Cosplay/nhf/touhou/houjuu_nue/electronics.py

"""
Electronic components
"""
from dataclasses import dataclass, field
from typing import Optional, Tuple
import math
import cadquery as Cq
from nhf.build import Model, TargetKind, target, assembly, submodel
from nhf.materials import Role, Material
from nhf.parts.box import MountingBox, Hole
from nhf.parts.fibre import tension_fibre
from nhf.parts.item import Item
from nhf.parts.fasteners import FlatHeadBolt, HexNut
from nhf.touhou.houjuu_nue.common import NUT_COMMON, BOLT_COMMON
import nhf.utils

@dataclass(frozen=True)
class LinearActuator(Item):
    stroke_length: float
    shaft_diam: float = 9.04

    front_hole_ext: float = 4.41
    front_hole_diam: float = 4.41
    front_length: float = 9.55
    front_width: float = 9.24
    front_height: float = 5.98

    segment1_length: float = 37.54
    segment1_width: float = 15.95
    segment1_height: float = 11.94

    segment2_length: float = 37.37
    segment2_width: float = 20.03
    segment2_height: float = 15.03

    back_hole_ext: float = 4.58
    back_hole_diam: float = 4.18
    back_length: float = 9.27
    back_width: float = 10.16
    back_height: float = 8.12

    @property
    def name(self) -> str:
        return f"LinearActuator {self.stroke_length}mm"

    @property
    def role(self) -> Role:
        return Role.MOTION

    @property
    def conn_length(self):
        return self.segment1_length + self.segment2_length + self.front_hole_ext + self.back_hole_ext

    def generate(self, pos: float=0) -> Cq.Assembly:
        assert -1e-6 <= pos <= 1 + 1e-6, f"Illegal position: {pos}"
        stroke_x = pos * self.stroke_length
        front = (
            Cq.Workplane('XZ')
            .cylinder(
                radius=self.front_width / 2,
                height=self.front_height,
                centered=True,
            )
            .box(
                length=self.front_hole_ext,
                width=self.front_width,
                height=self.front_height,
                combine=True,
                centered=(False, True, True)
            )
            .copyWorkplane(Cq.Workplane('XZ'))
            .cylinder(
                radius=self.front_hole_diam / 2,
                height=self.front_height,
                centered=True,
                combine='cut',
            )
        )
        front.copyWorkplane(Cq.Workplane('XZ')).tagPlane('conn')
        if stroke_x > 0:
            shaft = (
                Cq.Workplane('YZ')
                .cylinder(
                    radius=self.shaft_diam / 2,
                    height=stroke_x,
                    centered=(True, True, False)
                )
            )
        else:
            shaft = None
        segment1 = (
            Cq.Workplane()
            .box(
                length=self.segment1_length,
                height=self.segment1_width,
                width=self.segment1_height,
                centered=(False, True, True),
            )
        )
        segment2 = (
            Cq.Workplane()
            .box(
                length=self.segment2_length,
                height=self.segment2_width,
                width=self.segment2_height,
                centered=(False, True, True),
            )
        )
        back = (
            Cq.Workplane('XZ')
            .cylinder(
                radius=self.back_width / 2,
                height=self.back_height,
                centered=True,
            )
            .box(
                length=self.back_hole_ext,
                width=self.back_width,
                height=self.back_height,
                combine=True,
                centered=(False, True, True)
            )
            .copyWorkplane(Cq.Workplane('XZ'))
            .cylinder(
                radius=self.back_hole_diam / 2,
                height=self.back_height,
                centered=True,
                combine='cut',
            )
        )
        back.copyWorkplane(Cq.Workplane('XZ')).tagPlane('conn')
        result = (
            Cq.Assembly()
            .add(front, name="front",
                 loc=Cq.Location((-self.front_hole_ext, 0, 0)))
            .add(segment1, name="segment1",
                 loc=Cq.Location((stroke_x, 0, 0)))
            .add(segment2, name="segment2",
                 loc=Cq.Location((stroke_x + self.segment1_length, 0, 0)))
            .add(back, name="back",
                 loc=Cq.Location((stroke_x + self.segment1_length + self.segment2_length + self.back_hole_ext, 0, 0), (0, 1, 0), 180))
        )
        if shaft:
            result.add(shaft, name="shaft")
        return result

@dataclass(frozen=True)
class MountingBracket(Item):
    """
    Mounting bracket for a linear actuator
    """
    mass: float = 1.6
    hole_diam: float = 4.0
    width: float = 8.0
    height: float = 12.20
    thickness: float = 0.98
    length: float = 13.00
    hole_to_side_ext: float = 8.25

    def __post_init__(self):
        assert self.hole_to_side_ext - self.hole_diam / 2 > 0

    @property
    def name(self) -> str:
        return f"MountingBracket M{int(self.hole_diam)}"

    @property
    def role(self) -> Role:
        return Role.MOTION

    def generate(self) -> Cq.Workplane:
        result = (
            Cq.Workplane('XY')
            .box(
                length=self.hole_to_side_ext,
                width=self.width,
                height=self.height,
                centered=(False, True, True)
            )
            .copyWorkplane(Cq.Workplane('XY'))
            .cylinder(
                height=self.height,
                radius=self.width / 2,
                combine=True,
            )
            .copyWorkplane(Cq.Workplane('XY'))
            .box(
                length=2 * (self.hole_to_side_ext - self.thickness),
                width=self.width,
                height=self.height - self.thickness * 2,
                combine='cut',
            )
            .copyWorkplane(Cq.Workplane('XY'))
            .cylinder(
                height=self.height,
                radius=self.hole_diam / 2,
                combine='cut'
            )
            .copyWorkplane(Cq.Workplane('YZ'))
            .cylinder(
                height=self.hole_to_side_ext * 2,
                radius=self.hole_diam / 2,
                combine='cut'
            )
        )
        result.copyWorkplane(Cq.Workplane('YZ', origin=(self.hole_to_side_ext, 0, 0))).tagPlane("conn_side")
        result.copyWorkplane(Cq.Workplane('XY', origin=(0, 0, self.height/2))).tagPlane("conn_top")
        result.copyWorkplane(Cq.Workplane('YX', origin=(0, 0, -self.height/2))).tagPlane("conn_bot")
        result.copyWorkplane(Cq.Workplane('XY')).tagPlane("conn_mid")
        return result

@dataclass(frozen=True)
class BatteryBox18650(Item):
    """
    A number of 18650 batteries in series
    """
    mass: float = 17.4 + 68.80 * 3
    length: float = 75.70
    width_base: float = 61.46 - 18.48 - 20.18 * 2
    battery_dist: float = 20.18
    height: float = 19.66
    # space from bottom to battery begin
    thickness: float = 1.66
    battery_diam: float = 18.48
    battery_height: float = 68.80
    n_batteries: int = 3

    def __post_init__(self):
        assert 2 * self.thickness < min(self.length, self.height)

    @property
    def name(self) -> str:
        return f"BatteryBox 18650*{self.n_batteries}"

    @property
    def role(self) -> Role:
        return Role.ELECTRONIC

    def generate(self) -> Cq.Workplane:
        width = self.width_base + self.battery_dist * (self.n_batteries - 1) + self.battery_diam
        return (
            Cq.Workplane('XY')
            .box(
                length=self.length,
                width=width,
                height=self.height,
                centered=(True, True, False),
            )
            .copyWorkplane(Cq.Workplane('XY', origin=(0, 0, self.thickness)))
            .box(
                length=self.length - self.thickness*2,
                width=width - self.thickness*2,
                height=self.height - self.thickness,
                centered=(True, True, False),
                combine='cut',
            )
            .copyWorkplane(Cq.Workplane('XY', origin=(-self.battery_height/2, 0, self.thickness + self.battery_diam/2)))
            .rarray(
                xSpacing=1,
                ySpacing=self.battery_dist,
                xCount=1,
                yCount=self.n_batteries,
                center=True,
            )
            .cylinder(
                radius=self.battery_diam/2,
                height=self.battery_height,
                direct=(1, 0, 0),
                centered=(True, True, False),
                combine=True,
            )
        )


LINEAR_ACTUATOR_50 = LinearActuator(
    mass=40.8,
    stroke_length=50,
    shaft_diam=9.05,
    front_hole_ext=4.32,
    back_hole_ext=4.54,
    segment1_length=57.35,
    segment1_width=15.97,
    segment1_height=11.95,
    segment2_length=37.69,
    segment2_width=19.97,
    segment2_height=14.96,

    front_length=9.40,
    front_width=9.17,
    front_height=6.12,
    back_length=9.18,
    back_width=10.07,
    back_height=8.06,
)
LINEAR_ACTUATOR_30 = LinearActuator(
    mass=34.0,
    stroke_length=30,
)
LINEAR_ACTUATOR_21 = LinearActuator(
    # FIXME: Measure
    mass=0.0,
    stroke_length=21,
    front_hole_ext=4,
    back_hole_ext=4,
    segment1_length=34,
    segment2_length=34,
)
LINEAR_ACTUATOR_10 = LinearActuator(
    mass=41.3,
    stroke_length=10,
    front_hole_ext=4.02,
    back_hole_ext=4.67,
    segment1_length=13.29,
    segment1_width=15.88,
    segment1_height=12.07,
    segment2_length=42.52,
    segment2_width=20.98,
    segment2_height=14.84,
)
LINEAR_ACTUATOR_HEX_NUT = HexNut(
    mass=0.8,
    diam_thread=4,
    pitch=0.7,
    thickness=4.16,
    width=6.79,
)
LINEAR_ACTUATOR_BOLT = FlatHeadBolt(
    mass=1.7,
    diam_head=6.68,
    height_head=2.98,
    diam_thread=4.0,
    height_thread=15.83,
)
LINEAR_ACTUATOR_BRACKET = MountingBracket()

BATTERY_BOX = BatteryBox18650()

# Acrylic hex nut
ELECTRONIC_MOUNT_HEXNUT = HexNut(
    mass=0.8,
    diam_thread=4,
    pitch=0.7,
    thickness=3.57,
    width=6.81,
)

@dataclass(kw_only=True)
class Flexor:
    """
    Actuator assembly which flexes, similar to biceps
    """
    motion_span: float
    arm_radius: Optional[float] = None
    pos_smaller: bool = True

    actuator: LinearActuator = LINEAR_ACTUATOR_50
    nut: HexNut = LINEAR_ACTUATOR_HEX_NUT
    bolt: FlatHeadBolt = LINEAR_ACTUATOR_BOLT
    bracket: MountingBracket = LINEAR_ACTUATOR_BRACKET
    # Length of line attached to the flexor
    line_length: float = 0.0
    line_thickness: float = 0.5
    # By how much is the line permitted to slack. This reduces the effective stroke length
    line_slack: float = 0.0

    def __post_init__(self):
        assert self.line_slack <= self.line_length, f"Insufficient length: {self.line_slack} >= {self.line_length}"
        assert self.line_slack < self.actuator.stroke_length

    @property
    def mount_height(self):
        return self.bracket.hole_to_side_ext

    @property
    def d_open(self):
        return self.actuator.conn_length + self.actuator.stroke_length + self.line_length - self.line_slack
    @property
    def d_closed(self):
        return self.actuator.conn_length + self.line_length

    def open_pos(self) -> Tuple[float, float, float]:
        r, phi, r_ = nhf.geometry.contraction_span_pos_from_radius(
            d_open=self.d_open,
            d_closed=self.d_closed,
            theta=math.radians(self.motion_span),
            r=self.arm_radius,
            smaller=self.pos_smaller,
        )
        return r, math.degrees(phi), r_

    def target_length_at_angle(
            self,
            angle: float = 0.0
        ) -> float:
        """
        Length of the actuator at some angle
        """
        assert 0 <= angle <= self.motion_span
        r, phi, rp = self.open_pos()
        th = math.radians(phi - angle)

        result = math.sqrt(r * r + rp * rp - 2 * r * rp * math.cos(th))
        #result = math.sqrt((r * math.cos(th) - rp) ** 2 + (r * math.sin(th)) ** 2)
        assert self.d_closed -1e-6 <= result <= self.d_open + 1e-6,\
            f"Illegal length: {result} not in [{self.d_closed}, {self.d_open}]"
        return result


    def add_to(
            self,
            a: Cq.Assembly,
            target_length: float,
            tag_prefix: Optional[str] = None,
            tag_hole_front: Optional[str] = None,
            tag_hole_back: Optional[str] = None,
            tag_dir: Optional[str] = None):
        """
        Adds the necessary mechanical components to this assembly. Does not
        invoke `a.solve()`.
        """
        draft = max(0, target_length - self.d_closed - self.line_length)
        pos = draft / self.actuator.stroke_length
        line_l = target_length - draft - self.actuator.conn_length
        if tag_prefix:
            tag_prefix = tag_prefix + "_"
        else:
            tag_prefix = ""
        name_actuator = f"{tag_prefix}actuator"
        name_bracket_front = f"{tag_prefix}bracket_front"
        name_bracket_back = f"{tag_prefix}bracket_back"
        name_bolt_front = f"{tag_prefix}front_bolt"
        name_bolt_back = f"{tag_prefix}back_bolt"
        name_nut_front = f"{tag_prefix}front_nut"
        name_nut_back = f"{tag_prefix}back_nut"
        (
            a
            .add(self.actuator.assembly(pos=pos), name=name_actuator)
            .add(self.bracket.assembly(), name=name_bracket_front)
            .add(self.bolt.assembly(), name=name_bolt_front)
            .add(self.nut.assembly(), name=name_nut_front)
            .constrain(f"{name_bolt_front}?root", f"{name_bracket_front}?conn_top",
                       "Plane", param=0)
            .constrain(f"{name_nut_front}?bot", f"{name_bracket_front}?conn_bot",
                       "Plane")
            .add(self.bracket.assembly(), name=name_bracket_back)
            .add(self.bolt.assembly(), name=name_bolt_back)
            .add(self.nut.assembly(), name=name_nut_back)
            .constrain(f"{name_actuator}/back?conn", f"{name_bracket_back}?conn_mid",
                       "Plane", param=0)
            .constrain(f"{name_bolt_back}?root", f"{name_bracket_back}?conn_top",
                       "Plane", param=0)
            .constrain(f"{name_nut_back}?bot", f"{name_bracket_back}?conn_bot",
                       "Plane")
        )
        if self.line_length == 0.0:
            a.constrain(
                f"{name_actuator}/front?conn",
                f"{name_bracket_front}?conn_mid",
                "Plane", param=0)
        else:
            (
                a
                .addS(tension_fibre(
                    length=line_l,
                    hole_diam=self.nut.diam_thread,
                    thickness=self.line_thickness,
                ), name="fibre", role=Role.CONNECTION)
                .constrain(
                    f"{name_actuator}/front?conn",
                    "fibre?male",
                    "Plane"
                )
                .constrain(
                    f"{name_bracket_front}?conn_mid",
                    "fibre?female",
                    "Plane"
                )
            )
        if tag_hole_front:
            a.constrain(tag_hole_front, f"{name_bracket_front}?conn_side", "Plane")
        if tag_hole_back:
            a.constrain(tag_hole_back, f"{name_bracket_back}?conn_side", "Plane")
        if tag_dir:
            a.constrain(tag_dir, f"{name_bracket_front}?conn_mid", "Axis", param=0)


@dataclass
class ElectronicBoard(Model):

    name: str = "electronic-board"
    nut: HexNut = NUT_COMMON
    bolt: FlatHeadBolt = BOLT_COMMON
    length: float = 70.0
    width: float = 170.0
    mount_holes: list[Hole] = field(default_factory=lambda: [
        Hole(x=30, y=80),
        Hole(x=30, y=0),
        Hole(x=30, y=-80),
        Hole(x=-30, y=80),
        Hole(x=-30, y=0),
        Hole(x=-30, y=-80),
    ])
    panel_thickness: float = 25.4 / 16
    mount_panel_thickness: float = 25.4 / 4
    material: Material = Material.WOOD_BIRCH

    @property
    def mount_hole_diam(self) -> float:
        return self.bolt.diam_thread

    def __post_init__(self):
        super().__init__(name=self.name)

    @submodel(name="panel")
    def panel(self) -> MountingBox:
        return MountingBox(
            holes=self.mount_holes,
            hole_diam=self.mount_hole_diam,
            length=self.length,
            width=self.width,
            centred=(True, True),
            thickness=self.panel_thickness,
            generate_reverse_tags=True,
        )

    def assembly(self) -> Cq.Assembly:
        panel = self.panel()
        result = (
            Cq.Assembly()
            .addS(panel.generate(), name="panel",
                  role=Role.STRUCTURE, material=self.material)
        )
        for hole in panel.holes:
            spacer_name = f"{hole.tag}_spacer"
            bolt_name = f"{hole.tag}_bolt"
            (
                result
                .add(self.nut.assembly(), name=spacer_name)
                .add(self.bolt.assembly(), name=bolt_name)
                .constrain(
                    f"{spacer_name}?top",
                    f"panel?{hole.rev_tag}",
                    "Plane"
                )
                .constrain(
                    f"{bolt_name}?root",
                    f"panel?{hole.tag}",
                    "Plane", param=0
                )
            )
        return result.solve()