// https://gitorious.org/ozzloy/challenge-bot
// https://github.com/waynegramlich/challenge-bot
+$fn = 60;
-// sonar sensor measurements from https://www.thingiverse.com/thing:92869,
-// released under GPL.
-deck_depth = 4.7625; // 3/8 inch in mm
+// 3/16 inch in mm deck_depth = 4.7625;
+// 1/4 inch in mm - a little to be a squeeze fit
+deck_depth = 6.35 - 0.4;
sonar_plate_width = 20;
-sonar_plate_length = 45;
-sonar_plate_height = 1.2;
-sonar_sensor_radius = 8;
+// sonar sensor measurements taken with calipers:
+// 10.82 in between, 42.33 outside, 15.82 diameter
+// measured diameter of 15.82 with calipers,
+// but when printed ends up being too small
+sonar_sensor_radius = 15.82 / 2 + 0.3;
sonar_sensor_height = 13.8;
-sonar_holder_length = sonar_plate_length + 30;
-sonar_holder_depth = 3;
-
-difference (){
- union(){
- cube([sonar_holder_length, sonar_plate_width, sonar_holder_depth]);
- translate([sonar_plate_length + 5, 0, sonar_holder_depth]){
- cube([5, sonar_plate_width, deck_depth]);
- translate([0, 0, deck_depth]){
- cube([sonar_holder_length - sonar_plate_length - 5,
- sonar_plate_width,
- sonar_holder_depth]);
- }
- }
- }
- translate([45/2 - 13.5, 10, 0]){
- cylinder(r=sonar_sensor_radius, h = sonar_sensor_height, center = true);}
- translate([45/2 + 13.5, 10, 0]){
- cylinder(r=sonar_sensor_radius, h = sonar_sensor_height, center = true);}}
+between_sensor_centers = 15.82 + 10.82;
+sonar_plate_length = 3 + between_sensor_centers + sonar_sensor_radius + 3;
+sonar_holder_length = sonar_plate_length + 10;
+sonar_holder_width = sonar_plate_width + 3;
+sonar_holder_depth = 4;
+
+deck_holder_length = 30;
+deck_holder_width = sonar_holder_width;
+
+module sensors(){
+ translate([between_sensor_centers / 2, 0, 0]){
+ cylinder(r = sonar_sensor_radius, h = sonar_sensor_height);}
+ translate([-between_sensor_centers / 2, 0, 0]){
+ cylinder(r = sonar_sensor_radius, h = sonar_sensor_height);}}
+
+module sensor_holder(){
+ difference(){
+ cube([sonar_holder_length, sonar_holder_width, sonar_holder_depth]);
+ translate([sonar_holder_length / 2, sonar_holder_width / 2, -0.05]){
+ sensors();}}
+ translate([sonar_holder_length, 0, 0]){
+ cube([sonar_holder_depth + 0.3, deck_depth - 0.3, deck_depth - 0.3]);
+ translate([sonar_holder_depth + 0.3, 0, 0]){
+ // subtract a little bit (0.3) to make it fit
+ cube([deck_depth - 0.3, sonar_holder_width, deck_depth - 0.3]);}}}
+
+module deck_holder(){
+ cube([deck_holder_length, sonar_holder_depth, sonar_holder_width]);
+ cube([sonar_holder_depth,
+ sonar_holder_depth * 2 + deck_depth,
+ sonar_holder_width]);
+ translate([0, sonar_holder_depth + deck_depth, 0]){
+ cube([deck_holder_length, sonar_holder_depth, sonar_holder_width]);}
+ translate([sonar_holder_depth + deck_depth, 0, 0]){
+ cube([sonar_holder_depth,
+ sonar_holder_depth * 2 + deck_depth,
+ sonar_holder_width]);}}
+
+module sonar_table_top_holder(){
+ difference(){
+ union(){
+ cube([sonar_holder_length, sonar_holder_width, sonar_holder_depth]);
+ translate([sonar_holder_length, 0, 0]){
+ deck_holder();}}
+ translate([between_sensor_centers / 2 + sonar_sensor_radius + 3,
+ sonar_holder_width / 2,
+ -1]){
+ sensors();}
+ // cut out a bit of the circle to make it 3d printable,
+ // no severe overhang
+ translate([3 + sonar_sensor_radius,
+ sonar_holder_width - 3.025,
+ sonar_holder_depth / 2 - 0.025]){
+ cube([10, 6.1, sonar_holder_depth + .1], center = true);
+ translate([between_sensor_centers, 0, 0]){
+ cube([10, 6.1, sonar_holder_depth + .1], center = true);}}}}
+
+sensor_holder();