A nightstand noise generator based on M5Stack Atom Echo and integrating with Home Assistant
enclosure: fit Adafruit 1214 protoboard, fix plunger length
Tuned the daughterboard params for the actual Adafruit 1214 Perma-
Proto Small Mint Tin (54 × 33 mm with a 45.5 × 25.4 mm mounting hole
pattern) so it drops in flat without drilling. The four bottom-plate
standoffs now land exactly on the 1214's mounting holes.
While verifying the cap geometry against the new (taller) chamber,
caught a long-standing plunger-length bug: the calculation forgot
that the cap's flange itself eats `snooze_cap_flange_h` of the gap
between the chamber ceiling and the Atom button. The plunger was
2 mm too long, which meant the cap rested 2 mm higher than designed
AND the Atom button was held permanently depressed at rest — would
have shown up in firmware as a stuck press once a unit was assembled.
Other small cleanups in the same pass:
* Added back `spk_total_d` (51 mm) and a new `spk_magnet_protrusion`
(43 mm) to params (`spk_total_d` got dropped during the GRS rewrite
but the assembly view still referenced it).
* Updated the speaker reference geometry in `enclosure.scad` so it
sits on the bottom-plate posts (frame plate at z = spk_post_h, mag-
net hanging below) rather than the old "hanging from the top panel"
position.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
+36
-27
+10
-8
enclosure/enclosure.scad
+10
-8
enclosure/enclosure.scad
···
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// Bottom plate, attached from below.
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bottom_plate();
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-
// Snooze cap at rest position (flange touching the underside of the top
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-
// panel). The cap origin sits with its flange's bottom-front-left at
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-
// z = outer_h - top_t - snooze_cap_flange_h, x/y centered on the well.
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+
// Snooze cap at rest position: flange's top face touches the underside
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+
// of the top panel; plunger bottom kisses the Atom button. The cap is
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+
// rendered with its plunger bottom at its local z=0, so we place that
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+
// at the Atom button top (= atom_z_bottom + atom_body_h).
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flange_w_local = snooze_well_w + 2 * snooze_cap_flange_overhang;
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flange_d_local = snooze_well_d + 2 * snooze_cap_flange_overhang;
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translate([(outer_w - flange_w_local) / 2,
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wall_t + snooze_well_cy - flange_d_local / 2,
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-
outer_h - top_t - snooze_cap_flange_h - (inner_h - (atom_z_bottom + atom_body_h))])
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+
atom_z_bottom + atom_body_h])
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color("white", 0.6) snooze_cap();
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-
// Reference geometry — a translucent box where the Atom Echo lives,
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// for visual verification of clearances. Comment out for a clean view.
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+
// Reference geometry — a translucent box where the Atom Echo lives.
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%translate([(outer_w - atom_w) / 2,
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wall_t + snooze_well_cy - atom_d / 2,
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atom_z_bottom])
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cube([atom_w, atom_d, atom_body_h]);
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-
// Reference geometry — speaker frame footprint hanging from the top panel.
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+
// Reference geometry — speaker, sitting on the four bottom-plate posts.
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+
// Frame plate at z = spk_post_h; magnet hangs spk_magnet_protrusion below;
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+
// cone tip rises (spk_total_d - spk_magnet_protrusion) above.
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%translate([(outer_w - spk_frame) / 2,
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wall_t + spk_grille_cy - spk_frame / 2,
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-
outer_h - top_t - spk_total_d])
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+
spk_post_h - spk_magnet_protrusion])
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cube([spk_frame, spk_frame, spk_total_d]);
+16
-9
enclosure/lib/params.scad
+16
-9
enclosure/lib/params.scad
···
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// clearance between magnet bottom and bottom plate.
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// ============================================================
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spk_frame = 95; // largest lateral extent (mounting-ear to mounting-ear)
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spk_mount_pattern = 60; // square M3 hole pattern (centers)
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-
spk_mount_hole_d = 3.4; // M3 clearance
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-
spk_cone_cutout = 67; // baffle opening (estimate; measure & update)
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+
spk_frame = 95; // largest lateral extent (mounting-ear to mounting-ear)
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+
spk_mount_pattern = 60; // square M3 hole pattern (centers)
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+
spk_mount_hole_d = 3.4; // M3 clearance
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+
spk_cone_cutout = 67; // baffle opening (estimate; measure & update)
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+
spk_total_d = 51; // total speaker depth (cone tip to magnet bottom)
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+
spk_magnet_protrusion = 43; // magnet hangs this far below the frame plate
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// ============================================================
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// Daughterboard — protoboard the Atom presses onto.
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+
// Sized for the Adafruit 1214 (Perma-Proto Small Mint Tin Size):
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// 54 × 33 mm × 1.6 mm FR4, with 4 mounting holes on a 45.5 × 25.4 mm
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+
// rectangular pattern centered on the board.
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// ============================================================
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-
dboard_t = 1.6;
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dboard_w = atom_w + 14;
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-
dboard_d = atom_d + 14;
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-
dboard_pin_h = 6;
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-
dboard_standoff_h = 6;
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+
dboard_t = 1.6;
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+
dboard_w = 54; // Adafruit 1214 long axis
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+
dboard_d = 33; // Adafruit 1214 short axis
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+
dboard_screw_pattern_w = 45.5; // mounting hole pattern, long axis
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+
dboard_screw_pattern_d = 25.4; // mounting hole pattern, short axis
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+
dboard_pin_h = 6;
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+
dboard_standoff_h = 6;
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// ============================================================
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// Snooze cap + well
+5
-6
enclosure/parts/bottom-plate.scad
+5
-6
enclosure/parts/bottom-plate.scad
···
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module daughterboard_standoffs() {
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standoff_d = 5;
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-
standoff_id = 1.6;
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-
inset = 3;
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+
standoff_id = 1.6; // M2 self-tap pilot into PLA
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65
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-
for (sx = [dboard_cx - dboard_w / 2 + inset,
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-
dboard_cx + dboard_w / 2 - inset])
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-
for (sy = [dboard_cy - dboard_d / 2 + inset,
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-
dboard_cy + dboard_d / 2 - inset])
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+
for (sx = [dboard_cx - dboard_screw_pattern_w / 2,
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+
dboard_cx + dboard_screw_pattern_w / 2])
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+
for (sy = [dboard_cy - dboard_screw_pattern_d / 2,
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+
dboard_cy + dboard_screw_pattern_d / 2])
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difference() {
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translate([sx, sy, 0])
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cylinder(h = dboard_standoff_h, d = standoff_d);
+5
-4
enclosure/parts/snooze-cap.scad
+5
-4
enclosure/parts/snooze-cap.scad
···
20
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EPS = 0.05;
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// Distance the plunger has to descend below the flange to reach the Atom
23
-
// button. Derived from the chamber height and the Atom-on-daughterboard
24
-
// stack — when the flange top touches the underside of the top panel,
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-
// the plunger bottom should just kiss the Atom button.
23
+
// button. When the flange's TOP face touches the underside of the top
24
+
// panel, the plunger bottom should just kiss the Atom button — so the
25
+
// plunger spans from the flange's BOTTOM (top-panel-underside minus
26
+
// flange thickness) down to the button.
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atom_button_top_z = atom_z_bottom + atom_body_h;
27
-
plunger_h = inner_h - atom_button_top_z;
28
+
plunger_h = inner_h - snooze_cap_flange_h - atom_button_top_z;
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// Z layout of the cap, bottom-up:
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z_plunger_bot = 0;