Cosplay/nhf/touhou/houjuu_nue/__init__.py

"""
To build, execute
```
python3 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, field
import unittest
import cadquery as Cq
from nhf import Material, Role
from nhf.build import Model, TargetKind, target
from nhf.parts.joints import HirthJoint, TorsionJoint
from nhf.parts.handle import Handle
import nhf.touhou.houjuu_nue.wing as MW
import nhf.touhou.houjuu_nue.trident as MT
import nhf.utils

@dataclass
class Parameters(Model):
    """
    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: list[tuple[str, float, float]] = field(default_factory=lambda: [
        ("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: float = 6

    hs_hirth_joint: HirthJoint = field(default_factory=lambda: 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
    wing_root_wall_thickness: float = 8

    shoulder_torsion_joint: TorsionJoint = field(default_factory=lambda: TorsionJoint(
        track_disk_height=5.0,
        rider_disk_height=7.0,
        radius_axle=8.0,
    ))

    # Two holes on each side (top and bottom) are used to attach the shoulder
    # joint. This governs the distance between these two holes
    shoulder_attach_dist: float = 25
    shoulder_attach_diam: float = 8

    """
    Heights for various wing joints, where the numbers start from the first joint.
    """
    wing_s0_thickness: float = 40
    wing_s0_height: float = 100
    wing_r1_height: float = 100
    wing_r1_width: float = 400

    trident_handle: Handle = field(default_factory=lambda: Handle(
        diam=38,
        diam_inner=38-2 * 25.4/8,
        # M27-3
        diam_threading=27,
        thread_pitch=3,
        diam_connector_internal=18,
        simplify_geometry=False,
    ))

    def __post_init__(self):
        super().__init__(name="houjuu-nue")
        assert self.wing_root_radius > self.hs_hirth_joint.radius,\
            "Wing root must be large enough to accomodate joint"

    @target(name="trident/handle-connector")
    def handle_connector(self):
        return self.trident_handle.connector()
    @target(name="trident/handle-insertion")
    def handle_insertion(self):
        return self.trident_handle.insertion()


    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

    @target(name="harness", kind=TargetKind.DXF)
    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),
        ]

    @target(name="hs_joint_parent")
    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()
        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))
            .translate((0, 0, -self.hs_joint_base_thickness))
            .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)
        )
        # Creates a plane parallel to the holes but shifted to the base
        plane = result.faces(">Z").workplane(offset=-self.hs_joint_base_thickness)

        for i, (px, py) in enumerate(conn):
            (
                plane
                .pushPoints([(px, py)])
                .circle(1, forConstruction='True')
                .edges()
                .tag(f"h{i}")
            )
        result = (
            result
            .faces(">Z")
            .workplane()
            .union(hirth, 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

    @target(name="wing_root")
    def wing_root(self) -> Cq.Assembly:
        """
        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,
            shoulder_attach_dist=self.shoulder_attach_dist,
            shoulder_attach_diam=self.shoulder_attach_diam,
            wall_thickness=self.wing_root_wall_thickness,
            conn_height=self.wing_s0_height,
            conn_thickness=self.wing_s0_thickness,
        )

    @target(name="shoulder_parent")
    def shoulder_parent_joint(self) -> Cq.Workplane:
        result = (
            self.shoulder_torsion_joint.rider()
            .copyWorkplane(Cq.Workplane(
                'YZ', origin=Cq.Vector((90, 0, self.wing_root_wall_thickness))))
            .rect(25, 7, centered=(True, False))
            .extrude("next")
            .copyWorkplane(Cq.Workplane(
                'YX', origin=Cq.Vector((55, 0, self.wing_root_wall_thickness))))
            .hole(self.shoulder_attach_diam)
            .moveTo(0, self.shoulder_attach_dist)
            .hole(self.shoulder_attach_diam)
        )
        result.moveTo(0, 0).tagPlane('conn0')
        result.moveTo(0, self.shoulder_attach_dist).tagPlane('conn1')
        return result

    @target(name="shoulder_child")
    def shoulder_child_joint(self) -> Cq.Assembly:
        # FIXME: half of conn_height
        h = 100 / 2
        dh = h - self.shoulder_torsion_joint.total_height
        core = (
            Cq.Workplane('XY')
            .moveTo(0, 15)
            .box(50, 40, 2 * dh, centered=(True, False, True))
        )
        loc_rotate = Cq.Location((0, 0, 0), (1, 0, 0), 180)
        result = (
            Cq.Assembly()
            .add(core, name="core", loc=Cq.Location())
            .add(self.shoulder_torsion_joint.track(), name="track_top",
                 loc=Cq.Location((0, 0, dh), (0, 0, 1), -90))
            .add(self.shoulder_torsion_joint.track(), name="track_bot",
                 loc=Cq.Location((0, 0, -dh), (0, 0, 1), -90) * loc_rotate)
        )
        return result

    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 trident_assembly(self) -> Cq.Assembly:
        return MT.trident_assembly(self.trident_handle)

    def harness_assembly(self) -> Cq.Assembly:
        harness = self.harness()
        result = (
            Cq.Assembly()
            .add(harness, name="base", color=Material.WOOD_BIRCH.color)
            .constrain("base", "Fixed")
        )
        for name in ["l1", "l2", "l3", "r1", "r2", "r3"]:
            j = self.hs_joint_parent()
            (
                result
                .add(j, name=name, color=Role.PARENT.color)
                .constrain("base?mount", f"{name}?base", "Axis")
            )
            for i in range(4):
                result.constrain(f"base?{name}_{i}", f"{name}?h{i}", "Point")
        result.solve()
        return result

    def shoulder_assembly(self) -> Cq.Assembly:
        result = (
            Cq.Assembly()
            .add(self.shoulder_child_joint(), name="child",
                 color=Role.CHILD.color)
            .constrain("child/core", "Fixed")
            # Top parent joint
            .add(self.shoulder_torsion_joint.spring(), name="spring_top",
                 color=Role.DAMPING.color)
            .constrain("child/track_top?spring", "spring_top?top", "Plane")
            .constrain("child/track_top?directrix", "spring_top?directrix_bot", "Axis")
            .add(self.shoulder_parent_joint(), name="parent_top",
                 color=Role.PARENT.color)
            .constrain("parent_top?spring", "spring_top?bot", "Plane")
            .constrain("parent_top?directrix0", "spring_top?directrix_top", "Axis")
            # Bottom parent joint
            .add(self.shoulder_torsion_joint.spring(), name="spring_bot",
                 color=Role.DAMPING.color)
            .constrain("child/track_bot?spring", "spring_bot?top", "Plane")
            .constrain("child/track_bot?directrix", "spring_bot?directrix_bot", "Axis")
            .add(self.shoulder_parent_joint(), name="parent_bot",
                 color=Role.PARENT.color)
            .constrain("parent_bot?spring", "spring_bot?bot", "Plane")
            .constrain("parent_bot?directrix0", "spring_bot?directrix_top", "Axis")
            .solve()
        )
        return result

    def wing_r1_assembly(self) -> Cq.Assembly:
        result = (
            Cq.Assembly()
            .add(self.wing_root(), name="r1")
            .add(self.shoulder_assembly(), name="shoulder")
            .constrain("r1/scaffold", "Fixed")
            .constrain("r1/scaffold?conn_top0", "shoulder/parent_top?conn0", "Plane")
            .constrain("r1/scaffold?conn_top1", "shoulder/parent_top?conn1", "Plane")
            .constrain("r1/scaffold?conn_bot0", "shoulder/parent_bot?conn0", "Plane")
            .constrain("r1/scaffold?conn_bot1", "shoulder/parent_bot?conn1", "Plane")
            .solve()
        )
        return result

    def wings_assembly(self) -> Cq.Assembly:
        """
        Assembly of harness with all the wings
        """
        a_tooth = self.hs_hirth_joint.tooth_angle

        result = (
            Cq.Assembly()
            .add(self.harness_assembly(), name="harness", loc=Cq.Location((0, 0, 0)))
            .add(self.wing_root(), name="w0_r1")
            .add(self.wing_root(), name="w0_l1")
            .constrain("harness/base", "Fixed")
            .constrain("w0_r1/joint?mate", "harness/r1?mate", "Plane")
            .constrain("w0_r1/joint?directrix", "harness/r1?directrix",
                       "Axis", param=7 * a_tooth)
            .constrain("w0_l1/joint?mate", "harness/l1?mate", "Plane")
            .constrain("w0_l1/joint?directrix", "harness/l1?directrix",
                       "Axis", param=-1 * a_tooth)
            .solve()
        )
        return result


if __name__ == '__main__':
    p = Parameters()
    p.build_all()