"""Bench fixtures and fit coupons for the first leg (docs/leg-prototype-plan.md task T4, section 5), printed while the parts ship: .venv/bin/python cad/rig_bench.py # exports/rig/bench/: .step + print-ready .stl, print-plan.json dyno_lug_plate x 2 PETG an RS-04 on its 10 x M4 output-side lugs (M4 x 20, the leg's screw), standing on a board dyno_hub x 2 PETG on each motor's output (3 pin sockets, 9 x M5 x 25, the leg's D46 screw), three jaws dyno_spider x 2 TPU between the two hubs' jaws: B1 back-drives one motor with the other through it, and the spider takes the two axes' misalignment that would otherwise show as drag press_cage x 1 PETG B3, B4: a frame round the S-type load cell on the press's axis (the cell hangs from the top beam; what is tested comes up from the bottom beam) press_base, press_slider B3: an M12 x 80 bolt through the base's nut lifts the slider sleeve_block x 1 PA6-CF B3: a real stop post in an M8 insert, its TPU sleeve under sleeve_anvil (the link's edge) sleeve_anvil x 1 PA6-CF hung from the cell's lower thread puller_m5 x 4, puller_m8 x 2 PA6-CF B4: a heat-set insert as the hip frame has it (axis along the print's z), hung from the cell; the screw under test comes up into it bearing_disc x 3 PA6-CF B4: the upper link's material under an M5 head (B5, the tyre, runs on the rig with the leg: docs/leg-bench-tests.md) coupon_* (x 3 each) PA6-CF the leg's seats at -0.1, 0 and +0.1 mm: the hip frame's motor ring and 61812 seat, the upper link's hub face (D46 pattern), its knee eye (an eye sleeve), the lower links' knee boss (a 6201), the front link's apex eye (a 61812), the wheel link's hub journal (a 61812's inner race) with its circlip groove Every coupon carries its variant engraved (-0.1 / 0 / +0.1, the change to the seat's diameter from the leg's CAD). """ from __future__ import annotations import json import math import sys from pathlib import Path import cadquery as cq R = Path(__file__).resolve().parents[1] sys.path.insert(0, str(R / 'cad')) import fivebar as fb # noqa: E402 import gmi # noqa: E402 import printplan # noqa: E402 OUT = R / 'exports' / 'rig' / 'bench' FAST = gmi.FAST MI = gmi.motor_interface(fb.MOTOR) VARIANTS = (-0.1, 0.0, 0.1) # D46 (main session, 2026-10-27): the machined adapter's face: 8 x M5 tapped at these angles and 2 x Ø5 H7 dowels, PCD 50 D46_BOLTS_DEG = (0, 30, 90, 120, 180, 210, 270, 300) D46_DOWELS_DEG = (60, 150) D46_SPIGOT_RECESS = 40.1 def zc(r, z0, z1, x=0.0, y=0.0): return cq.Workplane('XY').workplane(offset=z0).center(x, y).circle(r).extrude(z1 - z0) def bx(x0, x1, y0, y1, z0, z1): return cq.Workplane('XY').box(x1 - x0, y1 - y0, z1 - z0).translate(((x0 + x1) / 2, (y0 + y1) / 2, (z0 + z1) / 2)) def pts(pcd, angles): return [(pcd / 2 * math.cos(math.radians(a)), pcd / 2 * math.sin(math.radians(a))) for a in angles] def engrave(s, text, x, y, z_top, size=5.0, depth=0.6): """Cut a label into the face at z_top.""" try: t = cq.Workplane('XY').workplane(offset=z_top - depth).center(x, y).text(text, size, depth + 0.2, combine=False, halign='center', valign='center') return s.cut(t) except Exception: return s def label(v: float) -> str: return '0' if v == 0 else f'{v:+.1f}' # ----------------------------------------------------------------------------------- the dyno (B1, B2) DYNO_AXIS_Z = 90.0 # the motors' axis above the board LUG_T = 14.0 # plate thickness at the lugs: an M4 x 20 then takes 6 mm of the 7 mm lug threads def dyno_lug_plate(): """PETG: a ring round the motor's lug circle (the output-side lug face against its back, y = 0; the output flange in the central hole, 0.5 mm proud of the lug face) on two legs and a foot with four slots for M6 bolts through the board. Printed on its foot.""" b = MI['case']['bolts'] ring = cq.Workplane('XZ', origin=(0, LUG_T, 0)).center(0, DYNO_AXIS_Z).circle(66.0).circle(29.0).extrude(LUG_T) s = ring for sx in (-1, 1): # legs to the foot s = s.union(bx(sx * 50 - 9, sx * 50 + 9, 0, LUG_T, 0, DYNO_AXIS_Z - 20)) g = cq.Workplane('YZ', origin=(sx * 50 - 4, 0, 0)).polyline([(-55, 8), (0, 8), (0, 60)]).close().extrude(8) s = s.union(g) s = s.union(bx(-75, 75, -60, LUG_T, 0, 8)) # foot (behind: the motor's side) for (x, z) in pts(b['pcd'], [fb.RS04_LUG0 + 36 * k for k in range(10)]): s = s.cut(cq.Workplane('XZ', origin=(0, LUG_T + 1, 0)).center(x, DYNO_AXIS_Z + z).circle(gmi.clear('M4') / 2).extrude(LUG_T + 2)) for a in fb.RS04_DOWELS: # Ø5 x 16 dowels into the motor's holes x, z = b['pcd'] / 2 * math.cos(math.radians(a)), b['pcd'] / 2 * math.sin(math.radians(a)) s = s.cut(cq.Workplane('XZ', origin=(0, 6.0, 0)).center(x, DYNO_AXIS_Z + z).circle(2.5 - 0.03).extrude(7.0)) for x in (-62, 62): for y in (-48, -20): s = s.cut(cq.Workplane('XY').workplane(offset=-1).center(x, y).slot2D(14, 6.8, 90).extrude(10)) return s def dyno_hub(): """PETG, one on each motor's output: a boss through the lug plate's hole onto the output flange (3 pin sockets, 9 x M5 x 25 counterbored from the jaw side), a disc, three 45 deg jaws at r 26-44. Built along +z from the output face.""" o = MI['output'] s = zc(27.0, 0.0, 13.5).union(zc(45.0, 13.5, 23.5)) for k in range(3): # jaws a0 = 120 * k - 22.5 jaw = (cq.Workplane('XY').workplane(offset=23.5).moveTo(26 * math.cos(math.radians(a0)), 26 * math.sin(math.radians(a0))) .lineTo(44 * math.cos(math.radians(a0)), 44 * math.sin(math.radians(a0))) .threePointArc((44 * math.cos(math.radians(a0 + 22.5)), 44 * math.sin(math.radians(a0 + 22.5))), (44 * math.cos(math.radians(a0 + 45)), 44 * math.sin(math.radians(a0 + 45)))) .lineTo(26 * math.cos(math.radians(a0 + 45)), 26 * math.sin(math.radians(a0 + 45))) .threePointArc((26 * math.cos(math.radians(a0 + 22.5)), 26 * math.sin(math.radians(a0 + 22.5))), (26 * math.cos(math.radians(a0)), 26 * math.sin(math.radians(a0)))).close().extrude(20.0)) s = s.union(jaw) for (x, y) in pts(o['bolts']['pcd'], o['bolts']['angles']): s = s.cut(zc(gmi.clear('M5') / 2, -1, 24, x, y)).cut(zc(4.75, 23.5 - 4.5, 45, x, y)) for (x, y) in pts(o['dowels']['pcd'], o['dowels']['angles']): s = s.cut(zc(o['dowels']['d'] / 2 + 0.03, -1, (o['dowels']['protrusion'] or 3.0) + 0.5, x, y)) return s def dyno_spider(): """TPU 95A: six 13.5 deg arms (r 26.3-43.7) on a ring, filling the gaps between the two hubs' interleaved jaws.""" s = zc(25.8, 0.0, 19.5).cut(zc(22.0, -1, 21)) for k in range(6): c = 60 * k + 30.0 # between a jaw (centred 0, 120, 240) and the a0, a1 = c - 6.6, c + 6.6 # other hub's (60, 180, 300) arm = (cq.Workplane('XY').moveTo(25.0 * math.cos(math.radians(a0)), 25.0 * math.sin(math.radians(a0))) .lineTo(43.7 * math.cos(math.radians(a0)), 43.7 * math.sin(math.radians(a0))) .threePointArc((43.7 * math.cos(math.radians(c)), 43.7 * math.sin(math.radians(c))), (43.7 * math.cos(math.radians(a1)), 43.7 * math.sin(math.radians(a1)))) .lineTo(25.0 * math.cos(math.radians(a1)), 25.0 * math.sin(math.radians(a1))).close().extrude(19.5)) s = s.union(arm) return s # ----------------------------------------------------------------------------------- B3, B4: the press cage # One printed frame holds the S-type load cell on the press's axis for both tests (docs/leg-bench-tests.md): # B4 the cell hangs from the top beam; an M12 x 80 stud from its lower thread carries a puller (an insert coupon, # insert facing down, keyed against turning by its wings on the side walls); the screw under test comes up through # the bottom beam into the insert, so its tension IS the cell's reading (torque-tension, proof load, pull-out); # B3 the same cell, now pushed: an M12 x 80 hex bolt through a nut in the press base lifts a slider carrying the # stop post (in its own M8 insert) and TPU sleeve against the anvil hung from the cell by an M12 x 30 screw. # The cell: Phidgets 3140_0 (S-type, 500 kg, M12 x 1.75 both ends, 51 x 76 x 19/26 mm), its 51 mm width across the # frame's depth so the cable gland points out of the front. Frame coordinates: the press axis along +y at x = 0, # z = CAGE_D / 2; y = 0 the frame's bottom face. It lies flat to print (z up) and on its side on the bench in use. CELL = {'w': 51.0, 'h': 76.0, 't': 26.0} CAGE_IN = 37.0 # half the window's width CAGE_WALL = 10.0 CAGE_D = 50.0 CAGE_BOT, CAGE_WIN, CAGE_TOP = 32.0, 182.0, 28.0 CAGE_H = CAGE_BOT + CAGE_WIN + CAGE_TOP Y_WIN0, Y_WIN1 = CAGE_BOT, CAGE_BOT + CAGE_WIN # 32, 214 Y_CELL0 = Y_WIN1 - CELL['h'] # the cell's lower face, 138 CBORE_UNDER = (33.0, 14.0) # under the bottom beam: the test screws' washer (the 3/8 in one is 31.75) and head CBORE_TOP = (20.0, 13.0) # on the top beam: the M12 x 30 into the cell's upper thread PULLER_H, PULLER_GAP = 60.0, 5.0 # the puller's insert face 5 mm above the bottom beam NUT12 = (19.4, 11.2) # an M12 nut's pocket: across flats, thickness def _ycyl(r, y0, y1, x=0.0, z=CAGE_D / 2): return cq.Workplane('XZ', origin=(0, y1, 0)).center(x, z).circle(r).extrude(y1 - y0) def _hex_pts(af, cx, cy): """A hexagon's corners, flats normal to the first axis (so it slides along the second).""" r = af / 2 / math.cos(math.radians(30)) return [(cx + r * math.cos(math.radians(30 + 60 * k)), cy + r * math.sin(math.radians(30 + 60 * k))) for k in range(6)] def press_cage(): """PETG: the frame (x +-47, y 0-242, z 0-50). Bottom beam y 0-32: the M12 x 80 press bolt or the screw under test through Ø13, a Ø33 x 14 counterbore from below for its head and washer. Top beam y 214-242: the M12 x 30 into the cell's upper thread through Ø13, its head in a Ø20 x 13 counterbore. Walls 10 mm; the window 74 x 182.""" o = CAGE_IN + CAGE_WALL s = bx(-o, o, 0, CAGE_H, 0, CAGE_D).cut(bx(-CAGE_IN, CAGE_IN, Y_WIN0, Y_WIN1, -1, CAGE_D + 1)) s = s.cut(_ycyl(6.5, -1, Y_WIN0 + 1)).cut(_ycyl(CBORE_UNDER[0] / 2, -1, CBORE_UNDER[1])) s = s.cut(_ycyl(6.5, Y_WIN1 - 1, CAGE_H + 1)).cut(_ycyl(CBORE_TOP[0] / 2, CAGE_H - CBORE_TOP[1], CAGE_H + 1)) for sx in (-1, 1): # 8 mm gussets in the top corners (the x0 = sx * CAGE_IN # base and slider fill the bottom ones) g = cq.Workplane('XY').polyline([(x0, Y_WIN1), (x0 - sx * 8, Y_WIN1), (x0, Y_WIN1 - 8)]).close().extrude(CAGE_D) s = s.union(g) return s def press_base(): """PETG: on the bottom beam inside the window (73 x 20 x 50); the press bolt's M12 nut in a pocket slid in from the front, 3 mm above the beam (the bolt's thrust goes straight into the beam).""" s = bx(-CAGE_IN + 0.5, CAGE_IN - 0.5, 0, 20, 0, CAGE_D) s = s.cut(_ycyl(6.5, -1, 21)) s = s.cut(_hex_pocket(3.0, 3.0 + NUT12[1])) return s def _hex_pocket(y0, y1, x=0.0, zc_=CAGE_D / 2): """An M12 nut's pocket round the press axis between y0 and y1, flats normal to x, run out of the front (z = CAGE_D).""" af = NUT12[0] h = cq.Workplane('XZ', origin=(0, y1, 0)).polyline(_hex_pts(af, x, zc_)).close().extrude(y1 - y0) return h.union(bx(x - af / 2, x + af / 2, y0, y1, zc_, CAGE_D + 1)) def press_slider(): """PETG: rides on the press bolt's tip (an M12 washer in the Ø24.5 recess underneath), 73 wide so the walls keep it square; the tab out of the front is for the dial indicator's tip.""" s = bx(-CAGE_IN + 0.5, CAGE_IN - 0.5, 0, 10, 0, CAGE_D) s = s.cut(_ycyl(12.25, -1, 2.5)) s = s.union(bx(20, 34, 0, 10, CAGE_D - 1, CAGE_D + 20)) return s def sleeve_block(): """PA6-CF: an L standing on the slider against the left wall: the upright (x -36.5 to -10, 40 tall) holds a stop post in an M8 insert (Ø9.6 x 16, as the hip frame) on its +x face, 25 mm up, so the post's 20 mm shoulder lies across the press axis with its TPU sleeve centred on it; the foot runs under the sleeve to x +25 so the anvil's push lands inside the block's footprint.""" up = bx(-CAGE_IN + 0.5, -10.0, 0, 40, 5, CAGE_D - 5) foot = bx(-10.0, 25.0, 0, 10, 5, CAGE_D - 5) s = up.union(foot) s = s.cut(cq.Workplane('YZ', origin=(-10.0 + 0.01, 0, 0)).center(25.0, CAGE_D / 2).circle(4.8).extrude(-16.0)) return s def sleeve_anvil(): """PA6-CF: a 30 x 30 flat face (like the upper link's edge) pressed onto the sleeve; on top, a Ø20 x 13 socket for the head of the M12 x 30 that hangs it from the cell's lower thread. Printed face down.""" s = bx(-15, 15, 0, 18, CAGE_D / 2 - 15, CAGE_D / 2 + 15) s = s.cut(_ycyl(10.0, 18 - 13.0, 19)) return s def puller(size: str): """PA6-CF, printed with the insert's axis along z as in the hip frame (insert face up on the bed's far side). In the cage it hangs insert-down from the M12 x 80 stud: the stud's nut in a pocket slid in from the side, the wings (73 wide) against the side walls take the test screw's torque. M5: Ø6.4 x 11 pilot; M8: Ø9.6 x 16.""" pilot, depth, clear = {'M5': (6.4, 11.0, 5.5), 'M8': (9.6, 16.0, 8.5)}[size] H = PULLER_H s = bx(-15, 15, -15, 15, 0, H).union(bx(-CAGE_IN + 0.5, CAGE_IN - 0.5, -15, 15, 0, 10)) s = s.cut(zc(6.25, -1, 8.8)) # the stud's way in nut = cq.Workplane('XY').workplane(offset=8.8).polyline(_hex_pts(NUT12[0], 0, 0)).close().extrude(NUT12[1]) nut = nut.union(bx(-NUT12[0] / 2, NUT12[0] / 2, 0, 16, 8.8, 8.8 + NUT12[1])) # slid in from +y s = s.cut(nut) s = s.cut(zc(6.25, 8.8 + NUT12[1] - 0.1, 34.0)) # the stud's end, below the nut s = s.cut(zc(pilot / 2, H - depth, H + 1)).cut(zc(clear / 2, 38.0 if size == 'M5' else 36.0, H - depth + 0.1)) return s def bearing_disc(): """PA6-CF, B4: the upper link's material under an M5 head (Ø20 x 6, Ø5.5), printed flat as the link's outer face; in the cage it sits on an M6 oversized washer, as the link sits on the adapter's face.""" return zc(10.0, 0, 6.0).cut(zc(gmi.clear('M5') / 2, -1, 7)) def cage_stack(): """The B3 and B4 heights in the frame's coordinates (mm), for the doc and the checks.""" head_engaged = 15.0 # M12 x 30 into the cell, assumed cell_low = Y_CELL0 shcs_head_low = cell_low - (30.0 - head_engaged) - 12.0 # M12 SHCS head: 18 x 12 post_axis = 52.0 + 10.0 + 25.0 # base top 52, slider 10, insert 25 up od = fb.TPU_SLEEVE[0] anvil_face = post_axis + od / 2 socket_floor = anvil_face + 18.0 - 13.0 stud_end = cell_low + head_engaged - 80.0 insert_face = Y_WIN0 + PULLER_GAP nut_low = insert_face + PULLER_H - 8.8 - NUT12[1] roof = CBORE_UNDER[1] return {'cell': (cell_low, Y_WIN1), 'b3_slack_mm': round(shcs_head_low - socket_floor, 1), 'b3_sleeve_od': od, 'b4_stud_end': stud_end, 'b4_nut': (nut_low, nut_low + NUT12[1]), 'b4_nut_engaged': stud_end <= nut_low, 'b4_insert_face': insert_face, 'b4_reach': {'M5 x 40 + 1.6 washer': round(roof - 1.6 + 40 - insert_face, 1), 'M5 x 40 + 6 disc + 1.6 washer': round(roof - 7.6 + 40 - insert_face, 1), 'M8 x 40 + 2.4 washer': round(roof - 2.4 + 40 - insert_face, 1)}} def _steel_cyl(d, y0, y1, x=0.0): return _ycyl(d / 2, y0, y1, x) def _hex_y(af, y0, y1): return cq.Workplane('XZ', origin=(0, y1, 0)).polyline(_hex_pts(af, 0, CAGE_D / 2)).close().extrude(y1 - y0) def press_scenes() -> dict: """The press cage set up for B4 (an M5 insert under test) and for B3 (a stop sleeve), in the frame's coordinates, bought parts as simple stand-ins: {scene: [(name, shape, colour)]}.""" PETG, CF, TPU, STEEL, CELLC, BRASS = (0.93, 0.93, 0.9), (0.22, 0.22, 0.24), (0.95, 0.55, 0.15), (0.62, 0.64, 0.68), (0.35, 0.47, 0.62), (0.82, 0.66, 0.3) st = cage_stack() c0, c1 = st['cell'] cell = bx(-CELL['t'] / 2, CELL['t'] / 2, c0, c1, CAGE_D / 2 - CELL['w'] / 2, CAGE_D / 2 + CELL['w'] / 2) for sx, yy in ((1, c0 + 22), (-1, c1 - 22)): # the S's two slots za, zb = CAGE_D / 2 - sx * (CELL['w'] / 2 + 1), CAGE_D / 2 + sx * 10 cell = cell.cut(bx(-CELL['t'] / 2 - 1, CELL['t'] / 2 + 1, yy - 2.5, yy + 2.5, min(za, zb), max(za, zb))) top_screw = _steel_cyl(12, c1 - 15, CAGE_H - CBORE_TOP[1]).union(_steel_cyl(18, CAGE_H - CBORE_TOP[1], CAGE_H - CBORE_TOP[1] + 12)) common = [('press_cage', press_cage(), PETG), ('load cell', cell, CELLC), ('M12 x 30 (top)', top_screw, STEEL)] # B4: the puller hung on the stud, an M5 x 40 and its washer from below ins = st['b4_insert_face'] pul = puller('M5').rotate((0, 0, 0), (1, 0, 0), 90).translate((0, ins + PULLER_H, CAGE_D / 2)) stud = _steel_cyl(12, st['b4_stud_end'], st['b4_stud_end'] + 80) nut = _hex_y(NUT12[0] - 0.4, st['b4_nut'][0] + 0.2, st['b4_nut'][1] - 0.2).cut(_steel_cyl(12, 0, CAGE_H)) roof = CBORE_UNDER[1] washer = _steel_cyl(18, roof - 1.6, roof).cut(_steel_cyl(6.4, 0, CAGE_H)) screw = _steel_cyl(5, roof - 1.6, roof - 1.6 + 40).union(_steel_cyl(8.5, roof - 6.6, roof - 1.6)) insert = _steel_cyl(6.4, ins, ins + 7.9).cut(_steel_cyl(5, 0, CAGE_H)) b4 = common + [('puller (PA6-CF)', pul, CF), ('M12 x 80 stud', stud, STEEL), ('M12 nut', nut, STEEL), ('M5 insert', insert, BRASS), ('M5 x 40 under test', screw, STEEL), ('washer', washer, STEEL)] # B3: base, bolt, slider, block with the post and its sleeve, the anvil on the M12 x 30 in the cell's lower thread od = fb.TPU_SLEEVE[0] y_slider, y_block = 52.0, 62.0 axis = y_block + 25.0 anvil_y = axis + od / 2 low_screw = _steel_cyl(12, c0 - 15, c0 + 15).union(_steel_cyl(18, c0 - 27, c0 - 15)) bolt = _steel_cyl(12, y_slider - 80, y_slider).union(_hex_y(18, y_slider - 87.5, y_slider - 80)) nut3 = _hex_y(NUT12[0] - 0.4, 3.2 + Y_WIN0, 3.0 + NUT12[1] - 0.2 + Y_WIN0).cut(_steel_cyl(12, 0, CAGE_H)) post = (cq.Workplane('YZ', origin=(-23.0, 0, 0)).center(axis, CAGE_D / 2).circle(4.0).extrude(13.0) .union(cq.Workplane('YZ', origin=(-10.0, 0, 0)).center(axis, CAGE_D / 2).circle(5.0).extrude(20.0)) .union(cq.Workplane('YZ', origin=(10.0, 0, 0)).center(axis, CAGE_D / 2).circle(8.0).extrude(8.0))) sleeve = (cq.Workplane('YZ', origin=(-8.0, 0, 0)).center(axis, CAGE_D / 2).circle(od / 2).circle(5.0).extrude(16.0)) b3 = common + [('press_base', press_base().translate((0, Y_WIN0, 0)), PETG), ('M12 nut', nut3, STEEL), ('M12 x 80 press bolt', bolt, STEEL), ('press_slider', press_slider().translate((0, y_slider, 0)), PETG), ('sleeve_block', sleeve_block().translate((0, y_block, 0)), CF), ('stop post', post, STEEL), ('TPU sleeve', sleeve, TPU), ('sleeve_anvil', sleeve_anvil().translate((0, anvil_y, 0)), CF), ('M12 x 30 (lower)', low_screw, STEEL)] return {'b4': b4, 'b3': b3} def render_setups() -> list: """exports/rig/bench/press-b4.png and press-b3.png: the press axis up, seen through the open front of the window.""" from cadagent.render import Renderer r = Renderer(OUT, size=(1100, 1300), subtitle='GYROPUP LEG RIG | BENCH') out = [] captions = {'b4': ('B4: an insert under test', 'The cell hangs from the top beam; the screw under test comes up into the puller'), 'b3': ('B3: a stop sleeve', 'The press bolt lifts the slider; the sleeve meets the anvil hung from the cell')} for k, items in press_scenes().items(): shapes = [((sh.rotate((0, 0, 0), (1, 0, 0), 90)).val(), col) for _, sh, col in items] f = f'press-{k}.png' r.render(f, shapes=shapes, view=(0.45, -1.0, 0.3), caption=captions[k][0], note=captions[k][1], zoom=0.95) out.append(OUT / f) return out # ----------------------------------------------------------------------------------- fit coupons (PA6-CF) def coupon_frame_ring(dv: float): """The hip frame round one motor, the part next to the leg: the 61812's lead-in from the motor side, its seat (Ø78 + dv, 10 mm) and the lip (Ø73) it stops on. The nominal one is the frame's whole lug ring (Ø124) with the 10 M4 lug holes counterbored as in the frame and the two Ø5 dowel holes, so a motor bolts on; the -0.1 / +0.1 variants are the seat in a thin ring. Printed lip side up (the frame prints web-down too).""" yf1 = fb.Y['frame'][1] yb0, yb1 = fb.Y['bearing'] z0 = yb0 - 2.0 h = yf1 - z0 ring = 62.0 if dv == 0 else fb.AC['bearing_od'] / 2 + 6.0 s = zc(ring, 0, h) s = s.cut(zc(fb.AC['bearing_od'] / 2 + 0.3, -1, yb0 - z0)) s = s.cut(zc(fb.AC['bearing_od'] / 2 + dv / 2, yb0 - z0 - 0.01, yb1 - z0)) s = s.cut(zc(fb.AC['lip_d'] / 2, yb1 - z0 - 0.01, h + 1)) if dv == 0: b = MI['case']['bolts'] for a in fb.lug_angles(True): x, y = b['pcd'] / 2 * math.cos(math.radians(a)), b['pcd'] / 2 * math.sin(math.radians(a)) s = s.cut(zc(gmi.clear('M4') / 2, -1, h + 1, x, y)) for a in fb.dowel_angles(True): x, y = b['pcd'] / 2 * math.cos(math.radians(a)), b['pcd'] / 2 * math.sin(math.radians(a)) s = s.cut(zc(2.5 - 0.03, -1, h + 1, x, y)) return engrave(s, label(dv), 0, -(fb.AC['lip_d'] / 2 + (5.5 if dv == 0 else 1.6)), h, 3.0) def coupon_hub_face(dv: float): """The upper link's hub against the machined adapter (D46): the Ø40.1 + dv spigot recess (3.3 deep), 8 x M5 clearance and 2 x Ø5 dowel holes on PCD 50 at D46's angles. Printed outer face down, as the link.""" t = 6.0 s = zc(fb.UPPER_HUB_R, 0, t) s = s.cut(zc((D46_SPIGOT_RECESS + dv) / 2, t - 3.3, t + 1)) for (x, y) in pts(50.0, D46_BOLTS_DEG): s = s.cut(zc(gmi.clear('M5') / 2, -1, t + 1, x, y)) for (x, y) in pts(50.0, D46_DOWELS_DEG): s = s.cut(zc(2.5 + 0.02 + dv / 2, -1, t + 1, x, y)) return engrave(s, label(dv), 0, 0, t - 3.3, 4) def coupon_knee_eye(dv: float): """The upper link's knee eye: one DIN 179 12 x 18 x 20 sleeve pressed into Ø(18 - 0.04 + dv), 22 mm of boss.""" s = zc(fb.UPPER_EYE_R, 0, 22.0).union(bx(-fb.UPPER_EYE_R, 0, -14, 14, 0, 22.0)) s = s.cut(zc(fb.EYE_SLEEVE[0] / 2 - 0.02 + dv / 2, -1, 23)) return engrave(s, label(dv), -13.0, 0, 22.0, 4) def coupon_knee_boss(dv: float): """A lower link's knee boss: a 6201 seat (Ø32.04 + dv, 10 mm) on the Ø27 web, Ø46 outside.""" bo = fb.KC['bearing_od'] s = zc(fb.KC['hub_od'] / 2, 0, 12.0) s = s.cut(zc(bo / 2 + 0.02 + dv / 2, 2.0, 13)).cut(zc(fb.KC['shoulder_d'] / 2, -1, 3)) return engrave(s.union(bx(fb.KC['hub_od'] / 2 - 3, fb.KC['hub_od'] / 2 + 12, -7, 7, 0, 6)), label(dv), fb.KC['hub_od'] / 2 + 5.5, 0, 6, 3.5) def coupon_apex_eye(dv: float): """The front link's apex eye: a 61812 seat (Ø78.04 + dv, 10 mm) against the Ø72 web, Ø90 outside.""" ao = fb.AC['bearing_od'] s = zc(ao / 2 + 6.0, 0, 13.0) s = s.cut(zc(ao / 2 + 0.02 + dv / 2, 3.0, 14)).cut(zc(36.0, -1, 4)) return engrave(s, label(dv), 0, -(ao / 2 + 3.0), 13.0, 3.0) def coupon_hub_stub(dv: float): """The wheel link's hub: the Ø60 + dv journal for a 61812's inner race against the Ø64 shoulder, the DIN 471-60 groove (Ø57 x 2.15) at the journal's end, the Ø48 bore. Printed shoulder down, as the wheel link.""" y0, y1 = fb.Y['circlip'] s = zc(32.0, 0, 4.0).union(zc(30.0 + dv / 2, 4.0, 4.0 + 13.0 + 3.0 + 3.0)) top = 4.0 + 13.0 + 3.0 + 3.0 g0 = top - 3.0 - (y1 - y0) # the groove 3 mm from the end (the hub's land) s = s.cut(zc(31.0, g0, g0 + (y1 - y0)).cut(zc(28.5, g0 - 1, g0 + (y1 - y0) + 1))) s = s.cut(zc(24.0, -1, top + 1)) return engrave(s, label(dv), 0, -28.0, 4.0, 3.0) # ----------------------------------------------------------------------------------- the list FIXTURES = { # name: (builder, material, qty, note) 'dyno_lug_plate': (dyno_lug_plate, 'petg', 2, 'PETG, 6 walls, 60 % gyroid; on a 19 mm plywood board, 4 x M6 through bolts each (B1, B2)'), 'dyno_hub': (dyno_hub, 'petg', 2, 'PETG, 100 %; 9 x M5 x 25 into the output (the leg\'s D46 screw), 3 pin sockets'), 'dyno_spider': (dyno_spider, 'tpu95', 2, 'TPU 95A, 100 %; one spare'), 'press_cage': (press_cage, 'petg', 1, 'PETG, 6 walls, 40 % gyroid; flat (B3, B4)'), 'press_base': (press_base, 'petg', 1, 'PETG, 6 walls, 40 % gyroid (B3)'), 'press_slider': (press_slider, 'petg', 1, 'PETG, 6 walls, 40 % gyroid (B3)'), 'sleeve_block': (sleeve_block, 'pa6-cf', 1, 'PA6-CF, 100 %; an M8 insert, a real stop post and TPU sleeve (B3)'), 'sleeve_anvil': (sleeve_anvil, 'pa6-cf', 1, 'PA6-CF, 100 %, face down (B3)'), 'puller_m5': (lambda: puller('M5'), 'pa6-cf', 3, 'PA6-CF, 6 walls, 60 % gyroid, insert face up (B4: two to 3.5 kN, one for the head test)'), 'puller_m8': (lambda: puller('M8'), 'pa6-cf', 1, 'PA6-CF, 6 walls, 60 % gyroid, insert face up (B4)'), 'bearing_disc': (bearing_disc, 'pa6-cf', 3, 'PA6-CF, 100 %, flat (B4: the link under an M5 head)'), } COUPONS = {'coupon_frame_ring': coupon_frame_ring, 'coupon_hub_face': coupon_hub_face, 'coupon_knee_eye': coupon_knee_eye, 'coupon_knee_boss': coupon_knee_boss, 'coupon_apex_eye': coupon_apex_eye, 'coupon_hub_stub': coupon_hub_stub} def parts() -> dict: out = {} for name, (fn, mat, qty, note) in FIXTURES.items(): out[name] = (fn(), mat, qty, note) for name, fn in COUPONS.items(): for dv in VARIANTS: tag = {-0.1: 'm01', 0.0: 'nom', 0.1: 'p01'}[dv] out[f'{name}_{tag}'] = (fn(dv), 'pa6-cf', 1, f'PA6-CF, 100 %, dried; the seat at {label(dv)} mm on the leg\'s') return out def main(): if '--render' in sys.argv: for f in render_setups(): print(f.relative_to(R)) return from cadagent.geometry import export_print_stl OUT.mkdir(parents=True, exist_ok=True) mats = json.loads((R / 'catalog/materials.json').read_text()) plan, report = {}, {} for name, (shape, mat, qty, note) in parts().items(): s = shape.val() cq.exporters.export(s, str(OUT / f'{name}.step')) rep = export_print_stl(s, OUT / f'{name}.stl') g = s.Volume() / 1000 * mats[mat]['density_g_cm3'] * (1.0 if '100 %' in note else 0.6) plan[name] = printplan.row(s, None, mat, qty, g, '100 %' in note, note) report[name] = {'valid': s.isValid(), 'solids': len(shape.solids().vals()), 'watertight': rep.get('watertight'), 'fits': plan[name]['fits'], 'grams': plan[name]['grams']} too_big = printplan.write(OUT / 'print-plan.json', plan, note='bench fixtures and fit coupons (task T4)') stack = cage_stack() (OUT / 'bench.json').write_text(json.dumps({'parts': report, 'too_big': too_big, 'variants_mm': list(VARIANTS), 'press_cage': stack, 'd46_face': {'bolts_deg': D46_BOLTS_DEG, 'dowels_deg': D46_DOWELS_DEG, 'spigot_recess': D46_SPIGOT_RECESS}}, indent=1) + '\n') bad = [n for n, r in report.items() if not (r['valid'] and r['solids'] == 1 and r['fits'] and r['watertight'] is not False)] tot = json.loads((OUT / 'print-plan.json').read_text()) print(f"bench: {len(report)} parts, {tot['total_hours']} h, {tot['total_grams']} g; problems: {bad or 'none'}") print(f" press cage: {stack}") for f in render_setups(): print(f' {f.relative_to(R)}') for n, r in report.items(): print(f" {n:24} {r['grams']:5d} g valid {r['valid']} solids {r['solids']} fits {r['fits']}") if __name__ == '__main__': main()