OctaSpHEAR / Octathingy: fix order of parameter declaration and includes, add separate ready to print parts for all components and new version of global view of the full microphone - this renders correctly now for both versions of the microphone and printed circuit board

Octathingy_EM200.scad

@@ -1,16 +1,16 @@
 //
 // Spherical Harmonics Ear Project (*SpHEAR)
 //
-// Octathingy, Second Order Ambisonics Microphone
+// OctaSpHEAR or Octathingy, Second Order Ambisonics Microphone
 //
 // based on:
 // "A second-order soundfield microphone with improved polar pattern shape"
 // by Eric Benjamin, Audio Engineering Society Convention Paper 8728, 
 // October 2012, San Francisco
 //
-// Microphone optimized for EM182 capsules and Zapnspark interface
+// Microphone optimized for EM200 14mm capsules and Zapnspark interface
 // 
-// Copyright 2015-2017, Fernando Lopez-Lezcano, All Rights Reserved
+// Copyright 2015-2019, Fernando Lopez-Lezcano, All Rights Reserved
 // nando@ccrma.stanford.edu
 //
 //  This program is free software: you can redistribute it and/or modify
@@ -30,151 +30,284 @@
 //   Attribution-NonCommercial-ShareAlike 4.0 International (CC BY-NC-SA 4.0)
 // http://creativecommons.org/licenses/by-nc-sa/4.0/
 
-include <Octathingy_common.scad>;
-include <SpHEAR_windscreen.scad>;
-include <TinySpHEAR_mount_pcb.scad>;
-include <Octathingy_mount_pcb.scad>;
+// microphone version
+// 1 -> original
+// 2 -> flower power
+mic_version = 2;
+
+// printed circuit board version
+// 1 -> single layer, milled in house
+// 2 -> double layer with ground plane, smaller, fabricated
+pcb_version = 2;
+
+// type of octathingy (for mic_version -> 1)
+// 0 -> regular octathingy (equilateral triangles in the square antiprism)
+// 1 -> tetrahedral compatible octathingy (same elevation angle as the tetrahedral mic)
+tetra_compat = 1;
 
 // dimensions of the EM200 electret microphone capsule
 capsule_radius = 14.55 / 2;
 capsule_height = 4.75;
-mic_radius = 16.6;
 
-// make triangular legs have the right height
-connect = 1;
-leg_thick = capsule_height * 0.45;
+// radius of capsule array
+mic_radius = (mic_version == 1) ? 18 : 20.5;
+
+// include shared modules
+//
+// http://dkprojects.net/openscad-threads/
+include <threads.scad>;
+
+include <SpHEAR_common.scad>
+include <Octathingy_common.scad>;
+include <SpHEAR_windscreen.scad>;
+include <Octathingy_mount_pcb.scad>;
 
-facets = 128;
+include <polygons.scad>;
 
 ////
-//// render the different assemblies
+//// overrides and parameters
 ////
 
-//// microphone body and array parameters
+// override Octathingy_common fudge (0.15)
+// 0.17 for Ultimaker 2+
+// 0.12 for Ultimaker 3
+fudge = 0.12;
+
+// mic_version 1: make triangular legs have the right height
+connect = 4;
+leg_thick = capsule_height * 0.55;
+
+// radius of windscreen thread
+//
+// adjusted with offset so that it is inset with respect to the body
+// so that the new shock mount sleeve fits over the thread into the body
 //
-// FIXME: for some reason octa_pcb_radius is not being found, changing
-//        the order of includes above messes up other mode parameters
-//        for now hardwire this parameter
-windscreen_thread_radius = 31.425;
-// windscreen_thread_radius = octa_pcb_radius;
+// octa_pcb_radius for pcb v2 is 27.42, the radius used is 25.6 
+windscreen_thread_offset = (pcb_version == 2 ? -1.82 : -1.82);
+windscreen_thread_radius = octa_pcb_radius + windscreen_thread_offset;
 windscreen_radius = windscreen_thread_radius + 5.0;
+
+// windscreen thread for pcb version 1
+// this is used for the upper part of the windscreen
+windscreen_thread_radius_pcb1 = 31.425;
+windscreen_radius_pcb1 = windscreen_thread_radius_pcb1 + 5.0;
+
+// do we need to override thread height?
 windscreen_thread_height = 8;
-windscreen_height = 72;
 
+windscreen_height = pcb_version == 2 ? 68.5 : 72;
 windscreen_thread_fit = 5 * fit;
 
+//
+ridge_width = 1.5;
 
-*rotate([0, 0, -22.5]) render_octa_capsule_array(206.8);
+// up from 1.7 in _common.scad
+capsule_cable_diam = 2.0;
+cable_wall = wall;
 
-// windscreen components
 
-*difference() {
-    union() {
-        rotate([0, 0, -22.5]) render_octa_capsule_flare(49.2);
+////////
+//// ready to print individual parts
+////////
 
-        *render_sphear_windscreen_thread_cover(64.3);
-    }
+// NOTE: remove the "*" at the beginning of a line to render that part
+//       make sure mic_version and pcb_version are set to the right version
 
-    *translate([-60, -60, 0]) {
-        cube([60, 60, 150]);
-    }
+// single capsule holder
+*if (mic_version == 2) {
+    // 3d print with support
+    rotate([180, 0, 0]) capsule_holder(holder_ratio, transition_ratio);
+} else {
+    // upper
+    render_octa_capsule_top(0);
+    // lower
+    *render_octa_capsule_bot(0);
 }
 
-difference() {
-    union() {
-    *render_sphear_lower_windscreen(tetra_pcb_mount_height - 10 + 15);
-
-    *render_sphear_upper_windscreen(tetra_pcb_mount_height - 10 + 15 + windscreen_height);
-    }
-    *translate([-60, -60, 0]) {
-        cube([60, 60, 120]);
-    }
+// capsule array core and stalk
+//
+if (mic_version == 2) {
+    // upper half (3d print with support)
+    *capsule_holder_core(mount_radius + wall, stalk_height, 1);
+    // lower half (with stalk - 3d print with support)
+    *rotate([180, 0, 0]) capsule_holder_core(mount_radius + wall, stalk_height, -1);
+    // connection ring
+    *translate([0, 0, 0]) capsule_holder_ring(shift = -0.2);
+} else {
+    *render_octa_capsule_stalk(0);
 }
 
-*rotate([0, 0, -22.5]) render_octa_pcb_mount(0, 0);
-
-*render_octa_cable_flare(0);
+// flare from body to capsule array stalk
+*rotate([0, 0, -22.5]) render_octa_capsule_flare(0);
 
-*rotate([0, 180, 0]) {
-    render_octa_connector_flare(0);
-}
+// body
+*rotate([0, 0, -22.5]) render_octa_pcb_mount(0, 1);
 
-// db25 flare
-*difference() {
-rotate([0, 180, 90 - 22.5]) {
+// flare from body to db25 connector
+// (3d print with support)
+*rotate([0, 0, 0 + 22.5]) {
     conn_offset = 2.0;
-    translate([0, 0, -mount_lip]) octa_mount_flare_dsub(pcb_low_clear + pcb_low_exp, mount_lip, 20,
+    octa_mount_flare_dsub(pcb_low_clear + pcb_low_exp - 5, mount_lip, 33 - 13,
                             octa_pcb_radius,
                             conn_core_o_diam / 2, conn_core_o_diam + conn_offset);
 }
-    *rotate([0, 0, 0]) translate([-60, -60, -60]) {
-        cube([60, 60, 120]);
-    }
-}
 
-*translate([0, 0, 4]) {
-    rotate([0, 0, 22.5]) {
-        conn_offset = 2.0;
-        octa_mount_stand(20, mount_lip, 20, octa_pcb_radius, conn_core_o_diam / 2, conn_core_o_diam + conn_offset);
-    }
-}
+// shock mount
+//
+// sleeve
+*octa_shock_mount_sleeve(octa_pcb_radius, internal_ring_height, true, true);
 
-// the whole body
-*render_octa_body(0, 10, 0);
+// external ring
+*render_octa_shock_mount_external_ring(0);
 
-// the whole microphone
-// or use render_octa_microphone_cutout(0, 0) for a "transparent" view
+// quick lock microphone stand mount
+*render_octa_shock_mount_stand(0);
+
+// threaded microphone stand mount
+*shock_mount_threaded_stand(20, 2, 1);
+
+// windscreen
 //
-*render_octa_microphone_cutout(0, 0, 0);
+*if (pcb_version == 2) {
+    // tapered lower windscreen for pcb2 (from pcb2 to pcb1 diameter)
+    render_sphear_lower_tapered_windscreen(windscreen_radius - 3, windscreen_radius_pcb1, 0);
+} else {
+    // regular lower windscreen for pcb1
+    render_sphear_lower_windscreen(windscreen_radius, 0);
+}
+// upper windscreen
+*render_sphear_upper_windscreen(windscreen_thread_radius_pcb1 + 5.0, 0);
 
-//// microphone shock mount
+// windscreen or shock mount attachment ring
+*sphear_windscreen_round_mount(windscreen_thread_height, windscreen_thread_radius, windscreen_radius - 1.75, 2 * wall, true);
 
-*difference() {
-render_octa_shock_mount_stand(0);
 
-*translate([0, 0, 0])
-    cube([60, 60, 60]);
-}
+////////
+//// full microphone with height offset for different parts
+////////
 
-// shock mount test
+// set to true to render printed circuit board and components for testing
+render_pcb = false;
 
-*rotate([0, 0, 0]) translate([0, 0, -55/2 - 28]) {
-    octa_shock_mount_internal_ring(55, octa_pcb_radius, 20, 0, 0);
-}
+// reduce resolution for quick tests
+// facets = 64;
+// cfacets = 64;
 
-*difference() {
-rotate([0, 0, 0]) translate([0, 0, -55/2 - 28]) {
-    octa_quik_release_stand_mount(30, octa_pcb_radius);
-}
-    *translate([0, -60, -60]) {
-        cube([60, 60, 60]);
+difference() {
+    // separate the parts slightly to show joints
+    stretch = 0.1;
+    //
+    union() {
+        // the capsule array
+        //
+        *if (mic_version == 1) {
+            // version 1 capsule array
+            //
+            rotate([0, 0, -22.5]) render_octa_capsule_array(202.8);
+            // stalk from flare to capsule array
+            rotate([0, 0, -22.5]) render_octa_capsule_stalk(pcb_version == 2 ? 43.2 : 49.2);
+        } else {
+            // version 2 flower power capsule array
+            //
+            translate([0, 0, 194.2]) rotate([0, 0, -22.5]) {
+                difference() {
+                    union() {
+                        // capsule array
+                        render_octa_capsule_holder_array();
+                        // upper half of spherical core
+                        capsule_holder_core(mount_radius + wall, stalk_height, 1);
+                        // lower half of spherical core (with stalk)
+                        translate([0, 0, -0.05]) capsule_holder_core(mount_radius + wall, stalk_height, -1);
+                        // connection ring
+                        *translate([0, 0, 0]) capsule_holder_ring(shift = -0.2);
+                    }
+                    *rotate([0, 0, 0]) translate([-50, -25, -25]) cube([50, 50, 50]);
+                }
+            }
+        }
+        // flare from body to stalk
+        *rotate([0, 0, -22.5]) render_octa_capsule_flare(pcb_version == 2 ? 42.4 + stretch : 49.2);
+        // body
+        *rotate([0, 0, -22.5]) render_octa_pcb_mount(0, 1);
+        // flare from body to db25 connector
+        *rotate([180, 0, 90 - 22.5]) {
+            conn_offset = 2.0;
+            translate([0, 0, -mount_lip]) octa_mount_flare_dsub(pcb_low_clear + pcb_low_exp - 5, mount_lip, 33 - 13,
+                                    octa_pcb_radius,
+                                    conn_core_o_diam / 2, conn_core_o_diam + conn_offset);
+        }
+        // thread cover (protects thread or locks down shock mount when windscreen not used)
+        *translate([0, 0, pcb_mount_height - 10 + 15]) {
+            sphear_windscreen_round_mount(windscreen_thread_height, windscreen_thread_radius,
+                windscreen_radius - 1.75, 2 * wall, true);
+        }
+        //
+        // windscreen
+        //
+        *if (pcb_version == 2) {
+            // tapered lower windscreen for pcb2 (from pcb2 to pcb1 diameter)
+            render_sphear_lower_tapered_windscreen(windscreen_radius - 3, windscreen_radius_pcb1, pcb_mount_height - 10 + 15);
+        } else {
+            // regular lower windscreen for pcb1
+            render_sphear_lower_windscreen(windscreen_radius, pcb_mount_height - 10 + 15);
+        }
+        // upper windscreen for both designs
+        *render_sphear_upper_windscreen(windscreen_thread_radius_pcb1 + 5.0, pcb_mount_height - 10 + 15 + windscreen_height);
+        //
+        // shock mount
+        //
+        // internal sleeve (slides over body from the top)
+        *translate([0, 0, pcb_version == 2 ? 3.0 : 9.1]) rotate([0, 0, 0]) {
+            octa_shock_mount_sleeve(octa_pcb_radius, internal_ring_height, true, true);
+        }
+        // external ring
+        *translate([0, 0, (pcb_version == 2 ? 3.0 : 9.1) + (internal_ring_height/2) - (external_ring_height/2)]) {
+            render_octa_shock_mount_external_ring(0);
+        }
+        // quick lock microphone stand mount
+        *translate([pcb_version == 2 ? 72.5 : 76, 0, pcb_version == 2 ? -25.5 : -19.5]) {
+           render_octa_shock_mount_stand(0);
+        }
+    }
+    //
+    // render to have a cutout view of microphone for debugging
+    //
+    z_rotation = 0;
+    *rotate([0, 0, z_rotation]) translate([-100, -100, -100]) {
+        cube([100, 100, 400]);
     }
 }
 
-difference() {
-shock_mount_threaded_stand(20, 2, 1);
-    *translate([0, -60, 0]) {
-        cube([60, 60, 60]);
+// serial number tests
+//
+*difference() {
+    union() {
+        // add a serial number
+        *translate([-25.5, 0, 43.2 + 7]) rotate([90, 0, -90]) scale ([0.2, 0.2, 0.5])
+            linear_extrude(0.5) text("8S004", halign = "center");
     }
 }
 
-// old code
-
-*translate([0, 0, 28])
-render_octa_shock_mount_external_ring(0);
-
-*translate([0, 0, -30])
-render_octa_shock_mount_internal_ring_bot(0);
+////
+//// old versions
+////
 
-*render_octa_shock_mount_internal_ring_top(0);
+// the whole body
+*translate([0, 0, -20]) render_octa_body(0, 10, 0);
 
-*render_octa_shock_mount_ring_connectors(5);
+// the whole microphone
+// or use render_octa_microphone_cutout(0, 0) for a "transparent" view
+//
+*rotate([0, 0, 90 - 22.5]) render_octa_microphone_cutout(0, 0, 0);
+*rotate([0, 0, 90 - 22.5]) render_octa_microphone(0, 0, 0);
 
-// the full mount
-*render_octa_shock_mount(0);
+////
+//// old microphone shock mount
+////
 
-// individual capsule holders
+// sleeve (body slips into it)
 
-*render_octa_capsule_top(0);
+*rotate([180, 0, 0]) translate([0, 0, -55/2 - 21 - (pcb_version == 2 ? -5 : 0)]) {
+    octa_shock_mount_internal_ring(internal_ring_height, octa_pcb_radius, 20, 0, 0);
+}
 
-*render_octa_capsule_bot(0);