585 lines
18 KiB
Python
585 lines
18 KiB
Python
from nhf import Material, Role
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from nhf.build import Model, target, assembly, TargetKind
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import nhf.utils
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import math
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from dataclasses import dataclass, field
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from enum import Enum
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import cadquery as Cq
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class AttachPoint(Enum):
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DOVETAIL_IN = 1
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DOVETAIL_OUT = 2
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NONE = 3
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@dataclass
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class Crown(Model):
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facets: int = 5
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# Lower circumference
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base_circ: float = 538.0
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# Upper circumference, at the middle
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tilt_circ: float = 640.0
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# Total height
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height: float = 120.0
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margin: float = 10.0
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thickness: float = 0.4 # 26 Gauge
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side_guard_thickness: float = 15.0
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side_guard_channel_radius: float = 90
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side_guard_channel_height: float = 10
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side_guard_hole_height: float = 15.0
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side_guard_hole_diam: float = 1.5
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side_guard_dovetail_height: float = 30.0
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material: Material = Material.METAL_BRASS
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material_side: Material = Material.PLASTIC_PLA
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def __post_init__(self):
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super().__init__(name="crown")
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assert self.tilt_circ > self.base_circ
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assert self.facet_width_upper / 2 > self.height / 2, "Top angle must be > 90 degrees"
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assert self.side_guard_channel_radius > self.radius_lower
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@property
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def facet_width_lower(self):
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return self.base_circ / self.facets
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@property
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def facet_width_upper(self):
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return self.tilt_circ / self.facets
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@property
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def radius_lower(self):
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return self.base_circ / (2 * math.pi)
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@property
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def radius_middle(self):
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return self.tilt_circ / (2 * math.pi)
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@property
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def radius_upper(self):
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return (self.tilt_circ + (self.tilt_circ - self.base_circ)) / (2 * math.pi)
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def profile_base(self) -> Cq.Sketch:
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# Generate the pentagonal shape
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dx_l = self.facet_width_lower
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dx_u = self.facet_width_upper
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dy = self.height
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return (
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Cq.Sketch()
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.polygon([
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(dx_l/2, 0),
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(dx_u/2, dy/2),
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(0, dy),
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(-dx_u/2, dy/2),
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(-dx_l/2, 0),
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])
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)
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@target(name="side", kind=TargetKind.DXF)
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def profile_side(self) -> Cq.Sketch:
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dy = self.facet_width_upper * 0.1
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x_side = self.facet_width_upper
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y_tip = self.height - self.margin
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eye = (
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Cq.Sketch()
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.segment(
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(0, y_tip),
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(dy, y_tip - dy),
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)
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.segment(
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(0, y_tip),
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(-dy, y_tip - dy),
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)
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.bezier([
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(dy, y_tip - dy),
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(0, y_tip - dy/2),
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(0, y_tip - dy/2),
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(-dy, y_tip - dy),
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])
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.assemble()
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)
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return (
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self.profile_base()
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.boolean(eye, mode='s')
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)
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@target(name="dot", kind=TargetKind.DXF)
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def profile_dot(self) -> Cq.Sketch:
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return (
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Cq.Sketch()
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.circle(self.margin / 2)
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)
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@target(name="front", kind=TargetKind.DXF)
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def profile_front(self) -> Cq.Sketch:
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dx_l = self.facet_width_lower
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dx_u = self.facet_width_upper
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dy = self.height
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window_length = dy / 5
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window_height = self.margin / 2
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window = (
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Cq.Sketch()
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.rect(window_length, window_height)
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)
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window_p1 = Cq.Location.from2d(
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dx_u/2 - self.margin - window_length * 0.4,
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dy/2 + self.margin/2,
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math.degrees(math.atan2(dy/2, -dx_u/2)),
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)
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window_p2 = Cq.Location.from2d(
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dx_l/2 - self.margin + window_length * 0.15,
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window_length/2 + self.margin,
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math.degrees(math.atan2(dy/2, (dx_u-dx_l)/2)),
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)
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# Carve the scale
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z = dy * 1/64 # "Pen" Thickness
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scale_pan_x = dx_l / 2 * 0.6
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scale_pan_y = dy / 2 * 0.7
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pan_dx = dx_l * 1/4
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pan_dy = dy * 1/16
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scale_pan = (
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Cq.Sketch()
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.arc(
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(- pan_dx/2, pan_dy),
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(0, 0),
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(+ pan_dx/2, pan_dy),
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)
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.segment(
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(+pan_dx/2, pan_dy),
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(+pan_dx/2 - z, pan_dy),
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)
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.arc(
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(-pan_dx/2 + z, pan_dy),
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(0, z),
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(+pan_dx/2 - z, pan_dy),
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)
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.segment(
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(-pan_dx/2, pan_dy),
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(-pan_dx/2 + z, pan_dy),
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)
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.assemble()
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)
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loc_scale_pan = Cq.Location.from2d(scale_pan_x, scale_pan_y)
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loc_scale_pan2 = Cq.Location.from2d(-scale_pan_x, scale_pan_y)
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scale_base_y = dy / 2 * 0.36
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scale_base_x = dx_l / 10
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assert scale_base_y < scale_pan_y
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assert scale_base_x < scale_pan_x
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scale_body = (
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Cq.Sketch()
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.arc(
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(scale_pan_x, scale_pan_y),
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(0, scale_base_y),
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(-scale_pan_x, scale_pan_y),
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)
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.segment(
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(-scale_pan_x, scale_pan_y),
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(-scale_pan_x+z, scale_pan_y+z),
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)
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.arc(
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(scale_pan_x - z, scale_pan_y+z),
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(0, scale_base_y + z),
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(-scale_pan_x + z, scale_pan_y+z),
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)
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.segment(
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(scale_pan_x, scale_pan_y),
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(scale_pan_x-z, scale_pan_y+z),
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)
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.assemble()
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.polygon([
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(scale_base_x, scale_base_y + z/2),
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(scale_base_x, self.margin),
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(scale_base_x-z, self.margin),
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(scale_base_x-z, scale_base_y-z),
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(-scale_base_x+z, scale_base_y-z),
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(-scale_base_x+z, self.margin),
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(-scale_base_x, self.margin),
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(-scale_base_x, scale_base_y + z/2),
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], mode='a')
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)
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# Needle
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needle_y_top = dy - self.margin
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needle_y_mid = dy * 0.7
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needle_dx = scale_base_x * 2
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y_shoulder = needle_y_mid - z * 2
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needle = (
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Cq.Sketch()
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.segment(
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(0, needle_y_mid),
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(z, y_shoulder),
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)
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.segment(
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(z, y_shoulder),
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(z, scale_base_y),
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)
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.segment(
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(z, scale_base_y),
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(-z, scale_base_y),
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)
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.segment(
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(-z, y_shoulder),
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(-z, scale_base_y),
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)
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.segment(
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(-z, y_shoulder),
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(0, needle_y_mid),
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)
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.assemble()
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)
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z2 = z * 2
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y1 = needle_y_mid + z2
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needle_head = (
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Cq.Sketch()
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.segment(
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(z, needle_y_mid),
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(z, y1),
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)
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.segment(
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(-z, needle_y_mid),
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(-z, y1),
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)
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# Outer edge
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.bezier([
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(0, needle_y_top),
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(0, (needle_y_top + needle_y_mid)/2),
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(needle_dx, (needle_y_top + needle_y_mid)/2),
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(z, needle_y_mid),
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])
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.bezier([
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(0, needle_y_top),
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(0, (needle_y_top + needle_y_mid)/2),
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(-needle_dx, (needle_y_top + needle_y_mid)/2),
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(-z, needle_y_mid),
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])
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# Inner edge
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.bezier([
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(0, needle_y_top - z2),
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(0, (needle_y_top + needle_y_mid)/2),
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(needle_dx-z2*2, (needle_y_top + needle_y_mid)/2),
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(z, y1),
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])
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.bezier([
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(0, needle_y_top - z2),
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(0, (needle_y_top + needle_y_mid)/2),
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(-needle_dx+z2*2, (needle_y_top + needle_y_mid)/2),
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(-z, y1),
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])
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.assemble()
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)
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return (
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self.profile_base()
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.boolean(window.moved(window_p1), mode='s')
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.boolean(window.moved(window_p1.flip_x()), mode='s')
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.boolean(window.moved(window_p2), mode='s')
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.boolean(window.moved(window_p2.flip_x()), mode='s')
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.boolean(scale_pan.moved(loc_scale_pan), mode='s')
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.boolean(scale_pan.moved(loc_scale_pan2), mode='s')
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.boolean(scale_body, mode='s')
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.boolean(needle, mode='s')
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.boolean(needle_head, mode='s')
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.clean()
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)
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@target(name="side-guard", kind=TargetKind.DXF)
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def profile_side_guard(self) -> Cq.Sketch:
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dx = self.facet_width_lower / 2
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dy = self.height
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# Main control points
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p_mid = Cq.Location.from2d(0, 0.5 * dy)
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p_mid_v = Cq.Location.from2d(10/57 * dx, 0)
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p_top1 = Cq.Location.from2d(0.408 * dx, 5/24 * dy)
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p_top1_v = Cq.Location.from2d(0.13 * dx, 0)
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p_top2 = Cq.Location.from2d(0.737 * dx, 0.255 * dy)
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p_top2_c1 = p_top2 * Cq.Location.from2d(-0.105 * dx, 0.033 * dy)
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p_top2_c2 = p_top2 * Cq.Location.from2d(-0.053 * dx, -0.09 * dy)
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p_top3 = Cq.Location.from2d(0.929 * dx, 0.145 * dy)
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p_top3_v = Cq.Location.from2d(0.066 * dx, 0.033 * dy)
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p_top4 = Cq.Location.from2d(0.85 * dx, 0.374 * dy)
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p_top4_v = Cq.Location.from2d(-0.053 * dx, 0.008 * dy)
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p_top5 = Cq.Location.from2d(0.54 * dx, 0.349 * dy)
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p_top5_c1 = p_top5 * Cq.Location.from2d(0.103 * dx, 0.017 * dy)
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p_top5_c2 = p_top5 * Cq.Location.from2d(0.158 * dx, 0.034 * dy)
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p_base_c = Cq.Location.from2d(1.245 * dx, 0.55 * dy)
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p_base = Cq.Location.from2d(dx, 0)
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bezier_groups = [
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[
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p_base,
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p_base_c,
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p_top5_c2,
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p_top5,
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],
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[
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p_top5,
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p_top5_c1,
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p_top4 * p_top4_v,
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p_top4,
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],
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[
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p_top4,
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p_top4 * p_top4_v.inverse.scale(4),
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p_top3 * p_top3_v,
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p_top3,
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],
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[
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p_top3,
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p_top3 * p_top3_v.inverse,
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p_top2_c2,
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p_top2,
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],
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[
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p_top2,
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p_top2_c1,
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p_top1 * p_top1_v,
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p_top1,
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],
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[
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p_top1,
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p_top1 * p_top1_v.inverse,
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p_mid * p_mid_v,
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p_mid,
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],
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]
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sketch = (
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Cq.Sketch()
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.segment(
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p_base.to2d_pos(),
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p_base.flip_x().to2d_pos(),
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)
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)
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for bezier_group in bezier_groups:
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sketch = (
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sketch
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.bezier([p.to2d_pos() for p in bezier_group])
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.bezier([p.flip_x().to2d_pos() for p in bezier_group])
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)
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return sketch.assemble()
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def side_guard_dovetail(self) -> Cq.Solid:
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"""
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Generates a dovetail coupling for the side guard
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"""
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dx = self.side_guard_thickness / 2
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wire = Cq.Wire.makePolygon([
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(dx * 0.5, 0),
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(dx * 0.7, dx),
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(-dx * 0.7, dx),
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(-dx * 0.5, 0),
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], close=True)
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return Cq.Solid.extrudeLinear(
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wire,
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[],
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(0,0,dx + self.side_guard_dovetail_height),
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).moved((0, 0, -dx))
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def side_guard(self, attach_left: AttachPoint, attach_right: AttachPoint) -> Cq.Workplane:
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"""
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Constructs the side guard using a cone. Via Gauss's Theorema Egregium,
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the surface of the cone can be deformed into a plane.
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"""
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angle_span = 360 / 5
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outer = Cq.Solid.makeCone(
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radius1=self.radius_lower + self.side_guard_thickness,
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radius2=self.radius_upper + self.side_guard_thickness,
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height=self.height,
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angleDegrees=angle_span,
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)
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inner = Cq.Solid.makeCone(
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radius1=self.radius_lower,
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radius2=self.radius_upper,
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height=self.height,
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angleDegrees=angle_span,
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)
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shell = (outer - inner).rotate((0,0,0), (0,0,1), -angle_span/2)
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dx = math.sin(math.radians(angle_span / 2)) * (self.radius_middle + self.side_guard_thickness)
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profile = (
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Cq.Workplane('YZ')
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.polyline([
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(0, self.height),
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(-dx, self.height / 2),
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(-dx, 0),
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(dx, 0),
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(dx, self.height / 2),
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])
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.close()
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.extrude(self.radius_upper + self.side_guard_thickness)
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.val()
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)
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#channel = (
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# Cq.Solid.makeCylinder(
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# radius=self.side_guard_channel_radius + 1.0,
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# height=self.side_guard_channel_height,
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# ) - Cq.Solid.makeCylinder(
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# radius=self.side_guard_channel_radius,
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# height=self.side_guard_channel_height,
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# )
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#)
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result = shell * profile# - channel
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for i in [-2, -1, 0, 1, 2]:
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phi = i * (math.pi / 14)
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hole = Cq.Solid.makeCylinder(
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radius=self.side_guard_hole_diam / 2,
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height=self.radius_upper * 2,
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pnt=(0, 0, self.side_guard_hole_height),
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dir=(math.cos(phi), math.sin(phi), 0),
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)
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result = result - hole
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radius_attach = self.radius_lower + self.side_guard_thickness / 2
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# tilt the dovetail by radius differential
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angle_tilt = math.degrees(math.atan2(self.radius_middle - self.radius_lower, self.height / 2))
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dovetail = self.side_guard_dovetail()
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loc_dovetail_left = Cq.Location.rot2d(angle_span / 2) * Cq.Location(radius_attach, 0, 0, 0, angle_tilt, 0)
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loc_dovetail_right = Cq.Location.rot2d(-angle_span / 2) * Cq.Location(radius_attach, 0, 0, 0, angle_tilt, 0)
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match attach_left:
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case AttachPoint.DOVETAIL_IN:
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loc_dovetail_left *= Cq.Location.rot2d(180)
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result = result - dovetail.moved(loc_dovetail_left)
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case AttachPoint.DOVETAIL_OUT:
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result = result + dovetail.moved(loc_dovetail_left)
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case AttachPoint.NONE:
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pass
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match attach_right:
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case AttachPoint.DOVETAIL_IN:
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result = result - dovetail.moved(loc_dovetail_right)
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case AttachPoint.DOVETAIL_OUT:
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loc_dovetail_right *= Cq.Location.rot2d(180)
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result = result + dovetail.moved(loc_dovetail_right)
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case AttachPoint.NONE:
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pass
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# Remove parts below the horizontal
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cut_h = self.radius_lower
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result -= Cq.Solid.makeCylinder(
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radius=self.radius_lower + self.side_guard_thickness,
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height=cut_h).moved((0,0,-cut_h))
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return result
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@target(name="side_guard_2")
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def side_guard_2(self) -> Cq.Workplane:
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return self.side_guard(
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attach_left=AttachPoint.DOVETAIL_OUT,
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attach_right=AttachPoint.DOVETAIL_IN,
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)
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@target(name="side_guard_3")
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def side_guard_3(self) -> Cq.Workplane:
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return self.side_guard(
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attach_left=AttachPoint.DOVETAIL_IN,
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attach_right=AttachPoint.DOVETAIL_IN,
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)
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def front_surrogate(self) -> Cq.Workplane:
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"""
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Create a surrogate cylindrical section structure for the front since we
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cannot bend extrusions
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|
"""
|
|
angle = 360 / 5
|
|
outer = Cq.Solid.makeCone(
|
|
radius1=self.radius_lower + self.thickness,
|
|
radius2=self.radius_upper + self.thickness,
|
|
height=self.height,
|
|
angleDegrees=angle,
|
|
)
|
|
inner = Cq.Solid.makeCone(
|
|
radius1=self.radius_lower,
|
|
radius2=self.radius_upper,
|
|
height=self.height,
|
|
angleDegrees=angle,
|
|
)
|
|
shell = (
|
|
outer.cut(inner)
|
|
.rotate((0,0,0), (0,0,1), -angle/2)
|
|
)
|
|
dx = math.sin(math.radians(angle / 2)) * self.radius_middle
|
|
profile = (
|
|
Cq.Workplane('YZ')
|
|
.polyline([
|
|
(0, self.height),
|
|
(-dx, self.height / 2),
|
|
(-dx, 0),
|
|
(dx, 0),
|
|
(dx, self.height / 2),
|
|
])
|
|
.close()
|
|
.extrude(self.radius_upper + self.side_guard_thickness)
|
|
.val()
|
|
)
|
|
return shell * profile
|
|
|
|
def assembly(self) -> Cq.Assembly:
|
|
"""
|
|
New assembly using conformal mapping on the cone.
|
|
"""
|
|
side_guard = self.side_guard_2()
|
|
a = Cq.Assembly()
|
|
for i in range(1,5):
|
|
a = a.addS(
|
|
side_guard,
|
|
name=f"side-{i}",
|
|
material=self.material_side,
|
|
loc=Cq.Location(rz=i*360/5)
|
|
)
|
|
a.addS(
|
|
self.front_surrogate(),
|
|
name="front",
|
|
material=self.material,
|
|
)
|
|
return a
|
|
|
|
def old_assembly(self) -> Cq.Assembly:
|
|
front = (
|
|
Cq.Workplane('XY')
|
|
.placeSketch(self.profile_front())
|
|
.extrude(self.thickness)
|
|
)
|
|
side = (
|
|
Cq.Workplane('XY')
|
|
.placeSketch(self.profile_side())
|
|
.extrude(self.thickness)
|
|
)
|
|
side_guard = (
|
|
Cq.Workplane('XY')
|
|
.placeSketch(self.profile_side_guard())
|
|
.extrude(self.thickness)
|
|
)
|
|
assembly = (
|
|
Cq.Assembly()
|
|
.addS(
|
|
front,
|
|
name="front",
|
|
material=self.material,
|
|
role=Role.DECORATION,
|
|
)
|
|
)
|
|
for i, pos in enumerate([-2, -1, 1, 2]):
|
|
x = self.facet_width_upper * pos
|
|
assembly = (
|
|
assembly
|
|
.addS(
|
|
side,
|
|
name=f"side{i}",
|
|
material=self.material,
|
|
role=Role.DECORATION,
|
|
loc=Cq.Location.from2d(x, 0),
|
|
)
|
|
.addS(
|
|
side_guard,
|
|
name=f"guard{i}",
|
|
material=self.material,
|
|
role=Role.DECORATION,
|
|
loc=Cq.Location(x, 0, self.thickness),
|
|
)
|
|
)
|
|
return assembly
|