add script used to generate g-code for cutting TeleBT boxes

diff --git a/mechanical/Notebook b/mechanical/Notebook
index 12885dc6e410416af3aa9dc173dec7527a501f1d..4800263606c4b918f812f7dc860fcca468977926 100644 (file)
--- a/mechanical/Notebook
+++ b/mechanical/Notebook
@@ -8,6 +8,10 @@ M22_Powerpole_Mount.zip
        used for battery charger attachment to TeleFire series, acquired
        via Thingiverse.        https://www.thingiverse.com/thing:2580868
 
+telebt-box.py
+       script to generate g-code used for cutting TeleBT boxes on
+       Bdale's cnc router
+
 teledongle-box.py
        script to generate g-code used for cutting TeleDongle boxes on
        Bdale's cnc router

diff --git a/mechanical/telebt-box.py b/mechanical/telebt-box.py
new file mode 100755 (executable)
index 0000000..afdce1e
--- /dev/null
+++ b/mechanical/telebt-box.py
@@ -0,0 +1,140 @@
+#! /usr/bin/python
+# Copyright 2013 by Bdale Garbee <bdale@gag.com>.  GPLv3
+
+# cut the required holes in a Hammond 1551K box to mount TeleBT
+
+# we assume the box is standing on edge, with the bottom of the box to the
+# "rear" (away from the front of the mill) against a reference plane, and
+# the left edge of the box also up against a reference block.
+
+# the Z reference plane is top surface of the box, X is the left edge of box
+
+import math
+
+Zfree = 0.1000         # height in Z to clear all obstructions
+Speed = 10             # cutting speed
+Zdepth = 0.125         # how deep we need to cut to go cleanly through the 
+                       # box wall, where the wall is 0.079 thick
+
+CutterSize = 0.0625    # 1/16" end mill
+RunOut = 0.0000                # how much larger slots are than desired 
+CutterOD = CutterSize + RunOut
+
+BoxWidth = 3.150       # measured one at 3.145, Hammond says 3.150, matters
+                       # because most dimensions are relative to center line!
+
+X_Switch = -1.060      # switch distance from center line
+Y_Switch = 0.185       # switch centerline above PCB top surface
+D_Switch = 0.270       # diameter of switch hole (250 mils plus clearance)
+
+X_USB = 0.935          # USB distance from center line
+Y_USB = -0.049         # USB centerline below PCB bottom surface
+
+#X_USB_slot = 0.325    # width of the USB slot
+#Y_USB_slot = 0.125    # height of the USB slot
+X_USB_slot = 0.350     # width of the USB slot  (account for plastic melting
+Y_USB_slot = 0.150     # height of the USB slot  around end mill)
+
+Y_SMA = -0.025         # SMA centerline below PCB bottom surface
+D_SMA = 0.281          # diameter of SMA hole (doc says 0.256)
+
+Y_Box_Bottom = 0.079   # thickness of box bottom wall
+Y_Standoff = 0.157     # height of standoff nubs in box
+Y_PCB = 0.063          # PCB thickness
+
+def plunge():
+       print "(plunge)"
+       print "G01 Z",-Zdepth," F",Speed
+
+def retract():
+       print "(retract)"
+       print "G00 Z",Zfree
+
+def park():
+       retract()
+       print "(park)"
+       print "G00 X0 Y5 Z0.25"
+
+print "%"
+
+print "G17 G20 G90"
+print "M3 S5000"
+
+retract()
+
+# cut power switch hole
+
+print
+print "(power switch hole)"
+
+X_Pos = (BoxWidth / 2) + X_Switch
+Y_Pos = -(Y_Box_Bottom + Y_Standoff + Y_PCB + Y_Switch)
+CutLineRadius = (D_Switch / 2) - (CutterOD / 2)
+
+print "G00 X",(X_Pos + CutLineRadius),"Y",Y_Pos
+print "G01 Z",-Zdepth," F",Speed
+print "G02 X%6.4f" % (X_Pos - CutLineRadius),"Y%6.4f" % Y_Pos,"I%6.4f" % -CutLineRadius,"J0 F",Speed
+print "G02 X%6.4f" % (X_Pos + CutLineRadius),"Y%6.4f" % Y_Pos,"I%6.4f" % CutLineRadius,"J0 F",Speed
+retract()
+
+print
+print "(SMA hole)"
+
+X_Pos = (BoxWidth / 2)
+Y_Pos = -(Y_Box_Bottom + Y_Standoff + Y_SMA)
+CutLineRadius = (D_SMA / 2) - (CutterOD / 2)
+
+print "G00 X",(X_Pos + CutLineRadius),"Y",Y_Pos
+print "G01 Z",-Zdepth," F",Speed
+print "G02 X%6.4f" % (X_Pos - CutLineRadius),"Y%6.4f" % Y_Pos,"I%6.4f" % -CutLineRadius,"J0 F",Speed
+print "G02 X%6.4f" % (X_Pos + CutLineRadius),"Y%6.4f" % Y_Pos,"I%6.4f" % CutLineRadius,"J0 F",Speed
+retract()
+
+print
+print "(USB slot)"
+
+print "(first end)"
+X_Pos = (BoxWidth / 2) + X_USB + ((X_USB_slot - Y_USB_slot)/2)
+Y_Pos = -(Y_Box_Bottom + Y_Standoff + Y_USB)
+CutLineRadius = (Y_USB_slot / 2) - (CutterOD / 2)
+
+print "G00 X",X_Pos,"Y",(Y_Pos - CutLineRadius)
+print "G01 Z",-Zdepth," F",Speed
+print "G03 X%6.4f" % X_Pos, "Y%6.4f" % (Y_Pos + CutLineRadius),"I0 J%6.4f" % CutLineRadius," F",Speed
+
+print "(top and second end)"
+X_Pos = (BoxWidth / 2) + X_USB - ((X_USB_slot - Y_USB_slot)/2)
+print "G01 X",X_Pos," F",Speed
+print "G03 X%6.4f" % X_Pos, "Y%6.4f" % (Y_Pos - CutLineRadius),"I0 J%6.4f" % -CutLineRadius," F",Speed
+
+print "(bottom)"
+X_Pos = (BoxWidth / 2) + X_USB + ((X_USB_slot - Y_USB_slot)/2)
+print "G01 X",X_Pos," F",Speed
+
+retract()
+
+print "(second pass - first end)"
+X_Pos = (BoxWidth / 2) + X_USB + ((X_USB_slot - Y_USB_slot)/2)
+Y_Pos = -(Y_Box_Bottom + Y_Standoff + Y_USB)
+CutLineRadius = (Y_USB_slot / 2) - (CutterOD / 2)
+
+print "G00 X",X_Pos,"Y",(Y_Pos - CutLineRadius)
+print "G01 Z",-Zdepth," F",Speed
+print "G03 X%6.4f" % X_Pos, "Y%6.4f" % (Y_Pos + CutLineRadius),"I0 J%6.4f" % CutLineRadius," F",Speed
+
+print "(second pass - top and second end)"
+X_Pos = (BoxWidth / 2) + X_USB - ((X_USB_slot - Y_USB_slot)/2)
+print "G01 X",X_Pos," F",Speed
+print "G03 X%6.4f" % X_Pos, "Y%6.4f" % (Y_Pos - CutLineRadius),"I0 J%6.4f" % -CutLineRadius," F",Speed
+
+print "(second pass - bottom)"
+X_Pos = (BoxWidth / 2) + X_USB + ((X_USB_slot - Y_USB_slot)/2)
+print "G01 X",X_Pos," F",Speed
+
+retract()
+
+park()
+
+print "M5 M2"
+print "%"
+