339 lines
14 KiB
OpenSCAD
339 lines
14 KiB
OpenSCAD
// ============================================================
|
||
// RPi5 Industrial Enclosure — 7" Capacitive Touchscreen
|
||
// Version: 006
|
||
//
|
||
// ASSEMBLY (three printed parts):
|
||
//
|
||
// REAR COVER — box, open face toward screen.
|
||
// • 4 corner towers, full cavity height, M3 pilot hole from front.
|
||
// • 3 prong guide columns on inner bottom face — the columns give
|
||
// the prong slots a solid ceiling so nothing falls through.
|
||
// • ALL SIDE WALLS ARE SOLID. No port holes.
|
||
//
|
||
// FRONT BEZEL — display frame.
|
||
// • 4× M3 countersunk holes, corners, aligned to tower holes.
|
||
// • Screw route: bezel face → screen gap → tower pilot hole.
|
||
// • Use M3 × 30 mm self-tapping screws.
|
||
//
|
||
// KICKSTAND — separate removable wedge plate.
|
||
// • Main wedge behind case creates the tilt.
|
||
// • Thin ledge extends UNDER the rear of the case 14 mm.
|
||
// The ledge carries the 3 prongs which enter the case
|
||
// through the BOTTOM face only — rear wall stays solid.
|
||
// • Slide ledge+prongs under the case from behind; prongs
|
||
// click up into their columns and lock the stand.
|
||
//
|
||
// Changes vs 005:
|
||
// • Right-wall USB-A rectangle REMOVED (and all side-wall cuts).
|
||
// Both left and right walls are now fully solid.
|
||
// • Prong slots moved to Z = 5.5–10.5 mm (inside cavity).
|
||
// Rear face (Z = 0) is completely uncut — no holes on back.
|
||
// • Kickstand gains a 14 mm ledge so prongs reach the new slot Z.
|
||
// • Cable glands removed (no rear-face holes).
|
||
// ============================================================
|
||
|
||
// ── SCREEN PARAMETERS ───────────────────────────────────────
|
||
scr_w = 164.9; // screen outer width (mm)
|
||
scr_h = 124.27; // screen outer height (mm)
|
||
scr_d = 12; // screen body depth (mm) ← confirm with calipers
|
||
scr_active_w = 154; // active area width (mm) ← confirm from datasheet
|
||
scr_active_h = 90; // active area height (mm) ← confirm from datasheet
|
||
scr_mount_x = 75; // rear M2.5 mount pattern X (mm) ← verify
|
||
scr_mount_y = 75; // rear M2.5 mount pattern Y (mm) ← verify
|
||
|
||
// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
|
||
pi_w = 85; // Pi board width (mm)
|
||
pi_h = 56; // Pi board height (mm)
|
||
pi_d = 17; // Pi board + tallest component (mm)
|
||
pi_mnt_x = 58; // Pi mount pattern X (mm)
|
||
pi_mnt_y = 49; // Pi mount pattern Y (mm)
|
||
pi_standoff = 5; // standoff: screen rear → Pi PCB (mm)
|
||
pi_offset_x = 0; // Pi centre X offset from screen centre (mm)
|
||
pi_offset_y = 0; // Pi centre Y offset from screen centre (mm)
|
||
|
||
// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
|
||
wall = 4.0; // wall thickness (mm)
|
||
chamfer = 1.5; // external edge chamfer (mm)
|
||
recess = 1.0; // screen recess depth in front bezel (mm)
|
||
|
||
// ── VENT PARAMETERS ──────────────────────────────────────────
|
||
vent_w = 3;
|
||
vent_l = 18;
|
||
vent_sp = 4;
|
||
soc_vent_sz = 28;
|
||
|
||
// ── KICKSTAND PARAMETERS ─────────────────────────────────────
|
||
ks_tilt = 75; // screen angle from horizontal when standing (deg)
|
||
ks_depth = 60; // wedge reach behind rear face (mm)
|
||
ks_thick = 5; // plate/ledge thickness (mm)
|
||
|
||
// Prong dimensions
|
||
ks_prong_n = 3; // number of prongs
|
||
ks_prong_w = 12; // prong width in X (mm)
|
||
ks_prong_h = 14; // prong engagement height (mm)
|
||
ks_prong_t = 5; // prong thickness in Z (mm)
|
||
ks_prong_clr = 0.25; // clearance per side (mm)
|
||
|
||
// Ledge: extends under the case so prongs reach inside the cavity
|
||
// without cutting through the rear wall.
|
||
ks_ledge = 14; // ledge depth in +Z under case (mm)
|
||
// must be > wall + ks_prong_t + margin
|
||
|
||
// Z start of prong slot measured from rear face.
|
||
// Must be > wall so the slot never touches the rear face.
|
||
ks_prong_z0 = wall + 1.5; // = 5.5 mm — slot from 5.25 to 10.75 mm
|
||
|
||
// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
|
||
m3_dia = 3.4; // M3 clearance hole (mm)
|
||
m3_pilot = 2.5; // M3 self-tapping pilot (mm)
|
||
m3_cs_dia = 6.5; // M3 countersink OD (mm)
|
||
m3_cs_depth = 3.5; // countersink depth (mm)
|
||
tower_w = 9; // corner tower footprint (mm square)
|
||
tower_hole_d = 14; // pilot hole depth into tower from front face (mm)
|
||
corner_inset = 7; // tower/hole centre from outer edge (mm)
|
||
|
||
// ── DERIVED ──────────────────────────────────────────────────
|
||
rear_d = pi_standoff + pi_d + 10; // cavity depth = 32 mm
|
||
enc_w = scr_w + 2*wall; // 172.9 mm
|
||
enc_h = scr_h + 2*wall; // 132.27 mm
|
||
enc_d = rear_d + wall; // 36 mm
|
||
|
||
pi_enc_cx = wall + scr_w/2 + pi_offset_x;
|
||
pi_enc_cy = wall + scr_h/2 + pi_offset_y;
|
||
pi_z = wall + pi_standoff;
|
||
|
||
ks_drop = ks_depth * tan(90 - ks_tilt); // wedge tip drop ≈ 16 mm
|
||
|
||
// Guide column dimensions (added back inside cavity after hollow)
|
||
col_w = ks_prong_w + wall; // 16 mm — solid wall each side of slot
|
||
col_h = ks_prong_h; // 14 mm — prong engagement
|
||
col_d = ks_ledge; // 14 mm — same as ledge depth
|
||
|
||
$fn = 48;
|
||
|
||
// ============================================================
|
||
// PRIMITIVES
|
||
// ============================================================
|
||
|
||
module cbox(w, h, d, c=chamfer) {
|
||
hull() {
|
||
translate([c, c, 0]) cube([w-2*c, h-2*c, d ]);
|
||
translate([0, c, c]) cube([w, h-2*c, d-2*c ]);
|
||
translate([c, 0, c]) cube([w-2*c, h, d-2*c ]);
|
||
}
|
||
}
|
||
|
||
module slot(len, w, d) {
|
||
r = w/2;
|
||
hull() {
|
||
translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
|
||
translate([0, len/2-r, 0]) cylinder(r=r, h=d);
|
||
}
|
||
}
|
||
|
||
module vent_row(n, len, w, spacing, depth) {
|
||
for(i = [0:n-1])
|
||
translate([i*(w+spacing), 0, 0])
|
||
slot(len, w, depth);
|
||
}
|
||
|
||
module m3_countersunk(total_d) {
|
||
cylinder(d=m3_dia, h=total_d+0.1);
|
||
cylinder(d1=m3_cs_dia, d2=m3_dia, h=m3_cs_depth+0.1);
|
||
}
|
||
|
||
// Prong slot cutter — called with origin at (prong_cx, 0, ks_prong_z0).
|
||
// Cuts bottom wall (Y: -0.1 → wall) + guide column (Y: wall → wall+col_h).
|
||
// Z extent stays within [ks_prong_z0-clr, ks_prong_z0+ks_prong_t+clr]
|
||
// which is entirely inside the cavity — rear face untouched.
|
||
module prong_slot_cut() {
|
||
translate([-ks_prong_w/2 - ks_prong_clr,
|
||
-0.1,
|
||
-ks_prong_clr])
|
||
cube([ks_prong_w + 2*ks_prong_clr,
|
||
wall + col_h + 0.2,
|
||
ks_prong_t + 2*ks_prong_clr]);
|
||
}
|
||
|
||
// ============================================================
|
||
// KICKSTAND (separate removable piece — print separately)
|
||
// ============================================================
|
||
//
|
||
// Side cross-section (Y-Z plane):
|
||
//
|
||
// Y=0 (case bottom) ─────┬─────────────────┐ ← ledge top (fits under case)
|
||
// Y=-ks_thick ─────┴─────────────────┘ ← ledge bottom
|
||
// Z=ks_ledge Z=0 │
|
||
// │ ← wedge (behind case)
|
||
// thick ╲ │ thin
|
||
// desk contact → ────────╲─┘
|
||
// Z=-ks_depth Z=0
|
||
//
|
||
// The ledge (Z=0→ks_ledge) slides under the case rear.
|
||
// Prongs rise from Y=0 at Z=ks_prong_z0, entering the case bottom slots.
|
||
// The wedge (Z=-ks_depth→0) rests on the desk and creates the tilt.
|
||
//
|
||
module kickstand() {
|
||
ks_front_h = ks_thick + ks_drop; // thick end of wedge
|
||
|
||
// 1. Wedge behind case (Z = -ks_depth → 0)
|
||
hull() {
|
||
translate([0, -ks_thick, 0 ]) cube([enc_w, ks_thick, wall]);
|
||
translate([0, -ks_front_h, -ks_depth]) cube([enc_w, ks_front_h, wall]);
|
||
}
|
||
|
||
// 2. Ledge under rear of case (Z = 0 → ks_ledge)
|
||
translate([0, -ks_thick, 0])
|
||
cube([enc_w, ks_thick, ks_ledge]);
|
||
|
||
// 3. Three prongs rising from ledge top (Y=0) into case bottom slots
|
||
for(i = [0:ks_prong_n-1]) {
|
||
px = enc_w * (i+1) / (ks_prong_n+1);
|
||
translate([px - ks_prong_w/2, 0, ks_prong_z0]) {
|
||
// Main shaft
|
||
cube([ks_prong_w, ks_prong_h - 2, ks_prong_t]);
|
||
// Tapered tip (45° chamfer for easy insertion)
|
||
translate([0, ks_prong_h - 2, 0])
|
||
hull() {
|
||
cube([ks_prong_w, 0.01, ks_prong_t ]);
|
||
translate([1, 2, 0])
|
||
cube([ks_prong_w-2, 0.01, ks_prong_t ]);
|
||
}
|
||
}
|
||
}
|
||
}
|
||
|
||
// ============================================================
|
||
// FRONT BEZEL
|
||
// ============================================================
|
||
module front_bezel() {
|
||
ci = corner_inset;
|
||
difference() {
|
||
cbox(enc_w, enc_h, wall + recess);
|
||
|
||
// Display window
|
||
translate([(enc_w - scr_active_w)/2,
|
||
(enc_h - scr_active_h)/2, -0.1])
|
||
cube([scr_active_w, scr_active_h, wall+recess+0.2]);
|
||
|
||
// 1 mm recess pocket grips screen edge
|
||
translate([(enc_w - scr_w)/2,
|
||
(enc_h - scr_h)/2, wall])
|
||
cube([scr_w, scr_h, recess+0.1]);
|
||
|
||
// 4× M3 countersunk screw holes at corners
|
||
for(x = [ci, enc_w-ci])
|
||
for(y = [ci, enc_h-ci])
|
||
translate([x, y, 0])
|
||
m3_countersunk(wall + recess);
|
||
}
|
||
}
|
||
|
||
// ============================================================
|
||
// REAR COVER
|
||
// ============================================================
|
||
module rear_cover() {
|
||
ci = corner_inset;
|
||
n_vent = 5;
|
||
vbw = n_vent*(vent_w+vent_sp) - vent_sp; // vent block width
|
||
|
||
difference() {
|
||
|
||
// ── SOLID GEOMETRY (nested CSG) ───────────────────────
|
||
union() {
|
||
|
||
// A) Shell with interior already removed.
|
||
// Nested so the additions below are NOT eaten by the hollow.
|
||
difference() {
|
||
cbox(enc_w, enc_h, enc_d);
|
||
translate([wall, wall, wall])
|
||
cube([scr_w, scr_h, enc_d]);
|
||
}
|
||
|
||
// B) Corner towers — full cavity height.
|
||
// M3 pilot hole is drilled from the open front face,
|
||
// clearly visible when looking into the case before assembly.
|
||
for(x = [ci, enc_w-ci])
|
||
for(y = [ci, enc_h-ci])
|
||
translate([x - tower_w/2, y - tower_w/2, wall])
|
||
cube([tower_w, tower_w, enc_d - wall]);
|
||
|
||
// C) Prong guide columns.
|
||
// One solid column per prong, rising from the inner bottom
|
||
// face (Y=wall) by col_h=14 mm, spanning Z=0→col_d=14 mm.
|
||
// The prong slot cuts through this column, giving a closed
|
||
// ceiling at Y=wall+col_h — prongs cannot fall through.
|
||
// The column Z=0→5.25 mm is NOT cut by the slot, so the
|
||
// rear face (Z=0) remains completely solid at these spots.
|
||
for(i = [0:ks_prong_n-1]) {
|
||
px = enc_w * (i+1) / (ks_prong_n+1);
|
||
translate([px - col_w/2, wall, 0])
|
||
cube([col_w, col_h, col_d]);
|
||
}
|
||
}
|
||
|
||
// ── CUTOUTS (applied to everything above) ─────────────
|
||
|
||
// Corner tower pilot holes from open front face
|
||
for(x = [ci, enc_w-ci])
|
||
for(y = [ci, enc_h-ci])
|
||
translate([x, y, enc_d + 0.1])
|
||
rotate([180, 0, 0])
|
||
cylinder(d=m3_pilot, h=tower_hole_d);
|
||
|
||
// Cooling — bottom intake slots (through bottom wall, Y direction)
|
||
translate([enc_w/2 - vbw/2, -0.1, wall + 6])
|
||
rotate([-90, 0, 0])
|
||
vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
|
||
|
||
// Cooling — top exhaust slots (through top wall, Y direction)
|
||
translate([enc_w/2 - vbw/2, enc_h - wall + 0.1, wall + 6])
|
||
rotate([90, 0, 0])
|
||
vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
|
||
|
||
// Cooling — SoC direct vent on rear panel
|
||
translate([pi_enc_cx - soc_vent_sz/2,
|
||
pi_enc_cy - soc_vent_sz/2,
|
||
enc_d - wall - 0.1]) {
|
||
n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
|
||
for(i = [0:n_soc-1])
|
||
translate([i*(vent_w+vent_sp),
|
||
soc_vent_sz/2 - vent_l/2, 0])
|
||
slot(vent_l, vent_w, wall+0.2);
|
||
}
|
||
|
||
// Kickstand prong slots — bottom face ONLY.
|
||
// Slot Z: [ks_prong_z0-clr, ks_prong_z0+ks_prong_t+clr]
|
||
// = [5.25, 10.75] mm — entirely past the rear wall (Z=0-4 mm).
|
||
// Rear face at Z=0 is untouched.
|
||
for(i = [0:ks_prong_n-1]) {
|
||
px = enc_w * (i+1) / (ks_prong_n+1);
|
||
translate([px, 0, ks_prong_z0])
|
||
prong_slot_cut();
|
||
}
|
||
|
||
// NOTE: All side-wall port cutouts removed — both left and right
|
||
// walls are solid. Access to Pi ports via short extension cables
|
||
// routed through user-drilled holes as needed for the installation.
|
||
}
|
||
}
|
||
|
||
// ============================================================
|
||
// SCENE — three parts exploded for inspection
|
||
// ============================================================
|
||
|
||
// Front bezel — floated forward
|
||
color("DarkSlateGray", 0.92)
|
||
translate([0, 0, enc_d + 14])
|
||
front_bezel();
|
||
|
||
// Rear cover — at origin
|
||
color("SlateGray", 0.88)
|
||
rear_cover();
|
||
|
||
// Kickstand — floated below and behind to show it is separate
|
||
// In real use: slide it up from below until prongs click into columns.
|
||
color("DimGray", 0.85)
|
||
translate([0, -(ks_thick + ks_drop + 20), 0])
|
||
kickstand();
|