epaper_door_case/params.scad

// ============================================================
//  Shared Parameters
//  include <params.scad> in all component files
// ============================================================
include <BOSL2/std.scad>

/* [Design Style] */
EPD_IS_LID = true;   // true: epd_case forms the lid ceiling; false: flat ceiling plate

/* [Shared Case] */
WALL     = 2.0;
CORNER_R = 2.5;

/* [Display Dimensions — GDEY0583T81] */
DISP_W = 125.4;
DISP_D = 99.5;
DISP_T = 1.2;
ACT_W  = 118.78;
ACT_D  = 88.22;

/* [EPD Case Parameters] */
EPD_ANGLE    = 47;    // 0 = flat/inline; 90 = display face coplanar with lid Y+ wall
LIP          = 1.5;
TOL          = 0.3;
DISP_W_TOL   = 0.1;  // per-side width tolerance for display pocket (was TOL=0.3; tightened for snug fit)
CHAM         = 1.0;
CHAM_ANGLE   = 60;
BEZEL_Y      = 2.5;
BEZEL_YP     = 2.0;   // extra Y+ (bottom) bezel padding; shifts display toward Y- within the lid
FPC_BEND_R   = 4.0;
DISP_Y_EXTRA = 1.25;  // extra pocket depth at Y+ so display can seat 1.25mm further in

/* [EPD Case Derived] */
epd_cav_w  = DISP_W + DISP_W_TOL * 2;
epd_cav_d  = DISP_D + TOL;
epd_case_w = epd_cav_w + WALL * 2;
epd_case_h = WALL + DISP_T + LIP;
_fpc_x1    = WALL + TOL + DISP_W - 55.47 - 12.50 - 2.5;
_fpc_xw    = 12.50 + 5.0;
_fpc_ro    = FPC_BEND_R + 0.30 + TOL;
_bend_my   = BEZEL_Y + DISP_D + DISP_Y_EXTRA + sqrt(_fpc_ro*_fpc_ro - (FPC_BEND_R - WALL)*(FPC_BEND_R - WALL));
epd_case_d = max(epd_cav_d + WALL + BEZEL_Y, _bend_my + WALL) + BEZEL_YP;
_cham_xy   = CHAM * tan(CHAM_ANGLE);
WIN_W_EXTRA = 0.3;  // extra clearance added to each side of window vs. active area
epd_win_w  = ACT_W + 2 * WIN_W_EXTRA;
epd_win_x  = WALL + TOL + (DISP_W - ACT_W) / 2 - WIN_W_EXTRA;
epd_win_y  = 3.30 + BEZEL_Y;

/* [Board Dimensions — EE04] */
PCB_L       = 80.00;
PCB_W       = 41.22;
PCB_T       = 1.93;
COMP_MAX_Z  = 7.29;
COMP_SIDE_Z = 3.82;

/* [Sliding Lid] */
LID_T       = 1.5;
FLANGE_H    = 3.0;
FLANGE_W    = FLANGE_H * tan(30);
SLIDE_CLEAR = 0.40;
LIP_H       = FLANGE_H + 3;   // Y- lip height; increase to move split toward lid, decrease toward base

/* [FPC Notch — must match EPD case slot geometry] */
FPC_NOTCH_W = _fpc_xw;    // slot X width: cable 12.5 + 2×2.5 mm clearance
FPC_U_T     = LID_T;
FPC_SLOT_W  = 4.1;        // ≈ sqrt(_fpc_ro²−(FPC_BEND_R−WALL)²) at epd_case z=0

/* [+Y Wall Cutouts] */
PWR_CX      = 10.3;
PWR_W       = 5.0;
PWR_H       = 2.5;
PWR_CZ      = 3.8;
PWR_COVER_T = 0.6;

USBC_CX        = 65.65;
USBC_W         = 9.0;
USBC_H         = 3.22;
USBC_CZ        = 4.31;
USBC_CBL_CLEAR = 1.5;

BTN_CX = [48.4, 39.075, 29.725, 20.425];
BTN_D  = 2.3;
BTN_CZ = 3.85;

/* [Plunger] */
PLUNGER_D      = 2.0;
FLANGE_D       = 2.9;
FLANGE_T       = 1.2;
PLUNGER_HEAD_H = 1.5;

/* [CPU Case] */
FLOOR          = 2.0;
SCREW_D        = 3.2;
SCREW_PILOT_D  = 1.7;   // M2 self-tapper pilot, SLA resin
BOSS_D         = 6.0;
BOSS_H         = 2.0;

/* [Locating Studs] */
STUD_CLEAR  = 0.10;
STUD_H      = PCB_T + 1.0;
PCB_HOLE_D  = 2.5;                         // PCB locating hole diameter
STUD_R      = (PCB_HOLE_D - 2*STUD_CLEAR) / 2;  // 1.15 mm → 2.3 mm dia stud

/* [PCB Standoff Positions — relative to PCB origin] */
PCB_BOSS_X1 = 2.5;
PCB_BOSS_X2 = PCB_L - 2.5;
PCB_BOSS_Y1 = 2.5;
PCB_BOSS_Y2 = PCB_W - 2.5;

/* [Interior Clearances] */
CLR_XN   = 2.0;
CLR_XP   = 44.0;
CLR_YN   = 15.0;
CLR_YP   = 1.77;
CLR_LID  = 3.5;
BATT_W   = 34.5;
BATT_D   = 51.0;
BATT_T   = 6.3;
CLR_BATX = 1.5;
CLR_BATY = 1.5;

/* [CPU Case Derived] */
PCB_Z        = FLOOR + BOSS_H;
BASE_INNER_H = BOSS_H + COMP_MAX_Z + CLR_LID;
BASE_H       = FLOOR + BASE_INNER_H;
PCB_OX       = WALL + CLR_XN;
PCB_OY       = WALL + CLR_YN;
CAV_L        = CLR_XN + PCB_L + CLR_XP;
CAV_W        = CLR_YN + PCB_W + CLR_YP;
OUT_L        = CAV_L + 2*WALL;
OUT_W        = CAV_W + 2*WALL;
LID_H        = FLANGE_H + LID_T;
LID_Y_LEN    = CAV_W;

// FPC alignment — derived from EPD case geometry (replaces hardcoded values in old cpu_case)
FPC_CX      = OUT_L/2 - epd_case_w/2 + (_fpc_x1 + _fpc_xw/2) - PCB_OX;
FPC_U_DEPTH = FPC_U_T - WALL - 3 + (epd_case_d - (BEZEL_Y + DISP_D));

/* [Shared Helper] */
// Corner-anchored box (origin at the -X,-Y,-Z corner) with rounded vertical edges,
// matching the pre-BOSL2 hull-of-cylinders convention used throughout this project.
module rounded_box(l, w, h, r) {
    cuboid([l, w, h], rounding=r, edges="Z", anchor=BOTTOM+FRONT+LEFT, $fn=32);
}