SpHEAR/Octathingy_mount_pcb.scad

//
// Spherical Harmonics Ear Project (*SpHEAR)
//
// 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
//
// Copyright 2015-2016, 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 <Octathingy_common.scad>;
include <CCRMA_logo.scad>;

////
//// overrides

mount_radius = 5;

////
//// default model parameters
////

// size of Zapnspark printed circuit board
// kicad length = 79.375
// measured length = 79.20 (2016.08.25)
pcb_length = 79.20;
// kicad width = 19.050
// measured width = 18.82 (2016.08.25)
pcb_width = 18.85;
// ultimaker spec thickness = 1.61
// measured thickness = 1.56 (w/ copper)
pcb_thickness = 1.58;

// tolerance to add to length and width of pcb
//
// measured 3d print width = 18.70 (with pcb_fit = 0.3)
// actual printed = 18.70 - 0.3 = 16.97
// total correction = 18.85 - 16.97 = 1.88
//
pcb_fit = 0.4;

// tolerance add to thickness of pcb
//
// printed with pcb_tfit = 0.15 -> 1.58 + 0.15 = 1.73 (ideal printed)
// measured print channel = 1.63 : 0.1 thinner (ultimaker 2 plus, 2016.08.24)
// measured pcb thickness = 1.58 (othermill)
//
pcb_tfit = 0.15;

// we leave part of the pcb exposed on the bottom of the body so that we
// can solder the wires that connect the microphone with the
// preamplifier, same at the top of the pcb to solder the wires
// to the capsules
pcb_low_exp = 12.0;
pcb_hi_exp = 8.0;

// lip fit for flares
lip_fit = 0.15;

// clearance from the bottom and top of pcb's to the start of the flare,
// this adds space for the protuding molex pins on which we solder
pcb_low_clear = 15.0;
pcb_hi_clear = 15.0;

// depth of slot into which the printed circuit board fits
pcb_slot_depth = 1.0;

// diameter of four conductor cable
cable_diam = 9.5;

// lip that mounts flares into main body box
mount_lip = 6.0;

// capsule array mount, height of flare and stalk
flare_height = 50;
stalk_height = 60;

// wall thickness
wall = 1.0;

// back and front clearance of pcb (components and leads)
pcb_front = 13.25;
pcb_back = 3.0;

// calculated minimum "radius" of microphone box
box_radius = pcb_front + (pcb_thickness + pcb_tfit) + pcb_back + 2 * wall;

// calculated main body corner radius
mount_corner = box_radius - pcb_width / 2 + pcb_slot_depth + 1.0;

// shock mount parameters
//

ring_sep = 30.0;
ring_height = 10.0;
rubber_band_angle = 40;
main_radius_inc = (ring_sep / 2) / tan(rubber_band_angle);

// gap between internal ring and microphone body
internal_ring_gap = 1.0;

// connector that joins the two internal rings
connector_w = 10.0;
connector_d = 2.0;

// wall thickness and height of shock mount rings
ring_wall = 4 * wall;
ring_ext_height = 6;

// gap between external ring and support arm
ring_arm_gap = 20;


// all eight printed circuit boards

module octa_pcb_clear(length, width, thick, slot_depth, front, back) {
    for (ytrans = [-1, 1]) {
        translate([0, ytrans * (front + back + thick), 0]) {
            for (rot = [0, 90, 180, 270]) {
                rotate([0, 0, rot]) {
                    pcb_clear(pcb_length + pcb_fit, pcb_width + pcb_fit, pcb_thickness + pcb_tfit, slot_depth, front, back);
                }
            }
        }
    }
}

// the main body of the microphone mount

module octa_mount_body(height, width, depth, radius, lower_lip, upper_lip, clear) {
    // outer shell
    difference() {
        rounded_box(height, width, depth, radius, 2 * wall);
        // upper lip for flare to microphone
        translate([0, 0, height - upper_lip]) {
            rounded_box(upper_lip, width, depth, radius, wall + lip_fit);
        }
        // lower lip for flare to cable
        translate([0, 0, 0]) {
            rounded_box(upper_lip, width, depth, radius, wall + lip_fit);
        }
    }
    // mounting slots for pcb's
    slot_len = 30;
    difference() {
        rounded_block(slot_len, width - wall - lip_fit, depth - wall - lip_fit, radius);
        union() {
            // hollow out the inside with slots for pcbs
            octa_pcb_clear(slot_len, pcb_width, pcb_thickness, pcb_slot_depth, pcb_front, pcb_back);
            // trim square angles
            for (ytrans = [-1, 1]) {
                translate([0, ytrans * (pcb_front + pcb_back + pcb_thickness), 0]) {
                    cylinder(r = pcb_front + pcb_thickness, h = height, $fn = facets);
                }
            }
        }
    }
    // add parts for clearance check
    if (clear == 1) {
        // electrolytic capacitors
        cap_diam = 10.2;
        for (rot = [0, 180, 270]) {
            rotate([0, 0, rot]) {
                translate([-pcb_front + cap_diam/2, 0, 0]) {
                    *cylinder(r = (cap_diam/2), h = 20, $fn = facets);
                }
            }
        }
        // PCBs
        for (rot = [0, 180, 270]) {
            rotate([0, 0, rot]) {
                translate([-(pcb_front + pcb_thickness), -pcb_width/2, -pcb_low_exp]) {
                    cube([pcb_thickness, pcb_width, pcb_length]);
                }
            }
        }
        // connectors
        cap_h = 12.3;
        cap_w = 10.53/2;
        for (rot = [0, 180, 270]) {
            rotate([0, 0, rot]) {
                translate([-pcb_front, -cap_w/2 - 2.5, 0]) {
                    *cube([cap_h, cap_w, 20]);
                }
            }
        }
    }
}

// flares from the body to the microphone stalk and cable

module octa_mount_flare(height, lip, transition, xradius, yradius, corner, top_radius, stalk_height, dot) {
    // bottom rounded box
    difference() {
        rounded_block(height, xradius, yradius, corner);
        rounded_block_relative(height, xradius, yradius, corner, -(2 * wall));
        // flange to mount on body
        rounded_block_relative(lip + 1.00, xradius, yradius, corner, - (wall));
        // and make a smooth transition to avoid overhangs
        translate([0, 0, lip + 1.00]) {
            hull() {
                rounded_block_relative(thin_mint, xradius, yradius, corner, - wall);
                translate([0, 0, 1.0]) {
                    rounded_block_relative(thin_mint, xradius, yradius, corner, - 2 * wall);
                }
            }
        }
    }
    // flare to round section
    translate([0, 0, height]) {
        difference() {
            hull() {
                rounded_block(thin_mint, xradius, yradius, corner);
                translate([0, 0, transition]) {
                    cylinder(r = top_radius, h = thin_mint, $fn = facets);
                }
            }
            hull() {
                rounded_block_relative(thin_mint, xradius, yradius, corner, - 2 * wall);
                translate([0, 0, transition]) {
                    cylinder(r = top_radius - wall, h = thin_mint, $fn = facets);
                }
            }
        }
    }
        // add an additional transition from the flare to the stalk
    flare_stalk = 2;
    mid_xradius = top_radius + (flare_stalk * (xradius - top_radius)) / transition;
    mid_yradius = top_radius + (flare_stalk * (yradius - top_radius)) / transition;
    mid_corner = top_radius + (flare_stalk * (corner - top_radius)) / transition;
    translate([0, 0, height + transition - flare_stalk]) {
        difference() {
            hull() {
                rounded_block(thin_mint, mid_xradius, mid_yradius, mid_corner);
                translate([0, 0, 2 * flare_stalk]) {
                    cylinder(r = top_radius, h = thin_mint, $fn = facets);
                }
            }
            hull() {
                rounded_block_relative(thin_mint, mid_xradius, mid_yradius, mid_corner, - wall);
                translate([0, 0, 2 * flare_stalk]) {
                    cylinder(r = top_radius - wall, h = thin_mint, $fn = facets);
                }
            }
        }
    }
    // cylindrical stalk
    translate([0, 0, height + transition]) {
        difference() {
            cylinder(r = top_radius, h = stalk_height, $fn = facets);
            cylinder(r = top_radius - wall, h = stalk_height, $fn = facets);
        }
        // add marker for "back of microphone" orientation
        if (dot == 1) {
            rotate([0, 0, 90]) {
                translate([0, top_radius - wall * 2 / 3, stalk_height - top_radius]) {
                    difference() {
                        sphere(r = top_radius / 3, $fn = 32);
                        translate([0, -top_radius + top_radius / 2, 0]) {
                            cube([top_radius, top_radius, top_radius], center = true);
                        }
                    }
                }
            }
        }
    }
}

// flares from the body to a dual cable housing

module octa_mount_flare_dual(height, lip, transition, xradius, yradius, corner, top_radius, stalk_height) {
    // hack to get it to render, fix problem in rounded_block when radius is equal to corner...
    delta = 0.001;
    // bottom rounded box
    difference() {
        rounded_block(height, xradius, yradius, corner);
        rounded_block_relative(height, xradius, yradius, corner, -(2 * wall));
        // flange to mount on body
        rounded_block_relative(lip + 1.00, xradius, yradius, corner, - (wall));
    }
    // flare to rounded section section
    translate([0, 0, height]) {
        difference() {
            hull() {
                rounded_block(thin_mint, xradius, yradius, corner);
                translate([0, 0, transition]) {
                    rounded_block(thin_mint, top_radius, top_radius * 2, top_radius - delta);
                }
            }
            hull() {
                rounded_block_relative(thin_mint, xradius, yradius, corner, - 2 * wall);
                translate([0, 0, transition]) {
                    rounded_block(thin_mint, top_radius - wall, (top_radius * 2) - 1.5 * wall, top_radius - wall - delta);
                }
            }
        }
    }
    // corner box cable stalk
    translate([0, 0, height + transition]) {
        difference() {
            rounded_block(stalk_height, top_radius, top_radius * 2, top_radius - delta);
            // add holes for two cables
            for (offset = [top_radius - wall/2, -(top_radius  - wall/2)]) {
                translate([0, offset, 0]){
                        cylinder(r = top_radius - wall, h = stalk_height, $fn = facets);
                }
            }
        }
    }
}

// top conical section that plugs into capsule array

module octa_capsule_array_mount(angles) {
    difference() {
        translate([0, 0, 0]) {
            rotate([0, 0, 45]) {
                difference() {
                    cylinder(h = mount_top_height, r1 = mount_radius + wall, r2 = mount_radius_capsule, $fn = facets);
                    cylinder(h = mount_top_height, r1 = mount_radius, r2 = mount_radius_capsule * 0.8, $fn = facets);
                }
            }
        }
        // indentations that match the four lower capsule holders
        // add ridge height adjustment
        translate([0, 0, mount_top_height + (mic_radius - capsule_height) + capsule_height * cos(90 - elev_angle) - 2]) {
            for (az = angles) {
                rotate([0, 180 - elev_angle, az + 45]) {
                    translate([0, 0, mic_radius - capsule_height]) {
                        capsule(leg_angles, 0, 1, ridge_wfit, ridge_hfit, 1);
                    }
                }
            }
        }
        // indentations at the top to open up the array a bit
        echo (mount_radius_capsule);
        translate([0, 0, mount_top_height + mount_radius_capsule / 8]) {
            for (rot = [45, 135, -135, -45]) {
                translate([0, 0, 0]) {
                    rotate([0, 90, rot]) {
                        linear_extrude(height = mount_radius * 2.0) {
                            minkowski() {
                                polygon(points = [[0, mount_radius_capsule * 0.35], [0, - mount_radius_capsule * 0.35], 
                                                  [mount_radius_capsule * 2 / 3, 0]]);
                                circle(r = 1.0, $fn = facets);
                            }
                        }
                    }
                }
            }
        }
    }
}

////
//// render all the different parts
////

// microphone body: flare to capsule array (slips into PCB holder body)
//
module render_octa_capsule_flare(z_offset) {
    translate([0, 0, z_offset]) {
        octa_mount_flare(pcb_hi_clear + pcb_hi_exp, mount_lip, flare_height, box_radius + wall,  box_radius * 2 - wall, 
                         mount_corner, mount_radius + wall, stalk_height, 1);
        translate([0, 0, pcb_hi_clear + pcb_hi_exp + flare_height + stalk_height]) {
            octa_capsule_array_mount([45, 135, -45, -135]);
        }
    }
}

// microphone body: main body, holds printed circuit boards
//
octa_pcb_mount_height = pcb_length - pcb_low_exp - pcb_hi_exp;

module render_octa_pcb_mount(z_offset, showint) {
    translate([0, 0, z_offset]) {
        octa_mount_body(octa_pcb_mount_height, box_radius + wall, box_radius * 2 - wall, mount_corner, mount_lip, mount_lip, 0);
    }
    // add ccrma logo
    rotate([0, 0, -90]) {
        translate([0, -(box_radius - 0.5), octa_pcb_mount_height / 2]) {
            rotate([90, 0, 0]) {
                logo_scale = 1 / 2.2;
                scale([logo_scale, logo_scale, 1.0]) {
                    ccrma_logo(1.65);
                }
            }
        }
    }
}

// microphone body: flare to microphone cable (slips into PCB holder body)
//
module render_octa_cable_flare(z_offset, flip) {
    translate([0, 0, z_offset]) {
        octa_mount_flare_dual(pcb_low_clear + pcb_low_exp, mount_lip, 20, box_radius + wall, box_radius * 2 - wall, 
                              mount_corner, cable_diam / 2 + wall, 10, 0);
    }
}

// microphone body: render all parts with a vertical separation
//
module render_octa_body(z_offset, spread, showint) {
    rotate([0, 180, 0]) {
        render_octa_cable_flare(0);
    }
    lippy = spread - mount_lip;
    render_octa_pcb_mount(lippy, showint);
    render_octa_capsule_flare(octa_pcb_mount_height + 2 * lippy);
}

// microphone: render the full assembly with a vertical separation
//
module render_octa_microphone(z_offset, spread) {
    render_octa_body(z_offset, spread);
    lippy = spread - mount_lip;
    render_octa_capsule_array(z_offset + octa_pcb_mount_height + mount_top_height +
            flare_height + stalk_height + pcb_hi_clear + pcb_hi_exp + 2 * lippy + spread + mic_radius);
}

// microphone: render the full assembly with a vertical separation
//             cut out halt of the assembly so that we can see the inside
//

module render_octa_microphone_cutout(z_offset, spread) {
    difference() {
        render_octa_microphone(z_offset, spread);
        // a cube that blots out 1/4 of the microphone
        rotate([0, 0, 45]) {
            translate([0, 0, -50]) {
                cube([50, 100, 650]);
            }
        }
    }
}

// shock mount: microphone clip on stand mount
//

module render_octa_shock_mount_stand(z_offset) {
    translate([z_offset]) {
        shock_mount_stand(mic_mount_height, mount_wall, mic_mount_wall);
    }
}

// shock mount: external ring
//

module render_octa_shock_mount_external_ring(z_offset) {
    translate([0, 0, z_offset]) {
        shock_mount_external_ring(ring_height, box_radius + wall, box_radius * 2 - wall, mount_corner, main_radius_inc, 0);
    }
}

// shock mount: bottom internal ring
//

module render_octa_shock_mount_internal_ring_bot(z_offset) {
    translate([0, 0, z_offset]) {
        shock_mount_internal_ring(ring_height, box_radius + wall, box_radius * 2 - wall, mount_corner, internal_ring_gap, 1);
    }
}

// shock mount: top internal ring
//

module render_octa_shock_mount_internal_ring_top(z_offset) {
    translate([0, 0, z_offset]) {
        shock_mount_internal_ring(ring_height, box_radius + wall, box_radius * 2 - wall, mount_corner, internal_ring_gap, 0);
    }
}

// shock mount: all four internal ring connectors
//

module render_octa_shock_mount_ring_connectors(offset) {
    for (o = [0, 1, 2, 3]) {
        translate([-18, (10 + offset) * o, 0]) {
            shock_mount_connector(ring_sep, 4, connector_w, connector_d, 0.1);
        }
    }
}

// shock mount: render all parts
//

module render_octa_shock_mount(z_offset) {
    // internal rings
    translate([0, 0, z_offset + ring_sep / 2]) {
        render_octa_shock_mount_internal_ring_top(0);
        rotate([0, 180, 0]) {
            render_octa_shock_mount_internal_ring_bot(ring_sep + 2);
        }
        // insert the connecting rods
        for (r = [0, 90, 180, 270]) {
            rotate([0, 0, r]) {
                translate([((r % 180) ? box_radius * 2 : box_radius) + 3 * wall + internal_ring_gap, 0, -1]) {
                    rotate([0, 90, 0]) {
                        translate([-4, -5, 1]) {
                            shock_mount_connector(ring_sep, 4, connector_w, connector_d, 0.1);
                        }
                    }
                }
            }
        }
    }
    // external ring
    translate([0, 0, z_offset - ring_height / 4]) {
        render_octa_shock_mount_external_ring(0);
    }
    // mount to stand
    translate([box_radius + mount_corner + ring_wall + ring_arm_gap + 8 + ring_wall / 2 + 4, 0, -(mic_mount_height + mic_mount_radius + ring_height / 4)]) {
        render_octa_shock_mount_stand(0);
    }
}