fix: Turning bar geometry

nhf/touhou/yasaka_kanako/onbashira.py

@@ -347,7 +347,10 @@ class Onbashira(Model):
     motor_coupler_conn_dx: float = 30.0
     motor_coupler_wall_thickness: float = 5.0
     motor_coupler_inner_gap: float = 1.0
-    turning_bar_parent_hole_diam: float = 8.0
+
+    turning_bar_tilt: float = 12.0
+    turning_bar_hole_dy: float = 20.0
+    turning_bar_parent_hole_diam_extra: float = 1.0
     turning_bar_child_hole_diam: float = 4.0
     turning_bar_width: float = 15.0
     turning_bar_height: float = 30.0
@@ -441,6 +444,14 @@ class Onbashira(Model):
         """
         return self.chamber_side_width / 2 / math.tan(math.radians(self.angle_side / 2))
 
+    def interior_length(self, section_length: float) -> float:
+        """
+        Given the outside length of a section, calculate the length between the
+        mount holes on the angle joints on the two ends of it.
+        """
+        z2 = self.angle_joint_gap - self.angle_joint_flange_thickness
+        return section_length + z2
+
     @target(name="sanding-block")
     def sanding_block(self) -> Cq.Workplane:
         # Dihedral angle / 2
@@ -1262,14 +1273,8 @@ class Onbashira(Model):
     ### Electronics ###
 
     @property
-    def turning_bar_hole_dy(self) -> float:
+    def turning_bar_parent_hole_diam(self) -> float:
-        """
+        return BOLT_COMMON.diam_thread + self.turning_bar_parent_hole_diam_extra
-        Distance between centre of mounting holes in the turning bar and top of
-        the side panels.
-        """
-        panel_to_mount = self.angle_joint_flange_thickness / 2 - self.angle_joint_gap / 2
-        return panel_to_mount + self.turning_bar_width / 2
-
     @target(name="turning-bar")
     def turning_bar(self) -> Cq.Workplane:
         """
@@ -1279,6 +1284,39 @@ class Onbashira(Model):
         _, dx = self.angle_joint_bind_pos.to2d_pos()
         t = 8
         w = self.turning_bar_width
+        h = self.turning_bar_height
+        flange = Cq.Solid.makeBox(
+            length=w,
+            width=t,
+            height=w/2,
+        ).moved(-w/2, 0, 0) + Cq.Solid.makeCylinder(
+            radius=w/2,
+            height=t,
+            pnt=(0, 0, 0),
+            dir=(0, 1, 0),
+        ) - Cq.Solid.makeCylinder(
+            radius=self.turning_bar_parent_hole_diam/2,
+            height=w*2,
+            pnt=(0, -w, 0),
+            dir=(0, 1, 0),
+        )
+        flange = flange.moved(0, -t, -w/2-h)
+
+        leg = (
+            Cq.Workplane('YZ')
+            .sketch()
+            .polygon([
+                (0, -h),
+                (-t, -h),
+                (-t-self.turning_bar_tilt, 0),
+                (-self.turning_bar_tilt, 0),
+            ])
+            .finalize()
+            .extrude(w)
+            .translate((-w/2, 0, 0))
+            .union(flange)
+            .val()
+        )
         result = (
             Cq.Workplane()
             .box(
@@ -1287,51 +1325,47 @@ class Onbashira(Model):
                 height=t,
                 centered=(True, True, False)
             )
-        )
+            .translate((0, -w/2-self.turning_bar_tilt, -t))
-        h = self.turning_bar_height
-        flange = Cq.Solid.makeBox(
-            length=w,
-            width=t,
-            height=w/2 + h,
-        ).moved(-w/2, -t, -w/2-h) + Cq.Solid.makeCylinder(
-            radius=w/2,
-            height=t,
-            pnt=(0, -t, -w/2-h),
-            dir=(0, 1, 0),
         )
         holeC = Cq.Solid.makeCylinder(
             radius=self.turning_bar_child_hole_diam/2,
             height=w,
         )
-        holeP = Cq.Solid.makeCylinder(
-            radius=self.turning_bar_parent_hole_diam/2,
-            height=w*2,
-            pnt=(0, -w, -w/2-h),
-            dir=(0, 1, 0),
-        )
         dxe = self.electronics_mount_dx
         result = (
             result
-            + flange.moved(dx, w/2, 0)
+            + leg.moved(dx, 0, 0)
-            + flange.moved(-dx, w/2, 0)
+            + leg.moved(-dx, 0, 0)
-            - holeC.moved(dxe, 0, 0)
+            - holeC.moved(dxe, -self.turning_bar_hole_dy, -w)
-            - holeC.moved(-dxe, 0, 0)
+            - holeC.moved(-dxe, -self.turning_bar_hole_dy, -w)
-            - holeP.moved(dx, 0, 0)
-            - holeP.moved(-dx, 0, 0)
         )
-        result.tagAbsolute("holeBO1", (dx, w/2, -w/2-h), direction="+Y")
+        result.tagAbsolute("holeBO1", (dx, 0, -w/2-h), direction="+Y")
-        result.tagAbsolute("holeBO2", (-dx, w/2, -w/2-h), direction="+Y")
+        result.tagAbsolute("holeBO2", (-dx, 0, -w/2-h), direction="+Y")
-        result.tagAbsolute("holeMO1", (dxe, 0, t))
+        result.tagAbsolute("holeMO1", (dxe, -self.turning_bar_hole_dy, 0))
-        result.tagAbsolute("holeMO2", (-dxe, 0, t))
+        result.tagAbsolute("holeMO2", (-dxe, -self.turning_bar_hole_dy, 0))
         return result
 
+    def profile_electronics_panel(self) -> Cq.Sketch:
+        """
+        Generic electronics panel
+        """
+        hole_dx = self.electronics_mount_dx
+        # Distance between the holes
+        y = self.interior_length(self.side_length3) - self.turning_bar_hole_dy * 2
+        l = y + 15
+        w = self.side_width * self.electronics_panel_width_ratio
+        return (
+            Cq.Sketch()
+            .rect(l, w)
+            .rect(y, hole_dx * 2, mode="c", tag="corner")
+            .vertices(tag="corner")
+            .circle(self.turning_bar_child_hole_diam/2, mode="s")
+            .reset()
+        )
+
     @target(name="electronics-panel1", kind=TargetKind.DXF)
     def profile_electronics_panel1(self) -> Cq.Sketch:
-        hole_dy = self.turning_bar_hole_dy
+        # Distance between the holes
-        hole_dx = self.electronics_mount_dx
-        l = self.side_length3 - hole_dy * 2 + 12
-        y = self.side_length3 - hole_dy * 2
-        w = self.side_width * self.electronics_panel_width_ratio
         controller_holes = [
             self.controller_loc * Cq.Location.from2d(*h).flip_y()
             for h in self.controller.holes
@@ -1342,12 +1376,7 @@ class Onbashira(Model):
             for loc in self.battery_box_locs
         ]
         profile = (
-            Cq.Sketch()
+            self.profile_electronics_panel()
-            .rect(l, w)
-            .rect(y, hole_dx * 2, mode="c", tag="corner")
-            .vertices(tag="corner")
-            .circle(self.turning_bar_child_hole_diam/2, mode="s")
-            .reset()
             .push([
                 h.to2d_pos() for h in controller_holes
             ] + [
@@ -1358,21 +1387,20 @@ class Onbashira(Model):
         return profile
 
     def electronics_panel1(self) -> Cq.Workplane:
-        hole_dy = self.turning_bar_hole_dy
         hole_dx = self.electronics_mount_dx
-        l = self.side_length3
+        y = self.interior_length(self.side_length3) - self.turning_bar_hole_dy * 2
+        l = y + 15
         t = self.side_thickness
         result = (
             Cq.Workplane()
             .placeSketch(self.profile_electronics_panel1())
             .extrude(t)
         )
-        x = l/2 - hole_dy
         for side, z, d in [("T", t, "+Z"), ("B", 0, "-Z")]:
-            result.tagAbsolute(f"holeLP{side}", (-x, hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeLP{side}", (-y/2, hole_dx, z), direction=d)
-            result.tagAbsolute(f"holeLS{side}", (-x, -hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeLS{side}", (-y/2, -hole_dx, z), direction=d)
-            result.tagAbsolute(f"holeRP{side}", (x, -hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeRP{side}", (y/2, -hole_dx, z), direction=d)
-            result.tagAbsolute(f"holeRS{side}", (x, hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeRS{side}", (y/2, hole_dx, z), direction=d)
         for (i, h) in enumerate(self.controller.holes):
             loc = self.controller_loc * Cq.Location.from2d(*h).flip_y()
             hx, hy = loc.to2d_pos()
@@ -1455,6 +1483,84 @@ class Onbashira(Model):
                 )
         return a.solve()
 
+    @target(name="electronics-panel2", kind=TargetKind.DXF)
+    def profile_electronics_panel2(self) -> Cq.Sketch:
+        n = 15
+        h_hole = 10
+        y = self.interior_length(self.side_length3) - self.turning_bar_hole_dy * 2
+        w_hole = self.side_width * self.electronics_panel_width_ratio * 0.75
+        profile = (
+            self.profile_electronics_panel()
+            .rarray(y / n, 0, n, 1)
+            .slot(w_hole, h_hole, mode="s", angle=90)
+        )
+        return profile
+
+    def electronics_panel2(self) -> Cq.Workplane:
+        hole_dx = self.electronics_mount_dx
+        y = self.interior_length(self.side_length3) - self.turning_bar_hole_dy * 2
+        l = y + 15
+        t = self.side_thickness
+        result = (
+            Cq.Workplane()
+            .placeSketch(self.profile_electronics_panel2())
+            .extrude(t)
+        )
+        for side, z, d in [("T", t, "+Z"), ("B", 0, "-Z")]:
+            result.tagAbsolute(f"holeLP{side}", (-y/2, hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeLS{side}", (-y/2, -hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeRP{side}", (y/2, -hole_dx, z), direction=d)
+            result.tagAbsolute(f"holeRS{side}", (y/2, hole_dx, z), direction=d)
+        return result
+
+    @assembly()
+    def assembly_electronics2(self) -> Cq.Assembly:
+        name_barL = "barL"
+        name_barR = "barR"
+        name_panel = "panel"
+        a = (
+            Cq.Assembly()
+            .addS(
+                self.turning_bar(),
+                name=name_barL,
+                material=self.material_brace,
+                role=Role.STRUCTURE,
+            )
+            .addS(
+                self.turning_bar(),
+                name=name_barR,
+                material=self.material_brace,
+                role=Role.STRUCTURE,
+            )
+            .addS(
+                self.electronics_panel2(),
+                name=name_panel,
+                material=self.material_auxiliary,
+                role=Role.STRUCTURE,
+            )
+            .constrain(
+                f"{name_panel}?holeLPB",
+                f"{name_barL}?holeMO1",
+                "Plane"
+            )
+            .constrain(
+                f"{name_panel}?holeLSB",
+                f"{name_barL}?holeMO2",
+                "Plane"
+            )
+            .constrain(
+                f"{name_panel}?holeRPB",
+                f"{name_barR}?holeMO1",
+                "Plane"
+            )
+            .constrain(
+                f"{name_panel}?holeRSB",
+                f"{name_barR}?holeMO2",
+                "Plane"
+            )
+        )
+        return a.solve()
+
     ### Side Panels
 
     @target(name="front-bracket")
@@ -1853,7 +1959,7 @@ class Onbashira(Model):
         h = self.angle_joint_flange_thickness
         # drill hole
         cyl = Cq.Solid.makeCylinder(
-            radius=self.rotor_bind_bolt_diam/2,
+            radius=BOLT_COMMON.diam_thread/2,
             height=h,
             pnt=(ri * math.cos(th), ri * math.sin(th), -h/2),
         )
@@ -2257,7 +2363,6 @@ class Onbashira(Model):
             result.tagAbsolute(f"holeRSM{i}", locrot * Cq.Location(dr0, -x, -py), direction="-X")
 
         # Generate the flange geometry
-        flange = self.angle_joint_flange()
         result = result + self.angle_joint_flange()
         th = math.pi / self.n_side
         ri = self.angle_joint_bind_radius
@@ -2495,6 +2600,8 @@ class Onbashira(Model):
         if has_part(parts, "electronics1"):
             a = a.add(self.assembly_electronics1(), name="electronics1")
             a = a.constrain("electronics1/controller", "Fixed")
+        if has_part(parts, "electronics2"):
+            a = a.add(self.assembly_electronics2(), name="electronics2")
         if has_part(parts, ["electronics1", "ring3"]):
             a = a.constrain(
                 f"electronics1/barL?holeBO2",
@@ -2506,6 +2613,17 @@ class Onbashira(Model):
                 f"ring3/side2?holeStatorL",
                 "Plane",
             )
+        if has_part(parts, ["electronics2", "ring3"]):
+            a = a.constrain(
+                f"electronics2/barL?holeBO2",
+                f"ring3/side3?holeStatorL",
+                "Plane",
+            )
+            a = a.constrain(
+                f"electronics2/barL?holeBO1",
+                f"ring3/side4?holeStatorL",
+                "Plane",
+            )
 
         if has_part(parts, ["motor", "ring2"]):
             for i in range(self.n_side // 2):