Jerry
449 lines
20 KiB
Python
449 lines
20 KiB
Python
"""Top-level integrated BLDC motor, controller, reducer, and housing assembly."""
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from __future__ import annotations
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import simplecadapi as scad
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try:
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from .bearings import (
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make_coaxial_bearing_rplacement,
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make_main_bearing_rassembly,
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make_planet_bearing_rplacement,
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make_standard_planet_bearing_rassembly,
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)
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from .common import connector_ref, ground_constraint_report
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from .dimensions import (
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FRONT_MOTOR_BEARING,
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FRONT_MOTOR_BEARING_CENTER_Z,
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INTERSTAGE_BEARING,
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INTERSTAGE_BEARING_CENTER_Z,
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OUTPUT_BEARING,
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OUTPUT_BEARING_1_CENTER_Z,
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OUTPUT_BEARING_2_CENTER_Z,
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PLANET_BEARING,
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PLANET_COUNT,
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REAR_BEARING_CENTER_Z,
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REAR_MOTOR_BEARING,
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STAGE_1,
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STAGE_2,
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TOTAL_REDUCTION,
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StageSpec,
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)
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from .electronics import make_integrated_controller_rassembly
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from .gears import (
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make_output_carrier_flange_rpart,
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make_planet_rplacement,
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make_stage1_carrier_sun_rpart,
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make_stage_planet_gear_rpart,
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make_stage_ring_gear_rpart,
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)
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from .housing import (
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make_motor_shell_rpart,
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make_output_bearing_cap_rpart,
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make_rear_bearing_spider_rpart,
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make_rear_electronics_cover_rpart,
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make_reducer_housing_rpart,
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)
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from .motor import make_bldc_rotor_rassembly, make_bldc_stator_rassembly
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except ImportError: # Support direct execution from this example directory.
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from bearings import (
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make_coaxial_bearing_rplacement,
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make_main_bearing_rassembly,
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make_planet_bearing_rplacement,
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make_standard_planet_bearing_rassembly,
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)
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from common import connector_ref, ground_constraint_report
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from dimensions import (
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FRONT_MOTOR_BEARING,
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FRONT_MOTOR_BEARING_CENTER_Z,
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INTERSTAGE_BEARING,
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INTERSTAGE_BEARING_CENTER_Z,
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OUTPUT_BEARING,
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OUTPUT_BEARING_1_CENTER_Z,
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OUTPUT_BEARING_2_CENTER_Z,
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PLANET_BEARING,
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PLANET_COUNT,
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REAR_BEARING_CENTER_Z,
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REAR_MOTOR_BEARING,
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STAGE_1,
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STAGE_2,
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TOTAL_REDUCTION,
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StageSpec,
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)
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from electronics import make_integrated_controller_rassembly
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from gears import (
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make_output_carrier_flange_rpart,
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make_planet_rplacement,
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make_stage1_carrier_sun_rpart,
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make_stage_planet_gear_rpart,
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make_stage_ring_gear_rpart,
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)
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from housing import (
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make_motor_shell_rpart,
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make_output_bearing_cap_rpart,
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make_rear_bearing_spider_rpart,
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make_rear_electronics_cover_rpart,
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make_reducer_housing_rpart,
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)
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from motor import make_bldc_rotor_rassembly, make_bldc_stator_rassembly
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@scad.requires_session
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def make_integrated_bldc_joint_actuator_rassembly(
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*, materials: dict[str, scad.Material]
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) -> scad.Assembly:
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"""Build and solve the complete compact 50 mm joint actuator."""
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component_specs = make_integrated_bldc_joint_actuator_components_rtuple(
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materials=materials
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)
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actuator = scad.make_assembly_rassembly(
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assembly_id="integrated_50mm_bldc_joint_actuator",
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name="50 mm 12-slot/14-pole BLDC joint actuator with 20:1 reducer and circular ESC",
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)
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for component_id, item, placement, name in component_specs:
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actuator = scad.add_component_rassembly(
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assembly=actuator,
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item=item,
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component_id=component_id,
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placement=placement,
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name=name,
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)
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actuator = _add_public_connectors_rassembly(assembly=actuator)
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actuator = _add_constraints_rassembly(assembly=actuator)
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actuator = scad.solve_assembly_constraints_rassembly(assembly=actuator, strict=True)
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ground_constraint_report(label="actuator", assembly=actuator)
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return actuator
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@scad.requires_session
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def make_integrated_bldc_joint_actuator_components_rtuple(
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*, materials: dict[str, scad.Material]
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) -> tuple[tuple[str, scad.Part | scad.Assembly, scad.Placement, str], ...]:
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"""Build the actuator component inventory without creating a parent assembly."""
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print(
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f"ratio_plan: stage1={STAGE_1.fixed_ring_ratio:.1f}:1 "
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f"stage2={STAGE_2.fixed_ring_ratio:.1f}:1 total={TOTAL_REDUCTION:.1f}:1"
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)
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reducer_housing = make_reducer_housing_rpart(material=materials["housing"])
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motor_shell = make_motor_shell_rpart(material=materials["housing"])
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rear_spider = make_rear_bearing_spider_rpart(material=materials["carrier"])
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rear_cover = make_rear_electronics_cover_rpart(material=materials["housing"])
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output_cap = make_output_bearing_cap_rpart(material=materials["carrier"])
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stator = make_bldc_stator_rassembly(
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steel_material=materials["electrical_steel"],
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copper_material=materials["copper"],
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)
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rotor = make_bldc_rotor_rassembly(
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steel_material=materials["gear"],
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magnet_material=materials["magnet"],
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)
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controller = make_integrated_controller_rassembly(
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pcb_material=materials["pcb"],
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terminal_material=materials["terminal"],
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)
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stage1_ring = make_stage_ring_gear_rpart(stage=STAGE_1, material=materials["gear"])
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stage1_planet = make_stage_planet_gear_rpart(stage=STAGE_1, material=materials["gear"])
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stage1_carrier = make_stage1_carrier_sun_rpart(material=materials["gear"])
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stage2_ring = make_stage_ring_gear_rpart(stage=STAGE_2, material=materials["gear"])
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stage2_planet = make_stage_planet_gear_rpart(stage=STAGE_2, material=materials["gear"])
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output_carrier = make_output_carrier_flange_rpart(stage=STAGE_2, material=materials["carrier"])
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rear_motor_bearing = make_main_bearing_rassembly(
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bearing_id="rear_motor_8x16x5",
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spec=REAR_MOTOR_BEARING,
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material=materials["gear"],
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)
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front_motor_bearing = make_main_bearing_rassembly(
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bearing_id="front_motor_8x19x6",
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spec=FRONT_MOTOR_BEARING,
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material=materials["gear"],
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)
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interstage_bearing = make_main_bearing_rassembly(
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bearing_id="interstage_5x10x3",
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spec=INTERSTAGE_BEARING,
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material=materials["gear"],
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)
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planet_bearing = make_standard_planet_bearing_rassembly(
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bearing_id="planet_3x6x3",
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spec=PLANET_BEARING,
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material=materials["gear"],
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)
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output_bearing = make_main_bearing_rassembly(
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bearing_id="output_16x24x5",
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spec=OUTPUT_BEARING,
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material=materials["gear"],
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)
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fixed_components = (
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("reducer_housing", reducer_housing, scad.identity_placement_rplacement(), "Fixed reducer housing"),
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("motor_shell", motor_shell, scad.identity_placement_rplacement(), "Fixed BLDC shell"),
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("rear_bearing_spider", rear_spider, scad.identity_placement_rplacement(), "Rear motor-bearing spider"),
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("rear_electronics_cover", rear_cover, scad.identity_placement_rplacement(), "Rear controller cover"),
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("output_bearing_cap", output_cap, scad.identity_placement_rplacement(), "Output bearing cap"),
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("stator", stator, scad.identity_placement_rplacement(), "12-slot fixed stator"),
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("rotor", rotor, scad.identity_placement_rplacement(), "14-pole rotor and direct sun shaft"),
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("controller", controller, scad.identity_placement_rplacement(), "Circular integrated controller"),
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("stage1_carrier", stage1_carrier, scad.identity_placement_rplacement(), "Stage 1 carrier and stage 2 sun"),
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("output_carrier", output_carrier, scad.identity_placement_rplacement(), "Stage 2 carrier and output flange"),
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("stage1_ring", stage1_ring, _stage_rplacement(stage=STAGE_1), "Stage 1 fixed ring insert"),
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("stage2_ring", stage2_ring, _stage_rplacement(stage=STAGE_2), "Stage 2 fixed ring insert"),
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)
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print(f"actuator_base_components: count={len(fixed_components)}")
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planet_components = []
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for stage, planet in ((STAGE_1, stage1_planet), (STAGE_2, stage2_planet)):
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for index in range(PLANET_COUNT):
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planet_components.append(
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(
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f"{stage.stage_id}_planet_{index + 1}",
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planet,
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make_planet_rplacement(stage=stage, index=index),
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f"{stage.label} planet {index + 1}",
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)
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)
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bearing_components = (
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(
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"rear_motor_bearing",
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rear_motor_bearing,
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make_coaxial_bearing_rplacement(center_z=REAR_BEARING_CENTER_Z),
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"Rear rotor bearing",
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),
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(
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"front_motor_bearing",
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front_motor_bearing,
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make_coaxial_bearing_rplacement(center_z=FRONT_MOTOR_BEARING_CENTER_Z),
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"Front rotor bearing",
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),
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(
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"interstage_bearing",
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interstage_bearing,
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make_coaxial_bearing_rplacement(center_z=INTERSTAGE_BEARING_CENTER_Z),
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"Stage 1 carrier support bearing",
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),
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(
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"output_bearing_1",
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output_bearing,
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make_coaxial_bearing_rplacement(center_z=OUTPUT_BEARING_1_CENTER_Z),
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"Rear output bearing",
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),
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(
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"output_bearing_2",
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output_bearing,
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make_coaxial_bearing_rplacement(center_z=OUTPUT_BEARING_2_CENTER_Z),
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"Front output bearing",
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),
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)
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planet_bearing_components = []
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for stage in (STAGE_1, STAGE_2):
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for index in range(PLANET_COUNT):
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planet_bearing_components.append(
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(
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f"{stage.stage_id}_planet_bearing_{index + 1}",
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planet_bearing,
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make_planet_bearing_rplacement(stage=stage, index=index),
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f"{stage.label} planet bearing {index + 1}",
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)
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)
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print(f"bearing_components: motor=2 interstage=1 output=2 planet={PLANET_COUNT * 2}")
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return tuple(
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[
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*fixed_components,
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*planet_components,
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*bearing_components,
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*planet_bearing_components,
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]
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)
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@scad.requires_session
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def _add_public_connectors_rassembly(*, assembly: scad.Assembly) -> scad.Assembly:
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forwarded = (
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("case_clamp_axis", "reducer_housing", "case_clamp_axis", "External split-clamp datum"),
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("case_mount_axis", "output_bearing_cap", "case_mount_axis", "Fixed actuator case datum"),
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("output_link_axis", "output_carrier", "output_link_axis", "Rotating six-hole output flange"),
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("phase_terminal_access", "controller", "phase_access", "Rear phase-terminal service datum"),
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("power_can_terminal_access", "controller", "power_can_access", "Rear power/CAN service datum"),
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)
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for connector_id, source_component_id, source_connector_id, name in forwarded:
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assembly = scad.forward_connector_rassembly(
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assembly=assembly,
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connector_id=connector_id,
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source_component_id=source_component_id,
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source_connector_id=source_connector_id,
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name=name,
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offset=None,
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)
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print("actuator_public_connectors: " + ",".join(item[0] for item in forwarded))
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return assembly
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@scad.requires_session
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def _add_constraints_rassembly(*, assembly: scad.Assembly) -> scad.Assembly:
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assembly = scad.ground_component_rassembly(assembly=assembly, component_id="reducer_housing")
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assembly = scad.ground_component_rassembly(assembly=assembly, component_id="stage1_ring")
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assembly = scad.ground_component_rassembly(assembly=assembly, component_id="stage2_ring")
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fixed_pairs = (
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("motor_shell_to_reducer_housing", "reducer_housing", "motor_mount_axis", "motor_shell", "reducer_mount_axis"),
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("rear_spider_to_motor_shell", "motor_shell", "rear_spider_axis", "rear_bearing_spider", "shell_axis"),
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("rear_cover_to_motor_shell", "motor_shell", "rear_cover_axis", "rear_electronics_cover", "shell_axis"),
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("stator_to_motor_shell", "motor_shell", "stator_axis", "stator", "shell_axis"),
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("controller_to_rear_cover", "rear_electronics_cover", "pcb_axis", "controller", "cover_axis"),
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("stage1_ring_fixed", "reducer_housing", "stage1_ring_axis", "stage1_ring", "axis"),
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("stage2_ring_fixed", "reducer_housing", "stage2_ring_axis", "stage2_ring", "axis"),
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("output_cap_to_reducer_housing", "reducer_housing", "output_cap_axis", "output_bearing_cap", "housing_axis"),
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)
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for constraint_id, a_component, a_connector, b_component, b_connector in fixed_pairs:
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assembly = scad.add_fixed_constraint_rassembly(
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assembly=assembly,
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constraint_id=constraint_id,
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connector_a=connector_ref(component_id=a_component, connector_id=a_connector),
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connector_b=connector_ref(component_id=b_component, connector_id=b_connector),
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name=constraint_id.replace("_", " "),
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)
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primary_revolutes = (
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("rotor_revolute", "reducer_housing", "front_motor_bearing_axis", "rotor", "front_bearing_axis"),
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("stage1_carrier_revolute", "reducer_housing", "stage1_carrier_axis", "stage1_carrier", "carrier_axis"),
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("output_carrier_revolute", "reducer_housing", "stage2_carrier_axis", "output_carrier", "carrier_axis"),
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)
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for constraint_id, a_component, a_connector, b_component, b_connector in primary_revolutes:
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assembly = scad.add_revolute_constraint_rassembly(
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assembly=assembly,
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constraint_id=constraint_id,
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connector_a=connector_ref(component_id=a_component, connector_id=a_connector),
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connector_b=connector_ref(component_id=b_component, connector_id=b_connector),
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drive_angle_degrees=0.0,
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angle_limit=None,
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name=constraint_id.replace("_", " "),
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)
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assembly = _add_stage_constraints_rassembly(
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assembly=assembly,
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stage=STAGE_1,
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sun_component="rotor",
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sun_connector="front_bearing_axis",
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ring_component="stage1_ring",
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carrier_component="stage1_carrier",
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)
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assembly = _add_stage_constraints_rassembly(
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assembly=assembly,
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stage=STAGE_2,
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sun_component="stage1_carrier",
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sun_connector="carrier_axis",
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ring_component="stage2_ring",
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carrier_component="output_carrier",
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)
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assembly = _add_bearing_constraints_rassembly(assembly=assembly)
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print("actuator_constraints: fixed=8 primary_revolute=3 planet_revolute=6 gear=6 internal=6 bearing_interfaces=22")
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return assembly
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@scad.requires_session
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def _add_stage_constraints_rassembly(
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*,
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assembly: scad.Assembly,
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stage: StageSpec,
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sun_component: str,
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sun_connector: str,
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ring_component: str,
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carrier_component: str,
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) -> scad.Assembly:
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for index in range(PLANET_COUNT):
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planet_component = f"{stage.stage_id}_planet_{index + 1}"
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assembly = scad.add_revolute_constraint_rassembly(
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assembly=assembly,
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constraint_id=f"{planet_component}_revolute",
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connector_a=connector_ref(component_id=carrier_component, connector_id=f"planet_{index + 1}_axis"),
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connector_b=connector_ref(component_id=planet_component, connector_id="axis"),
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drive_angle_degrees=None,
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angle_limit=None,
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name=f"{stage.label} planet {index + 1} bearing axis",
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)
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assembly = scad.add_gear_constraint_rassembly(
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assembly=assembly,
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constraint_id=f"{stage.stage_id}_sun_planet_{index + 1}_mesh",
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connector_a=connector_ref(component_id=sun_component, connector_id=sun_connector),
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connector_b=connector_ref(component_id=planet_component, connector_id="axis"),
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pitch_radius_a=stage.sun_pitch_radius,
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pitch_radius_b=stage.planet_pitch_radius,
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phase_offset=None,
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name=f"{stage.label} sun to planet {index + 1} external mesh",
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)
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assembly = scad.add_belt_constraint_rassembly(
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assembly=assembly,
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constraint_id=f"{stage.stage_id}_ring_planet_{index + 1}_internal_mesh",
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connector_a=connector_ref(component_id=ring_component, connector_id="axis"),
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connector_b=connector_ref(component_id=planet_component, connector_id="axis"),
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pulley_radius_a=stage.ring_pitch_radius,
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pulley_radius_b=stage.planet_pitch_radius,
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phase_offset=None,
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name=f"{stage.label} fixed-ring to planet {index + 1} internal mesh",
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)
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print(
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f"{stage.stage_id}_mesh: sun_r={stage.sun_pitch_radius:.3f} "
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f"planet_r={stage.planet_pitch_radius:.3f} center={stage.planet_center_radius:.3f}"
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)
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return assembly
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@scad.requires_session
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def _add_bearing_constraints_rassembly(*, assembly: scad.Assembly) -> scad.Assembly:
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interfaces = (
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("rear_bearing_outer_to_spider", "rear_bearing_spider", "bearing_axis", "rear_motor_bearing", "outer_axis"),
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("rear_bearing_inner_to_rotor", "rotor", "rear_bearing_axis", "rear_motor_bearing", "inner_axis"),
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("front_bearing_outer_to_housing", "reducer_housing", "front_motor_bearing_axis", "front_motor_bearing", "outer_axis"),
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("front_bearing_inner_to_rotor", "rotor", "front_bearing_axis", "front_motor_bearing", "inner_axis"),
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("interstage_bearing_outer_to_housing", "reducer_housing", "interstage_bearing_axis", "interstage_bearing", "outer_axis"),
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("interstage_bearing_inner_to_carrier", "stage1_carrier", "interstage_bearing_axis", "interstage_bearing", "inner_axis"),
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("output_bearing_1_outer_to_cap", "output_bearing_cap", "bearing_1_axis", "output_bearing_1", "outer_axis"),
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("output_bearing_1_inner_to_carrier", "output_carrier", "bearing_1_axis", "output_bearing_1", "inner_axis"),
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("output_bearing_2_outer_to_cap", "output_bearing_cap", "bearing_2_axis", "output_bearing_2", "outer_axis"),
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("output_bearing_2_inner_to_carrier", "output_carrier", "bearing_2_axis", "output_bearing_2", "inner_axis"),
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)
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for constraint_id, a_component, a_connector, b_component, b_connector in interfaces:
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|
assembly = scad.add_revolute_constraint_rassembly(
|
|
assembly=assembly,
|
|
constraint_id=constraint_id,
|
|
connector_a=connector_ref(component_id=a_component, connector_id=a_connector),
|
|
connector_b=connector_ref(component_id=b_component, connector_id=b_connector),
|
|
drive_angle_degrees=None,
|
|
angle_limit=None,
|
|
name=constraint_id.replace("_", " "),
|
|
)
|
|
for stage, carrier_component in ((STAGE_1, "stage1_carrier"), (STAGE_2, "output_carrier")):
|
|
for index in range(PLANET_COUNT):
|
|
planet = f"{stage.stage_id}_planet_{index + 1}"
|
|
bearing = f"{stage.stage_id}_planet_bearing_{index + 1}"
|
|
assembly = scad.add_revolute_constraint_rassembly(
|
|
assembly=assembly,
|
|
constraint_id=f"{bearing}_outer_to_planet",
|
|
connector_a=connector_ref(component_id=planet, connector_id="bearing_axis"),
|
|
connector_b=connector_ref(component_id=bearing, connector_id="outer_axis"),
|
|
drive_angle_degrees=None,
|
|
angle_limit=None,
|
|
name=f"{stage.label} planet {index + 1} bearing outer-ring fit",
|
|
)
|
|
assembly = scad.add_revolute_constraint_rassembly(
|
|
assembly=assembly,
|
|
constraint_id=f"{bearing}_inner_to_pin",
|
|
connector_a=connector_ref(
|
|
component_id=carrier_component,
|
|
connector_id=f"planet_{index + 1}_bearing_axis",
|
|
),
|
|
connector_b=connector_ref(component_id=bearing, connector_id="inner_axis"),
|
|
drive_angle_degrees=None,
|
|
angle_limit=None,
|
|
name=f"{stage.label} planet {index + 1} bearing inner-ring pin fit",
|
|
)
|
|
return assembly
|
|
|
|
|
|
@scad.requires_session
|
|
def _stage_rplacement(*, stage: StageSpec) -> scad.Placement:
|
|
return scad.make_placement_rplacement(origin=(0.0, 0.0, stage.bottom_z))
|