fix: Overthick elbow and wrist

nhf/parts/box.py

@@ -75,6 +75,7 @@ class MountingBox(Model):
     profile_callback: Optional[Callable[[Cq.Sketch], Cq.Sketch]] = None
 
     def __post_init__(self):
+        assert self.thickness > 0
         for i, hole in enumerate(self.holes):
             if hole.tag is None:
                 hole.tag = f"conn{i}"

nhf/touhou/houjuu_nue/joints.py

@@ -72,7 +72,7 @@ ELBOW_AXLE_BOLT = FlatHeadBolt(
     diam_head=6.87,
     height_head=3.06,
     diam_thread=4.0,
-    height_thread=20.0,
+    height_thread=15.0,
 )
 ELBOW_AXLE_WASHER = Washer(
     mass=0.0,
@@ -888,11 +888,10 @@ class DiskJoint(Model):
 
     radius_housing: float = 22.0
     radius_disk: float = 20.0
-    radius_axle: float = 3.0
 
-    housing_thickness: float = 4.0
+    housing_thickness: float = 2.0
-    disk_thickness: float = 8.0
+    disk_thickness: float = 6.0
-    tongue_thickness: float = 10.0
+    tongue_thickness: float = 12.0
 
     # Amount by which the wall carves in
     wall_inset: float = 2.0
@@ -924,7 +923,6 @@ class DiskJoint(Model):
 
         assert self.housing_upper_carve_offset > 0
         assert self.spring_tail_hole_height > self.spring.thickness
-        assert self.tongue_thickness <= self.total_thickness
 
         assert self.axle_bolt.diam_thread == self.axle_washer.diam_thread
         assert self.axle_bolt.diam_thread == self.axle_hex_nut.diam_thread
@@ -937,6 +935,10 @@ class DiskJoint(Model):
             return a
         return None
 
+    @property
+    def radius_axle(self) -> float:
+        return self.axle_bolt.diam_thread
+
     @property
     def total_thickness(self) -> float:
         return self.housing_thickness * 2 + self.disk_thickness
@@ -1268,8 +1270,11 @@ class ElbowJoint(Model):
             yield -x, f"conn_bot{i}"
 
     @property
-    def total_thickness(self):
+    def total_thickness(self) -> float:
-        return self.disk_joint.total_thickness
+        candidate1 = self.disk_joint.axle_bolt.height_thread
+        candidate2 = self.disk_joint.total_thickness + self.disk_joint.axle_hex_nut.thickness
+        head_thickness = self.disk_joint.axle_bolt.height_head
+        return head_thickness + max(candidate1, candidate2)
 
     @property
     def motion_span(self) -> float:
@@ -1338,6 +1343,8 @@ class ElbowJoint(Model):
         def post(sketch: Cq.Sketch) -> Cq.Sketch:
             y_outer = self.disk_joint.total_thickness / 2
             y_inner = self.disk_joint.tongue_thickness / 2
+            if y_outer < y_inner:
+                return sketch
             y = (y_outer + y_inner) / 2
             width = self.lip_side_depression_width
             height = y_outer - y_inner

nhf/touhou/houjuu_nue/wing.py

@@ -29,6 +29,11 @@ ELBOW_PARAMS = dict(
     actuator=LINEAR_ACTUATOR_50,
     parent_arm_width=15,
 )
+ELBOW_DISK_PARAMS = dict(
+    housing_thickness=2.5,
+    disk_thickness=6.8,
+    tongue_thickness=12.3,
+)
 WRIST_DISK_PARAMS = dict(
     movement_angle=30,
     radius_disk=13.0,
@@ -116,8 +121,8 @@ class WingProfile(Model):
         self.wrist_axle_loc = self.wrist_bot_loc * \
             Cq.Location.from2d(0, self.wrist_height * self.wrist_axle_pos)
 
-        assert self.elbow_joint.total_thickness < min(self.s1_thickness, self.s2_thickness)
+        #assert self.elbow_joint.total_thickness < min(self.s1_thickness, self.s2_thickness)
-        assert self.wrist_joint.total_thickness < min(self.s2_thickness, self.s3_thickness)
+        #assert self.wrist_joint.total_thickness < min(self.s2_thickness, self.s3_thickness)
 
         self.shoulder_joint.angle_neutral = -self.shoulder_angle_neutral - self.shoulder_angle_bias
         self.shoulder_axle_loc = Cq.Location.from2d(self.shoulder_tip_x, self.shoulder_tip_y - self.shoulder_width / 2, 0)
@@ -642,6 +647,29 @@ class WingProfile(Model):
             profile_callback=carve_sides,
         )
         return mbox
+    def _actuator_mount(self, thickness: float, joint: ElbowJoint) -> MountingBox:
+        def post(sketch: Cq.Sketch) -> Cq.Sketch:
+            x = thickness / 2 - self.light_strip.height / 2
+            w = self.light_strip.height
+            h = self.light_strip.width
+            return (
+                sketch
+                .push([(x, 0), (-x, 0)])
+                .rect(w, h, mode='s')
+                #.push([(0, x), (0, -x)])
+                #.rect(h, w, mode='s')
+            )
+
+        return MountingBox(
+            length=thickness,
+            width=thickness,
+            thickness=self.spacer_thickness,
+            holes=[Hole(x=0,y=0)],
+            centred=(True, True),
+            hole_diam=joint.hole_diam,
+            centre_left_right_tags=True,
+            profile_callback=post,
+        )
 
     @target(name="profile-s1", kind=TargetKind.DXF)
     def profile_s1(self) -> Cq.Sketch:
@@ -709,14 +737,9 @@ class WingProfile(Model):
         )
     @submodel(name="spacer-s1-elbow-act")
     def spacer_s1_elbow_act(self) -> MountingBox:
-        return MountingBox(
+        return self._actuator_mount(
-            length=self.s1_thickness,
+            thickness=self.s1_thickness,
-            width=self.s1_thickness,
+            joint=self.elbow_joint
-            thickness=self.spacer_thickness,
-            holes=[Hole(x=0,y=0)],
-            centred=(True, True),
-            hole_diam=self.elbow_joint.hole_diam,
-            centre_left_right_tags=True,
         )
     @assembly()
     def assembly_s1(self) -> Cq.Assembly:
@@ -838,14 +861,9 @@ class WingProfile(Model):
         )
     @submodel(name="spacer-s2-elbow-act")
     def spacer_s2_elbow_act(self) -> MountingBox:
-        return MountingBox(
+        return self._actuator_mount(
-            length=self.s2_thickness,
+            thickness=self.s2_thickness,
-            width=self.s2_thickness,
+            joint=self.elbow_joint
-            thickness=self.spacer_thickness,
-            holes=[Hole(x=0,y=0)],
-            centred=(True, True),
-            hole_diam=self.elbow_joint.hole_diam,
-            centre_left_right_tags=True,
         )
     @submodel(name="spacer-s2-wrist")
     def spacer_s2_wrist(self) -> MountingBox:
@@ -855,14 +873,9 @@ class WingProfile(Model):
         )
     @submodel(name="spacer-s2-wrist-act")
     def spacer_s2_wrist_act(self) -> MountingBox:
-        return MountingBox(
+        return self._actuator_mount(
-            length=self.s2_thickness,
+            thickness=self.s2_thickness,
-            width=self.s2_thickness,
+            joint=self.wrist_joint
-            thickness=self.spacer_thickness,
-            holes=[Hole(x=0,y=0)],
-            centred=(True, True),
-            hole_diam=self.wrist_joint.hole_diam,
-            centre_left_right_tags=True,
         )
     @assembly()
     def assembly_s2(self) -> Cq.Assembly:
@@ -979,14 +992,9 @@ class WingProfile(Model):
         )
     @submodel(name="spacer-s3-wrist-act")
     def spacer_s3_wrist_act(self) -> MountingBox:
-        return MountingBox(
+        return self._actuator_mount(
-            length=self.s3_thickness,
+            thickness=self.s3_thickness,
-            width=self.s3_thickness,
+            joint=self.wrist_joint
-            thickness=self.spacer_thickness,
-            holes=[Hole(x=0,y=0)],
-            centred=(True, True),
-            hole_diam=self.wrist_joint.hole_diam,
-            centre_left_right_tags=True,
         )
     @assembly()
     def assembly_s3(self) -> Cq.Assembly:
@@ -1160,6 +1168,7 @@ class WingR(WingProfile):
         disk_joint=DiskJoint(
             movement_angle=55,
             spring_angle_at_0=75,
+            **ELBOW_DISK_PARAMS,
         ),
         flexor_offset_angle=15,
         flexor_mount_angle_child=-75,
@@ -1416,6 +1425,7 @@ class WingL(WingProfile):
         disk_joint=DiskJoint(
             spring_angle_at_0=100,
             movement_angle=50,
+            **ELBOW_DISK_PARAMS,
         ),
         angle_neutral=30.0,
         flexor_mount_angle_child=220,
@@ -1442,6 +1452,7 @@ class WingL(WingProfile):
     wrist_height: float = 43.0
     wrist_joint: ElbowJoint = field(default_factory=lambda: ElbowJoint(
         disk_joint=DiskJoint(
+            tongue_thickness=8.0,
             **WRIST_DISK_PARAMS,
         ),
         flip=False,