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Bearing couplers

This commit is contained in:
Leni Aniva 2025-05-29 14:04:12 -07:00
parent d937fc9513
commit 6709e4f32e
Signed by: aniva
GPG Key ID: D5F96287843E8DFB
1 changed files with 209 additions and 79 deletions
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288
nhf/touhou/yasaka_kanako/onbashira.py
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@ -31,6 +31,15 @@ BOLT_COMMON = FlatHeadBolt(
height_thread=30.0,
pitch=1.0,
)
BOLT_BEARING = FlatHeadBolt(
# FIXME: measure
mass=0.0,
diam_head=12.8,
height_head=2.8,
diam_thread=4.0,
height_thread=30.0,
pitch=1.0,
)
@dataclass(frozen=True)
@ -124,12 +133,12 @@ class Onbashira(Model):
angle_joint_flange_thickness: float = 7.8
angle_joint_flange_radius: float = 23.0
angle_joint_flange_extension: float = 23.0
angle_joint_extra_hole_offset: float = 20.0
# Mating structure on the angle joint
angle_joint_conn_thickness: float = 4.0
angle_joint_conn_depth: float = 15.0
angle_joint_conn_width: float = 15.0
angle_joint_bind_radius: float = 135.0
chamber_side_length: float = 400.0
chamber_side_width_ex: float = 20.0
@ -140,26 +149,33 @@ class Onbashira(Model):
barrel_length: float = 25.4 * 12
# Gap between the stator edge and the inner face of the barrel
stator_gap: float = 10.0
stator_gap: float = 3.0
# Radius from barrel centre to axis
rotation_radius: float = 66.0
rotation_radius: float = 64.0
n_bearing_balls: int = 12
# Size of ball bearings
bearing_ball_diam: float = 25.4 * 1/2
bearing_ball_gap: float = .5
# Thickness of bearing disks
bearing_thickness: float = 20.0
bearing_track_radius: float = 100.0
bearing_track_radius: float = 97.0
# Gap between the inner and outer bearing disks
bearing_gap: float = 10.0
bearing_disk_gap: float = 10.0
bearing_spindle_max_diam: float = 13.0
bearing_disk_thickness: float = 25.4 / 8
bearing_gasket_extend: float = 12.0
bearing_disk_thickness: float = 25.4 / 16
rotor_inner_radius: float = 40.0
# Coupling mechanism onto the chassis
stator_coupler_width: float = 14.0
stator_coupler_thickness: float = 30.0
stator_coupler_thickness_inner: float = 10.0
stator_bind_radius: float = 117.0
# Extra bind sites for stator to prevent warping
stator_bind_extra: int = 2
rotor_inner_radius: float = 36.0
rotor_bind_bolt_diam: float = BOLT_COMMON.diam_thread
rotor_bind_radius: float = 82.0
rotor_bind_extra: int = 1
rotor_spacer_outer_diam: float = 15.0
stator_bind_radius: float = 135.0
handle_base_height: float = 10.0
handle_thickness: float = 17.0
@ -171,7 +187,7 @@ class Onbashira(Model):
material_side: Material = Material.WOOD_BIRCH
material_bearing: Material = Material.PLASTIC_PLA
material_spacer: Material = Material.PLASTIC_PLA
material_bearing_ball: Material = Material.ACRYLIC_TRANSPARENT
material_bearing_ball: Material = Material.PLASTIC_PLA
material_barrel: Material = Material.ACRYLIC_BLACK
material_brace: Material = Material.PLASTIC_PLA
material_fastener: Material = Material.STEEL_STAINLESS
@ -179,10 +195,9 @@ class Onbashira(Model):
def __post_init__(self):
assert self.n_side >= 3
# Bulk must be large enough for the barrel + bearing to rotate
assert self.bulk_radius - self.side_thickness - self.bearing_thickness - self.bearing_diam > self.rotation_radius + self.barrel_diam / 2
assert self.bearing_gap < 0.95 * self.bearing_ball_diam
assert self.rotor_bind_bolt_diam < self.rotor_bind_radius < self.bearing_track_radius
assert self.rotor_inner_radius < self.bearing_track_radius < self.stator_bind_radius
assert self.bulk_radius - self.side_thickness - self.bearing_thickness > self.rotation_radius + self.barrel_diam / 2
assert BOLT_COMMON.diam_thread < self.rotor_bind_radius < self.bearing_track_radius
assert self.rotor_inner_radius < self.bearing_track_radius < self.angle_joint_bind_radius
assert self.angle_joint_thickness > self.side_thickness
for (x, y) in self.angle_joint_bolt_position:
@ -240,18 +255,6 @@ class Onbashira(Model):
Radius of the bulk (surface of each side) to the centre
"""
return self.chamber_side_width / 2 / math.tan(math.radians(self.angle_side / 2))
@property
def bearing_diam(self) -> float:
return self.bearing_ball_diam + self.bearing_ball_gap
@property
def bearing_disk_gap(self) -> float:
"""
Gap between two bearing disks to touch the bearing balls
"""
diag = self.bearing_ball_diam
dx = self.bearing_gap
return math.sqrt(diag ** 2 - dx ** 2)
@target(name="sanding-block")
def sanding_block(self) -> Cq.Workplane:
@ -267,15 +270,64 @@ class Onbashira(Model):
.extrude(self.side_width * 1.5)
)
@target(name="stator-coupler")
def stator_coupler(self) -> Cq.Workplane:
"""
Couples the stator to the chassis
"""
r1 = self.angle_joint_bind_radius
r2 = self.stator_bind_radius
assert r1 > r2
l = r1 - r2
w = self.stator_coupler_width
h = self.stator_coupler_thickness
h_step = h - self.stator_coupler_thickness_inner
intersector = Cq.Solid.makeBox(
length=l + w,
width=w,
height=h_step,
).moved(0, -w/2, 0)
profile = (
Cq.Sketch()
.rect(l, w)
.push([
(-l/2, 0),
(l/2, 0),
])
.circle(w/2, mode="a")
.push([
(-l/2, 0),
(l/2, 0),
])
.circle(BOLT_COMMON.diam_thread/2, mode="s")
)
result = (
Cq.Workplane()
.placeSketch(profile)
.extrude(h)
)
dx = l / 2
result = result - intersector
result.tagAbsolute(f"holeOB", (-dx, 0, 0), direction="-Z")
result.tagAbsolute(f"holeIB", (+dx, 0, h_step), direction="-Z")
result.tagAbsolute(f"holeOF", (-dx, 0, h), direction="+Z")
result.tagAbsolute(f"holeIF", (+dx, 0, h), direction="+Z")
return result
@target(name="bearing-stator", kind=TargetKind.DXF)
def profile_bearing_stator(self) -> Cq.Sketch:
assert self.stator_bind_radius < self.angle_joint_bind_radius
return (
Cq.Sketch()
.regularPolygon(self.side_width - self.side_thickness, self.n_side)
.circle(self.bulk_radius - self.side_thickness - self.stator_gap)
#.regularPolygon(self.side_width - self.side_thickness - self.stator_gap, self.n_side*2)
.circle(self.bearing_track_radius + self.bearing_gap/2, mode="s")
.reset()
.regularPolygon(
self.stator_bind_radius, self.n_side,
self.stator_bind_radius, self.n_side * (1 + self.stator_bind_extra),
mode="c", tag="bolt")
.vertices(tag="bolt")
.circle(self.rotor_bind_bolt_diam/2, mode="s")
@ -286,20 +338,30 @@ class Onbashira(Model):
.placeSketch(self.profile_bearing_stator())
.extrude(self.bearing_disk_thickness)
)
br = self.stator_bind_radius
th1 = math.radians(360 / self.n_side)
th2 = math.radians(360 / (self.n_side * (1 + self.stator_bind_extra)))
for i in range(self.n_side):
angle = (i+0.5) * math.radians(360 / self.n_side)
angle = (i+0.5) * th1
result.faces(">Z").moveTo(
self.stator_bind_radius * math.cos(angle),
self.stator_bind_radius * math.sin(angle),
br * math.cos(angle),
br * math.sin(angle),
).tagPlane(f"holeF{i}")
result.faces("<Z").moveTo(
self.stator_bind_radius * math.cos(-angle),
self.stator_bind_radius * math.sin(-angle),
br * math.cos(-angle),
br * math.sin(-angle),
).tagPlane(f"holeB{i}", direction="-Z")
for j in range(1, 1 + self.stator_bind_extra):
angle2 = angle + (j + 1) * th2
result.faces("<Z").moveTo(
br * math.cos(-angle2),
br * math.sin(-angle2),
).tagPlane(f"holeE{i}", direction="-Z")
return result
@target(name="bearing-rotor", kind=TargetKind.DXF)
def profile_bearing_rotor(self) -> Cq.Sketch:
bolt_angle = 180 / self.n_side
bolt_angle = (180 / self.n_side) * 1.5
n_binds = 1 + self.rotor_bind_extra
return (
Cq.Sketch()
.circle(self.bearing_track_radius - self.bearing_gap/2)
@ -312,8 +374,10 @@ class Onbashira(Model):
.circle(self.barrel_diam/2, mode="s")
.reset()
.regularPolygon(
self.rotor_bind_radius, self.n_side,
mode="c", tag="bolt", angle=bolt_angle)
r=self.rotor_bind_radius,
n=self.n_side * n_binds,
mode="c", tag="bolt",
angle=bolt_angle)
.vertices(tag="bolt")
.circle(self.rotor_bind_bolt_diam/2, mode="s")
)
@ -325,7 +389,7 @@ class Onbashira(Model):
)
@target(name="bearing-gasket", kind=TargetKind.DXF)
def profile_bearing_gasket(self) -> Cq.Sketch:
dr = self.bearing_ball_diam
dr = self.bearing_gasket_extend
eps = 0.05
return (
Cq.Sketch()
@ -336,7 +400,7 @@ class Onbashira(Model):
self.bearing_track_radius, self.n_bearing_balls,
mode="c", tag="corners")
.vertices(tag="corners")
.circle(self.bearing_ball_diam/2 * (1+eps), mode="s")
.circle(BOLT_BEARING.diam_thread, mode="s")
)
def bearing_gasket(self) -> Cq.Workplane:
return (
@ -353,11 +417,8 @@ class Onbashira(Model):
"""
pass
def bearing_ball(self) -> Cq.Solid:
return Cq.Solid.makeSphere(radius=self.bearing_ball_diam/2, angleDegrees1=-90)
@target(name="rotor-spacer")
def rotor_spacer(self) -> Cq.Solid:
@target(name="stator-spacer")
def stator_spacer(self) -> Cq.Solid:
outer = Cq.Solid.makeCylinder(
radius=self.rotor_spacer_outer_diam/2,
height=self.bearing_disk_gap,
@ -367,16 +428,31 @@ class Onbashira(Model):
height=self.bearing_disk_gap
)
return outer - inner
@target(name="rotor-spacer")
def rotor_spacer(self) -> Cq.Solid:
outer = Cq.Solid.makeCylinder(
radius=self.rotor_spacer_outer_diam/2,
height=self.bearing_disk_gap,
)
inner = Cq.Solid.makeCylinder(
radius=BOLT_BEARING.diam_thread/2,
height=self.bearing_disk_gap
)
return outer - inner
@property
def bearing_spindle_height(self) -> float:
h = self.bearing_disk_gap + 2 * self.bearing_disk_thickness
return h * 2
@target(name="bearing-spindle")
def bearing_spindle(self) -> Cq.Solid:
r1 = self.bearing_gap / 2
r2 = self.bearing_spindle_max_diam
h = self.bearing_disk_gap
cone1 = Cq.Solid.makeCone(
radius1=r2,
radius2=r1,
height=h/2
h = self.bearing_disk_gap + 2 * self.bearing_disk_thickness
cone1 = Cq.Solid.makeCylinder(
radius=r1,
height=h/2,
)
cone2 = Cq.Solid.makeCone(
radius1=r1,
@ -384,17 +460,33 @@ class Onbashira(Model):
height=h/2,
)
hole = Cq.Solid.makeCylinder(
radius=(BOLT_COMMON.diam_thread + 1)/2,
radius=(BOLT_BEARING.diam_thread + 1)/2,
height=h*2
).moved(0, 0, -h)
top = (cone1 + cone2.moved(0, 0, h/2)) - hole
return top + top.rotate((0,0,0),(1,0,0),180)
def assembly_barrel(self) -> Cq.Assembly:
def barrel(self) -> Cq.Compound:
"""
One gun barrel
"""
outer = Cq.Solid.makeCylinder(
radius=self.barrel_diam/2,
height=self.barrel_length,
)
inner = Cq.Solid.makeCylinder(
radius=self.barrel_diam/2-self.barrel_wall_thickness,
height=self.barrel_length
)
return outer - inner
@assembly()
def assembly_machine(self) -> Cq.Assembly:
"""
The assembly with gun barrels
"""
z_lower = -self.bearing_disk_gap/2 - self.bearing_disk_thickness
gasket_h = self.bearing_spindle_height / 2
a = (
Cq.Assembly()
.addS(
@ -427,36 +519,52 @@ class Onbashira(Model):
)
.addS(
self.bearing_gasket(),
name="gasket",
name="gasket_bot",
material=self.material_bearing,
role=Role.ROTOR,
loc=Cq.Location(0, 0, -self.bearing_disk_thickness/2)
loc=Cq.Location(0, 0, -gasket_h-self.bearing_disk_thickness)
)
.addS(
self.bearing_gasket(),
name="gasket_top",
material=self.material_bearing,
role=Role.ROTOR,
loc=Cq.Location(0, 0, gasket_h)
)
)
z = -self.bearing_disk_gap/2
for i in range(self.n_side):
loc_barrel = Cq.Location.rot2d((i+1/2) * 360/self.n_side) * \
Cq.Location(self.rotation_radius, 0, -self.barrel_length/2)
a = a.addS(
self.barrel(),
name=f"barrel{i}",
material=self.material_barrel,
role=Role.DECORATION,
loc=loc_barrel,
)
loc = Cq.Location.rot2d(i * 360/self.n_side) * Cq.Location(self.rotor_bind_radius, 0, z)
a = a.addS(
self.rotor_spacer(),
name=f"spacerRotor{i}",
material=self.material_spacer,
role=Role.STRUCTURE,
loc=loc
)
loc = Cq.Location.rot2d((i+0.5) * 360/self.n_side) * Cq.Location(self.stator_bind_radius, 0, z)
a = a.addS(
self.rotor_spacer(),
name=f"spacerStator{i}",
material=self.material_spacer,
role=Role.STRUCTURE,
loc=loc
)
#a = a.addS(
# self.stator_spacer(),
# name=f"spacerRotor{i}",
# material=self.material_spacer,
# role=Role.STRUCTURE,
# loc=loc
#)
loc = Cq.Location.rot2d((i+0.5) * 360/self.n_side) * Cq.Location(self.angle_joint_bind_radius, 0, z)
#a = a.addS(
# self.rotor_spacer(),
# name=f"spacerStator{i}",
# material=self.material_spacer,
# role=Role.STRUCTURE,
# loc=loc
#)
for i in range(self.n_bearing_balls):
ball = self.bearing_ball()
ball = self.bearing_spindle()
loc = Cq.Location.rot2d(i * 360/self.n_bearing_balls) * Cq.Location(self.bearing_track_radius, 0, 0)
a = a.addS(
ball,
name=f"bearing_ball{i}",
name=f"bearing_spindle{i}",
material=self.material_bearing_ball,
role=Role.BEARING,
loc=loc,
@ -692,7 +800,7 @@ class Onbashira(Model):
.regularPolygon(self.side_width - self.side_thickness, self.n_side)
.reset()
.regularPolygon(
self.stator_bind_radius, self.n_side,
self.angle_joint_bind_radius, self.n_side,
mode="c", tag="bolt")
.vertices(tag="bolt")
.circle(self.rotor_bind_bolt_diam/2, mode="s")
@ -707,8 +815,8 @@ class Onbashira(Model):
# Mark all attachment points
for i in range(self.n_side):
angle = (i+0.5) * math.radians(360 / self.n_side)
x = self.stator_bind_radius * math.cos(angle)
y = self.stator_bind_radius * math.sin(angle)
x = self.angle_joint_bind_radius * math.cos(angle)
y = self.angle_joint_bind_radius * math.sin(angle)
result.tagAbsolute(f"holeF{i}", (x, y, self.side_thickness), direction="+Z")
result.tagAbsolute(f"holeB{i}", (x, -y, 0), direction="-Z")
return result
@ -743,7 +851,7 @@ class Onbashira(Model):
.extrude(self.angle_joint_flange_thickness)
.translate((0, 0, -self.angle_joint_flange_thickness/2))
)
ri = self.stator_bind_radius
ri = self.angle_joint_bind_radius
h = self.angle_joint_flange_thickness
# drill hole
cyl = Cq.Solid.makeCylinder(
@ -878,7 +986,7 @@ class Onbashira(Model):
.extrude(self.angle_joint_gap)
.translate((0, 0, -flange_z))
)
ri = self.stator_bind_radius
ri = self.angle_joint_bind_radius
h = self.angle_joint_gap
# Drill holes for connectors
cyl = Cq.Solid.makeCylinder(
@ -1027,7 +1135,8 @@ class Onbashira(Model):
flange = self.angle_joint_flange()
result = result + self.angle_joint_flange()
th = math.pi / self.n_side
ri = self.stator_bind_radius
ri = self.angle_joint_bind_radius
h = self.angle_joint_gap
result.tagAbsolute("holeStatorL", (ri * math.cos(th), ri * math.sin(th), h/2), direction="+Z")
result.tagAbsolute("holeStatorR", (ri * math.cos(th), ri * math.sin(th), -h/2), direction="-Z")
return result
@ -1153,11 +1262,13 @@ class Onbashira(Model):
flange = self.angle_joint_flange()
result = result + self.angle_joint_flange()
th = math.pi / self.n_side
ri = self.stator_bind_radius
ri = self.angle_joint_bind_radius
h = self.angle_joint_gap
result.tagAbsolute("holeStatorL", (ri * math.cos(th), ri * math.sin(th), h/2), direction="+Z")
result.tagAbsolute("holeStatorR", (ri * math.cos(th), ri * math.sin(th), -h/2), direction="-Z")
return result
@assembly()
def assembly_ring(self, base) -> Cq.Assembly:
a = Cq.Assembly()
r = self.bulk_radius
@ -1280,9 +1391,9 @@ class Onbashira(Model):
self.handle(),
name="handle",
material=self.material_brace,
role=Role.STRUCTURE,
role=Role.HANDLE,
)
#.add(self.assembly_barrel(), name="barrel")
.add(self.assembly_machine(), name="machine")
)
# Add handle
for ih, (x, y) in enumerate(self.angle_joint_bolt_position):
@ -1298,6 +1409,25 @@ class Onbashira(Model):
)
for i in range(self.n_side):
j = (i + 1) % self.n_side
ir = (self.n_side - i) % self.n_side
coupler_name = f"stator_coupler{i}"
a = a.addS(
self.stator_coupler(),
name=coupler_name,
material=self.material_brace,
role=Role.STRUCTURE,
)
a = a.constrain(
f"{coupler_name}?holeOB",
f"ring1/side{i}?holeStatorL",
"Plane",
)
a = a.constrain(
f"{coupler_name}?holeIF",
f"machine/stator2?holeB{ir}",
"Plane",
)
for ih in range(len(self.angle_joint_bolt_position)):
a = a.constrain(
f"chamber/side{i}?holeFPI{ih}",