Trackball/hardware/trackball.scad

/*
 * Trackball
 *
 * Copyright (c) 2022 - 2023 Thomas Buck (thomas@xythobuz.de)
 *                           Philipp Schönberger (mail@phschoen.de)
 *
 * Required parts:
 *  - 1x Raspberry Pi Pico
 *  - 4x Cherry MX compatible switches and keycaps
 *  - 1x Billard ball, diameter 38mm 
 *  - 3x Si3N4 static bearing balls, diameter 3mm
 *  - 1x PMW3360 sensor with breakout board
 *  - 8x M2 screw, length 5mm
 *  - 8x M2 heat melt insert, length 4mm
 *
 * For the PMW3360 breakout board get this:
 * https://github.com/jfedor2/pmw3360-breakout
 *
 * 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/>.
 */

include<mx_switch.scad>; // need include since the parameters are in there
include <pico.scad>;     // need include since the parameters are in there

use<usbc.scad>;
use<sensor_pmw3360.scad>;
use<pico.scad>;
use<bearing.scad>; 
use<ball_and_bearing.scad>; 
use<util.scad>; 
use<external/led_ring.scad>; 

include<config.scad>; 

translate([$t*assembly_dist,$t*-assembly_dist,0])
top_hand_wrest();

trackball_top();

translate([0,0,-$t*assembly_dist])
trackball_bot();

// %translate([-13,38,5-trackball_dia/2])
// scale(150)
// rotate([0,0,-133])
// import("external/mouse_scan_v1.stl");

module trackball_bot()
{
    difference() {
        color("green")
        trans_bot_of_top_part() 
        translate([0,0,-wall]) 
        linear_extrude(wall) 
        {
            hull()
            projection() {
                trackball_top();
            }
            projection() {
                top_hand_wrest();
            }
        }

        trackball_bot_screw_cuts();
    }
}

module trackball_bot_screw_cuts(e=2) 
{
    pos= [
            //     offset           angle
            [ trackball_dia/2 + 15, 52 + 15 ],
            [ trackball_dia/2 + 15, 52 - 40 ],
            [ trackball_dia/2 + 15, 52 - 15 + 180 ],
            [ trackball_dia/2 + 15, 52 + 40 + 180 ],
            [ trackball_dia/2 + 75, 52 - 90 -10],
            [ trackball_dia/2 + 75, 52 - 90 +10],
    ];
    
    for(p = pos)
    rotate([0,0,p[1]]) 
    translate([p[0],0,0])
    translate([0,0,7-$e*2])
    trans_bot_of_top_part() 
    rotate([0,180,0]) 
    {
        m3_screw_insert_cut(8);
    }
}

module trackball_top()
{
    if (draw_ball_bearing_holder)
    %ball_and_bearing_holder();
    
    difference()
    {
        hull()
        {
            intersection_top_part(is_wristrest = false)
            trackball_top_hull(with_bot_cuts=true);

            trans_bot_of_top_part() 
            linear_extrude($e) 
            projection() {
                intersection_top_part(is_wristrest = false)
                trackball_top_hull(with_bot_cuts=true);
            }
        }

        top_body_cutouts();
    }
}

module intersection_top_part(is_wristrest = false)
{
    intersection() 
    {
        rotate([0,0,-38])
        translate([37.1,-50,-50]) 
        trans_bot_of_top_part()
        if(is_wristrest == true)
            cube([100,200,200]);
        else
            translate([-100,0,0]) 
            cube([100,200,200]);
        
        children();
    }
}

module m3_screw_insert_cut(l=20)
{
    // screw thread cutout
    color("silver")
    cylinder(d=3,h=50);

    // insert cutout itself
    color("gold")
    cylinder(d=4.6+$c*2,h=7);
    
    // screw head cutout for sliding in
    translate([0,0,l]) 
    color("silver")
    cylinder(d=6+$c*2,h=50);

    // insert iself
    // % color("gold")
    // cylinder(d=4.6,h=5.7);
}

module wrest_screw_cutout()
{
    for(i=[1,-1])
    rotate([0,0,-38])
    translate([31,i*15,14]) 
    trans_bot_of_top_part()
    rotate([0,20,0]) 
    rotate([0,90,0]) 
    {
        m3_screw_insert_cut(20);
    }
}

module top_hand_wrestv1()
{
    difference()
    {
        intersection_top_part(is_wristrest = true)
        rotate([0,0,-38])
        translate([60,0,0]) 
        trans_bot_of_top_part()
        intersection() 
        {

            scale([3.5,1.5,1])
            cylinder(r = 20, h = trackball_dia+17);
        
            translate([15,0,20-trackball_dia/2]) 
            rotate([0,30,0])
            scale([1.3,1.4,1])
            sphere(d=70);
        }

        // screw cutout for attaching the wrist rest to the top part
        wrest_screw_cutout();


        // screw cutouts for the bottom plate 
        translate([0,0,-$e])
        trackball_bot_screw_cuts(e=0);

        // pi pico cutout
        rotate([0,0,50])
        trans_bot_of_top_part()
        translate([3,-80,3])
        {
            %if(draw_pico) pico_wrap();
            pico_cutout(20);
        }
    }
}
module top_hand_wrest()
{
    difference()
    {

        intersection_top_part(is_wristrest = true)
        rotate([0,0,-38])
        translate([60,0,0]) 
        trans_bot_of_top_part()
        intersection() {
            translate([-200,-200,0]) 
            cube([400,400,100]);

            minkowski() {
                intersection() 
                {

                    scale([3.5,1.5,1])
                    cylinder(r = 20, h = trackball_dia+17);
                
                    translate([15,0,20-trackball_dia/2]) 
                    rotate([0,30,0])
                    scale([1.3,1.4,1])
                    sphere(d=70);
                }

                sphere(r = 3);

            }
        }

        // screw cutout for attaching the wrist rest to the top part
        wrest_screw_cutout();

        // screw cutouts for the bottom plate 
        translate([0,0,-$e])
        trackball_bot_screw_cuts(e=0);

        // pi pico cutout
        rotate([0,0,50])
        trans_bot_of_top_part()
        translate([3,-80,3])
        {
            %if(draw_pico) pico_wrap();
            pico_cutout(20);
        }
    }
}

module pico_cutout(extra)
{
    translate([-pico_w / 2, -pico_l / 2, -extra]) {

        // pcb cutout
        cube([pico_w, pico_l, 4 + extra]);

        // screw cutouts
        for (x = [0, pico_hole_d_x])
        for (y = [0, pico_hole_d_y])
        translate([pico_hole_x + x, pico_hole_y + y, extra])
        cylinder(d = pico_hole_d, h = pico_d + 2+5);

        // cable channels 
        translate([pico_w/2-9/2,pico_l-10,0])
        cube([9, trackball_dia+10, 4 + extra+2]);
    }
}

module top_body_cutouts()
{
    // space for roller holder
    bearing_rot_trans()
    translate([0,0,-bearing_h])
    cylinder(d = bearing_mount_dia + 1, h = trackball_dia / 2 + bearing_h);
    
    // room for ball itself
    sphere($fn = $fn * 2, d = trackball_dia + $c * 2 + 4);
        
    // grub screws for the bearing holder
    bearing_rot_trans()
    rotate([0,-90,90])
    translate([-bearing_h+4, 0, 0])
    {
        cylinder(d = grub_screw_dia, h = trackball_dia);
        
        translate([0, 0, bearing_mount_grub_screw_l]) // outside of wall
        
        translate([0, 0, bearing_mount_dia/2 +wall/2]) // outside of wall
        cylinder(d = grub_channel_dia, h = trackball_dia);
    }
        
    // sensor lens
    sensor_cutout();
    %if(draw_sensor) sensor_pos();

    // switch cutouts
    //translate([0, 0, trackball_dia / 2 + ball_h])
    switch_rot_trans(0)
    translate([10,10,0]) 
    {
        // switch cutout itself
        mx_switch_cutout(mx_co_depth);

        %if(draw_switches)
        translate([0,0,10]) 
        mx_switch();
    }

    switch_rot_trans(0,false)
    translate([10,10,0]) 
    {
        // cable channel
        rotate([-40,0,0])
        rotate([0,180,0])
        cylinder(d=3,h=trackball_dia);
    }

    // led ring
    translate([0,0,-trackball_dia/2]) 
    {
        led_ring(cutout=true, extra = trackball_dia/2);
        %if(draw_led) led_ring();
    }
        
    // screw cutouts for the wrist rest
    wrest_screw_cutout();

    // screw cutouts for the bottom plate 
    translate([0,0,-$e])
    trackball_bot_screw_cuts(e=0);
    
    // pico cutout
    rotate([0,0,50])
    trans_bot_of_top_part()
    translate([3,-80,3])
    {
        pico_cutout(20);
        pico_cutout(20);
    }
    
    // usb cutout
    rotate([0,0,180+50])
    trans_bot_of_top_part()
    translate([0,-trackball_dia/2-8,2])
    {
        %if(draw_usb_c)usb_c();
        usb_c_cutout();   
    }
}

module switch_rot_trans(r,x_rot=true)
{
    for ( i = [0:len(sw)-1] )
    {
        rotate([0,0,sw[i][0][2]])
        translate(sw[i][1])
        rotate([90+(x_rot ? sw[i][0][0] : 0),0,sw[i][0][1]])
        translate([-sw_mount_w/2 - r, -sw_mount_w/2 - r, -r - r/2])
        children();
    }
}

module trans_bot_of_top_part()
{
    translate([0, 0, -trackball_dia / 2 -11])
    children();
}

module trackball_top_hull(with_bot_cuts=true)
{
    difference() {
        color("orange")
        union(){
            hull() {
                // bearing holder cylinders
                bearing_rot_trans()
                bearing_holder_mount();
                
                // base circle
                trans_bot_of_top_part()
                cylinder(d = base_dia, h = $e);
                
                // switch 
                switch_rot_trans(sw_mount_r)
                translate([0,0,sw_mount_r*2]) 
                fully_rounded_cube([sw_mount_w + sw_mount_r*2,
                                    sw_mount_w + sw_mount_r*2,
                                    mx_co_depth], sw_mount_r);
            }
        }
    }
}