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OpenSCAD source code: Proto board holder with bottom inserts
// Test support frame for proto boards
// Ed Nisley KE4ZNU - Jan 2017
// June 2017 - Add side-mount bracket, inserts into bottom
Layout = "Frame";
ClampFlange = true;
Channel = false;
//- Extrusion parameters - must match reality!
ThreadThick = 0.25;
ThreadWidth = 0.40;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1;
HoleWindage = 0.2;
//- Screw sizes
inch = 25.4;
Tap4_40 = 0.089 * inch;
Clear4_40 = 0.110 * inch;
Head4_40 = 0.211 * inch;
Head4_40Thick = 0.065 * inch;
Nut4_40Dia = 0.228 * inch;
Nut4_40Thick = 0.086 * inch;
Washer4_40OD = 0.270 * inch;
Washer4_40ID = 0.123 * inch;
ID = 0;
OD = 1;
LENGTH = 2;
Insert = [3.9,4.6,5.8];
//- PCB sizes
PCBSize = [80.0,120.0,1.6];
PCBShelf = 1.0; // support rim under PCB
Clearance = 2*[ThreadWidth,ThreadWidth,0];
WallThick = 4.0;
FrameHeight = IntegerMultiple(3/8 * inch,1.0);
echo(str("Inner height: ",FrameHeight));
ScrewOffset = 0.0 + Clear4_40/2;
ScrewSites = [[-1,1],[-1,1]]; // -1/0/+1 = left/mid/right and bottom/mid/top
OAHeight = FrameHeight + Clearance[2] + PCBSize[2];
echo(str("OAH: ",OAHeight));
FlangeExtension = 3.0;
FlangeThick = IntegerMultiple(2.0,ThreadThick);
Flange = PCBSize
+ 2*[ScrewOffset,ScrewOffset,0]
+ 2*[Washer4_40OD,Washer4_40OD,0]
+ [2*FlangeExtension,2*FlangeExtension,(FlangeThick - PCBSize[2])]
;
echo(str("Flange: ",Flange));
NumSides = 4*5;
WireChannel = [Flange[0],15.0,3.0 + PCBSize[2]];
WireChannelOffset = [Flange[0]/2,25.0,(FrameHeight + PCBSize[2] - WireChannel[2]/2)];
//- Adjust hole diameter to make the size come out right
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
}
//- Build things
if (Layout == "Frame")
difference() {
union() { // body block
translate([0,0,OAHeight/2])
cube(PCBSize + Clearance + [2*WallThick,2*WallThick,FrameHeight],center=true);
for (x=[-1,1], y=[-1,1]) { // screw bosses
translate([x*(PCBSize[0]/2 + ScrewOffset),
y*(PCBSize[1]/2 + ScrewOffset),
0])
cylinder(r=Washer4_40OD,h=OAHeight,$fn=NumSides);
}
if (ClampFlange) // flange for work holder
linear_extrude(height=Flange[2])
hull()
for (i=[-1,1], j=[-1,1]) {
translate([i*(Flange[0]/2 - Washer4_40OD/2),j*(Flange[1]/2 - Washer4_40OD/2)])
circle(d=Washer4_40OD,$fn=NumSides);
}
}
for (x=[-1,1], y=[-1,1]) { // screw position indexes
translate([x*(PCBSize[0]/2 + ScrewOffset),
y*(PCBSize[1]/2 + ScrewOffset),
-Protrusion])
rotate(x*y*180/(2*6))
PolyCyl(Clear4_40,(OAHeight + 2*Protrusion),6); // screw clearance holes
translate([x*(PCBSize[0]/2 + ScrewOffset),
y*(PCBSize[1]/2 + ScrewOffset),
-Protrusion])
rotate(x*y*180/(2*6))
PolyCyl(Insert[OD],OAHeight - PCBSize[2] - 3*ThreadThick + Protrusion,6); // inserts
if (false)
translate([x*(PCBSize[0]/2 + ScrewOffset),
y*(PCBSize[1]/2 + ScrewOffset),
OAHeight - PCBSize[2]])
PolyCyl(1.2*Washer4_40OD,(PCBSize[2] + Protrusion),NumSides); // washer recess
}
translate([0,0,OAHeight/2]) // through hole below PCB
cube(PCBSize - 2*[PCBShelf,PCBShelf,0] + [0,0,2*OAHeight],center=true);
translate([0,0,(OAHeight - (PCBSize[2] + Clearance[2])/2 + Protrusion/2)]) // PCB pocket on top
cube(PCBSize + Clearance + [0,0,Protrusion],center=true);
if (Channel)
translate(WireChannelOffset) // opening for wires from bottom side
cube(WireChannel + [0,0,Protrusion],center=true);
}
// Add-on bracket to hold smaller PCB upright at edge
PCB2Insert = [3.0,4.9,4.1];
PCB2OC = 45.0;
if (Layout == "Bracket")
difference() {
hull() // frame body block
for (x=[-1,1]) // bosses around screws
translate([x*(PCBSize[0]/2 + ScrewOffset),0,0])
cylinder(r=Washer4_40OD,h=OAHeight,$fn=NumSides);
for (x=[-1,1]) // frame screw holes
translate([x*(PCBSize[0]/2 + ScrewOffset),0,-Protrusion])
rotate(x*180/(2*6))
PolyCyl(Clear4_40,(OAHeight + 2*Protrusion),6);
for (x=[-1,1]) // PCB insert holes
translate([x*PCB2OC/2,(Washer4_40OD + Protrusion),OAHeight/2])
rotate([90,0,0])
cylinder(d=PCB2Insert[OD],h=2*(Washer4_40OD + Protrusion),$fn=6);
}
@ednisley

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commented Jun 10, 2017

More details on my blog at http://wp.me/poZKh-6Pn

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