hardware/DESIGN_PIPELINE.md

@@ -4,7 +4,7 @@
 
 ## Active / Ready for CAD prototype
 
-### Camera node case v4 — status panel + strap mount
+### Camera node case v4 — upright status panel + strap mount
 
 **Status:** Parametric OpenSCAD source created; body/lid/preview STLs exported and validated watertight. Ready for CAD review, exact part measurement, and first prototype print.
 
@@ -20,16 +20,18 @@
 
 **Design direction:**
 
-- Stand-mounted camera node enclosure; the case still does **not** mount to the GoPro.
-- Primary mounting is now reusable cloth zip ties / Velcro straps through rear case channels, not a clamp/dovetail.
-- Front has a recessed/flush service lid similar to a field-service status panel.
+- Stand-mounted upright camera node enclosure; the case still does **not** mount to the GoPro.
+- Visual direction now matches the original green appliance-style reference: tall vertical body, large inset front panel, centered OLED near the upper third, blank middle area, two long rounded lower slots, and bottom-center cable exit.
+- This replaces the rejected wide/low generic electronics-box layout from the first v4 attempt.
+- Primary mounting is reusable cloth zip ties / Velcro straps through low-profile external rear belt-loop channels, not a clamp/dovetail.
+- Front has a recessed/flush full-height service lid similar to a field-service status panel.
 - Lid includes cutouts for:
   - 1.3-inch OLED/status screen.
   - separate 3 mm power LED.
   - single 3 mm RGB status LED replacing red/green status LEDs.
   - small rocker on/off switch.
-  - lower vent/style slots.
-- Body includes screw bosses, recessed lid pocket, lid locating geometry, bottom cable exit/strain-relief notch, and two rear horizontal strap channels to resist rotation on a stand.
+  - two long rounded lower front slots styled after the reference.
+- Body includes screw bosses, recessed lid pocket, lid locating geometry, bottom cable exit/strain-relief notch, and two rear horizontal external belt-loop strap channels to resist rotation on a stand.
 - Internal envelope is sized for known module dimensions plus service clearance:
   - ESP32-C3 Super Mini: 22.5 × 18 mm.
   - ESP-01S: ~24.7 × 14.3 × 12 mm.

hardware/README.md

@@ -5,7 +5,7 @@
 
 ## Overview
 
-Each camera node is two ESP boards in a small stand-mounted case. The case **does not attach to the camera**; it straps to a tripod/lighting stand with reusable cloth zip ties / Velcro straps. Powered by a standard USB power bank.
+Each camera node is two ESP boards in a small upright stand-mounted case. The case **does not attach to the camera**; it straps to a tripod/lighting stand with reusable cloth zip ties / Velcro straps. Powered by a standard USB power bank.
 
 ```
      ┌─────────────────┐
@@ -31,7 +31,7 @@ Each camera node is two ESP boards in a small stand-mounted case. The case **doe
 |------|-----|------|-------|
 | ESP32-C3 Super Mini | 1 | ~$4–$6 | MQTT / hub-side bridge; known board envelope 22.5 × 18 mm |
 | ESP-01S / ESP8266 module | 1 | ~$2–$3 | Camera-side GoPro Wi-Fi bridge; known envelope ~24.7 × 14.3 × 12 mm |
-| 1.3-inch OLED/status screen | 1 | ~$4–$8 | Prototype CAD assumes ~31 × 16 mm visible window / ~35 × 19 mm panel clearance; confirm exact module |
+| 1.3-inch OLED/status screen | 1 | ~$4–$8 | Prototype CAD assumes ~31 × 16 mm visible window / ~37 × 22 mm panel recess; confirm exact module |
 | 3 mm power LED | 1 | <$1 | Separate always-power/5V indicator |
 | 3 mm RGB status LED | 1 | <$1 | Replaces separate red/green status LEDs; firmware can map node states to color |
 | Small rocker switch | 1 | ~$1–$3 | On/off switch; prototype CAD assumes 13 × 19 mm snap-in opening |
@@ -48,17 +48,17 @@ Each camera node is two ESP boards in a small stand-mounted case. The case **doe
 **Current source:** `hardware/case/camera-node-case-v4.scad`
 **Pipeline:** `hardware/DESIGN_PIPELINE.md`
 
-The v4 case replaces the v3 clamp/dovetail concept with a simpler strap-mounted field enclosure:
+The current v4 CAD replaces the rejected wide/low electronics-box layout with a tall appliance-style enclosure matching the original upright reference: a clean vertical body, large inset front panel, OLED near the top, open blank middle area, two long rounded lower slots, and a bottom-center cable exit. It also replaces the v3 clamp/dovetail concept with a simpler strap-mounted field enclosure:
 
 1. **Case body** — shell sized around ESP32-C3 Super Mini + ESP-01S with service/wiring clearance.
-2. **Flush/recessed front service lid** — screw-on front status panel with locating lip.
+2. **Flush/recessed full-height front service lid** — screw-on front panel with locating lip and a restrained raised/recessed border.
 3. **Front panel controls/indicators**:
    - 1.3-inch OLED/status screen window.
    - 3 mm **PWR** LED.
    - single 3 mm **RGB STAT** LED for state-dependent colors.
    - small rectangular rocker switch cutout.
-   - lower vent/style slots.
-4. **Rear strap channels** — two raised horizontal cloth zip-tie / Velcro strap paths to reduce rotation on a tripod/stand.
+   - two long rounded lower front slots styled after the reference appliance face.
+4. **Rear strap channels** — two low-profile external belt-loop cloth zip-tie / Velcro strap paths to reduce rotation on a tripod/stand without visually dominating the body.
 5. **Bottom cable exit** — cable/strain-relief notch for USB/power wiring.
 
 ### Export wrappers
@@ -167,12 +167,12 @@ Prototype v4 nominal CAD dimensions:
 
 | Part / feature | W × D × H (mm) |
 |---|---|
-| Case shell external | ~68 × 42 × 32 |
-| Case with rear strap bridges | ~68 × 45.2 × 32 |
-| Front recessed lid | visible panel ~60 × 2 × 26; total with locating lip ~60 × 3 × 26 |
+| Case shell external | ~56 × 36 × 82 |
+| Case with rear strap bridges | ~56 × 40 × 82 |
+| Front recessed lid | visible panel ~48 × 2 × 74; total with locating lip ~48 × 3 × 74 |
 | OLED visible window assumption | ~31 × 16 |
 | Rocker cutout assumption | ~13 × 19 |
-| Rear strap channels | two horizontal pass-through paths, ~48 mm usable slot width, ~4.2 mm strap-thickness clearance |
+| Rear strap channels | two low-profile external belt-loop paths, ~33 mm usable slot width, ~4.2 mm strap-thickness clearance |
 | Board clearance targets | ESP32-C3 22.5 × 18 mm + ESP-01S 24.7 × 14.3 × 12 mm plus wiring/service clearance |
 
 These dimensions are placeholders for the first CAD prototype. Measure the actual OLED module, rocker switch, LEDs, screws, USB cable bend radius, and strap width/thickness before committing to production prints.

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

@@ -1,33 +1,34 @@
 // RemoteRig camera node case v4
-// Parametric OpenSCAD prototype for a status-panel camera node enclosure.
+// 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, 35 x 19 mm panel clearance.
+// - 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.
 
-$fn = 48;
+$fn = 56;
 
 // ----- Main enclosure parameters -----
-case_w = 68;                 // external width; room for OLED + LEDs + switch
-case_d = 42;                 // external depth; board stack + wiring clearance
-case_h = 32;                 // external height
+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 = 3.0;
+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;
-lid_h = case_h - 6;
+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
-lid_lip_inset = 2.1;
-// Central body opening avoids the four corner screw bosses.  Separate local
-// clearances below handle the OLED/switch bodies without cutting away bosses.
-service_opening_w = 46.0;
-service_opening_h = 11.5;
+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
@@ -36,29 +37,29 @@ boss_d = 6.0;
 boss_len = 8.0;
 
 // Front panel components
-// OLED values are intentionally conservative prototype placeholders.
 oled_window_w = 31.0;
 oled_window_h = 16.0;
-oled_bezel_w = 35.0;         // engraved/recessed visual outline around window
-oled_bezel_h = 19.0;
+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;
-vent_slot_w = 7.0;
-vent_slot_h = 1.7;
+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
-strap_bridge_w = case_w - 12;
-strap_bridge_h = 7.5;        // outer raised tab height
+// 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 = 3.2;           // clearance behind bridge for strap material
-strap_bridge_y = strap_gap_y + 2.2;
-strap_z1 = 8.5;
-strap_z2 = 23.5;
+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 = 6.0;
+cable_notch_h = 6.5;
 
 // ----- Utility geometry -----
 module rounded_box(size=[10,10,10], r=2, center_xy=true) {
@@ -68,6 +69,14 @@ module rounded_box(size=[10,10,10], r=2, center_xy=true) {
             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);
 }
@@ -81,17 +90,23 @@ module screw_boss(x, z) {
 }
 
 module strap_bridge(zc) {
-    // Raised rear bridge with a smooth-ish strap tunnel through it.
-    // It intentionally overlaps the main shell by ~2.2 mm so the STL is a
-    // single printable body, not separate coincident strap-tab volumes.
-    translate([0, case_d/2 + strap_bridge_y/2 - 2.2, zc - strap_bridge_h/2])
+    // 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=2.0);
-            // Through-slot for the cloth tie.  It cuts all the way through Y,
-            // while leaving side posts that tie the upper/lower rails together.
-            // Matching rear-wall cutouts are made in camera_node_body_v4().
-            translate([0, 0, (strap_bridge_h - strap_slot_h)/2])
-                rounded_box([strap_bridge_w - 8.0, strap_bridge_y + 0.8, strap_slot_h], r=1.2);
+                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);
         }
 }
 
@@ -101,52 +116,37 @@ module camera_node_body_v4() {
         union() {
             difference() {
                 union() {
-                    // Outer shell.
-                    translate([0,0,0]) rounded_box([case_w, case_d, case_h], r=corner_r);
+                    // 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.
+                    // Rear cloth zip-tie / Velcro strap bridges kept flat/quiet.
                     strap_bridge(strap_z1);
                     strap_bridge(strap_z2);
                 }
 
-            // Front recessed lid pocket (shallow, so the lid can sit flush).
-            translate([0, -case_d/2 - 0.2, case_h/2])
-                cube([lid_w + lid_clearance, front_recess_d + 0.3, lid_h + lid_clearance], center=true);
+                // 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 recessed ledge/frame.
+                // 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])
-                cube([service_opening_w, service_depth + 0.4, service_opening_h], center=true);
-
-            // Local front clearances for the OLED module and rocker-switch body.
-            // These keep the screw-boss corner material intact while still leaving
-            // room for front-panel components and wiring to enter the body cavity.
-            translate([0, -case_d/2 + service_depth/2, (case_h - lid_h)/2 + lid_h - 9.5])
-                cube([oled_bezel_w + 2.0, service_depth + 0.4, oled_bezel_h + 3.0], center=true);
-            translate([15.5, -case_d/2 + service_depth/2, (case_h - lid_h)/2 + 12.0])
-                cube([rocker_w + 3.0, service_depth + 0.4, rocker_h + 3.0], center=true);
-
-            // Rear-wall pass-through slots for reusable cloth zip-ties / Velcro.
-            // The slots align with the raised bridges, so straps can thread through
-            // the back of the case instead of sitting in a closed decorative groove.
-            for (zc=[strap_z1, strap_z2])
-                translate([0, case_d/2 + 1.0, zc])
-                    cube([strap_bridge_w - 8.0, 8.0, strap_slot_h], center=true);
+                    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 cable exit / strain-relief notch on lower front edge.
+                // Bottom center cable exit / strain-relief notch.
                 translate([0, -case_d/2 + 2.0, -0.05])
-                cube([cable_notch_w, 9.0, cable_notch_h], center=true);
+                    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 + 4.2;
+            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);
@@ -154,11 +154,9 @@ module camera_node_body_v4() {
             screw_boss( screw_x, screw_z_high);
         }
 
-        // Final body-level pilot holes cut through the front frame into the
-        // protected bosses. Without this pass the boss pilot holes can be
-        // hidden behind solid frame material.
+        // 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 + 4.2;
+        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])
@@ -170,45 +168,41 @@ module camera_node_body_v4() {
 module camera_node_lid_v4() {
     difference() {
         union() {
-            // Visible flush panel.
-            translate([0,0,0]) rounded_box([lid_w, lid_t, lid_h], r=0.65);
+            // 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 central service opening and helps
-            // panel alignment.  Center it on the body's central opening so it
-            // does not collide with lower vent geometry.
-            lip_h = service_opening_h - 0.5;
-            translate([0, lid_t/2 + lid_lip_t/2 - 0.2, (lid_h - lip_h)/2])
-                rounded_box([service_opening_w - 0.5, lid_lip_t, lip_h], r=0.45);
-
-            // Shallow raised text pads/labels are omitted for print simplicity; add decals or paint-fill.
+            // 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 module outline/recess.
-        translate([0, -0.2, lid_h - 9.5])
-            cube([oled_window_w, lid_t + lid_lip_t + 0.8, oled_window_h], center=true);
-        translate([0, -0.35, lid_h - 9.5])
-            cube([oled_bezel_w, 0.7, oled_bezel_h], center=true);
+        // 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);
 
-        // LED holes: separate power LED and single RGB status LED.
-        translate([-17.0, -0.2, 11.5]) y_cylinder(d=led_hole_d, h=lid_t + lid_lip_t + 1.0);
-        translate([-9.0, -0.2, 11.5]) y_cylinder(d=led_hole_d, h=lid_t + lid_lip_t + 1.0);
+        // 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);
 
-        // Rocker switch snap-in opening.
-        translate([15.5, -0.2, 12.0])
-            cube([rocker_w, lid_t + lid_lip_t + 1.0, rocker_h], center=true);
+        // 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);
 
-        // Lower vent / style slots.
-        for (i=[-2:2])
-            translate([i*9.5, -0.2, 4.8])
-                cube([vent_slot_w, lid_t + lid_lip_t + 1.0, vent_slot_h], center=true);
+        // 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 = 4.2;
+        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, -0.15, z]) y_cylinder(d=screw_head_d, h=1.2);
+            translate([x, -lid_t/2 + 0.55, z]) y_cylinder(d=screw_head_d, h=1.3);
         }
     }
 }
@@ -217,12 +211,17 @@ module camera_node_lid_v4() {
 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 - 0.2, (case_h - lid_h)/2])
+        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([-13, -1, 9]) cube([22.5, 18, 4], center=true);
-    color([0,0.2,0.8,0.35]) translate([13, -1, 20]) cube([24.7, 14.3, 12], center=true);
+    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"'