Cosplay/nhf/parts/joints.py

from dataclasses import dataclass
import math
import cadquery as Cq
import nhf.parts.springs as springs
from nhf import Role
import nhf.utils

TOL = 1e-6

@dataclass
class HirthJoint:
    """
    A Hirth joint attached to a cylindrical base
    """

    # r
    radius: float = 60
    # r_i
    radius_inner: float = 40
    base_height: float = 20
    n_tooth: float = 16
    # h_o
    tooth_height: float = 16

    def __post_init__(self):
        # Ensures tangent doesn't blow up
        assert self.n_tooth >= 5
        assert self.radius > self.radius_inner

    @property
    def tooth_angle(self):
        return 360 / self.n_tooth

    @property
    def total_height(self):
        return self.base_height + self.tooth_height


    def generate(self, is_mated=False, tol=0.01):
        """
        is_mated: If set to true, rotate the teeth so they line up at 0 degrees.

        FIXME: Mate is not exact when number of tooth is low
        """
        phi = math.radians(self.tooth_angle)
        alpha = 2 * math.atan(self.radius / self.tooth_height * math.tan(phi/2))
        #alpha = math.atan(self.radius * math.radians(180 / self.n_tooth) / self.tooth_height)
        gamma = math.radians(90 / self.n_tooth)
        # Tooth half height
        l = self.radius * math.cos(gamma)
        a = self.radius * math.sin(gamma)
        t = a / math.tan(alpha / 2)
        beta = math.asin(t / l)
        dx = self.tooth_height * math.tan(alpha / 2)
        profile = (
            Cq.Workplane('YZ')
            .polyline([
                (0, 0),
                (dx, self.tooth_height),
                (-dx, self.tooth_height),
            ])
            .close()
            .extrude(-self.radius)
            .val()
            .rotate((0, 0, 0), (0, 1, 0), math.degrees(beta))
            .moved(Cq.Location((0, 0, self.base_height)))
        )
        core = Cq.Solid.makeCylinder(
            radius=self.radius_inner,
            height=self.tooth_height,
            pnt=(0, 0, self.base_height),
        )
        angle_offset = self.tooth_angle / 2 if is_mated else 0
        result = (
            Cq.Workplane('XY')
            .cylinder(
                radius=self.radius,
                height=self.base_height + self.tooth_height,
                centered=(True, True, False))
            .faces(">Z")
            .tag("bore")
            .cut(core)
            .polarArray(
                radius=self.radius,
                startAngle=angle_offset,
                angle=360,
                count=self.n_tooth)
            .cutEach(
                lambda loc: profile.moved(loc),
            )
        )
        (
            result
            .polyline([
                (0, 0, self.base_height),
                (0, 0, self.base_height + self.tooth_height)
            ], forConstruction=True)
            .tag("mate")
        )
        (
            result
            .polyline([(0, 0, 0), (1, 0, 0)], forConstruction=True)
            .tag("directrix")
        )
        return result

    def assembly(self, offset: int = 1):
        """
        Generate an example assembly
        """
        tab = (
            Cq.Workplane('XY')
            .box(100, 10, 2, centered=False)
        )
        obj1 = (
            self.generate()
            .faces(tag="bore")
            .cboreHole(
                diameter=10,
                cboreDiameter=20,
                cboreDepth=3)
            .union(tab)
        )
        obj2 = (
            self.generate(is_mated=True)
            .union(tab)
        )
        angle = offset * self.tooth_angle
        result = (
            Cq.Assembly()
            .add(obj1, name="obj1", color=Role.PARENT.color)
            .add(obj2, name="obj2", color=Role.CHILD.color)
            .constrain("obj1", "Fixed")
            .constrain("obj1?mate", "obj2?mate", "Plane")
            .constrain("obj1?directrix", "obj2?directrix", "Axis", param=angle)
            .solve()
        )
        return result

def comma_joint(radius=30,
                shaft_radius=10,
                height=10,
                flange=10,
                flange_thickness=25,
                n_serration=16,
                serration_angle_offset=0,
                serration_height=5,
                serration_inner_radius=20,
                serration_theta=2 * math.pi / 48,
                serration_tilt=-30,
                right_handed=False):
    """
    Produces a "o_" shaped joint, with serrations to accomodate a torsion spring
    """
    assert flange_thickness <= radius
    flange_poly = [
        (0, radius - flange_thickness),
        (0, radius),
        (flange + radius, radius),
        (flange + radius, radius - flange_thickness)
    ]
    if right_handed:
        flange_poly = [(x, -y) for x,y in flange_poly]
    sketch = (
        Cq.Sketch()
        .circle(radius)
        .polygon(flange_poly, mode='a')
        .circle(shaft_radius, mode='s')
    )
    serration_poly = [
        (0, 0), (radius, 0),
        (radius, radius * math.tan(serration_theta))
    ]
    serration = (
        Cq.Workplane('XY')
        .sketch()
        .polygon(serration_poly)
        .circle(radius, mode='i')
        .circle(serration_inner_radius, mode='s')
        .finalize()
        .extrude(serration_height)
        .translate(Cq.Vector((-serration_inner_radius, 0, height)))
        .rotate(
            axisStartPoint=(0, 0, 0),
            axisEndPoint=(0, 0, height),
            angleDegrees=serration_tilt)
        .val()
    )
    serrations = (
        Cq.Workplane('XY')
        .polarArray(radius=serration_inner_radius,
                    startAngle=0+serration_angle_offset,
                    angle=360+serration_angle_offset,
                    count=n_serration)
        .eachpoint(lambda loc: serration.located(loc))
    )
    result = (
        Cq.Workplane()
        .add(sketch)
        .extrude(height)
        .union(serrations)
        .clean()
    )

    result.polyline([
        (0, 0, height - serration_height),
        (0, 0, height + serration_height)],
        forConstruction=True).tag("serrated")
    result.polyline([
        (0, radius, 0),
        (flange + radius, radius, 0)],
        forConstruction=True).tag("tail")
    result.faces('>X').tag("tail_end")
    return result

def comma_assembly():
    joint1 = comma_joint()
    joint2 = comma_joint()
    spring = springs.torsion_spring()
    result = (
        Cq.Assembly()
        .add(joint1, name="joint1", color=Cq.Color(0.8,0.8,0.5,0.3))
        .add(joint2, name="joint2", color=Cq.Color(0.8,0.8,0.5,0.3))
        .add(spring, name="spring", color=Cq.Color(0.5,0.5,0.5,1))
        .constrain("joint1?serrated", "spring?bot", "Plane")
        .constrain("joint2?serrated", "spring?top", "Plane")
        .constrain("joint1?tail", "FixedAxis", (1, 0, 0))
        .constrain("joint2?tail", "FixedAxis", (-1, 0, 0))
        .solve()
    )
    return result

@dataclass
class TorsionJoint:
    """
    This jonit consists of a rider puck on a track puck. IT is best suited if
    the radius has to be small and vertical space is abundant.

    The rider part consists of:
    1. A cylinderical base
    2. A annular extrusion with the same radius as the base, but with slots
        carved in
    3. An annular rider

    The track part consists of:
    1. A cylindrical base
    2. A slotted annular extrusion where the slot allows the spring to rest
    3. An outer and an inner annuli which forms a track the rider can move on
    """

    # Radius limit for rotating components
    radius: float = 40
    track_disk_height: float = 10
    rider_disk_height: float = 8

    radius_spring: float = 15
    radius_axle: float = 6

    # If true, cover the spring hole. May make it difficult to insert the spring
    # considering the stiffness of torsion spring steel.
    spring_hole_cover_track: bool = False
    spring_hole_cover_rider: bool = False

    # Also used for the height of the hole for the spring
    spring_thickness: float = 2
    spring_height: float = 15

    spring_tail_length: float = 40

    groove_radius_outer: float = 35
    groove_radius_inner: float = 20
    groove_depth: float = 5
    rider_gap: float = 1
    rider_n_slots: float = 4

    # Degrees of the first and last rider slots
    rider_slot_begin: float = 0
    rider_slot_span: float = 90

    right_handed: bool = False


    def __post_init__(self):
        assert self.radius > self.groove_radius_outer
        assert self.groove_radius_outer > self.groove_radius_inner
        assert self.groove_radius_inner > self.radius_spring
        assert self.spring_height > self.groove_depth, "Groove is too deep"
        assert self.radius_spring > self.radius_axle

    @property
    def total_height(self):
        return self.track_disk_height + self.rider_disk_height + self.spring_height

    @property
    def _radius_spring_internal(self):
        return self.radius_spring - self.spring_thickness

    def _slot_polygon(self, flip: bool=False):
        r1 = self.radius_spring - self.spring_thickness
        r2 = self.radius_spring
        flip = flip != self.right_handed
        if flip:
            r1 = -r1
            r2 = -r2
        return [
            (0, r2),
            (self.spring_tail_length, r2),
            (self.spring_tail_length, r1),
            (0, r1),
        ]
    def _directrix(self, height, theta=0):
        c, s = math.cos(theta), math.sin(theta)
        r2 = self.radius_spring
        l = self.spring_tail_length
        if self.right_handed:
            r2 = -r2
        # This is (0, r2) and (l, r2) transformed by rotation matrix
        # [[c, s], [-s, c]]
        return [
            (0, 0, height),
            (c, s, height)
        ]
        return [
            (s * r2,         -s * l + c * r2, height),
            (c * l + s * r2, -s * l + c * r2, height),
        ]


    def spring(self):
        return springs.torsion_spring(
            radius=self.radius_spring,
            height=self.spring_height,
            thickness=self.spring_thickness,
            tail_length=self.spring_tail_length,
        )

    def track(self):
        groove_profile = (
            Cq.Sketch()
            .circle(self.radius)
            .circle(self.groove_radius_outer, mode='s')
            .circle(self.groove_radius_inner, mode='a')
            .circle(self.radius_spring, mode='s')
        )
        spring_hole_profile = (
            Cq.Sketch()
            .circle(self.radius)
            .circle(self.radius_spring, mode='s')
        )
        slot_height = self.spring_thickness
        if not self.spring_hole_cover_track:
            slot_height += self.groove_depth
        slot = (
            Cq.Workplane('XY')
            .sketch()
            .polygon(self._slot_polygon(flip=False))
            .finalize()
            .extrude(slot_height)
            .val()
        )
        result = (
            Cq.Workplane('XY')
            .cylinder(
                radius=self.radius,
                height=self.track_disk_height,
                centered=(True, True, False))
            .faces('>Z')
            .tag("spring")
            .placeSketch(spring_hole_profile)
            .extrude(self.spring_thickness)
            # If the spring hole profile is not simply connected, this workplane
            # will have to be created from the `spring-mate` face.
            .faces('>Z')
            .placeSketch(groove_profile)
            .extrude(self.groove_depth)
            .faces('>Z')
            .hole(self.radius_axle * 2)
            .cut(slot.moved(Cq.Location((0, 0, self.track_disk_height))))
        )
        # Insert directrix`
        result.polyline(self._directrix(self.track_disk_height),
                        forConstruction=True).tag("directrix")
        return result

    def rider(self):
        def slot(loc):
            wire = Cq.Wire.makePolygon(self._slot_polygon(flip=False))
            face = Cq.Face.makeFromWires(wire)
            return face.located(loc)
        wall_profile = (
            Cq.Sketch()
            .circle(self.radius, mode='a')
            .circle(self.radius_spring, mode='s')
            .parray(
                r=0,
                a1=self.rider_slot_begin,
                da=self.rider_slot_span,
                n=self.rider_n_slots)
            .each(slot, mode='s')
            #.circle(self._radius_wall, mode='a')
        )
        contact_profile = (
            Cq.Sketch()
            .circle(self.groove_radius_outer, mode='a')
            .circle(self.groove_radius_inner, mode='s')
        )
        if not self.spring_hole_cover_rider:
            contact_profile = (
                contact_profile
                .parray(
                    r=0,
                    a1=self.rider_slot_begin,
                    da=self.rider_slot_span,
                    n=self.rider_n_slots)
                .each(slot, mode='s')
                .reset()
            )
            #.circle(self._radius_wall, mode='a')
        middle_height = self.spring_height - self.groove_depth - self.rider_gap - self.spring_thickness
        result = (
            Cq.Workplane('XY')
            .cylinder(
                radius=self.radius,
                height=self.rider_disk_height,
                centered=(True, True, False))
            .faces('>Z')
            .tag("spring")
            .workplane()
            .placeSketch(wall_profile)
            .extrude(middle_height)
            .faces(tag="spring")
            .workplane()
            # The top face might not be in one piece.
            .workplane(offset=middle_height)
            .placeSketch(contact_profile)
            .extrude(self.groove_depth + self.rider_gap)
            .faces(tag="spring")
            .workplane()
            .circle(self._radius_spring_internal)
            .extrude(self.spring_height)
            #.faces(tag="spring")
            #.workplane()
            .hole(self.radius_axle * 2)
        )
        theta_begin = math.radians(self.rider_slot_begin) + math.pi
        theta_span = math.radians(self.rider_slot_span)
        if abs(math.remainder(self.rider_slot_span, 360)) < TOL:
            theta_step = theta_span / self.rider_n_slots
        else:
            theta_step = theta_span / (self.rider_n_slots - 1)
        for i in range(self.rider_n_slots):
            theta = theta_begin - i * theta_step
            result.polyline(self._directrix(self.rider_disk_height, theta),
                            forConstruction=True).tag(f"directrix{i}")
        return result

    def rider_track_assembly(self, directrix=0):
        rider = self.rider()
        track = self.track()
        spring = self.spring()
        result = (
            Cq.Assembly()
            .add(spring, name="spring", color=Role.DAMPING.color)
            .add(track, name="track", color=Role.PARENT.color)
            .constrain("track?spring", "spring?top", "Plane")
            .constrain("track?directrix", "spring?directrix_bot", "Axis")
            .add(rider, name="rider", color=Role.CHILD.color)
            .constrain("rider?spring", "spring?bot", "Plane")
            .constrain(f"rider?directrix{directrix}", "spring?directrix_top", "Axis")
            .solve()
        )
        return result