Cosplay/nhf/touhou/houjuu_nue/__init__.py

"""
This cosplay consists of 3 components:

## Trident

The trident is composed of individual segments, made of acrylic, and a 3D
printed head (convention rule prohibits metal) with a metallic paint. To ease
transportation, the trident handle has individual segments with threads and can
be assembled on site.

## Snake

A 3D printed snake with a soft material so it can wrap around and bend

## Wings

This is the crux of the cosplay and the most complex component. The wings mount
on a wearable harness. Each wing consists of 4 segments with 3 joints. Parts of
the wing which demands transluscency are created from 1/16" acrylic panels.
These panels serve double duty as the exoskeleton.

The wings are labeled r1,r2,r3,l1,l2,l3. The segments of the wings are labeled
from root to tip s0 (root),
s1, s2, s3. The joints are named (from root to tip)
shoulder, elbow, wrist in analogy with human anatomy.
"""
from dataclasses import dataclass
import unittest
import cadquery as Cq
import nhf.joints
import nhf.handle
from nhf import Material
from nhf.joints import HirthJoint
from nhf.handle import Handle
import nhf.touhou.houjuu_nue.wing as MW
import nhf.touhou.houjuu_nue.trident as MT

@dataclass
class Parameters:
    """
    Defines dimensions for the Houjuu Nue cosplay
    """

    # Thickness of the exoskeleton panel in millimetres
    panel_thickness: float = 25.4 / 16

    # Harness
    harness_thickness: float = 25.4 / 8
    harness_width: float = 300
    harness_height: float = 400
    harness_fillet: float = 10

    harness_wing_base_pos = [
        ("r1", 70, 150),
        ("l1", -70, 150),
        ("r2", 100, 0),
        ("l2", -100, 0),
        ("r3", 70, -150),
        ("l3", -70, -150),
    ]

    # Holes drilled onto harness for attachment with HS joint
    harness_to_root_conn_diam = 6

    hs_hirth_joint: HirthJoint = HirthJoint(
        radius=30,
        radius_inner=20,
        tooth_height=10,
        base_height=5
    )

    # Wing root properties
    #
    # The Houjuu-Scarlett joint mechanism at the base of the wing
    hs_joint_base_width: float = 85
    hs_joint_base_thickness: float = 10
    hs_joint_corner_fillet: float = 5
    hs_joint_corner_cbore_diam: float = 12
    hs_joint_corner_cbore_depth: float = 2
    hs_joint_corner_inset: float = 12

    hs_joint_axis_diam: float = 12
    hs_joint_axis_cbore_diam: float = 20
    hs_joint_axis_cbore_depth: float = 3

    # Exterior radius of the wing root assembly
    wing_root_radius: float = 40

    """
    Heights for various wing joints, where the numbers start from the first joint.
    """
    wing_r1_height: float = 100
    wing_r1_width: float = 400
    wing_r2_height: float = 100
    wing_r3_height: float = 100

    trident_handle: Handle = Handle(
        diam=38,
        diam_inner=33,
        # M27-3
        diam_threading=27,
        thread_pitch=3,
        diam_connector_internal=18,
        simplify_geometry=False,
    )

    def __post_init__(self):
        assert self.wing_root_radius > self.hs_hirth_joint.radius,\
            "Wing root must be large enough to accomodate joint"


    def print_geometries(self):
        return [
            self.hs_joint_parent()
        ]

    def harness_profile(self) -> Cq.Sketch:
        """
        Creates the harness shape
        """
        w, h = self.harness_width / 2, self.harness_height / 2
        sketch = (
            Cq.Sketch()
            .polygon([
                (0.7 * w, h),
                (w, 0),
                (0.7 * w, -h),
                (0.7 * -w, -h),
                (-w, 0),
                (0.7 * -w, h),
            ])
            #.rect(self.harness_width, self.harness_height)
            .vertices()
            .fillet(self.harness_fillet)
        )
        for tag, x, y in self.harness_wing_base_pos:
            conn = [(px + x, py + y) for px, py in self.hs_joint_harness_conn()]
            sketch = (
                sketch
                .push(conn)
                .tag(tag)
                .circle(self.harness_to_root_conn_diam / 2, mode='s')
                .reset()
            )
        return sketch

    def harness(self) -> Cq.Shape:
        """
        Creates the harness shape
        """
        result = (
            Cq.Workplane('XZ')
            .placeSketch(self.harness_profile())
            .extrude(self.harness_thickness)
        )
        result.faces(">Y").tag("mount")
        plane = result.faces(">Y").workplane()
        for tag, x, y in self.harness_wing_base_pos:
            conn = [(px + x, py + y) for px, py in self.hs_joint_harness_conn()]
            for i, (px, py) in enumerate(conn):
                (
                    plane
                    .moveTo(px, py)
                    .circle(1, forConstruction='True')
                    .edges()
                    .tag(f"{tag}_{i}")
                )
        return result

    def hs_joint_harness_conn(self) -> list[tuple[int, int]]:
        """
        Generates a set of points corresponding to the connectorss
        """
        dx = self.hs_joint_base_width / 2 - self.hs_joint_corner_inset
        return [
            (dx, dx),
            (dx, -dx),
            (-dx, -dx),
            (-dx, dx),
        ]

    def hs_joint_parent(self):
        """
        Parent part of the Houjuu-Scarlett joint, which is composed of a Hirth
        coupling, a cylindrical base, and a mounting base.
        """
        hirth = self.hs_hirth_joint.generate()
        #hirth = (
        #    hirth
        #    .faces("<Z")
        #    .workplane()
        #    .transformed(
        #        offset=Cq.Vector(0, 0, -self.hs_joint_ring_thickness / 2),
        #        rotate=Cq.Vector(90, 0, 0))
        #    # This hole will drill only to the centre and not through. This is
        #    # intended.
        #    .hole(5)
        #    .val()
        #)
        conn = self.hs_joint_harness_conn()
        result = (
            Cq.Workplane('XY')
            .box(
                self.hs_joint_base_width,
                self.hs_joint_base_width,
                self.hs_joint_base_thickness,
                centered=(True, True, False))
            .edges("|Z")
            .fillet(self.hs_joint_corner_fillet)
            .faces(">Z")
            .workplane()
            .pushPoints(conn)
            .cboreHole(
                diameter=self.harness_to_root_conn_diam,
                cboreDiameter=self.hs_joint_corner_cbore_diam,
                cboreDepth=self.hs_joint_corner_cbore_depth)
        )
        plane = result.faces(">Z").workplane(offset=-self.hs_joint_base_thickness)
        for i, (px, py) in enumerate(conn):
            (
                plane
                .moveTo(px, py)
                .circle(1, forConstruction='True')
                .edges()
                .tag(f"h{i}")
            )
        result = (
            result
            .faces(">Z")
            .workplane()
            .union(hirth.translate((0, 0, self.hs_joint_base_thickness)), tol=0.1)
            .clean()
        )
        result = (
            result.faces("<Z")
            .workplane()
            .cboreHole(
                diameter=self.hs_joint_axis_diam,
                cboreDiameter=self.hs_joint_axis_cbore_diam,
                cboreDepth=self.hs_joint_axis_cbore_depth,
            )
            .clean()
        )
        result.faces("<Z").tag("base")
        return result

    def wing_root(self) -> Cq.Shape:
        """
        Generate the wing root which contains a Hirth joint at its base and a
        rectangular opening on its side, with the necessary interfaces.
        """
        return MW.wing_root(joint=self.hs_hirth_joint)

    def wing_r1_profile(self) -> Cq.Sketch:
        """
        Generates the first wing segment profile, with the wing root pointing in
        the positive x axis.
        """
        # Depression of the wing middle
        bend = 200
        factor = 0.7
        result = (
            Cq.Sketch()
            .segment((0, 0), (0, self.wing_r1_height))
            .spline([
                (0, self.wing_r1_height),
                (0.5 * self.wing_r1_width, self.wing_r1_height - factor * bend),
                (self.wing_r1_width, self.wing_r1_height - bend),
            ])
            .segment(
                (self.wing_r1_width, self.wing_r1_height - bend),
                (self.wing_r1_width, -bend),
            )
            .spline([
                (self.wing_r1_width, - bend),
                (0.5 * self.wing_r1_width, - factor * bend),
                (0, 0),
            ])
            .assemble()
        )
        return result

    def wing_r1(self) -> Cq.Solid:
        profile = self.wing_r1_profile()
        result = (
            Cq.Workplane("XY")
            .placeSketch(profile)
            .extrude(self.panel_thickness)
            .val()
        )
        return result

    ######################
    #    Assemblies      #
    ######################

    def harness_assembly(self):
        harness = self.harness()
        result = (
            Cq.Assembly()
            .add(harness, name="harness", color=Material.WOOD_BIRCH.color)
            .constrain("harness", "Fixed")
        )
        for name in ["l1", "l2", "l3", "r1", "r2", "r3"]:
            j = self.hs_joint_parent()
            (
                result
                .add(j, name=f"hs_{name}", color=Material.PLASTIC_PLA.color)
                #.constrain(f"harness?{name}", f"hs_{name}p?mate", "Point")
                .constrain("harness?mount", f"hs_{name}?base", "Axis")
            )
            for i in range(4):
                result.constrain(f"harness?{name}_{i}", f"hs_{name}?h{i}", "Point")
        angle = 6 * self.hs_hirth_joint.tooth_angle
        (
            result.add(self.wing_root(), name="w0_r1", color=Material.PLASTIC_PLA.color)
            .constrain("w0_r1?mate", "hs_r1?mate", "Plane")
            .constrain("w0_r1?directrix", "hs_r1?directrix", "Axis", param=angle)
        )
        result.solve()
        return result

    def trident_assembly(self):
        return MT.trident_assembly(self.trident_handle)