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additional mechanical parts for housing

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This commit is contained in:
Thomas Gohle
2026-05-25 19:45:09 +02:00
parent 23fae3e290
commit 251f7ed376
9 changed files with 15916 additions and 23296 deletions
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firmware/ATTINY85_2026_MorseThrowie/ATTINY85_2026_MorseThrowie.ino Normal file
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/*
=============================================================================
FireFly Morse Throwie
- a light controled (LED as Sensor) morseblinker throwie with ATTiny45/85
=============================================================================
Project definitions, sources
-----------------------------------------------------------------------------
Version: 0.1 - Attiny85 Version
Date : 25.05.2026
-----------------------------------------------------------------------------
Inspired by Karl Lunt's FireFly project I wrote some code to make this
Throwie lasting longer, blinking only at low light levels and morse also
some text.
http://www.seanet.com/~karllunt/fireflyLED.html
How it works (only the Morsethrowy part):
LED detects light level, using bleeding out time of LED pn-capacitor.
If dark enough blink a text in morsecode (ATTiny45 = 22 Chars, text will
be defined in line 191/192 of this file)
To save energy go to powersave mode after blinking or light level is
over threshold. Tests this every 8s (maximum time for watchdog timer
possible for ATTiny). Repeat this endless
The wiring, it's very simple, see also HW part of the Project.
+---+ +------\/------+
| | ATTINY45 /85 |
> | -+1=PB5 VCC=8+-> to SuperCap / DC-DC 3V/5V
xxx Ohm < | | |
> +------+2=PB3 PB2=7+-
| | |
----- +------+3=PB4 PB1=6+-
LED / \ | | |
----- | +--+4=GND PB0=5+-
| | | | |
+---+ | +--------------+
|
+---------------------> to battery GND
You can use other pins if necessary, theoretical up to 3 LEDs, as example I
tried out to connect another one at PB2&PB1. working fine. Basic wiring:
+ LED_N_Side), wired to a digital pin, NOT Vcc
|
<
> 100 - 460 ohm resistor depending Voltage
<
|
|
-----
/ \ LED, maybe a 5mm, clear plastic is good
-----
|
|
+ LED_P_Side), wired to a digital pin, NOT Gnd
-----------------------------------------------------------------------------
Im just a newbe in ATTiny / Arduino programming, so many thanks to:
Programming ATTiny with Arduino IDE:
http://highlowtech.org/?p=1695
LED Lightsensor, Arduino Playground:
http://playground.arduino.cc/Learning/LEDSensor
Powersaving Mode for Attiny45/85:
A good description by Martin Nawrath nawrath@khm.de and the folks at
http://www.insidegadgets.com/2011/02/05/reduce-attiny-power-consumption-by-sleeping-with-the-watchdog-timer/
With this description I got ~5uA during sleep mode.
in Morse-Mode with LED OFF: 1.7mA
LED ON: 6.9mA
--> I hope to run this throwies ~40days with one CR2032.
Morsecode
To translate a text into morsecode, there are several ways. You can use
this fine online translator:
http://morsecode.scphillips.com/jtranslator.html
There is also a great morse coder / encoder from Matthias Esterl aka madc.
Works fine for Arduino, but not for ATTiny because of RAM limitations. But
maybe this is helpful if your project works with an Arduino.
https://gist.github.com/madc/4474559
For this project I use a simple case structur. Looks arkward, but the
ATTiny45 has only 256byte RAM but 4kFlash. A data structure is better programming
but needs a lot of RAM we not have. Therefore this ugly case structure.
This will waste the flash memory but we have enough and saving RAM for
our payload - the ASCII-string with the morsetext.
BTW - Morsecode itself:
'A', ".-" 'B', "-..." 'C', "-.-."
'D', "-.." 'E', "." 'F', "..-."
'G', "--." 'H', "...." 'I', ".."
'J', ".---" 'K', ".-.-" 'L', ".-.."
'M', "--" 'N', "-." 'O', "---"
'P', ".--." 'Q', "--.-" 'R', ".-."
'S', "..." 'T', "-" 'U', "..-"
'V', "...-" 'W', ".--" 'X', "-..-"
'Y', "-.--" 'Z', "--.."
'1', ".----" '2', "..---" '3', "...--"
'4', "....-" '5', "....." '6', "-...."
'7', "--..." '8', "---.." '9', "----."
'0', "-----"
'.', ".-.-.-" ',', "--..--" '?', "..--.."
'!', "-.-.--" ':', "---..." ';', "-.-.-."
'(', "-.--." ')', "-.--.-" '"', ".-..-."
'@', ".--.-." '&', ".-..."
-----------------------------------------------------------------------------
Legal stuff / Copyright:
Creative Commons Attribution ShareAlike 3.0.:
http://creativecommons.org/licenses/by-sa/3.0/legalcode
-----------------------------------------------------------------------------
*/
// ===========================================================================
// Ok folks, let's start
// ===========================================================================
// for sleep Mode / Powersave we need some additional stuff. Its alredy there,
// if you installed the Attiny extension for Arduino IDE, no additional
// installing needed.
#include <avr/sleep.h>
#include <avr/wdt.h>
// ===========================================================================
// Some definitions for powersave depending of ATTiny type.
#ifndef cbi
#define cbi(sfr, bit) (_SFR_BYTE(sfr) &= ~_BV(bit))
#endif
#ifndef sbi
#define sbi(sfr, bit) (_SFR_BYTE(sfr) |= _BV(bit))
#endif
// ===========================================================================
// for ATTiny85
// Unit length < 150 will hard to be read for optical morse code
// > 300 are too slow in my feeling for longer text
//
// for ATTiny85 at 8MHz (for 1MHz see ATTiny45)
// Unit length < 5 will hard to be read for optical morse code
// > 10 are too slow in my feeling for longer text
//
//
#define unitLength 100
// ---------------------------------------------------------------------------
// LED Pin definitions,
// theoretical you can use up to 3 LED. For example you can use it for a
// landmark beacon. So if you point this LEDs to different directions you can
// detect the position in dependence of your location to the bacon.
#define LED1_N_SIDE 3
#define LED1_P_SIDE 4
// ===========================================================================
// Variables
// ===========================================================================
// ###########################################################################
// # and now the text, but be aware, only 256Byte RAM for Attiny45 #
// # so there are only 22 Chars left for your message. #
// # BTW with an Attiny85 you will have additional 256byte #
// # => more than for twitter :-) #
// # => for FireFly with SuperCap: less ist better, charge last longer #
String morseText =
"TOGO LAB";
// # "....5....1....5....2.."; just a ruler, remember 22 Chars for ATTiny #
// IT IS USELESS
// HAIL GLOW CLOUD
// ###########################################################################
// Define light trigger threshold. best way to set it on dusk / dawn level
// diffuse red ones are less sensitive than clear green ones...
int darknessThreshold = 17000;
// Interrupt Flag, should be volatile, means: read from RAM, not register
// because registers are used for interrupt handling, it have to be volatile.
volatile boolean f_wdt = 1;
// ===========================================================================
// Setup watchdog
// 0=16ms, 1=32ms,2=64ms,3=128ms,4=250ms,5=500ms
// 6=1 sec,7=2 sec, 8=4 sec, 9= 8sec
// ===========================================================================
void setup()
{
setup_watchdog(9);
}
// ===========================================================================
// Main
// ===========================================================================
void loop(){
if (f_wdt==1) { // wait for timed out watchdog
// flag is set when a watchdog timeout occurs
f_wdt=0; // reset flag
// if it's dark enough [>darknesThreshold] morse
if (sensDarkness(LED1_N_SIDE, LED1_P_SIDE) > darknessThreshold){
// looks like it's dark, so do your job
morse(LED1_N_SIDE, LED1_P_SIDE);
}
}
// set all used port to intput to save power
pinMode(LED1_N_SIDE,INPUT);
pinMode(LED1_P_SIDE,INPUT);
system_sleep();
f_wdt=0; // 2nd time sleep
system_sleep();
}
// ===========================================================================
// Subroutines for Sleeping
// ===========================================================================
// set system into the sleep state
// system wakes up when wtchdog is timed out
void system_sleep() {
cbi(ADCSRA,ADEN); // switch Analog to
// Digitalconverter OFF
set_sleep_mode(SLEEP_MODE_PWR_DOWN); // sleep mode is set here
sleep_enable();
sleep_mode(); // System sleeps here
sleep_disable(); // System continues execution here when
// watchdog timed out
sbi(ADCSRA,ADEN); // switch Analog to Digitalconverter ON
}
// ----------------------------------------------------------------------------
// Setup for watchdog. Parameter ii for sleeping time:
// 0 = 16ms, 1 = 32ms, 2 = 64ms,
// 3 = 128ms, 4 = 250ms, 5 = 500ms
// 6 = 1 sec, 7 = 2 sec, 8 = 4 sec,
// 9 = 8 sec
void setup_watchdog(int ii) {
byte bb;
int ww;
if (ii > 9 ) ii=9;
bb=ii & 7;
if (ii > 7) bb|= (1<<5);
bb|= (1<<WDCE);
ww=bb;
MCUSR &= ~(1<<WDRF);
WDTCR |= (1<<WDCE) | (1<<WDE); // start timed sequence
WDTCR = bb; // set new watchdog timeout value
WDTCR |= _BV(WDIE);
}
// -----------------------------------------------------------------------------
// Watchdog Interrupt Service / is executed when watchdog timed out
ISR(WDT_vect) {
f_wdt=1; // set global flag
}
// =============================================================================
// Subroutines for light sensor
// =============================================================================
// Function sensDarkness
// Usage: sensDarkness(Pin-No. N-Side of LED, Pin-No. P-Side of LED):
// will result "darkness-level" - the higher the darker:
// 30000 = pitch black
// 0 = sunshine
int sensDarkness(int LED_N, int LED_P){
unsigned int i; //Parameter bleed-out LED capacitor
// charge the capacitor of LED
pinMode(LED_N,OUTPUT);
pinMode(LED_P,OUTPUT);
digitalWrite(LED_N,HIGH);
digitalWrite(LED_P,LOW);
// Isolate the N end of the diode and turn off internal pull-up resistor
pinMode(LED_N,INPUT);
digitalWrite(LED_N,LOW);
// Count how long it takes the diode to bleed back down to a logic zero
for ( i = 0; i < 30000; i++) {
if ( digitalRead(LED_N)==0) break;
}
// thats it, return result
return i;
}
// =============================================================================
// Subroutines for morse text
// =============================================================================
// -----------------------------------------------------------------------------
// Function dit = ".", a dit is as long as a unitLength, used in morse()
//
void dit(int LED_P){
digitalWrite( LED_P, HIGH ); delay( unitLength );
digitalWrite( LED_P, LOW ); delay( unitLength );
}
// -----------------------------------------------------------------------------
// Function dah = "-", a dah is as long as a 3*unitLength
//
void dah(int LED_P){
digitalWrite( LED_P, HIGH ); delay( unitLength*3 );
digitalWrite( LED_P, LOW ); delay( unitLength );
}
// -----------------------------------------------------------------------------
// Function morse:
// hand over text and LED Pins
// because you want to use more than one LED hand over also LED Pins
void morse(int LED_N, int LED_P){
// Because I have more Flash than RAM I decided to use a case structure.
// Its not so pretty, but I can use the RAM to hold my morseText.
//
// set N-Side of LED Low, so you can set P-side high to let them flash
pinMode( LED_N, OUTPUT);
pinMode( LED_P, OUTPUT);
digitalWrite( LED_N, LOW);
// send it to defined LED
for(int i=0; i<=morseText.length(); i++)
{
switch( morseText[i] )
{
// Chars A-Z
case 'A': // .-
dit(LED_P); dah(LED_P);
break;
case 'B': // -...
dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case 'C': // -.-.
dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
break;
case 'D': // -..
dah(LED_P); dit(LED_P); dit(LED_P);
break;
case 'E': // .
dit(LED_P);
break;
case 'F': // ..-.
dit(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
break;
case 'G': // --.
dah(LED_P); dah(LED_P); dit(LED_P);
break;
case 'H': // ....
dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case 'I': // ..
dit(LED_P); dit(LED_P);
break;
case 'J': // .---
dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
break;
case 'K': // .-.-
dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
break;
case 'L': // .-..
dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P);
break;
case 'M': // --
dah(LED_P); dah(LED_P);
break;
case 'N': // -.
dah(LED_P); dit(LED_P);
break;
case 'O': // ---
dah(LED_P); dah(LED_P); dah(LED_P);
break;
case 'P': // .--.
dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P);
break;
case 'Q': // --.-
dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
break;
case 'R': // .-.
dit(LED_P); dah(LED_P); dit(LED_P);
break;
case 'S': // ...
dit(LED_P); dit(LED_P); dit(LED_P);
break;
case 'T': // -
dah(LED_P);
break;
case 'U': // ..-
dit(LED_P); dit(LED_P); dah(LED_P);
break;
case 'V': // ...-
dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
break;
case 'W': // .--
dit(LED_P); dah(LED_P); dah(LED_P);
break;
case 'X': // -..-
dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
break;
case 'Y': // -.--
dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
break;
case 'Z': // --..
dah(LED_P);dah(LED_P); dit(LED_P); dit(LED_P);
break;
// Numbers
case '1': // .----
dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
break;
case '2': // ..---
dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
break;
case '3': // ...--
dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
break;
case '4': // ....-
dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
break;
case '5': // .....
dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case '6': // -....
dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case '7': // --...
dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case '8': // ---..
dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P);
break;
case '9': // ----.
dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P);
break;
case '0': // -----
dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
break;
// Special Signs
case ' ': // Gap
delay( unitLength*5 );
break;
case '.': // .-.-.-
dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
break;
case ',': // --..--
dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
break;
case '?': // ..--..
dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P);
break;
case '!': // -.-.--
dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
break;
case ':': // ---...
dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
break;
case ';': // -.-.-.
dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
break;
case '(': // -.--.
dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P);
break;
case ')': // -.--.-
dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
break;
case '"': // .-..-.
dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
break;
case '@': // .--.-.
dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
break;
case '&': // .-...
dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
}
// wait at end of sign
delay( unitLength*3 );
}
}
// -----------------------------------------------------------------------------
// That's all, folks :-)
// -----------------------------------------------------------------------------

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// theoretical you can use up to 3 LED. For example you can use it for a
// landmark beacon. So if you point this LEDs to different directions you can
// detect the position in dependence of your location to the bacon.
#define LED1_N_SIDE 4
#define LED1_P_SIDE 3
#define LED1_N_SIDE 3
#define LED1_P_SIDE 4
// ===========================================================================
// Variables

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/*
FireFly tetrahedron adapter
Base STL: tetrahedron40mmC.stl
Purpose:
- Import original 40 mm foldable tetrahedron STL
- Scale it to 60 mm base geometry
- Add cable holes, vent/drain holes, and optional PCB mounting holes
Workflow:
1. Set PART = "upper"
2. Render with F6
3. Export STL
4. Set PART = "lower"
5. Render with F6
6. Export STL
Notes:
- Hole coordinates are defined on the original 40 mm STL coordinate system.
- The script scales them automatically to 60 mm.
- First export should be treated as v0.1 prototype.
*/
/* =========================
Main selection
========================= */
PART = "upper"; // "upper", "lower", or "both_preview"
/* =========================
Input file
========================= */
input_stl = "tetrahedron40mmC.stl";
/* =========================
Scaling
========================= */
// Original tetrahedron edge length
original_edge_mm = 40;
// Target mechanical base size
target_edge_mm = 60;
// XY scale from 40 mm to 60 mm
scale_xy = target_edge_mm / original_edge_mm; // 1.5
// Keep original thickness.
// Set to 1.2 or 1.3 if you want a slightly thicker part.
scale_z = 1.0;
/* =========================
General hole settings
========================= */
hole_fn = 40;
cut_height = 20;
/* =========================
Feature switches
========================= */
add_upper_cable_holes = true;
add_upper_hanger_hole = true;
add_lower_vent_holes = true;
add_lower_cable_holes = true;
add_lower_pcb_mount_holes = true;
// Keep this false for the first prototype.
// Standoffs may interfere with folding depending on print orientation.
add_lower_pcb_standoffs = false;
/* =========================
Hole sizes
========================= */
cable_hole_d = 3.2; // for small solar-panel wires
hanger_hole_d = 3.5; // for small ring / wire / eyelet
vent_hole_d = 2.0; // condensation vent / drain holes
pcb_screw_hole_d = 2.2; // M2 clearance-ish
pcb_standoff_d = 6.0;
pcb_standoff_h = 3.0;
/* =========================
Coordinate reference
=========================
The uploaded STL is approximately:
X: -34.64 to +34.64
Y: -20.00 to +60.00
Z: -0.10 to +2.00
The original model is a flat foldable tetrahedron net.
Coordinates below are before scaling.
*/
/* =========================
Upper part hole positions
========================= */
// Cable holes for three solar panels.
// Adjust after checking where your real panel wires exit.
upper_cable_points = [
[-18, 20],
[ 24, 7],
[ 24, 33]
];
// Optional hanger hole close to one upper fold/vertex area.
// If this weakens the corner too much, disable it and use an external loop instead.
upper_hanger_points = [
[0, 38]
];
/* =========================
Lower part hole positions
========================= */
// Cable transfer holes between upper solar section and lower electronics bay.
lower_cable_points = [
[-10, 20],
[ 12, 13],
[ 12, 27]
];
// Small vent/drain hole clusters near likely lower/edge areas.
// These are deliberately small.
lower_vent_centres = [
[ 0, 3],
[ 0, 37],
[-30, 20],
[ 31, 20]
];
// Approximate triangular PCB mounting pattern.
// Tune this after measuring your actual red triangle PCB.
lower_pcb_mount_points = [
[ 0, 8],
[ 25, 20],
[ 0, 32]
];
/* =========================
Basic modules
========================= */
module base_import_scaled()
{
scale([scale_xy, scale_xy, scale_z])
import(input_stl, convexity = 10);
}
module vertical_hole(p, d)
{
translate([p[0] * scale_xy, p[1] * scale_xy, 1])
cylinder(h = cut_height, d = d, center = true, $fn = hole_fn);
}
module vent_cluster(p)
{
// Small 2 x 3 vent/drain pattern.
// Pitch is in final millimetres, not original model coordinates.
pitch = 3.0;
for (ix = [-1, 0, 1])
for (iy = [0, 1])
translate([
p[0] * scale_xy + ix * pitch,
p[1] * scale_xy + iy * pitch,
1
])
cylinder(h = cut_height, d = vent_hole_d, center = true, $fn = hole_fn);
}
module pcb_standoff(p)
{
// Standoff added on top of the flat STL.
// Use only if you confirm it does not block folding.
translate([p[0] * scale_xy, p[1] * scale_xy, 2.1 * scale_z])
cylinder(h = pcb_standoff_h, d = pcb_standoff_d, center = false, $fn = hole_fn);
}
/* =========================
Upper tetrahedron
========================= */
module upper_part()
{
difference()
{
base_import_scaled();
if (add_upper_cable_holes)
{
for (p = upper_cable_points)
vertical_hole(p, cable_hole_d);
}
if (add_upper_hanger_hole)
{
for (p = upper_hanger_points)
vertical_hole(p, hanger_hole_d);
}
}
}
/* =========================
Lower tetrahedron
========================= */
module lower_part()
{
difference()
{
union()
{
base_import_scaled();
if (add_lower_pcb_standoffs)
{
for (p = lower_pcb_mount_points)
pcb_standoff(p);
}
}
if (add_lower_cable_holes)
{
for (p = lower_cable_points)
vertical_hole(p, cable_hole_d);
}
if (add_lower_vent_holes)
{
for (p = lower_vent_centres)
vent_cluster(p);
}
if (add_lower_pcb_mount_holes)
{
for (p = lower_pcb_mount_points)
vertical_hole(p, pcb_screw_hole_d);
}
}
}
/* =========================
Output
========================= */
if (PART == "upper")
{
upper_part();
}
else if (PART == "lower")
{
lower_part();
}
else if (PART == "both_preview")
{
translate([-80, 0, 0])
upper_part();
translate([80, 0, 0])
lower_part();
}
else
{
echo("Invalid PART setting. Use upper, lower, or both_preview.");
}

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