sl-mechanical
3e4764b3eb
Add parametric OpenSCAD designs for the SaltyRover stable 4-wheel variant. Reuses existing 25mm stem, sensor head, and all SaltyLab sensor mounts without modification. Files: - saltyrover_chassis.scad 480×500mm deck, stem collar, FC+Orin standoffs, motor attachment holes, battery tray opening; RENDER deck_2d for waterjet/CNC DXF - rover_motor_mount.scad L-bracket + axle clamp plate per motor; uses caliper-verified axle dims from BOM.md; dropout slot for tool-free motor swap; RENDER bracket_2d for CNC DXF - rover_battery_tray.scad Slide-out tray for 2-4 × 420×88×56mm packs laid flat (low CG); T-slot rails, spring latch - rover_stem_adapter.scad Flange + split clamp locks 25mm stem to deck collar; 550mm stem option for rover height - rover_BOM.md Assembly sequence, fastener table, mass estimate (~13.4kg), height stack diagram Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
219 lines
9.6 KiB
OpenSCAD
219 lines
9.6 KiB
OpenSCAD
// ============================================================
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// saltyrover_chassis.scad — SaltyRover 4-Wheel Base Plate
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// Rev A 2026-03-01 sl-mechanical
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// ============================================================
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// Parametric deck plate for the stable 4-wheel SaltyRover.
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// Low/wide/stable design — reuses sensor head + 25 mm stem.
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//
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// Coordinate convention:
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// Z = 0 deck top face
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// +Y forward
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// +X right (motor side)
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//
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// Battery orientation:
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// Packs laid FLAT (56 mm tall, 420 mm running left-right,
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// 88 mm per pack fore-aft). N packs arranged fore-aft.
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// 2-pack tray: 430 × 186 mm opening.
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// 4-pack tray: 430 × 362 mm opening.
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//
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// Motor positions are at ±TRACK_W/2 (X), ±AXLE_BASE/2 (Y).
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// Motor brackets (rover_motor_mount.scad) bolt to deck edge
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// and extend BRKT_REACH mm outward to hold axle at AXLE_H.
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//
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// RENDER options:
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// "assembly" full deck + phantom batteries + stem stub
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// "deck" deck plate only (review)
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// "deck_2d" floor projection → DXF for waterjet/CNC
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// ============================================================
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RENDER = "assembly";
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// ── Deck footprint ────────────────────────────────────────
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ROVER_L = 500.0; // fore-aft (Y)
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ROVER_W = 480.0; // left-right (X) — sized around battery width
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DECK_T = 8.0; // deck thickness
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DECK_R = 15.0; // corner fillet radius
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// ── Drive geometry (caliper-verified motor data from BOM.md) ──
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TRACK_W = 540.0; // motor axle CL to CL, left-right
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AXLE_BASE = 340.0; // motor axle CL to CL, fore-aft
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AXLE_H = 127.0; // axle CL above ground (10×2.125" wheel, caliper)
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GND_CLR = 50.0; // minimum chassis ground clearance
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// Height of deck bottom above ground:
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// GND_CLR + battery_tray_floor + battery_height
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BATT_FLOOR_T = 3.0;
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BATT_PACK_H = 56.0; // flat-laid pack height
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DECK_BOT_H = GND_CLR + BATT_FLOOR_T + BATT_PACK_H; // 109 mm
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// Axle above deck top = AXLE_H - (DECK_BOT_H + DECK_T) ≈ +10 mm
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// ── Battery packs (BOM.md caliper-verified: 420×88×56 mm) ──
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// Laid flat, 420 mm running left-right (X), 88 mm per pack (Y),
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// 56 mm tall (Z). BATT_N packs arranged side-by-side fore-aft.
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BATT_X_DIM = 420.0;
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BATT_Y_DIM = 88.0; // per-pack fore-aft depth
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BATT_N = 2; // packs fore-aft (2 = 176 mm; 4 = 352 mm)
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TRAY_MARGIN = 5.0; // extra margin on each side of tray opening
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// ── Stem socket (deck centre) ─────────────────────────────
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STEM_BORE = 25.5; // 25 mm tube + 0.5 clearance
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STEM_COLLAR_OD = 50.0;
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STEM_COLLAR_H = 22.0; // raised boss height above deck top
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// ── FC mount (MAMBA F722S, 30.5×30.5 M3) ─────────────────
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FC_SPACING = 30.5;
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FC_HOLE_D = 3.2;
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FC_STANDOFF_H= 6.0;
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// FC centred forward of battery tray
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FC_X = 0.0;
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FC_Y = ROVER_L/2 - 60.0; // near front edge
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// ── Jetson Orin NX mount ─────────────────────────────────
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// ⚠ Verify hole pattern against your carrier board.
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// Default: 58×49 mm M3 (same as RPi HAT pattern used on Orin NX cards).
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ORIN_HOLE_X = 58.0;
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ORIN_HOLE_Y = 49.0;
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ORIN_HOLE_D = 3.2;
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ORIN_STANDOFF = 8.0;
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ORIN_X = 0.0;
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ORIN_Y = -(ROVER_L/2 - 55.0); // near rear edge
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// ── Motor bracket attachment bolt pattern ────────────────
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// 2× M5 bolts through deck edge at each motor corner.
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MOT_BOLT_D = 5.3; // M5 clearance
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MOT_BOLT_SPC = 30.0; // bolt spacing fore-aft at each motor position
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// ── Lightening holes ──────────────────────────────────────
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LH_D = 55.0;
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// ── Fasteners ─────────────────────────────────────────────
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M3_D = 3.2;
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M4_D = 4.3;
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M5_D = 5.3;
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$fn = 64;
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e = 0.01;
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// ─────────────────────────────────────────────────────────
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// rounded_plate_2d()
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// ─────────────────────────────────────────────────────────
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module rounded_plate_2d(l, w, r) {
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offset(r=r, $fn=32) offset(r=-r)
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square([l, w], center=true);
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}
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// ─────────────────────────────────────────────────────────
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// rover_deck()
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// ─────────────────────────────────────────────────────────
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module rover_deck() {
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tray_w = BATT_X_DIM + 2*TRAY_MARGIN; // 430 mm
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tray_l = BATT_Y_DIM * BATT_N + 2*TRAY_MARGIN; // 186 or 362 mm
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difference() {
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// ── Deck plate ────────────────────────────────
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translate([0, 0, -DECK_T])
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linear_extrude(DECK_T)
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rounded_plate_2d(ROVER_W, ROVER_L, DECK_R);
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// ── Battery tray opening (centred, through deck) ──
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translate([-tray_w/2, -tray_l/2, -DECK_T - e])
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cube([tray_w, tray_l, DECK_T + 2*e]);
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// ── Lightening holes ──────────────────────────
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// 3 columns × 2 rows, outside battery opening
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for (hx = [-ROVER_W/4, 0, ROVER_W/4])
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for (hy = [-(tray_l/2 + LH_D/2 + 20),
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(tray_l/2 + LH_D/2 + 20)])
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if (abs(hy) < ROVER_L/2 - LH_D/2 - 10)
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translate([hx, hy, -DECK_T - e])
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cylinder(d=LH_D, h=DECK_T + 2*e);
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// ── FC mount holes ────────────────────────────
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for (fx=[-FC_SPACING/2, FC_SPACING/2])
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for (fy=[-FC_SPACING/2, FC_SPACING/2])
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translate([FC_X + fx, FC_Y + fy, -DECK_T - e])
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cylinder(d=FC_HOLE_D, h=DECK_T + 2*e);
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// ── Orin mount holes ──────────────────────────
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for (ox=[-ORIN_HOLE_X/2, ORIN_HOLE_X/2])
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for (oy=[-ORIN_HOLE_Y/2, ORIN_HOLE_Y/2])
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translate([ORIN_X + ox, ORIN_Y + oy, -DECK_T - e])
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cylinder(d=ORIN_HOLE_D, h=DECK_T + 2*e);
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// ── Motor bracket bolt holes (4 corners × 2 bolts) ──
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for (sx=[-1,1], sy=[-1,1])
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for (by=[-MOT_BOLT_SPC/2, MOT_BOLT_SPC/2])
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translate([sx*ROVER_W/2 - sx*(DECK_T/2 + e),
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sy*AXLE_BASE/2 + by,
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-DECK_T - e])
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rotate([0, 90, 0])
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cylinder(d=MOT_BOLT_D, h=DECK_T + 2*e);
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// ── Stem bore through deck ────────────────────
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translate([0, 0, -DECK_T - e])
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cylinder(d=STEM_BORE, h=DECK_T + 2*e);
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// ── Cable routing slots (×2 per side, fore and aft) ──
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for (cy=[-ROVER_L/2 - e, ROVER_L/2 - 16])
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for (cx=[-55, 55])
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translate([cx - 7, cy, -DECK_T - e])
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cube([14, 16, DECK_T + 2*e]);
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}
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// ── Stem collar (raised boss) ─────────────────────
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difference() {
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cylinder(d=STEM_COLLAR_OD, h=STEM_COLLAR_H);
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translate([0, 0, -e])
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cylinder(d=STEM_BORE, h=STEM_COLLAR_H + 2*e);
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}
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// ── FC standoff posts (×4) ────────────────────────
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for (fx=[-FC_SPACING/2, FC_SPACING/2])
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for (fy=[-FC_SPACING/2, FC_SPACING/2])
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translate([FC_X + fx, FC_Y + fy, 0])
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cylinder(d=6, h=FC_STANDOFF_H);
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// ── Orin standoff posts (×4) ──────────────────────
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for (ox=[-ORIN_HOLE_X/2, ORIN_HOLE_X/2])
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for (oy=[-ORIN_HOLE_Y/2, ORIN_HOLE_Y/2])
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translate([ORIN_X + ox, ORIN_Y + oy, 0])
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cylinder(d=6, h=ORIN_STANDOFF);
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}
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// ─────────────────────────────────────────────────────────
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// Render selector
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// ─────────────────────────────────────────────────────────
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if (RENDER == "assembly") {
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color("Silver", 0.90) rover_deck();
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// Phantom battery packs (2 × laid flat)
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tray_w = BATT_X_DIM + 2*TRAY_MARGIN;
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tray_l = BATT_Y_DIM * BATT_N + 2*TRAY_MARGIN;
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for (pn = [0 : BATT_N - 1])
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color("Gold", 0.30)
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translate([-BATT_X_DIM/2,
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-BATT_Y_DIM*BATT_N/2 + pn*BATT_Y_DIM,
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-(DECK_T + BATT_FLOOR_T + BATT_PACK_H)])
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cube([BATT_X_DIM, BATT_Y_DIM, BATT_PACK_H]);
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// Phantom stem stub
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color("Silver", 0.25)
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translate([0, 0, STEM_COLLAR_H])
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cylinder(d=25, h=400);
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// Motor position markers (spheres at axle CLs)
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axle_z = AXLE_H - (DECK_BOT_H + DECK_T); // above deck top
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for (sx=[-1,1], sy=[-1,1])
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color("Tomato", 0.5)
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translate([sx*TRACK_W/2, sy*AXLE_BASE/2, axle_z])
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sphere(d=20);
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} else if (RENDER == "deck") {
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rover_deck();
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} else if (RENDER == "deck_2d") {
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projection(cut=true)
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translate([0, 0, -DECK_T/2])
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rover_deck();
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}
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