semicircular tip) ──────────────
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for (side = [-1, 1]) {
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translate([side*(PLATE_X_HALF - FORK_DEPTH), -FORK_W/2, -1])
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cube([FORK_DEPTH + 1, FORK_W, PLATE_THICK + 2]);
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translate([side*(PLATE_X_HALF - FORK_DEPTH), 0, -1])
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cylinder(d=FORK_W, h=PLATE_THICK + 2);
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}
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// ── Bearing seat relief (prevents Ø37.8 mm collar binding on edge) ─
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for (side = [-1, 1])
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translate([side*PLATE_X_HALF - side*(BEARING_SEAT_OD/2 + 1),
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-BEARING_SEAT_OD/2, -1])
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cube([BEARING_SEAT_OD/2 + 2, BEARING_SEAT_OD, PLATE_THICK + 2]);
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// ── Dropout clamp bolt through-holes ─────────────────────────────
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for (side = [-1, 1])
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for (dx = [-CLAMP_BOLT_DX, CLAMP_BOLT_DX])
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for (dy = [-CLAMP_BOLT_DY, CLAMP_BOLT_DY])
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translate([side*WHEELBASE/2 + dx, dy, -1])
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cylinder(d=CLAMP_BOLT_D, h=PLATE_THICK + 2);
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// ── Alignment pin holes (Ø4) ──────────────────────────────────────
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for (side = [-1, 1])
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for (dy = [-CLAMP_BOLT_DY + 8, CLAMP_BOLT_DY - 8])
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translate([side*WHEELBASE/2, dy, -1])
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cylinder(d=CLAMP_ALIGN_D, h=PLATE_THICK + 2);
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// ── Stem socket bore ──────────────────────────────────────────────
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translate([0, 0, -1])
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cylinder(d=STEM_BORE, h=PLATE_THICK + 2);
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// ── Stem flange bolt holes (4× M5, 90° pattern on STEM_FLANGE_BC) ─
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for (a = [0, 90, 180, 270])
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rotate([0, 0, a])
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translate([STEM_FLANGE_BC/2, 0, -1])
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cylinder(d=M5, h=PLATE_THICK + 2);
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// ── FC mount (MAMBA F722S 30.5 × 30.5 M3) ────────────────────────
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for (x = [FC_X_OFFSET - FC_PITCH/2, FC_X_OFFSET + FC_PITCH/2])
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for (y = [-FC_PITCH/2, FC_PITCH/2])
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translate([x, y, -1])
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cylinder(d=FC_HOLE_D, h=PLATE_THICK + 2);
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// ── Wiring / cable pass-through slots (2×, flanking stem) ─────────
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for (dy = [-30, 30])
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hull() {
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translate([15, dy, -1]) cylinder(d=14, h=PLATE_THICK + 2);
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translate([-15, dy, -1]) cylinder(d=14, h=PLATE_THICK + 2);
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}
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// ── Lightening slots (between FC zone and dropout zones) ──────────
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for (sx = [-1, 1]) {
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// One slot each side of stem, in the structural corridor
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lx = sx * (WHEELBASE/4);
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hull() {
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translate([lx, -(PLATE_DEPTH/2 - 22), -1]) cylinder(d=18, h=PLATE_THICK+2);
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translate([lx, (PLATE_DEPTH/2 - 22), -1]) cylinder(d=18, h=PLATE_THICK+2);
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}
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}
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}
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}
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// =============================================================================
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// STEM FLANGE RING (laser-cut, qty 2 — one above, one below plate)
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// =============================================================================
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module stem_flange() {
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difference() {
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cylinder(d=STEM_FLANGE_OD, h=STEM_FLANGE_T);
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// Stem bore (tight fit — tube presses into flange)
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translate([0, 0, -1])
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cylinder(d=STEM_BORE, h=STEM_FLANGE_T + 2);
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// 4× M5 flange bolts
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for (a = [0, 90, 180, 270])
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rotate([0, 0, a])
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translate([STEM_FLANGE_BC/2, 0, -1])
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cylinder(d=M5, h=STEM_FLANGE_T + 2);
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}
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}
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// =============================================================================
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// DROPOUT CLAMP — LOWER (round bore, base-section diameter)
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// =============================================================================
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module clamp_lower() {
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difference() {
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hull() {
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translate([-CLAMP_L/2 + CLAMP_H/2, 0, 0]) cylinder(d=CLAMP_H, h=CLAMP_THICK);
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translate([ CLAMP_L/2 - CLAMP_H/2, 0, 0]) cylinder(d=CLAMP_H, h=CLAMP_THICK);
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}
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// Round bore (base zone)
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translate([0, 0, -1]) cylinder(d=AXLE_BASE_DIA + 0.4, h=CLAMP_THICK + 2);
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// Slide-in slot (open toward wheel side)
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translate([-CLAMP_L/2 - 1, -FORK_W/2, -1])
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cube([CLAMP_L/2 + 1, FORK_W, CLAMP_THICK + 2]);
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// Clamp bolts
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for (dx = [-CLAMP_BOLT_DX, CLAMP_BOLT_DX])
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for (dy = [-CLAMP_BOLT_DY, CLAMP_BOLT_DY])
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translate([dx, dy, -1]) cylinder(d=CLAMP_BOLT_D, h=CLAMP_THICK + 2);
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// Alignment pins
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for (dy = [-CLAMP_BOLT_DY + 8, CLAMP_BOLT_DY - 8])
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translate([0, dy, -1]) cylinder(d=CLAMP_ALIGN_D, h=CLAMP_THICK + 2);
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}
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}
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// =============================================================================
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// DROPOUT CLAMP — UPPER (D-cut bore, anti-rotation)
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// =============================================================================
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module clamp_upper() {
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dcut_r = DCUT_R;
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dcut_d = sqrt(pow(dcut_r, 2) - pow(DCUT_FC/2, 2));
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difference() {
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hull() {
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translate([-CLAMP_L/2 + CLAMP_H/2, 0, 0]) cylinder(d=CLAMP_H, h=CLAMP_THICK);
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translate([ CLAMP_L/2 - CLAMP_H/2, 0, 0]) cylinder(d=CLAMP_H, h=CLAMP_THICK);
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}
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// D-cut bore
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translate([0, 0, -1])
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linear_extrude(CLAMP_THICK + 2)
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dcut_profile_2d(dcut_r, dcut_d);
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// Slide-in slot
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translate([-CLAMP_L/2 - 1, -FORK_W/2, -1])
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cube([CLAMP_L/2 + 1, FORK_W, CLAMP_THICK + 2]);
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// Clamp bolts
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for (dx = [-CLAMP_BOLT_DX, CLAMP_BOLT_DX])
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for (dy = [-CLAMP_BOLT_DY, CLAMP_BOLT_DY])
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translate([dx, dy, -1]) cylinder(d=CLAMP_BOLT_D, h=CLAMP_THICK + 2);
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// Alignment pins
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for (dy = [-CLAMP_BOLT_DY + 8, CLAMP_BOLT_DY - 8])
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translate([0, dy, -1]) cylinder(d=CLAMP_ALIGN_D, h=CLAMP_THICK + 2);
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// Orientation emboss
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translate([0, dcut_d + 1.5, CLAMP_THICK - 0.8])
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linear_extrude(1)
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polygon([[0,0],[-3,-5],[3,-5]]);
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}
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}
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// ── D-cut 2D profile helper ───────────────────────────────────────────────────
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module dcut_profile_2d(r, flat_d) {
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intersection() {
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circle(r=r);
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translate([-r - 1, -r - 1])
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square([2*(r+1), r + 1 + flat_d]);
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}
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}
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// =============================================================================
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// AXLE GHOST (visualisation only)
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// =============================================================================
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module axle_ghost() {
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cylinder(d=BEARING_SEAT_OD, h=12);
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translate([0,0,12]) cylinder(d=AXLE_BASE_DIA, h=AXLE_BASE_LEN);
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translate([0,0,12+AXLE_BASE_LEN]) cylinder(d=AXLE_DCUT_DIA, h=AXLE_DCUT_LEN);
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}
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// =============================================================================
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// DXF EXPORT
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// =============================================================================
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//
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// Part 1 — Base plate:
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// openscad prototype_baseplate.scad -D 'RENDER="plate_2d"' -o baseplate.dxf
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//
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// Part 2 — Dropout clamp, lower (× 2):
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// openscad prototype_baseplate.scad -D 'RENDER="clamp_lower_2d"' -o clamp_lower.dxf
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//
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// Part 3 — Dropout clamp, upper (× 2):
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// openscad prototype_baseplate.scad -D 'RENDER="clamp_upper_2d"' -o clamp_upper.dxf
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//
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// Part 4 — Stem flange ring (× 2, one each side of plate):
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// openscad prototype_baseplate.scad -D 'RENDER="stem_flange_2d"' -o stem_flange.dxf
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//
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// Materials:
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// Plate + flanges : 6 mm 5052-H32 aluminium (preferred)
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// 8 mm clear acrylic (quick proto)
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// Dropout clamps : 8 mm 6061-T6 aluminium
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// Stem tube : 38.1 mm OD × 1.5 mm wall 6061-T6 (or 1.5" EMT)
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// Cut stem to ~1050 mm — allows batteries from ~100 mm to ~950 mm height.
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// =============================================================================
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