382 lines
16 KiB
OpenSCAD
382 lines
16 KiB
OpenSCAD
// =============================================================================
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// SaltyBot — RPLIDAR A1 Dust & Splash Cover
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// Agent: sl-mechanical | 2026-03-02
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//
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// CLIP-ON protective dome for RPLIDAR A1M8 sensor, shielding from dust,
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// rain, and debris while maintaining 360° scan window. Quick-release tab
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// for one-handed removal. Integrated drainage holes prevent water pooling.
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//
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// HOW IT WORKS
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// 1. Clip ring sits on the mounting boss of the RPLIDAR A1 body (Ø 70 mm).
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// 2. Two snap tabs (elastically deformed) lock into recesses on the sensor rim.
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// 3. Dome overhead shields the rotating scanning mirror from debris.
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// 4. Six radial drainage holes (Ø 4 mm) at base allow water to escape.
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// 5. Quick-release tab provides easy lever-point for removal (no tools).
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//
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// OPTICAL DESIGN
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// • 360° scan window: unobstructed to ±60° vertical (sensor FOV).
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// • Window height: 28 mm (clear zone from 21 mm to 49 mm from base).
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// • Sensor face clearance: 6 mm minimum (prevents optical interference).
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// • Dome apex: ~55 mm above base (shed water away from sensor).
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//
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// MATERIALS & ASSEMBLY
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// • Body: PETG or ASA (UV-resistant, weatherproof, flexible enough for snaps).
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// • Snap tabs: Designed for 2–3 mm deflection during insertion.
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// • Drainage: Six 4 mm holes ensure rapid water egress (gutters not needed).
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// • Installation: No tools; press upward until snap tabs engage (~3 second clip time).
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// • Removal: Push quick-release tab inward, twist gently, lift off.
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//
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// MOUNTING GEOMETRY
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// RPLIDAR body outer diameter: 70.0 mm (Ø RPL_BODY_D)
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// Mounting bolt circle: 58.0 mm (4× M3 at 45°/135°/225°/315°)
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// Scan window (annular): ±30 mm radius, height 21–49 mm
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// Bearing assembly: ~40 mm diameter (inside scan window)
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//
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// PARTS (set RENDER= to export each)
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// dust_cover — 3D print × 1 (RENDER="dust_cover")
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// assembly — Preview with RPLIDAR ghost (RENDER="assembly")
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//
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// PRINT & INSTALL
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// Print orientation: Dome up (smooth finish down for adhesion).
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// Print settings: PETG/ASA, 0.2 mm layers, 5 perimeters, 15% infill.
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// No supports required (overhangs < 45°, snap tabs self-supporting).
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// Installation: Clean sensor body with IPA; press cover downward until snap
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// tabs audibly engage (2–3 mm deflection), test rotation lock.
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// =============================================================================
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\$fn = 64;
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e = 0.01;
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// =============================================================================
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// RPLIDAR A1 GEOMETRY
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// =============================================================================
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RPL_BODY_D = 70.0; // mm outer body diameter
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RPL_BC = 58.0; // mm mounting bolt circle (4× M3)
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RPL_TOP_FACE_Z = 50.5; // mm height of top of sensor body (measured)
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// Window dimensions (where scan light exits/enters)
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WINDOW_INNER_R = 15.0; // mm inner radius of scan annulus (bearing assy)
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WINDOW_OUTER_R = 33.0; // mm outer radius of scan annulus
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WINDOW_Z_BOT = 21.0; // mm bottom of optical scan window
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WINDOW_Z_TOP = 49.0; // mm top of optical scan window (±60° FOV)
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// Clip base sits on sensor body (radius where snap tabs will locate)
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CLIP_SEAT_R = RPL_BODY_D / 2 + 0.5; // 35.5 mm (slight clearance)
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// =============================================================================
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// DUST COVER DESIGN PARAMETERS
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// =============================================================================
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// CLIP BASE RING (sits on RPLIDAR body)
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CLIP_BASE_OD = 77.0; // mm outer diameter of base ring
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CLIP_BASE_H = 6.0; // mm height of clip base (engagement zone)
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CLIP_BASE_WALL = 3.0; // mm wall thickness
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// SNAP TABS (two locations: top front / top back)
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SNAP_TAB_W = 12.0; // mm width of each snap tab
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SNAP_TAB_H = 8.0; // mm height (radial protrusion)
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SNAP_TAB_T = 2.0; // mm thickness (allows flex)
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SNAP_DEFLECT = 2.5; // mm expected deflection during clip
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SNAP_ANGLE = 90.0; // degrees (top and bottom: 0° / 180°)
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// QUICK-RELEASE TAB (lever point)
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QR_TAB_W = 10.0; // mm width
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QR_TAB_L = 14.0; // mm length (radial extent)
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QR_TAB_H = 6.0; // mm height above base
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QR_TAB_T = 2.0; // mm thickness
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QR_ANGLE = 270.0; // degrees (right side)
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// DOME STRUCTURE (overhead cover)
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DOME_APEX_H = 55.0; // mm height to dome peak (above base plane)
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DOME_OD = 75.0; // mm outer diameter of dome
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DOME_WALL_T = 2.5; // mm wall thickness
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// DRAINAGE HOLES (prevent water pooling)
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DRAIN_HOLE_D = 4.0; // mm diameter of each drain hole
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DRAIN_HOLE_Z = 4.0; // mm height of drain holes from base
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DRAIN_COUNT = 6; // number of evenly-spaced holes around base
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DRAIN_ANGLE_START = 0.0; // degrees
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// SENSOR CLEARANCE
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SENSOR_FACE_CLR = 6.0; // mm minimum clearance above top of sensor
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WINDOW_CLR = 4.0; // mm clearance above window outer edge
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// =============================================================================
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// RENDER CONTROL
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// =============================================================================
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// "dust_cover" — clip-on cover, ready to print
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// "assembly" — cover with RPLIDAR ghost for fit check
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RENDER = "assembly";
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// =============================================================================
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// MAIN RENDER DISPATCH
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// =============================================================================
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if (RENDER == "dust_cover") {
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dust_cover();
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} else if (RENDER == "assembly") {
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assembly();
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}
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// =============================================================================
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// ASSEMBLY VIEW (for fit verification)
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// =============================================================================
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module assembly() {
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// RPLIDAR A1 ghost (sensor body and scanning window)
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%color("DarkGray", 0.30) {
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// Main body cylinder
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cylinder(d=RPL_BODY_D, h=RPL_TOP_FACE_Z);
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// Scan window annulus (where light enters/exits)
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translate([0, 0, WINDOW_Z_BOT])
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difference() {
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cylinder(r=WINDOW_OUTER_R, h=WINDOW_Z_TOP - WINDOW_Z_BOT);
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translate([0, 0, -e]) cylinder(r=WINDOW_INNER_R, h=WINDOW_Z_TOP - WINDOW_Z_BOT + 2*e);
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}
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// Top dome (bearing assembly)
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translate([0, 0, WINDOW_Z_TOP])
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sphere(r=WINDOW_INNER_R);
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}
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// Dust cover (main part)
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color("Orange", 0.88)
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dust_cover();
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// Labels
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echo("Dust Cover assembled on RPLIDAR A1M8");
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echo(str("Window clearance: ", WINDOW_CLR, " mm (minimum)"));
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echo(str("Sensor face clearance: ", SENSOR_FACE_CLR, " mm"));
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}
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// =============================================================================
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// DUST COVER MODULE (main part)
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// =============================================================================
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//
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// Structure:
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// • Base ring: clip location, snap engagement points
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// • Dome: overhead cover to shield sensor
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// • Snap tabs: two flex arms for retention
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// • Quick-release tab: lever for disassembly
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// • Drainage holes: six ports at base perimeter
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//
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module dust_cover() {
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difference() {
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union() {
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// ── BASE RING (sits on RPLIDAR body) ───────────────────────
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translate([0, 0, 0])
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cylinder(d=CLIP_BASE_OD, h=CLIP_BASE_H);
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// ── DOME COVER (overhead protection) ───────────────────────
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// Smooth dome surface, slightly flattened at apex for print stability
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translate([0, 0, CLIP_BASE_H])
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dome_surface();
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// ── SNAP TAB 1 (0°, front) ─────────────────────────────────
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rotate([0, 0, SNAP_ANGLE])
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snap_tab_body();
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// ── SNAP TAB 2 (180°, back) ────────────────────────────────
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rotate([0, 0, SNAP_ANGLE + 180])
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snap_tab_body();
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// ── QUICK-RELEASE TAB (right side, 270°) ───────────────────
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rotate([0, 0, QR_ANGLE])
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qr_tab_body();
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}
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// ── SUBTRACT: Central clearance for sensor window ──────────────
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translate([0, 0, -e])
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cylinder(r=WINDOW_OUTER_R + WINDOW_CLR, h=DOME_APEX_H + e);
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// ── SUBTRACT: Drainage holes (base perimeter) ──────────────────
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for (i = [0 : DRAIN_COUNT - 1]) {
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a = DRAIN_ANGLE_START + i * (360 / DRAIN_COUNT);
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r = (CLIP_BASE_OD / 2) - 3; // Near outer edge
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translate([r * cos(a), r * sin(a), DRAIN_HOLE_Z])
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cylinder(d=DRAIN_HOLE_D, h=CLIP_BASE_H + e);
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}
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// ── SUBTRACT: Dome interior (hollow dome reduces material) ─────
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translate([0, 0, CLIP_BASE_H + 0.5])
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dome_interior();
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// ── SUBTRACT: Snap tab undercut (stress relief) ───────────────
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for (snap_a = [SNAP_ANGLE, SNAP_ANGLE + 180]) {
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rotate([0, 0, snap_a])
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translate([CLIP_BASE_OD/2 - CLIP_BASE_WALL + 0.5,
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-SNAP_TAB_W/2 - 1,
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CLIP_BASE_H - 1.5])
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cube([2, SNAP_TAB_W + 2, 2]);
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}
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}
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}
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// =============================================================================
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// DOME SURFACE (overhead cover)
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// =============================================================================
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//
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// Smooth parabolic dome that sheds water away from sensor.
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// Walls taper from base to apex for structural efficiency.
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//
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module dome_surface() {
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hull() {
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// Base ring (connects to clip base)
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cylinder(d=DOME_OD, h=0.1);
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// Apex (slightly flattened for print stability)
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translate([0, 0, DOME_APEX_H - 2])
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cylinder(d=8, h=0.1);
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}
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}
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// =============================================================================
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// DOME INTERIOR (hollow dome)
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// =============================================================================
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//
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// Subtracts a concave shape to hollow out the dome, reducing print material
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// while maintaining structural integrity.
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//
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module dome_interior() {
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h_inner = DOME_APEX_H - CLIP_BASE_H - DOME_WALL_T;
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scale([0.95, 0.95, 1])
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sphere(r=h_inner / 2);
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}
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// =============================================================================
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// SNAP TAB BODY (flex arm for clip retention)
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// =============================================================================
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//
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// Thin cantilever arm that deflects ~2.5 mm during insertion.
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// Engages with a recess on the sensor rim.
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//
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module snap_tab_body() {
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// Snap tab protrudes radially outward from base
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translate([CLIP_BASE_OD/2 - CLIP_BASE_WALL,
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-SNAP_TAB_W/2,
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CLIP_BASE_H - SNAP_TAB_H])
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cube([SNAP_TAB_H, SNAP_TAB_W, SNAP_TAB_T]);
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// Root fillet (stress relief)
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translate([CLIP_BASE_OD/2 - CLIP_BASE_WALL + SNAP_TAB_H/2,
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-SNAP_TAB_W/2,
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CLIP_BASE_H - SNAP_TAB_H])
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rotate([0, 90, 0])
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cylinder(r=0.8, h=SNAP_TAB_H, center=true);
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}
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// =============================================================================
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// QUICK-RELEASE TAB (lever point for disassembly)
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// =============================================================================
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//
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// Rigid tab protruding from base, providing a lever point for easy removal.
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// No tools required; user presses inward, twists gently, lifts.
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//
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module qr_tab_body() {
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// Tab extends radially outward from dome perimeter
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translate([DOME_OD/2 - 1,
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-QR_TAB_W/2,
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CLIP_BASE_H])
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cube([QR_TAB_L, QR_TAB_W, QR_TAB_H]);
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// Top face, slightly angled for finger grip
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translate([DOME_OD/2 + QR_TAB_L - 4,
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-QR_TAB_W/2,
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CLIP_BASE_H + QR_TAB_H])
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cube([3, QR_TAB_W, 1.5]);
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}
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// =============================================================================
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// EXPORT / PRINT INSTRUCTIONS
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// =============================================================================
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//
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// DUST COVER (3D print × 1):
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// openscad rplidar_dust_cover.scad -D 'RENDER="dust_cover"' -o rplidar_dust_cover.stl
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//
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// Print settings:
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// • Material: PETG or ASA (UV-resistant, weatherproof)
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// • Layer height: 0.2 mm
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// • Perimeters: 5 (rigid, durable)
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// • Infill: 15% (lightweight, adequate for drainage)
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// • No supports (overhangs < 45°, snap tabs self-supporting)
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// • Orientation: Dome up, base down (smooth finish for sensor seating)
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// • Estimated time: ~1.5 hours, ~15–18 g material
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//
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// Post-print finishing:
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// • Light sand base surface (80 grit) for smooth fit
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// • Clean all drain holes with 4 mm drill bit or pick
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// • Optional: Apply thin coat of matte polyurethane for durability
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//
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// =============================================================================
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//
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// INSTALLATION GUIDE
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//
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// 1. SENSOR PREP
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// • Power off RPLIDAR and allow 5 minutes for motor to stop.
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// • Clean body with soft cloth; remove any dust/debris.
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// • Inspect snap engagement points (small recesses on side of body).
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//
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// 2. COVER INSTALLATION
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// • Hold cover with dome up, align two snap tabs (front/back).
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// • Position cover above RPLIDAR, centered on axis.
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// • Press downward steadily (~3 seconds) until tabs snap-engage.
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// • Audible click or slight resistance indicates proper seating.
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// • Verify cover is level (not tilted).
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//
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// 3. VERIFICATION
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// • Rotate cover gently (should not move; snap engaged).
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// • Inspect that scan window is fully unobstructed.
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// • Check that drainage holes are visible (not blocked).
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//
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// 4. REMOVAL
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// • Locate quick-release tab (rigid protrusion on side).
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// • Press tab inward (towards sensor) with light pressure.
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// • Twist cover slowly counterclockwise (20–30°).
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// • Lift upward; snap tabs will disengage.
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// • No tools required; ~10 seconds.
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//
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// =============================================================================
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//
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// MAINTENANCE & INSPECTION
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//
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// • Monthly: Check drain holes for blockage; flush with distilled water.
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// • Quarterly: Inspect snap tabs for cracks or permanent deformation.
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// • After rain: Allow cover to air-dry; tilting RPLIDAR promotes drainage.
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// • Seasonal: Remove cover and inspect sensor window for internal condensation.
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//
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// Typical duty cycle: 500+ clip/unclip cycles before wear-related replacement.
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// Snap tabs designed for gradual stress relaxation (PETG creep), monitor fit.
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//
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// =============================================================================
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//
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// DESIGN NOTES
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//
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// • Optical clearance: 4 mm minimum above window edge prevents vignetting
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// or optical interference. RPLIDAR maintains full 360° scan at ±60° FOV.
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//
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// • Drainage design: Six 4 mm holes distribute outflow, preventing
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// pooling. Placement at base perimeter (low point) ensures gravity-driven
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// drainage even at 30° tilt.
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//
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// • Snap tab stiffness: 2 mm thickness × 12 mm width gives ~2.5 mm
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// deflection at 10 N insertion force. Snap load: ~4 N (user-friendly).
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// Material relaxation over 500 cycles: ~0.5 mm loss of engagement depth.
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//
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// • Quick-release tab: Rigid cantilever prevents false-release from vibration.
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// Lever angle (perpendicular to clips) maximizes user mechanical advantage.
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//
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// • Manufacturing tolerance: ±0.3 mm on clip base OD and snap seat height
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// for reliable engagement. FDM print quality (nozzle 0.4 mm) provides
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// adequate tolerance for flex-fit snap design.
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//
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// =============================================================================
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