355 lines
15 KiB
OpenSCAD
355 lines
15 KiB
OpenSCAD
// ============================================================
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// RPi5 Industrial Enclosure — 7" Capacitive Touchscreen
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// Version: 005
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//
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// ASSEMBLY LOGIC (read before printing):
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//
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// THREE separate printed parts:
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//
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// 1. REAR COVER — the main box. Open face points toward screen.
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// Four corner TOWERS rise from the open front face; each tower
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// has a self-tapping M3 pilot hole that opens toward the screen.
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// The kickstand prong columns rise from the inner bottom face.
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//
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// 2. FRONT BEZEL — the display frame. Four countersunk M3 holes at
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// the corners align with the rear cover's tower holes.
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// Assembly: lay screen face-down, place rear cover over it,
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// lay bezel over the front, drive 4× M3×30 self-tapping screws
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// from the bezel face through into the corner towers.
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//
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// 3. KICKSTAND — separate wedge plate. Slide its 3 prongs upward
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// into the 3 slots in the case bottom wall. The prong guide
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// columns inside the case prevent the prongs from falling into
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// the main cavity and give a solid 14 mm engagement.
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//
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// Changes vs 004:
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// - Screen resized to 164.9 × 124.27 mm (7" 1024×600 capacitive)
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// - Corner towers replace insert bosses: visible M3 holes on the
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// OPEN front face of the rear cover — no hidden geometry
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// - Prong guide columns (nested-difference CSG) give the slots a
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// closed ceiling so the kickstand prongs cannot fall through
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// - Left-wall USB-C touch cutout permanently removed
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// - Wall 4 mm retained
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// ============================================================
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// ── SCREEN PARAMETERS ───────────────────────────────────────
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scr_w = 164.9; // screen outer width (mm)
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scr_h = 124.27; // screen outer height (mm)
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scr_d = 12; // screen body depth (mm) ← confirm with calipers
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scr_active_w = 154; // active display width (mm) ← confirm
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scr_active_h = 90; // active display height (mm) ← confirm
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scr_mount_x = 75; // rear M2.5 hole pattern X (mm) ← verify
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scr_mount_y = 75; // rear M2.5 hole pattern Y (mm) ← verify
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// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
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pi_w = 85; // Pi board width (mm)
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pi_h = 56; // Pi board height (mm)
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pi_d = 17; // Pi board + tallest component (mm)
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pi_mnt_x = 58; // Pi mount hole pattern X (mm)
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pi_mnt_y = 49; // Pi mount hole pattern Y (mm)
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pi_standoff = 5; // standoff: screen rear → Pi PCB (mm)
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pi_offset_x = 0; // Pi centre X offset from screen centre (mm)
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pi_offset_y = 0; // Pi centre Y offset from screen centre (mm)
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// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
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wall = 4.0; // wall thickness (mm)
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chamfer = 1.5; // external edge chamfer (mm)
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recess = 1.0; // screen recess depth in front bezel (mm)
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// ── VENT PARAMETERS ──────────────────────────────────────────
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vent_w = 3; // slot width (mm)
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vent_l = 18; // slot length (mm)
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vent_sp = 4; // gap edge-to-edge (mm)
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soc_vent_sz = 28; // SoC vent zone (mm, square)
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// ── CABLE GLAND PARAMETERS ───────────────────────────────────
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gland_count = 2; // number of M16 cable glands
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gland_dia = 16.5; // M16 clearance hole diameter (mm)
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gland_spacing= 36; // gland centre-to-centre (mm)
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// ── KICKSTAND PARAMETERS ─────────────────────────────────────
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ks_tilt = 75; // screen angle from horizontal when standing (deg)
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ks_depth = 60; // plate reach behind rear face (mm)
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ks_thick = 5; // plate thickness at thin (prong) end (mm)
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ks_prong_n = 3; // number of prongs
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ks_prong_w = 12; // prong width in X (mm)
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ks_prong_h = 14; // prong engagement height (mm) — guided inside column
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ks_prong_t = 5; // prong thickness in Z (mm)
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ks_prong_clr = 0.25; // clearance per side for slide fit (mm)
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// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
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m3_dia = 3.4; // M3 clearance hole (mm)
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m3_pilot = 2.5; // M3 self-tapping pilot hole (mm)
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m3_cs_dia = 6.5; // M3 countersink OD (mm)
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m3_cs_depth = 3.5; // countersink depth (mm)
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// Corner tower — a full-depth solid pillar at each inner corner.
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// The M3 pilot hole is drilled from the open front face of the rear cover.
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tower_w = 10; // tower footprint width and depth (mm)
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tower_hole_d = 12; // M3 pilot hole depth from front face (mm)
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// ── DERIVED DIMENSIONS ───────────────────────────────────────
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rear_d = pi_standoff + pi_d + 10; // rear cavity depth = 32 mm
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enc_w = scr_w + 2*wall; // outer width = 172.9 mm
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enc_h = scr_h + 2*wall; // outer height = 132.27 mm
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enc_d = rear_d + wall; // rear cover depth = 36 mm
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// Pi centre in enclosure coordinates
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pi_enc_cx = wall + scr_w/2 + pi_offset_x;
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pi_enc_cy = wall + scr_h/2 + pi_offset_y;
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pi_z = wall + pi_standoff; // Pi PCB Z from rear face
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// Corner tower position — inset so tower is entirely within the wall zone
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// (tower must NOT overlap the screen footprint X=wall..wall+scr_w)
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tower_cx = wall/2; // tower centre offset from outer edge
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// Four tower centre positions
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tower_xs = [tower_cx, enc_w - tower_cx];
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tower_ys = [tower_cx, enc_h - tower_cx];
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// Kickstand wedge geometry
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ks_drop = ks_depth * tan(90 - ks_tilt); // tip drop ≈ 16 mm
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// Prong column Z extent (guide column behind and into cavity)
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col_z_size = ks_prong_t + 2*wall; // = 13 mm
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col_y_size = ks_prong_h; // = 14 mm (above inner bottom face)
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col_x_size = ks_prong_w + wall; // = 16 mm (centred on prong)
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$fn = 48;
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// ============================================================
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// PRIMITIVES
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// ============================================================
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module cbox(w, h, d, c=chamfer) {
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hull() {
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translate([c, c, 0]) cube([w-2*c, h-2*c, d ]);
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translate([0, c, c]) cube([w, h-2*c, d-2*c ]);
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translate([c, 0, c]) cube([w-2*c, h, d-2*c ]);
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}
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}
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module slot(len, w, d) {
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r = w/2;
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hull() {
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translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
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translate([0, len/2-r, 0]) cylinder(r=r, h=d);
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}
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}
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module vent_row(n, len, w, spacing, depth) {
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for(i = [0:n-1])
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translate([i*(w+spacing), 0, 0])
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slot(len, w, depth);
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}
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// Countersunk M3 through-hole for bezel face
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module m3_countersunk(total_depth) {
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cylinder(d=m3_dia, h=total_depth+0.1);
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cylinder(d1=m3_cs_dia, d2=m3_dia, h=m3_cs_depth+0.1);
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}
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// Prong slot cutter — used in both the rear cover and the guide column
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// Origin at the prong centre-X, outer bottom face (Y=0), prong-Z start
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module prong_slot_cut() {
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translate([-ks_prong_w/2 - ks_prong_clr,
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-0.1,
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-ks_prong_clr])
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cube([ks_prong_w + 2*ks_prong_clr,
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wall + ks_prong_h + 0.2,
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ks_prong_t + 2*ks_prong_clr]);
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}
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// ============================================================
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// KICKSTAND (separate removable piece, print separately)
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// ============================================================
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module kickstand() {
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ks_front_h = ks_thick + ks_drop; // height at the thick/front end
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// Wedge plate — thin at prong end (Z=0), thick at desk end (Z=-ks_depth)
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hull() {
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translate([0, -ks_thick, 0])
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cube([enc_w, ks_thick, wall]);
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translate([0, -ks_front_h, -ks_depth])
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cube([enc_w, ks_front_h, wall]);
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}
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// Three tapered prongs on the top edge (rear/thin end)
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for(i = [0:ks_prong_n-1]) {
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px = enc_w * (i+1) / (ks_prong_n+1);
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translate([px - ks_prong_w/2, 0, 0]) {
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// Body of prong
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cube([ks_prong_w, ks_prong_h - 2, ks_prong_t]);
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// Tapered tip (last 2 mm, narrowed 1 mm per side)
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translate([0, ks_prong_h - 2, 0])
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hull() {
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cube([ks_prong_w, 0.01, ks_prong_t]);
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translate([1, 2, 0])
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cube([ks_prong_w - 2, 0.01, ks_prong_t]);
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}
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}
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}
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}
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// ============================================================
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// FRONT BEZEL (removable — 4× M3 countersunk screws)
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// ============================================================
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module front_bezel() {
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difference() {
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cbox(enc_w, enc_h, wall + recess);
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// Display window
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translate([(enc_w - scr_active_w)/2,
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(enc_h - scr_active_h)/2,
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-0.1])
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cube([scr_active_w, scr_active_h, wall+recess+0.2]);
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// 1 mm recess pocket — bezel lip grips screen edge
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translate([(enc_w - scr_w)/2,
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(enc_h - scr_h)/2,
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wall])
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cube([scr_w, scr_h, recess+0.1]);
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// 4× M3 countersunk screw holes, aligned to corner towers
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for(x = tower_xs) for(y = tower_ys)
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translate([x, y, 0])
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m3_countersunk(wall + recess);
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}
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}
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// ============================================================
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// REAR COVER
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// ============================================================
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//
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// CORNER TOWER DESIGN — replaces hidden insert bosses:
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// Each corner has a solid square tower (tower_w × tower_w) that
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// runs the FULL DEPTH of the cavity (from inner rear face to the
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// open front at Z=enc_d). An M3 pilot hole enters from the front
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// face (Z=enc_d) and goes tower_hole_d into the tower body.
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// Because the tower reaches the front opening, the holes are
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// plainly visible from the front of the assembled unit — no
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// hidden geometry.
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//
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// PRONG COLUMN DESIGN — prevents prongs falling into cavity:
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// A solid rectangular column rises from the inner bottom face at
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// each prong position. The prong slot cuts through the bottom wall
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// AND the column. The column ceiling is at Y=wall+ks_prong_h,
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// which acts as the hard stop for the prong — it cannot travel
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// beyond that height. The column is added AFTER the main interior
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// hollow is subtracted (nested-difference CSG), so the hollow
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// does not remove it.
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//
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module rear_cover() {
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n_vent = 5;
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vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;
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difference() {
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// ── SOLID GEOMETRY ────────────────────────────────────
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union() {
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// 1. Main shell with interior already removed
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// (nested so subsequent additions are NOT removed by hollow)
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difference() {
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cbox(enc_w, enc_h, enc_d);
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// Interior hollow — from rear inner face to front opening
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translate([wall, wall, wall])
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cube([scr_w, scr_h, enc_d]);
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}
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// 2. Corner towers — full cavity height, clearly visible from front
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for(x = tower_xs) for(y = tower_ys)
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translate([x - tower_w/2, y - tower_w/2, wall])
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cube([tower_w, tower_w, enc_d - wall]);
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// 3. Prong guide columns — solid pillars on inner bottom face
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// One per prong, gives 14 mm of guided engagement
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for(i = [0:ks_prong_n-1]) {
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px = enc_w * (i+1) / (ks_prong_n+1);
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translate([px - col_x_size/2,
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wall,
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0])
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cube([col_x_size, col_y_size, col_z_size]);
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}
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}
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// ── ALL CUTOUTS ───────────────────────────────────────
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// Corner tower M3 pilot holes (from front/open face, going inward)
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for(x = tower_xs) for(y = tower_ys)
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translate([x, y, enc_d + 0.1])
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rotate([180, 0, 0])
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cylinder(d=m3_pilot, h=tower_hole_d);
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// ── PORT CUTOUTS ──────────────────────────────────────
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pi_bot = pi_enc_cy - pi_h/2;
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pi_top = pi_enc_cy + pi_h/2;
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// LEFT WALL — USB-C power + HDMI ×2
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translate([-0.1, pi_bot + 3, pi_z + 2]) cube([wall+0.2, 11, 11]);
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translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17, 9]);
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translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17, 9]);
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// RIGHT WALL — RJ45 + USB-A ×4
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translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
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cube([wall+0.2, 22, 16]);
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translate([enc_w-wall-0.1, pi_bot + 2, pi_z + 1])
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cube([wall+0.2, 50, 15]);
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// ── COOLING VENTS ─────────────────────────────────────
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// Bottom intake
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translate([enc_w/2 - vent_block_w/2, -0.1, wall + 6])
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rotate([-90, 0, 0])
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vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
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// Top exhaust
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translate([enc_w/2 - vent_block_w/2, enc_h - wall + 0.1, wall + 6])
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rotate([90, 0, 0])
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vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
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// SoC direct-vent on rear panel
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translate([pi_enc_cx - soc_vent_sz/2,
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pi_enc_cy - soc_vent_sz/2,
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enc_d - wall - 0.1]) {
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n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
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for(i = [0:n_soc-1])
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translate([i*(vent_w+vent_sp), soc_vent_sz/2 - vent_l/2, 0])
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slot(vent_l, vent_w, wall+0.2);
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}
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// ── CABLE GLANDS — rear panel face ────────────────────
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for(i = [0:gland_count-1]) {
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cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
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translate([cx, wall + gland_dia/2 + 4, -0.1])
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cylinder(d=gland_dia, h=wall+0.2);
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}
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// ── KICKSTAND PRONG SLOTS ─────────────────────────────
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// Each slot cuts through the outer bottom wall AND the guide
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// column above it. The column ceiling at Y=wall+ks_prong_h
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// is the hard stop — the prong cannot fall through.
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for(i = [0:ks_prong_n-1]) {
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px = enc_w * (i+1) / (ks_prong_n+1);
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translate([px, 0, 0])
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prong_slot_cut();
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}
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}
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}
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// ============================================================
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// SCENE — three parts exploded for visual clarity
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// ============================================================
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// FRONT BEZEL — floated forward (toward viewer)
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color("DarkSlateGray", 0.92)
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translate([0, 0, enc_d + 14])
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front_bezel();
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// REAR COVER — at origin
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color("SlateGray", 0.88)
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rear_cover();
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// KICKSTAND — floated below the case to show it is a separate piece
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color("DimGray", 0.85)
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translate([0, -(ks_thick + ks_drop + 20), 0])
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kickstand();
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