Initial parametric Feather case generator
This commit is contained in:
Nick Estes
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# frozen_string_literal: true
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module FeatherCaseWizard
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class ConfigError < StandardError; end
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class Config
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SCHEMA_VERSION = 1
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PROFILES = %w[generic gps oled128x64].freeze
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FORMATS = %w[stl 3mf].freeze
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FACES = %w[front rear left right].freeze
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SHAPES = %w[circle rect roundrect slot].freeze
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COUPONS = %w[insert_coupon switch_coupon fit_coupon].freeze
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DEFAULT_PARAMETERS = {
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"top_profile" => "generic",
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"wing_count" => 1,
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"wing_pitch" => 11.0,
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"stack_height_override" => 0.0,
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"generic_component_height" => 3.0,
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"generic_top_gap" => 2.0,
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"gps_antenna_height" => 4.0,
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"gps_top_gap" => 5.0,
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"oled_component_height" => 2.4,
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"oled_face_gap" => 0.8,
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"button_a" => true,
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"button_b" => true,
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"button_c" => true,
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"button_reset" => false,
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"button_projection" => 1.5,
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"button_cap_size" => [5.0, 3.2],
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"button_flange_size" => [6.6, 3.6],
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"button_flange_thickness" => 0.9,
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"button_travel" => 0.5,
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"button_contact_extension" => 0.7,
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"battery_enabled" => false,
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"battery_length" => 69.0,
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"battery_diameter" => 18.0,
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"battery_radial_clearance" => 0.6,
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"battery_end_clearance" => 1.0,
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"switch_hole_diameter" => 12.0,
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"switch_hole_compensation" => 0.3,
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"switch_cap_diameter" => 8.0,
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"switch_flange_diameter" => 16.2,
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"switch_body_length" => 24.0,
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"switch_body_diameter" => 12.0,
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"switch_wire_allowance" => 3.0,
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"tripod_insert_enabled" => false,
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"tripod_insert_length" => 6.4,
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"tripod_insert_hole_diameter" => 8.8,
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"tripod_thread_clearance_diameter" => 6.8,
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"tripod_boss_diameter" => 14.0,
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"m25_insert_length" => 4.0,
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"m25_insert_hole_diameter" => 3.7,
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"m25_screw_clearance" => 2.8,
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"m25_boss_diameter" => 7.0,
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"insert_entry_chamfer" => 0.6,
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"insert_melt_relief" => 0.8,
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"wall_thickness" => 2.4,
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"floor_thickness" => 2.4,
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"lid_thickness" => 3.2,
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"corner_radius" => 4.0,
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"board_bottom_clearance" => 5.4,
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"board_side_clearance" => 7.0,
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"board_rear_clearance" => 4.0,
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"usb_board_wall_gap" => 1.2,
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"lid_lip_depth" => 2.4,
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"lid_lip_thickness" => 1.2,
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"fit_clearance" => 0.35,
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"hole_compensation" => 0.2,
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"lid_screw_head_diameter" => 5.2,
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"lid_screw_head_height" => 2.5,
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"usb_opening_width" => 12.5,
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"usb_opening_height" => 7.0,
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"usb_opening_radius" => 1.5,
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"usb_vertical_offset" => 0.0
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}.freeze
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ADVANCED_FIELDS = {
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"Stack" => %w[wing_pitch generic_component_height generic_top_gap
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gps_antenna_height gps_top_gap oled_component_height oled_face_gap],
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"Shell and fit" => %w[wall_thickness floor_thickness lid_thickness corner_radius
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board_bottom_clearance board_side_clearance board_rear_clearance
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usb_board_wall_gap lid_lip_depth lid_lip_thickness fit_clearance
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hole_compensation lid_screw_head_diameter lid_screw_head_height],
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"M2.5 inserts" => %w[m25_insert_length m25_insert_hole_diameter
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m25_screw_clearance m25_boss_diameter
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insert_entry_chamfer insert_melt_relief],
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"Tripod insert" => %w[tripod_insert_length tripod_insert_hole_diameter
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tripod_thread_clearance_diameter tripod_boss_diameter],
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"Battery and switch" => %w[battery_length battery_diameter battery_radial_clearance
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battery_end_clearance switch_hole_diameter
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switch_hole_compensation switch_cap_diameter
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switch_flange_diameter switch_body_length
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switch_body_diameter switch_wire_allowance],
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"USB-C opening" => %w[usb_opening_width usb_opening_height
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usb_opening_radius usb_vertical_offset],
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"OLED buttons" => %w[button_projection button_flange_thickness
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button_travel button_contact_extension]
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}.freeze
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attr_reader :data
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def self.create(name:, slug:)
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new(
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"schema_version" => SCHEMA_VERSION,
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"name" => name,
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"slug" => slug,
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"generator" => {},
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"parameters" => deep_copy(DEFAULT_PARAMETERS),
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"cutouts" => [],
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"outputs" => {
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"formats" => ["3mf"],
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"coupons" => [],
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"assembly_exploded_view" => 8
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}
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)
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end
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def self.load(path)
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raw = YAML.safe_load_file(path, permitted_classes: [], permitted_symbols: [],
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aliases: false)
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raise ConfigError, "Configuration must be a YAML mapping" unless raw.is_a?(Hash)
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new(raw)
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rescue Psych::Exception => e
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raise ConfigError, "Cannot read configuration: #{e.message}"
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end
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def self.deep_copy(value)
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Marshal.load(Marshal.dump(value))
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end
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def initialize(data)
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@data = stringify_keys(data)
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normalize!
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validate!
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end
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def name = data.fetch("name")
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def slug = data.fetch("slug")
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def parameters = data.fetch("parameters")
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def cutouts = data.fetch("cutouts")
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def outputs = data.fetch("outputs")
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def generator = data.fetch("generator")
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def package_dir(root = CASES_ROOT)
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root.join(slug)
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end
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def printable_parts
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parts = %w[body lid]
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if parameters["top_profile"] == "oled128x64" &&
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%w[button_a button_b button_c button_reset].any? { |key| parameters[key] }
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parts << "buttons"
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end
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parts + outputs["coupons"]
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end
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def model_parameters
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parameters.merge("extra_cutouts" => scad_cutouts)
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end
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def dimensions
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p = parameters
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effective_floor = p["tripod_insert_enabled"] ?
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[p["floor_thickness"], p["tripod_insert_length"] + p["insert_melt_relief"] + 1.2].max :
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p["floor_thickness"]
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effective_board_clearance = [
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p["board_bottom_clearance"],
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p["m25_insert_length"] + p["insert_melt_relief"] + 0.6
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].max
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board_origin_x = p["wall_thickness"] + p["usb_board_wall_gap"]
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board_origin_y = p["wall_thickness"] + p["board_side_clearance"]
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board_top_z = effective_floor + effective_board_clearance + 1.6
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top_pcb_z = board_top_z + (
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p["stack_height_override"].positive? ?
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p["stack_height_override"] : p["wing_count"] * p["wing_pitch"]
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)
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component_height, top_gap = case p["top_profile"]
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when "gps"
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[p["gps_antenna_height"], p["gps_top_gap"]]
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when "oled128x64"
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[p["oled_component_height"], p["oled_face_gap"]]
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else
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[p["generic_component_height"], p["generic_top_gap"]]
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end
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plain_length = board_origin_x + 50.8 + p["board_rear_clearance"] +
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p["wall_thickness"]
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plain_width = board_origin_y + 22.86 + p["board_side_clearance"] +
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p["wall_thickness"]
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if p["battery_enabled"]
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partition_y = board_origin_y + 22.86 + 1
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battery_y = partition_y + p["wall_thickness"] +
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p["battery_radial_clearance"] + p["battery_diameter"] / 2
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battery_start_x = board_origin_x + p["battery_end_clearance"]
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battery_end_x = battery_start_x + p["battery_length"]
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switch_x = battery_end_x + [
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p["switch_body_diameter"] / 2 + 0.8,
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p["switch_flange_diameter"] / 2 + 0.5
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].max
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length = [plain_length, switch_x + p["switch_flange_diameter"] / 2 +
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1.2 + p["wall_thickness"]].max
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width = [plain_width, battery_y + p["battery_diameter"] / 2 +
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p["battery_radial_clearance"] + p["wall_thickness"]].max
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battery_z = effective_floor + p["battery_radial_clearance"] +
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p["battery_diameter"] / 2
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switch_z = [
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effective_floor + p["switch_flange_diameter"] / 2 + 1,
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battery_z
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].max
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battery_ceiling = [
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battery_z + p["battery_diameter"] / 2 + p["battery_radial_clearance"],
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switch_z + p["switch_flange_diameter"] / 2 + 1
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].max
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else
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length = plain_length
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width = plain_width
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battery_ceiling = 0
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end
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{
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"length" => length,
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"width" => width,
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"height" => [top_pcb_z + component_height + top_gap, battery_ceiling].max,
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"floor" => effective_floor,
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"lip_bottom" => [top_pcb_z + component_height + top_gap, battery_ceiling].max -
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p["lid_lip_depth"]
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}
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end
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def scad_cutouts
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dims = dimensions
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cutouts.map do |cutout|
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face = cutout.fetch("face")
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horizontal = cutout.fetch("horizontal")
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u = case face
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when "front" then dims["width"] - horizontal
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when "rear", "left" then horizontal
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when "right" then dims["length"] - horizontal
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end
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width = cutout.fetch("width")
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height = cutout.fetch("height", width)
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radius = cutout.fetch("radius", [width, height].min / 2)
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[face, cutout.fetch("shape"), u, cutout.fetch("z"), width, height, radius]
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end
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end
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def to_yaml
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data["resolved"] = {"extra_cutouts" => scad_cutouts}
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data.to_yaml(line_width: -1)
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end
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def validate!
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raise ConfigError, "Unsupported schema_version" unless data["schema_version"] == SCHEMA_VERSION
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raise ConfigError, "Project name cannot be empty" if name.to_s.strip.empty?
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unless slug.match?(/\A[a-z0-9]+(?:-[a-z0-9]+)*\z/)
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raise ConfigError, "Slug must contain lowercase letters, numbers, and single hyphens"
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end
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raise ConfigError, "Unsupported top profile" unless PROFILES.include?(parameters["top_profile"])
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raise ConfigError, "wing_count must be between 1 and 8" unless (1..8).cover?(parameters["wing_count"])
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raise ConfigError, "At least one export format is required" if outputs["formats"].empty?
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unless (outputs["formats"] - FORMATS).empty?
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raise ConfigError, "Unsupported export format"
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end
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unless (outputs["coupons"] - COUPONS).empty?
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raise ConfigError, "Unsupported calibration coupon"
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end
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positive = DEFAULT_PARAMETERS.keys - %w[usb_vertical_offset stack_height_override]
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positive.each do |key|
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value = parameters[key]
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next if value == true || value == false
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next if value.is_a?(Array) && value.all? { |item| item.to_f.positive? }
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next unless value.is_a?(Numeric)
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raise ConfigError, "#{key} must be positive" unless value.to_f.positive?
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end
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raise ConfigError, "stack_height_override cannot be negative" if
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parameters["stack_height_override"].negative?
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raise ConfigError, "wall_thickness must be at least 1.2 mm" if
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parameters["wall_thickness"] < 1.2
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raise ConfigError, "lid_lip_thickness must be at least 1.2 mm" if
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parameters["lid_lip_thickness"] < 1.2
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validate_cutouts!
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self
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end
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private
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def normalize!
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data["schema_version"] = Integer(data.fetch("schema_version", SCHEMA_VERSION))
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data["generator"] ||= {}
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data["parameters"] = self.class.deep_copy(DEFAULT_PARAMETERS).merge(data["parameters"] || {})
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data["cutouts"] ||= []
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data["outputs"] ||= {}
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data["outputs"]["formats"] ||= ["3mf"]
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data["outputs"]["coupons"] ||= []
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data["outputs"]["assembly_exploded_view"] ||= 8
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rescue ArgumentError, TypeError => e
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raise ConfigError, "Invalid configuration value: #{e.message}"
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end
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def validate_cutouts!
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dims = dimensions
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names = {}
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cutouts.each do |cutout|
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name = cutout["name"].to_s.strip
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raise ConfigError, "Every cutout needs a name" if name.empty?
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raise ConfigError, "Duplicate cutout name: #{name}" if names[name]
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names[name] = true
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face = cutout["face"]
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shape = cutout["shape"]
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raise ConfigError, "Invalid face for #{name}" unless FACES.include?(face)
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raise ConfigError, "Invalid shape for #{name}" unless SHAPES.include?(shape)
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width = Float(cutout["width"])
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height = Float(cutout.fetch("height", width))
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horizontal = Float(cutout["horizontal"])
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z = Float(cutout["z"])
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wall_width = %w[front rear].include?(face) ? dims["width"] : dims["length"]
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unless horizontal - width / 2 >= 0 && horizontal + width / 2 <= wall_width
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raise ConfigError, "#{name} extends beyond the #{face} wall"
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end
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if z - height / 2 < dims["floor"]
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raise ConfigError, "#{name} intersects the case floor"
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end
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if z + height / 2 > dims["lip_bottom"]
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raise ConfigError, "#{name} intersects the lid locating lip"
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end
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radius = Float(cutout.fetch("radius", [width, height].min / 2))
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raise ConfigError, "#{name} dimensions must be positive" unless
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width.positive? && height.positive? && radius.positive?
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rescue ArgumentError, TypeError, KeyError => e
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raise ConfigError, "Invalid cutout #{name.inspect}: #{e.message}"
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end
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end
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def stringify_keys(value)
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case value
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when Hash
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value.to_h { |key, item| [key.to_s, stringify_keys(item)] }
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when Array
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value.map { |item| stringify_keys(item) }
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else
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value
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end
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end
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end
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end
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