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--- projects:tesla_car:doorhandles [2018/05/02 00:37] – created admin
+++ projects:tesla_car:doorhandles [2018/09/11 00:50] (current) – [Mylar sheet] admin
@@ Line 1: / Line 1: @@
-= Tesla Model S door handles =
+====== Tesla Model S door handles ======
 Until about 2017, the Model S door handles suffered two problems. These were:
   * Water ingress damaged multiple parts. These were:
@@ Line 9: / Line 9: @@
     * Non working LED illumination module was probably hammered in by Tesla, which caused cracks in the plastic with water ingress and corrosion as a consequence.
-== Remedy RR-RH ==
+==== Remedy RR-RH ====
 Original part after taking out:
+{{ :projects:tesla_car:img_20180120_215926.resized.jpg?direct&400 |}}
+A solution for the switches was to combine both moving switches in a stationary holder. After designing with FreeCAD, the following came out:
+==== Mylar sheet ====
+One of the objectives is to make the doorhandles water-proof. For this the following material has been tested:
+  * IASOPET OAN 26μm, Zolltarif PET Folie 39206219, BOPP Folie 39202021 (delivered from the company Strohmeier+Ernst GmbH & Co KG, Pilgerplatt 10, 33378 Rheda-Wiedenbrück, Mr. Gottlieb Ernst, Tlf. 05242-406603, Kunde Nr. 500002)
+  * Hostaphan RNT/36μm, (Delivered by the company Pütz GmbH + Co. Folien KG, Obere Waldstr. 26 + 26a, 65232 Taunusstein-Wehen, Tlf. Mrs. Manuela Erdmann, Tlf. 06128-964270)
+==== FreeCad ====
+The following script creates the RR_RH part:
+<code python>
+#!/usr/bin/python
+# This script creates a small 3d printable enclosure for two switches
+# to improve the constuction of a tesla retracting door handle.
+#
+# copyright: Marc Nijdam
+# Date of creation: 05.02.2018
+#
+# To run this independent of an instance of freecad, uncomment following lines.
+#import sys
+#sys.path.append("/usr/lib/freecad/lib")
+#import FreeCAD
+#import FreeCADGui
+# Otherwise, copy paste this code into the freecad python console.
+import WebGui
+import PartDesignGui
+import math
+import Part
+import os.path
+# helper functions
+# sketches a line from a to b on a sketch object: App.getDocument("tesla_RR_RH").some_sketch
+def sketch_line(pl_obj,a,b):
+	return pl_obj.addGeometry(Part.LineSegment(App.Vector(a[0],a[1]),App.Vector(b[0],b[1])),False)
+# returns sum of two coordinates
+def addp(a,b):
+	return ([a[0] + b[0], a[1] + b[1]])
+#
+# coordinate system
+#     ________
+#    !       \_
+#    !         !
+#    !         !
+#  ^ !     ____!
+#  y !_(o)!
+#
+#    x >
+#
+# creation mode: 0:final shape, 1:3d printable shape
+print_3d = 1
+# parameters: stack
+hb = 2.0 # height of bottom area
+hb1 = 4.0 # thickness of base 1
+hb_mid = 4.0 # thickness of base_mid
+# parameters: wall thickness
+#     _____
+#    !    !##2##
+#    !    !1   3
+#    !    !##4##
+#  ^ !     ____!
+#  y !_(o)!
+#
+#    x >
+tw1 = 1.8 # thickness wall 1
+tw2 = 1.0 # thickness wall 2
+tw3 = 1.8 # thickness wall 3
+tw4 = 1.8 # thickness wall 4
+# parameters: switch Panasonic ASQ10410
+sw_dim = [5.4, 13.3, 12.3] # switch (W x L x H)
+sw_area = [13.4, 10.0, hb] # left bottom area where switches are [x,y,z]
+sw_offset = [2.71, 6.66, 7.25] # offset for switch left bottom front corner
+sw_rotation = [90, 0, 90] # default rotation angle for importing switch
+sw_gap = 0.1 # extra margin around switch
+bc_vpos = 3.2 # bottom corner vertical space
+#
+#  (switch side view)
+#
+#               _^_
+#              !  !
+#             #####___-----
+#             !           !
+#             !           !
+#             ! ()     {} !    () pin     {} hole
+#             !___________!
+#               #   #   #
+# left bottom ^
+# corner is reference point (0,0)
+#
+sw_pin = [2.7, 7.2] # position of pin referenced to left bottom corner
+pin_d = 3.0 # diameter of side pins at switches
+pin_p = 1.5 # sideways distance of protruding pin
+sw_hole = [2.7 + 8.3, 7.2] # position of hole referenced to left bottom corner
+#
+#     (switches top view)
+#    _..__  _
+#   [_<>__||_] SW1: Width: 13.3, pin: 2.7, pin > hole: 8.3, rest: 2.3
+#     ''__.._
+#    [||__<>_] SW2: Width: 13.3, hole: 2.3, hole > pin : 8.3, rest: 2.7, D_hole-right border = 13.3-2.3 = 11.0
+#         ''
+# Total width for reciprocal switch mounting: 2.7 + 11.0 = 13.7mm = sw_pin[0] + (sw_dim[1] - (sw_dim[1] - sw_hole[0]))
+#  = sw_pin[0] + sw_hole[0]
+# Therefore y dimension of wall 2 to position in sw_area = max(sw_dim[1], sw_pin[0] + sw_hole[0])
+sw_fname = "/home/mni/Backup/projects/programming/freecad/tesla_adapter_pieces/asq10410.step" # file obtained from Panasonic
+# parameters: mounting hole position
+mnt_pos = [10.0, 5.0] # [x,y]
+mnt_hole1 = 10.0 # diameter of hole at base 1
+mnt_hole2 = 3.0 # diameter of hole at base 2
+# parameters: total object size
+obj_dim = [26.0, 26.0, sw_dim[2] + hb + sw_gap] # maximum dimensions of object
+# parameters: pipe dimensions
+w_trench = 2.5 # diameter of trench for cable
+# parameters: small corner to cut away
+crn_dim = [3.0, 1.5, obj_dim[2]] # small corner to cut material away
+crn_c_angle = 88 # ref drawing 9b
+# Screwhead
+screw_head_d = 4 # screwhead diameter
+### deriving points
+#
+# calculations based on choniometrical identities
+# Using:
+#   w_trench: closest distance between two (parallel) lines PQ and MN
+#   w       : closest wall thickness (distance between lines HG and QP, FG and PN, MN and EF)
+#   point F is pivot point
+#   point A, B, C, D, F, I, J, K and L are fixed points.
+#   other points depend on value of w and w_trench.
+#   Point X is in the middle, between point I and L
+#
+#   Line PS is perpendicular to line MN (drawing is not to scale)
+#     _________________________
+#    !                        B----------------------------------C
+#    !                        |                                  |
+#    !                        |  J---------------------------K   |
+#    !                        |  |                           |   |
+#    !                        |  |                           |   |
+#    !                        |  |                           |   |
+#    !                        |  |                           |   |
+#    !                        |  |                           |   |
+#    !                        |  |                           |   |
+#    !                        |  I------Q     X     M----S---L   T
+#    !                        |          \     .    \     \      |
+#    !                        A-----H     \     .    \     E-----D
+#    !                               \     \     .    \V    W
+#    !                                \     \     U    \     \
+#    !                                 \     \     .    \     \
+#    !                                  \     P-----.----N     \
+#    !                                   \           .          \
+#    !              (0)       ____________G-----------Z----------F
+#    !                       )
+#    !                     _/
+#    !---------------------
+#                                    (Drawing 4 - wall)
+#
+#
+#
+#
+#   Additionally helper points U, V and W are defined, as well as T
+#   Calculation is based on defining helper line XZ, parallel to SF.
+#   In the middle between points U and W, is point V, which is also
+#   the middle point between points X and F. The line UW is perpendicular
+#   to line XZ. Furthermore, the distance of the line:
+#     UW = 0.5 * w_trench + w
+#   Therefore the distance of points UV is m = 0.5 * UW
+#   With that we can calculate the angles a and b which we use to calculate
+#   the coordinates of the remaining points.
+#
+sw_width = max(sw_dim[1], sw_pin[0] + sw_hole[0]) # maximum width (in y-direction) for two reciprocal positioned switches
+Xmax = min(sw_area[0] + sw_dim[0] * 2 + tw3, obj_dim[0]) # Make sure, wall thickness never exceed maximum object size
+Ymax = min(sw_area[1] + sw_width + tw2, obj_dim[1]) # Make sure, wall thickness never exceed maximum object size
+w = max(max(max(tw1,tw2),tw3),tw4) # find the thickest wall as base to create strong walls around the wire trench
+m = (0.5 * w_trench + w) * 0.5
+XV = math.sqrt( ((obj_dim[0] - sw_area[0] - sw_dim[0]) / 2) ** 2 +  ((sw_area[1] - bc_vpos) / 2) ** 2)
+a = math.asin(m/XV) # in radians
+b = math.asin( (sw_area[1] - bc_vpos) / (XV * 2) ) # in radians
+wh_trench = w_trench / math.sin(a + b)
+wh = w / math.sin(a + b)
+# outer wall
+pt_a = [sw_area[0] - tw1, sw_area[1] - tw4] # starting point
+pt_b = [sw_area[0] - tw1, Ymax]
+pt_c = [Xmax, Ymax]
+pt_d = [Xmax, sw_area[1] - tw4]
+pt_f = [obj_dim[0], bc_vpos]
+pt_x = [sw_area[0] + sw_dim[0], sw_area[1]]
+pt_e = [obj_dim[0] - (sw_area[1] - tw4 - bc_vpos) / math.tan(a + b), sw_area[1] - tw4]
+pt_g = addp(pt_f, [ - (2 * wh + wh_trench), 0])
+pt_h = [pt_g[0] - (pt_f[0] - pt_e[0]), pt_a[1]]
+# inner wall
+pt_i = [sw_area[0], sw_area[1]]
+pt_j = addp(pt_b, [tw1, -tw2])
+pt_k = addp(pt_c, [-tw3, -tw2])
+pt_l = addp(pt_d, [-tw3, tw4])
+pt_m = addp(pt_x, [wh_trench/2, 0])
+pt_n = [pt_m[0] + (sw_area[1] - bc_vpos - w) / math.tan(a + b), bc_vpos + w]
+pt_p = addp(pt_n, [-wh_trench, 0])
+pt_q = addp(pt_m, [-wh_trench, 0])
+# Initialization
+App.newDocument("tesla_RR_RH")
+App.setActiveDocument("tesla_RR_RH")
+App.ActiveDocument=App.getDocument("tesla_RR_RH")
+Gui.ActiveDocument=Gui.getDocument("tesla_RR_RH")
+App.activeDocument().saveAs("/home/mni/Backup/projects/programming/freecad/tesla_adapter_pieces/rear_right_side6.fcstd")
+ad = App.getDocument("tesla_RR_RH")
+gd = Gui.getDocument("tesla_RR_RH")
+# 0. Create grid (key g, key r), set camera position
+Gui.activateWorkbench("DraftWorkbench")
+gd.activeView().setCamera('#Inventor V2.1 ascii \n OrthographicCamera {\n viewportMapping ADJUST_CAMERA \n position 0 0 87 \n orientation 0 0 1  0 \n nearDistance -112.88701 \n farDistance 287.28702 \n aspectRatio 1 \n focalDistance 87 \n height 143.52005 }')
+# 1. Create sketch for ground object
+#     _____
+#    !####!
+#    !####!
+#    !####!_____
+#  ^ !#########!
+#  y !#(o)!
+#
+#    x >
+r = mnt_hole1/2.0
+q = 8.2 # bottom corner horizontal space
+a1=-math.asin((mnt_pos[0]-q)/r) # starting angle of arc
+a2=-math.pi/2 - math.asin((mnt_pos[0]-q)/r) # end angle of arc
+xa1=mnt_pos[0] + math.sqrt(r ** 2 - (mnt_pos[1]-bc_vpos) ** 2)
+ya2=mnt_pos[1] - math.sqrt(r ** 2 - (mnt_pos[0]-q) ** 2)
+Gui.activateWorkbench("PartDesignWorkbench")
+ad.addObject('PartDesign::Body','sw_housing_RR_RH')
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','base_sketch')
+ad.base_sketch.Support = (ad.XY_Plane, [''])
+ad.base_sketch.MapMode = 'FlatFace'
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('base_sketch')
+so=ad.base_sketch # sketch object
+gd.setEdit('base_sketch')
+sketch_line(so, [0.0, 0.0]                          , [0.0, obj_dim[1]])
+sketch_line(so, [0.0, obj_dim[1]]                   , [sw_area[0] - tw1, obj_dim[1]])
+sketch_line(so, [sw_area[0] - tw1, obj_dim[1]]      , [sw_area[0]-tw1, sw_area[1]-tw4])
+sketch_line(so, [sw_area[0] - tw1, sw_area[1] - tw4], pt_h)
+sketch_line(so, pt_h, pt_p)
+sketch_line(so, pt_p, pt_n)
+sketch_line(so, pt_n, pt_e)
+sketch_line(so, pt_e, [obj_dim[0], sw_area[1]-tw4])
+sketch_line(so, [obj_dim[0], sw_area[1]-tw4]    , [obj_dim[0], bc_vpos])
+sketch_line(so, [obj_dim[0], bc_vpos]           , [xa1, bc_vpos])
+so.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1]),App.Vector(0,0,1), r),a2,a1),False)
+sketch_line(so, [q, ya2], [q, 0.0])
+sketch_line(so, [q, 0.0], [0.0, 0.0])
+so.addGeometry(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1]),App.Vector(0,0,1), mnt_hole2/2.0),False)
+ad.recompute()
+# ... pad base_sketch
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pad","base")
+ad.base.Profile = so
+ad.base.Length = hb1 + hb_mid
+ad.base.Length2 = 100.000000
+ad.base.Type = 0
+ad.base.UpToFace = None
+ad.base.Reversed = 0
+ad.base.Midplane = 0
+ad.base.Offset = 0.000000
+gd.setEdit('base', 0)
+Gui.Selection.clearSelection()
+gd.base.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.base.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.base.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.base.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.base.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+so.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 2. create maximum size floor under switch area and pad
+#     _____
+#    !    !#####
+#    !    !#####
+#    !    !#####
+#  ^ !     ____!
+#  y !_(o)!
+#
+#    x >
+gd.activeView().viewAxonometric()
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','floorbase')
+ad.floorbase.Support = (ad.XY_Plane, [''])
+ad.floorbase.MapMode = 'FlatFace'
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('floorbase')
+bs=ad.floorbase
+gd.setEdit('floorbase')
+sketch_line(bs, [sw_area[0]-tw1, sw_area[1]-tw4], [sw_area[0]-tw1, obj_dim[1]    ])
+sketch_line(bs, [sw_area[0]-tw1, obj_dim[1]    ], [obj_dim[0]    , obj_dim[1]    ])
+sketch_line(bs, [obj_dim[0]    , obj_dim[1]    ], [obj_dim[0]    , sw_area[1]-tw4])
+sketch_line(bs, [obj_dim[0]    , sw_area[1]-tw4], pt_e)
+sketch_line(bs, pt_e, pt_n)
+sketch_line(bs, pt_n, pt_p)
+sketch_line(bs, pt_p, pt_h)
+sketch_line(bs, pt_h, [sw_area[0]-tw1, sw_area[1]-tw4])
+ad.recompute()
+# ... pad main_switchfloor
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pad","main_switchfloor")
+ad.main_switchfloor.Profile = bs
+ad.main_switchfloor.Length = hb
+ad.main_switchfloor.Length2 = 100.000000
+ad.main_switchfloor.Type = 0
+ad.main_switchfloor.UpToFace = None
+ad.main_switchfloor.Reversed = 0
+ad.main_switchfloor.Midplane = 0
+ad.main_switchfloor.Offset = 0.000000
+gd.setEdit('main_switchfloor', 0)
+Gui.Selection.clearSelection()
+gd.main_switchfloor.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.main_switchfloor.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.main_switchfloor.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.main_switchfloor.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.main_switchfloor.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+bs.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 3. Create sketch for switch walls and pad
+#  ref. Drawing 4 - wall
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch_walls_sketch')
+ad.switch_walls_sketch.Support = (ad.main_switchfloor,["Face14"]) # found by testing...
+ad.switch_walls_sketch.MapMode = 'FlatFace'
+gd.setEdit('switch_walls_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('switch_walls_sketch')
+wsk=ad.switch_walls_sketch
+# sketch for outside wall:
+sketch_line(wsk, pt_a, pt_b)
+sketch_line(wsk, pt_b, pt_c)
+sketch_line(wsk, pt_c, pt_d)
+sketch_line(wsk, pt_d, pt_e)
+sketch_line(wsk, pt_e, pt_f)
+sketch_line(wsk, pt_f, pt_g)
+sketch_line(wsk, pt_g, pt_h)
+sketch_line(wsk, pt_h, pt_a)
+# sketch for inside wall:
+sketch_line(wsk, pt_i, pt_j)
+sketch_line(wsk, pt_j, pt_k)
+sketch_line(wsk, pt_k, pt_l)
+sketch_line(wsk, pt_l, pt_m)
+sketch_line(wsk, pt_m, pt_n)
+sketch_line(wsk, pt_n, pt_p)
+sketch_line(wsk, pt_p, pt_q)
+sketch_line(wsk, pt_q, pt_i)
+ad.recompute()
+# ... Pad walls
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pad","switch_walls")
+ad.switch_walls.Profile = wsk
+ad.switch_walls.Length = obj_dim[2] - hb
+ad.switch_walls.Length2 = 100.0
+ad.switch_walls.Type = 0
+ad.switch_walls.UpToFace = None
+ad.switch_walls.Reversed = 0
+ad.switch_walls.Midplane = 0
+ad.switch_walls.UpToFace = None
+gd.setEdit('switch_walls', 0)
+Gui.Selection.clearSelection()
+gd.switch_walls.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.switch_walls.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.switch_walls.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.switch_walls.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.switch_walls.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+wsk.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 5. create a maximum 0.8mm fillet for inside bottom edges
+Gui.activateWorkbench("PartDesignWorkbench")
+ad.sw_housing_RR_RH.newObject("PartDesign::Fillet","Fillet")
+ad.Fillet.Radius = min(0.8, w_trench / 4)
+ad.Fillet.Base = (App.ActiveDocument.switch_walls,["Face26"])
+Gui.Selection.clearSelection()
+gd.hide("switch_walls")
+ad.recompute()
+gd.setEdit('Fillet', 0)
+gd.Fillet.ShapeColor=Gui.ActiveDocument.sw_housing_RR_RH.ShapeColor
+gd.Fillet.LineColor=Gui.ActiveDocument.sw_housing_RR_RH.LineColor
+gd.Fillet.PointColor=Gui.ActiveDocument.sw_housing_RR_RH.PointColor
+gd.Fillet.Transparency=Gui.ActiveDocument.sw_housing_RR_RH.Transparency
+gd.Fillet.DisplayMode=Gui.ActiveDocument.sw_housing_RR_RH.DisplayMode
+ad.recompute()
+gd.resetEdit()
+# 6. Create sketch for m3 screwhead
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','screwhead_sketch')
+ad.screwhead_sketch.Support = (ad.Fillet,["Face4"]) # found by testing...
+ad.screwhead_sketch.MapMode = 'FlatFace'
+gd.setEdit('screwhead_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('screwhead_sketch')
+ssk=ad.screwhead_sketch
+ssk.addGeometry(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1],0),App.Vector(0,0,1),screw_head_d),False)
+ad.recompute()
+# ... create a pocket from top downwards
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","screwhead")
+ad.screwhead.Profile = ssk
+ad.screwhead.Length = obj_dim[2]-(hb1+hb_mid)
+ad.screwhead.Length2 = 100.0
+ad.screwhead.Type = 0
+ad.screwhead.UpToFace = None
+ad.screwhead.Reversed = 0
+ad.screwhead.Midplane = 0
+ad.screwhead.UpToFace = None
+ad.screwhead.Offset = 0.0
+gd.setEdit('screwhead', 0)
+Gui.Selection.clearSelection()
+gd.screwhead.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.screwhead.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.screwhead.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.screwhead.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.screwhead.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+ssk.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 7. Create sketch for slope
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','slope_sketch')
+ad.slope_sketch.Support = (ad.screwhead,["Face35"]) # found by testing...
+ad.slope_sketch.MapMode = 'FlatFace'
+gd.setEdit('slope_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('slope_sketch')
+lsk=ad.slope_sketch
+sketch_line(lsk, [-10.5, hb1 + hb_mid], [-obj_dim[0], hb]) # previous height: sw_pin[2] + hb - pin_d/2
+sketch_line(lsk, [-obj_dim[0], hb]                  , [-obj_dim[0], obj_dim[2]])
+sketch_line(lsk, [-obj_dim[0], obj_dim[2]]          , [-10.5, obj_dim[2]])
+sketch_line(lsk, [-10.5, obj_dim[2]]                , [-10.5, hb1 + hb_mid])
+ad.recompute()
+# ... create a pocket for the slope with 11.5mm
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","slope")
+ad.slope.Profile = lsk
+ad.slope.Length = sw_area[0] - tw1
+ad.slope.Length2 = 100.0
+ad.slope.Type = 0
+ad.slope.UpToFace = None
+ad.slope.Reversed = 0
+ad.slope.Midplane = 0
+ad.slope.UpToFace = None
+gd.setEdit('slope', 0)
+Gui.Selection.clearSelection()
+gd.slope.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.slope.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.slope.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.slope.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.slope.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+lsk.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 8. create pockets for switch side pin
+#
+#____(2)_____(3)   <----- Top of object
+#  \  !       !
+#  \  !       !
+#  \  !       !
+#  \  !       !
+#  \  !<----->!    width corresponds with pin diameter
+#  \  !       !
+#  \  !       !
+#  \ (1)  0  (4)   <------ Pin center (ref: sw_hole)
+#  \   \     /
+#  \    '-_-'
+#
+#     pin radius: pin_d / 2
+#     pin thickness: tw1 - 0.3
+#     column height: tw1
+#     column length: sw_dim[2] - sw_pin[2]
+#     column width: pin_d
+#
+# Pocket 1
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch1_pocket_sketch')
+ad.switch1_pocket_sketch.Support = (ad.slope,["Face5"]) # found by testing...
+ad.switch1_pocket_sketch.MapMode = 'FlatFace'
+gd.setEdit('switch1_pocket_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('switch1_pocket_sketch')
+swp1=ad.switch1_pocket_sketch
+# all coordinates relative to pin center
+sp_0 = [sw_area[1] + sw_pin[0] , obj_dim[2] - sw_dim[2] + sw_pin[1]]
+sp_1 = addp(sp_0, [- pin_d / 2, 0])
+sp_2 = [sp_1[0], obj_dim[2]]
+sp_3 = addp(sp_2, [pin_d, 0])
+sp_4 = addp(sp_1, [pin_d, 0])
+sketch_line(swp1, sp_1, sp_2)
+sketch_line(swp1, sp_2, sp_3)
+sketch_line(swp1, sp_3, sp_4)
+swp1.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(sp_0[0], sp_0[1]), App.Vector(0,0,1), pin_d / 2), math.pi, 0),False)
+ad.recompute()
+# ... create a pocket for the switch side-pin
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","switch1_pocket")
+ad.switch1_pocket.Profile = swp1
+ad.switch1_pocket.Length = tw1 - 0.3
+ad.switch1_pocket.Length2 = 100.0
+ad.switch1_pocket.Type = 0
+ad.switch1_pocket.UpToFace = None
+ad.switch1_pocket.Reversed = 0
+ad.switch1_pocket.Midplane = 0
+ad.switch1_pocket.UpToFace = None
+gd.setEdit('switch1_pocket', 0)
+Gui.Selection.clearSelection()
+gd.switch1_pocket.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.switch1_pocket.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.switch1_pocket.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.switch1_pocket.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.switch1_pocket.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+swp1.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# Pocket 2
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch2_pocket_sketch')
+ad.switch2_pocket_sketch.Support = (ad.switch1_pocket,["Face23"]) # found by testing...
+ad.switch2_pocket_sketch.MapMode = 'FlatFace'
+gd.setEdit('switch2_pocket_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('switch2_pocket_sketch')
+swp2=ad.switch2_pocket_sketch
+# all coordinates relative to pin center
+sp_0 = [-(sw_area[1] + sw_hole[0]) , obj_dim[2] - sw_dim[2] + sw_pin[1]]
+sp_1 = addp(sp_0, [- pin_d / 2, 0])
+sp_2 = [sp_1[0], obj_dim[2]]
+sp_3 = addp(sp_2, [pin_d, 0])
+sp_4 = addp(sp_1, [pin_d, 0])
+sketch_line(swp2, sp_1, sp_2)
+sketch_line(swp2, sp_2, sp_3)
+sketch_line(swp2, sp_3, sp_4)
+swp2.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(sp_0[0], sp_0[1]), App.Vector(0,0,1), pin_d / 2), math.pi, 0),False)
+ad.recompute()
+# ... create a pocket for the switch side-pin
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","switch2_pocket")
+ad.switch2_pocket.Profile = swp2
+ad.switch2_pocket.Length = tw3 - 0.3
+ad.switch2_pocket.Length2 = 100.0
+ad.switch2_pocket.Type = 0
+ad.switch2_pocket.UpToFace = None
+ad.switch2_pocket.Reversed = 0
+ad.switch2_pocket.Midplane = 0
+ad.switch2_pocket.UpToFace = None
+gd.setEdit('switch2_pocket', 0)
+Gui.Selection.clearSelection()
+gd.switch2_pocket.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.switch2_pocket.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.switch2_pocket.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.switch2_pocket.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.switch2_pocket.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+swp2.ViewObject.Visibility=False
+ad.recompute()
+gd.resetEdit()
+# 9. cut away small corner
+#
+# Coordinate system:
+#     _____
+#    !    !####X   <--- small corner to cut away
+#    !    !#   #
+#    !    !## ##
+#  ^ !     __\\_
+# -y !_(o)!
+#   +x >
+#            .--- crn_dim[0]
+#           \/
+#       2_______1
+#      !        !  \
+#      !        !  !_   crn_dim[1]
+#      3__    c !  !
+#         ''--__4 /
+#
+#      (drawing 9b - corner cut)
+#
+#      Angle c is somewhat smaller
+#      than 90 degrees
+#
+#
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','corner_cut_sketch')
+ad.corner_cut_sketch.Support = (ad.switch2_pocket,["Face39"]) # found by testing...
+ad.corner_cut_sketch.MapMode = 'FlatFace'
+gd.setEdit('corner_cut_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('corner_cut_sketch')
+ccs=ad.corner_cut_sketch
+cc_1 = [obj_dim[0], -obj_dim[1]]
+cc_2 = addp(cc_1, [-crn_dim[0], 0])
+cc_4 = addp(cc_1, [0          , crn_dim[1]])
+cc_3 = addp(cc_4, [-crn_dim[0], -crn_dim[0]/math.tan(crn_c_angle * math.pi / 180)])
+sketch_line(ccs, cc_1, cc_2)
+sketch_line(ccs, cc_2, cc_3)
+sketch_line(ccs, cc_3, cc_4)
+sketch_line(ccs, cc_4, cc_1)
+ad.recompute()
+gd.resetEdit()
+# create pocket
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","corner_cut")
+ad.corner_cut.Profile = ccs
+ad.corner_cut.Length = obj_dim[2] * 1.5
+ad.corner_cut.Length2 = 100.0
+ad.corner_cut.Type = 0
+ad.corner_cut.UpToFace = None
+ad.corner_cut.Reversed = 0
+ad.corner_cut.Midplane = 0
+ad.corner_cut.UpToFace = None
+gd.setEdit('corner_cut', 0)
+Gui.Selection.clearSelection()
+ccs.ViewObject.Visibility=False
+gd.corner_cut.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.corner_cut.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.corner_cut.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.corner_cut.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.corner_cut.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+ad.recompute()
+gd.resetEdit()
+# 10. last final operation: create pocket from
+#     circle on bottom face for the print_3d option:
+# if set, cut out cylinder which cannot be 3d printed
+r_circle = mnt_hole1/2.0
+ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','cut_sketch')
+ad.cut_sketch.Support = (ad.corner_cut,["Face38"]) # found by testing...
+ad.cut_sketch.MapMode = 'FlatFace'
+gd.setEdit('cut_sketch')
+Gui.activateWorkbench('SketcherWorkbench')
+ActiveSketch = ad.getObject('cut_sketch')
+csk=ad.cut_sketch
+csk.addGeometry(Part.Circle(App.Vector(mnt_pos[0],-mnt_pos[1],0),App.Vector(0,0,1), r_circle),False)
+ad.recompute()
+gd.resetEdit()
+# create pocket
+Gui.activateWorkbench('PartDesignWorkbench')
+ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","baseprt")
+ad.baseprt.Profile = csk
+ad.baseprt.Length = hb1
+ad.baseprt.Length2 = 100.0
+ad.baseprt.Type = 0
+ad.baseprt.UpToFace = None
+ad.baseprt.Reversed = 0
+ad.baseprt.Midplane = 0
+ad.baseprt.UpToFace = None
+gd.setEdit('baseprt', 0)
+Gui.Selection.clearSelection()
+csk.ViewObject.Visibility=False
+gd.baseprt.ShapeColor=gd.sw_housing_RR_RH.ShapeColor
+gd.baseprt.LineColor=gd.sw_housing_RR_RH.LineColor
+gd.baseprt.PointColor=gd.sw_housing_RR_RH.PointColor
+gd.baseprt.Transparency=gd.sw_housing_RR_RH.Transparency
+gd.baseprt.DisplayMode=gd.sw_housing_RR_RH.DisplayMode
+ad.recompute()
+gd.resetEdit()
+# 11. import switches if file is present
+if os.path.isfile(sw_fname) and print_3d == 1:
+	import ImportGui
+	# import switch1
+	ImportGui.insert(sw_fname,"tesla_RR_RH")
+	App.activeDocument().Part__Feature.Placement=App.Placement(App.Vector(sw_offset[0] + sw_area[0], sw_offset[1] + sw_area[1], sw_offset[2] + sw_area[2] + sw_gap), App.Rotation(90,0,90), App.Vector(0,0,0))
+	#import switch2
+	ImportGui.insert(sw_fname,"tesla_RR_RH")
+	App.activeDocument().Part__Feature001.Placement=App.Placement(App.Vector(sw_offset[0] + sw_area[0] + sw_dim[0], sw_offset[1] + sw_area[1] + (sw_pin[1] - (sw_dim[1] - sw_hole[1])), sw_offset[2] + sw_area[2] + sw_gap), App.Rotation(-90,0,90), App.Vector(0,0,0))
+# finished
+Gui.SendMsgToActiveView("ViewFit")
+Gui.activeDocument().activeView().viewAxonometric()
+</code>

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