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@@ -51,7 +51,7 @@ def scale_from_motor(
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reducer_axial_allowance_mm: float = 42.0,
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min_radial_scale: float = 0.45,
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max_radial_scale: float = 1.50,
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min_axial_scale: float = 0.55,
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min_axial_scale: float = 0.42,
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max_axial_scale: float = 1.80,
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) -> HousingScale:
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target_inner_radius = motor_radial_diameter_mm / 2.0 + radial_clearance_mm
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@@ -0,0 +1,255 @@
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from pathlib import Path
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import math
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import cadquery as cq
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AXIS = cq.Vector(0.0, 1.0, 0.0)
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def _point_on_xz(radius: float, angle_degrees: float, y: float) -> cq.Vector:
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angle = math.radians(angle_degrees)
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return cq.Vector(radius * math.cos(angle), y, radius * math.sin(angle))
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def _cylinder(radius: float, y0: float, length: float, x: float = 0.0, z: float = 0.0):
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return cq.Solid.makeCylinder(radius, length, cq.Vector(x, y0, z), AXIS)
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def _ring(outer_radius: float, inner_radius: float, y0: float, length: float):
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return _cylinder(outer_radius, y0, length).cut(_cylinder(inner_radius, y0, length))
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def _conical_ring(
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outer_start: float,
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outer_end: float,
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inner_start: float,
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inner_end: float,
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y0: float,
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length: float,
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):
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outer = cq.Solid.makeCone(outer_start, outer_end, length, cq.Vector(0.0, y0, 0.0), AXIS)
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inner = cq.Solid.makeCone(inner_start, inner_end, length, cq.Vector(0.0, y0, 0.0), AXIS)
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return outer.cut(inner)
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def _sector_cut(angle_center: float, angle_width: float, y0: float, length: float, radius: float = 100.0):
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start = math.radians(angle_center - angle_width / 2.0)
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end = math.radians(angle_center + angle_width / 2.0)
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points = [
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(0.0, 0.0),
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(radius * math.cos(start), radius * math.sin(start)),
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(radius * math.cos(end), radius * math.sin(end)),
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]
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plane = cq.Plane(origin=(0.0, y0, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, 1.0, 0.0))
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return cq.Workplane(plane).polyline(points).close().extrude(length).val()
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def _annular_sector_cut(
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angle_center: float,
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angle_width: float,
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inner_radius: float,
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outer_radius: float,
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y0: float,
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length: float,
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profile_fillet_radius: float = 0.0,
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axial_fillet_radius: float = 0.0,
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):
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start = math.radians(angle_center - angle_width / 2.0)
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middle = math.radians(angle_center)
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end = math.radians(angle_center + angle_width / 2.0)
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inner_start = (inner_radius * math.cos(start), inner_radius * math.sin(start))
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inner_middle = (inner_radius * math.cos(middle), inner_radius * math.sin(middle))
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inner_end = (inner_radius * math.cos(end), inner_radius * math.sin(end))
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outer_start = (outer_radius * math.cos(start), outer_radius * math.sin(start))
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outer_middle = (outer_radius * math.cos(middle), outer_radius * math.sin(middle))
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outer_end = (outer_radius * math.cos(end), outer_radius * math.sin(end))
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plane = cq.Plane(origin=(0.0, y0, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, 1.0, 0.0))
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cutter = (
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cq.Workplane(plane)
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.moveTo(*inner_start)
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.lineTo(*outer_start)
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.threePointArc(outer_middle, outer_end)
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.lineTo(*inner_end)
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.threePointArc(inner_middle, inner_start)
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.close()
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.extrude(length)
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)
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if profile_fillet_radius > 0.0:
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# Round the corners of the annular profile (fillet axes parallel to Y).
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cutter = cutter.edges("|Y").fillet(profile_fillet_radius)
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if axial_fillet_radius > 0.0:
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# Round only the straight radial edges at the two axial ends. This
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# produces the R10/R5/R2 window run-outs present in the source STEP.
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end_edges = [
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edge
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for edge in cutter.edges("%LINE").vals()
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if abs(edge.Center().y - y0) < 1.0e-6
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or abs(edge.Center().y - (y0 + length)) < 1.0e-6
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]
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cutter = cutter.newObject(end_edges).fillet(axial_fillet_radius)
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return cutter.val()
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def _radial_bar(angle_degrees: float, y0: float, length: float, inner_radius: float, outer_radius: float, width: float):
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radial_length = outer_radius - inner_radius
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bar = (
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cq.Workplane("XY")
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.box(radial_length, length, width)
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.translate(((inner_radius + outer_radius) / 2.0, y0 + length / 2.0, 0.0))
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)
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return bar.rotate((0.0, 0.0, 0.0), (0.0, 1.0, 0.0), -angle_degrees).val()
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def _rounded_radial_slot(angle_degrees: float, y0: float, length: float):
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"""A 40 mm wide radial window with R2 corners in its axial section."""
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plane = cq.Plane(
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origin=(40.0, y0 + length / 2.0, 0.0),
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xDir=(0.0, 1.0, 0.0),
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normal=(1.0, 0.0, 0.0),
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)
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slot = (
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cq.Workplane(plane)
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.rect(length - 4.0, 36.0)
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.offset2D(2.0)
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.extrude(42.0)
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.rotate((0.0, 0.0, 0.0), (0.0, 1.0, 0.0), -angle_degrees)
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)
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return slot.val()
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def _support_blend(angle_degrees: float, mirrored: bool):
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"""One of the six R2 blends between the R64 and R29.2 support arcs."""
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sharp = (-62.80715975198, 12.298808230444)
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inner_tangent = (-62.1855700706093, 15.131254904777)
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lobe_tangent = (-63.6707499640005, 16.8512614004542)
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inner_center = (0.0, 0.0)
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blend_center = (-61.6824120316291, 17.0669284278203)
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lobe_center = (-34.6410161514, 20.0)
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def transform(point):
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x, z = point
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if mirrored:
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axis = math.radians(150.0)
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ux, uz = math.cos(axis), math.sin(axis)
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projection = x * ux + z * uz
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x, z = 2.0 * projection * ux - x, 2.0 * projection * uz - z
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angle = math.radians(angle_degrees)
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return (
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x * math.cos(angle) - z * math.sin(angle),
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x * math.sin(angle) + z * math.cos(angle),
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)
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def arc_middle(center, start, end, radius):
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ux = (start[0] - center[0]) / radius + (end[0] - center[0]) / radius
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uz = (start[1] - center[1]) / radius + (end[1] - center[1]) / radius
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scale = radius / math.hypot(ux, uz)
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return center[0] + ux * scale, center[1] + uz * scale
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points = [transform(point) for point in (sharp, inner_tangent, lobe_tangent)]
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centers = [transform(point) for point in (inner_center, blend_center, lobe_center)]
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plane = cq.Plane(origin=(0.0, 90.2, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, -1.0, 0.0))
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return (
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cq.Workplane(plane)
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.moveTo(*points[0])
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.threePointArc(arc_middle(centers[0], points[0], points[1], 64.0), points[1])
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.threePointArc(arc_middle(centers[1], points[1], points[2], 2.0), points[2])
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.threePointArc(arc_middle(centers[2], points[2], points[0], 29.2), points[0])
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.close()
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.extrude(10.0)
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.val()
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)
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def build():
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# Front cylindrical shell and its smaller continuation.
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part = cq.Workplane(obj=_ring(79.4, 74.4, -10.0, 22.0))
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part = part.union(_ring(78.4, 74.4, 12.0, 43.2))
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# Nine radial R2 holes through the front lip, spaced every 40 degrees.
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for angle in (90.0, 50.0, 10.0, -30.0, -70.0, -110.0, -150.0, -190.0, -230.0):
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start = _point_on_xz(72.0, angle, -5.0)
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direction = _point_on_xz(1.0, angle, 0.0)
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direction = cq.Vector(direction.x, 0.0, direction.z)
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part = part.cut(cq.Solid.makeCylinder(2.0, 10.0, start, direction))
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# Six long ventilation windows, 40-degree openings with 20-degree ribs.
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for center in (-110.0, -50.0, 10.0, 70.0, 130.0, 190.0):
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part = part.cut(
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_annular_sector_cut(center, 40.0, 70.0, 82.0, 12.0, 40.0, axial_fillet_radius=10.0)
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)
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# Taper from the large front shell to the narrower middle shell.
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part = part.union(_conical_ring(78.4, 73.2, 74.4, 69.2, 55.2, 20.0))
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part = part.union(_ring(73.2, 60.0, 75.2, 5.0))
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# Three small axial holes in the first shoulder ring.
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for angle in (30.0, 150.0, 270.0):
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p = _point_on_xz(64.0, angle, 75.2)
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part = part.cut(cq.Solid.makeCylinder(2.0, 5.0, p, AXIS))
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# Three-lobed support plate: a disk with three large circular openings.
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support = cq.Workplane(obj=_ring(73.2, 64.0, 80.2, 10.0))
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for x, z in ((34.6410161514, 20.0), (-34.6410161514, 20.0), (0.0, -40.0)):
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support = support.cut(_cylinder(29.2, 80.2, 10.0, x, z))
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part = part.union(support)
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# Thin middle shell and its second, angularly shifted six-window pattern.
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part = part.union(_ring(73.2, 69.2, 90.2, 30.0))
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for center in (-150.0, -90.0, -30.0, 30.0, 90.0, 150.0):
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part = part.cut(
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_annular_sector_cut(center, 40.0, 65.0, 76.0, 90.2, 20.0, axial_fillet_radius=5.0)
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)
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# Rear shell is one continuous 2:7 taper. Its inner cavity changes from
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# a steep R69.2 -> R63.6 cone to the matching shallow taper at Y=125.8.
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taper_outer = cq.Solid.makeCone(
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73.2, 64.91428571428571, 29.0, cq.Vector(0.0, 120.2, 0.0), AXIS
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)
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taper_inner_a = cq.Solid.makeCone(69.2, 63.6, 5.6, cq.Vector(0.0, 120.2, 0.0), AXIS)
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taper_inner_b = cq.Solid.makeCone(63.6, 59.2, 15.4, cq.Vector(0.0, 125.8, 0.0), AXIS)
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part = part.union(taper_outer.cut(taper_inner_a).cut(taper_inner_b))
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hub = cq.Workplane(obj=_ring(38.0, 26.0, 129.2, 4.0)).union(
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_ring(38.0, 30.0, 133.2, 16.0)
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)
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part = part.union(hub)
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# Stop 0.0001 mm before the coincident rear-plate face so OpenCascade
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# keeps the six ribs in one valid solid.
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for center in (30.0, 90.0, 150.0, 210.0, 270.0, 330.0):
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part = part.cut(_rounded_radial_slot(center, 131.2, 9.9999))
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# Central bore through the solid rear plate, then its six fan windows.
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part = part.cut(_cylinder(30.0, 141.2, 8.0))
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for center in (45.0, 105.0, 165.0, 225.0, 285.0, 345.0):
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cutter = _annular_sector_cut(
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center, 30.0, 38.0, 59.2, 141.2, 8.0, profile_fillet_radius=2.0
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)
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part = part.cut(cutter)
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# These holes pass through both the end plate and the previously added hub.
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for angle in (-90.0, -30.0, 30.0, 90.0, 150.0, 210.0):
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p = _point_on_xz(34.0, angle, 141.2)
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part = part.cut(cq.Solid.makeCylinder(1.81198, 8.0, p, AXIS))
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# Add the small support blends last so they cannot interfere with fusing
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# the face-connected rear shell and end plate.
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for mirrored in (False, True):
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for angle in (0.0, 120.0, 240.0):
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part = part.union(_support_blend(angle, mirrored))
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# Remove only the six 0.0001 mm run-out residuals after the complete part
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# is connected. This reaches the exact Y=141.2 boundary without causing
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# the earlier coincident-face split into six solids.
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for center in (30.0, 90.0, 150.0, 210.0, 270.0, 330.0):
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full_slot = _rounded_radial_slot(center, 131.2, 10.0)
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stable_slot = _rounded_radial_slot(center, 131.2, 9.9999)
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part = part.cut(full_slot.cut(stable_slot))
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return part
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if __name__ == "__main__":
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output = Path(__file__).resolve().with_name("外壳框架.step")
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cq.exporters.export(build(), str(output))
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print(output)
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