514 lines
16 KiB
Python
514 lines
16 KiB
Python
"""
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This file describes the shapes of the wing shells. The joints are defined in
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`__init__.py`.
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"""
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import math
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from enum import Enum
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from dataclasses import dataclass
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from typing import Mapping, Tuple
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import cadquery as Cq
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from nhf import Material, Role
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from nhf.parts.joints import HirthJoint
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import nhf.utils
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def wing_root_profiles(
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base_sweep=150,
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wall_thickness=8,
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base_radius=40,
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middle_offset=30,
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middle_height=80,
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conn_thickness=40,
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conn_height=100) -> tuple[Cq.Wire, Cq.Wire]:
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assert base_sweep < 180
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assert middle_offset > 0
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theta = math.pi * base_sweep / 180
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c, s = math.cos(theta), math.sin(theta)
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c_1, s_1 = math.cos(theta * 0.75), math.sin(theta * 0.75)
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c_2, s_2 = math.cos(theta / 2), math.sin(theta / 2)
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r1 = base_radius
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r2 = base_radius - wall_thickness
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base = (
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Cq.Sketch()
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.arc(
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(c * r1, s * r1),
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(c_1 * r1, s_1 * r1),
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(c_2 * r1, s_2 * r1),
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)
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.arc(
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(c_2 * r1, s_2 * r1),
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(r1, 0),
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(c_2 * r1, -s_2 * r1),
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)
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.arc(
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(c_2 * r1, -s_2 * r1),
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(c_1 * r1, -s_1 * r1),
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(c * r1, -s * r1),
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)
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.segment(
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(c * r1, -s * r1),
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(c * r2, -s * r2),
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)
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.arc(
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(c * r2, -s * r2),
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(c_1 * r2, -s_1 * r2),
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(c_2 * r2, -s_2 * r2),
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)
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.arc(
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(c_2 * r2, -s_2 * r2),
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(r2, 0),
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(c_2 * r2, s_2 * r2),
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)
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.arc(
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(c_2 * r2, s_2 * r2),
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(c_1 * r2, s_1 * r2),
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(c * r2, s * r2),
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)
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.segment(
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(c * r2, s * r2),
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(c * r1, s * r1),
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)
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.assemble(tag="wire")
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.wires().val()
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)
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assert isinstance(base, Cq.Wire)
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# The interior sweep is given by theta, but the exterior sweep exceeds the
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# interior sweep so the wall does not become thinner towards the edges.
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# If the exterior sweep is theta', it has to satisfy
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#
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# sin(theta) * r2 + wall_thickness = sin(theta') * r1
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x, y = conn_thickness / 2, middle_height / 2
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t = wall_thickness
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dx = middle_offset
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middle = (
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Cq.Sketch()
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# Interior arc, top point
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.arc(
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(x - t, y - t),
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(x - t + dx, 0),
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(x - t, -y + t),
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)
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.segment(
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(x - t, -y + t),
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(-x, -y+t)
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)
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.segment((-x, -y))
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.segment((x, -y))
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# Outer arc, bottom point
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.arc(
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(x, -y),
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(x + dx, 0),
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(x, y),
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)
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.segment(
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(x, y),
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(-x, y)
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)
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.segment((-x, y-t))
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#.segment((x2, a))
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.close()
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.assemble(tag="wire")
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.wires().val()
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)
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assert isinstance(middle, Cq.Wire)
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x, y = conn_thickness / 2, conn_height / 2
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t = wall_thickness
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tip = (
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Cq.Sketch()
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.segment((-x, y), (x, y))
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.segment((x, -y))
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.segment((-x, -y))
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.segment((-x, -y+t))
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.segment((x-t, -y+t))
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.segment((x-t, y-t))
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.segment((-x, y-t))
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.close()
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.assemble(tag="wire")
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.wires().val()
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)
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return base, middle, tip
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def wing_root(joint: HirthJoint,
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bolt_diam: int = 12,
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union_tol=1e-4,
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shoulder_attach_diam=8,
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shoulder_attach_dist=25,
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conn_thickness=40,
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conn_height=100,
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wall_thickness=8) -> Cq.Assembly:
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"""
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Generate the contiguous components of the root wing segment
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"""
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tip_centre = Cq.Vector((-150, 0, -80))
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attach_theta = math.radians(5)
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c, s = math.cos(attach_theta), math.sin(attach_theta)
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attach_points = [
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(15, 4),
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(15 + shoulder_attach_dist * c, 4 + shoulder_attach_dist * s),
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]
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root_profile, middle_profile, tip_profile = wing_root_profiles(
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conn_thickness=conn_thickness,
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conn_height=conn_height,
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wall_thickness=8,
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)
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middle_profile = middle_profile.located(Cq.Location(
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(-40, 0, -40), (0, 1, 0), 30
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))
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antetip_profile = tip_profile.located(Cq.Location(
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(-95, 0, -75), (0, 1, 0), 60
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))
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tip_profile = tip_profile.located(Cq.Location(
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tip_centre, (0, 1, 0), 90
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))
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profiles = [
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root_profile,
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middle_profile,
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antetip_profile,
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tip_profile,
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]
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result = None
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for p1, p2 in zip(profiles[:-1], profiles[1:]):
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seg = (
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Cq.Workplane('XY')
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.add(p1)
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.toPending()
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.workplane() # This call is necessary
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.add(p2)
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.toPending()
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.loft()
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)
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if result:
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result = result.union(seg, tol=union_tol)
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else:
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result = seg
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result = (
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result
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# Create connector holes
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.copyWorkplane(
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Cq.Workplane('bottom', origin=tip_centre + Cq.Vector((0, -50, 0)))
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)
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.pushPoints(attach_points)
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.hole(shoulder_attach_diam)
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)
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# Generate attach point tags
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for sign in [False, True]:
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y = conn_height / 2 - wall_thickness
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side = "bottom" if sign else "top"
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y = y if sign else -y
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plane = (
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result
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# Create connector holes
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.copyWorkplane(
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Cq.Workplane(side, origin=tip_centre +
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Cq.Vector((0, y, 0)))
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)
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)
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if side == "bottom":
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side = "bot"
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for i, (px, py) in enumerate(attach_points):
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tag = f"conn_{side}{i}"
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plane.moveTo(px, -py if side == "top" else py).tagPlane(tag)
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result.faces("<Z").tag("base")
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result.faces(">X").tag("conn")
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j = (
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joint.generate(is_mated=True)
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.faces("<Z")
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.hole(bolt_diam)
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)
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color = Material.PLASTIC_PLA.color
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result = (
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Cq.Assembly()
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.add(result, name="scaffold", color=color)
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.add(j, name="joint", color=Role.CHILD.color,
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loc=Cq.Location((0, 0, -joint.total_height)))
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)
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return result
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@dataclass
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class WingProfile:
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shoulder_height: float = 100
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elbow_height: float = 100
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elbow_x: float = 240
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elbow_y: float = 30
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# Tilt of elbow w.r.t. shoulder
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elbow_angle: float = 20
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wrist_height: float = 70
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# Bottom point of the wrist
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wrist_x: float = 400
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wrist_y: float = 200
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# Tile of wrist w.r.t. shoulder
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wrist_angle: float = 40
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# Extends from the wrist to the tip of the arrow
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arrow_height: float = 300
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arrow_angle: float = 7
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# Relative (in wrist coordinate) centre of the ring
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ring_x: float = 40
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ring_y: float = 20
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ring_radius_inner: float = 22
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def __post_init__(self):
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assert self.ring_radius > self.ring_radius_inner
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self.elbow_theta = math.radians(self.elbow_angle)
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self.elbow_c = math.cos(self.elbow_theta)
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self.elbow_s = math.sin(self.elbow_theta)
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self.elbow_top_x, self.elbow_top_y = self.elbow_to_abs(0, self.elbow_height)
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self.wrist_theta = math.radians(self.wrist_angle)
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self.wrist_c = math.cos(self.wrist_theta)
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self.wrist_s = math.sin(self.wrist_theta)
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self.wrist_top_x, self.wrist_top_y = self.wrist_to_abs(0, self.wrist_height)
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self.arrow_theta = math.radians(self.arrow_angle)
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self.arrow_x, self.arrow_y = self.wrist_to_abs(0, -self.arrow_height)
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self.arrow_tip_x = self.arrow_x + (self.arrow_height + self.wrist_height) \
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* math.sin(self.arrow_theta - self.wrist_theta)
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self.arrow_tip_y = self.arrow_y + (self.arrow_height + self.wrist_height) \
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* math.cos(self.arrow_theta - self.wrist_theta)
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# [[c, s], [-s, c]] * [ring_x, ring_y]
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self.ring_abs_x = self.wrist_top_x + self.wrist_c * self.ring_x - self.wrist_s * self.ring_y
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self.ring_abs_y = self.wrist_top_y + self.wrist_s * self.ring_x + self.wrist_c * self.ring_y
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@property
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def ring_radius(self) -> float:
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dx = self.ring_x
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dy = self.ring_y
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return (dx * dx + dy * dy) ** 0.5
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def elbow_to_abs(self, x: float, y: float) -> Tuple[float, float]:
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elbow_x = self.elbow_x + x * self.elbow_c - y * self.elbow_s
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elbow_y = self.elbow_y + x * self.elbow_s + y * self.elbow_c
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return elbow_x, elbow_y
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def wrist_to_abs(self, x: float, y: float) -> Tuple[float, float]:
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wrist_x = self.wrist_x + x * self.wrist_c - y * self.wrist_s
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wrist_y = self.wrist_y + x * self.wrist_s + y * self.wrist_c
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return wrist_x, wrist_y
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def profile(self) -> Cq.Sketch:
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"""
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Net profile of the wing starting from the wing root with no divisions
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"""
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result = (
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Cq.Sketch()
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.segment(
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(0, 0),
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(0, self.shoulder_height),
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tag="shoulder")
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.arc(
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(0, self.shoulder_height),
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(self.elbow_top_x, self.elbow_top_y),
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(self.wrist_top_x, self.wrist_top_y),
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tag="s1_top")
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#.segment(
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# (self.wrist_x, self.wrist_y),
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# (wrist_top_x, wrist_top_y),
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# tag="wrist")
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.arc(
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(0, 0),
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(self.elbow_x, self.elbow_y),
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(self.wrist_x, self.wrist_y),
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tag="s1_bot")
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)
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result = (
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result
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.segment(
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(self.wrist_x, self.wrist_y),
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(self.arrow_x, self.arrow_y)
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)
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.segment(
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(self.arrow_x, self.arrow_y),
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(self.arrow_tip_x, self.arrow_tip_y)
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)
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.segment(
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(self.arrow_tip_x, self.arrow_tip_y),
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(self.wrist_top_x, self.wrist_top_y)
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)
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)
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# Carve out the ring
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result = result.assemble()
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result = (
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result
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.push([(self.ring_abs_x, self.ring_abs_y)])
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.circle(self.ring_radius, mode='a')
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.circle(self.ring_radius_inner, mode='s')
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.clean()
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)
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return result
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def _mask_elbow(self) -> list[Tuple[float, float]]:
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"""
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Polygon shape to mask out parts above the elbow
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"""
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abscissa = 200
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return [
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(0, -abscissa),
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(self.elbow_x, self.elbow_y),
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(self.elbow_top_x, self.elbow_top_y),
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(0, abscissa)
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]
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def _mask_wrist(self) -> list[Tuple[float, float]]:
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abscissa = 200
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return [
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(0, -abscissa),
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(self.wrist_x - self.wrist_s * abscissa,
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self.wrist_y - self.wrist_c * abscissa),
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(self.wrist_top_x, self.wrist_top_y),
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(0, abscissa),
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]
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def profile_s1(self) -> Cq.Sketch:
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profile = (
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self.profile()
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.reset()
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.polygon(self._mask_elbow(), mode='i')
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)
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return profile
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def surface_s1(self,
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thickness: float = 25.4/16,
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shoulder_mount_inset: float = 20,
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shoulder_joint_child_height: float = 80,
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elbow_mount_inset: float = 20,
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elbow_joint_parent_height: float = 60,
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front: bool = True) -> Cq.Workplane:
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assert shoulder_joint_child_height < self.shoulder_height
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assert elbow_joint_parent_height < self.elbow_height
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h = (self.shoulder_height - shoulder_joint_child_height) / 2
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tags_shoulder = [
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("shoulder_bot", (shoulder_mount_inset, h), 90),
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("shoulder_top", (shoulder_mount_inset, h + shoulder_joint_child_height), 270),
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]
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h = (self.elbow_height - elbow_joint_parent_height) / 2
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tags_elbow = [
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("elbow_bot",
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self.elbow_to_abs(-elbow_mount_inset, h),
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self.elbow_angle + 90),
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("elbow_top",
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self.elbow_to_abs(-elbow_mount_inset, h + elbow_joint_parent_height),
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self.elbow_angle + 270),
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]
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profile = self.profile_s1()
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tags = tags_shoulder + tags_elbow
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return nhf.utils.extrude_with_markers(profile, thickness, tags, reverse=front)
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def profile_s2(self) -> Cq.Sketch:
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profile = (
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self.profile()
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.reset()
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.polygon(self._mask_wrist(), mode='i')
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.reset()
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.polygon(self._mask_elbow(), mode='s')
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)
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return profile
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def surface_s2(self,
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thickness: float = 25.4/16,
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elbow_mount_inset: float = 20,
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elbow_joint_child_height: float = 80,
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wrist_mount_inset: float = 20,
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wrist_joint_parent_height: float = 60,
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front: bool = True) -> Cq.Workplane:
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assert elbow_joint_child_height < self.elbow_height
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h = (self.elbow_height - elbow_joint_child_height) / 2
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tags_elbow = [
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("elbow_bot",
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self.elbow_to_abs(elbow_mount_inset, h),
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self.elbow_angle + 90),
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("elbow_top",
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self.elbow_to_abs(elbow_mount_inset, h + elbow_joint_child_height),
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self.elbow_angle + 270),
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]
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h = (self.wrist_height - wrist_joint_parent_height) / 2
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tags_wrist = [
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("wrist_bot",
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self.wrist_to_abs(-wrist_mount_inset, h),
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self.wrist_angle + 90),
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("wrist_top",
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self.wrist_to_abs(-wrist_mount_inset, h + wrist_joint_parent_height),
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self.wrist_angle + 270),
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]
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profile = self.profile_s2()
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tags = tags_elbow + tags_wrist
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return nhf.utils.extrude_with_markers(profile, thickness, tags, reverse=front)
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def profile_s3(self) -> Cq.Sketch:
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profile = (
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self.profile()
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.reset()
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.polygon(self._mask_wrist(), mode='s')
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)
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return profile
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def surface_s3(self,
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thickness: float = 25.4/16,
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wrist_mount_inset: float = 20,
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wrist_joint_child_height: float = 80,
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front: bool = True) -> Cq.Workplane:
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assert wrist_joint_child_height < self.wrist_height
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h = (self.wrist_height - wrist_joint_child_height) / 2
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tags = [
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("wrist_bot",
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self.elbow_to_abs(wrist_mount_inset, h),
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self.elbow_angle + 90),
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("wrist_top",
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self.elbow_to_abs(wrist_mount_inset, h + wrist_joint_child_height),
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self.elbow_angle + 270),
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]
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profile = self.profile_s3()
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return nhf.utils.extrude_with_markers(profile, thickness, tags, reverse=front)
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def wing_r1s1_profile(self) -> Cq.Sketch:
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"""
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Generates the first wing segment profile, with the wing root pointing in
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the positive x axis.
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"""
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w = 270
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# Depression of the wing middle, measured
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h = 0
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# spline curve easing extension
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theta = math.radians(30)
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c_th, s_th = math.cos(theta), math.sin(theta)
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bend = 30
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ext = 40
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ext_dh = -5
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assert ext * 2 < w
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factor = 0.7
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|
|
result = (
|
|
Cq.Sketch()
|
|
.segment((0, 0), (0, self.shoulder_height))
|
|
.spline([
|
|
(0, self.shoulder_height),
|
|
((w - s_th * self.elbow_height) / 2, self.shoulder_height / 2 + (self.elbow_height * c_th - h) / 2 - bend),
|
|
(w - s_th * self.elbow_height, self.elbow_height * c_th - h),
|
|
])
|
|
.segment(
|
|
(w - s_th * self.elbow_height, self.elbow_height * c_th -h),
|
|
(w, -h),
|
|
)
|
|
.spline([
|
|
(0, 0),
|
|
(w / 2, -h / 2 - bend),
|
|
(w, -h),
|
|
])
|
|
.assemble()
|
|
)
|
|
return result
|