Cosplay/nhf/touhou/houjuu_nue/__init__.py

from dataclasses import dataclass
import unittest
import cadquery as Cq
import nhf.joints
from nhf import Material

@dataclass(frozen=True)
class Parameters:

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

    # Harness
    harness_thickness: float = 25.4 / 8
    harness_width = 300
    harness_height = 400
    harness_fillet = 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_wing_base_hole_diam = 6

    # Wing root properties
    """
    The Houjuu-Scarlett joint mechanism at the base of the wing
    """
    hs_joint_base_width = 85
    hs_joint_base_thickness = 10
    hs_joint_ring_thickness = 5
    hs_joint_tooth_height = 10
    hs_joint_radius = 30
    hs_joint_radius_inner = 20
    hs_joint_corner_fillet = 5
    hs_joint_corner_cbore_diam = 12
    hs_joint_corner_cbore_depth = 2
    hs_joint_corner_inset = 12

    hs_joint_axis_diam = 12
    hs_joint_axis_cbore_diam = 20
    hs_joint_axis_cbore_depth = 3


    """
    Radius of the mounting mechanism of the wing root. This is constrained by
    the size of the harness.
    """
    root_radius: float = 60

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


    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_wing_base_hole_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 = nhf.joints.hirth_joint(
            radius=self.hs_joint_radius,
            radius_inner=self.hs_joint_radius_inner,
            tooth_height=self.hs_joint_tooth_height,
            base_height=self.hs_joint_ring_thickness).val()
        #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_wing_base_hole_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.move(Cq.Location((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_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

    def wing_root(self,
                  side_width=30,
                  side_height=100) -> 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.
        """
        result = (
            Cq.Workplane("XY")
            .circle(self.root_radius)
            .transformed(offset=Cq.Vector(80, 0, 80),
                         rotate=Cq.Vector(0, 45, 0))
            .rect(side_width, side_height)
            .loft()
            .val()
        )
        return result

    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}p", color=Material.PLASTIC_PLA.color)
                #.constrain(f"harness?{name}", f"hs_{name}p?mate", "Point")
                .constrain("harness?mount", f"hs_{name}p?base", "Axis")
            )
            for i in range(4):
                result.constrain(f"harness?{name}_{i}", f"hs_{name}p?h{i}", "Point")
        result.solve()
        return result