344 lines
14 KiB
OpenSCAD
344 lines
14 KiB
OpenSCAD
// ============================================================
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// RPLIDAR A1 Mount Bracket — Issue #596
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// Agent : sl-mechanical
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// Date : 2026-03-14
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// Part catalogue:
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// 1. tnut_base — 2020 T-slot rail interface plate with M5 T-nut captive pockets
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// 2. column — hollow elevation column, 120 mm tall, 3 stiffening ribs, cable bore
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// 3. scan_platform — top plate with Ø40 mm BC M3 mounting pattern, vibration seats
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// 4. vibe_ring — silicone FC-grommet isolation ring for scan_platform bolts
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// 5. cable_guide — snap-on cable management clip for column body
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//
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// BOM:
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// 2 × M5×10 BHCS + M5 T-nuts (tnut_base to rail)
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// 4 × M3×8 SHCS (scan_platform to RPLIDAR A1)
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// 4 × M3 silicone FC grommets Ø8.5 OD / Ø3.2 bore (anti-vibe)
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// 4 × M3 hex nuts (captured in scan_platform)
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//
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// Print settings (PETG):
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// tnut_base / column / scan_platform : 5 perimeters, 40 % gyroid, no supports
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// vibe_ring : 3 perimeters, 20 % gyroid, no supports
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// cable_guide : 3 perimeters, 30 % gyroid, no supports
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//
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// Export commands:
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// openscad -D 'RENDER="tnut_base"' -o tnut_base.stl rplidar_mount.scad
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// openscad -D 'RENDER="column"' -o column.stl rplidar_mount.scad
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// openscad -D 'RENDER="scan_platform"' -o scan_platform.stl rplidar_mount.scad
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// openscad -D 'RENDER="vibe_ring"' -o vibe_ring.stl rplidar_mount.scad
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// openscad -D 'RENDER="cable_guide"' -o cable_guide.stl rplidar_mount.scad
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// openscad -D 'RENDER="assembly"' -o assembly.png rplidar_mount.scad
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// ============================================================
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// ── Render selector ─────────────────────────────────────────
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RENDER = "assembly"; // tnut_base | column | scan_platform | vibe_ring | cable_guide | assembly
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// ── Global constants ────────────────────────────────────────
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$fn = 64;
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EPS = 0.01;
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// 2020 rail
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RAIL_W = 20.0; // extrusion cross-section
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RAIL_H = 20.0;
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SLOT_NECK_H = 3.2; // T-slot opening width
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TNUT_W = 9.8; // M5 T-nut width
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TNUT_H = 5.5; // T-nut height (depth into slot)
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TNUT_L = 12.0; // T-nut body length
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M5_D = 5.2; // M5 clearance bore
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M5_HEAD_D = 9.5; // M5 BHCS head diameter
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M5_HEAD_H = 4.0; // M5 BHCS head height
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// Base plate
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BASE_L = 60.0; // length along rail axis
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BASE_W = 30.0; // width across rail
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BASE_T = 8.0; // plate thickness
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BOLT_PITCH = 40.0; // M5 bolt pitch along rail (centre-to-centre)
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// Elevation column
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COL_OD = 25.0; // column outer diameter
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COL_ID = 17.0; // inner bore (cable routing)
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ELEV_H = 120.0; // scan plane above rail top face
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COL_WALL = (COL_OD - COL_ID) / 2;
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RIB_W = 3.0; // stiffening rib width
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RIB_H = 3.5; // rib radial height
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CABLE_SLOT_W = 8.0; // cable entry slot width
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CABLE_SLOT_H = 5.0; // cable entry slot height
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// Scan platform
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PLAT_D = 60.0; // platform disc diameter (clears RPLIDAR body Ø100 mm well)
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PLAT_T = 6.0; // platform thickness
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RPL_BC_D = 40.0; // RPLIDAR M3 bolt circle diameter (4 bolts at 45 °)
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RPL_BORE_D = 36.0; // central pass-through for scan motor cable
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M3_D = 3.2; // M3 clearance bore
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M3_NUT_W = 5.5; // M3 hex nut across-flats
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M3_NUT_H = 2.4; // M3 hex nut height
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GROM_OD = 8.5; // FC silicone grommet OD
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GROM_ID = 3.2; // grommet bore
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GROM_H = 3.0; // grommet seat depth
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CONN_SLOT_W = 12.0; // connector side-exit slot width
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CONN_SLOT_H = 5.0; // connector slot height
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// Vibe ring
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VRING_OD = GROM_OD + 1.6; // printed retainer OD
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VRING_ID = GROM_ID + 0.3; // pass-through with grommet seated
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VRING_T = 2.0; // ring flange thickness
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// Cable guide clip
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CLIP_W = 14.0;
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CLIP_T = 3.5;
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CLIP_GAP = COL_OD + 0.4; // snap-fit gap (slight interference)
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SNAP_T = 1.8;
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CABLE_CH_W = 8.0;
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CABLE_CH_H = 5.0;
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// ── Utility modules ─────────────────────────────────────────
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module chamfer_cube(size, ch=1.0) {
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// simple chamfered box (bottom edge only for printability)
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hull() {
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translate([ch, ch, 0])
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cube([size[0]-2*ch, size[1]-2*ch, EPS]);
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translate([0, 0, ch])
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cube(size - [0, 0, ch]);
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}
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}
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module hex_pocket(af, depth) {
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// hex nut pocket (flat-to-flat af)
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cylinder(d = af / cos(30), h = depth, $fn = 6);
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}
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// ── Part 1: tnut_base ───────────────────────────────────────
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module tnut_base() {
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difference() {
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// Body
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union() {
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chamfer_cube([BASE_L, BASE_W, BASE_T], ch=1.5);
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// Column socket boss centred on plate top face
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translate([BASE_L/2, BASE_W/2, BASE_T])
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cylinder(d=COL_OD + 4.0, h=8.0);
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}
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// M5 bolt holes (counterbored for BHCS heads from underneath)
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for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
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translate([x, BASE_W/2, -EPS]) {
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cylinder(d=M5_D, h=BASE_T + 8.0 + 2*EPS);
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// counterbore from bottom
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cylinder(d=M5_HEAD_D, h=M5_HEAD_H + EPS);
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}
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// T-nut captive pockets (accessible from bottom)
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for (x = [BASE_L/2 - BOLT_PITCH/2, BASE_L/2 + BOLT_PITCH/2])
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translate([x - TNUT_L/2, BASE_W/2 - TNUT_W/2, BASE_T - TNUT_H])
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cube([TNUT_L, TNUT_W, TNUT_H + EPS]);
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// Column bore into boss
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translate([BASE_L/2, BASE_W/2, BASE_T - EPS])
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cylinder(d=COL_OD + 0.3, h=8.0 + 2*EPS);
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// Cable exit slot through base (offset 5 mm from column centre)
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translate([BASE_L/2 - CABLE_SLOT_W/2, BASE_W/2 + COL_OD/4, -EPS])
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cube([CABLE_SLOT_W, CABLE_SLOT_H, BASE_T + 8.0 + 2*EPS]);
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// Weight relief pockets on underside
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for (x = [BASE_L/2 - BOLT_PITCH/2 + 10, BASE_L/2 + BOLT_PITCH/2 - 10])
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for (y = [7, BASE_W - 7])
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translate([x - 5, y - 5, -EPS])
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cube([10, 10, BASE_T/2]);
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}
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}
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// ── Part 2: column ──────────────────────────────────────────
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module column() {
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// Actual column height: ELEV_H minus base boss engagement (8 mm) and platform seating (6 mm)
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col_h = ELEV_H - 8.0 - PLAT_T;
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difference() {
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union() {
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// Hollow tube
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cylinder(d=COL_OD, h=col_h);
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// Three 120°-spaced stiffening ribs along full height
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for (a = [0, 120, 240])
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rotate([0, 0, a])
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translate([COL_OD/2 - EPS, -RIB_W/2, 0])
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cube([RIB_H, RIB_W, col_h]);
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// Bottom spigot (fits into base boss bore)
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translate([0, 0, -6.0])
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cylinder(d=COL_OD - 0.4, h=6.0 + EPS);
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// Top spigot (seats into scan_platform recess)
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translate([0, 0, col_h - EPS])
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cylinder(d=COL_OD - 0.4, h=6.0);
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}
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// Inner cable bore
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translate([0, 0, -6.0 - EPS])
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cylinder(d=COL_ID, h=col_h + 12.0 + 2*EPS);
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// Cable entry slot at bottom (aligns with base slot)
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translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, 2.0])
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cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
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// Cable exit slot at top (90° rotated for tidy routing)
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rotate([0, 0, 90])
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translate([-CABLE_SLOT_W/2, -COL_OD/2 - EPS, col_h - CABLE_SLOT_H - 4.0])
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cube([CABLE_SLOT_W, CABLE_SLOT_H + EPS, CABLE_SLOT_H]);
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// Cable clip snap groove (at mid-height)
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translate([0, 0, col_h / 2])
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difference() {
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cylinder(d=COL_OD + 2*RIB_H + 0.8, h=4.0, center=true);
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cylinder(d=COL_OD - 0.2, h=4.0 + 2*EPS, center=true);
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}
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}
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}
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// ── Part 3: scan_platform ───────────────────────────────────
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module scan_platform() {
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difference() {
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union() {
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// Main disc
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cylinder(d=PLAT_D, h=PLAT_T);
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// Rim lip for stiffness
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translate([0, 0, PLAT_T])
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difference() {
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cylinder(d=PLAT_D, h=2.0);
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cylinder(d=PLAT_D - 4.0, h=2.0 + EPS);
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}
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}
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// Central cable pass-through
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translate([0, 0, -EPS])
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cylinder(d=RPL_BORE_D, h=PLAT_T + 4.0);
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// Column spigot socket (bottom recess)
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translate([0, 0, -EPS])
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cylinder(d=COL_OD - 0.4 + 0.4, h=6.0);
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// RPLIDAR M3 mounting holes — 4× on Ø40 BC at 45°/135°/225°/315°
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for (a = [45, 135, 225, 315])
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rotate([0, 0, a])
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translate([RPL_BC_D/2, 0, -EPS]) {
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// Through bore
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cylinder(d=M3_D, h=PLAT_T + 2*EPS);
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// Grommet seat (countersunk from top)
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translate([0, 0, PLAT_T - GROM_H])
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cylinder(d=GROM_OD + 0.3, h=GROM_H + EPS);
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// Captured M3 hex nut pocket (from bottom)
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translate([0, 0, 1.5])
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hex_pocket(M3_NUT_W + 0.3, M3_NUT_H + 0.2);
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}
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// Connector side-exit slots (2× opposing, at 0° and 180°)
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for (a = [0, 180])
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rotate([0, 0, a])
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translate([-CONN_SLOT_W/2, PLAT_D/2 - CONN_SLOT_H, -EPS])
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cube([CONN_SLOT_W, CONN_SLOT_H + EPS, PLAT_T + 2*EPS]);
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// Weight relief pockets (2× lateral)
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for (a = [90, 270])
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rotate([0, 0, a])
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translate([-10, 15, 1.5])
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cube([20, 8, PLAT_T - 3.0]);
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}
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}
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// ── Part 4: vibe_ring ───────────────────────────────────────
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// Printed silicone-grommet retainer ring — press-fits over M3 bolt with grommet seated
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module vibe_ring() {
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difference() {
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union() {
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cylinder(d=VRING_OD, h=VRING_T + GROM_H);
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// Flange
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cylinder(d=VRING_OD + 2.0, h=VRING_T);
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}
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// Bore
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translate([0, 0, -EPS])
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cylinder(d=VRING_ID, h=VRING_T + GROM_H + 2*EPS);
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}
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}
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// ── Part 5: cable_guide ─────────────────────────────────────
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// Snap-on cable clip for column mid-section
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module cable_guide() {
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arm_t = SNAP_T;
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gap = CLIP_GAP;
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difference() {
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union() {
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// Saddle body (U-shape wrapping column)
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difference() {
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cylinder(d=gap + 2*CLIP_T, h=CLIP_W);
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translate([0, 0, -EPS])
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cylinder(d=gap, h=CLIP_W + 2*EPS);
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// Open front slot for snap insertion
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translate([-gap/2, 0, -EPS])
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cube([gap, gap/2 + CLIP_T + EPS, CLIP_W + 2*EPS]);
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}
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// Snap arms
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for (s = [-1, 1])
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translate([s*(gap/2 - arm_t), 0, 0])
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mirror([s < 0 ? 1 : 0, 0, 0])
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translate([0, -arm_t/2, 0])
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cube([arm_t + 1.5, arm_t, CLIP_W]);
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// Cable channel bracket (side-mounted)
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translate([gap/2 + CLIP_T, -(CABLE_CH_W/2 + CLIP_T), 0])
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cube([CLIP_T + CABLE_CH_H, CABLE_CH_W + 2*CLIP_T, CLIP_W]);
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}
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// Cable channel cutout
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translate([gap/2 + CLIP_T + CLIP_T - EPS, -CABLE_CH_W/2, -EPS])
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cube([CABLE_CH_H + EPS, CABLE_CH_W, CLIP_W + 2*EPS]);
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// Snap tip undercut (both arms)
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for (s = [-1, 1])
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translate([s*(gap/2 + CLIP_T + 1.0), -arm_t, -EPS])
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rotate([0, 0, s*30])
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cube([2, arm_t*2, CLIP_W + 2*EPS]);
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}
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}
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// ── Assembly / render dispatch ───────────────────────────────
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module assembly() {
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// tnut_base at origin
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color("SteelBlue")
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tnut_base();
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// column rising from base boss
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color("DodgerBlue")
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translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0])
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column();
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// scan_platform at top of column
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col_h_actual = ELEV_H - 8.0 - PLAT_T;
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color("CornflowerBlue")
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translate([BASE_L/2, BASE_W/2, BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 - EPS])
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scan_platform();
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// vibe rings (4×) seated in platform holes
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for (a = [45, 135, 225, 315])
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color("Gray", 0.7)
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translate([BASE_L/2, BASE_W/2,
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BASE_T + 8.0 - 6.0 + col_h_actual + 6.0 + PLAT_T - GROM_H])
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rotate([0, 0, a])
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translate([RPL_BC_D/2, 0, 0])
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vibe_ring();
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// cable_guide clipped at column mid-height
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color("LightSteelBlue")
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translate([BASE_L/2, BASE_W/2,
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BASE_T + 8.0 - 6.0 + (ELEV_H - 8.0 - PLAT_T)/2 - CLIP_W/2])
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cable_guide();
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}
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// ── Dispatch ────────────────────────────────────────────────
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if (RENDER == "tnut_base") tnut_base();
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else if (RENDER == "column") column();
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else if (RENDER == "scan_platform") scan_platform();
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else if (RENDER == "vibe_ring") vibe_ring();
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else if (RENDER == "cable_guide") cable_guide();
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else assembly();
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