SpHEAR/TinySpHEAR_H2N_common.scad

//
// Spherical Harmonics Ear Project (*SpHEAR)
//
// TinySpHEAR, First Order (B-format) Ambisonics Microphone
// Common files for H2N add-on array
// 
// Copyright 2016-2017, Fernando Lopez-Lezcano, All Rights Reserved
// nando@ccrma.stanford.edu
//
//  This program is free software: you can redistribute it and/or modify
//  it under the terms of the GNU General Public License as published by
//  the Free Software Foundation, either version 3 of the License, or
//  (at your option) any later version.
//
//  This program is distributed in the hope that it will be useful,
//  but WITHOUT ANY WARRANTY; without even the implied warranty of
//  MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
//  GNU General Public License for more details.
//
//  You should have received a copy of the GNU General Public License
//  along with this program.  If not, see <http://www.gnu.org/licenses/>.
//
// 3d Models released under the Creative Commons license as follows:
//   Attribution-NonCommercial-ShareAlike 4.0 International (CC BY-NC-SA 4.0)
// http://creativecommons.org/licenses/by-nc-sa/4.0/

include <SpHEAR_common.scad>;
include <TinySpHEAR_common.scad>;
include <TinySpHEAR_mount_pcb.scad>;

// outline of H2N front
// include<h2n/H2N_front_outline.scad>;
// outline of H2N top
// include<h2n/H2N_top_up_outline.scad>;

facets = 128;

// dimensions of the EM200 electret microphone capsule (measured 14.59 max)
capsule_radius = 14.6 / 2;
capsule_height = 4.75;
mic_radius = 11;

// adjust the depth of slots in mount
mic_to_mount_fit = -0.4;

// make triangular legs have the height of the capsule
connect = 1;
leg_thick = capsule_height;

// dimensions of H2R recorder

// width and depth at middle of ring
h2n_width = 62.00;
h2n_depth = 42.66;

h2n_width_up = 57.0;

// h2n_column_height = 40;
// h2n_column_height = 25.3;
h2n_column_height = 23.2;
transition_height = 30;

// measured = 11.50, should be 13.1 -> ratio = 

h2n_side_band = 1.5;
h2n_side_band_w = 13.4;
// h2n_width_m: tried taking out 0.5mm from the original measurement of 63.0, but 
// it is too much and the "Menu" button stops working, 0.25mm seems fine
h2n_width_m = 63.0 - 0.25;
h2n_depth_m = 36.4;

h2n_band_height = 6.0;

// base band width
h2n_band_wall = 1.6;

// wall for the stalk
h2n_stalk_wall = 1.0;

// walls for the columns
h2n_col_wall = 2 * wall;

// tilt for the columnds
h2n_col_tilt = 4.0;

// radius of mount stalk
h2n_mount_radius = mount_radius;

// fit for connector from column to bridge
h2n_mount_fit = 0.04;

// bridge dimensions
h2n_bridge_base_height = 7.0;
h2n_bridge_stalk_height = 45.0;

// bridge base dimensions
h2n_bridge_circle = 24.00;
h2n_bridge_band_w = 13.25;
h2n_bridge_band_h = 3.30; // 26.5 - h2n_column_height;

// we need to make the dial cover slightly elliptical
h2n_bridge_circle_max = 26.5;
h2n_bridge_circle_ratio = h2n_bridge_circle_max / h2n_bridge_circle;


module tube(or, ir, h) {
    difference() {
        cylinder(r = or, h = h, $fn = facets);
        cylinder(r = ir, h = h, $fn = facets);
    }
}

// main support ring

module h2n_ring(width, depth, radius, height, tilt, slot_w, slot_d, band_wall, wall, col_rad, col_wall) {
    // main support ring
    difference() {
        conical_rounded_box(height, width / 2 + band_wall, depth / 2 +  band_wall, radius - thin_mint, band_wall, height * tan(tilt));
        for (m = [0, 1]) mirror([m, 0, 0]) {
            translate([-(width / 2 + col_rad - col_wall), 0, 0]) {
                tilted_cylinder(col_rad, height, height * tan(tilt));
            }
        }
    }
    // inner band
    difference() {
        conical_rounded_box(height, width / 2 + wall - h2n_side_band, depth / 2 + wall, radius - thin_mint, wall, height * tan(tilt));
        for (m = [0, 1]) mirror([m, 0, 0]) {
            // cut slots on the sides
            translate([-width / 2 - wall / 2, -h2n_side_band_w / 2, 0]) {
                cube([width / 2, h2n_side_band_w, height + thin_mint]);
            }
        }
    }
    // add TinySpHEAR "branding"
    translate([0, -(h2n_depth_m / 2 + band_wall), h2n_band_height / 2]) scale(0.5) {
        rotate([90 - h2n_col_tilt, 0, 0]) {
            linear_extrude(height = 0.2, center = "true") {
                text("TinySpHEAR", size = 8.0, spacing = 1.1, halign = "center", valign = "center", font = "Liberation Sans");
            }
        }
    }
}

// side columns

module tilted_cylinder(radius, height, offset) {
    hull() {
        cylinder(r = radius, h = thin_mint, $fn = facets);
        translate([offset, 0, height]) {
            cylinder(r = radius, h = thin_mint, $fn = facets);
        }
    }
}

module tilted_rounded_box(height, width, depth, radius, wall, offset) {
    difference() {
        hull() {
            rounded_block(thin_mint, width, depth, radius);
            translate([offset, 0, height]) {
                rounded_block(thin_mint, width, depth, radius);
            }
        }
        hull() {
            rounded_block_relative(thin_mint, width, depth, radius, -wall);
            translate([offset, 0, height]) {
                rounded_block_relative(thin_mint, width, depth, radius, -wall);
            }
        }
    }
}

module conical_rounded_box(height, width, depth, radius, wall, inset) {
    difference() {
        hull() {
            rounded_block(thin_mint, width, depth, radius);
            translate([0, 0, height]) {
                rounded_block_relative(thin_mint, width, depth, radius, -inset);
            }
        }
        hull() {
            rounded_block_relative(thin_mint, width, depth, radius, -wall);
            translate([0, 0, height]) {
                rounded_block_relative(thin_mint, width, depth, radius, -(wall + inset));
            }
        }
    }
}

module tilted_cube(width, depth, height, offset) {
    hull() {
        cube([width, depth, thin_mint]);
        translate([offset, 0, height]) {
            cube([width, depth, thin_mint]);
        }
    }
}

module tilted_half_rounded_box(height, width, depth, radius, wall, offset, e = 0.1) {
    difference() {
        tilted_rounded_box(height, width, depth, radius, wall, offset);
        translate([0, -(depth + e), 0]) {
            tilted_cube(width + e, (depth + e) * 2, height, offset);
        }
    }
}

module half_rounded_box(height, width, depth, radius, wall, e = 0.1) {
    difference() {
        rounded_box(height, width , depth, radius, wall);
        translate([0, -(depth + e), 0]) {
            cube([width + e, 2 * (depth + e), height]);
        }
    }
}

module h2n_column_core(height, ring_height, tilt, transition, radius, col_wall, wall, offset) {
    hull() {
        // angled column
        difference() {
            tilted_cylinder(radius + col_wall + offset, height, height * tan(tilt));
            translate([0, -(radius + col_wall + offset), 0]) {
                tilted_cube((radius + col_wall) * 2, (radius + col_wall) * 2, height, height * tan(tilt));
            }
        }
        // side sleeves
        // we should derive the geometry for the aligment magic below...
        side_fit = 0.5;
        translate([(radius + col_wall) / 2 + 2 * wall - side_fit, 0, 0]) {
            difference() {
                tilted_half_rounded_box(height, 3.8 + offset, h2n_side_band_w / 2 + wall + offset * 1.1,
                    2.0, wall, height * tan(tilt));
                translate([col_wall / 2 + wall - radius * 3 / 2 - side_fit, 0, 0]) {
                    tilted_cylinder(radius, height, height * tan(tilt));
                }
            }
        }
    }
}

module h2n_column(height, ring_height, tilt, transition, radius, col_wall, wall) {
    // side tubes for cables
    difference() {
        h2n_column_core(height, ring_height, tilt, transition, radius, col_wall, wall, 0);
        // hollow out the cylinder
        tilted_cylinder(radius, height, height * tan(tilt));
        // this fine adjustment determines how much the side walls "hug" the H2N
        width_fit = 0.2;
        translate([radius + 2 * wall - width_fit, 0, 0]) {
            tilted_half_rounded_box(height + thin_mint, 3.8, h2n_side_band_w / 2, 1.5, 4 * wall, height * tan(tilt));
        }
        // trim side of tubes with a vertical plane
        translate([-(radius * 2 + col_wall) + col_wall / 2, -(radius + col_wall), 0]) {
            cube([col_wall * 2, (radius + col_wall) * 2, 30]);
        }
    }
   // add a thicker wall at the bottom of the side trim
    difference() {
        translate([-(radius), -(radius + col_wall), 0]) {
            cube([wall, (radius + col_wall) * 2, height]);
        }
        difference() {
            tilted_cylinder(radius * 4, height, height * tan(tilt));
            tilted_cylinder(radius + col_wall, height, height * tan(tilt));
        }
    }
    // connector to bridge
    translate([height * tan(tilt), 0, height]) {
        connector_height = 5.0;
        difference() {
            union() {
                difference() {
                    union() {
                        cylinder(r = radius + wall - h2n_mount_fit, h = connector_height, $fn = facets);
                        h2n_column_core(h2n_bridge_band_h, ring_height, 0, transition, radius, col_wall, wall, -(wall + h2n_mount_fit));
                    }
                    cylinder(r = radius, h = connector_height, $fn = facets);
                    translate([1.5, -(radius + wall) * 2, 0]) {
                        cube([radius + wall, (radius + wall) * 4, connector_height]);
                    }
                }
                // add anchor for retaining screw
                difference() {
                    translate([-radius, 0, radius]) {
                        sphere(r = radius * 2/3, $fn = facets);
                    }
                    // and clip out the rest of the sphere
                    difference() {
                        cylinder(r = 2 * radius + wall, h = height);
                        cylinder(r = radius + wall - h2n_mount_fit, h = height);
                    }
                    translate([0, 0, connector_height]) {
                        cylinder(r = radius + wall, h = connector_height);
                    }
                }
            }
            // make hole for screw
            translate([-(radius + 2 * wall), 0, radius]) {
                rotate([0, 90, 0]) {
                    cylinder(r = 0.5, h = radius + wall, $fn = facets);
                }
            }
        }
    }
}

module h2n_columns(width, height, ring_height, tilt, transition, radius, col_wall, wall) {
    for (m = [0, 1]) mirror([m, 0, 0]) {
        translate([-(width / 2 + col_wall - wall / 2), 0, 0]) {
            h2n_column(height, ring_height, tilt, transition, radius, col_wall, wall);
        }
    }
}

// old version of columns

module h2n_columns_old(width, height, ring_height, tilt, transition, radius, col_wall, wall) {
    // side tubes for cables
    slot_height = 25.0;
    for (m = [0, 1]) mirror([m, 0, 0]) {
        translate([-(width / 2 + radius - col_wall), 0, 0]) {
            difference() {
                // angled column
                tilted_cylinder(radius + col_wall, height, height * tan(tilt));
                tilted_cylinder(radius, height, height * tan(tilt));
                // slots in the columns for cables
                translate([radius - col_wall - ring_height * tan(tilt), - radius * 2, -ring_height]) {
                    rotate([0, tilt, 0]) {
                        cube([5.0, radius * 4, slot_height]);
                        translate([radius + col_wall, radius - col_wall, slot_height]) {
                            rotate([0, 90, 90]) {
                                cylinder(r = radius + col_wall, h = 15.0, $fn = facets);
                            }
                        }
                    }
                }
                // trim side of tubes with a vertical plane
                translate([-(radius * 2 + col_wall) + col_wall / 2, -(radius + col_wall), 0]) {
                    cube([col_wall * 2, (radius + col_wall) * 2, 30]);
                }
            }
            // add a thicker wall at the bottom of the side trim
            difference() {
                translate([-(radius), -(radius + col_wall), 0]) {
                    cube([wall, (radius + col_wall) * 2, height]);
                }
                difference() {
                    tilted_cylinder(radius * 4, height, height * tan(tilt));
                    tilted_cylinder(radius + col_wall, height, height * tan(tilt));
                }
            }
        }
        // connector to bridge
        translate([-(width / 2 + radius - col_wall - height * tan(tilt)), 0, height]) {
            connector_height = 5.0;
            difference() {
                tube(radius + wall - h2n_mount_fit, radius, connector_height);
                translate([0, -(radius + wall), connector_height / 2]) {
                    cube([radius + wall, (radius + wall) * 2, connector_height / 2]);
                }
            }
        }
        // side sleeves
        sleeve_height = slot_height;
        // XXX sleeve_height = slot_height - mount_radius - col_wall;
        for (m = [0, 1]) mirror([m, 0, 0]) {
            // we should derive the geometry for the aligment magic below...
            side_fit = 1.05;
            translate([-(width / 2 - (radius + col_wall) / 2 + wall - side_fit), 0, 0]) {
                difference() {
                    tilted_half_rounded_box(sleeve_height, 3.8, h2n_side_band_w / 2 + wall, 2.0, wall, sleeve_height * tan(tilt));
                    translate([col_wall / 2 + wall - radius * 3 / 2 - side_fit, 0, 0]) {
                        tilted_cylinder(radius, height, height * tan(tilt));
                    }
                }
            }
        }
    }
}

// bridge that connects to capsule array

module semi_cylinder(r, h, e = thin_mint) {
    difference() {
        cylinder(h, r, r, $fn = facets);
        translate ([-r*2, -r, 0])
            cube([2*(r+e), 2*(r+e), h]);
    }
}

module quarter_sphere(r, e = thin_mint) {
    difference() {
        sphere(r, $fn = facets);
        translate([-(r+e), -(r+e), -(r+e)])
            cube([2*(r+e), 2*(r+e), r+e]);
        translate([-(r+e), -(r+e), -e])
            cube([r, 2*(r+e), (r+e)]);
    }
}

module cylcube(width, depth, height, wall) {
    difference() {
        semi_cylinder(r = depth, h = height);
        semi_cylinder(r = depth - wall, h = height);
    }
    translate([-(width + depth / 2), -depth, 0]) {
        difference() {
            cube([(width + depth / 2), depth * 2, height]);
            translate([0, wall, 0]) {
                cube([(width + depth), (depth - wall) * 2, height]);
            }
        }
    }
}

// old version of the bridge

module h2n_bridge_old(width, base_height, stalk_height, radius, col_wall, wall) {
    // capsule array mount with the right orientation (left front top = #1)
    rotate([0, 0, -90]) translate([0, 0, base_height + stalk_height]) {
        tetra_capsule_array_mount([-45, 135]);
    }
    // stalk
    translate([0, 0, base_height]) {
        difference() {
            tube(radius + wall, radius, stalk_height);
            // remove stalk segment that is inside the bridge
            translate([width / 2, 0, -1.0]) {
                rotate([0, -90, 0]) {
                    semi_cylinder(r = radius + col_wall, h = width);
                }
            }
        }
        // add marker for "back of microphone" orientation
        rotate([0, 0, 0]) {
            translate([0, radius + wall - wall * 2 / 3, stalk_height - radius]) {
                difference() {
                    sphere(r = radius / 3, $fn = 32);
                    translate([0, -radius + radius / 2, 0]) {
                        cube([radius, radius, radius], center = true);
                    }
                }
            }
        }
    }
    // top of bridge
    translate([width / 2, 0, base_height]) {
        rotate([0, -90, 0]) {
            difference() {
                // curvy ceiling
                semi_cylinder(r = radius + col_wall, h = width);
                semi_cylinder(r = radius + col_wall - wall, h = width);
                // make a hole for the cables
                translate([0, 0, width / 2]) {
                    rotate([0, 90, 0]) {
                        cylinder(r = radius, h = 10, $fn = facets);
                    }
                }
            }
        }
    }
    // caps at ends
    for (m = [0, 1]) mirror([m, 0, 0]) {
        translate([width / 2, 0, base_height]) {
            difference() {
                quarter_sphere(r = radius + col_wall);
                quarter_sphere(r = radius + col_wall - wall);
            }
        }
    }
    // base of bridge
    translate([0, 0, 0]) {
        for (m = [0, 1]) mirror([m, 0, 0]) {
            translate([width / 2, 0, 0]) {
                cylcube(width / 2, radius + col_wall, base_height, wall);
            }
        }
    }
    // reinforcement beams at the base
    translate([-col_wall / 2, -(radius + wall), 0]) {
        cube([col_wall, (radius + wall) * 2, col_wall]);
    }
    for (m = [0, 1]) mirror([m, 0, 0]) {
        translate([-width / 2 + radius + wall, -(radius + wall), 0]) {
            cube([col_wall, (radius + wall) * 2, col_wall]);
        }
    }
}

// base plate for upper band cover

module h2n_center_cover(width, base_height, stalk_height, radius, col_wall, wall, offset) {
    bot_step = h2n_bridge_band_h;
    difference() {
        union() {
            for (m = [0, 1]) mirror([m, 0, 0]) {
                // core of bridge
                translate([width/2, -thin_mint / 2, 0]) {
                    cylcube(width / 2 + offset, radius + offset + 2 * wall, bot_step, wall);
                }
                // we should derive the geometry for the aligment magic below...
                side_fit = 1.05;
                corner_radius = 2.0;
                tilted_half_rounded_box(bot_step, width / 2 + offset - wall / 2, h2n_side_band_w / 2 + offset + wall,
                    corner_radius, wall, 0);
            }
        }
        // clear the inside
        // outer frame
        rounded_block(bot_step + thin_mint, width / 2 + offset - 1.5 * wall, h2n_side_band_w / 2 + offset, 2);
        // inner frame
        translate([-(width + offset) / 2, -(radius + wall + offset), 0]) {
            cube([width + offset, (radius + wall + offset) * 2, bot_step + thin_mint]);
        }
    }
}

// base plate for upper center dial cover

module h2n_center_dial_cover(radius, wall, offset) {
    scale([h2n_bridge_circle_ratio, 1, 1]) {
        tube(radius + wall + offset, radius + offset, h2n_bridge_band_h);
    }
}

// the core of the bridge, a solid offset-able version

module h2n_bridge_core(width, base_height, stalk_height, radius, col_wall, wall, offset) {
    hull() {
        // top of bridge
        translate([width / 2, 0, base_height]) {
            rotate([0, -90, 0]) {
                // curvy ceiling
                semi_cylinder(r = radius + offset + col_wall, h = width + offset);
            }
        }
        // spherical caps at ends
        for (m = [0, 1]) mirror([m, 0, 0]) {
            translate([width / 2, 0, base_height]) {
                quarter_sphere(r = radius + offset + col_wall);
            }
        }
        // bottom plate
        h2n_center_cover(width, base_height, stalk_height, radius, col_wall, wall, offset);
    }
    // add cover for center dial
    hull() {
        cylinder(r = mount_radius + offset, h = base_height + radius, $fn = facets);
        h2n_center_dial_cover(h2n_bridge_circle / 2, wall, offset);
    }
}

// the bridge that holds the capsule array

module h2n_bridge(width, base_height, stalk_height, radius, col_wall, stalk_wall, wall) {
    // capsule array mount with the right orientation (left front top = #1)0
    rotate([0, 0, -90]) translate([0, 0, base_height + stalk_height]) {
        tetra_capsule_array_mount([-45, 135], mount_radius, stalk_wall);
    }
    difference() {
        union() {
            h2n_bridge_core(width, base_height, stalk_height, radius, col_wall, wall, 0);
            // stalk
            translate([0, 0, base_height]) {
                difference() {
                    tube(radius + stalk_wall, radius, stalk_height);
                    // remove stalk segment that is inside the bridge
                    translate([width / 2, 0, -1.0]) {
                        rotate([0, -90, 0]) {
                            semi_cylinder(r = radius + stalk_wall, h = width);
                        }
                    }
                }
                // add marker for "back of microphone" orientation
                rotate([0, 0, 0]) {
                    translate([0, radius + stalk_wall - stalk_wall * 2 / 3, stalk_height - (radius + stalk_wall)]) {
                        difference() {
                            sphere(r = (radius + stalk_wall) / 3, $fn = 64);
                            translate([0, -(radius + stalk_wall) + (radius + stalk_wall) / 2, 0]) {
                                cube([radius + stalk_wall, radius + stalk_wall, radius + stalk_wall], center = true);
                            }
                        }
                    }
                }
            }
            // small supports for the screws that attach to the columns
            for (m = [0, 1]) mirror([m, 0, 0]) {
                translate([-(width / 2 + radius + 2 * wall), 0, radius]) {
                    rotate([0, 90, 0]) {
                        cylinder(r = 1.5, h = 2 * wall, $fn = facets);
                    }
                }
            }
        }
        h2n_bridge_core(width, base_height, stalk_height, radius, col_wall, wall, -wall);
        // make a hole in the bridge for the cables
        cylinder(r = radius, h = base_height + radius + 2 * wall, $fn = facets);
        // cut a window for the XY and MS leds
        translate([0, h2n_bridge_circle_max, 0]) {
            rotate([90, 0, 0]) cylinder(r = 2.0, h = h2n_bridge_circle_max * 2, $fn = facets);
        }
        // holes for screws that attach to the columns
        translate([-(width + 3 * radius + 2 * wall) / 2, 0, radius]) {
            rotate([0, 90, 0]) {
                cylinder(r = 0.5, h = width + 4 * radius, $fn = facets);
            }
        }
    }
}

// render the whole thing

difference() {
union() {

*h2n_ring(h2n_width_m, h2n_depth_m, h2n_depth * 0.425, h2n_band_height, h2n_col_tilt,
         h2n_side_band_w, h2n_side_band, h2n_band_wall, h2n_band_wall, mount_radius, h2n_col_wall);

*h2n_columns(h2n_width_m, h2n_column_height, h2n_band_height, h2n_col_tilt,
            transition_height, h2n_mount_radius, h2n_col_wall, wall);

*translate([0, 0, h2n_column_height]) {
    h2n_bridge((h2n_width_m / 2 + mount_radius - h2n_col_wall - h2n_column_height * tan(h2n_col_tilt)) * 2,
               h2n_bridge_base_height, h2n_bridge_stalk_height, mount_radius, h2n_col_wall, h2n_stalk_wall, wall);
}

*rotate([0, 0, 90]) {
    render_tetra_capsule_array(h2n_column_height + h2n_bridge_base_height + h2n_bridge_stalk_height + 26);
}

}
*translate([-40, -50, 0]) {
    cube([80, 50, 80]);
}
}

// individual capsule holders

*render_tetra_capsule_top(0);

*render_tetra_capsule_bot(0);

// make sure dimensions are fine
*translate([-(h2n_width_m - 0.1) / 2, - 0.5, 0]) {
    cube([h2n_width_m - 0.1, 1, 1]);
}
*translate([-0.5, -(h2n_depth_m - 0.1) / 2, 0]) {
    cube([1, h2n_depth_m - 0.1, 1]);
}

// some tests with traced profiles
*difference() {
    translate([0, -2.5, 0]) {
        scale([2.15, 2.15, 1.0]) {
            H2N_top_up_outline(5.0);
        }
    }
// scale([1.75, 1.75, 1.0]) {
    translate([0, -2.4, 0]) {
        scale([2.02, 2.02, 1.0]) {
            H2N_top_up_outline(5.0);
        }
    }
}

*scale(1.665) {
    translate([0, 10, -0]) {
        rotate([0, 0, 0]) {
            H2N_front_outline(1.0);
        }
    }
}
*rotate([0, 0, 4]) translate([35, 0, 0])
    cube([2, 80, 4]);