| 1 | // challenge-bot |
| 2 | // GNU AGPLv3 (or later at your option) |
| 3 | // project available at these locations: |
| 4 | // https://gitorious.org/ozzloy/challenge-bot |
| 5 | // https://github.com/waynegramlich/challenge-bot |
| 6 | |
| 7 | /* |
| 8 | this holds an hc-sr04 sonar sensor to a 3/16 inch deck. |
| 9 | http://fritzing.org/projects/hc-sr04-project |
| 10 | it can hold the sonar sensor either facing down, or forwards. |
| 11 | when facing down, it can detect if it passes over the edge of a table. |
| 12 | when facing forwards, it can detect and follow something in front of it. |
| 13 | */ |
| 14 | |
| 15 | $fn = 60; |
| 16 | |
| 17 | use <oshw.scad> |
| 18 | // 3/16 inch in mm deck_depth = 4.7625; |
| 19 | // 1/4 inch in mm = 6.35 |
| 20 | // subtract a little to be a squeeze fit |
| 21 | deck_depth = 4.7625 - 0.4; |
| 22 | // sonar sensor measurements taken with calipers: |
| 23 | // 10.82 in between, 42.33 outside, 15.82 diameter |
| 24 | // measured diameter of 15.82 with calipers, |
| 25 | // but when printed ends up being too small, so add some |
| 26 | sonar_diameter = 15.82 + 0.4; |
| 27 | sonar_radius = sonar_diameter / 2; |
| 28 | sonar_height = 13.8; |
| 29 | between_sonar_centers = sonar_diameter + 10.82; |
| 30 | // the sonar cylinders are placed on the pcb at slightly different positions |
| 31 | // from one sensor to the next, so this allows for that variance. |
| 32 | between_sonar_centers_variance = 2; |
| 33 | // keep at least this much plastic surrounding the sonar cylinder on all sides |
| 34 | buffer = 3; |
| 35 | sonar_holder_length = buffer + between_sonar_centers + sonar_diameter + buffer; |
| 36 | sonar_holder_width = buffer + sonar_diameter + buffer; |
| 37 | // sonar_holder_depth is deck_depth minus a little bit to make arm fit |
| 38 | // into deck holder |
| 39 | sonar_holder_depth = deck_depth - 0.7875; |
| 40 | |
| 41 | deck_holder_length = sonar_holder_depth * 2 + deck_depth + 15; |
| 42 | |
| 43 | oshw_dy = 120.366; |
| 44 | oshw_dx = 133.888; |
| 45 | |
| 46 | // 3/16 inch in mm deck_depth = 4.7625; |
| 47 | // 1/4 inch in mm = 6.35 |
| 48 | // subtract a little to be a squeeze fit |
| 49 | deck_depth = 4.7625 - 0.4; |
| 50 | // sonar sensor measurements taken with calipers: |
| 51 | // 10.82 in between, 42.33 outside, 15.82 diameter |
| 52 | // measured diameter of 15.82 with calipers, |
| 53 | // but when printed ends up being too small, so add some |
| 54 | sonar_diameter = 15.82 + 0.4; |
| 55 | sonar_radius = sonar_diameter / 2; |
| 56 | sonar_height = 13.8; |
| 57 | between_sonar_centers = sonar_diameter + 10.82; |
| 58 | // the sonar cylinders are placed on the pcb at slightly different positions |
| 59 | // from one sensor to the next, so this allows for that variance. |
| 60 | between_sonar_centers_variance = 2; |
| 61 | // keep at least this much plastic surrounding the sonar cylinder on all sides |
| 62 | buffer = 3; |
| 63 | sonar_holder_length = buffer + between_sonar_centers + sonar_diameter + buffer; |
| 64 | sonar_holder_width = buffer + sonar_diameter + buffer; |
| 65 | // sonar_holder_depth is deck_depth minus a little bit to make arm fit |
| 66 | // into deck holder |
| 67 | sonar_holder_depth = deck_depth - 0.7875; |
| 68 | |
| 69 | deck_holder_length = sonar_holder_depth * 2 + deck_depth + 15; |
| 70 | |
| 71 | module sonars() { |
| 72 | translate([between_sonar_centers / 2, 0, 0]) { |
| 73 | cylinder(r = sonar_radius, h = sonar_height); } |
| 74 | // for the variance with which the physical sonar cylinders are placed |
| 75 | translate([between_sonar_centers / 2 - between_sonar_centers_variance, 0, 0]) { |
| 76 | cylinder(r = sonar_radius, h = sonar_height); |
| 77 | translate([0, -sonar_radius, 0]) { |
| 78 | cube([between_sonar_centers_variance, sonar_diameter, sonar_height]); } } |
| 79 | translate([-between_sonar_centers / 2, 0, 0]) { |
| 80 | cylinder(r = sonar_radius, h = sonar_height); } } |
| 81 | |
| 82 | module sonar_holder() { |
| 83 | elbow_length = deck_depth; |
| 84 | rounded_corner_radius = buffer; |
| 85 | difference() { |
| 86 | cube([sonar_holder_length, sonar_holder_width, sonar_holder_depth]); |
| 87 | translate([sonar_holder_length / 2, sonar_holder_width / 2, -0.05]) { |
| 88 | sonars(); } |
| 89 | translate([sonar_holder_length - rounded_corner_radius, |
| 90 | sonar_holder_width - rounded_corner_radius, |
| 91 | 0]) { |
| 92 | corner_rounder(rounded_corner_radius, sonar_holder_depth); } } |
| 93 | translate([sonar_holder_length, 0, 0]) { |
| 94 | cube([elbow_length, deck_depth, sonar_holder_depth]); |
| 95 | translate([elbow_length, 0, 0]) { |
| 96 | linear_extrude(height = sonar_holder_depth) { |
| 97 | polygon([[ 0, 0], |
| 98 | [sonar_holder_depth, 0], |
| 99 | [sonar_holder_depth, sonar_holder_width / 2], |
| 100 | [ 0, |
| 101 | sonar_holder_width / 2 + sonar_holder_depth]]); } |
| 102 | translate([0, (sonar_holder_width + sonar_holder_depth) / 2, 0]) { |
| 103 | cube([sonar_holder_depth / 2, |
| 104 | (sonar_holder_width - sonar_holder_depth) / 2 + 0.8, |
| 105 | sonar_holder_depth]); } |
| 106 | translate([-1.7, sonar_holder_width + 0.8, 0]) { |
| 107 | linear_extrude(height = sonar_holder_depth) { |
| 108 | polygon([[ 0, 0], |
| 109 | [sonar_holder_depth / 2 + 1.7, 4], |
| 110 | [sonar_holder_depth / 2 + 1.7, 0]]); } } } } } |
| 111 | |
| 112 | module deck_holder() { |
| 113 | deck_holder_width = sonar_holder_width - deck_depth; |
| 114 | deck_holder_height = sonar_holder_depth * 2 + deck_depth; |
| 115 | linear_extrude(height = deck_holder_width) { |
| 116 | difference() { |
| 117 | square([deck_holder_length, deck_holder_height]); |
| 118 | translate([sonar_holder_depth - 0.15, sonar_holder_depth - 0.15]) { |
| 119 | square(deck_depth + 0.3); } |
| 120 | translate([deck_holder_height, sonar_holder_depth - 0.3]) { |
| 121 | square([deck_holder_length - (deck_holder_height), |
| 122 | deck_depth + 0.6]); } } } |
| 123 | translate([deck_holder_length - oshw_dy * 0.05, 0, deck_holder_width / 2]) |
| 124 | scale([0.1, 1, 0.1]) |
| 125 | rotate(v = [1, 0, 0], a = 90) |
| 126 | rotate(90) |
| 127 | linear_extrude(height = 0.5) |
| 128 | oshw(); |
| 129 | translate([deck_holder_length - oshw_dy * 0.05, |
| 130 | deck_holder_height + 0.5, |
| 131 | deck_holder_width / 2]) |
| 132 | rotate(v = [1, 0, 0], a = 90) |
| 133 | rotate(90) |
| 134 | scale([0.1, 0.1, 1]) |
| 135 | linear_extrude(height = 0.5) |
| 136 | oshw(); } |
| 137 | |
| 138 | module corner_rounder_2d(radius) { |
| 139 | difference() { |
| 140 | square(radius); |
| 141 | circle(radius); } } |
| 142 | |
| 143 | module corner_rounder(radius, height) { |
| 144 | linear_extrude(height = height) { |
| 145 | corner_rounder_2d(radius); } } |