remote-rig/hardware/case/camera-node-case-v4.scad

// RemoteRig camera node case v4
// Upright appliance-style OpenSCAD prototype for a strap-mounted camera node.
// Units: millimeters. Coordinate system: X=width, Y=depth/front-back, Z=height.
// Front/service lid is on the -Y face. Rear strap channels are on the +Y face.
//
// v4 visual direction: tall/upright appliance/control box matching the original
// reference image, replacing the rejected wide, low generic electronics box.
// Nominal body: 56 W x 36 D x 82 H mm; with low rear strap bridges ~40 D.
//
// Prototype assumptions to confirm against purchased parts:
// - 1.3 inch OLED module/window opening: 31 x 16 mm visible window, 37 x 22 mm panel recess.
// - Small rocker switch cutout: 13 x 19 mm rectangular snap-in opening.
// - LEDs: two 3 mm panel LEDs (PWR + RGB STAT) with 3.2 mm holes.
// - Boards: ESP32-C3 Super Mini 22.5 x 18 mm, ESP-01S 24.7 x 14.3 x 12 mm.

$fn = 56;

// ----- Main enclosure parameters -----
case_w = 56;                 // upright appliance-style external width
case_d = 36;                 // depth for module stack + wiring clearance
case_h = 82;                 // tall vertical appliance-style height
wall = 2.2;
corner_r = 4.0;
front_recess_d = 2.0;        // lid sits in this front pocket, nominally flush
lid_clearance = 0.35;
lid_w = case_w - 8;          // nearly full-height/front-width inset panel
lid_h = case_h - 8;
lid_t = 2.0;
lid_lip_t = 1.2;             // locating lip protrudes inside service opening
service_opening_w = lid_w - 10.0;
service_opening_h = lid_h - 16.0;

// Hardware
screw_d = 2.4;               // M2 self-tapping / pilot; confirm hardware
screw_head_d = 4.6;
boss_d = 6.0;
boss_len = 8.0;

// Front panel components
oled_window_w = 31.0;
oled_window_h = 16.0;
oled_bezel_w = 37.0;         // shallow recessed visual outline around window
oled_bezel_h = 22.0;
oled_z = 53.0;               // upper third, clear of top screw counterbores
led_hole_d = 3.2;            // 3 mm LED clearance
rocker_w = 13.0;             // prototype cutout; measure purchased rocker
rocker_h = 19.0;
front_slot_w = 34.0;         // two long rounded horizontal slots near lower front
front_slot_h = 3.2;

// Rear reusable cloth zip-tie / Velcro strap channels: low-profile external loops.
strap_bridge_w = case_w - 14;
strap_bridge_h = 6.5;        // outer raised rail height
strap_slot_h = 4.2;          // strap thickness opening; adjust for cloth ties
strap_gap_y = 2.4;           // clearance behind bridge for strap material
strap_bridge_y = strap_gap_y + 2.4;
strap_z1 = 23.0;
strap_z2 = 50.0;

// Cable exit
cable_notch_w = 13.0;
cable_notch_h = 6.5;

// ----- Utility geometry -----
module rounded_box(size=[10,10,10], r=2, center_xy=true) {
    // Rounded in XY, straight in Z.
    linear_extrude(height=size[2])
        offset(r=r)
            square([size[0]-2*r, size[1]-2*r], center=center_xy);
}

module xz_rounded_prism(w, d, h, r=2) {
    // Rounded rectangle in the visible X/Z plane, extruded through Y.
    rotate([-90,0,0])
        linear_extrude(height=d, center=true)
            offset(r=r)
                square([w-2*r, h-2*r], center=true);
}

module y_cylinder(d, h, center=true) {
    rotate([90,0,0]) cylinder(d=d, h=h, center=center);
}

module screw_boss(x, z) {
    translate([x, -case_d/2 + front_recess_d + boss_len/2, z])
        difference() {
            y_cylinder(d=boss_d, h=boss_len);
            y_cylinder(d=screw_d, h=boss_len + 0.8);
        }
}

module strap_bridge(zc) {
    // Low external rear belt-loop bridge for cloth ties/Velcro.
    // The slot is entirely behind the rear wall so it does not expose the
    // electronics cavity; a small overlap keeps the bridge connected to shell.
    bridge_overlap_y = 0.8;
    translate([0, case_d/2 + strap_bridge_y/2 - bridge_overlap_y, zc - strap_bridge_h/2])
        union() {
            difference() {
                rounded_box([strap_bridge_w, strap_bridge_y, strap_bridge_h], r=1.8);
                translate([0, -strap_bridge_y/2 + bridge_overlap_y + 0.05 + (strap_bridge_y + 1.0)/2,
                           (strap_bridge_h - strap_slot_h)/2])
                    rounded_box([strap_bridge_w - 9.0, strap_bridge_y + 1.0, strap_slot_h], r=1.1);
            }

            // Rear-wall weld pad: mechanically joins the external bridge to the
            // shell while keeping the belt slot outside the electronics cavity.
            translate([0, -strap_bridge_y/2 + bridge_overlap_y, strap_bridge_h/2])
                cube([strap_bridge_w, 0.9, strap_bridge_h], center=true);
        }
}

// ----- Printable body -----
module camera_node_body_v4() {
    difference() {
        union() {
            difference() {
                union() {
                    // Upright outer shell with softened appliance-like corners.
                    rounded_box([case_w, case_d, case_h], r=corner_r);

                    // Rear cloth zip-tie / Velcro strap bridges kept flat/quiet.
                    strap_bridge(strap_z1);
                    strap_bridge(strap_z2);
                }

                // Full-height front recessed lid pocket, like the green reference panel.
                translate([0, -case_d/2 + front_recess_d/2, case_h/2])
                    cube([lid_w + lid_clearance, front_recess_d + 0.4, lid_h + lid_clearance], center=true);

                // Through service opening behind the lid, leaving a strong inset frame.
                service_depth = front_recess_d + wall + 2.0;
                translate([0, -case_d/2 + service_depth/2, case_h/2])
                    xz_rounded_prism(service_opening_w, service_depth + 0.4, service_opening_h, r=2.0);

                // Interior electronics cavity: ESP32-C3 Super Mini + ESP-01S plus wiring/service clearance.
                cavity_d = case_d - front_recess_d - 2*wall;
                translate([0, -case_d/2 + front_recess_d + wall + cavity_d/2, case_h/2])
                    cube([case_w - 2*wall, cavity_d, case_h - 2*wall], center=true);

                // Bottom center cable exit / strain-relief notch.
                translate([0, -case_d/2 + 2.0, -0.05])
                    xz_rounded_prism(cable_notch_w, 9.0, cable_notch_h, r=1.8);
            }

            // Four protected screw bosses are added after shell hollowing so the
            // electronics cavity cannot cut away the receiving material.
            screw_x = lid_w/2 - 5.0;
            screw_z_low = (case_h - lid_h)/2 + 5.0;
            screw_z_high = case_h - screw_z_low;
            screw_boss(-screw_x, screw_z_low);
            screw_boss( screw_x, screw_z_low);
            screw_boss(-screw_x, screw_z_high);
            screw_boss( screw_x, screw_z_high);
        }

        // Final body-level pilot holes cut through the front frame into the protected bosses.
        screw_x = lid_w/2 - 5.0;
        screw_z_low = (case_h - lid_h)/2 + 5.0;
        screw_z_high = case_h - screw_z_low;
        for (x=[-screw_x, screw_x], z=[screw_z_low, screw_z_high])
            translate([x, -case_d/2 + front_recess_d + boss_len/2, z])
                y_cylinder(d=screw_d, h=boss_len + front_recess_d + 4.0);
    }
}

// ----- Printable front service lid / status panel -----
module camera_node_lid_v4() {
    difference() {
        union() {
            // Visible full-height flush panel; restrained and not a busy slab.
            rounded_box([lid_w, lid_t, lid_h], r=0.65);

            // Rear locating lip fits inside the large service opening.
            translate([0, lid_t/2 + lid_lip_t/2 - 0.2, lid_h/2])
                xz_rounded_prism(service_opening_w - 0.8, lid_lip_t, service_opening_h - 0.8, r=1.5);
        }

        // OLED window and shallow black-bezel-style recess near the top.
        translate([0, -lid_t/2 + 0.35, oled_z])
            xz_rounded_prism(oled_bezel_w, 0.9, oled_bezel_h, r=1.3);
        translate([0, -0.2, oled_z])
            xz_rounded_prism(oled_window_w, lid_t + lid_lip_t + 0.9, oled_window_h, r=0.5);

        // Subtle secondary indicators flanking the rocker, below the OLED bezel.
        translate([-15.0, -0.2, 33.0]) y_cylinder(d=led_hole_d, h=lid_t + lid_lip_t + 1.0);
        translate([ 15.0, -0.2, 33.0]) y_cylinder(d=led_hole_d, h=lid_t + lid_lip_t + 1.0);

        // Small rocker lower on the panel, offset away from the OLED, screws, and slots.
        translate([0, -0.2, 33.0])
            xz_rounded_prism(rocker_w, lid_t + lid_lip_t + 1.0, rocker_h, r=0.8);

        // Two long rounded horizontal slots near the lower front, matching the reference.
        translate([0, -0.2, 17.0])
            xz_rounded_prism(front_slot_w, lid_t + lid_lip_t + 1.0, front_slot_h, r=front_slot_h/2);
        translate([0, -0.2, 11.0])
            xz_rounded_prism(front_slot_w, lid_t + lid_lip_t + 1.0, front_slot_h, r=front_slot_h/2);

        // Screw clearance/counterbore holes.
        screw_x = lid_w/2 - 5.0;
        screw_z_low = 5.0;
        screw_z_high = lid_h - screw_z_low;
        for (x=[-screw_x, screw_x], z=[screw_z_low, screw_z_high]) {
            translate([x, -0.2, z]) y_cylinder(d=screw_d + 0.4, h=lid_t + lid_lip_t + 1.0);
            translate([x, -lid_t/2 + 0.55, z]) y_cylinder(d=screw_head_d, h=1.3);
        }
    }
}

// ----- Non-print preview assembly -----
module camera_node_preview_v4(show_lid=true) {
    color("lightgray") camera_node_body_v4();
    if (show_lid)
        translate([0, -case_d/2 + lid_t/2 + 0.03, (case_h - lid_h)/2])
            color("gainsboro") camera_node_lid_v4();

    // Dark OLED bezel/window cue for visual review only (not part of exported lid STL when rendering lid).
    if (show_lid)
        translate([0, -case_d/2 - 0.08, (case_h - lid_h)/2 + oled_z])
            color("black") xz_rounded_prism(oled_bezel_w, 0.6, oled_bezel_h, r=1.3);

    // Internal board volume guides (not printed): ESP32-C3 and ESP-01S envelopes.
    color([0,0.45,0,0.35]) translate([-9, -1, 26]) cube([22.5, 18, 4], center=true);
    color([0,0.2,0.8,0.35]) translate([9, -1, 45]) cube([24.7, 14.3, 12], center=true);
}

// Select part to render from OpenSCAD CLI with: -D 'part="body"'
part = "preview"; // "body", "lid", or "preview"

if (part == "body") {
    camera_node_body_v4();
} else if (part == "lid") {
    camera_node_lid_v4();
} else {
    camera_node_preview_v4();
}