implement cross fading

README.md

@@ -1,15 +1,74 @@
 textclock
 =========
 
+# Introduction
+
 textclock is a parametric 3d-printable textclock. It's currently in development.
 
-It's designed to be used with a 60 led/m SK6812 led-strip, and an esp8266 (using micropython) 
-for control. Using an ESP32 is also possible, but timer handling and pins
-might need to be changed.
+It's designed to be used with a 60 led/m SK6812 led-strip, and an esp8266 using micropython for control. 
+Using an ESP32 or any other micropython-capable board is also possible, but timer handling and pins might 
+need to be changed.
+
+The letterface is available in English and German, but can be easily adapted to other languages, as well as your
+specific needs. The letters "stamped" into clock are just configuration files with text - look at the 
+[english one](hardware/config_sk6812_english_minimal.scad) for a glimpse.
 
-The letterface is available in English and German, but can be easily adapted to other languages.
+The configuration for most parameters is also adjustable in the [config_common.scad](hardware/config_common.scad) file. 
 
 ![rendering](doc/render.png)
 
+# Requirements
+
+## Parts / BOM
+
+In the default configuration the clock requires the following parts:
+
+### 3d printed parts
+
+__Note: Please read the Printed parts (IMPORTANT!)" section before you print them__
+
+- letter plate (front face of the clock, includes the letters shown and separation between them)
+- led holder plate (used with fixation plate to clamp the led strips between them)
+- led fixation plate (used to clamp strips & serves as mount for electronics)
+- backplate/wallmount (to close the case and enable mounting it to a wall)
+
+### hardware
+- M2.5 brass threaded inserts
+- M2.5 machine screws (short, maybe 6mm?)
+
+### electronics
+- ESP8266 (or ESP32) NodeMCU-style board 
+- SK6812 60 LEDs/m RGBW strip
+- DS1307 RTC module (I used a dual module called "Tiny RTC" that additionally includes an eeprom, and just didn't it)
+- THT angled pin headers (2.54mm)
+- Jumper wires (F-F, just cut them up)
+- misc. cables (you can use the jumper wire remains)
+
+Since the 3d files are written in OpenSCAD, you can modify them to your needs and available electronics or led strips.  
+
+## Printed parts (IMPORTANT!)
+
+- 0.15mm layer height (some parameters in `config_common.scad` need to be changed if you want to use a different height)
+- 0.4mm nozzle (for more detailed letters, you could potentially use a smaller nozzle)
+- Filament: __Your filament choice is crucial for success.__ It must be opaque enough to block the light at ~1mm height, 
+  but let light through at 0.15mm (single layer height). You can print a smaller test print
+  to determine if your filament is suitable.   
+
+# Assembly
+
+## Printed parts
+
+### Install threaded inserts
+
+### Install led strips
+
+## Electronics
+
+### Prepare ESP8266
+
+First step is to solder the angled pin headers to the ESP8266 board. Please note, that you may need to remove the 
+standard headers first. 
+
+## Software
 
 The process of installing the software is described in the [software-folders README](software/README.md)

hardware/README.md

@@ -0,0 +1,10 @@
+### Recreate required stls
+
+To recreate the required STL-files, you can run `build.bat`. Please note, that OpensCAD needs to be installed in `%PROGRAMFILES%\OpenSCAD\openscad.exe`.
+
+If you want to manually recreate the files, you need to open, render & export the following files in OpenSCAD:
+- led_fixation_plate.scad
+- led_holder_plate.scad
+- backplate_wall.scad
+- letter_plate.scad
+

hardware/backplate_wall.scad

@@ -10,6 +10,7 @@ CABLE_SLOT_WIDTH = 30;
 CABLE_SLOT_HEIGHT = 50;
 CABLE_ROUND_EDGES = 2;
 
+REDUCED_SIZE = 2*OUTER_WALL_THICKNESS + INNER_PLATE_TOLERANCE;
 
 module wall_mount_holes() {
     translate([TOTAL_WIDTH/2, TOTAL_HEIGHT/5*4, -0.05])
@@ -22,14 +23,24 @@ module wall_mount_holes() {
 module backplate_wall() {
     difference() {
         intersection() {
-            round_edges_cube();
-            cube([TOTAL_WIDTH,
-                  TOTAL_HEIGHT,
+            translate([REDUCED_SIZE/2, REDUCED_SIZE/2, 0])
+            cube([TOTAL_WIDTH - REDUCED_SIZE,
+                  TOTAL_HEIGHT - REDUCED_SIZE,
                   WALLMOUNT_PLATE_THICKNESS]);
         }
         wall_mount_holes();
         corner_holes(offset=20, d=SCREW_DIAMETER, h=100);
-        corner_holes(offset=WALLMOUNT_PLATE_THICKNESS+0.01, d=SCREW_DIAMETER*2, h=WALLMOUNT_PLATE_THICKNESS-1.5);
+        corner_holes(offset=WALLMOUNT_PLATE_THICKNESS+0.01, 
+                     d=SCREW_DIAMETER*2, 
+                     h=WALLMOUNT_PLATE_THICKNESS-1.5);
+        translate([OUTER_WALL_THICKNESS,OUTER_WALL_THICKNESS, 1.5]) 
+            cube([SCREW_DIAMETER, SCREW_DIAMETER, WALLMOUNT_PLATE_THICKNESS], center=false);
+        translate([TOTAL_WIDTH-2*OUTER_WALL_THICKNESS,OUTER_WALL_THICKNESS, 1.5]) 
+            cube([SCREW_DIAMETER, SCREW_DIAMETER, WALLMOUNT_PLATE_THICKNESS], center=false);
+        translate([TOTAL_WIDTH-2*OUTER_WALL_THICKNESS,TOTAL_HEIGHT-2*OUTER_WALL_THICKNESS, 1.5]) 
+            cube([SCREW_DIAMETER, SCREW_DIAMETER, WALLMOUNT_PLATE_THICKNESS], center=false);
+        translate([OUTER_WALL_THICKNESS,TOTAL_HEIGHT-2*OUTER_WALL_THICKNESS, 1.5]) 
+            cube([SCREW_DIAMETER, SCREW_DIAMETER, WALLMOUNT_PLATE_THICKNESS], center=false);
         translate([TOTAL_WIDTH/2-CABLE_SLOT_WIDTH/2,-CABLE_ROUND_EDGES,-0.01]) 
             rounded_cube([CABLE_SLOT_WIDTH, CABLE_SLOT_HEIGHT+CABLE_ROUND_EDGES, WALLMOUNT_PLATE_THICKNESS+0.1], CABLE_ROUND_EDGES);
     }

hardware/build.bat

@@ -7,7 +7,7 @@ RD /Q /S %OUTPUT_DIRECTORY%
 IF NOT EXIST "%OUTPUT_DIRECTORY%" ( MKDIR %OUTPUT_DIRECTORY% )
 
 ECHO Creating STLs
-FOR /F  %%x IN (files_to_print.txt) DO (
+FOR %%x IN (led_fixation_plate led_holder_plate backplate_wall letter_plate) DO (
 	ECHO - %%x.stl
 	%OPENSCAD% -o %OUTPUT_DIRECTORY%\%%x.stl %%x.scad
 )

hardware/common.scad

@@ -33,7 +33,9 @@ module triangle(point1, point2, depth) {
 }
 
 module round_edges_cube(offset=0) {
-    translate([0, 0, -50]) rounded_cube([TOTAL_WIDTH, TOTAL_HEIGHT, 100], r=ROUND_EDGES_RADIUS, offset=offset);
+    translate([0, 0, -50]) 
+        rounded_cube([TOTAL_WIDTH, TOTAL_HEIGHT, 100], 
+                     r=ROUND_EDGES_RADIUS, offset=offset);
 }
 
 module fit_inner_cube() {

hardware/config.scad

@@ -1,4 +1,5 @@
 include <config_common.scad>
 include <config_sk6812_english_minimal.scad>
 //include <config_sk6812_german.scad>
+//include <config_tester.scad>
 include <constants_calculated.scad>

hardware/config_common.scad

@@ -1,35 +1,45 @@
 $fn=20;
 
+// Distance between two leds on a strip - depending on your mounting direction, only one is actually relevant,
+// but to keep the clock square, they should be the
 LED_STRIPE_HORIZ_DISTANCE = 16.66;
 LED_STRIPE_VERT_DISTANCE = 16.66;
 
-LED_STRIPE_LED_WIDTH = 8; // The stripe-segments are soldered together, at those points the distance between leds varies a lot, sometimes resoldering is required
+// The size of a single led module on that strip
+
+// The stripe-segments are soldered together, at those points the distance between leds varies a lot,
+// sometimes resoldering is required, so the distances between the leds match up
+LED_STRIPE_LED_WIDTH = 8;
 LED_STRIPE_LED_HEIGHT = 8;
 
+// Since there are small capacitors right next to the leds, we need to provide a little space for them
 LED_STRIPE_CAP_WIDTH = 3;
 LED_STRIPE_CAP_HEIGHT = 5;
 LED_STRIPE_CAP_DEPTH = 1.5; // 1;
 
+// Defines the offset for those capacitors from the leds
 LED_STRIPE_CAP_OFFSET_X = -4;
 LED_STRIPE_CAP_OFFSET_Y = 0;
 
+// Parameters for the screw holes
 LETTER_PLATE_SCREW_INSERT_HEIGHT = 6; // 3.5;
 LETTER_PLATE_SCREW_INSERT_WALL_THICKNESS = 2;
-LETTER_PLATE_SCREW_INSERT_DIAMETER = 4;
+LETTER_PLATE_SCREW_INSERT_DIAMETER = 4; // M3 threaded insert diameter
 LETTER_PLATE_SCREW_WALL_DIAMETER = LETTER_PLATE_SCREW_INSERT_DIAMETER + LETTER_PLATE_SCREW_INSERT_WALL_THICKNESS;
-SCREW_DIAMETER = 3.2; // M3 plus tolerance
+SCREW_DIAMETER = 3.2; // M3 screw diameter with tolerance
 
+// Parameters for the corner holes (used to mount wallplate)
 CORNER_MOUNTING_HOLE_INSERT_HEIGHT = LETTER_PLATE_SCREW_INSERT_HEIGHT;
 CORNER_MOUNTING_HOLE_INSERT_DIAMETER = LETTER_PLATE_SCREW_INSERT_DIAMETER;
 CORNER_MOUNTING_HOLE_INSERT_WALL_THICKNESS = LETTER_PLATE_SCREW_INSERT_WALL_THICKNESS;
-CORNER_MOUNTING_HOLE_WALL_DIAMETER = CORNER_MOUNTING_HOLE_INSERT_DIAMETER + CORNER_MOUNTING_HOLE_INSERT_WALL_THICKNESS;
+CORNER_MOUNTING_HOLE_WALL_DIAMETER = CORNER_MOUNTING_HOLE_INSERT_DIAMETER + CORNER_MOUNTING_HOLE_INSERT_WALL_THICKNESS + 1;
 CORNER_MOUNTING_HOLE_OFFSET = 1.85;
 
 OUTER_HOLES_DIST = 2;
 INNER_HOLES_DIST = 4;
 
 LETTER_PLATE_LETTER_BOTTOM = 0.15;
-LETTER_PLATE_THICKNESS = 1;
+LETTER_PLATE_THICKNESS = 1.05;
 LETTER_SEPARATOR_THICKNESS = 2;
 LETTER_SEPARATOR_HEIGHT = 10;
 
@@ -43,16 +53,21 @@ LED_FIXATION_CUTOUT_HEIGHT = 11;
 LED_FIXATION_CUTOUT_WIDTH = 6;
 LED_FIXATION_PLATE_THICKNESS = 2;
 
+// Height of the backplate
 WALLMOUNT_PLATE_THICKNESS = 6;
 
 ELECTRONICS_HEIGHT = 15;
 
 OUTER_WALL_THICKNESS = 2;
-OUTER_WALL_HEIGHT = 2 + LETTER_SEPARATOR_HEIGHT + (LED_HOLDER_PLATE_HEIGHT-LED_HOLDER_PLATE_DIVIDER_CUTOUT_DEPTH) + LED_FIXATION_PLATE_THICKNESS + 
-    ELECTRONICS_HEIGHT;
+OUTER_WALL_HEIGHT = 2 + LETTER_SEPARATOR_HEIGHT +
+    (LED_HOLDER_PLATE_HEIGHT-LED_HOLDER_PLATE_DIVIDER_CUTOUT_DEPTH) +
+    LED_FIXATION_PLATE_THICKNESS + ELECTRONICS_HEIGHT;
 // 2mm height tolerance to adjust fitting and led-stripe height
 
 ROUND_EDGES_RADIUS = 3;
 
 CONFIG_HORIZ_EXTRA = 0;
 CONFIG_VERT_EXTRA = 0;
+
+
+TESTER_MODE = false;

hardware/config_tester.scad

@@ -0,0 +1,15 @@
+// This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
+// https://creativecommons.org/licenses/by-nc-sa/4.0/
+// (c) 2018 Florian Roks <florian.roks (a) gmail.com>
+
+FONT_NAMES = ["DejaVu Sans Mono"];
+
+FONT_SIZES = [10];
+
+LETTERFACE = ["LO", 
+              "VE"];
+
+LETTERFACE_FONTS = ["00",
+                    "00"];
+
+TESTER_MODE = true;

hardware/constants_calculated.scad

@@ -9,10 +9,10 @@ TOTAL_WIDTH = LED_STRIPE_HORIZ_DISTANCE * LETTER_MATRIX_WIDTH + 2 * HORIZ_SIDE_E
 TOTAL_HEIGHT = LED_STRIPE_VERT_DISTANCE * LETTER_MATRIX_HEIGHT + 2 * VERT_SIDE_EXTRA;
 TOTAL_DEPTH = OUTER_WALL_HEIGHT;
 
-echo("WIDTH=", TOTAL_WIDTH, "HEIGHT=", TOTAL_HEIGHT);
+//echo("WIDTH=", TOTAL_WIDTH, "HEIGHT=", TOTAL_HEIGHT);
 
 LETTER_PLATE_MOUNTING_HOLE_POSITIONS = [
-                    [OUTER_HOLES_DIST, OUTER_HOLES_DIST], 
+                    [OUTER_HOLES_DIST, OUTER_HOLES_DIST],
                     [OUTER_HOLES_DIST, LETTER_MATRIX_HEIGHT - OUTER_HOLES_DIST],
                     [LETTER_MATRIX_WIDTH - OUTER_HOLES_DIST, OUTER_HOLES_DIST],
                     [LETTER_MATRIX_WIDTH - OUTER_HOLES_DIST, LETTER_MATRIX_HEIGHT - OUTER_HOLES_DIST],

hardware/letter_plate.scad

@@ -90,9 +90,10 @@ module screw_holes(z_offset, d) {
 module corner_hole_wall(offset=0,h=OUTER_WALL_HEIGHT) {
     translate([CORNER_MOUNTING_HOLE_WALL_DIAMETER/2,
                CORNER_MOUNTING_HOLE_WALL_DIAMETER/2,
-               h/2])
-        cylinder(h=h, 
-                 d=CORNER_MOUNTING_HOLE_WALL_DIAMETER+offset, 
+               (h - WALLMOUNT_PLATE_THICKNESS)/2])
+        cube(size = [CORNER_MOUNTING_HOLE_WALL_DIAMETER+offset,
+                     CORNER_MOUNTING_HOLE_WALL_DIAMETER+offset, 
+                     h - WALLMOUNT_PLATE_THICKNESS], 
                  center=true);
 }
 
@@ -132,14 +133,14 @@ module corner_holes_walls_bump() {
     }
 }
 
-module outer_walls_bump() {
+module outer_walls_bump(additional_height=0) {
     union() {
-        cube([TOTAL_WIDTH, OUTER_WALL_THICKNESS+1, LETTER_SEPARATOR_HEIGHT]);
-        cube([OUTER_WALL_THICKNESS+1, TOTAL_HEIGHT, LETTER_SEPARATOR_HEIGHT]);
+        cube([TOTAL_WIDTH, OUTER_WALL_THICKNESS+1, LETTER_SEPARATOR_HEIGHT + additional_height]);
+        cube([OUTER_WALL_THICKNESS+1, TOTAL_HEIGHT, LETTER_SEPARATOR_HEIGHT + additional_height]);
         translate([0,TOTAL_HEIGHT-OUTER_WALL_THICKNESS-1,0]) 
-            cube([TOTAL_WIDTH, OUTER_WALL_THICKNESS+1, LETTER_SEPARATOR_HEIGHT]);
+            cube([TOTAL_WIDTH, OUTER_WALL_THICKNESS+1, LETTER_SEPARATOR_HEIGHT + additional_height]);
         translate([TOTAL_WIDTH-OUTER_WALL_THICKNESS-1,0,0]) 
-            cube([OUTER_WALL_THICKNESS+1, TOTAL_HEIGHT, LETTER_SEPARATOR_HEIGHT]);
+            cube([OUTER_WALL_THICKNESS+1, TOTAL_HEIGHT, LETTER_SEPARATOR_HEIGHT + additional_height]);
     }
 }
 
@@ -157,22 +158,39 @@ module clock_front() {
                 inner_separator_grid();
                 outer_walls_bump();
                 screw_hole_walls(z_offset=LETTER_SEPARATOR_HEIGHT - LETTER_SEPARATOR_HEIGHT);
-                corner_holes_walls_bump();
+//                corner_holes_walls_bump();
+
                 corner_holes_walls();
             }
         }
         letter_cutouts();
         screw_holes(z_offset=LETTER_SEPARATOR_HEIGHT - LETTER_PLATE_SCREW_INSERT_HEIGHT, d=LETTER_PLATE_SCREW_INSERT_DIAMETER);
         corner_holes(d=CORNER_MOUNTING_HOLE_INSERT_DIAMETER, 
 		             h=CORNER_MOUNTING_HOLE_INSERT_HEIGHT, 
-					 offset=OUTER_WALL_HEIGHT);
+					 offset=OUTER_WALL_HEIGHT - WALLMOUNT_PLATE_THICKNESS);
         translate([TOTAL_WIDTH/2, 0, OUTER_WALL_HEIGHT-ELECTRONICS_HEIGHT/2+CABLE_SLOT_CORNERS])
             rotate([90,90,0])
                 translate([-ELECTRONICS_HEIGHT/2, -CABLE_SLOT_WIDTH/2, -100/2]) rounded_cube([ELECTRONICS_HEIGHT, CABLE_SLOT_WIDTH, 100], CABLE_SLOT_CORNERS);
     }
 
 }
 
+module tester_plate() {
+    difference() {
+        intersection() {
+            round_edges_cube();
+
+            union() {
+                front_plate();
+                inner_separator_grid();
+                outer_walls_bump(1.6);
+            }
+        }
+        letter_cutouts();
+    }
+
+}
+
 // arranged for 3d-printing / stl-export
-clock_front();
+if (TESTER_MODE == true) { tester_plate(); } else { clock_front(); }
 

hardware/textclock.scad

@@ -9,9 +9,9 @@ use <letter_plate.scad>;
 use <backplate_wall.scad>;
 include <config.scad>
 
-exploded_view = false;
+exploded_view = true;
 
-exploded_offset_diff = 10;
+exploded_offset_diff = 30;
 
 led_holder_plate_z_offset = LETTER_SEPARATOR_HEIGHT-LED_HOLDER_PLATE_DIVIDER_CUTOUT_DEPTH;
 
@@ -30,6 +30,6 @@ translate([0,
             (exploded_view ? 3*exploded_offset_diff : 0) + led_fixation_plate_z_offset])
     led_fixation_plate();
 
-translate([0, 0, OUTER_WALL_HEIGHT])
-    #backplate_wall();
+translate([0, 0, exploded_view ? 4*exploded_offset_diff : 0 ])
+    backplate_wall();
 

software/README.md

@@ -1,7 +1,7 @@
 ## Installing micropython on the clock
 
 ### Prerequisites
-1. Make sure python is installed
+1. Make sure python is installed on your computer
 2. [Install esptool](https://docs.espressif.com/projects/esptool/en/latest/esp8266/index.html)
    ```
    pip3 install esptool