1188 lines
41 KiB
Python
1188 lines
41 KiB
Python
import math
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from dataclasses import dataclass, field
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from typing import Optional, Tuple
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import cadquery as Cq
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from nhf import Material, Role
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from nhf.build import Model, target, assembly
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from nhf.parts.springs import TorsionSpring
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from nhf.parts.fasteners import FlatHeadBolt, HexNut, ThreaddedKnob
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from nhf.parts.joints import TorsionJoint, HirthJoint
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from nhf.parts.box import Hole, MountingBox, box_with_centre_holes
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from nhf.touhou.houjuu_nue.electronics import Flexor, LinearActuator
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import nhf.geometry
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import nhf.utils
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TOL = 1e-6
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# Parts used
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# uxcell 2 Pcs Star Knobs Grips M12 x 30mm Male Thread Steel Zinc Stud Replacement PP
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HS_JOINT_KNOB = ThreaddedKnob(
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mass=77.3,
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diam_thread=12.0,
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height_thread=30.0,
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diam_knob=50.0,
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diam_neck=25.0,
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height_neck=12.5,
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height_knob=15.0,
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)
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# Tom's world 8Pcs M12-1.75 Hex Nut Assortment Set Stainless Steel 304(18-8)
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# Metric Hexagon Nut for Bolts, Bright Finish, Full Thread (M12)
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HS_JOINT_HEX_NUT = HexNut(
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mass=14.9,
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diam_thread=12.0,
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pitch=1.75,
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thickness=9.7,
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width=18.9,
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)
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SHOULDER_AXIS_BOLT = FlatHeadBolt(
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# FIXME: measure
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mass=0.0,
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diam_head=10.0,
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height_head=3.0,
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diam_thread=6.0,
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height_thread=20.0,
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)
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# Hoypeyfiy 10 Pieces Torsion Spring Woodworking DIY 90 Degrees Torsional
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# Springs Repair Maintenance Spring
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SHOULDER_TORSION_SPRING = TorsionSpring(
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mass=2.2,
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# inner diameter = 9
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radius=9/2 + 1.2,
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thickness=1.3,
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height=7.5,
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)
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# KALIONE 10 Pieces Torsion Spring, Stainless Steel Small Torsion Springs, Tiny
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# Torsional Spring, 90° Deflection Compression Spring Kit for Repair Tools
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# Woodworking DIY, 50mm
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ELBOW_TORSION_SPRING = TorsionSpring(
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mass=1.7,
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radius=9 / 2,
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thickness=1.3,
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height=6.5,
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tail_length=45.0,
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right_handed=False,
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)
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@dataclass
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class RootJoint(Model):
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"""
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The Houjuu-Scarlett Mechanism
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"""
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knob: ThreaddedKnob = HS_JOINT_KNOB
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hex_nut: HexNut = HS_JOINT_HEX_NUT
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hirth_joint: HirthJoint = field(default_factory=lambda: HirthJoint(
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radius=25.0,
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radius_inner=15.0,
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tooth_height=7.0,
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base_height=5.0,
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n_tooth=24,
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))
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parent_width: float = 85
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parent_thickness: float = 10
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parent_corner_fillet: float = 5
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parent_corner_cbore_diam: float = 12
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parent_corner_cbore_depth: float = 2
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parent_corner_inset: float = 12
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parent_mount_thickness: float = 25.4 / 16
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child_corner_dx: float = 17.0
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child_corner_dz: float = 24.0
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axis_diam: float = 12.0
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axis_cbore_diam: float = 20
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axis_cbore_depth: float = 3
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corner_hole_diam: float = 6.0
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child_height: float = 60.0
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child_width: float = 50.0
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child_mount_thickness: float = 25.4 / 4
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def corner_pos(self) -> list[tuple[int, int]]:
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"""
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Generates a set of points corresponding to the connectorss
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"""
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dx = self.parent_width / 2 - self.parent_corner_inset
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return [
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(dx, dx),
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(dx, -dx),
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(-dx, -dx),
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(-dx, dx),
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]
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@property
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def total_height(self) -> float:
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return self.parent_thickness + self.hirth_joint.total_height
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@target(name="parent")
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def parent(self):
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"""
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Parent part of the Houjuu-Scarlett joint, which is composed of a Hirth
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coupling, a cylindrical base, and a mounting base.
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"""
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hirth = self.hirth_joint.generate()
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conn = self.corner_pos()
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result = (
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Cq.Workplane('XY')
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.box(
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self.parent_width,
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self.parent_width,
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self.parent_thickness,
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centered=(True, True, False))
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.translate((0, 0, -self.parent_thickness))
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.edges("|Z")
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.fillet(self.parent_corner_fillet)
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.faces(">Z")
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.workplane()
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.pushPoints(conn)
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.cboreHole(
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diameter=self.corner_hole_diam,
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cboreDiameter=self.parent_corner_cbore_diam,
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cboreDepth=self.parent_corner_cbore_depth)
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)
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# Creates a plane parallel to the holes but shifted to the base
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plane = result.faces(">Z").workplane(offset=-self.parent_thickness)
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for i, (px, py) in enumerate(conn):
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plane.moveTo(px, py).tagPoint(f"h{i}")
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result = (
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result
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.faces(">Z")
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.workplane()
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.union(hirth, tol=0.1)
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.clean()
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)
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result = (
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result.faces("<Z")
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.workplane()
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.hole(diameter=self.axis_diam)
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.cut(self.hex_nut.generate().translate((0, 0, -self.parent_thickness)))
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)
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result.faces("<Z").tag("base")
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return result
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@target(name="child")
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def child(self) -> Cq.Workplane:
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hirth = self.hirth_joint.generate(is_mated=True)
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dy = self.child_corner_dx
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dx = self.child_corner_dz
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conn = [
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(-dx, -dy),
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(dx, -dy),
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(dx, dy),
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(-dx, dy),
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]
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result = (
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Cq.Workplane('XY')
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.box(
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self.child_height,
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self.child_width,
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self.hirth_joint.base_height,
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centered=(True, True, False))
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#.translate((0, 0, -self.base_joint.base_height))
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#.edges("|Z")
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#.fillet(self.hs_joint_corner_fillet)
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.faces(">Z")
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.workplane()
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.pushPoints(conn)
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.hole(self.corner_hole_diam)
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)
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# Creates a plane parallel to the holes but shifted to the base
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plane = result.faces(">Z").workplane(offset=-self.hirth_joint.base_height)
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for i, (px, py) in enumerate(conn):
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plane.moveTo(px, py).tagPlane(f"conn{i}")
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result = (
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result
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.faces(">Z")
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.workplane()
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.union(hirth, tol=0.1)
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.clean()
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)
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result = (
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result.faces("<Z")
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.workplane()
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.hole(self.axis_diam)
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)
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return result
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def assembly(self,
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offset: int = 0,
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fastener_pos: float = 0,
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ignore_fasteners: bool = False) -> Cq.Assembly:
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"""
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Specify knob position to determine the position of the knob from fully
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inserted (0) or fully uninserted (1)
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"""
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knob_h = self.hex_nut.thickness
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result = (
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Cq.Assembly()
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.addS(self.parent(), name="parent",
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material=Material.PLASTIC_PLA,
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role=Role.PARENT)
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.constrain("parent", "Fixed")
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.addS(self.child(), name="child",
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material=Material.PLASTIC_PLA,
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role=Role.CHILD)
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)
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if not ignore_fasteners:
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(
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result
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.addS(self.hex_nut.assembly(), name="hex_nut")
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.addS(self.knob.assembly(), name="knob",
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loc=Cq.Location((0, 0, knob_h * fastener_pos)))
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.constrain("knob/thread", "Fixed")
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.constrain("hex_nut?bot", "parent?base", "Plane", param=0)
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.constrain("hex_nut?dirX", "parent@faces@>X", "Axis", param=0)
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)
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self.hirth_joint.add_constraints(
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result,
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"parent",
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"child",
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offset=offset
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)
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return result.solve()
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@dataclass
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class ShoulderJoint(Model):
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bolt: FlatHeadBolt = SHOULDER_AXIS_BOLT
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height: float = 70.0
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torsion_joint: TorsionJoint = field(default_factory=lambda: TorsionJoint(
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radius_track=18,
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radius_rider=18,
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groove_depth=4.8,
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groove_radius_outer=16,
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groove_radius_inner=13,
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track_disk_height=5.0,
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rider_disk_height=5.0,
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radius_axle=3.0,
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spring=SHOULDER_TORSION_SPRING,
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rider_slot_begin=0,
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rider_n_slots=1,
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rider_slot_span=0,
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))
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# On the parent side, drill vertical holes
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parent_conn_hole_diam: float = 4.0
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# Position of the holes relative centre line
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parent_conn_hole_pos: list[Tuple[float, float]] = field(default_factory=lambda: [
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(20, 8),
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(20, -8),
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])
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# Distance from centre of lips to the axis
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parent_lip_ext: float = 40.0
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parent_lip_length: float = 25.0
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parent_lip_width: float = 30.0
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parent_lip_thickness: float = 5.0
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# The parent side has arms which connect to the lips
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parent_arm_width: float = 25.0
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parent_arm_height: float = 12.0
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# Generates a child guard which covers up the internals. The lip length is
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# relative to the +X surface of the guard.
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child_guard_ext: float = 30.0
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child_guard_width: float = 25.0
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# guard length measured from axle
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child_lip_length: float = 40.0
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child_lip_width: float = 20.0
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child_conn_hole_diam: float = 4.0
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# Measured from centre of axle
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child_conn_hole_pos: list[float] = field(default_factory=lambda: [8, 19, 30])
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child_core_thickness: float = 3.0
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# Rotates the torsion joint to avoid collisions or for some other purpose
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axis_rotate_bot: float = 90
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axis_rotate_top: float = 0
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directrix_id: int = 0
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angle_neutral: float = -15.0
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angle_max_deflection: float = 90.0
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def __post_init__(self):
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assert self.parent_lip_length * 2 < self.height
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@property
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def radius(self):
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return self.torsion_joint.radius
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def parent_lip_loc(self, left: bool=True) -> Cq.Location:
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"""
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2d location of the arm surface on the parent side, relative to axle
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"""
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dy = self.parent_arm_width / 2
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sign = 1 if left else -1
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loc_dir = Cq.Location((0,sign * dy,0), (0, 0, 1), sign * 90)
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return Cq.Location.from2d(self.parent_lip_ext, 0, 0) * loc_dir
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@property
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def _max_contraction_angle(self) -> float:
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return self.angle_max_deflection + self.angle_neutral
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def _contraction_cut_geometry(self, parent: bool = False, mirror: bool=False) -> Cq.Solid:
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"""
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Generates a cylindrical sector which cuts away overlapping regions of the child and parent
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"""
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aspect = self.child_guard_width / self.parent_arm_width
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theta = math.radians(self._max_contraction_angle)
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theta_p = math.atan(math.sin(theta) / (math.cos(theta) + aspect))
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angle = math.degrees(theta_p)
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assert 0 <= angle <= 90
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# outer radius of the cut, overestimated
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cut_radius = math.sqrt(self.child_guard_width ** 2 + self.parent_arm_width ** 2)
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span = 180
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result = (
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Cq.Solid.makeCylinder(
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height=self.height,
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radius=cut_radius,
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angleDegrees=span,
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).cut(Cq.Solid.makeCylinder(
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height=self.height,
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radius=self.torsion_joint.radius,
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))
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)
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if parent:
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angle = - span - angle
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else:
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angle = self._max_contraction_angle - angle
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result = result.located(Cq.Location((0,0,-self.height/2), (0,0,1), angle))
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if mirror:
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result = result.mirror('XZ')
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return result
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def parent(self, top: bool = False) -> Cq.Assembly:
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joint = self.torsion_joint
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# Thickness of the lip connecting this joint to the wing root
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assert self.parent_arm_width <= joint.radius_track * 2
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assert self.parent_lip_ext > joint.radius_track
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arm = (
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Cq.Solid.makeBox(
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self.parent_lip_ext + self.parent_lip_width / 2,
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self.parent_arm_width,
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self.parent_arm_height)
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.located(Cq.Location((0, -self.parent_arm_width/2 , 0)))
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.cut(Cq.Solid.makeCylinder(joint.radius_track, self.parent_arm_height))
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.cut(self._contraction_cut_geometry(parent=True, mirror=top))
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)
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lip_args = dict(
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length=self.parent_lip_length,
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width=self.parent_lip_width,
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thickness=self.parent_lip_thickness,
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hole_diam=self.parent_conn_hole_diam,
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generate_side_tags=False,
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)
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lip1 = MountingBox(
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**lip_args,
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holes=[
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Hole(x=self.height / 2 - x, y=-y)
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for x, y in self.parent_conn_hole_pos
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],
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)
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lip2 = MountingBox(
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**lip_args,
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holes=[
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Hole(x=self.height / 2 - x, y=y)
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for x, y in self.parent_conn_hole_pos
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],
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)
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lip_dy = self.parent_arm_width / 2 - self.parent_lip_thickness
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# Flip so the lip's holes point to -X
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loc_axis = Cq.Location((0,0,0), (0, 1, 0), -90)
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loc_dir1 = Cq.Location((0,lip_dy,0), (0, 0, 1), -90)
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loc_dir2 = Cq.Location((0,-lip_dy,0), (0, 0, 1), 90)
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loc_pos = Cq.Location((self.parent_lip_ext, 0, 0))
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rot = -self.axis_rotate_top if top else self.axis_rotate_bot
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lip_p_tag, lip_n_tag = "lip_right", "lip_left"
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if not top:
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lip_p_tag, lip_n_tag = lip_n_tag, lip_p_tag
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result = (
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Cq.Assembly()
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.add(joint.track(), name="track",
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loc=Cq.Location((0, 0, 0), (0, 0, 1), rot))
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.add(arm, name="arm")
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.add(lip1.generate(), name=lip_p_tag, loc=loc_pos * loc_dir1 * loc_axis)
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.add(lip2.generate(), name=lip_n_tag, loc=loc_pos * loc_dir2 * loc_axis)
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)
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return result
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@target(name="parent-bot")
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def parent_bot(self) -> Cq.Assembly:
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return self.parent(top=False)
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@target(name="parent-top")
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def parent_top(self) -> Cq.Assembly:
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return self.parent(top=True)
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@property
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def child_height(self) -> float:
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"""
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Calculates the y distance between two joint surfaces on the child side
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of the shoulder joint.
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"""
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joint = self.torsion_joint
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return self.height - 2 * joint.total_height + 2 * joint.rider_disk_height
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|
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@target(name="child")
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def child(self) -> Cq.Assembly:
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"""
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Creates the top/bottom shoulder child joint
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"""
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joint = self.torsion_joint
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assert all(r < self.child_lip_length for r in self.child_conn_hole_pos)
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# Half of the height of the bridging cylinder
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dh = self.height / 2 - joint.total_height
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core_start_angle = 30
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core_end_angle1 = 90
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core_end_angle2 = 180
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radius_core_inner = joint.radius_rider - self.child_core_thickness
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core_profile1 = (
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Cq.Sketch()
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.arc((0, 0), joint.radius_rider, core_start_angle, core_end_angle1-core_start_angle)
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.segment((0, 0))
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.close()
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.assemble()
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.circle(radius_core_inner, mode='s')
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)
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core_profile2 = (
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Cq.Sketch()
|
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.arc((0, 0), joint.radius_rider, -core_start_angle, -(core_end_angle2-core_start_angle))
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.segment((0, 0))
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.close()
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.assemble()
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.circle(radius_core_inner, mode='s')
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)
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core_guard = (
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Cq.Workplane('XY')
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.box(
|
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length=self.child_guard_ext,
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width=self.child_guard_width,
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height=self.height,
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centered=(False, True, True),
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)
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.copyWorkplane(Cq.Workplane('XY'))
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.cylinder(
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radius=self.radius,
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height=self.height,
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combine='cut',
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centered=True,
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)
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.copyWorkplane(Cq.Workplane('XY'))
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.box(
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length=self.child_guard_ext,
|
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width=self.child_lip_width,
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height=self.height - self.torsion_joint.total_height * 2,
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combine='cut',
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centered=(False, True, True),
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)
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.cut(self._contraction_cut_geometry(parent=False))
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)
|
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core = (
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Cq.Workplane('XY')
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.placeSketch(core_profile1)
|
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.toPending()
|
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.extrude(dh * 2)
|
|
.copyWorkplane(Cq.Workplane('XY'))
|
|
.placeSketch(core_profile2)
|
|
.toPending()
|
|
.extrude(dh * 2)
|
|
.translate(Cq.Vector(0, 0, -dh))
|
|
.union(core_guard)
|
|
)
|
|
assert self.child_lip_width / 2 <= joint.radius_rider
|
|
lip_thickness = joint.rider_disk_height
|
|
lip = box_with_centre_holes(
|
|
length=self.child_lip_length,
|
|
width=self.child_lip_width,
|
|
height=lip_thickness,
|
|
hole_loc=self.child_conn_hole_pos,
|
|
hole_diam=self.child_conn_hole_diam,
|
|
)
|
|
theta = self.torsion_joint.spring.angle_neutral - self.torsion_joint.rider_slot_span
|
|
loc_rotate = Cq.Location((0, 0, 0), (1, 0, 0), 180)
|
|
loc_axis_rotate_bot = Cq.Location((0, 0, 0), (0, 0, 1), self.axis_rotate_bot + self.angle_neutral)
|
|
loc_axis_rotate_top = Cq.Location((0, 0, 0), (0, 0, 1), self.axis_rotate_top + self.angle_neutral)
|
|
result = (
|
|
Cq.Assembly()
|
|
.add(core, name="core", loc=Cq.Location())
|
|
.add(joint.rider(rider_slot_begin=-90, reverse_directrix_label=True), name="rider_top",
|
|
loc=loc_axis_rotate_top * Cq.Location((0, 0, dh), (0, 0, 1), -90) * Cq.Location((0, 0, 0), (0, 0, 1), theta))
|
|
.add(joint.rider(rider_slot_begin=180), name="rider_bot",
|
|
loc=loc_axis_rotate_bot * Cq.Location((0, 0, -dh), (0, 0, 1), -90) * loc_rotate)
|
|
.add(lip, name="lip_top",
|
|
loc=Cq.Location((self.child_guard_ext, 0, dh)))
|
|
.add(lip, name="lip_bot",
|
|
loc=Cq.Location((self.child_guard_ext, 0, -dh)) * loc_rotate)
|
|
)
|
|
return result
|
|
|
|
@assembly()
|
|
def assembly(
|
|
self,
|
|
fastener_pos: float = 0.0,
|
|
deflection: float = 0.0,
|
|
ignore_fasteners: bool = False,
|
|
) -> Cq.Assembly:
|
|
assert deflection <= self.angle_max_deflection
|
|
directrix = self.directrix_id
|
|
mat = Material.RESIN_TRANSPERENT
|
|
mat_spring = Material.STEEL_SPRING
|
|
bolt_z = self.height / 2 + self.bolt.height_thread * (fastener_pos - 1)
|
|
result = (
|
|
Cq.Assembly()
|
|
.addS(self.child(), name="child",
|
|
role=Role.CHILD, material=mat)
|
|
.constrain("child/core", "Fixed")
|
|
.addS(self.torsion_joint.spring.assembly(deflection=-deflection), name="spring_top",
|
|
role=Role.DAMPING, material=mat_spring)
|
|
.addS(self.parent_top(),
|
|
name="parent_top",
|
|
role=Role.PARENT, material=mat)
|
|
.addS(self.torsion_joint.spring.assembly(deflection=deflection), name="spring_bot",
|
|
role=Role.DAMPING, material=mat_spring)
|
|
.addS(self.parent_bot(),
|
|
name="parent_bot",
|
|
role=Role.PARENT, material=mat)
|
|
)
|
|
if not ignore_fasteners:
|
|
(
|
|
result
|
|
# Fasteners
|
|
.addS(self.bolt.assembly(), name="bolt_top",
|
|
loc=Cq.Location((0, 0, bolt_z)))
|
|
.constrain("bolt_top?root", 'Fixed')
|
|
.addS(self.bolt.assembly(), name="bolt_bot",
|
|
loc=Cq.Location((0, 0, -bolt_z), (1,0,0), 180))
|
|
.constrain("bolt_bot?root", 'Fixed')
|
|
)
|
|
TorsionJoint.add_constraints(
|
|
result,
|
|
rider="child/rider_top",
|
|
track="parent_top/track",
|
|
spring="spring_top",
|
|
directrix=directrix)
|
|
TorsionJoint.add_constraints(
|
|
result,
|
|
rider="child/rider_bot",
|
|
track="parent_bot/track",
|
|
spring="spring_bot",
|
|
directrix=directrix)
|
|
return result.solve()
|
|
|
|
|
|
@dataclass
|
|
class Beam:
|
|
"""
|
|
A I-shaped spine with two feet
|
|
"""
|
|
|
|
foot_length: float = 40.0
|
|
foot_width: float = 20.0
|
|
foot_height: float = 5.0
|
|
spine_thickness: float = 4.0
|
|
spine_length: float = 10.0
|
|
total_height: float = 50.0
|
|
|
|
hole_diam: float = 6.0
|
|
# distance between the centres of the two holes
|
|
hole_dist: float = 24.0
|
|
|
|
def __post_init__(self):
|
|
assert self.spine_height > 0
|
|
assert self.hole_diam + self.hole_dist < self.foot_length
|
|
assert self.hole_dist - self.hole_diam >= self.spine_length
|
|
|
|
@property
|
|
def spine_height(self):
|
|
return self.total_height - self.foot_height * 2
|
|
|
|
def foot(self) -> Cq.Workplane:
|
|
"""
|
|
just one foot
|
|
"""
|
|
dx = self.hole_dist / 2
|
|
result = (
|
|
Cq.Workplane('XZ')
|
|
.box(self.foot_length, self.foot_width, self.foot_height,
|
|
centered=(True, True, False))
|
|
.faces(">Y")
|
|
.workplane()
|
|
.pushPoints([(dx, 0), (-dx, 0)])
|
|
.hole(self.hole_diam)
|
|
)
|
|
plane = result.faces(">Y").workplane()
|
|
plane.moveTo(dx, 0).tagPlane("conn1")
|
|
plane.moveTo(-dx, 0).tagPlane("conn0")
|
|
return result
|
|
|
|
def generate(self, flip: bool = False) -> Cq.Assembly:
|
|
beam = (
|
|
Cq.Workplane('XZ')
|
|
.box(self.spine_length, self.spine_thickness, self.spine_height)
|
|
)
|
|
h = self.spine_height / 2 + self.foot_height
|
|
|
|
tag_p, tag_n = "top", "bot"
|
|
if flip:
|
|
tag_p, tag_n = tag_n, tag_p
|
|
result = (
|
|
Cq.Assembly()
|
|
.add(beam, name="beam")
|
|
.add(self.foot(), name=tag_p,
|
|
loc=Cq.Location((0, h, 0)))
|
|
.add(self.foot(), name=tag_n,
|
|
loc=Cq.Location((0, -h, 0), (1, 0, 0), 180))
|
|
)
|
|
return result
|
|
|
|
|
|
@dataclass
|
|
class DiskJoint(Model):
|
|
"""
|
|
Sandwiched disk joint for the wrist and elbow
|
|
|
|
We embed a spring inside the joint, with one leg in the disk and one leg in
|
|
the housing. This provides torsion resistance.
|
|
"""
|
|
spring: TorsionSpring = ELBOW_TORSION_SPRING
|
|
|
|
radius_housing: float = 22.0
|
|
radius_disk: float = 20.0
|
|
radius_axle: float = 3.0
|
|
|
|
housing_thickness: float = 4.0
|
|
disk_thickness: float = 7.0
|
|
|
|
# Amount by which the wall carves in
|
|
wall_inset: float = 2.0
|
|
# Height of the spring hole; if you make it too short the spring can't enter
|
|
spring_tail_hole_height: float = 2.0
|
|
|
|
# Spring angle at 0 degrees of movement
|
|
spring_angle_at_0: float = 90.0
|
|
spring_slot_offset: float = 5.0
|
|
|
|
# Angular span of movement
|
|
movement_angle: float = 120.0
|
|
# leave some gap for cushion
|
|
movement_gap: float = 5.0
|
|
# Angular span of tongue on disk
|
|
tongue_span: float = 30.0
|
|
tongue_length: float = 10.0
|
|
|
|
generate_inner_wall: bool = False
|
|
|
|
|
|
def __post_init__(self):
|
|
super().__init__(name="disk-joint")
|
|
assert self.radius_housing > self.radius_disk > self.radius_axle
|
|
assert self.spring.height < self.housing_thickness + self.disk_thickness
|
|
|
|
assert self.housing_upper_carve_offset > 0
|
|
assert self.spring_tail_hole_height > self.spring.thickness
|
|
|
|
@property
|
|
def neutral_movement_angle(self) -> Optional[float]:
|
|
a = self.spring.angle_neutral - self.spring_angle_at_0
|
|
if 0 <= a and a <= self.movement_angle:
|
|
return a
|
|
return None
|
|
|
|
@property
|
|
def total_thickness(self) -> float:
|
|
return self.housing_thickness * 2 + self.disk_thickness
|
|
@property
|
|
def disk_bot_thickness(self) -> float:
|
|
"""
|
|
Pads the bottom of the disk up to spring height
|
|
"""
|
|
return max(0, self.disk_thickness + self.spring.thickness - self.spring.height)
|
|
|
|
@property
|
|
def opening_span(self) -> float:
|
|
return self.movement_angle + self.tongue_span
|
|
|
|
@property
|
|
def housing_upper_carve_offset(self) -> float:
|
|
"""
|
|
Distance between the spring track and the outside of the upper housing
|
|
"""
|
|
return self.spring_tail_hole_height + (self.disk_thickness - self.disk_bot_thickness) - self.spring.height
|
|
|
|
@property
|
|
def housing_upper_dz(self) -> float:
|
|
"""
|
|
Distance between the default upper housing location and the median line
|
|
"""
|
|
return self.total_thickness / 2 - self.housing_thickness
|
|
|
|
def _disk_cut(self) -> Cq.Workplane:
|
|
return (
|
|
Cq.Solid.makeBox(
|
|
length=self.spring.tail_length,
|
|
width=self.spring.thickness,
|
|
height=self.spring.height-self.disk_bot_thickness,
|
|
)
|
|
.located(Cq.Location((0, self.spring.radius_inner, self.disk_bot_thickness)))
|
|
.rotate((0, 0, 0), (0, 0, 1), self.spring_slot_offset)
|
|
)
|
|
|
|
@target(name="disk")
|
|
def disk(self) -> Cq.Workplane:
|
|
radius_tongue = self.radius_disk + self.tongue_length
|
|
tongue = (
|
|
Cq.Solid.makeCylinder(
|
|
height=self.disk_thickness,
|
|
radius=radius_tongue,
|
|
angleDegrees=self.tongue_span,
|
|
).cut(Cq.Solid.makeCylinder(
|
|
height=self.disk_thickness,
|
|
radius=self.radius_disk,
|
|
))
|
|
)
|
|
result = (
|
|
Cq.Workplane('XY')
|
|
.cylinder(
|
|
height=self.disk_thickness,
|
|
radius=self.radius_disk,
|
|
centered=(True, True, False)
|
|
)
|
|
.union(tongue, tol=TOL)
|
|
.copyWorkplane(Cq.Workplane('XY'))
|
|
.cylinder(
|
|
height=self.disk_thickness,
|
|
radius=self.spring.radius,
|
|
centered=(True, True, False),
|
|
combine='cut',
|
|
)
|
|
.cut(self._disk_cut())
|
|
)
|
|
plane = result.copyWorkplane(Cq.Workplane('XY'))
|
|
theta = math.radians(self.spring_slot_offset)
|
|
plane.tagPlane("dir", direction=(math.cos(theta), math.sin(theta), 0))
|
|
plane.workplane(offset=self.disk_thickness).tagPlane("mate_top")
|
|
plane.workplane(offset=self.disk_bot_thickness).tagPlane("mate_spring")
|
|
result.copyWorkplane(Cq.Workplane('YX')).tagPlane("mate_bot")
|
|
|
|
return result
|
|
|
|
def wall(self) -> Cq.Compound:
|
|
height = self.disk_thickness + self.wall_inset
|
|
wall = Cq.Solid.makeCylinder(
|
|
radius=self.radius_housing,
|
|
height=height,
|
|
angleDegrees=360 - self.opening_span - self.movement_gap*2,
|
|
).cut(Cq.Solid.makeCylinder(
|
|
radius=self.radius_disk,
|
|
height=height,
|
|
)).rotate((0, 0, 0), (0, 0, 1), self.opening_span+self.movement_gap)
|
|
return wall
|
|
|
|
@target(name="housing-lower")
|
|
def housing_lower(self) -> Cq.Workplane:
|
|
result = (
|
|
Cq.Workplane('XY')
|
|
.cylinder(
|
|
radius=self.radius_housing,
|
|
height=self.housing_thickness,
|
|
centered=(True, True, False),
|
|
)
|
|
.cut(Cq.Solid.makeCylinder(
|
|
radius=self.radius_axle,
|
|
height=self.housing_thickness,
|
|
))
|
|
)
|
|
result.faces(">Z").tag("mate")
|
|
result.faces(">Z").workplane().tagPlane("dirX", direction="+X")
|
|
result = result.cut(
|
|
self
|
|
.wall()
|
|
.located(Cq.Location((0, 0, self.housing_thickness - self.wall_inset)))
|
|
#.rotate((0, 0, 0), (1, 0, 0), 180)
|
|
#.located(Cq.Location((0, 0, self.disk_thickness + self.housing_thickness)))
|
|
)
|
|
return result
|
|
|
|
@target(name="housing-upper")
|
|
def housing_upper(self) -> Cq.Workplane:
|
|
carve_angle = -(self.spring_angle_at_0 - self.spring_slot_offset)
|
|
carve = (
|
|
Cq.Solid.makeCylinder(
|
|
radius=self.spring.radius,
|
|
height=self.spring_tail_hole_height,
|
|
).fuse(Cq.Solid.makeBox(
|
|
length=self.spring.tail_length,
|
|
width=self.spring.thickness,
|
|
height=self.spring_tail_hole_height,
|
|
).located(Cq.Location((0, -self.spring.radius, 0))))
|
|
).rotate((0, 0, 0), (0, 0, 1), carve_angle)
|
|
result = (
|
|
Cq.Workplane('XY')
|
|
.cylinder(
|
|
radius=self.radius_housing,
|
|
height=self.housing_thickness,
|
|
centered=(True, True, False),
|
|
)
|
|
)
|
|
theta = math.radians(carve_angle)
|
|
result.faces("<Z").tag("mate")
|
|
p_xy = result.copyWorkplane(Cq.Workplane('XY'))
|
|
p_xy.tagPlane("dirX", direction="+X")
|
|
p_xy.tagPlane("dir", direction=(math.cos(theta), math.sin(theta), 0))
|
|
result = result.faces(">Z").hole(self.radius_axle * 2)
|
|
|
|
# tube which holds the spring interior
|
|
if self.generate_inner_wall:
|
|
tube = (
|
|
Cq.Solid.makeCylinder(
|
|
radius=self.radius_spring_internal,
|
|
height=self.disk_thickness + self.housing_thickness,
|
|
).cut(Cq.Solid.makeCylinder(
|
|
radius=self.radius_axle,
|
|
height=self.disk_thickness + self.housing_thickness,
|
|
))
|
|
)
|
|
result = result.union(tube)
|
|
wall = (
|
|
self.wall()
|
|
.located(Cq.Location((0, 0, -self.disk_thickness-self.wall_inset)))
|
|
)
|
|
result = (
|
|
result
|
|
.union(wall, tol=TOL)
|
|
#.cut(carve)
|
|
.cut(carve.located(Cq.Location((0, 0, -self.housing_upper_carve_offset))))
|
|
)
|
|
return result.clean()
|
|
|
|
def add_constraints(self,
|
|
assembly: Cq.Assembly,
|
|
housing_lower: str,
|
|
housing_upper: str,
|
|
disk: str,
|
|
angle: float = 0.0,
|
|
) -> Cq.Assembly:
|
|
assert 0 <= angle <= self.movement_angle
|
|
deflection = angle - self.neutral_movement_angle
|
|
spring_name = disk.replace("/", "__Z") + "_spring"
|
|
(
|
|
assembly
|
|
.addS(
|
|
self.spring.assembly(deflection=-deflection),
|
|
name=spring_name,
|
|
role=Role.DAMPING,
|
|
material=Material.STEEL_SPRING)
|
|
.constrain(f"{disk}?mate_bot", f"{housing_lower}?mate", "Plane")
|
|
.constrain(f"{disk}?mate_top", f"{housing_upper}?mate", "Plane")
|
|
.constrain(f"{housing_lower}?dirX", f"{housing_upper}?dirX", "Axis", param=0)
|
|
.constrain(f"{housing_upper}?dir", f"{spring_name}?dir_top", "Axis", param=0)
|
|
.constrain(f"{spring_name}?dir_bot", f"{disk}?dir", "Axis", param=0)
|
|
.constrain(f"{disk}?mate_spring", f"{spring_name}?bot", "Plane")
|
|
#.constrain(f"{housing_lower}?dirX", f"{housing_upper}?dir", "Axis", param=0)
|
|
#.constrain(f"{housing_lower}?dirX", f"{disk}?dir", "Axis", param=angle)
|
|
#.constrain(f"{housing_lower}?dirY", f"{disk}?dir", "Axis", param=angle - 90)
|
|
)
|
|
return (
|
|
assembly
|
|
)
|
|
|
|
|
|
def assembly(self, angle: Optional[float] = 0) -> Cq.Assembly:
|
|
if angle is None:
|
|
angle = self.neutral_movement_angle
|
|
if angle is None:
|
|
angle = 0
|
|
else:
|
|
assert 0 <= angle <= self.movement_angle
|
|
result = (
|
|
Cq.Assembly()
|
|
.addS(self.disk(), name="disk", role=Role.CHILD)
|
|
.addS(self.housing_lower(), name="housing_lower", role=Role.PARENT)
|
|
.addS(self.housing_upper(), name="housing_upper", role=Role.CASING)
|
|
.constrain("housing_lower", "Fixed")
|
|
)
|
|
result = self.add_constraints(
|
|
result,
|
|
housing_lower="housing_lower",
|
|
housing_upper="housing_upper",
|
|
disk="disk",
|
|
angle=angle,
|
|
)
|
|
return result.solve()
|
|
|
|
|
|
@dataclass(kw_only=True)
|
|
class ElbowJoint(Model):
|
|
"""
|
|
Creates the elbow and wrist joints.
|
|
|
|
This consists of a disk joint, where each side of the joint has mounting
|
|
holes for connection to the exoskeleton. Each side 2 mounting feet on the
|
|
top and bottom, and each foot has 2 holes.
|
|
|
|
On the parent side, additional bolts are needed to clamp the two sides of
|
|
the housing together.
|
|
"""
|
|
|
|
disk_joint: DiskJoint = field(default_factory=lambda: DiskJoint(
|
|
movement_angle=60,
|
|
))
|
|
|
|
# Distance between the child/parent arm to the centre
|
|
child_arm_radius: float = 40.0
|
|
parent_arm_radius: float = 40.0
|
|
|
|
lip_thickness: float = 5.0
|
|
lip_length: float = 60.0
|
|
hole_pos: list[float] = field(default_factory=lambda: [15, 25])
|
|
parent_arm_width: float = 10.0
|
|
# Angle of the beginning of the parent arm
|
|
parent_arm_angle: float = 180.0
|
|
|
|
# Size of the mounting holes
|
|
hole_diam: float = 4.0
|
|
|
|
material: Material = Material.RESIN_TRANSPERENT
|
|
|
|
# If set to true, the joint is flipped upside down.
|
|
flip: bool = False
|
|
angle_neutral: float = 30.0
|
|
|
|
actuator: Optional[LinearActuator]
|
|
flexor: Optional[Flexor] = None
|
|
# Rotates the entire flexor
|
|
flexor_offset_angle: float = 0
|
|
# Rotates the surface of the mount
|
|
flexor_mount_rot: float = 0
|
|
|
|
def __post_init__(self):
|
|
assert self.child_arm_radius > self.disk_joint.radius_housing
|
|
assert self.parent_arm_radius > self.disk_joint.radius_housing
|
|
self.disk_joint.tongue_length = self.child_arm_radius - self.disk_joint.radius_disk - self.lip_thickness / 2
|
|
if self.actuator:
|
|
self.flexor = Flexor(
|
|
actuator=self.actuator,
|
|
motion_span=self.motion_span
|
|
)
|
|
|
|
@property
|
|
def total_thickness(self):
|
|
return self.disk_joint.total_thickness
|
|
|
|
@property
|
|
def motion_span(self) -> float:
|
|
return self.disk_joint.movement_angle
|
|
|
|
def parent_arm_loc(self) -> Cq.Location:
|
|
"""
|
|
2d Location of the centre of the arm surface on the parent side, assuming
|
|
axle is at position 0, and parent direction is -X
|
|
"""
|
|
return Cq.Location.from2d(-self.parent_arm_radius, 0, 0)
|
|
def child_arm_loc(self, angle: float = 0.0) -> Cq.Location:
|
|
"""
|
|
2d Location of the centre of the arm surface on the child side, assuming
|
|
axle is at position 0, and parent direction is -X
|
|
"""
|
|
result = Cq.Location.rot2d(self.angle_neutral + angle) * Cq.Location.from2d(self.child_arm_radius, 0, 180)
|
|
return result.flip_y() if self.flip else result
|
|
def actuator_mount(self) -> Cq.Workplane:
|
|
holes = [
|
|
Hole(x=0, y=0, tag="mount"),
|
|
]
|
|
mbox = MountingBox(
|
|
length=self.disk_joint.total_thickness,
|
|
width=self.disk_joint.total_thickness,
|
|
thickness=self.lip_thickness,
|
|
holes=holes,
|
|
hole_diam=self.hole_diam,
|
|
centred=(True, True),
|
|
generate_side_tags=False,
|
|
)
|
|
return mbox.generate()
|
|
def actuator_mount_loc(
|
|
self,
|
|
child: bool = False,
|
|
# If set to true, use the local coordinate system
|
|
unflip: bool = False,
|
|
) -> Cq.Location:
|
|
# Moves the hole so the axle of the mount is perpendicular to it
|
|
loc_mount = Cq.Location.from2d(self.flexor.mount_height, 0) * Cq.Location.rot2d(180)
|
|
loc_mount_orient = Cq.Location.rot2d(self.flexor_mount_rot * (-1 if child else 1))
|
|
# Moves the hole to be some distance apart from 0
|
|
mount_r, mount_loc_angle, mount_parent_r = self.flexor.open_pos()
|
|
loc_span = Cq.Location.from2d(mount_r if child else mount_parent_r, 0)
|
|
r = (-mount_loc_angle - self.angle_neutral if child else 0) + 180 + self.flexor_offset_angle
|
|
loc_rot = Cq.Location.rot2d(r)
|
|
loc = loc_rot * loc_span * loc_mount_orient * loc_mount
|
|
return loc.flip_y() if self.flip and not child and not unflip else loc
|
|
|
|
def lip(self) -> Cq.Workplane:
|
|
sign = -1 if self.flip else 1
|
|
holes = [
|
|
h
|
|
for i, x in enumerate(self.hole_pos)
|
|
for h in [
|
|
Hole(x=sign * x, tag=f"conn_top{i}"),
|
|
Hole(x=-sign * x, tag=f"conn_bot{i}")
|
|
]
|
|
]
|
|
mbox = MountingBox(
|
|
length=self.lip_length,
|
|
width=self.disk_joint.total_thickness,
|
|
thickness=self.lip_thickness,
|
|
holes=holes,
|
|
hole_diam=self.hole_diam,
|
|
centred=(True, True),
|
|
generate_side_tags=False,
|
|
generate_reverse_tags=True,
|
|
)
|
|
return mbox.generate()
|
|
|
|
@target(name="child")
|
|
def child_joint(self) -> Cq.Assembly:
|
|
angle = -self.disk_joint.tongue_span / 2
|
|
dz = self.disk_joint.disk_thickness / 2
|
|
# We need to ensure the disk is on the "other" side so
|
|
flip_x = Cq.Location((0, 0, 0), (1, 0, 0), 180)
|
|
flip_z = Cq.Location((0, 0, 0), (0, 0, 1), 180)
|
|
lip_dz = self.lip_thickness
|
|
loc_lip = (
|
|
Cq.Location((0, 0, 0), (0, 1, 0), 180) *
|
|
Cq.Location((-lip_dz, 0, 0), (1, 0, 0), 90) *
|
|
Cq.Location((0, 0, 0), (0, 1, 0), 90)
|
|
)
|
|
loc_disk = flip_x * flip_z * Cq.Location((-self.child_arm_radius, 0, 0))
|
|
loc_cut_rel = Cq.Location((0, self.disk_joint.spring.radius_inner, -self.disk_joint.disk_bot_thickness))
|
|
disk_cut = self.disk_joint._disk_cut().located(
|
|
loc_lip.inverse * loc_cut_rel * loc_disk)
|
|
result = (
|
|
Cq.Assembly()
|
|
.add(self.disk_joint.disk(), name="disk", loc=Cq.Location((0, 0, -dz), (0,0,1), angle))
|
|
.add(self.lip().cut(disk_cut), name="lip", loc=loc_disk.inverse * loc_lip)
|
|
)
|
|
# Orientes the hole surface so it faces +X
|
|
loc_thickness = Cq.Location((-self.lip_thickness, 0, 0), (0, 1, 0), 90)
|
|
if self.flexor:
|
|
result.add(
|
|
self.actuator_mount(),
|
|
name="act",
|
|
loc=self.actuator_mount_loc(child=True) * loc_thickness)
|
|
return result
|
|
|
|
@target(name="parent-lower")
|
|
def parent_joint_lower(self) -> Cq.Workplane:
|
|
return self.disk_joint.housing_lower()
|
|
|
|
@target(name="parent-upper")
|
|
def parent_joint_upper(self, generate_mount: bool=False):
|
|
axial_offset = Cq.Location((self.parent_arm_radius, 0, 0))
|
|
housing_dz = self.disk_joint.housing_upper_dz
|
|
conn_h = self.disk_joint.total_thickness
|
|
conn_w = self.parent_arm_width
|
|
connector = (
|
|
Cq.Solid.makeBox(
|
|
length=self.parent_arm_radius,
|
|
width=conn_w,
|
|
height=conn_h,
|
|
).located(Cq.Location((0, -conn_w/2, 0)))
|
|
#Cq.Solid.makeCylinder(
|
|
# height=conn_h,
|
|
# radius=self.parent_arm_radius - self.lip_thickness / 2,
|
|
# angleDegrees=self.parent_arm_span)
|
|
.cut(Cq.Solid.makeCylinder(
|
|
height=conn_h,
|
|
radius=self.disk_joint.radius_housing,
|
|
))
|
|
.located(Cq.Location((0, 0, -conn_h / 2)))
|
|
.rotate((0,0,0), (0,0,1), 180)
|
|
#.rotate((0,0,0), (0,0,1), 180-self.parent_arm_span / 2)
|
|
)
|
|
housing = self.disk_joint.housing_upper()
|
|
housing_loc = Cq.Location(
|
|
(0, 0, housing_dz),
|
|
(0, 0, 1),
|
|
-self.disk_joint.tongue_span / 2 + self.angle_neutral
|
|
)
|
|
lip_dz = self.lip_thickness
|
|
result = (
|
|
Cq.Assembly()
|
|
# rotate so 0 degree is at +X
|
|
.add(housing, name="housing", loc=housing_loc)
|
|
.add(self.lip(), name="lip", loc=
|
|
axial_offset.inverse *
|
|
Cq.Location((0, 0, 0), (0, 1, 0), 180) *
|
|
Cq.Location((-lip_dz, 0, 0), (1, 0, 0), 90) *
|
|
Cq.Location((0, 0, 0), (0, 1, 0), 90))
|
|
.add(connector, name="connector")
|
|
#.constrain("housing", "Fixed")
|
|
#.constrain("connector", "Fixed")
|
|
#.solve()
|
|
)
|
|
if self.flexor:
|
|
if generate_mount:
|
|
# Orientes the hole surface so it faces +X
|
|
loc_thickness = Cq.Location((-self.lip_thickness, 0, 0), (0, 1, 0), 90)
|
|
result.add(
|
|
self.actuator_mount(),
|
|
name="act",
|
|
loc=self.actuator_mount_loc(child=False) * loc_thickness)
|
|
else:
|
|
result.add(
|
|
Cq.Edge.makeLine((-1,0,0), (1,0,0)),
|
|
name="act",
|
|
loc=self.actuator_mount_loc(child=False))
|
|
return result
|
|
|
|
@assembly()
|
|
def assembly(self,
|
|
angle: float = 0,
|
|
generate_mount: bool = False,
|
|
ignore_actuators: bool = False) -> Cq.Assembly:
|
|
assert 0 <= angle <= self.motion_span
|
|
result = (
|
|
Cq.Assembly()
|
|
.addS(self.child_joint(), name="child",
|
|
role=Role.CHILD, material=self.material)
|
|
.addS(self.parent_joint_lower(), name="parent_lower",
|
|
role=Role.CASING, material=self.material)
|
|
.addS(self.parent_joint_upper(generate_mount=generate_mount), name="parent_upper",
|
|
role=Role.PARENT, material=self.material)
|
|
#.constrain("child/disk?mate_bot", "Fixed")
|
|
)
|
|
result = self.disk_joint.add_constraints(
|
|
result,
|
|
housing_lower="parent_lower",
|
|
housing_upper="parent_upper/housing",
|
|
disk="child/disk",
|
|
angle=angle,
|
|
)
|
|
if not ignore_actuators and self.flexor:
|
|
target_length = self.flexor.target_length_at_angle(
|
|
angle=angle,
|
|
)
|
|
self.flexor.add_to(
|
|
result,
|
|
target_length=target_length,
|
|
tag_hole_back="parent_upper/act",
|
|
tag_hole_front="child/act?mount",
|
|
tag_dir="parent_lower?mate",
|
|
)
|
|
return result.solve()
|
|
|
|
if __name__ == '__main__':
|
|
p = ShoulderJoint()
|
|
p.build_all()
|
|
p = DiskJoint()
|
|
p.build_all()
|