cq/enclosure.py

import cadquery as cq

usb_h = 10.5
usb_v = 5.2

socket_distance_x = 10.8
socket_distance_y = 36.55
socket_width = 28

# the width of the bezel on the side of the inner relay
side_bezel_width = 3.14

# how far the plug in the middle is from the side
# where the socket that powers the relay coil is
distance_from_socket_to_end = 46

relay_x_size = 120.2
relay_y_size = 168

# dimensions of the socket for coil power on the side
end_socket_width = 30.4
end_socket_height = 22.6

# the distance from the side of the socket to the edge of the box
# for the socket that powers the relay coil
end_socket_distance_from_side = 3.47 + 3  # add 3mm for tape

reset_button_dist_from_socket = 5.27
reset_width = 18.7
reset_height = 35.04
reset_lip_height = 3.37  # probably not needed

# parameter definitions
p_outerWidth = relay_x_size + 15  # Outer width of box enclosure
p_outerLength = relay_y_size  # Outer length of box enclosure
p_outerHeight = 33.6 + 30  # Outer height of box enclosure

p_thickness = 3.0  # Thickness of the box walls
p_sideRadius = 10.0  # Radius for the curves around the sides of the box
p_topAndBottomRadius = (
    2.0  # Radius for the curves on the top and bottom edges of the box
)

p_screwpostInset = 12.0  # How far in from the edges the screw posts should be place.
p_screwpostID = 4.0  # Inner Diameter of the screw post holes, should be roughly screw diameter not including threads
p_screwpostOD = 10.0  # Outer Diameter of the screw posts.\nDetermines overall thickness of the posts

p_boreDiameter = 8.0  # Diameter of the counterbore hole, if any
p_boreDepth = 1.0  # Depth of the counterbore hole, if
p_countersinkDiameter = 0.0  # Outer diameter of countersink. Should roughly match the outer diameter of the screw head
p_countersinkAngle = 90.0  # Countersink angle (complete angle between opposite sides, not from center to one side)
p_flipLid = True  # Whether to place the lid with the top facing down or not.
p_lipHeight = 1.0  # Height of lip on the underside of the lid.\nSits inside the box body for a snug fit.

# outer shell
oshell = (
    cq.Workplane("XY")
    .rect(p_outerWidth, p_outerLength)
    .extrude(p_outerHeight + p_lipHeight)
)

# weird geometry happens if we make the fillets in the wrong order
if p_sideRadius > p_topAndBottomRadius:
    oshell = oshell.edges("|Z").fillet(p_sideRadius)
    oshell = oshell.edges("#Z").fillet(p_topAndBottomRadius)
else:
    oshell = oshell.edges("#Z").fillet(p_topAndBottomRadius)
    oshell = oshell.edges("|Z").fillet(p_sideRadius)

# inner shell
ishell = (
    oshell.faces("<Z")
    .workplane(p_thickness, True)
    .rect((p_outerWidth - 2.0 * p_thickness), (p_outerLength - 2.0 * p_thickness))
    .extrude(
        (p_outerHeight - 2.0 * p_thickness), False
    )  # set combine false to produce just the new boss
)
ishell = ishell.edges("|Z").fillet(p_sideRadius - p_thickness)

# make the box outer box
box = oshell.cut(ishell)

# make the screw posts
POSTWIDTH = p_outerWidth - 2.0 * p_screwpostInset
POSTLENGTH = p_outerLength - 2.0 * p_screwpostInset

box = (
    box.faces(">Z")
    .workplane(-p_thickness)
    .rect(POSTWIDTH, POSTLENGTH, forConstruction=True)
    .vertices()
    .circle(p_screwpostOD / 2.0)
    .circle(p_screwpostID / 2.0)
    .extrude(-1.0 * (p_outerHeight + p_lipHeight - p_thickness), True)
)

# split lid into top and bottom parts
(lid, bottom) = (
    box.faces(">Z")
    .workplane(-p_thickness - p_lipHeight)
    .split(keepTop=True, keepBottom=True)
    .all()
)  # splits into two solids

lid = (
    lid.workplane()
    .rect(
        socket_width + socket_distance_x,
        socket_distance_y + (socket_width),
        forConstruction=True,
    )
    .tag("sockets")
    .vertices()
    .rect(socket_width, socket_width)
    .cutThruAll()
)

bottom = (
    bottom.faces(">Y")
    .workplane()
    .center(0, -end_socket_height + 8)
    .rect(end_socket_width, end_socket_height)
    .cutBlind("next")
)

holes = (
    cq.Workplane("XY")
    .rect((p_outerWidth - 20.0 * p_thickness), (p_outerLength - 20.0 * p_thickness))
    .vertices()
    .cylinder(10, 3.1 / 2)
)

bottom = bottom.cut(holes)

bottom = (
    bottom.faces(">Y[0]")
    .workplane(offset=0)
    .move(0, -(p_outerHeight / 2) - usb_v - 3.3)
    .box(usb_h, usb_v, 10, combine="cut")
)

# lid = (lid.center(socket_width-8, socket_distance_y+(socket_width)-3)
#       .rect(reset_height, reset_width)
#       .cutThruAll())

# translate the lid, and subtract the bottom from it to produce the lid inset
lowerLid = lid.translate((0, 0, -p_lipHeight))
cutlip = lowerLid.cut(bottom).translate(
    (p_outerWidth + p_thickness, 0, p_thickness - p_outerHeight + p_lipHeight)
)

# compute centers for screw holes
topOfLidCenters = (
    cutlip.faces(">Z")
    .workplane(centerOption="CenterOfMass")
    .rect(POSTWIDTH, POSTLENGTH, forConstruction=True)
    .vertices()
)

# add holes of the desired type
if p_boreDiameter > 0 and p_boreDepth > 0:
    print("first")
    topOfLid = topOfLidCenters.cboreHole(
        p_screwpostID, p_boreDiameter, p_boreDepth, 2.0 * p_thickness
    )
elif p_countersinkDiameter > 0 and p_countersinkAngle > 0:
    print("second")
    topOfLid = topOfLidCenters.cskHole(
        p_screwpostID, p_countersinkDiameter, p_countersinkAngle, 2.0 * p_thickness
    )
else:
    print("third")
    topOfLid = topOfLidCenters.hole(p_screwpostID, 2.0 * p_thickness)

# flip lid upside down if desired
if p_flipLid:
    topOfLid = topOfLid.rotateAboutCenter((1, 0, 0), 180)

# return the combined result
result = topOfLid.union(bottom)

cq.exporters.export(bottom, "/home/deck/model_files/enclosure_bottom.step")
cq.exporters.export(topOfLid, "/home/deck/model_files/enclosure_lid.step")

try:
    show_object(bottom)
except NameError:
    pass