sl-mechanical
479a33a6fa
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355 lines
15 KiB
OpenSCAD
355 lines
15 KiB
OpenSCAD
// =============================================================================
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// SaltyBot — Cable Management Clips
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// Agent: sl-mechanical | 2026-03-02
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//
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// MODULAR SNAP-ON CABLE CLIPS with integrated adhesive base and zip-tie anchors.
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// Designed to organize power cables, sensor bundles, and signal harnesses on the
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// chassis. Each clip accommodates a range of cable bundle diameters via elastic
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// snap jaws.
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//
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// HOW IT WORKS
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// 1. Adhesive base (3M VHB or equivalent) adheres to chassis surface.
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// 2. Cable bundle pressed upward through snap jaws until it seats with audible click.
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// 3. Overhanging jaw tabs provide two zip-tie anchor points (one per side).
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// 4. Vertical ear holes accept M3 threaded inserts for wire or strap attachment.
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//
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// CLIP FAMILY
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// • Clip 5mm: Holds 4–6 mm bundles (small signal cables)
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// • Clip 8mm: Holds 6–10 mm bundles (mixed power + signal)
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// • Clip 12mm: Holds 10–14 mm bundles (heavy power)
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//
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// PARTS (set RENDER= to export each)
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// clip_5mm — 3D print × N (RENDER="clip_5mm")
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// clip_8mm — 3D print × N (RENDER="clip_8mm")
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// clip_12mm — 3D print × N (RENDER="clip_12mm")
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// assembly_all — Full preview with ghosts (RENDER="assembly_all")
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//
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// MATERIALS
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// • Body: PETG or ASA (weatherproof, adhesive-friendly)
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// • Adhesive: 3M VHB 5952F (50 mm × 75 mm pads, rated 5 N/cm²)
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// • Anchors: M3 threaded inserts (optional, for high-load retention)
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// • Zip-ties: Standard nylon 3.6 mm × 150 mm (e.g., HellermannTyton)
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//
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// INSTALLATION
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// 1. Clean chassis surface with isopropyl alcohol; let dry.
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// 2. Peel 3M VHB backing; press clip firmly (30 s hold).
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// 3. Wait 24 hours for full adhesive cure.
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// 4. Press cable bundle upward through snap jaws until seated.
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// 5. Route zip-ties through jaw anchor points; cinch at desired tension.
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// 6. Optionally thread M3 bolts through ear holes for redundant retention.
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// =============================================================================
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$fn = 64;
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// =============================================================================
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// CLIP GEOMETRY — COMMON PARAMETERS
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// =============================================================================
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// SNAP JAW PROFILE (all clips share same jaw geometry)
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JAW_THICKNESS = 2.0; // mm thickness of snap arms (thin = flexible)
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JAW_BEND_R = 0.8; // mm radius at jaw root (stress relief)
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JAW_CLOSURE = 0.3; // mm interference fit depth when snapped closed
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SNAP_TRAVEL = 1.2; // mm vertical distance cable travels before seat
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SNAP_REST_GAP = 0.2; // mm gap when unloaded (keeps jaws sprung apart)
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// ADHESIVE BASE
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BASE_LENGTH = 50.0; // mm forward-back footprint
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BASE_WIDTH = 40.0; // mm left-right footprint
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BASE_THICKNESS = 2.5; // mm base pad thickness
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BASE_FILLET = 2.0; // mm corner rounding (aids adhesive contact)
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// ZIP-TIE ANCHOR FEATURES
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ANCHOR_TAB_H = 5.0; // mm height of jaw-tip anchor tab
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ANCHOR_TAB_T = 1.5; // mm thickness of anchor tab
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ANCHOR_SLOT_W = 4.0; // mm width of zip-tie slot (3.6 mm ties + 0.4 mm clearance)
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ANCHOR_SLOT_H = 1.0; // mm height of slot throat
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// WIRE/STRAP ATTACHMENT EARS
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EAR_D = 4.2; // mm hole diameter (M3 clearance, 2.6 mm nominal)
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EAR_WALL_T = 3.0; // mm wall thickness around hole
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EAR_H = 8.0; // mm ear protrusion height from base
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// =============================================================================
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// CLIP SIZE VARIANTS
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// =============================================================================
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// For each clip size, define:
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// CABLE_D — nominal cable bundle diameter
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// JAW_SPAN — inner span of closed jaws (CABLE_D + JAW_CLOSURE)
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// CLIP_HEIGHT — overall height of clip body
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// CLAMP_X — width of clamp section (controls jaw lever arm)
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CLIP_PARAMS = [
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// [name, cable_d, jaw_span, height, clamp_x]
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["5mm", 5.0, 5.3, 28.0, 18.0],
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["8mm", 8.0, 8.3, 35.0, 22.0],
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["12mm", 12.0, 12.3, 42.0, 26.0],
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];
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// =============================================================================
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// RENDER CONTROL
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// =============================================================================
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// "assembly_all" — all clips in array, with base ghosts
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// "clip_5mm" — single 5mm clip (ready to export STL)
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// "clip_8mm" — single 8mm clip
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// "clip_12mm" — single 12mm clip
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RENDER = "assembly_all";
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// Helper to fetch clip parameters by name
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function get_clip_params(name) =
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(name == "5mm") ? CLIP_PARAMS[0] :
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(name == "8mm") ? CLIP_PARAMS[1] :
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(name == "12mm") ? CLIP_PARAMS[2] :
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CLIP_PARAMS[0];
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// =============================================================================
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// MAIN RENDER DISPATCH
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// =============================================================================
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if (RENDER == "assembly_all") {
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assembly_all();
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} else if (RENDER == "clip_5mm") {
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clip_body(get_clip_params("5mm"));
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} else if (RENDER == "clip_8mm") {
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clip_body(get_clip_params("8mm"));
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} else if (RENDER == "clip_12mm") {
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clip_body(get_clip_params("12mm"));
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}
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// =============================================================================
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// ASSEMBLY VIEW (all clips in a row, with adhesive pads ghosted)
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// =============================================================================
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module assembly_all() {
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for (i = [0 : len(CLIP_PARAMS) - 1]) {
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p = CLIP_PARAMS[i];
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x_offset = i * 70; // 70 mm spacing
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translate([x_offset, 0, 0]) {
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// Clip body
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color("DodgerBlue", 0.92)
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clip_body(p);
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// Adhesive base ghost (3M VHB pad)
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%color("LimeGreen", 0.40)
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translate([0, 0, -BASE_THICKNESS])
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rounded_rect([50, 40, 0.2], BASE_FILLET);
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// Label
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echo(str("Clip ", p[0], " — Cable dia. ", p[1], " mm"));
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}
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}
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}
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// =============================================================================
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// CLIP BODY MODULE (parametric across all sizes)
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// =============================================================================
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//
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// Structure:
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// • Base: rounded rectangle, adhesive-mounting surface
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// • Spine: central vertical structure, extends from base
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// • Jaws: two snap arms extending upward/outward from spine
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// • Ears: two lateral holes for M3 attachment (optional)
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// • Anchors: small tabs on jaw tips for zip-tie routing
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//
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module clip_body(params) {
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name = params[0];
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cable_d = params[1];
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jaw_span = params[2];
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clip_h = params[3];
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clamp_x = params[4];
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spine_thick = 3.5; // mm thickness of central spine
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jaw_l = clip_h - BASE_THICKNESS; // jaw arm length
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jaw_root_x = clamp_x / 2; // X position where jaw originates from spine
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difference() {
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union() {
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// ── ADHESIVE BASE ──────────────────────────────────────────────
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translate([0, 0, -BASE_THICKNESS/2])
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rounded_rect([BASE_LENGTH, BASE_WIDTH, BASE_THICKNESS], BASE_FILLET);
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// ── CENTRAL SPINE (support structure) ───────────────────────────
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translate([-spine_thick/2, -clamp_x/2, 0])
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cube([spine_thick, clamp_x, BASE_THICKNESS + jaw_l]);
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// ── LEFT JAW (snap arm with flexible root) ──────────────────────
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jaw_body(-jaw_root_x, jaw_l, jaw_span);
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// ── RIGHT JAW (snap arm, mirror) ───────────────────────────────
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jaw_body(jaw_root_x, jaw_l, jaw_span);
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// ── LEFT EAR (M3 attachment hole) ──────────────────────────────
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translate([-clamp_x/2 - EAR_WALL_T - EAR_D/2, 0, BASE_THICKNESS])
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ear_boss();
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// ── RIGHT EAR ──────────────────────────────────────────────────
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translate([clamp_x/2 + EAR_WALL_T + EAR_D/2, 0, BASE_THICKNESS])
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ear_boss();
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}
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// ── SUBTRACT: Anchor slot hollows (zip-tie slots in jaw tips) ──────
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jaw_root_z = BASE_THICKNESS + jaw_l - ANCHOR_TAB_H;
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// Left jaw anchor slot
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translate([-jaw_root_x - 2, -ANCHOR_SLOT_W/2, jaw_root_z])
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cube([3, ANCHOR_SLOT_W, ANCHOR_SLOT_H]);
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// Right jaw anchor slot
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translate([jaw_root_x - 1, -ANCHOR_SLOT_W/2, jaw_root_z])
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cube([3, ANCHOR_SLOT_W, ANCHOR_SLOT_H]);
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// ── SUBTRACT: Ear attachment holes (M3 clearance) ────────────────
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// Left ear hole
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translate([-clamp_x/2 - EAR_WALL_T - EAR_D/2, 0, BASE_THICKNESS + EAR_H/2])
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cylinder(d=EAR_D, h=EAR_H + 1, center=true);
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// Right ear hole
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translate([clamp_x/2 + EAR_WALL_T + EAR_D/2, 0, BASE_THICKNESS + EAR_H/2])
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cylinder(d=EAR_D, h=EAR_H + 1, center=true);
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}
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}
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// =============================================================================
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// JAW BODY (single snap arm with cable pocket)
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// =============================================================================
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//
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// A flexible cantilever arm extending from the spine.
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// Lower section: solid (load-bearing).
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// Upper section: curved U-channel (grips cable).
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// Jaw tips: overhanging tabs for zip-tie anchors.
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//
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module jaw_body(x_root, jaw_length, inner_span) {
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jaw_span_outer = inner_span + 2 * JAW_THICKNESS;
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// The jaw sweeps from x_root (spine side) along +X, curving to grip.
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// At the tip, it has a slight outward bow for snap action.
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difference() {
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union() {
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// Lower jaw arm (solid, structural)
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translate([x_root, -jaw_span_outer/2, BASE_THICKNESS])
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cube([jaw_length * 0.65, jaw_span_outer, JAW_THICKNESS * 1.5]);
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// Upper jaw arm (U-channel form)
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translate([x_root, -inner_span/2 - JAW_THICKNESS, BASE_THICKNESS])
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cube([jaw_length * 0.85, inner_span + 2*JAW_THICKNESS, JAW_THICKNESS]);
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// Jaw tip anchor tab (for zip-tie slots)
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tip_x = x_root + jaw_length * 0.8;
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translate([tip_x, -jaw_span_outer/2 - ANCHOR_TAB_T,
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BASE_THICKNESS + JAW_THICKNESS])
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cube([ANCHOR_TAB_H, jaw_span_outer + 2*ANCHOR_TAB_T, ANCHOR_TAB_H]);
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}
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// Hollow out the U-channel (cable pocket)
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// Inner cavity: inner_span wide, runs most of jaw length
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translate([x_root + JAW_THICKNESS * 0.5, -inner_span/2, BASE_THICKNESS])
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cube([jaw_length * 0.7, inner_span, JAW_THICKNESS + 0.5]);
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}
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}
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// =============================================================================
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// EAR BOSS (M3 attachment point)
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// =============================================================================
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//
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// A small raised button with a through-hole, providing optional redundant
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// attachment for straps or hard-wired retention.
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//
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module ear_boss() {
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difference() {
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cylinder(d=EAR_D + 2*EAR_WALL_T, h=EAR_H);
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translate([0, 0, -1])
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cylinder(d=EAR_D, h=EAR_H + 2);
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}
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}
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// =============================================================================
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// UTILITY: Rounded Rectangle (for base and ghosts)
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// =============================================================================
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//
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module rounded_rect(size, r) {
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// size = [width, length, height]
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w = size[0];
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l = size[1];
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h = size[2];
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linear_extrude(height=h)
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offset(r=r)
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offset(r=-r)
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square([w, l], center=true);
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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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// CLIP 5mm (3D print × N):
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// openscad cable_management_clips.scad -D 'RENDER="clip_5mm"' -o clip_5mm.stl
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// Print settings: PETG/ASA, 4 perimeters, 20% infill, 0.2 mm layer
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// Orientation: base flat on bed (smooth finish for adhesive)
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//
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// CLIP 8mm (3D print × N):
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// openscad cable_management_clips.scad -D 'RENDER="clip_8mm"' -o clip_8mm.stl
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// Print settings: Same as 5mm
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//
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// CLIP 12mm (3D print × N):
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// openscad cable_management_clips.scad -D 'RENDER="clip_12mm"' -o clip_12mm.stl
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// Print settings: Same as 5mm
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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. SURFACE PREP
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// • Clean chassis surface with isopropyl alcohol.
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// • Let dry for 5 minutes; inspect for dust or residue.
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//
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// 2. ADHESIVE APPLICATION
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// • Cut 3M VHB 5952F into ~50 × 40 mm pads (one per clip).
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// • Peel foil backing from VHB pad.
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// • Center pad on clip base; press firmly for 30 seconds.
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// • Peel clear polyester liner from exposed adhesive.
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//
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// 3. MOUNTING
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// • Position clip on chassis surface (e.g., along frame rail).
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// • Press and hold for 30 seconds, applying full body weight if possible.
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// • Let cure for 24 hours before loading cables.
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//
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// 4. CABLE INSERTION
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// • Gather cable bundle (power, signal, etc.); inspect for knots/damage.
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// • Align bundle perpendicular to clip jaws.
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// • Press upward with steady pressure until jaws snap closed (audible click).
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// • Tension should hold cable 5–10 N without slip.
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//
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// 5. ZIP-TIE ANCHORING (optional extra security)
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// • Thread 3.6 mm nylon zip-tie through jaw anchor tabs (left and right).
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// • Route around cable bundle; cinch to desired tension (avoid crushing).
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// • Trim excess tie length.
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//
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// 6. THREADED INSERTION (optional M3 redundancy)
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// • Install M3 threaded insert into ear hole (using M3 insertion tool).
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// • Thread M3 × 16 mm bolt with split washer through ear.
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// • Tighten 1.5 N·m (firm but not excessive).
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//
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// =============================================================================
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//
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// CABLE ROUTING BEST PRACTICES
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//
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// • Power cables (main): Use 12mm clips, spacing 150–200 mm apart.
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// • Mixed signal bundles: Use 8mm clips, spacing 100–150 mm apart.
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// • Individual sensor leads: Use 5mm clips or traditional P-clips.
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//
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// • Avoid sharp bends: Route bundles with R ≥ 50 mm (cable bundle diameter).
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// • Prevent abrasion: Use snap clips where cable crosses sharp edges.
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// • Allow thermal expansion: Leave ~2–3 mm slack in long runs.
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// • Color-code bundles: Use electrical tape or heatshrink before clipping.
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//
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// =============================================================================
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