latest changes

firmware/README.md

 For old-school debugging a serial port will be presented by the firmware.
 Open it using eg. `picocom`, or with the included `debug.sh` script.
 
+For dependencies to compile, on Arch install these.
+
+    sudo pacman -S arm-none-eabi-gcc arm-none-eabi-newlib picocom cmake
+
 ## Proper Debugging
 
 You can also use the SWD interface for proper hardware debugging.

hardware/external/pico_case.scad

+resolution = 20; //[10, 20, 30, 50, 100]
+$fn = resolution;
+
+show_frame = false; // [true, false]
+show_pico = true; // [true, false]
+show_lid = false; // [true, false]
+show_button = false; // [true, false]
+
+module rounded_plate(w, h, t, d) {
+    translate([0, (d/2), 0])
+    cube([w, (h-d), t]);
+    translate([(d/2), 0, 0])
+    cube([(w-d), h, t]);
+    translate([(d/2), (d/2), 0])
+    cylinder(h=t, d=d);
+    translate([w-(d/2), (d/2), 0])
+    cylinder(h=t, d=d);
+    translate([(d/2), h-(d/2), 0])
+    cylinder(h=t, d=d);
+    translate([w-(d/2), h-(d/2), 0])
+    cylinder(h=t, d=d);
+}
+
+module usb_port() {
+    translate([0.3, 0, 0])
+    color("grey")
+    difference() {
+        union() {
+            cube([7.4, 6, 2.7]);
+            translate([-0.3, 5.4, -0.1])
+            cube([8, 0.6, 2.9]);
+        }
+    }
+}
+
+module switch() {
+    color("grey")
+    cube([3.5, 4.5, 1]);
+    color("white")
+    translate([(3.5/2), (4.5/2), 0])
+    cylinder(h=1.5, d=3);
+}
+
+p_w = 21;
+p_h = 51;
+p_t = 1.0;
+os = 0.35;
+b = 2;
+
+module pico() {
+    translate([((p_w-8)/2), ((p_h+1.3)-6), p_t])
+    usb_port();
+
+    translate([5.25, 36.6, 0.6])
+    switch();
+
+    difference() {
+        color("green")
+        cube([p_w, p_h, 1]);
+
+        translate([((p_w/2)-5.7), 2, -0.01])
+        cylinder(h=p_t+0.02, d=2.1);
+       
+        translate([(p_w-((p_w/2)-5.7)), 2, -0.01])
+        cylinder(h=p_t+0.02, d=2.1);
+
+        translate([((p_w/2)-5.7), (p_h-2), -0.01])
+        cylinder(h=p_t+0.02, d=2.1);
+
+        translate([(p_w-((p_w/2)-5.7)), (p_h-2), -0.01])
+        cylinder(h=p_t+0.02, d=2.1);
+    }
+}
+
+if (show_pico) {
+    translate([(os+b), (os+b), 3.4])
+    pico();
+}
+
+if (show_frame) {
+    union() {
+        difference() {
+            // Outer frame
+            rounded_plate(p_w+(2*(os+b)), p_h+(2*(os+b)), 10, (2*(os+b)));
+            
+            // Board cut-out
+            translate([b, b, -1])
+            cube([p_w+(2*os), p_h+(2*os), 12]);
+            
+            // USB port cut-out
+//            translate([b+os+((p_w-10)/2), b+os+((p_h+1)-6), 3.4])
+//            cube([10, 8, 4.7]);
+            translate([b+os+((p_w-10)/2), b+(2*os)+p_h-1, 8.1])
+            rotate([-90, 0, 0])
+            rounded_plate(10, 4.7, 4.7, 2);
+            
+            // Lid release cut-out
+            difference() {
+                union() {
+                    translate([b+os+((p_w-10)/2), -1, 10-1])
+                    cube([10, 8, 2]);
+                    translate([b+os+((p_w-6)/2), -1, 10-1])
+                    rotate([-90, 0, 0])
+                    cylinder(h=4, d=2); 
+                    translate([b+os+((p_w-6)/2), -1, 10-2])
+                    cube([6, 8, 3]);
+                    translate([b+os+((p_w+6)/2), -1, 10-1])
+                    rotate([-90, 0, 0])
+                    cylinder(h=4, d=2); 
+                }
+                translate([b+os+((p_w+10)/2), -1, 10-1])
+                rotate([-90, 0, 0])
+                cylinder(h=4, d=2); 
+                translate([b+os+((p_w-10)/2), -1, 10-1])
+                rotate([-90, 0, 0])
+                cylinder(h=4, d=2); 
+            }
+            
+            // Outer frame
+            translate([1, 1, 10-1.2])
+            rounded_plate(p_w+(2*(os+b))-2, p_h+(2*(os+b))-2, 2, (2*(os+b))-2);
+
+            // Left top retainer cut-out
+            translate([b+os+(p_w/2)-(3.2/2)-7.1, b+p_h+(2*os), 10-3+0.2])
+            cube([3.2, 0.7, 1.0]);
+
+            // Right top retainer cut-out
+            translate([b+os+(p_w/2)-(3.2/2)+7.1, b+p_h+(2*os), 10-3+0.2])
+            cube([3.2, 0.7, 1.0]);
+
+            // Left bottom retainer cut-out
+            translate([b+os+(p_w/2)-(4/2)-7.1, b+os-0.7, 10-3+0.2])
+            cube([4, 0.7, 1.0]);
+
+            // Right bottom retainer cut-out
+            translate([b+os+(p_w/2)-(4/2)+7.1, b+os-0.7, 10-3+0.2])
+            cube([4, 0.7, 1.0]);
+
+            // Left retainer cut-out
+            translate([b-0.7, b+os+(p_h/2)-2, 10-3+0.2])
+            cube([0.7, 4, 1.0]);
+
+            // Right retainer cut-out
+            translate([b+(2*os)+p_w, b+os+(p_h/2)-2, 10-3+0.2])
+            cube([0.7, 4, 1.0]);
+        }
+        
+        // Left support rail
+        translate([b+os+(p_w/2)-(3/2)-5.5, 0, 0])
+        cube([3, p_h+(2*(os+b)), 3.4]);
+       
+        // Right support rail
+        translate([b+os+(p_w/2)-(3/2)+5.5, 0, 0])
+        cube([3, p_h+(2*(os+b)), 3.4]);
+
+        // Left top retainer
+        translate([b+os+(p_w/2)-(2.2/2)-6.1, b+p_h+(2*os)-0.6, 3.4+1+0.5])
+        cube([2.2, 0.6, 0.8]);
+
+        // Right top retainer
+        translate([b+os+(p_w/2)-(2.2/2)+6.1, b+p_h+(2*os)-0.6, 3.4+1+0.5])
+        cube([2.2, 0.6, 0.8]);
+
+        // Left bottom retainer
+        translate([b+os+(p_w/2)-(3/2)-5.7, b, 3.4+1+0.])
+        cube([3, 0.6, 0.8]);
+
+        // Right bottom retainer
+        translate([b+os+(p_w/2)-(3/2)+5.7, b, 3.4+1+0.5])
+        cube([3, 0.6, 0.8]);
+    }
+}
+
+if (show_lid) {
+    difference() {
+        union() {
+            translate([1+os, 1+os, 10-1.2])
+            rounded_plate(p_w+(2*b)-2, p_h+(2*b)-2, 1, (2*b)-2);
+            translate([(os+b), (os+b), 10-3])
+            rounded_plate(p_w, p_h, 2, (2*b)-3);
+            
+            // Left top retainer
+            translate([b+os+(p_w/2)-(2.2/2)-7.1, b+p_h+os, 10-3+0.4])
+            cube([2.2, 0.6, 0.6]);
+
+            // Right top retainer
+            translate([b+os+(p_w/2)-(2.2/2)+7.1, b+p_h+os, 10-3+0.4])
+            cube([2.2, 0.6, 0.6]);
+
+            // Left bottom retainer
+            translate([b+os+(p_w/2)-(3/2)-7.1, b+os-0.5, 10-3+0.3])
+            cube([3, 0.6, 0.6]);
+
+            // Right bottom retainer
+            translate([b+os+(p_w/2)-(3/2)+7.1, b+os-0.5, 10-3+0.3])
+            cube([3, 0.6, 0.6]);
+
+            // Left retainer
+            translate([b+os-0.6, b+os+(p_h/2)-1.5, 10-3+0.3])
+            cube([0.6, 3, 0.6]);            
+
+            // Right retainer
+            translate([b+os+p_w, b+os+(p_h/2)-1.5, 10-3+0.3])
+            cube([0.6, 3, 0.6]);            
+        }
+
+        // USB port cut-out
+        translate([b+os+((p_w-10)/2), b+p_h+(2*os)-2, 10-4.2])
+        cube([10, 8, 2.4]);
+
+        // Lid release cut-out
+        translate([b+os+((p_w-10)/2), -1, 10-4.2])
+        cube([10, 8, 3]);
+        
+        // Switch cut-out
+        translate([(os+b)+7, (os+b)+38.85, 0])
+        cylinder(h=10, d=5);
+        
+        // Inset
+        translate([(os+b)+1, (os+b)+1, 10-4])
+        cube([p_w-2, p_h-2, 3]);
+    }
+    // Switch surround
+    translate([(os+b), (os+b)+38.85-6, 10-2])
+    cube([p_w, 1, 1]);    
+
+    translate([(os+b), (os+b)+38.85+5, 10-2])
+    cube([p_w, 1, 1]);    
+
+}
+
+
+if (show_button) {
+    color("red")
+    union() {
+        translate([(os+b)+7, (os+b)+38.85, 7.5])
+        cylinder(h=2.3, d=4.4);
+        difference() {
+            translate([(os+b)+7, (os+b)+38.85, 6.5])
+            cylinder(h=2, d=7.6);
+            translate([(os+b)+7, (os+b)+38.85, 6.5])
+            cylinder(h=1, d=6.6);
+        }
+    }
+}

hardware/trackball.scad

 //roller_mount_tri();
 
 //trackball_top();
-trackball_bottom();
+//trackball_bottom();
 
-//assembly();
+assembly();
 //print();
 
 // #######################
 
 base_dia = 62;
 
-m3_thread = 2.7;
-m2_thread = 1.8;
+grub_screw_dia = 2.8;
+grub_channel_dia = 4.0;
 
 roller_thread_dia = roller_dia + 5.0;
 roller_h = roller_dia + 7.0;
 
 assembly_dist = 20;
 
+roller_holder_sider_cut = 1.5;
+roller_holder_h_compensation = -0.1;
+
+bottom_add_wall = 4;
+
+screw_dia = 3.2;
+screw_off = base_dia / 2 - 10;
+screw_head_d = 6.0;
+screw_head_h = 3.5;
+screw_angles = [ 15, -15, 180 + 15, 180 - 15 ];
+screw_insert_dia = 4.8;
+screw_insert_h = 6.0;
+
 function sphere_r_at_h(h, r) = r * sin(acos(h / r));
 function sphere_angle_at_rh(h, r) = acos(h / r);
 
     difference() {
         color("magenta")
         union() {
-            // top screw part
             translate([0, 0,  roller_h-roller_dia/2 + roller_ball_h_off-3])
             cylinder(d1 = roller_mount_dia, d2=roller_dia+1,  h = 3);
             
             cylinder(d = roller_mount_dia, h = roller_h-roller_dia/2 + roller_ball_h_off-3);
         }
         
+        translate([-roller_mount_dia / 2 - 1, roller_mount_dia / 2 - roller_holder_sider_cut, -1])
+        cube([roller_mount_dia + 2, roller_mount_dia / 2 + 1, roller_h + 2]);
+        
         translate([0, 0, -$e])
         cylinder(d = roller_thread_hole, h = $e+ roller_h - roller_dia / 2 + roller_ball_h_off + roller_ball_hold_off);
     
-        translate([0, 0, roller_h - roller_dia / 2])
+        translate([0, 0, roller_h - roller_dia / 2 + roller_holder_h_compensation])
         sphere(d = roller_dia, $fn = $fn * 2);
 
         if (cut_roller_holder)
     translate([0, 0, -roller_h/2])
     rotate([0,-90,0])
     translate([-2, 0, 2]) {
-        cylinder(d = m2_thread, h = ball_dia);
+        cylinder(d = grub_screw_dia, h = ball_dia);
         
         translate([0, 0, roller_mount_dia / 4 + wall])
-        cylinder(d = m2_thread + 1, h = ball_dia);
+        cylinder(d = grub_channel_dia, h = ball_dia);
     }
         
     // sensor lens
     }
 }
 
-bottom_add_wall = 4;
-
 module trackball_bottom_wrap() {
     %rotate([0, 180, 0])
     pico_wrap();
     }
 }
 
-screw_dia = 3.2;
-screw_off = base_dia / 2 - 10;
-screw_head_d = 6.0;
-screw_head_h = 3.5;
-screw_angles = [ 15, -15, 180 + 15, 180 - 15 ];
-screw_insert_dia = 4.8;
-screw_insert_h = 8.0;
-
 module trackball_bottom() {
     difference() {
         trackball_bottom_wrap();