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2026-07-22 13:48:46 +08:00
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+"""Circular integrated controller PCB, power stages, and rear terminals."""
+
+from __future__ import annotations
+
+import math
+
+import simplecadapi as scad
+
+try:
+    from .common import (
+        apply_tags,
+        connector_ref,
+        ground_constraint_report,
+        make_axial_hole_cutters_rsolids,
+        make_axis_part_rpart,
+        radial_centers,
+    )
+    from .dimensions import (
+        PCB_BOTTOM_Z,
+        PCB_CENTER_BORE_RADIUS,
+        PCB_MOUNT_HOLE_RADIUS,
+        PCB_RADIUS,
+        PCB_STANDOFF_PCD,
+        PCB_THICKNESS,
+        REAR_COLUMN_PCD,
+    )
+except ImportError:  # Support direct execution from this example directory.
+    from common import (
+        apply_tags,
+        connector_ref,
+        ground_constraint_report,
+        make_axial_hole_cutters_rsolids,
+        make_axis_part_rpart,
+        radial_centers,
+    )
+    from dimensions import (
+        PCB_BOTTOM_Z,
+        PCB_CENTER_BORE_RADIUS,
+        PCB_MOUNT_HOLE_RADIUS,
+        PCB_RADIUS,
+        PCB_STANDOFF_PCD,
+        PCB_THICKNESS,
+        REAR_COLUMN_PCD,
+    )
+
+
+PHASE_TERMINAL_CENTER = (-11.0, 0.0)
+POWER_CAN_TERMINAL_CENTER = (11.0, 0.0)
+MOSFET_ANGLES = (22.5, 67.5, 112.5, 202.5, 247.5, 292.5)
+
+
+def make_integrated_controller_rassembly(
+    *,
+    pcb_material: scad.Material,
+    terminal_material: scad.Material,
+) -> scad.Assembly:
+    """Build the circular ESC with six power devices and two service terminals."""
+
+    pcb = _make_controller_pcb_rpart(material=pcb_material)
+    mosfet = _make_mosfet_package_rpart(material=terminal_material)
+    phase_terminal = _make_terminal_block_rpart(
+        part_id="three_phase_terminal",
+        name="Three-position motor phase terminal",
+        width=8.0,
+        pin_count=3,
+        material=terminal_material,
+    )
+    power_terminal = _make_terminal_block_rpart(
+        part_id="power_can_terminal",
+        name="Four-position DC power and CAN terminal",
+        width=8.0,
+        pin_count=4,
+        material=terminal_material,
+    )
+    controller = scad.make_assembly_rassembly(
+        assembly_id="integrated_circular_motor_controller",
+        name="44.4 mm circular integrated BLDC controller",
+    )
+    controller = scad.add_component_rassembly(
+        assembly=controller,
+        item=pcb,
+        component_id="pcb",
+        placement=scad.identity_placement_rplacement(),
+        name="Circular controller PCB",
+    )
+    controller = scad.ground_component_rassembly(assembly=controller, component_id="pcb")
+
+    for index, angle in enumerate(MOSFET_ANGLES):
+        radians = math.radians(angle)
+        center = (13.2 * math.cos(radians), 13.2 * math.sin(radians))
+        component_id = f"mosfet_{index + 1}"
+        z = PCB_BOTTOM_Z + PCB_THICKNESS
+        controller = scad.add_component_rassembly(
+            assembly=controller,
+            item=mosfet,
+            component_id=component_id,
+            placement=scad.make_placement_rplacement(origin=(center[0], center[1], z)),
+            name=f"Power MOSFET package {index + 1}",
+        )
+        controller = scad.add_fixed_constraint_rassembly(
+            assembly=controller,
+            constraint_id=f"{component_id}_soldered",
+            connector_a=connector_ref(component_id="pcb", connector_id=component_id),
+            connector_b=connector_ref(component_id=component_id, connector_id="solder_axis"),
+            name=f"MOSFET {index + 1} solder attachment",
+        )
+
+    for component_id, item, center, connector_id in (
+        ("phase_terminal", phase_terminal, PHASE_TERMINAL_CENTER, "phase_terminal"),
+        ("power_can_terminal", power_terminal, POWER_CAN_TERMINAL_CENTER, "power_can_terminal"),
+    ):
+        controller = scad.add_component_rassembly(
+            assembly=controller,
+            item=item,
+            component_id=component_id,
+            placement=scad.make_placement_rplacement(origin=(center[0], center[1], -38.5)),
+            name=item.name,
+        )
+        controller = scad.add_fixed_constraint_rassembly(
+            assembly=controller,
+            constraint_id=f"{component_id}_soldered",
+            connector_a=connector_ref(component_id="pcb", connector_id=connector_id),
+            connector_b=connector_ref(component_id=component_id, connector_id="solder_axis"),
+            name=f"{component_id.replace('_', ' ')} solder and screw retention",
+        )
+
+    for connector_id in ("cover_axis", "phase_access", "power_can_access"):
+        controller = scad.forward_connector_rassembly(
+            assembly=controller,
+            connector_id=connector_id,
+            source_component_id="pcb",
+            source_connector_id=connector_id,
+            name=connector_id.replace("_", " "),
+            offset=None,
+        )
+    controller = scad.solve_assembly_constraints_rassembly(assembly=controller, strict=True)
+    ground_constraint_report(label="controller", assembly=controller)
+    print("controller_packaging: pcb_d=44.4 mosfets=6 phase_pins=3 power_can_pins=4")
+    return controller
+
+
+def _make_controller_pcb_rpart(*, material: scad.Material) -> scad.Part:
+    board = scad.make_cylinder_rsolid(
+        radius=PCB_RADIUS,
+        height=PCB_THICKNESS,
+        bottom_face_center=(0.0, 0.0, PCB_BOTTOM_Z),
+        axis=(0.0, 0.0, 1.0),
+    )
+    cutters: list[scad.Solid] = [
+        scad.make_cylinder_rsolid(
+            radius=PCB_CENTER_BORE_RADIUS,
+            height=PCB_THICKNESS + 2.0,
+            bottom_face_center=(0.0, 0.0, PCB_BOTTOM_Z - 1.0),
+            axis=(0.0, 0.0, 1.0),
+        )
+    ]
+    cutters.extend(
+        make_axial_hole_cutters_rsolids(
+            count=4,
+            pcd=PCB_STANDOFF_PCD,
+            hole_radius=PCB_MOUNT_HOLE_RADIUS,
+            bottom_z=PCB_BOTTOM_Z - 1.0,
+            height=PCB_THICKNESS + 2.0,
+            angle_offset=45.0,
+        )
+    )
+    cutters.extend(
+        make_axial_hole_cutters_rsolids(
+            count=4,
+            pcd=REAR_COLUMN_PCD,
+            hole_radius=3.45,
+            bottom_z=PCB_BOTTOM_Z - 1.0,
+            height=PCB_THICKNESS + 2.0,
+        )
+    )
+    for x, count in ((PHASE_TERMINAL_CENTER[0], 3), (POWER_CAN_TERMINAL_CENTER[0], 4)):
+        for pin in range(count):
+            y = (pin - (count - 1) / 2.0) * 1.8
+            cutters.append(
+                scad.make_cylinder_rsolid(
+                    radius=0.65,
+                    height=PCB_THICKNESS + 2.0,
+                    bottom_face_center=(x, y, PCB_BOTTOM_Z - 1.0),
+                    axis=(0.0, 0.0, 1.0),
+                )
+            )
+    board = scad.cut_rsolid(board, cutters, skip_non_intersecting=False)
+    board = apply_tags(
+        shape=board,
+        tags=("role.circular_esc_pcb", "role.controller_mounting_holes", "group.integrated_electronics"),
+    )
+    connectors = [
+        ("cover_axis", (0.0, 0.0, PCB_BOTTOM_Z + PCB_THICKNESS / 2.0), "Rear-cover PCB plane"),
+        ("phase_terminal", (*PHASE_TERMINAL_CENTER, PCB_BOTTOM_Z), "Phase terminal solder datum"),
+        ("power_can_terminal", (*POWER_CAN_TERMINAL_CENTER, PCB_BOTTOM_Z), "Power/CAN terminal solder datum"),
+        ("phase_access", (*PHASE_TERMINAL_CENTER, -37.0), "Phase terminal service axis"),
+        ("power_can_access", (*POWER_CAN_TERMINAL_CENTER, -37.0), "Power/CAN service axis"),
+    ]
+    for index, angle in enumerate(MOSFET_ANGLES):
+        radians = math.radians(angle)
+        center = (13.2 * math.cos(radians), 13.2 * math.sin(radians))
+        connectors.append(
+            (
+                f"mosfet_{index + 1}",
+                (center[0], center[1], PCB_BOTTOM_Z + PCB_THICKNESS),
+                f"MOSFET {index + 1} solder datum",
+            )
+        )
+    print("pcb_holes: center=10.0 mount=4 column_notches=4 terminal_pins=7")
+    return make_axis_part_rpart(
+        part_id="circular_controller_pcb",
+        body=board,
+        name="44.4 mm circular ESC PCB with service cutouts",
+        material=material,
+        connectors=connectors,
+    )
+
+
+def _make_mosfet_package_rpart(*, material: scad.Material) -> scad.Part:
+    package = scad.make_box_rsolid(
+        width=4.0,
+        height=3.0,
+        depth=1.4,
+        bottom_face_center=(0.0, 0.0, 0.0),
+    )
+    package = apply_tags(shape=package, tags=("role.power_mosfet", "group.three_phase_bridge"))
+    return make_axis_part_rpart(
+        part_id="reusable_power_mosfet",
+        body=package,
+        name="Reusable power MOSFET package",
+        material=material,
+        connectors=(("solder_axis", (0.0, 0.0, 0.0), "PCB solder plane"),),
+    )
+
+
+def _make_terminal_block_rpart(
+    *,
+    part_id: str,
+    name: str,
+    width: float,
+    pin_count: int,
+    material: scad.Material,
+) -> scad.Part:
+    body = scad.make_box_rsolid(
+        width=width,
+        height=6.0,
+        depth=4.9,
+        bottom_face_center=(0.0, 0.0, 0.0),
+    )
+    access_cutters = []
+    for pin in range(pin_count):
+        y = (pin - (pin_count - 1) / 2.0) * 1.8
+        access_cutters.append(
+            scad.make_cylinder_rsolid(
+                radius=0.75,
+                height=width + 2.0,
+                bottom_face_center=(-width / 2.0 - 1.0, y, 2.45),
+                axis=(1.0, 0.0, 0.0),
+            )
+        )
+    body = scad.cut_rsolid(body, access_cutters, skip_non_intersecting=False)
+    body = apply_tags(shape=body, tags=("role.rear_wiring_terminal", "role.service_access"))
+    print(f"terminal_{part_id}: pins={pin_count} access_holes={pin_count} width={width:.1f}")
+    return make_axis_part_rpart(
+        part_id=part_id,
+        body=body,
+        name=name,
+        material=material,
+        connectors=(("solder_axis", (0.0, 0.0, 4.9), "PCB solder and screw datum"),),
+    )