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OpenSCAD-Examples
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PSU Enclosure, finished

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Nicolas Massé 8 years ago
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4 changed files with 232 additions and 117 deletions
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  1. 139
      013-PSU-Enclosure/box.scad
  2. 83
      013-PSU-Enclosure/common.scad
  3. 10
      013-PSU-Enclosure/cover.scad
  4. 117
      013-PSU-Enclosure/psu-enclosure.scad

139
013-PSU-Enclosure/box.scad
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include <MCAD/units.scad>;
include <common.scad>
use <OpenSCAD-Pattern-Filling/pattern.scad>;
module one_unit(unit_height) {
translate([ 0, unit_height ]) {
unit_voltmeter_size = [ 23 * mm, 10.5 * mm, wall_size + 2 * epsilon ];
unit_voltmeter_spacing = 15 * mm;
translate([ 0, unit_voltmeter_spacing ])
cube(unit_voltmeter_size);
unit_hole_diameter = 8 * mm;
unit_hole_spacing = 10 * mm;
translate([ unit_voltmeter_size.x / 2 - unit_hole_spacing / 2 - unit_hole_diameter / 2, 0 ])
cylinder(d = unit_hole_diameter, h = wall_size + 2 * epsilon);
translate([ unit_voltmeter_size.x / 2 + unit_hole_spacing / 2 + unit_hole_diameter / 2, 0 ])
cylinder(d = unit_hole_diameter, h = wall_size + 2 * epsilon);
}
}
module three_units(unit_height) {
rotate([ 90, 0, 0 ]) {
translate([ 30 * mm, 0, -epsilon ])
one_unit(unit_height);
translate([ 65 * mm, 0, -epsilon ])
one_unit(unit_height);
translate([ 100 * mm, 0, -epsilon ])
one_unit(unit_height);
}
}
module main_socket(socket_position) {
// Main socket
socket_dimension = [ wall_size + 2 * epsilon, 31 * mm, 22 * mm ];
socket_mounting_holes_diameter = 2.5 * mm;
socket_mounting_holes_position = [ 0, - 4.5 * mm, socket_dimension.z / 2 ];
translate([ -wall_size - epsilon + socket_position.x, useful_size.y + socket_position.y, socket_position.z ]) {
cube(socket_dimension);
translate(socket_mounting_holes_position)
rotate([ 0, 90, 0 ])
cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
translate([ socket_mounting_holes_position.x, socket_dimension.y - socket_mounting_holes_position.y, socket_mounting_holes_position.z ] )
rotate([ 0, 90, 0 ])
cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
}
}
module main_switch(switch_position) {
// Main switch
switch_dimension = [ wall_size + 2 * epsilon, 19 * mm, 13 * mm ];
translate([ -wall_size - epsilon + switch_position.x, useful_size.y + switch_position.y, switch_position.z ]) {
cube(switch_dimension);
}
}
module fan_vent(fan_vent_position) {
// Fan vent
fan_vent_size = [ 76.5 * mm, 76.5 * mm, wall_size + 2 * epsilon ];
fan_vent_diameter = 90 * mm;
fan_vent_mounting_hole_position = [ 36 * mm, 36 * mm ];
fan_vent_mounting_hole_diameter = 5.5 * mm;
translate([ -wall_size - epsilon, useful_size.y - fan_vent_position.x - fan_vent_size.x / 2, fan_vent_position.y + fan_vent_size.y / 2 ])
rotate([ 0, 90, 0 ]) {
intersection() {
translate(-[ fan_vent_size.x, fan_vent_size.y] / 2)
cube(fan_vent_size);
cylinder(d = fan_vent_diameter, h = wall_size + 2 * epsilon, $fn = 180);
spray_pattern([ fan_vent_size / -2, fan_vent_size / 2 ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
}
}
at_four_corners([ -fan_vent_mounting_hole_position, fan_vent_mounting_hole_position ])
cylinder(d = fan_vent_mounting_hole_diameter, h = wall_size + 2 * epsilon);
}
}
module back_vent() {
// Back vents
back_vent_crop = [ [ 10 * mm, 10 * mm ],
[ 30 * mm, 10 * mm ] ];
back_vent_additional_margin = 30 * mm;
back_vent_size = [ useful_size.y - back_vent_crop[0].x - back_vent_crop[1].x, useful_size.z - back_vent_crop[0].y - back_vent_crop[1].y ];
translate([ useful_size.x - epsilon, 0, 0 ])
rotate([ 0, 0, 180 ])
rotate([ 0, -90, 0 ])
rotate([ 0, 0, -90 ])
intersection() {
spray_pattern([ back_vent_crop[1], back_vent_size + back_vent_crop[1] ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
}
translate(back_vent_crop[1])
cube([ back_vent_size.x, back_vent_size.y, wall_size + 2 * epsilon ]);
}
}
module two_leds(position) {
rotate([ 90, 0, 0 ]) {
led_hole_diameter = 5 * mm;
led_margin = 10 * mm;
translate(position + [ 0, 0, -epsilon ])
cylinder(d = led_hole_diameter, h = wall_size + 2 * epsilon);
translate(position + [ 0, led_margin, -epsilon ])
cylinder(d = led_hole_diameter, h = wall_size + 2 * epsilon);
}
}
module main_switch(position) {
rotate([ 90, 0, 0 ]) {
main_switch_size = [ 12 * mm, 19.5 * mm, 0 ];
translate(position - main_switch_size / 2 + [ 0, 0, -epsilon ])
cube(main_switch_size + [ 0, 0, wall_size + 2 * epsilon ]);
}
}
module backplate_mount(position) {
backplate_mount_screw_hole_diameter = 2.5 * mm;
backplate_mount_screw_hole_height = 8 * mm;
at_four_corners([ position, position + [ 94.75 * mm, -135 * mm ] ]) {
difference() {
cylinder(d = backplate_mount_screw_hole_diameter + wall_size * 2, h = backplate_mount_screw_hole_height);
translate([ 0, 0, epsilon ])
cylinder(d = backplate_mount_screw_hole_diameter, h = backplate_mount_screw_hole_height + 2 * epsilon);
}
}
}
difference() {
rounded_box(useful_size, wall_size, round_radius, cover_screw_hole_diameter);
main_socket([ 0, -133 * mm, 20 * mm ]);
main_switch([ 0, -127 * mm, 60 * mm ]);
fan_vent([ 10 * mm, 5 * mm ]);
back_vent();
three_units(unit_height = 40 * mm);
two_leds([ 15 * mm, 60 * mm, 0 ]);
main_switch([ 15 * mm, 20 * mm, 0 ]);
}
backplate_mount([ 36 * mm, useful_size.y - 8 * mm, 0 ]);

83
013-PSU-Enclosure/common.scad
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include <MCAD/units.scad>;
$fn = 36;
// Size of the enclosure
useful_size = [ 15 * cm, 17 * cm, 9 * cm ];
// Thickness of the walls
wall_size = 3 * mm;
// Edges are soften with this radius
round_radius = 3 * mm;
// Vent Parameters (hexagon structure)
vent_alveolus_size = 8 * mm;
vent_margin = 1 * mm;
vent_xstep = cos(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
vent_ystep = sin(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
// Screw hole diameter for the four screws holding the cover
cover_screw_hole_diameter = 2.5 * mm;
module box(useful_size, wall_size) {
difference() {
translate([ -wall_size, -wall_size, -wall_size ])
cube([ useful_size.x + 2 * wall_size, useful_size.y + 2 * wall_size, useful_size.z + wall_size ]);
translate([ 0, 0, epsilon])
cube([ useful_size.x, useful_size.y, useful_size.z ]);
}
}
module rounded_corner(round_radius, length) {
difference() {
cube([ round_radius, round_radius, length ]);
translate([ round_radius, round_radius, -epsilon ])
cylinder(r=round_radius, h=length + 2 * epsilon);
}
}
module at_four_corners(box) {
translate([ box[0].x, box[0].y, 0 ])
children();
translate([ box[1].x, box[0].y, 0 ])
rotate([ 0, 0, 90 ])
children();
translate([ box[1].x, box[1].y, 0 ])
rotate([ 0, 0, 180 ])
children();
translate([ box[0].x, box[1].y, 0 ])
rotate([ 0, 0, 270 ])
children();
}
module rounded_box(useful_size, wall_size, round_radius, cover_screw_hole_diameter = 0) {
difference() {
union() {
box(useful_size, wall_size);
if (cover_screw_hole_diameter == 0) {
at_four_corners([ [ 0, 0 ], useful_size ])
rounded_corner(round_radius, useful_size.z);
} else {
at_four_corners([ [ 0, 0 ], useful_size ]) {
reinforcement_size = wall_size + cover_screw_hole_diameter;
difference() {
cube([ reinforcement_size, reinforcement_size, useful_size.z ]);
translate([ reinforcement_size + epsilon, reinforcement_size + epsilon, -epsilon ])
rotate([ 0, 0, 180 ])
rounded_corner(round_radius, useful_size.z + 2 * epsilon);
translate([ cover_screw_hole_diameter / 2, cover_screw_hole_diameter / 2, epsilon ])
cylinder(d = cover_screw_hole_diameter, h = useful_size.z + epsilon);
}
translate([ 0, reinforcement_size, 0 ])
rounded_corner(round_radius, useful_size.z);
translate([ reinforcement_size, 0, 0 ])
rounded_corner(round_radius, useful_size.z);
}
}
}
at_four_corners([ [ -wall_size, -wall_size ], useful_size + [ wall_size, wall_size ] ])
translate([ -epsilon, -epsilon, -wall_size - epsilon ])
rounded_corner(round_radius, useful_size.z + wall_size + 2 * epsilon);
}
}

10
013-PSU-Enclosure/cover.scad
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include <MCAD/units.scad>;
include <common.scad>
difference() {
rounded_box([ useful_size.x, useful_size.y, 0 ], wall_size, round_radius);
at_four_corners([ [ 0, 0 ], useful_size ]) {
translate([ (cover_screw_hole_diameter + 0.5) / 2 , (cover_screw_hole_diameter + 0.5) / 2 , -wall_size - epsilon ])
cylinder(d = cover_screw_hole_diameter + 0.5, h = wall_size + 2 * epsilon);
}
}

117
013-PSU-Enclosure/psu-enclosure.scad
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@ -1,117 +0,0 @@
include <MCAD/units.scad>;
use <OpenSCAD-Pattern-Filling/pattern.scad>;
$fn = 36;
useful_size = [ 14 * cm, 17 * cm, 9 * cm ];
wall_size = 3 * mm;
round_radius = 3 * mm;
// Vent Parameters
vent_alveolus_size = 8 * mm;
vent_margin = 1 * mm;
vent_xstep = cos(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
vent_ystep = sin(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
module box(useful_size, wall_size) {
difference() {
translate([ -wall_size, -wall_size, -wall_size ])
cube([ useful_size.x + 2 * wall_size, useful_size.y + 2 * wall_size, useful_size.z + wall_size ]);
translate([ 0, 0, epsilon])
cube([ useful_size.x, useful_size.y, useful_size.z ]);
}
}
module rounded_corner(round_radius, length) {
difference() {
cube([ round_radius, round_radius, length ]);
translate([ round_radius, round_radius, -epsilon ])
cylinder(r=round_radius, h=length + 2 * epsilon);
}
}
module at_four_corners(box) {
translate([ box[0].x, box[0].y, 0 ])
children();
translate([ box[1].x, box[0].y, 0 ])
rotate([ 0, 0, 90 ])
children();
translate([ box[1].x, box[1].y, 0 ])
rotate([ 0, 0, 180 ])
children();
translate([ box[0].x, box[1].y, 0 ])
rotate([ 0, 0, 270 ])
children();
}
module rounded_box(useful_size, wall_size, round_radius) {
difference() {
union() {
box(useful_size, wall_size);
at_four_corners([ [ 0, 0 ], useful_size ])
rounded_corner(round_radius, useful_size.z);
}
at_four_corners([ [ -wall_size, -wall_size ], useful_size + [ wall_size, wall_size ] ])
translate([ -epsilon, -epsilon, -wall_size - epsilon ])
rounded_corner(round_radius, useful_size.z + wall_size + 2 * epsilon);
}
}
difference() {
rounded_box(useful_size, wall_size, round_radius);
// Main socket
socket_position = [ 0, -133 * mm, 20 * mm ];
socket_dimension = [ wall_size + 2 * epsilon, 31 * mm, 22 * mm ];
socket_mounting_holes_diameter = 2.5 * mm;
socket_mounting_holes_position = [ 0, - 4.5 * mm, socket_dimension.z / 2 ];
translate([ -wall_size - epsilon + socket_position.x, useful_size.y + socket_position.y, socket_position.z ]) {
cube(socket_dimension);
translate(socket_mounting_holes_position)
rotate([ 0, 90, 0 ])
cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
translate([ socket_mounting_holes_position.x, socket_dimension.y - socket_mounting_holes_position.y, socket_mounting_holes_position.z ] )
rotate([ 0, 90, 0 ])
cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
}
// Main switch
switch_position = [ 0, -127 * mm, 60 * mm ];
switch_dimension = [ wall_size + 2 * epsilon, 19 * mm, 13 * mm ];
translate([ -wall_size - epsilon + switch_position.x, useful_size.y + switch_position.y, switch_position.z ]) {
cube(switch_dimension);
}
// Fan vent
fan_vent_size = [ 76.5 * mm, 76.5 * mm, wall_size + 2 * epsilon ];
fan_vent_position = [ 10 * mm, 5 * mm ];
fan_vent_diameter = 90 * mm;
fan_vent_mounting_hole_position = [ 36 * mm, 36 * mm ];
fan_vent_mounting_hole_diameter = 5.5 * mm;
translate([ -wall_size - epsilon, useful_size.y - fan_vent_position.x - fan_vent_size.x / 2, fan_vent_position.y + fan_vent_size.y / 2 ])
rotate([ 0, 90, 0 ]) {
intersection() {
translate(-[ fan_vent_size.x, fan_vent_size.y] / 2)
cube(fan_vent_size);
cylinder(d = fan_vent_diameter, h = wall_size + 2 * epsilon, $fn = 180);
spray_pattern([ fan_vent_size / -2, fan_vent_size / 2 ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
}
}
at_four_corners([ -fan_vent_mounting_hole_position, fan_vent_mounting_hole_position ])
cylinder(d = fan_vent_mounting_hole_diameter, h = wall_size + 2 * epsilon);
}
// Back vents
back_vent_crop = [ 10 * mm, 10 * mm ];
back_vent_size = [ useful_size.y - 2 * back_vent_crop.x, useful_size.z - 2 * back_vent_crop.y ];
translate([ useful_size.x - epsilon, 0, 0 ])
rotate([ 0, 0, 180 ])
rotate([ 0, -90, 0 ])
rotate([ 0, 0, -90 ])
spray_pattern([ back_vent_crop, back_vent_size + back_vent_crop ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
}
}
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