some work on firmware and 3d design

firmware/include/pmw3360.h

@@ -5,7 +5,14 @@
 #ifndef __PMW3360_H__
 #define __PMW3360_H__
 
+struct pmw_motion {
+    bool motion;
+    int32_t delta_x;
+    int32_t delta_y;
+};
+
 int pmw_init(void);
+struct pmw_motion pmw_get(void);
 
 /*
  * 0x00: 100 cpi (minimum cpi)

firmware/include/usb_hid.h

@@ -5,6 +5,11 @@
 #ifndef __USB_HID_H__
 #define __USB_HID_H__
 
+struct usb_hid_mouse {
+    int32_t delta_x;
+    int32_t delta_y;
+};
+
 void hid_task(void);
 
 #endif // __USB_HID_H__

firmware/include/util.h

@@ -8,6 +8,8 @@
 void heartbeat_init(void);
 void heartbeat_run(void);
 
+int32_t convert_two_complement(int32_t b);
+
 bool str_startswith(const char *str, const char *start);
 
 void reset_to_bootloader(void);

firmware/src/pmw3360.c

@@ -31,6 +31,9 @@
 #error PMW3360 API requires a board with SPI pins
 #endif
 
+static volatile int32_t delta_x = 0, delta_y = 0;
+static volatile bool mouse_motion = false;
+
 #ifdef PMW_IRQ_COUNTERS
 static uint64_t pmw_irq_count_all = 0;
 static uint64_t pmw_irq_count_motion = 0;
@@ -57,6 +60,26 @@ void pmw_print_status(void) {
 #endif // PMW_IRQ_COUNTERS
 }
 
+struct pmw_motion pmw_get(void) {
+    struct pmw_motion r;
+    r.motion = mouse_motion;
+    r.delta_x = 0;
+    r.delta_y = 0;
+
+    if (r.motion) {
+        gpio_set_irq_enabled(PMW_MOTION_PIN, GPIO_IRQ_EDGE_FALL, false);
+
+        r.delta_x = delta_x;
+        r.delta_y = delta_y;
+        delta_x = 0;
+        delta_y = 0;
+
+        gpio_set_irq_enabled(PMW_MOTION_PIN, GPIO_IRQ_EDGE_FALL, true);
+    }
+
+    return r;
+}
+
 static inline void pmw_cs_select() {
     asm volatile("nop \n nop \n nop");
     gpio_put(PICO_DEFAULT_SPI_CSN_PIN, 0); // Active low
@@ -225,16 +248,6 @@ static void pmw_spi_init(void) {
     bi_decl(bi_1pin_with_name(PICO_DEFAULT_SPI_CSN_PIN, "SPI CS"));
 }
 
-// TODO
-int16_t delta_x = 0, delta_y = 0;
-int convTwosComp(int b){
-    //Convert from 2's complement
-    if(b & 0x8000){
-        b = -1 * ((b ^ 0xffff) + 1);
-    }
-    return b;
-}
-
 static void pmw_handle_interrupt(void) {
     struct pmw_motion_report motion_report = pmw_motion_read();
 
@@ -265,8 +278,12 @@ static void pmw_handle_interrupt(void) {
     }
 #endif // PMW_IRQ_COUNTERS
 
-    delta_x += convTwosComp(motion_report.delta_x_l | (motion_report.delta_x_h << 8));
-    delta_y += convTwosComp(motion_report.delta_y_l | (motion_report.delta_y_h << 8));
+    uint16_t delta_x_raw = motion_report.delta_x_l | (motion_report.delta_x_h << 8);
+    uint16_t delta_y_raw = motion_report.delta_y_l | (motion_report.delta_y_h << 8);
+
+    delta_x += convert_two_complement(delta_x_raw);
+    delta_y += convert_two_complement(delta_y_raw);
+    mouse_motion = true;
 }
 
 static void pmw_motion_irq(void) {

firmware/src/usb_hid.c

@@ -30,9 +30,6 @@
 #include "usb_descriptors.h"
 #include "usb_hid.h"
 
-// TODO
-extern int16_t delta_x, delta_y;
-
 static void send_hid_report(uint8_t report_id, uint32_t btn) {
     // skip if hid is not ready yet
     if ( !tud_hid_ready() ) return;

firmware/src/util.c

@@ -41,6 +41,13 @@ bool str_startswith(const char *str, const char *start) {
     return (strncmp(str, start, l) == 0);
 }
 
+int32_t convert_two_complement(int32_t b) {
+    if (b & 0x8000) {
+        b = -1 * ((b ^ 0xffff) + 1);
+    }
+    return b;
+}
+
 void reset_to_bootloader(void) {
 #ifdef PICO_DEFAULT_LED_PIN
     reset_usb_boot(1 << PICO_DEFAULT_LED_PIN, 0);

hardware/external/threads.scad

@@ -1,431 +0,0 @@
-/*
- * ISO-standard metric threads, following this specification:
- *          http://en.wikipedia.org/wiki/ISO_metric_screw_thread
- *
- * Copyright 2022 Dan Kirshner - dan_kirshner@yahoo.com
- * This program is free software: you can redistribute it and/or modify
- * it under the terms of the GNU General Public License as published by
- * the Free Software Foundation, either version 3 of the License, or
- * (at your option) any later version.
- *
- * This program is distributed in the hope that it will be useful,
- * but WITHOUT ANY WARRANTY; without even the implied warranty of
- * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
- * GNU General Public License for more details.
- *
- * See <http://www.gnu.org/licenses/>.
- *
- * Version 2.7.  2022-02-27  Increase minimum thread segments.
- * Version 2.6.  2021-05-16  Contributed patches for leadin (thanks,
-                             jeffery.spirko@tamucc.edu) and aligning thread
-                             "facets" (triangulation) with base cylinder
-                             (thanks, rambetter@protonmail.com).
- * Version 2.5.  2020-04-11  Leadin option works for internal threads.
- * Version 2.4.  2019-07-14  Add test option - do not render threads.
- * Version 2.3.  2017-08-31  Default for leadin: 0 (best for internal threads).
- * Version 2.2.  2017-01-01  Correction for angle; leadfac option.  (Thanks to
- *                           Andrew Allen <a2intl@gmail.com>.)
- * Version 2.1.  2016-12-04  Chamfer bottom end (low-z); leadin option.
- * Version 2.0.  2016-11-05  Backwards compatibility (earlier OpenSCAD) fixes.
- * Version 1.9.  2016-07-03  Option: tapered.
- * Version 1.8.  2016-01-08  Option: (non-standard) angle.
- * Version 1.7.  2015-11-28  Larger x-increment - for small-diameters.
- * Version 1.6.  2015-09-01  Options: square threads, rectangular threads.
- * Version 1.5.  2015-06-12  Options: thread_size, groove.
- * Version 1.4.  2014-10-17  Use "faces" instead of "triangles" for polyhedron
- * Version 1.3.  2013-12-01  Correct loop over turns -- don't have early cut-off
- * Version 1.2.  2012-09-09  Use discrete polyhedra rather than linear_extrude ()
- * Version 1.1.  2012-09-07  Corrected to right-hand threads!
- */
-
-// Examples.
-//
-// Standard M8 x 1.
-// metric_thread (diameter=8, pitch=1, length=4);
-
-// Square thread.
-// metric_thread (diameter=8, pitch=1, length=4, square=true);
-
-// Non-standard: long pitch, same thread size.
-//metric_thread (diameter=8, pitch=4, length=4, thread_size=1, groove=true);
-
-// Non-standard: 20 mm diameter, long pitch, square "trough" width 3 mm,
-// depth 1 mm.
-//metric_thread (diameter=20, pitch=8, length=16, square=true, thread_size=6,
-//               groove=true, rectangle=0.333);
-
-// English: 1/4 x 20.
-//english_thread (diameter=1/4, threads_per_inch=20, length=1);
-
-// Tapered.  Example -- pipe size 3/4" -- per:
-// http://www.engineeringtoolbox.com/npt-national-pipe-taper-threads-d_750.html
-// english_thread (diameter=1.05, threads_per_inch=14, length=3/4, taper=1/16);
-
-// Thread for mounting on Rohloff hub.
-//difference () {
-//   cylinder (r=20, h=10, $fn=100);
-//
-//   metric_thread (diameter=34, pitch=1, length=10, internal=true, n_starts=6);
-//}
-
-
-// ----------------------------------------------------------------------------
-function segments (diameter) = min (150, max (ceil (diameter*6), 25));
-
-
-// ----------------------------------------------------------------------------
-// diameter -    outside diameter of threads in mm. Default: 8.
-// pitch    -    thread axial "travel" per turn in mm.  Default: 1.
-// length   -    overall axial length of thread in mm.  Default: 1.
-// internal -    true = clearances for internal thread (e.g., a nut).
-//               false = clearances for external thread (e.g., a bolt).
-//               (Internal threads should be "cut out" from a solid using
-//               difference ()).  Default: false.
-// n_starts -    Number of thread starts (e.g., DNA, a "double helix," has
-//               n_starts=2).  See wikipedia Screw_thread.  Default: 1.
-// thread_size - (non-standard) axial width of a single thread "V" - independent
-//               of pitch.  Default: same as pitch.
-// groove      - (non-standard) true = subtract inverted "V" from cylinder
-//                (rather thanadd protruding "V" to cylinder).  Default: false.
-// square      - true = square threads (per
-//               https://en.wikipedia.org/wiki/Square_thread_form).  Default:
-//               false.
-// rectangle   - (non-standard) "Rectangular" thread - ratio depth/(axial) width
-//               Default: 0 (standard "v" thread).
-// angle       - (non-standard) angle (deg) of thread side from perpendicular to
-//               axis (default = standard = 30 degrees).
-// taper       - diameter change per length (National Pipe Thread/ANSI B1.20.1
-//               is 1" diameter per 16" length). Taper decreases from 'diameter'
-//               as z increases.  Default: 0 (no taper).
-// leadin      - 0 (default): no chamfer; 1: chamfer (45 degree) at max-z end;
-//               2: chamfer at both ends, 3: chamfer at z=0 end.
-// leadfac     - scale of leadin chamfer length (default: 1.0 = 1/2 thread).
-// test        - true = do not render threads (just draw "blank" cylinder).
-//               Default: false (draw threads).
-module metric_thread (diameter=8, pitch=1, length=1, internal=false, n_starts=1,
-                      thread_size=-1, groove=false, square=false, rectangle=0,
-                      angle=30, taper=0, leadin=0, leadfac=1.0, test=false)
-{
-   // thread_size: size of thread "V" different than travel per turn (pitch).
-   // Default: same as pitch.
-   local_thread_size = thread_size == -1 ? pitch : thread_size;
-   local_rectangle = rectangle ? rectangle : 1;
-
-   n_segments = segments (diameter);
-   h = (test && ! internal) ? 0 : (square || rectangle) ? local_thread_size*local_rectangle/2 : local_thread_size / (2 * tan(angle));
-
-   h_fac1 = (square || rectangle) ? 0.90 : 0.625;
-
-   // External thread includes additional relief.
-   h_fac2 = (square || rectangle) ? 0.95 : 5.3/8;
-
-   tapered_diameter = diameter - length*taper;
-
-   difference () {
-      union () {
-         if (! groove) {
-            if (! test) {
-               metric_thread_turns (diameter, pitch, length, internal, n_starts,
-                                    local_thread_size, groove, square, rectangle, angle,
-                                    taper);
-            }
-         }
-
-         difference () {
-
-            // Solid center, including Dmin truncation.
-            if (groove) {
-               cylinder (r1=diameter/2, r2=tapered_diameter/2,
-                         h=length, $fn=n_segments);
-            } else if (internal) {
-               cylinder (r1=diameter/2 - h*h_fac1, r2=tapered_diameter/2 - h*h_fac1,
-                         h=length, $fn=n_segments);
-            } else {
-
-               // External thread.
-               cylinder (r1=diameter/2 - h*h_fac2, r2=tapered_diameter/2 - h*h_fac2,
-                         h=length, $fn=n_segments);
-            }
-
-            if (groove) {
-               if (! test) {
-                  metric_thread_turns (diameter, pitch, length, internal, n_starts,
-                                       local_thread_size, groove, square, rectangle,
-                                       angle, taper);
-               }
-            }
-         }
-
-         // Internal thread lead-in: take away from external solid.
-         if (internal) {
-
-            // "Negative chamfer" z=0 end if leadin is 2 or 3.
-            if (leadin == 2 || leadin == 3) {
-
-               // Fixes by jeffery.spirko@tamucc.edu.
-               cylinder (r1=diameter/2 - h + h*h_fac1*leadfac,
-                         r2=diameter/2 - h,
-                         h=h*h_fac1*leadfac, $fn=n_segments);
-               /*
-               cylinder (r1=diameter/2,
-                         r2=diameter/2 - h*h_fac1*leadfac,
-                         h=h*h_fac1*leadfac, $fn=n_segments);
-               */
-            }
-
-            // "Negative chamfer" z-max end if leadin is 1 or 2.
-            if (leadin == 1 || leadin == 2) {
-               translate ([0, 0, length + 0.05 - h*h_fac1*leadfac]) {
-
-                  cylinder (r1=tapered_diameter/2 - h,
-                            h=h*h_fac1*leadfac,
-                            r2=tapered_diameter/2 - h + h*h_fac1*leadfac,
-                            $fn=n_segments);
-                  /*
-                  cylinder (r1=tapered_diameter/2 - h*h_fac1*leadfac,
-                            h=h*h_fac1*leadfac,
-                            r2=tapered_diameter/2,
-                            $fn=n_segments);
-                  */
-               }
-            }
-         }
-      }
-
-      if (! internal) {
-
-         // Chamfer z=0 end if leadin is 2 or 3.
-         if (leadin == 2 || leadin == 3) {
-            difference () {
-               cylinder (r=diameter/2 + 1, h=h*h_fac1*leadfac, $fn=n_segments);
-
-               cylinder (r2=diameter/2, r1=diameter/2 - h*h_fac1*leadfac, h=h*h_fac1*leadfac,
-                         $fn=n_segments);
-            }
-         }
-
-         // Chamfer z-max end if leadin is 1 or 2.
-         if (leadin == 1 || leadin == 2) {
-            translate ([0, 0, length + 0.05 - h*h_fac1*leadfac]) {
-               difference () {
-                  cylinder (r=diameter/2 + 1, h=h*h_fac1*leadfac, $fn=n_segments);
-
-                  cylinder (r1=tapered_diameter/2, r2=tapered_diameter/2 - h*h_fac1*leadfac, h=h*h_fac1*leadfac,
-                            $fn=n_segments);
-               }
-            }
-         }
-      }
-   }
-}
-
-
-// ----------------------------------------------------------------------------
-// Input units in inches.
-// Note: units of measure in drawing are mm!
-module english_thread (diameter=0.25, threads_per_inch=20, length=1,
-                      internal=false, n_starts=1, thread_size=-1, groove=false,
-                      square=false, rectangle=0, angle=30, taper=0, leadin=0,
-                      leadfac=1.0, test=false)
-{
-   // Convert to mm.
-   mm_diameter = diameter*25.4;
-   mm_pitch = (1.0/threads_per_inch)*25.4;
-   mm_length = length*25.4;
-
-   echo (str ("mm_diameter: ", mm_diameter));
-   echo (str ("mm_pitch: ", mm_pitch));
-   echo (str ("mm_length: ", mm_length));
-   metric_thread (mm_diameter, mm_pitch, mm_length, internal, n_starts,
-                  thread_size, groove, square, rectangle, angle, taper, leadin,
-                  leadfac, test);
-}
-
-// ----------------------------------------------------------------------------
-module metric_thread_turns (diameter, pitch, length, internal, n_starts,
-                            thread_size, groove, square, rectangle, angle,
-                            taper)
-{
-   // Number of turns needed.
-   n_turns = floor (length/pitch);
-
-   intersection () {
-
-      // Start one below z = 0.  Gives an extra turn at each end.
-      for (i=[-1*n_starts : n_turns+1]) {
-         translate ([0, 0, i*pitch]) {
-            metric_thread_turn (diameter, pitch, internal, n_starts,
-                                thread_size, groove, square, rectangle, angle,
-                                taper, i*pitch);
-         }
-      }
-
-      // Cut to length.
-      translate ([0, 0, length/2]) {
-         cube ([diameter*3, diameter*3, length], center=true);
-      }
-   }
-}
-
-
-// ----------------------------------------------------------------------------
-module metric_thread_turn (diameter, pitch, internal, n_starts, thread_size,
-                           groove, square, rectangle, angle, taper, z)
-{
-   n_segments = segments (diameter);
-   fraction_circle = 1.0/n_segments;
-   for (i=[0 : n_segments-1]) {
-
-      // Keep polyhedron "facets" aligned -- circumferentially -- with base
-      // cylinder facets.  (Patch contributed by rambetter@protonmail.com.)
-      rotate ([0, 0, (i + 0.5)*360*fraction_circle + 90]) {
-         translate ([0, 0, i*n_starts*pitch*fraction_circle]) {
-            //current_diameter = diameter - taper*(z + i*n_starts*pitch*fraction_circle);
-            thread_polyhedron ((diameter - taper*(z + i*n_starts*pitch*fraction_circle))/2,
-                               pitch, internal, n_starts, thread_size, groove,
-                               square, rectangle, angle);
-         }
-      }
-   }
-}
-
-
-// ----------------------------------------------------------------------------
-module thread_polyhedron (radius, pitch, internal, n_starts, thread_size,
-                          groove, square, rectangle, angle)
-{
-   n_segments = segments (radius*2);
-   fraction_circle = 1.0/n_segments;
-
-   local_rectangle = rectangle ? rectangle : 1;
-
-   h = (square || rectangle) ? thread_size*local_rectangle/2 : thread_size / (2 * tan(angle));
-   outer_r = radius + (internal ? h/20 : 0); // Adds internal relief.
-   //echo (str ("outer_r: ", outer_r));
-
-   // A little extra on square thread -- make sure overlaps cylinder.
-   h_fac1 = (square || rectangle) ? 1.1 : 0.875;
-   inner_r = radius - h*h_fac1; // Does NOT do Dmin_truncation - do later with
-                                // cylinder.
-
-   translate_y = groove ? outer_r + inner_r : 0;
-   reflect_x   = groove ? 1 : 0;
-
-   // Make these just slightly bigger (keep in proportion) so polyhedra will
-   // overlap.
-   x_incr_outer = (! groove ? outer_r : inner_r) * fraction_circle * 2 * PI * 1.02;
-   x_incr_inner = (! groove ? inner_r : outer_r) * fraction_circle * 2 * PI * 1.02;
-   z_incr = n_starts * pitch * fraction_circle * 1.005;
-
-   /*
-    (angles x0 and x3 inner are actually 60 deg)
-
-                          /\  (x2_inner, z2_inner) [2]
-                         /  \
-   (x3_inner, z3_inner) /    \
-                  [3]   \     \
-                        |\     \ (x2_outer, z2_outer) [6]
-                        | \    /
-                        |  \  /|
-             z          |[7]\/ / (x1_outer, z1_outer) [5]
-             |          |   | /
-             |   x      |   |/
-             |  /       |   / (x0_outer, z0_outer) [4]
-             | /        |  /     (behind: (x1_inner, z1_inner) [1]
-             |/         | /
-    y________|          |/
-   (r)                  / (x0_inner, z0_inner) [0]
-
-   */
-
-   x1_outer = outer_r * fraction_circle * 2 * PI;
-
-   z0_outer = (outer_r - inner_r) * tan(angle);
-   //echo (str ("z0_outer: ", z0_outer));
-
-   //polygon ([[inner_r, 0], [outer_r, z0_outer],
-   //        [outer_r, 0.5*pitch], [inner_r, 0.5*pitch]]);
-   z1_outer = z0_outer + z_incr;
-
-   // Give internal square threads some clearance in the z direction, too.
-   bottom = internal ? 0.235 : 0.25;
-   top    = internal ? 0.765 : 0.75;
-
-   translate ([0, translate_y, 0]) {
-      mirror ([reflect_x, 0, 0]) {
-
-         if (square || rectangle) {
-
-            // Rule for face ordering: look at polyhedron from outside: points must
-            // be in clockwise order.
-            polyhedron (
-               points = [
-                         [-x_incr_inner/2, -inner_r, bottom*thread_size],         // [0]
-                         [x_incr_inner/2, -inner_r, bottom*thread_size + z_incr], // [1]
-                         [x_incr_inner/2, -inner_r, top*thread_size + z_incr],    // [2]
-                         [-x_incr_inner/2, -inner_r, top*thread_size],            // [3]
-
-                         [-x_incr_outer/2, -outer_r, bottom*thread_size],         // [4]
-                         [x_incr_outer/2, -outer_r, bottom*thread_size + z_incr], // [5]
-                         [x_incr_outer/2, -outer_r, top*thread_size + z_incr],    // [6]
-                         [-x_incr_outer/2, -outer_r, top*thread_size]             // [7]
-                        ],
-
-               faces = [
-                         [0, 3, 7, 4],  // This-side trapezoid
-
-                         [1, 5, 6, 2],  // Back-side trapezoid
-
-                         [0, 1, 2, 3],  // Inner rectangle
-
-                         [4, 7, 6, 5],  // Outer rectangle
-
-                         // These are not planar, so do with separate triangles.
-                         [7, 2, 6],     // Upper rectangle, bottom
-                         [7, 3, 2],     // Upper rectangle, top
-
-                         [0, 5, 1],     // Lower rectangle, bottom
-                         [0, 4, 5]      // Lower rectangle, top
-                        ]
-            );
-         } else {
-
-            // Rule for face ordering: look at polyhedron from outside: points must
-            // be in clockwise order.
-            polyhedron (
-               points = [
-                         [-x_incr_inner/2, -inner_r, 0],                        // [0]
-                         [x_incr_inner/2, -inner_r, z_incr],                    // [1]
-                         [x_incr_inner/2, -inner_r, thread_size + z_incr],      // [2]
-                         [-x_incr_inner/2, -inner_r, thread_size],              // [3]
-
-                         [-x_incr_outer/2, -outer_r, z0_outer],                 // [4]
-                         [x_incr_outer/2, -outer_r, z0_outer + z_incr],         // [5]
-                         [x_incr_outer/2, -outer_r, thread_size - z0_outer + z_incr], // [6]
-                         [-x_incr_outer/2, -outer_r, thread_size - z0_outer]    // [7]
-                        ],
-
-               faces = [
-                         [0, 3, 7, 4],  // This-side trapezoid
-
-                         [1, 5, 6, 2],  // Back-side trapezoid
-
-                         [0, 1, 2, 3],  // Inner rectangle
-
-                         [4, 7, 6, 5],  // Outer rectangle
-
-                         // These are not planar, so do with separate triangles.
-                         [7, 2, 6],     // Upper rectangle, bottom
-                         [7, 3, 2],     // Upper rectangle, top
-
-                         [0, 5, 1],     // Lower rectangle, bottom
-                         [0, 4, 5]      // Lower rectangle, top
-                        ]
-            );
-         }
-      }
-   }
-}
-
-
-

hardware/trackball.scad

@@ -15,9 +15,6 @@
  * For the PMW3360 breakout board get this:
  * https://github.com/jfedor2/pmw3360-breakout
  *
- * The "Threads" library used by this project is:
- * Copyright 2022 Dan Kirshner - dan_kirshner@yahoo.com
- *
  * This program is free software: you can redistribute it and/or modify
  * it under the terms of the GNU General Public License as published by
  * the Free Software Foundation, either version 3 of the License, or
@@ -34,10 +31,6 @@
 // https://www.thingiverse.com/thing:421524
 use <external/cherry_mx.scad>
 
-// https://dkprojects.net/openscad-threads/
-use <external/threads.scad>
-//use <threadlib.scad>
-
 // ######################
 // ## Rendering Select ##
 // ######################
@@ -48,7 +41,9 @@ use <external/threads.scad>
 //mx_switch_cutout(wall);
 //mx_switch_test();
 //roller_mount_test();
+
 roller_mount_tri();
+
 //roller_holder();
 //trackball();
 
@@ -63,12 +58,11 @@ roller_ball_h = 8;
 roller_count = 3;
 
 wall = 3.0;
-
-cut_roller_holder = false;
-draw_threads = true;
 $c = 0.1;
 $e = 0.01;
 
+cut_roller_holder = false;
+
 // #######################
 // ## Raspberry Pi Pico ##
 // #######################
@@ -124,6 +118,16 @@ sensor_pin_pitch = 0.89;
 
 sensor_pin1_to_optical_center = 5.66;
 
+sensor_lens_cutout_r = 2.0;
+sensor_lens_cutout_w = 4.0;
+sensor_lens_cutout_growth = 0.25;
+sensor_lens_cutout_to_chip = 6.71 - 1.60;
+sensor_lens_baseplate_h = 2.40;
+
+sensor_lens_d = 19.0;
+sensor_lens_w = 21.35;
+sensor_lens_off = 10.97;
+
 // ######################
 // ## MX Switch Cutout ##
 // ######################
@@ -149,10 +153,12 @@ mx_travel = 3.9;
 // ### Implementation ###
 // ######################
 
-m3_thread=2.7;
-m2_thread=1.8;
+base_dia = pico_l + 9;
+
+m3_thread = 2.7;
+m2_thread = 1.8;
+
 roller_thread_dia = roller_dia + 5.0;
-roller_thread_pitch = 2.0;
 roller_h = roller_dia + 7.0;
 roller_ball_h_off = 0.4;
 roller_ball_hold_off = 0.5;
@@ -167,7 +173,7 @@ ball_h = 15; // todo
 
 switch_test_w = 25;
 
-$fn = 42;
+$fn = 100;
 
 function sphere_r_at_h(h, r) = r * sin(acos(h / r));
 function sphere_angle_at_rh(h, r) = acos(h / r);
@@ -230,6 +236,38 @@ module pico() {
     }
 }
 
+module sensor_lens_cutout_intern() {
+    cylinder(d = sensor_lens_cutout_r * 2, h = $e);
+    
+    translate([-sensor_lens_cutout_r, 0, 0])
+    cube([sensor_lens_cutout_r * 2, sensor_lens_cutout_w, $e]);
+}
+
+module rounded_cube(x, y, z, r) {
+    hull()
+    for (tx = [r, x - r])
+    for (ty = [r, y - r])
+    translate([tx, ty, 0])
+    cylinder(d = r * 2, h = z);
+}
+
+module sensor_lens_cutout() {
+    translate([0, 0, sensor_lens_cutout_to_chip])
+    hull() {
+        translate([0, 0, sensor_lens_baseplate_h - $e])
+        sensor_lens_cutout_intern();
+        
+        scale(1 + sensor_lens_cutout_growth * sensor_lens_baseplate_h)
+        sensor_lens_cutout_intern();
+    }
+    
+    translate([-sensor_lens_d / 2, -sensor_lens_w + sensor_lens_off, 0])
+    rounded_cube(sensor_lens_d, sensor_lens_w, sensor_lens_cutout_to_chip, 6);
+    
+    translate([-3 / 2, -sensor_lens_w + sensor_lens_off - 0.5, 0])
+    cube([3, 0.5, sensor_lens_cutout_to_chip]);
+}
+
 module sensor() {
     translate([-sensor_w / 2, -sensor_l / 2, 0])
     difference() {
@@ -258,13 +296,18 @@ module sensor() {
     translate([-sensor_pin_d / 2 + x, -sensor_pin_w / 2, -sensor_chip_h + sensor_pin_off_top])
     cube([sensor_pin_d, sensor_pin_w, sensor_pin_h]);
     
-    color("cyan")
-    translate([0, -sensor_l / 2 + sensor_cut_off_y + sensor_cut_h - sensor_cut_edge_to_pin1 - sensor_pin1_to_optical_center, -sensor_chip_h + 1])
-    cylinder(d = 0.2, h = sensor_ball_to_chip_bottom - 1);
+    translate([0, -sensor_l / 2 + sensor_cut_off_y + sensor_cut_h - sensor_cut_edge_to_pin1 - sensor_pin1_to_optical_center, 0]) {
+        color("cyan")
+        translate([0, 0, -sensor_chip_h + 1])
+        cylinder(d = 0.2, h = sensor_ball_to_chip_bottom - 1);
+        
+        %color("blue")
+        sensor_lens_cutout();
+    }
 }
 module ball_and_roller() {
     color("red")
-    sphere(d = ball_dia, $fn = 200);
+    sphere(d = ball_dia, $fn = $fn * 2);
     
     for (r = [0 : roller_count - 1])
     rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
@@ -275,44 +318,43 @@ module ball_and_roller() {
 }
 
 module roller_holder() {
-
-    echo(roller_h);
     translate([0, 0, -roller_h + roller_dia / 2])
     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);
+            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([0, 0, -$e]) {
-            cylinder(d = roller_thread_hole, h = $e+ roller_h - roller_dia / 2 + roller_ball_h_off + roller_ball_hold_off);
-        }
+        translate([0, 0, -$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])
-            sphere(d = roller_dia , $fn=$fn*4 );
+        sphere(d = roller_dia, $fn = $fn * 2);
 
-        
-        if (cut_roller_holder) {
-            translate([-roller_thread_dia / 2 - 1, -roller_thread_dia, -1])
-                cube([roller_thread_dia + 2, roller_thread_dia, roller_h + 2]);
-        }
+        if (cut_roller_holder)
+        translate([-roller_thread_dia / 2 - 1, -roller_thread_dia, -1])
+        cube([roller_thread_dia + 2, roller_thread_dia, roller_h + 2]);
     }
     
     %color("blue")
-    sphere(d = roller_dia);
+    sphere(d = roller_dia, $fn = $fn * 2);
 }
 
 module roller_mount() {
-    echo(roller_h);
     translate([0, 0, -1-roller_h + roller_dia / 2]) {
         difference() {
             cylinder(d=roller_mount_dia+wall,h=roller_h/2);
-            translate([0,0,1])
+            
+            translate([0, 0, 1])
             cylinder(d=roller_mount_dia+$c*2,h=roller_h/2+$e);
+
+            if (cut_roller_holder)
+            translate([-roller_thread_dia / 2 - 1, -roller_thread_dia, -1])
+            cube([roller_thread_dia + 2, roller_thread_dia, roller_h + 2]);
         }
     }
 }
@@ -322,62 +364,103 @@ module roller_mount_test() {
     roller_mount();
 }
 
-module roller_mount_tri() {
+roller_mount_holder_gap = 0.8;
+sensor_pcb_mount_gap = 2.0;
 
-difference() {
-    union(){
-        difference() {
-             hull() {
-                translate([0, 0, 0])
+sensor_pcb_support_h = 1.6 + 3.4;
+
+module roller_mount_tri() {
+    %ball_and_roller();
+    
+    difference() {
+        union() {
+            difference() {
+                hull() {
+                    for (r = [0 : roller_count - 1])
+                    rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
+                    translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
+                    rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
+                    translate([0, 0, -roller_h])
+                    cylinder(d = roller_mount_dia + wall + 1, h = roller_h - 3);
+                    
+                    translate([0, 0, -ball_dia / 2 - 11])
+                    cylinder(d = base_dia, h = $e);
+                }
+            
                 for (r = [0 : roller_count - 1])
                 rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
                 translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
                 rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
                 translate([0, 0, -roller_h])
-                cylinder(d=roller_mount_dia+wall+1,h=roller_h+1);
+                cylinder(d = roller_mount_dia + roller_mount_holder_gap, h = ball_dia / 2 + roller_h);
                 
-                translate([0,0,-ball_dia/2-5])
-                cylinder(d=base_dia,h=$e);
+                sphere($fn = $fn * 2, d = ball_dia + $c * 2 + 4);
             }
-            
-            for (r = [0 : roller_count - 1])
-            rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
-            translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
-            rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
-            translate([0, 0, -roller_h])
-            cylinder(d=roller_mount_dia+0.2,h=ball_dia/2+roller_h);
-            
-            sphere($fn=$fn*4, d=ball_dia+$c*2+1);
-            
         }
-        for (r = [0 : roller_count - 1])
-        rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
-        translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
-        rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
-        translate([0, 0, 0])
-        roller_mount();
-    }
         
-        translate([0, 0, 0])
         for (r = [0 : roller_count - 1])
         rotate([0, 0, roller_mount_angle_off + 360 / roller_count * r])
         translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
         rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
         translate([0, 0, -roller_h/2])
         rotate([0,-90,0])
-        translate([0,0,2])
-        {
-        cylinder(d=m2_thread,h=ball_dia);
-            translate([0,0,roller_mount_dia/4+wall])
-        cylinder(d=m2_thread+1,h=ball_dia);
+        translate([-2, 0, 2]) {
+            cylinder(d = m2_thread, h = ball_dia);
+            
+            translate([0, 0, roller_mount_dia / 4 + wall])
+            cylinder(d = m2_thread + 1, h = ball_dia);
         }
-}
+        
+        translate([0, 0, -ball_dia / 2 - ball_h])
+        translate([0, sensor_l / 2 - sensor_cut_off_y - sensor_cut_h + sensor_cut_edge_to_pin1 + sensor_pin1_to_optical_center, ball_h + sensor_chip_h - sensor_ball_to_chip_bottom])
+        translate([0, -sensor_l / 2 + sensor_cut_off_y + sensor_cut_h - sensor_cut_edge_to_pin1 - sensor_pin1_to_optical_center, 0])
+        sensor_lens_cutout();
+        
+        translate([-1, -1, -ball_dia / 2 - ball_h])
+        translate([0, sensor_l / 2 - sensor_cut_off_y - sensor_cut_h + sensor_cut_edge_to_pin1 + sensor_pin1_to_optical_center, ball_h + sensor_chip_h - sensor_ball_to_chip_bottom])
+        translate([-sensor_w / 2, -sensor_l / 2, -10])
+        cube([sensor_w + 2, sensor_l + 2, sensor_pcb_h + 10 + sensor_pcb_mount_gap]);
+        
+        // TODO test cable cutout
+        translate([-6, 0, -30.1])
+        cube([12, 50, 2]);
+        
+        if (cut_roller_holder)
+        translate([0, -base_dia / 2 - 1, -40])
+        cube([base_dia / 2 + 1, base_dia + 2, 40]);
+    }
     
+    translate([-sensor_w / 2, -sensor_l / 2, sensor_pcb_h])
+    translate([0, 0, -ball_dia / 2 - ball_h])
+    translate([0, sensor_l / 2 - sensor_cut_off_y - sensor_cut_h + sensor_cut_edge_to_pin1 + sensor_pin1_to_optical_center, ball_h + sensor_chip_h - sensor_ball_to_chip_bottom])
+    for (x = [0, sensor_hole_dist_x])
+    for (y = [0, sensor_hole_dist_y])
+    translate([sensor_hole_off_x + x, sensor_hole_off_y + y, 0])
+    difference() {
+        union() {
+            color("magenta")
+            cylinder(d = sensor_hole_dia + 1.5, h = sensor_pcb_mount_gap);
             
+            color("black")
+            translate([0, 0, -sensor_pcb_support_h])
+            cylinder(d = sensor_hole_dia + 0.5, h = sensor_pcb_support_h);
+        }
+        
+        cylinder(d = sensor_hole_dia - 0.2, h = sensor_pcb_mount_gap + 1);
+    }
+    
+    color("black")
+    for (x = [-5, 0, 5])
+    for (y = [-8, 0, 6.5])
+    if (((x == 0) && (y != 0)) || ((x != 0) && (y == 0)))
+    translate([x, y + 2, -30])
+    cylinder(d = sensor_hole_dia + 0.5, h = 8.5);
+        
+    %translate([0, 0, -ball_dia / 2 - ball_h])
+    translate([0, sensor_l / 2 - sensor_cut_off_y - sensor_cut_h + sensor_cut_edge_to_pin1 + sensor_pin1_to_optical_center, ball_h + sensor_chip_h - sensor_ball_to_chip_bottom])
+    sensor();
 }
 
-base_dia = pico_l + 9;
-
 module trackball() {
     %translate([0, 0, ball_dia / 2 + ball_h])
     ball_and_roller();
@@ -394,12 +477,9 @@ module trackball() {
     translate([sphere_r_at_h(roller_ball_h - ball_dia / 2, ball_dia / 2), 0, -ball_dia / 2 + roller_ball_h])
     rotate([0, 180 + sphere_angle_at_rh(roller_ball_h - ball_dia / 2, ball_dia / 2), 0])
     translate([0, 0, -roller_dia / 2])
-    translate([0, 0, -roller_h + roller_dia / 2 - roller_ball_h_off])
     roller_mount();
     
     color("grey")
     translate([0, 0, -8])
     cylinder(d = base_dia, h = wall);
 }
-
-