nhf/parts/joints.py

@@ -100,7 +100,7 @@ class HirthJoint:
         (
             result
             .polyline([(0, 0, 0), (1, 0, 0)], forConstruction=True)
-            .tag("directrix")
+            .tag("dir")
         )
         return result
 
@@ -132,7 +132,7 @@ class HirthJoint:
             .add(obj2, name="obj2", color=Role.CHILD.color)
             .constrain("obj1", "Fixed")
             .constrain("obj1?mate", "obj2?mate", "Plane")
-            .constrain("obj1?directrix", "obj2?directrix", "Axis", param=angle)
+            .constrain("obj1?dir", "obj2?dir", "Axis", param=angle)
             .solve()
         )
         return result
@@ -249,7 +249,8 @@ class TorsionJoint:
     """
 
     # Radius limit for rotating components
-    radius: float = 40
+    radius_track: float = 40
+    radius_rider: float = 38
     track_disk_height: float = 10
     rider_disk_height: float = 8
 
@@ -281,7 +282,8 @@ class TorsionJoint:
 
 
     def __post_init__(self):
-        assert self.radius > self.groove_radius_outer
+        assert self.radius_track > self.groove_radius_outer
+        assert self.radius_rider > self.groove_radius_outer
         assert self.groove_radius_outer > self.groove_radius_inner
         assert self.groove_radius_inner > self.radius_spring
         assert self.spring_height > self.groove_depth, "Groove is too deep"
@@ -289,8 +291,18 @@ class TorsionJoint:
 
     @property
     def total_height(self):
+        """
+        Total height counting from bottom to top
+        """
         return self.track_disk_height + self.rider_disk_height + self.spring_height
 
+    @property
+    def radius(self):
+        """
+        Maximum radius of this joint
+        """
+        return max(self.radius_rider, self.radius_track)
+
     @property
     def _radius_spring_internal(self):
         return self.radius_spring - self.spring_thickness
@@ -335,14 +347,14 @@ class TorsionJoint:
         # TODO: Cover outer part of track only. Can we do this?
         groove_profile = (
             Cq.Sketch()
-            .circle(self.radius)
+            .circle(self.radius_track)
             .circle(self.groove_radius_outer, mode='s')
             .circle(self.groove_radius_inner, mode='a')
             .circle(self.radius_spring, mode='s')
         )
         spring_hole_profile = (
             Cq.Sketch()
-            .circle(self.radius)
+            .circle(self.radius_track)
             .circle(self.radius_spring, mode='s')
         )
         slot_height = self.spring_thickness
@@ -359,7 +371,7 @@ class TorsionJoint:
         result = (
             Cq.Workplane('XY')
             .cylinder(
-                radius=self.radius,
+                radius=self.radius_track,
                 height=self.track_disk_height,
                 centered=(True, True, False))
             .faces('>Z')
@@ -375,12 +387,12 @@ class TorsionJoint:
             .hole(self.radius_axle * 2)
             .cut(slot.moved(Cq.Location((0, 0, self.track_disk_height))))
         )
-        # Insert directrix`
+        # Insert directrix
         result.polyline(self._directrix(self.track_disk_height),
-                        forConstruction=True).tag("directrix")
+                        forConstruction=True).tag("dir")
         return result
 
-    def rider(self, rider_slot_begin=None):
+    def rider(self, rider_slot_begin=None, reverse_directrix_label=False):
         if not rider_slot_begin:
             rider_slot_begin = self.rider_slot_begin
         def slot(loc):
@@ -389,11 +401,11 @@ class TorsionJoint:
             return face.located(loc)
         wall_profile = (
             Cq.Sketch()
-            .circle(self.radius, mode='a')
+            .circle(self.radius_rider, mode='a')
             .circle(self.radius_spring, mode='s')
             .parray(
                 r=0,
-                a1=self.rider_slot_begin,
+                a1=rider_slot_begin,
                 da=self.rider_slot_span,
                 n=self.rider_n_slots)
             .each(slot, mode='s')
@@ -409,7 +421,7 @@ class TorsionJoint:
                 contact_profile
                 .parray(
                     r=0,
-                    a1=self.rider_slot_begin,
+                    a1=rider_slot_begin,
                     da=self.rider_slot_span,
                     n=self.rider_n_slots)
                 .each(slot, mode='s')
@@ -420,7 +432,7 @@ class TorsionJoint:
         result = (
             Cq.Workplane('XY')
             .cylinder(
-                radius=self.radius,
+                radius=self.radius_rider,
                 height=self.rider_disk_height,
                 centered=(True, True, False))
             .faces('>Z')
@@ -442,16 +454,17 @@ class TorsionJoint:
             #.workplane()
             .hole(self.radius_axle * 2)
         )
-        theta_begin = math.radians(self.rider_slot_begin) + math.pi
+        theta_begin = math.radians(rider_slot_begin)
         theta_span = math.radians(self.rider_slot_span)
         if abs(math.remainder(self.rider_slot_span, 360)) < TOL:
             theta_step = theta_span / self.rider_n_slots
         else:
             theta_step = theta_span / (self.rider_n_slots - 1)
         for i in range(self.rider_n_slots):
-            theta = theta_begin - i * theta_step
+            theta = theta_begin + i * theta_step
+            j = self.rider_n_slots - i - 1 if reverse_directrix_label else i
             result.polyline(self._directrix(self.rider_disk_height, theta),
-                            forConstruction=True).tag(f"directrix{i}")
+                            forConstruction=True).tag(f"dir{j}")
         return result
 
     def rider_track_assembly(self, directrix=0):
@@ -462,11 +475,26 @@ class TorsionJoint:
             Cq.Assembly()
             .add(spring, name="spring", color=Role.DAMPING.color)
             .add(track, name="track", color=Role.PARENT.color)
-            .constrain("track?spring", "spring?top", "Plane")
+            .add(rider, name="rider", color=Role.PARENT.color)
-            .constrain("track?directrix", "spring?directrix_bot", "Axis")
+        )
-            .add(rider, name="rider", color=Role.CHILD.color)
+        TorsionJoint.add_constraints(result,
-            .constrain("rider?spring", "spring?bot", "Plane")
+                                     rider="rider", track="track", spring="spring",
-            .constrain(f"rider?directrix{directrix}", "spring?directrix_top", "Axis")
+                                     directrix=directrix)
-            .solve()
+        return result.solve()
+
+    @staticmethod
+    def add_constraints(assembly: Cq.Assembly,
+                        rider: str, track: str, spring: str,
+                        directrix: int = 0):
+        """
+        Add the necessary constraints to a RT assembly
+        """
+        (
+            assembly
+            .constrain(f"{track}?spring", f"{spring}?top", "Plane")
+            .constrain(f"{track}?dir", f"{spring}?dir_top",
+                       "Axis", param=0)
+            .constrain(f"{rider}?spring", f"{spring}?bot", "Plane")
+            .constrain(f"{rider}?dir{directrix}", f"{spring}?dir_bot",
+                       "Axis", param=0)
         )
-        return result

nhf/parts/springs.py

@@ -46,11 +46,14 @@ def torsion_spring(radius=12,
             centered=False)
     )
     r = -radius if right_handed else radius
-    result.polyline([(0, r, 0), (tail_length, r, 0)],
+    plane = result.copyWorkplane(Cq.Workplane('XY'))
-                    forConstruction=True).tag("directrix_bot")
+    plane.polyline([(0, r, 0), (tail_length, r, 0)],
-    c, s = math.cos(omega * math.pi / 180), math.sin(omega * math.pi / 180)
+                   forConstruction=True).tag("dir_bot")
-    result.polyline([
+    omega = math.radians(omega)
-        (s * tail_length, c * r - s * tail_length, height),
+    c, s = math.cos(omega), math.sin(omega)
-        (c * tail_length + s * r, c * r - s * tail_length, height)],
+    l = -tail_length
-        forConstruction=True).tag("directrix_top")
+    plane.polyline([
+        (-s * r,        c * r, height),
+        (c * l - s * r, c * r + s * l, height)],
+        forConstruction=True).tag("dir_top")
     return result

nhf/parts/test.py

@@ -35,11 +35,13 @@ class TestJoints(unittest.TestCase):
     def test_torsion_joint(self):
         j = joints.TorsionJoint()
         for slot in range(j.rider_n_slots):
-            with self.subTest(slot=slot):
+            with self.subTest(slot=slot, right_handed=False):
                 self.torsion_joint_case(j, slot)
     def test_torsion_joint_right_handed(self):
         j = joints.TorsionJoint(right_handed=True)
-        self.torsion_joint_case(j, 1)
+        for slot in range(j.rider_n_slots):
+            with self.subTest(slot=slot, right_handed=True):
+                self.torsion_joint_case(j, slot)
     def test_torsion_joint_covered(self):
         j = joints.TorsionJoint(
             spring_hole_cover_track=True,

nhf/touhou/houjuu_nue/__init__.py

@@ -30,7 +30,6 @@ s1, s2, s3. The joints are named (from root to tip)
 shoulder, elbow, wrist in analogy with human anatomy.
 """
 from dataclasses import dataclass, field
-import unittest
 import cadquery as Cq
 from nhf import Material, Role
 from nhf.build import Model, TargetKind, target, assembly
@@ -93,6 +92,9 @@ class Parameters(Model):
     wing_root_wall_thickness: float = 8
 
     shoulder_torsion_joint: TorsionJoint = field(default_factory=lambda: TorsionJoint(
+        radius_track=35,
+        radius_rider=35,
+        groove_radius_outer=32,
         track_disk_height=5.0,
         rider_disk_height=7.0,
         radius_axle=8.0,
@@ -114,6 +116,9 @@ class Parameters(Model):
     wing_s1_thickness: float = 20
     wing_s1_spacer_thickness: float = 25.4 / 8
     wing_s1_spacer_width: float = 20
+    wing_s1_spacer_hole_diam: float = 8
+    wing_s1_shoulder_spacer_hole_dist: float = 20
+    wing_s1_shoulder_spacer_width: float = 60
 
     trident_handle: Handle = field(default_factory=lambda: Handle(
         diam=38,
@@ -132,6 +137,8 @@ class Parameters(Model):
         super().__init__(name="houjuu-nue")
         assert self.wing_root_radius > self.hs_hirth_joint.radius,\
             "Wing root must be large enough to accomodate joint"
+        assert self.wing_s1_shoulder_spacer_hole_dist > self.wing_s1_spacer_hole_diam, \
+            "Spacer holes are too close to each other"
 
     @target(name="trident/handle-connector")
     def handle_connector(self):
@@ -304,14 +311,32 @@ class Parameters(Model):
             conn_thickness=self.wing_s0_thickness,
         )
 
-    @target(name="shoulder_parent")
+    @target(name="shoulder_joint_parent")
-    def shoulder_parent_joint(self) -> Cq.Workplane:
+    def shoulder_joint_parent(self) -> Cq.Workplane:
+        joint = self.shoulder_torsion_joint
+        # Thickness of the lip connecting this joint to the wing root
+        lip_thickness = 10
+        lip_width = 25
+        lip_guard_ext = 40
+        lip_guard_height = self.wing_root_wall_thickness + lip_thickness
+        assert lip_guard_ext > joint.radius_track
+
+        lip_guard = (
+            Cq.Solid.makeBox(lip_guard_ext, lip_width, lip_guard_height)
+            .located(Cq.Location((0, -lip_width/2 , 0)))
+            .cut(Cq.Solid.makeCylinder(joint.radius_track, lip_guard_height))
+        )
         result = (
-            self.shoulder_torsion_joint.rider()
+            joint.track()
+            .union(lip_guard, tol=1e-6)
+
+            # Extrude the handle
             .copyWorkplane(Cq.Workplane(
                 'YZ', origin=Cq.Vector((88, 0, self.wing_root_wall_thickness))))
-            .rect(25, 7, centered=(True, False))
+            .rect(lip_width, lip_thickness, centered=(True, False))
             .extrude("next")
+
+            # Connector holes on the lip
             .copyWorkplane(Cq.Workplane(
                 'YX', origin=Cq.Vector((57, 0, self.wing_root_wall_thickness))))
             .hole(self.shoulder_attach_diam)
@@ -322,27 +347,117 @@ class Parameters(Model):
         result.moveTo(0, self.shoulder_attach_dist).tagPlane('conn1')
         return result
 
-    @target(name="shoulder_child")
+    @target(name="shoulder_joint_child")
-    def shoulder_child_joint(self) -> Cq.Assembly:
+    def shoulder_joint_child(self) -> Cq.Assembly:
-        # FIXME: half of conn_height
+        """
-        h = 100 / 2
+        Creates the top/bottom shoulder child joint
-        dh = h - self.shoulder_torsion_joint.total_height
+        """
+
+        joint = self.shoulder_torsion_joint
+        # Half of the height of the bridging cylinder
+        dh = self.wing_s0_height / 2 - joint.total_height
+        core_start_angle = 30
+        core_end_angle1 = 90
+        core_end_angle2 = 180
+        core_thickness = 2
+
+        core_profile1 = (
+            Cq.Sketch()
+            .arc((0, 0), joint.radius_rider, core_start_angle, core_end_angle1-core_start_angle)
+            .segment((0, 0))
+            .close()
+            .assemble()
+            .circle(joint.radius_rider - core_thickness, mode='s')
+        )
+        core_profile2 = (
+            Cq.Sketch()
+            .arc((0, 0), joint.radius_rider, -core_start_angle, -(core_end_angle2-core_start_angle))
+            .segment((0, 0))
+            .close()
+            .assemble()
+            .circle(joint.radius_rider - core_thickness, mode='s')
+        )
         core = (
             Cq.Workplane('XY')
-            .moveTo(0, 15)
+            .placeSketch(core_profile1)
-            .box(50, 40, 2 * dh, centered=(True, False, True))
+            .toPending()
+            .extrude(dh * 2)
+            .copyWorkplane(Cq.Workplane('XY'))
+            .placeSketch(core_profile2)
+            .toPending()
+            .extrude(dh * 2)
+            .translate(Cq.Vector(0, 0, -dh))
         )
+        # Create the upper and lower lips
+        lip_height = self.wing_s1_thickness
+        lip_thickness = joint.rider_disk_height
+        lip_ext = 40 + joint.radius_rider
+        hole_dx = self.wing_s1_shoulder_spacer_hole_dist
+        assert lip_height / 2 <= joint.radius_rider
+        lip = (
+            Cq.Workplane('XY')
+            .box(lip_ext, lip_height, lip_thickness,
+                 centered=(False, True, False))
+            .copyWorkplane(Cq.Workplane('XY'))
+            .cylinder(radius=joint.radius_rider, height=lip_thickness,
+                      centered=(True, True, False),
+                      combine='cut')
+            .faces(">Z")
+            .workplane()
+        )
+        hole_x = lip_ext - hole_dx / 2
+        for i in range(2):
+            plane = (
+                lip
+                .moveTo(hole_x - i * hole_dx, 0)
+            )
+            lip = plane.hole(self.wing_s1_spacer_hole_diam)
+            plane.tagPlane(f"hole{i}")
+
         loc_rotate = Cq.Location((0, 0, 0), (1, 0, 0), 180)
         result = (
             Cq.Assembly()
             .add(core, name="core", loc=Cq.Location())
-            .add(self.shoulder_torsion_joint.track(), name="track_top",
+            .add(joint.rider(rider_slot_begin=-90, reverse_directrix_label=True), name="rider_top",
                  loc=Cq.Location((0, 0, dh), (0, 0, 1), -90))
-            .add(self.shoulder_torsion_joint.track(), name="track_bot",
+            .add(joint.rider(rider_slot_begin=180), name="rider_bot",
                  loc=Cq.Location((0, 0, -dh), (0, 0, 1), -90) * loc_rotate)
+            .add(lip, name="lip_top",
+                 loc=Cq.Location((0, 0, dh)))
+            .add(lip, name="lip_bot",
+                 loc=Cq.Location((0, 0, -dh)) * loc_rotate)
         )
         return result
 
+    @assembly()
+    def shoulder_assembly(self) -> Cq.Assembly:
+        directrix = 0
+        result = (
+            Cq.Assembly()
+            .add(self.shoulder_joint_child(), name="child",
+                 color=Role.CHILD.color)
+            .constrain("child/core", "Fixed")
+            .add(self.shoulder_torsion_joint.spring(), name="spring_top",
+                 color=Role.DAMPING.color)
+            .add(self.shoulder_joint_parent(), name="parent_top",
+                 color=Role.PARENT.color)
+            .add(self.shoulder_torsion_joint.spring(), name="spring_bot",
+                 color=Role.DAMPING.color)
+            .add(self.shoulder_joint_parent(), name="parent_bot",
+                 color=Role.PARENT.color)
+        )
+        TorsionJoint.add_constraints(result,
+                                     rider="child/rider_top",
+                                     track="parent_top",
+                                     spring="spring_top",
+                                     directrix=directrix)
+        TorsionJoint.add_constraints(result,
+                                     rider="child/rider_bot",
+                                     track="parent_bot",
+                                     spring="spring_bot",
+                                     directrix=directrix)
+        return result.solve()
+
     @target(name="wing/s1-spacer", kind=TargetKind.DXF)
     def wing_s1_spacer(self) -> Cq.Workplane:
         result = (
@@ -357,6 +472,36 @@ class Parameters(Model):
         result.faces(">Y").tag("dir")
         return result
 
+    @target(name="wing/s1-shoulder-spacer", kind=TargetKind.DXF)
+    def wing_s1_shoulder_spacer(self) -> Cq.Workplane:
+        dx = self.wing_s1_shoulder_spacer_hole_dist
+        result = (
+            Cq.Workplane('XZ')
+            .sketch()
+            .rect(self.wing_s1_shoulder_spacer_width,
+                  self.wing_s1_thickness)
+            .push([
+                (0, 0),
+                (dx, 0),
+            ])
+            .circle(self.wing_s1_spacer_hole_diam / 2, mode='s')
+            .finalize()
+            .extrude(self.wing_s1_spacer_thickness)
+        )
+        # Tag the mating surfaces to be glued
+        result.faces("<Z").tag("mate1")
+        result.faces(">Z").tag("mate2")
+
+        # Tag the directrix
+        result.faces(">Y").tag("dir")
+
+        # Tag the holes
+        plane = result.faces(">Y").workplane()
+        # Side closer to the parent is 0
+        plane.moveTo(dx, 0).tagPlane("hole0")
+        plane.tagPlane("hole1")
+        return result
+
     @target(name="wing/r1s1", kind=TargetKind.DXF)
     def wing_r1s1_profile(self) -> Cq.Sketch:
         return MW.wing_r1s1_profile()
@@ -379,35 +524,6 @@ class Parameters(Model):
             plane.moveTo(px, sign * py).tagPlane(name)
         return result
 
-    @assembly()
-    def shoulder_assembly(self) -> Cq.Assembly:
-        result = (
-            Cq.Assembly()
-            .add(self.shoulder_child_joint(), name="child",
-                 color=Role.CHILD.color)
-            .constrain("child/core", "Fixed")
-            # Top parent joint
-            .add(self.shoulder_torsion_joint.spring(), name="spring_top",
-                 color=Role.DAMPING.color)
-            .constrain("child/track_top?spring", "spring_top?top", "Plane")
-            .constrain("child/track_top?directrix", "spring_top?directrix_bot", "Axis")
-            .add(self.shoulder_parent_joint(), name="parent_top",
-                 color=Role.PARENT.color)
-            .constrain("parent_top?spring", "spring_top?bot", "Plane")
-            .constrain("parent_top?directrix0", "spring_top?directrix_top", "Axis")
-            # Bottom parent joint
-            .add(self.shoulder_torsion_joint.spring(), name="spring_bot",
-                 color=Role.DAMPING.color)
-            .constrain("child/track_bot?spring", "spring_bot?top", "Plane")
-            .constrain("child/track_bot?directrix", "spring_bot?directrix_bot", "Axis")
-            .add(self.shoulder_parent_joint(), name="parent_bot",
-                 color=Role.PARENT.color)
-            .constrain("parent_bot?spring", "spring_bot?bot", "Plane")
-            .constrain("parent_bot?directrix0", "spring_bot?directrix_top", "Axis")
-            .solve()
-        )
-        return result
-
     @assembly()
     def wing_r1s1_assembly(self) -> Cq.Assembly:
         result = (
@@ -427,6 +543,13 @@ class Parameters(Model):
                 .constrain(f"panel_front?{tag}", f"{tag}_spacer?mate1", "Plane")
                 .constrain(f"panel_back?{tag}", f"{tag}_spacer?mate2", "Plane")
             )
+        (
+            result
+            .add(self.shoulder_assembly(), name="shoulder")
+            .constrain("shoulder_bot_spacer?dir",
+                       "shoulder/child/core?mate_bot",
+                       "Plane")
+        )
 
         result.solve()
         return result