Cosplay/nhf/touhou/houjuu_nue/electronics.py

"""
Electronic components
"""
from dataclasses import dataclass
from typing import Optional
import cadquery as Cq
from nhf.materials import Role
from nhf.parts.item import Item
from nhf.parts.fasteners import FlatHeadBolt, HexNut
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 = 37.55
    segment1_width: float = 15.95
    segment1_height: float = 11.94

    segment2_length: float = 37.47
    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:
        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 = 8.10

    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


LINEAR_ACTUATOR_SHOULDER = LinearActuator(
    mass=34.0,
    stroke_length=30,
)
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()

@dataclass(frozen=True)
class LinearActuatorAssembly:

    # FIXME: Measure
    actuator: LinearActuator = LINEAR_ACTUATOR_SHOULDER
    nut: HexNut = LINEAR_ACTUATOR_HEX_NUT
    bolt: FlatHeadBolt = LINEAR_ACTUATOR_BOLT
    bracket: MountingBracket = LINEAR_ACTUATOR_BRACKET

    def add_to(
            self,
            a: Cq.Assembly,
            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()`.
        """
        if tag_prefix:
            tag_prefix = 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(), 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_actuator}/front?conn", f"{name_bracket_front}?conn_mid",
                       "Plane", param=0)
            .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 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)