342 lines
14 KiB
OpenSCAD
342 lines
14 KiB
OpenSCAD
// ============================================================
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// uwb_anchor_mount.scad — Wall/Ceiling UWB Anchor Mount Bracket
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// Issue: #564 Agent: sl-mechanical Date: 2026-03-14
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// (supersedes Rev A stem-collar mount — see git history)
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// ============================================================
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//
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// Parametric wall or ceiling mount bracket for ESP32 UWB Pro anchor.
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// Designed for fixed-infrastructure deployment: anchors screw into
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// wall or ceiling drywall/timber with standard M4 or #6 wood screws,
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// at a user-defined tilt angle so the UWB antenna faces the desired
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// coverage zone.
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//
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// Architecture:
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// Wall base -> flat backplate with 2x screw holes (wall or ceiling)
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// Tilt knuckle -> single-axis articulating joint; 15deg detent steps
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// locked with M3 nyloc bolt; range 0-90deg
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// Anchor cradle-> U-cradle holding ESP32 UWB Pro PCB on M2.5 standoffs
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// USB-C channel-> routed groove on tilt arm + exit slot in cradle back wall
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// Label slot -> rear window slot for printed anchor-ID card strip
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//
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// Part catalogue:
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// Part 1 -- wall_base() Backplate + 2-ear pivot block + detent arc
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// Part 2 -- tilt_arm() Pivoting arm with knuckle + cradle stub
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// Part 3 -- anchor_cradle() PCB cradle, standoffs, USB-C slot, label window
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// Part 4 -- cable_clip() Snap-on USB-C cable guide for tilt arm
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// Part 5 -- assembly_preview()
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//
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// Hardware BOM:
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// 2x M4 x 30mm wood screws (or #6 drywall screws) wall fasteners
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// 1x M3 x 20mm SHCS + M3 nyloc nut tilt pivot bolt
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// 4x M2.5 x 8mm SHCS PCB-to-cradle
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// 4x M2.5 hex nuts captured in standoffs
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// 1x USB-C cable anchor power
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//
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// ESP32 UWB Pro interface (verify with calipers):
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// PCB size : UWB_L x UWB_W x UWB_H (55 x 28 x 10 mm default)
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// Mounting holes : M2.5, 4x corners on UWB_HOLE_X x UWB_HOLE_Y pattern
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// USB-C port : centred on short edge, UWB_USBC_W x UWB_USBC_H
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// Antenna area : top face rear half -- 10mm keep-out of bracket material
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//
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// Tilt angles (15deg detent steps, set TILT_DEG before export):
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// 0deg -> horizontal face-up (ceiling, antenna faces down)
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// 30deg -> 30deg downward tilt (wall near ceiling) [default]
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// 45deg -> diagonal (wall mid-height)
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// 90deg -> vertical face-out (wall, antenna faces forward)
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//
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// RENDER options:
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// "assembly" full assembly at TILT_DEG (default)
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// "wall_base_stl" Part 1
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// "tilt_arm_stl" Part 2
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// "anchor_cradle_stl" Part 3
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// "cable_clip_stl" Part 4
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//
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// Export commands:
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// openscad uwb_anchor_mount.scad -D 'RENDER="wall_base_stl"' -o uwb_wall_base.stl
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// openscad uwb_anchor_mount.scad -D 'RENDER="tilt_arm_stl"' -o uwb_tilt_arm.stl
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// openscad uwb_anchor_mount.scad -D 'RENDER="anchor_cradle_stl"' -o uwb_anchor_cradle.stl
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// openscad uwb_anchor_mount.scad -D 'RENDER="cable_clip_stl"' -o uwb_cable_clip.stl
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// ============================================================
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$fn = 64;
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e = 0.01;
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// -- Tilt angle (override per anchor, 0-90deg, 15deg steps) ------------------
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TILT_DEG = 30;
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// -- ESP32 UWB Pro PCB dimensions (verify with calipers) ---------------------
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UWB_L = 55.0;
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UWB_W = 28.0;
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UWB_H = 10.0;
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UWB_HOLE_X = 47.5;
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UWB_HOLE_Y = 21.0;
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UWB_USBC_W = 9.5;
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UWB_USBC_H = 4.0;
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UWB_ANTENNA_L = 20.0;
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// -- Wall base geometry -------------------------------------------------------
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BASE_W = 60.0;
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BASE_H = 50.0;
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BASE_T = 5.0;
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BASE_SCREW_D = 4.5;
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BASE_SCREW_HD = 8.5;
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BASE_SCREW_HH = 3.5;
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BASE_SCREW_SPC = 35.0;
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KNUCKLE_T = BASE_T + 4.0;
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// -- Tilt arm geometry --------------------------------------------------------
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ARM_W = 12.0;
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ARM_T = 5.0;
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ARM_L = 35.0;
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PIVOT_D = 3.3;
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PIVOT_NUT_AF = 5.5;
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PIVOT_NUT_H = 2.4;
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DETENT_D = 3.2;
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DETENT_R = 8.0;
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// -- Anchor cradle geometry ---------------------------------------------------
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CRADLE_WALL_T = 3.5;
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CRADLE_BACK_T = 4.0;
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CRADLE_FLOOR_T = 3.0;
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CRADLE_LIP_H = 4.0;
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CRADLE_LIP_T = 2.5;
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STANDOFF_H = 3.0;
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STANDOFF_OD = 5.5;
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LABEL_W = UWB_L - 4.0;
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LABEL_H = UWB_W * 0.55;
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LABEL_T = 1.2;
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// -- USB-C routing ------------------------------------------------------------
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USBC_CHAN_W = 11.0;
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USBC_CHAN_H = 7.0;
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// -- Cable clip ---------------------------------------------------------------
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CLIP_CABLE_D = 4.5;
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CLIP_T = 2.0;
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CLIP_BODY_W = 16.0;
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CLIP_BODY_H = 10.0;
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// -- Fasteners ----------------------------------------------------------------
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M2P5_D = 2.7;
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M3_D = 3.3;
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M3_NUT_AF = 5.5;
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M3_NUT_H = 2.4;
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// ============================================================
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// RENDER DISPATCH
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// ============================================================
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RENDER = "assembly";
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if (RENDER == "assembly") assembly_preview();
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else if (RENDER == "wall_base_stl") wall_base();
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else if (RENDER == "tilt_arm_stl") tilt_arm();
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else if (RENDER == "anchor_cradle_stl") anchor_cradle();
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else if (RENDER == "cable_clip_stl") cable_clip();
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// ============================================================
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// ASSEMBLY PREVIEW
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// ============================================================
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module assembly_preview() {
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%color("Wheat", 0.22)
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translate([-BASE_W/2, -10, -BASE_H/2])
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cube([BASE_W, 10, BASE_H + 40]);
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color("OliveDrab", 0.85) wall_base();
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color("SteelBlue", 0.85)
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translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0]) tilt_arm();
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color("DarkSlateGray", 0.85)
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translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
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translate([0, ARM_T, ARM_L]) anchor_cradle();
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%color("ForestGreen", 0.38)
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translate([0, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
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translate([-UWB_L/2, ARM_T+CRADLE_BACK_T,
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ARM_L+CRADLE_FLOOR_T+STANDOFF_H])
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cube([UWB_L, UWB_W, UWB_H]);
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color("DimGray", 0.70)
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translate([ARM_W/2, KNUCKLE_T, 0]) rotate([TILT_DEG,0,0])
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translate([0, ARM_T+e, ARM_L/2]) rotate([0,-90,90]) cable_clip();
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}
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// ============================================================
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// PART 1 -- WALL BASE
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// ============================================================
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// Flat backplate, 2x countersunk M4/#6 wood screws on 35mm centres.
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// Two pivot ears straddle the tilt arm; M3 pivot bolt through both.
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// Detent arc on +X ear inner face: 7 notches at 15deg steps (0-90deg).
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// Shallow rear recess for installation-zone label strip.
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// Same part for wall mount and ceiling mount.
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//
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// Print: backplate flat on bed, PETG, 5 perims, 40% gyroid.
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module wall_base() {
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ear_h = ARM_W + 3.0;
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ear_t = 6.0;
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ear_sep = ARM_W + 1.0;
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difference() {
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union() {
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translate([-BASE_W/2, -BASE_T, -BASE_H/2])
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cube([BASE_W, BASE_T, BASE_H]);
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for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
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translate([ex, -BASE_T+e, -ear_h/2])
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cube([ear_t, KNUCKLE_T+e, ear_h]);
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for (ex = [-(ear_sep/2 + ear_t), ear_sep/2])
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hull() {
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translate([ex, -BASE_T, -ear_h/4])
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cube([ear_t, BASE_T-1, ear_h/2]);
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translate([ex + (ex<0 ? ear_t*0.5 : 0), -BASE_T, -ear_h/6])
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cube([ear_t*0.5, 1, ear_h/3]);
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}
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}
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for (sz = [-BASE_SCREW_SPC/2, BASE_SCREW_SPC/2]) {
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translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
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cylinder(d=BASE_SCREW_D, h=BASE_T+2*e);
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translate([0, -BASE_T-e, sz]) rotate([-90,0,0])
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cylinder(d1=BASE_SCREW_HD, d2=BASE_SCREW_D, h=BASE_SCREW_HH+e);
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}
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translate([-(ear_sep/2+ear_t+e), KNUCKLE_T*0.55, 0])
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rotate([0,90,0]) cylinder(d=PIVOT_D, h=ear_sep+2*ear_t+2*e);
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translate([ear_sep/2+ear_t-PIVOT_NUT_H-0.4, KNUCKLE_T*0.55, 0])
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rotate([0,90,0])
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cylinder(d=PIVOT_NUT_AF/cos(30), h=PIVOT_NUT_H+0.5, $fn=6);
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for (da = [0 : 15 : 90])
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translate([ear_sep/2-e,
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KNUCKLE_T*0.55 + DETENT_R*sin(da),
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DETENT_R*cos(da)])
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rotate([0,90,0]) cylinder(d=DETENT_D, h=ear_t*0.45+e);
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translate([0, -BASE_T-e, 0]) rotate([-90,0,0])
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cube([BASE_W-12, BASE_H-16, 1.6], center=true);
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translate([0, -BASE_T+1.5, 0])
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cube([BASE_W-14, BASE_T-3, BASE_H-20], center=true);
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}
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}
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// ============================================================
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// PART 2 -- TILT ARM
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// ============================================================
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// Pivoting arm linking wall_base ears to anchor_cradle.
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// Knuckle (Z=0): M3 pivot bore + spring-plunger detent pocket (3mm).
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// Cradle end (Z=ARM_L): 2x M3 bolt attachment stub.
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// USB-C cable channel groove on outer +Y face, full arm length.
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//
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// Print: knuckle face flat on bed, PETG, 5 perims, 40% gyroid.
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module tilt_arm() {
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total_h = ARM_L + 10;
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difference() {
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union() {
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translate([-ARM_W/2, 0, 0]) cube([ARM_W, ARM_T, total_h]);
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translate([0, ARM_T/2, 0]) rotate([90,0,0])
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cylinder(d=ARM_W, h=ARM_T, center=true);
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translate([-ARM_W/2, 0, ARM_L])
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cube([ARM_W, ARM_T+CRADLE_BACK_T, ARM_T]);
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}
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translate([-ARM_W/2-e, ARM_T/2, 0]) rotate([0,90,0])
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cylinder(d=PIVOT_D, h=ARM_W+2*e);
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translate([0, ARM_T+e, 0]) rotate([90,0,0])
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cylinder(d=3.2, h=4+e);
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translate([-USBC_CHAN_W/2, ARM_T-e, ARM_T+4])
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cube([USBC_CHAN_W, USBC_CHAN_H, ARM_L-ARM_T-8]);
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for (bx = [-ARM_W/4, ARM_W/4])
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translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([90,0,0])
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cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
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for (bx = [-ARM_W/4, ARM_W/4])
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translate([bx, ARM_T/2, ARM_L+ARM_T/2]) rotate([-90,0,0])
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cylinder(d=M3_NUT_AF/cos(30), h=M3_NUT_H+0.5, $fn=6);
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translate([0, ARM_T/2, ARM_L/2])
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cube([ARM_W-4, ARM_T-2, ARM_L-18], center=true);
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}
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}
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// ============================================================
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// PART 3 -- ANCHOR CRADLE
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// ============================================================
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// Open-front U-cradle for ESP32 UWB Pro PCB.
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// 4x M2.5 standoffs on UWB_HOLE_X x UWB_HOLE_Y pattern.
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// Back wall: USB-C exit slot + routing groove, label card slot,
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// antenna keep-out cutout (material removed above antenna area).
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// Front retaining lip prevents PCB sliding out.
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// Two attachment tabs bolt to tilt_arm cradle stub via M3.
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//
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// Label card slot: insert paper/laminate strip to ID this anchor
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// (e.g. "UWB-A3 NE-CORNER"), accessible from open cradle end.
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//
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// Print: back wall flat on bed, PETG, 5 perims, 40% gyroid.
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module anchor_cradle() {
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outer_l = UWB_L + 2*CRADLE_WALL_T;
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outer_w = UWB_W + CRADLE_FLOOR_T;
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pcb_z = CRADLE_FLOOR_T + STANDOFF_H;
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total_z = pcb_z + UWB_H + 2;
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difference() {
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union() {
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translate([-outer_l/2, 0, 0]) cube([outer_l, outer_w, total_z]);
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translate([-outer_l/2, outer_w-CRADLE_LIP_T, 0])
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cube([outer_l, CRADLE_LIP_T, CRADLE_LIP_H]);
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for (tx = [-ARM_W/4, ARM_W/4])
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translate([tx-4, -CRADLE_BACK_T, 0])
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cube([8, CRADLE_BACK_T+1, total_z]);
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}
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translate([-UWB_L/2, 0, pcb_z]) cube([UWB_L, UWB_W+1, UWB_H+4]);
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translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2-UWB_USBC_H/2])
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cube([UWB_USBC_W+2, CRADLE_BACK_T+2*e, UWB_USBC_H+2],
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center=[true,false,false]);
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translate([0, -CRADLE_BACK_T-e, -e])
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cube([USBC_CHAN_W, USBC_CHAN_H, pcb_z+UWB_H/2+USBC_CHAN_H],
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center=[true,false,false]);
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translate([0, -CRADLE_BACK_T-e, pcb_z+UWB_H/2])
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cube([LABEL_W, LABEL_T+0.3, LABEL_H], center=[true,false,false]);
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translate([0, -e, pcb_z+UWB_H-UWB_ANTENNA_L])
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cube([UWB_L-4, CRADLE_BACK_T+2*e, UWB_ANTENNA_L+4],
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center=[true,false,false]);
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for (tx = [-ARM_W/4, ARM_W/4])
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translate([tx, ARM_T/2-CRADLE_BACK_T, total_z/2])
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rotate([-90,0,0])
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cylinder(d=M3_D, h=ARM_T+CRADLE_BACK_T+2*e);
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for (side_x = [-outer_l/2-e, outer_l/2-CRADLE_WALL_T-e])
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translate([side_x, 2, pcb_z+2])
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cube([CRADLE_WALL_T+2*e, UWB_W-4, UWB_H-4]);
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}
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for (hx = [-UWB_HOLE_X/2, UWB_HOLE_X/2])
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for (hy = [(outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2,
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(outer_w-UWB_W)/2 + (UWB_W-UWB_HOLE_Y)/2 + UWB_HOLE_Y])
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difference() {
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translate([hx, hy, CRADLE_FLOOR_T-e])
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cylinder(d=STANDOFF_OD, h=STANDOFF_H+e);
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translate([hx, hy, CRADLE_FLOOR_T-2*e])
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cylinder(d=M2P5_D, h=STANDOFF_H+4);
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}
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}
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// ============================================================
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// PART 4 -- CABLE CLIP
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// ============================================================
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// Snap-on C-clip retaining USB-C cable along tilt arm outer face.
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// Presses onto ARM_T-wide arm with flexible PETG snap tongues.
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// Print x2-3 per anchor, spaced 25mm along arm.
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//
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// Print: clip-opening face down, PETG, 3 perims, 20% infill.
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module cable_clip() {
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ch_r = CLIP_CABLE_D/2 + CLIP_T;
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snap_t = 1.6;
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difference() {
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union() {
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translate([-CLIP_BODY_W/2, 0, 0])
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cube([CLIP_BODY_W, CLIP_T, CLIP_BODY_H]);
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translate([0, CLIP_T+ch_r, CLIP_BODY_H/2]) rotate([0,90,0])
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difference() {
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cylinder(r=ch_r, h=CLIP_BODY_W, center=true);
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cylinder(r=CLIP_CABLE_D/2, h=CLIP_BODY_W+2*e, center=true);
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translate([0, ch_r+e, 0])
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cube([CLIP_CABLE_D*0.85, ch_r*2+2*e, CLIP_BODY_W+2*e],
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center=true);
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}
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for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
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translate([tx, -ARM_T-1, 0])
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cube([snap_t, ARM_T+1+CLIP_T, CLIP_BODY_H]);
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for (tx = [-CLIP_BODY_W/2+1.5, CLIP_BODY_W/2-1.5-snap_t])
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translate([tx+snap_t/2, -ARM_T-1, CLIP_BODY_H/2])
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rotate([0,90,0]) cylinder(d=2, h=snap_t, center=true);
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}
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translate([0, -ARM_T-1-e, CLIP_BODY_H/2])
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cube([CLIP_BODY_W-6, ARM_T+2, CLIP_BODY_H-4], center=true);
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}
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}
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