// P6 project
// http://reso-nance.org/wiki/projets/p6/accueil
// Moule 3D pour un capteur piézo-électrique
// Moulage en silicone
// mars 2016
 
// Variables
$fn=80; // résolution
epaisseur=3; 
interieur=6;
 
// Affichage de l'objet
p6_mold();
 
// Objet 3D
module p6_mold(){
    container();
    piezo();
}
 
// Modules
module container(){
    difference(){
        cylinder(r = 26, h = epaisseur+interieur);
        translate([0,0,epaisseur]) cylinder(r = 23, h = interieur+1);    
  }
}
 
module piezo(){
    cylinder(r = 23, h = epaisseur);
    cylinder(r = 20, h = epaisseur + 3);
    cylinder(r = 14, h = epaisseur + 4);
   // pour les fils
    //translate([14,0,0]) cylinder(r = 2, h = epaisseur + interieur);
   rotate([90,0,0]) translate([-2,7,0]) cube([4,2,20]);
}

/*
 * P6 Box
 * Laser cuttable box for 6 piezo sensors
 *
 * http://reso-nance.org - 03/2016
 * GNU/GPLv3 license
 */
 
///////////////////////////////////////////////
thickness = 3; // épaisseur contreplaqué de 3mm
piezo_r = 23; // rayons des trous pour les piezo
margin = 10; // marges
nblayers = 8; // 8 couches
 
grid_unit = margin + piezo_r * 2;  
length = 3*grid_unit+margin;//178mm = 3 piezos
width = 2*grid_unit+margin;//122mm = 2 piezos
height = nblayers * thickness; //24mm
$fn = 90;
 
 
///////////////////////////////////////////////
p6_3d(); // 3d view
//p6_dxf(); // export to dxf
 
 
///////////////////////////////////////////////
module p6_dxf(){
    for (layer=[0:nblayers-1]){
        //x=layer*(width+margin);
        x=(layer%2)*(width+margin);
        y=round(layer/2)%(nblayers/2)*(length+margin);
        z=(layer*thickness)-height+1;
        rotate([0,0,-90]) projection(cut=true) translate([x,y,z]) 
        //plate(height);
         p6_3d();
    }
}
 
 
module p6_3d(){
     piezos(thickness,20);
     pcb_mount(20);
    //plate_drills(4*thickness,20);
    // Holes
    difference() {
        plate(height);  // Box shape
        plate_drills(3*thickness+0.05,4,5*thickness);
        piezos(2*thickness);
        wires(6*thickness);
        pcb();
        translate([margin,margin,thickness]) 
            plate(4*thickness, width-2*margin, length-2*margin);
        translate([margin,margin,1]) linear_extrude(height = 2) 
            text("P6", size = 60, font = str("Liberation Sans", ":style=Bold"));
        plate_drills(4*thickness+0.05,8,thickness);
    }
 
    difference(){
        plate_drills(4*thickness,20);
        plate_drills(4*thickness+0.05,8,thickness);
    }
}
 
///////////////////////////////////////////////
module piezos(h=thickness, r=piezo_r)
{        
    z = height - h;
    for (row=[1:3]){ // Grid of 2x3 piezos
        for (col=[1:2]){
            translate([col*grid_unit-piezo_r ,row*grid_unit-piezo_r, z]) 
            cylinder(h=h+0.05,r=r);
        }
    }
}
 
module plate(h=thickness, w=width, l=length, mink_r=10)
{
    translate([mink_r,mink_r,0]) minkowski()
    {
        cube([w-mink_r*2,l-mink_r*2,h]);
        cylinder(r=mink_r,h=0.01);
    }
}
 
module wires(h=thickness,w=7,l=4)
{
    z = height - thickness - h;
    for (row=[1:3]){
        for (col=[1:2]){
            translate([col*grid_unit-piezo_r-w/2 ,row*grid_unit-(piezo_r*2+l)+1, z]) 
            cube([w,l,h+0.05]);
        }
    }
}
module pcb()
{
    w=74;
    l=65;
    w2=24;
    margin=5;
    l2=15+margin;
    translate([(width-w2)/2,length-l2,3*thickness]) cube([w2,l2,2*thickness]); // plug
    difference(){
        translate([(width-w)/2,length-l-margin,thickness]) cube([w,l,2*thickness]);
        translate([(width-w+20)/2,length+10-l-margin,thickness]) cube([w-20,l-20,2*thickness]);
    }
}
 
module pcb_mount(){
     w=74;
    l=65;
     difference(){
        translate([(width-w)/2,3*margin,thickness]) 
         cube([w,l,2*thickness]);
        translate([(width-w)/2+10,3*margin+10,thickness]) 
         cube([w-20,l-20,2*thickness]);
    }
}
 
module plate_drills(h=thickness,d=3,z=thickness)
{
    translate([width-10,margin+2,z]) cylinder(d=d,h=h);
    translate([margin+2,length-10,z]) cylinder(d=d,h=h);
}