"""The body's frame (milestone M5, task T2): the parts that carry both hip modules, the compute, the battery and the power skid, and the deck that carries the lidar and the turret. Robot frame (mm), see cad/body_params.py. import body_frame as bf parts = bf.frame_parts(layout_mounts) # {name: Part}: SendCutSend sheet, printed, bought (envelopes) asm = bf.assembled(parts) # {name: (shape in the robot frame, kind, colour)} The spine: two identical C-channel cheeks (SendCutSend 5052-H32 3/16 in, two bends, eight PEM SS-M5-0 nuts each), held 31 mm apart by eight M4 x 31 hex standoffs in the hip frames' bolt rows (M4 flat heads flush in countersinks on the frame side). Each hip frame bolts to its own cheek's outer face with its six M5 inserts (M5 x 12 ISO 7380 button heads from inside the gap, 3 mm hex, 3 N m). The floor tray (5052-H32 0.100 in, 15 mm lips down) lies on the cheeks' upper flanges, the belly plate (6061-T6 0.100 in) under their lower flanges; with the standoffs that makes a closed box between the legs. The deck (5052-H32 0.100 in, lips down) stands on four printed PA6-CF posts over the tray; the compute pallet (6061-T6 0.125 in, countersunk) sits on four printed TPU isolators on the tray; the power plate on four printed posts; the turret's riser (printed PA6-CF) on the deck. """ from __future__ import annotations import functools import json import math import os from dataclasses import dataclass, field import cadquery as cq import body_params as bp import body_sheet as bs T5 = bp.STOCK[bp.CHEEK]['t'] # cheek thickness GAP_Y = bp.SPACER_L / 2 # the cheeks' inner (gap-side) faces at y = +-GAP_Y FACE_Y = bp.SPINE_W / 2 # their outer faces, where the hip frames bear ZT = bp.z_spine_top() # the cheeks' flange outer faces: z = +-ZT CHEEK_H = 2 * ZT CHEEK_L = bp.SPINE_X[1] - bp.SPINE_X[0] PEM_W = None # set below: the flange nuts' distance from the gap-side face @dataclass class Part: name: str kind: str # 'sheet' | 'printed' | 'bought' shape: object # in the robot frame qty: int = 1 sheet: bs.SheetPart = None # sheet parts: the definition (flat pattern, order, checks) local: object = None # sheet parts: the formed solid in the part's own frame material: str = '' mass_g: float = None note: str = '' colour: tuple = (0.6, 0.6, 0.6) print_rotation: tuple = None # printed parts: rotation onto the bed (axis, deg) stage: str = 'P1' # P0 skid, P1 open frame, P2 head, P3 shell: the ledger counts a part from its stage on until: str = None # the last stage it is on the robot (the PETG bay until P2: the P3 tub replaces it) # ------------------------------------------------------------------------------------------- helpers def box(x0, x1, y0, y1, z0, z1): (x0, x1), (y0, y1), (z0, z1) = sorted((x0, x1)), sorted((y0, y1)), sorted((z0, z1)) return cq.Workplane('XY').box(x1 - x0, y1 - y0, z1 - z0, centered=False).translate((x0, y0, z0)) def cyl_z(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 cyl_y(r, y0, y1, x=0.0, z=0.0): return cq.Workplane('XZ', origin=(0, y1, 0)).center(x, z).circle(r).extrude(y1 - y0) def hexagon_z(af, z0, z1, x=0.0, y=0.0): return cq.Workplane('XY').workplane(offset=z0).center(x, y).polygon(6, af / math.cos(math.pi / 6)).extrude(z1 - z0) def hexagon_y(af, y0, y1, x=0.0, z=0.0): return cq.Workplane('XZ', origin=(0, y1, 0)).center(x, z).polygon(6, af / math.cos(math.pi / 6)).extrude(y1 - y0) def button_head_y(d, length, y_face, direction, x, z): """An ISO 7380 button head screw along y: the head's underside on y_face, the shank going `direction` (+1/-1).""" head_d, head_h = {3: (5.7, 1.65), 4: (7.6, 2.2), 5: (9.5, 2.75), 6: (10.5, 3.3)}[int(d)] s = direction head = cyl_y(head_d / 2, min(y_face, y_face - s * head_h), max(y_face, y_face - s * head_h), x, z) shank = cyl_y(d / 2, min(y_face, y_face + s * length), max(y_face, y_face + s * length), x, z) return head.union(shank) def button_head_z(d, length, z_face, direction, x, y): head_d, head_h = {3: (5.7, 1.65), 4: (7.6, 2.2), 5: (9.5, 2.75), 6: (10.5, 3.3)}[int(d)] s = direction head = cyl_z(head_d / 2, min(z_face, z_face - s * head_h), max(z_face, z_face - s * head_h), x, y) shank = cyl_z(d / 2, min(z_face, z_face + s * length), max(z_face, z_face + s * length), x, y) return head.union(shank) # ------------------------------------------------------------------------------------------- the cheeks (spine) def cheek_to_part(x, z): """Left cheek, robot (x, z) -> part (u, v).""" return (bp.SPINE_X[1] - x, z + ZT) def place_cheek(shape, side='left'): """Part frame (base outer face z = 0 is the gap-side face; flanges towards +z = outwards) -> robot frame.""" s = shape.rotate((0, 0, 0), (1, 0, 0), 90).rotate((0, 0, 0), (0, 0, 1), 180).translate((bp.SPINE_X[1], GAP_Y, -ZT)) return s if side == 'left' else s.rotate((0, 0, 0), (0, 0, 1), 180) def pem_w(stock=bp.CHEEK, spec='SS-M5-0'): """Where a flange's PEM nut goes (OML distance from the base's outer face): half a die from the bend's centreline (hole edge), N from the bend area, and K from the free edge (the flange is long enough for both).""" s, P = bp.STOCK[stock], bp.PEM[spec] lo = max(s['ossb'] + (s['half_die'] - s['ba'] / 2) + P['H'] / 2, s['ossb'] + P['N']) hi = bp.CHEEK_FLANGE - P['K'] if lo > hi: raise ValueError(f'flange {bp.CHEEK_FLANGE} mm too short for {spec}: needs {lo:.2f}..{hi:.2f}') return round((lo + hi) / 2, 2) PEM_W = pem_w() PEM_Y = GAP_Y + PEM_W # robot |y| of the flange nuts (and of the tray's and belly's screws) FLANGE_NUT_X = (-62.0, -20.0, 20.0, 62.0) # clear of the frame's insert bosses at x = 0, +-83 (12.5 mm round # each) and K from the cheek's ends # the standoffs stand in the hip frames' bolt rows (z = +-67.5, 2.5 mm inside the bolts' +-70), beside the bolts (x 0 and # +-83): each leg's roll moment reaches its cheek as a push at one bolt row and a pull at the other, and the standoffs # carry it straight across to the # other frame in compression and tension instead of bending the cheeks' webs. cad/body_studies.py S1 at the rig's loads # on the body (2026-10-27, 3/16 in cheeks): this layout SF 1.96 (2.29 away from the standoffs' bonded ends); three at # z +-40..45 (x 0, +-80) 0.92 (2.67 away: their ends take the bolt rows' load); none 1.33. The frame screw at x 0 has # 1.2 mm between its head and the hexes either side: the key's short arm goes in between SPACER_HEX = 6.0 # McMaster 95947A065 (M4 x 31, 6 mm hex) SPACERS_XZ = [(10.0, 67.5), (-10.0, 67.5), (72.0, 67.5), (-72.0, 67.5), (10.0, -67.5), (-10.0, -67.5), (72.0, -67.5), (-72.0, -67.5)] if os.environ.get('GYROPUP_BODY_SPACERS'): # a study can try another layout (cad/body_studies.py) SPACERS_XZ = [tuple(p) for p in json.loads(os.environ['GYROPUP_BODY_SPACERS'])] def harness_windows(): """Where each RS-04's harness leaves its motor (left leg, robot x-z): the leg's own clocking (fivebar.harness_angle: the grommet, a radial exit at r 58 near the rear cover, points out nearest level, the front motor forwards and the rear one backwards). Both now leave past the cheek's ends, so they need no window: each lead turns in round the cheek's end into the spine's gap (the cable chase) and up through the tray's slot. The right leg is the left one turned 180 deg about z, so its exits are these with x negated. [(name, (x, z), angle)]""" fb = bp._fivebar() out = [] for (mx, front) in ((fb.motors()[0][0], True), (fb.motors()[1][0], False)): a = fb.harness_angle(front) ex = (mx + RS04_EXIT_R * math.cos(math.radians(a)), RS04_EXIT_R * math.sin(math.radians(a))) out.append(('rs04_front' if front else 'rs04_rear', ex, a)) return out RS04_EXIT_R = 58.0 # the harness grommet's radius from the motor axis (cad/fivebar.py RS04_HARNESS) def cheek_windows(): """(name, x0, x1, z0, z1, corner r) of the cheek's windows, left cheek, robot frame; sized round the exits and kept clear of the frame's bearing faces (|z| 60..74 within |x| <= 95), half a die from the flanges' bends, and a thickness plus 2 mm inside the cheek's ends (a window is shifted along x, not cut short).""" s = bp.STOCK[bp.CHEEK] end = s['t'] + 2.0 out = [('wheel_harness', -20.0, 20.0, -25.0, 25.0, 6.0)] for name, (ex, ez), a in harness_windows(): if ex + 6.0 >= bp.SPINE_X[1] or ex - 6.0 <= bp.SPINE_X[0]: # past the cheek's end: the harness drops beside it continue x0, x1 = ex - 16.0, ex + 16.0 if x1 > bp.SPINE_X[1] - end: x0, x1 = x0 - (x1 - (bp.SPINE_X[1] - end)), bp.SPINE_X[1] - end if x0 < bp.SPINE_X[0] + end: x0, x1 = bp.SPINE_X[0] + end, x1 + (bp.SPINE_X[0] + end - x0) if ez < 0: # going down: a window above the frame's lower bearing face z0, z1 = max(-57.0, ez - 9.0), ez + 15.0 else: # going up under the upper flange: the window stops below the flange's bearing face z0, z1 = ez - 15.0, min(57.0, ez + 9.0) out.append((name, round(x0, 1), round(x1, 1), round(z0, 1), round(z1, 1), 5.0)) return out def cheek_part() -> bs.SheetPart: """One C-channel cheek (CHEEK_L x CHEEK_H OML, two CHEEK_FLANGE flanges outwards): holes for the hip frame's six inserts, countersinks for the standoffs, the harness windows; SS-M5-0 nuts in both flanges for the tray and the belly.""" feats = [] m = bp.frame_mounts() for x, z in m['holes']: feats.append(bs.Feature('hole', 'base', cheek_to_part(x, z), 5.5, note='hip frame insert, M5 x 12 ISO 7380 from the gap')) for x, z in SPACERS_XZ: # countersunk on the frame side: the heads sit flush under the motors' covers feats.append(bs.Feature('csk', 'base', cheek_to_part(x, z), 4.5, spec='M4', side='z1', note='M4 x 31 hex standoff, M4 x 10 flat head')) for name, x0, x1, z0, z1, r in cheek_windows(): u0, v0 = cheek_to_part(x1, z0) u1, v1 = cheek_to_part(x0, z1) feats.append(bs.Feature('slot', 'base', ((u0 + u1) / 2, (v0 + v1) / 2), size=(u1 - u0, v1 - v0, r), note=name)) for x in FLANGE_NUT_X: for edge in ('N', 'S'): feats.append(bs.Feature('pem', edge, (bp.SPINE_X[1] - x, PEM_W), bp.PEM['SS-M5-0']['H'], spec='SS-M5-0', note='floor tray' if edge == 'N' else 'belly plate')) return bs.SheetPart('cheek', bp.CHEEK, CHEEK_L, CHEEK_H, flanges=[bs.Flange('S', bp.CHEEK_FLANGE), bs.Flange('N', bp.CHEEK_FLANGE)], features=feats, qty=2, note='one part for both sides (the right cheek is the left one turned 180 deg about z); ' 'bends both 90 deg the same way; PEM SS-M5-0 pressed from the flanges\' inner (frame) side') # ------------------------------------------------------------------------------------------- tray, belly, deck, pallet def place_tray(shape, z_top): """A tray-like part (flanges towards +z in its frame) upside down with its base's outer (top) face at z_top, its part (u, v) = (x + 160, 127 - y).""" return shape.rotate((0, 0, 0), (1, 0, 0), 180).translate((bp.BODY_X[0], bp.BODY_HALF_Y, z_top)) def tray_uv(x, y): return (x - bp.BODY_X[0], bp.BODY_HALF_Y - y) def tray_part(mounts=None) -> bs.SheetPart: """The floor tray: 320 x 254, 15 mm lips down; screws into the cheeks' upper flange nuts; the posts' screws; the holes the layout asks for (mounts['tray']: [(x, y, d, note) | ('slot', x, y, lx, ly, r, note) | ('pem', x, y, spec, note)]).""" feats = [] for x in FLANGE_NUT_X: for s in (1, -1): feats.append(bs.Feature('hole', 'base', tray_uv(x, s * PEM_Y), 5.5, note='M5 x 10 ISO 7380 into the cheek flange nut')) for (x, y) in bp.POSTS: feats.append(bs.Feature('hole', 'base', tray_uv(x, y), 5.5, note='post, M5 x 12 ISO 7380 from below')) feats += _mount_features((mounts or {}).get('tray', []), tray_uv) return bs.SheetPart('floor_tray', bp.TRAY, bp.BODY_X[1] - bp.BODY_X[0], 2 * bp.BODY_HALF_Y, flanges=[bs.Flange(e, bp.TRAY_LIP) for e in ('S', 'N', 'W', 'E')], features=feats, note='lips 15 mm down all round, open corners with round reliefs') def _mount_features(rows, uv): out = [] for r in rows: if r[0] == 'slot': _, x, y, lx, ly, rad, note = r u, v = uv(x, y) out.append(bs.Feature('slot', 'base', (u, v), size=(lx, ly, rad), note=note)) elif r[0] == 'pem': _, x, y, spec, note = r out.append(bs.Feature('pem', 'base', uv(x, y), bp.PEM[spec]['H'], spec=spec, note=note)) elif r[0] == 'csk': _, x, y, spec, d, note = r out.append(bs.Feature('csk', 'base', uv(x, y), d, spec=spec, note=note)) else: x, y, d, note = r out.append(bs.Feature('hole', 'base', uv(x, y), d, note=note)) return out def belly_uv(x, y): return (x - bp.BODY_X[0], bp.BELLY_HALF_Y - y) def place_belly(shape): """Flat part: part (u, v, 0..t) -> robot, its top face (part z = 0) against the cheeks' lower flanges.""" return shape.rotate((0, 0, 0), (1, 0, 0), 180).translate((bp.BODY_X[0], bp.BELLY_HALF_Y, -ZT)) def belly_part(mounts=None) -> bs.SheetPart: feats = [] for x in FLANGE_NUT_X: for s in (1, -1): feats.append(bs.Feature('hole', 'base', belly_uv(x, s * PEM_Y), 5.5, note='M5 x 10 ISO 7380 up into the cheek flange nut')) feats += _mount_features((mounts or {}).get('belly', []), belly_uv) return bs.SheetPart('belly_plate', bp.BELLY, bp.BODY_X[1] - bp.BODY_X[0], 2 * bp.BELLY_HALF_Y, features=feats, note='flat; the power skid hangs under it (the plate is the VESCs\' heat sink)') def deck_part(mounts=None) -> bs.SheetPart: """The deck: 320 x 254, 25 mm lips down; the posts, the lidar (1/4-20 + two Ø4.06 pins), the riser's four screws, the fan's intake field inside the riser, the turret harness and lidar cable passes.""" feats = [] for (x, y) in bp.POSTS: feats.append(bs.Feature('hole', 'base', tray_uv(x, y), 5.5, note='post, M5 x 12 ISO 7380 from above')) lid = bp.lidar() feats.append(bs.Feature('hole', 'base', tray_uv(lid['x'], 0.0), lid['centre_clear_d'], note='VLP-16 1/4-20 x 3/8 in from below')) for (x, y) in lid['pins']: feats.append(bs.Feature('hole', 'base', tray_uv(x, y), 3.95, note='VLP-16 locating pin 5/32 in (ream to a light press)')) t = bp.tm() for (x, y) in RISER_FEET: feats.append(bs.Feature('hole', 'base', tray_uv(t['pan_x'] + x, y), 5.5, note='riser, M5 x 16 from below through the turret plate (D59) into its insert')) for (x, y) in turret_plate_end_holes(): feats.append(bs.Feature('hole', 'base', tray_uv(x, y), 5.5, note='the turret plate\'s ends (P2): M5 x 10 down into its PEM nuts')) for (x, y) in intake_cells(): feats.append(bs.Feature('slot', 'base', tray_uv(x, y), size=(INTAKE_CELL, INTAKE_CELL, 1.5), note='fan intake')) feats += _mount_features((mounts or {}).get('deck', []), tray_uv) return bs.SheetPart('deck', bp.DECK, bp.BODY_X[1] - bp.BODY_X[0], 2 * bp.BODY_HALF_Y, flanges=[bs.Flange(e, bp.DECK_LIP) for e in ('S', 'N', 'W', 'E')], features=feats, note='lips 25 mm down all round (its stiffness: the front cantilevers past the front posts)') INTAKE_CELL = 8.0 # square cells, 3 mm webs: a child's finger does not reach the fan 45 mm below INTAKE_PITCH = 11.0 INTAKE_R = round((bp.j501().get('fan') or {}).get('blade_diameter', 88.0) / 2 + 2.0, 1) # the field round the J501 fan's axis: its blades + 2 mm RISER_FEET = [(40.0, 40.0), (-40.0, 40.0), (-40.0, -40.0), (40.0, -40.0)] # under the TM bolts (turret.TM_BOLTS) def intake_cells(): """The fan's intake field in the deck (robot x, y): square cells on a grid centred on the fan's axis, within INTAKE_R of it, under the riser's ring (12 mm inside its edge) and clear of the riser's feet.""" t = bp.tm() fx, fy = bp.j501_stack()['fan_xy'] out = [] n = int(INTAKE_R // INTAKE_PITCH) + 1 half = INTAKE_CELL * 0.71 for i in range(-n, n + 1): for j in range(-n, n + 1): x, y = fx + i * INTAKE_PITCH, fy + j * INTAKE_PITCH if math.hypot(x - fx, y - fy) + half > INTAKE_R: continue if math.hypot(x - t['pan_x'], y) + half > t['foot_r'] - 12.0: continue if any(math.hypot(x - (t['pan_x'] + a), y - b) < RISER_FOOT_R + 3.0 + half for a, b in RISER_FEET): continue out.append((round(x, 2), round(y, 2))) return out def pallet_uv(x, y): return (x - PALLET_X[0], PALLET_Y[1] - y) PALLET_X = None PALLET_Y = None def pallet_part(mounts=None) -> bs.SheetPart: """The compute pallet (6061-T6 0.125 in, SendCutSend countersinks): the J501 carrier on four M3 x 16 hex standoffs (M3 x 6 flat heads from below), the AGX module's cooler tie-down (four M3 x 35 flat heads up through 16 mm spacer tubes into the module-to-heatsink standoffs, the j501-agx rule), four printed TPU isolators to the tray.""" feats = [] j = bp.j501() for (xp, yp) in j['holes']: x, y = bp.pcb_to_robot(xp, yp) feats.append(bs.Feature('csk', 'base', pallet_uv(x, y), 3.4, spec='M3', side='z1', note='J501 carrier standoff, M3 x 6 flat head from below')) for (xp, yp) in j['module_holes']: x, y = bp.pcb_to_robot(xp, yp) feats.append(bs.Feature('csk', 'base', pallet_uv(x, y), 3.4, spec='M3', side='z1', note='cooler tie-down, M3 x 35 flat head from below')) for (x, y) in ISOLATORS: feats.append(bs.Feature('hole', 'base', pallet_uv(x, y), 8.0, note='printed TPU isolator\'s neck; M4 x 20 through it into the tray\'s nut')) feats += _mount_features((mounts or {}).get('pallet', []), pallet_uv) W, H = PALLET_X[1] - PALLET_X[0], PALLET_Y[1] - PALLET_Y[0] u0 = VN_NOTCH[0] - PALLET_X[0] # the notch at the front middle: the VN-100 sits on the tray under the v0, v1 = PALLET_Y[1] - VN_NOTCH[1], PALLET_Y[1] + VN_NOTCH[1] # carrier's front, clear of the isolated pallet outline = [(0.0, 0.0), (W, 0.0), (W, v0), (u0, v0), (u0, v1), (W, v1), (W, H), (0.0, H)] return bs.SheetPart('compute_pallet', bp.PALLET, W, H, features=feats, outline=outline, note='countersinks 90 deg M3 from the underside (SendCutSend countersinking); the notch clears the VN-100') VN_NOTCH = (-46.0, 22.0) # (x where the notch starts, its half-width): the VN-100 on the tray under the carrier def place_pallet(shape): z_top = bp.z_pallet_top() return shape.rotate((0, 0, 0), (1, 0, 0), 180).translate((PALLET_X[0], PALLET_Y[1], z_top)) def _pallet_box(): """The pallet's outline: the PCB's four corner holes and the module pattern with a margin, and the isolators.""" j = bp.j501() pts = [bp.pcb_to_robot(*h) for h in j['holes']] xs, ys = [p[0] for p in pts], [p[1] for p in pts] return ((min(xs) - 22.0, max(xs) + 22.0), (min(ys) - 14.0, max(ys) + 14.0)) PALLET_X, PALLET_Y = _pallet_box() ISOLATORS = [(PALLET_X[0] + 12.0, PALLET_Y[0] + 9.0), (PALLET_X[0] + 12.0, PALLET_Y[1] - 9.0), # the rear pair 8 mm (flat) (PALLET_X[1] - 9.0, PALLET_Y[0] + 9.0), (PALLET_X[1] - 9.0, PALLET_Y[1] - 9.0)] # from the tray's rear bend # ------------------------------------------------------------------------------------------- printed parts POST_H = None def post_height(): return bp.TOP - bp.STOCK[bp.DECK]['t'] - bp.z_tray_top() POST_END = 14.0 # solid at each end round the M5 insert (11 deep) POST_WALL = 4.0 # lever 5: hollow between the ends (the inserts need 4 mm walls) POST_M3_PILOT = 8.0 # the shell's M3 inserts: through the 7.5 mm boss into the hollow (an M3 x 16 goes 6.4 mm in) def post(): """A deck post (PA6-CF, 100 %): square POST_W, hollow between solid ends (lever 5: 4 mm walls; it carries 290 N at the landing's 8.65 g), M5 heat-set inserts (94459A775, Ø6.4 x 11 pilot) both ends; M3 inserts (94459A140) for the P3 shell in bosses: on its +-y faces at the side walls' screw heights, on its +-x faces at the front and rear faces' (every corner uses one of each). Printed standing: the pull-out crosses the layers (the coupon test).""" import body_shell as bs3 h = post_height() w = bp.POST_W zt = bp.z_tray_top() s = box(-w / 2, w / 2, -w / 2, w / 2, 0.0, h).edges('|Z').fillet(3.0) core = box(-w / 2 + POST_WALL, w / 2 - POST_WALL, -w / 2 + POST_WALL, w / 2 - POST_WALL, POST_END, h - POST_END) for z in bs3.POST_Z_SIDE: # a boss behind each M3 insert (7.5 deep from the face) for sy in (1, -1): core = core.cut(box(-4.5, 4.5, *sorted((sy * w / 2, sy * (w / 2 - 7.5))), z - zt - 4.5, z - zt + 4.5)) for z in bs3.POST_Z_FACE: for sx in (1, -1): core = core.cut(box(*sorted((sx * w / 2, sx * (w / 2 - 7.5))), -4.5, 4.5, z - zt - 4.5, z - zt + 4.5)) s = s.cut(core) s = s.cut(cyl_z(3.2, -1.0, 11.0)).cut(cyl_z(3.2, h - 11.0, h + 1.0)) for z in bs3.POST_Z_SIDE: for sy in (1, -1): s = s.cut(cyl_y(2.0, *sorted((sy * w / 2, sy * (w / 2 - POST_M3_PILOT))), 0.0, z - zt)) for z in bs3.POST_Z_FACE: for sx in (1, -1): s = s.cut(cq.Workplane('YZ', origin=(min(sx * w / 2, sx * (w / 2 - POST_M3_PILOT)), 0, 0)).center(0.0, z - zt).circle(2.0).extrude(POST_M3_PILOT)) return s PLATE_POST_W = 16.0 def plate_post(): """A power-plate post (PA6-CF, 100 %): 16 mm square x PLATE_H, M5 heat-set inserts (94459A775) both ends; printed standing, as the deck posts.""" import body_layout as bl h, w = bl.PLATE_H, PLATE_POST_W s = box(-w / 2, w / 2, -w / 2, w / 2, 0.0, h).edges('|Z').fillet(2.5) return s.cut(cyl_z(3.2, -1.0, 11.0)).cut(cyl_z(3.2, h - 11.0, h + 1.0)) ISOLATOR_D = 16.0 ISOLATOR_CAP_T = 1.5 # an M4 x 20 and its washer then engage 3.6 mm of the tray's S-M4-0 (cad/body_joints.py) def isolator(): """A pallet isolator (TPU 95A, printed): a Ø16 x ISOLATOR_H foot under the pallet with a Ø7.6 x 3.2 neck up through the pallet's Ø8 hole, and a separate Ø12 x 3 cap above it; an M4 x 20 socket head with a washer goes down through both into the tray's S-M4-0 nut, snug, not tight: the pallet touches only TPU.""" h = bp.ISOLATOR_H foot = cyl_z(ISOLATOR_D / 2, 0.0, h).union(cyl_z(3.8, h, h + bp.STOCK[bp.PALLET]['t'] - 0.2)) cap = cyl_z(6.0, h + bp.STOCK[bp.PALLET]['t'] + 0.5, h + bp.STOCK[bp.PALLET]['t'] + 0.5 + ISOLATOR_CAP_T) # Ø12: clear of the carrier's standoffs return foot.union(cap).cut(cyl_z(2.3, -1.0, h + 10.0)) def din_rail(length, hole_off=None): """A printed TS35 rail piece (PA6-CF): the standard hat (35 wide, 7.5 deep, 27 between the lips), its lips 1.0 mm thick for the converters' clips, two M4 countersunk holes. Check the clip on the first print; a cut steel TS35 is the fallback.""" t, w, d, inner = 1.0, 35.0, 7.5, 27.0 base = box(-inner / 2 + 1.5, inner / 2 - 1.5, -length / 2, length / 2, 0.0, 2.0) sides = [box(sx * inner / 2 - (1.5 if sx > 0 else 0.0), sx * inner / 2 + (0.0 if sx > 0 else 1.5), -length / 2, length / 2, 0.0, d) for sx in (-1, 1)] lips = [box(min(sx * inner / 2, sx * w / 2), max(sx * inner / 2, sx * w / 2), -length / 2, length / 2, d - t, d) for sx in (-1, 1)] s = base for b in sides + lips: s = s.union(b) off = hole_off if hole_off is not None else length / 4 for v in (-off, off): s = s.cut(cyl_z(2.25, -1.0, 3.0, 0.0, v)).cut(cyl_z(4.2, 1.0, 3.0, 0.0, v)) return s def din_rails(items): """D65: no DIN-rail converter is left on the body (the TRACO replaces both): {}.""" return {} DCDC_FOOT_T, DCDC_WALL_T = 4.0, 6.0 # the upright at y -124..-118: the P3 wall's ribs start at -124.1 def _plate_top(): import body_layout as bl return bp.z_tray_top() + bl.PLATE_H + bp.STOCK['5052-0.100']['t'] def dcdc_bracket_holes(): """The converter's bracket: two M4 down into the plate's flush nuts on its inner side (robot x, y).""" import body_layout as bl d = bl.DCDC return [(40.0, d['y'][1] + 3.0), (120.0, d['y'][1] + 3.0)] # beyond the switch under the plate (x 52..112) def dcdc_screws(): """The converter's four M3 through its base flange's slots into inserts in the bracket's upright (robot x, z).""" import body_layout as bl d = bl.DCDC z0 = _plate_top() + DCDC_FOOT_T return [(x, z) for x in (d['x'][0] + 5.0, d['x'][1] - 5.0) for z in (z0 + 3.0, z0 + d['h'] - 3.0)] def dcdc_bracket(): """The TRACO TEP 150-4815WI's bracket (PA6-CF): a foot on the tray under the converter, screwed down beyond its ends, and an upright on its inner side its baseplate bolts to (four M3 from the carrier's side: the converter goes on the bracket first, then the bracket on the tray). The converter's outer face stays at |y| 121: the left ear bracket's nyloc nuts stand inside the wall to 122.6.""" import body_layout as bl d = bl.DCDC zp = _plate_top() x0, x1 = d['x'][0], d['x'][1] yw = d['y'][0] - DCDC_WALL_T s = box(x0, x1, yw, d['y'][1] + 6.0, zp, zp + DCDC_FOOT_T) s = s.union(box(x0, x1, yw, d['y'][0], zp, zp + DCDC_FOOT_T + d['h'])) for x, y in dcdc_bracket_holes(): s = s.cut(cyl_z(2.25, zp - 1, zp + DCDC_FOOT_T + 1, x, y)) for x, z in dcdc_screws(): # M3 inserts through the upright s = s.cut(cyl_y(2.0, yw - 1, d['y'][0] + 1, x, z)) for x, y in [(44.0, -96.0)]: # the plate post's screw head under the foot s = s.cut(cyl_z(5.5, zp - 1, zp + 3.0, x, y)) return s # ------------------------------------------------------------------------------------------- the turret mount plate (D59) TURRET_PLATE = {'stock': '6061-0.125', 'L': 160.0, 'W': 140.0, # under the deck at the riser, centred on the pan axis 'end_pem_x': 10.0, # its two PEM SS-M5-0 this far in from its +-x ends, on y = 0 'foot_pad_r': 22.0, # the plate stays whole under each Ø44 riser foot (its screw); 135 g budget 'notch': (4.0, 26.0)} # the rear-right corner cut away (x, y) for the turret harness's drop TURRET_PLATE_POCKETS = [(23.0, 55.0, 24.0, 22.0), (23.0, -55.0, 24.0, 22.0), # (x, y, length, width) robot: the front corners (-108.0, 56.0, 16.0, 20.0)] # and the rear-left one (the rear-right is the notch) def turret_plate_xy(): """The plate's corner (x0, y0) in the robot frame and its size: centred on the turret's pan axis.""" t = bp.tm() P = TURRET_PLATE return t['pan_x'] - P['L'] / 2, -P['W'] / 2, P['L'], P['W'] def plate_t_uv(x, y): x0, y0, L, W = turret_plate_xy() return (x - x0, W / 2 - y) def turret_plate_part(mounts=None) -> bs.SheetPart: """D59: the turret mount plate, SendCutSend 6061-T6 0.125 in, flat, bolted under the deck at the riser: the riser's four M5 screws come up through it and the deck into the riser's feet (M5 x 16 now: 3.2 mm longer), and two M5 screws go down through the deck into its two PEM SS-M5-0 nuts at its +-x ends. Two plates in bending under the riser's feet take the turret's tip-over (D2) from SF 1.3 to over 2. It is open over the J501 fan's intake field (the deck's cells, 1 mm clear: the intersection of the fan's field and the riser's ring, less a 20 mm pad round each riser foot) and notched at its rear-right corner, where the turret's harness drops through the deck.""" import cadquery as cq x0, y0, L, W = turret_plate_xy() P = TURRET_PLATE t = bp.tm() fx, fy = bp.j501_stack()['fan_xy'] fan_uv = plate_t_uv(fx, fy) pan_uv = plate_t_uv(t['pan_x'], 0.0) feet_uv = [plate_t_uv(t['pan_x'] + a, b) for a, b in RISER_FEET] r_field = INTAKE_R + 1.0 # the cells' corners are within INTAKE_R of the fan's axis r_ring = t['foot_r'] - 12.0 + 1.0 # and within the riser's ring less 12 mm def opening(th): o = (cq.Workplane('XY').center(*fan_uv).circle(r_field).extrude(th + 2).translate((0, 0, -1)) .intersect(cq.Workplane('XY').center(*pan_uv).circle(r_ring).extrude(th + 2).translate((0, 0, -1)))) for f in feet_uv: o = o.cut(cq.Workplane('XY').center(*f).circle(P['foot_pad_r']).extrude(th + 4).translate((0, 0, -2))) return o feats = [bs.Feature('cutout', 'base', fan_uv, make=opening, note='open over the J501 fan\'s intake field')] for (u, v) in feet_uv: feats.append(bs.Feature('hole', 'base', (u, v), 5.5, note='riser foot: M5 x 16 up through the plate and the deck into its insert')) for u in (P['end_pem_x'], L - P['end_pem_x']): feats.append(bs.Feature('pem', 'base', (u, W / 2), bp.PEM['SS-M5-0']['H'], spec='SS-M5-0', note='M5 x 10 ISO 7380 down through the deck into this nut')) import body_shell as bs3 for (x, y) in bs3.duct_tabs(): # P3: the fan duct hangs from three tapped holes feats.append(bs.Feature('hole', 'base', plate_t_uv(x, y), 2.5, note='tap M3 x 0.5: the fan duct\'s tab (M3 x 5 from below)')) for (x, y, lx, ly) in TURRET_PLATE_POCKETS: # lightening, where neither a riser foot nor a nut needs the plate feats.append(bs.Feature('slot', 'base', plate_t_uv(x, y), size=(lx, ly, 5.0), note='lightening pocket')) nx, ny = P['notch'] outline = [(0.0, 0.0), (L, 0.0), (L, W), (nx, W), (nx, W - ny), (0.0, W - ny)] # v = W is y = -W/2: the right side return bs.SheetPart('turret_plate', P['stock'], L, W, features=feats, outline=outline, note='flat; under the deck at the riser (D59); PEM SS-M5-0 pressed from its underside, their bodies down') def place_turret_plate(shape): """Flat part (u, v, 0..t) -> robot: its top face against the deck's underside (part z = 0 up after the turn).""" x0, y0, L, W = turret_plate_xy() zd = bp.TOP - bp.STOCK[bp.DECK]['t'] return shape.rotate((0, 0, 0), (1, 0, 0), 180).translate((x0, W / 2, zd)) def turret_plate_end_holes(): """The two Ø5.5 holes the plate's end screws need in the deck (robot x, y): drilled by hand in the P1 deck, cut in a Rev B deck.""" x0, y0, L, W = turret_plate_xy() return [(x0 + TURRET_PLATE['end_pem_x'], 0.0), (x0 + L - TURRET_PLATE['end_pem_x'], 0.0)] RISER_LEG_R = 9.0 RISER_FOOT_R = 22.0 # each leg ends in a Ø44 x 4 foot: it spreads the turret's fall load on the 0.100 in deck (D2; it was Ø36 until D2's convergence run put the deck at SF 1.92 at the Ø36 foot's rim) RISER_FOOT_T = 4.0 RISER_TOP_T = 9.0 RISER_FOOT_PILOT = 12.0 # the feet's insert pilots: an M5 x 16 through the turret plate and deck reaches 10.3 mm in def riser(): """The turret riser (PA6-CF, 100 % solid), in the TM frame (pan axis at the origin, its top face = the TM face at z = RISER_H, its feet on z = 0): a Ø144 top ring (the turret's foot) with the TM pattern (4 x M5 inserts on 80 x 80, 2 x Ø5 dowel holes, the Ø45 hole), four legs under the TM bolts, open sides between them for the J501 fan's intake air; M5 inserts in the feet for the deck's screws.""" t = bp.tm() H = bp.RISER_H ro = t['foot_r'] ring = cyl_z(ro, H - RISER_TOP_T, H).cut(cyl_z(30.0, H - RISER_TOP_T - 1, H + 1)) s = ring for (x, y) in RISER_FEET: s = s.union(cyl_z(RISER_LEG_R, 0.0, H - RISER_TOP_T + 0.01, x, y)).union(cyl_z(RISER_FOOT_R, 0.0, RISER_FOOT_T, x, y)) for (x, y) in t['bolts']: s = s.cut(cyl_z(3.2, H - 9.5, H + 1.0, x, y)) # M5 insert from the top (the turret) for (x, y) in RISER_FEET: s = s.cut(cyl_z(3.2, -1.0, RISER_FOOT_PILOT, x, y)) # M5 insert from below (the deck; P2's M5 x 16 goes 10.3 in) for (x, y) in t['dowels']: s = s.cut(cyl_z(2.5 - 0.03, H - 8.0, H + 1.0, x, y)) s = s.cut(cyl_z(t['hole_d'] / 2, H - RISER_TOP_T - 1, H + 1)) return s # ------------------------------------------------------------------------------------------- bought parts (envelopes) def spacers(): """The eight M4 hex standoffs (McMaster 95947A065: 6 mm hex, 31 mm, female both ends) between the cheeks.""" out = None for x, z in SPACERS_XZ: s = hexagon_y(SPACER_HEX, -GAP_Y, GAP_Y, x, z).cut(cyl_y(2.05, -GAP_Y - 1, GAP_Y + 1, x, z)) # threaded through: the screws go in out = s if out is None else out.union(s) return out def spacer_screws(): """Sixteen M4 x 10 ISO 10642 flat heads, flush in the cheeks' countersinks (envelope: the shank and the cone).""" out = None for x, z in SPACERS_XZ: for side in (1, -1): y0 = side * FACE_Y shank = cyl_y(2.0, min(y0, y0 - side * 10.0), max(y0, y0 - side * 10.0), x, z) out = shank if out is None else out.union(shank) return out def frame_screws(side='left'): """The six M5 x 12 ISO 7380 per hip frame, heads in the gap on the cheek's inner face.""" out = None m = bp.frame_mounts() for x, z in m['holes']: p = bp.to_robot((x, m['centre_plane_y'], z), side) sgn = 1 if side == 'left' else -1 s = button_head_y(5, bp.FRAME_SCREW['length'], sgn * GAP_Y, sgn, p[0], p[2]) out = s if out is None else out.union(s) return out def pem_bodies(part: bs.SheetPart, place): """The PEM nuts' bodies (envelopes) on a sheet part, placed: each on the side away from where its screw enters. Flange nuts on the cheeks: the screws come from the tray (above) and the belly plate (below), so the bodies hang on the flanges' inner sides, towards the frame.""" out = None t = part.t for f in part.features: if f.kind != 'pem': continue P = bp.PEM[f.spec] (x, y, z), n = part.to3d(f) if f.panel == 'base': # base nuts: body on the part's +z (inner) side b = cyl_z(P['body_d'] / 2, t, t + P['body_h'], x, y) elif f.panel in ('N', 'S'): # flange nuts: body on the flange's inner side (towards the base's middle) yi = y - t if f.panel == 'N' else y + t b = cyl_y(P['body_d'] / 2, min(yi, yi - (P['body_h'] if f.panel == 'N' else -P['body_h'])), max(yi, yi - (P['body_h'] if f.panel == 'N' else -P['body_h'])), x, z) else: continue out = b if out is None else out.union(b) return place(out) if out is not None else None # ------------------------------------------------------------------------------------------- the frame @functools.lru_cache(maxsize=4) def _cached_cheek(): p = cheek_part() return p, p.solid() def frame_parts(mounts=None) -> dict: """Every frame part: {name: Part} in the robot frame.""" out = {} cp, cl = _cached_cheek() for side in ('left', 'right'): out[f'cheek_{side}'] = Part(f'cheek_{side}', 'sheet', place_cheek(cl, side), 1, cp, cl, cp.s['material'], colour=(0.72, 0.75, 0.80), note=cp.note) for name, fn, place, colour in (('floor_tray', tray_part, lambda s: place_tray(s, bp.z_tray_top()), (0.62, 0.66, 0.72)), ('belly_plate', belly_part, place_belly, (0.55, 0.58, 0.64)), ('deck', deck_part, lambda s: place_tray(s, bp.TOP), (0.20, 0.22, 0.25)), ('compute_pallet', pallet_part, place_pallet, (0.70, 0.72, 0.76))): sp = fn(mounts) loc = sp.solid() out[name] = Part(name, 'sheet', place(loc), 1, sp, loc, sp.s['material'], colour=colour, note=sp.note) ph = post() zt = bp.z_tray_top() for k, (x, y) in enumerate(bp.POSTS): out[f'post_{k + 1}'] = Part(f'post_{k + 1}', 'printed', ph.translate((x, y, zt)), 1, material='pa6-cf', colour=(0.25, 0.27, 0.30), note='PA6-CF, 100 % solid, printed standing; 2 x M5 inserts') t = bp.tm() out['riser'] = Part('riser', 'printed', riser().translate((t['pan_x'], 0.0, bp.TOP)), 1, material='pa6-cf', colour=(0.25, 0.27, 0.30), note='PA6-CF, 100 % solid, printed on its top face; 8 x M5 inserts, 2 x Ø5 dowels', print_rotation=((1, 0, 0), 180)) tp = turret_plate_part(mounts) # D59: under the deck at the riser, ordered with P2 tl = tp.solid() out['turret_plate'] = Part('turret_plate', 'sheet', place_turret_plate(tl), 1, tp, tl, tp.s['material'], colour=(0.78, 0.80, 0.84), note=tp.note, stage='P2') out['turret_plate_nuts'] = Part('turret_plate_nuts', 'bought', pem_bodies(tp, place_turret_plate), 2, colour=(0.6, 0.6, 0.62), note='PEM SS-M5-0 (pressed by SendCutSend)', stage='P2') iso = isolator() for k, (x, y) in enumerate(ISOLATORS): out[f'isolator_{k + 1}'] = Part(f'isolator_{k + 1}', 'printed', iso.translate((x, y, zt)), 1, material='tpu95', colour=(0.15, 0.15, 0.17), note='TPU 95A: the pallet\'s isolator foot, neck and cap') import body_layout as _bl if mounts is not None: for name, (length, off, (x, y, z)) in din_rails(_bl.layout()['items']).items(): out[name] = Part(name, 'printed', din_rail(length, off).translate((x, y, z)), 1, material='pa6-cf', colour=(0.55, 0.57, 0.6), note='PA6-CF TS35 rail piece; 2 x M4 x 10 flat heads into the nuts below') # ---- the power plate (the P0 skid), its standoffs, the bus bars on their insulators import body_layout as bl pp = power_plate_part(mounts) loc = pp.solid() out['power_plate'] = Part('power_plate', 'sheet', place_plate(loc), 1, pp, loc, pp.s['material'], colour=(0.66, 0.70, 0.75), note=pp.note) zt = bp.z_tray_top() pl = plate_post() for k, (x, y) in enumerate(PLATE_STANDOFFS): out[f'plate_post_{k + 1}'] = Part(f'plate_post_{k + 1}', 'printed', pl.translate((x, y, zt)), 1, material='pa6-cf', colour=(0.25, 0.27, 0.30), note='PA6-CF, 100 %; M5 inserts both ends; printed standing') bus = bus_bar_part() bloc = bus.solid() ins = bus_insulator() zp = zt + bl.PLATE_H + bp.STOCK['5052-0.100']['t'] if mounts is not None and mounts.get('_bus_xy'): for k, (bx, by) in enumerate(mounts['_bus_xy']): out[f'bus_bar_{k + 1}'] = Part(f'bus_bar_{k + 1}', 'sheet', bloc.translate((bx, by, zp + BUS_INS_H)), 1, bus if k == 0 else None, bloc, bus.s['material'], colour=(0.85, 0.45, 0.2) if k == 0 else (0.25, 0.25, 0.27), note=bus.note) out[f'bus_insulator_{k + 1}'] = Part(f'bus_insulator_{k + 1}', 'printed', ins.translate((bx, by, zp)), 1, material='petg', colour=(0.2, 0.2, 0.22), note='PETG, 100 % (never a carbon-filled filament: carbon ' 'conducts, and the plate is bonded to the - bus); 4 x M3 inserts; test: > 10 MOhm at 50 V ' 'from every lug screw to the plate before power') out['dcdc_bracket'] = Part('dcdc_bracket', 'printed', dcdc_bracket(), 1, material='pa6-cf', colour=(0.25, 0.27, 0.30), note='PA6-CF; two M4 x 10 down into the tray\'s nuts; the converter on four M3 x 8 through its upright') # ---- the battery bay under the belly plate (D65: two DeWalt packs; cad/body_battery.py) import body_battery as bb out.update(bb.bay_parts()) out['spacers'] = Part('spacers', 'bought', spacers(), len(SPACERS_XZ), colour=(0.8, 0.8, 0.82), note='M4 x 31 hex standoff, 6 mm hex, female-female, aluminium (95947A065)') out['spacer_screws'] = Part('spacer_screws', 'bought', spacer_screws(), 2 * len(SPACERS_XZ), colour=(0.15, 0.15, 0.17), note='M4 x 10 ISO 10642 flat head') for side in ('left', 'right'): out[f'frame_screws_{side}'] = Part(f'frame_screws_{side}', 'bought', frame_screws(side), 6, colour=(0.15, 0.15, 0.17), note='M5 x 12 ISO 7380 into the hip frame\'s inserts') out[f'cheek_nuts_{side}'] = Part(f'cheek_nuts_{side}', 'bought', pem_bodies(cp, lambda s, sd=side: place_cheek(s, sd)), 8, colour=(0.6, 0.6, 0.62), note='PEM SS-M5-0 (pressed by SendCutSend)') return out STAGES = ('P0', 'P1', 'P2', 'P3') def on_robot(p, stage) -> bool: """Whether a part is on the robot at a stage (its stage .. its until).""" i = STAGES.index(stage) return STAGES.index(getattr(p, 'stage', 'P1')) <= i and (getattr(p, 'until', None) is None or i <= STAGES.index(p.until)) def all_parts(mounts=None) -> dict: """The frame's parts and the P3 shell's (cad/body_shell.py): every part of every stage.""" import body_shell as bs3 out = frame_parts(mounts) out.update(bs3.shell_parts()) return out # ------------------------------------------------------------------------------------------- the legs, placed def legs(h_mm, lean_deg=0.0, with_bought=True): """Both legs at a stance in the robot frame: {name: shape}. The left is cad/fivebar.py's module shifted by Y_OFF; the right is the same leg turned 180 deg about z (the physical right leg: same parts, same motors).""" fb = bp._fivebar() phi = fb.stance(h_mm, lean_deg) if phi is None: return None yo = bp.y_off() out = {} real = fb.gmi.STEP_FRAMES.pop(fb.MOTOR, None) # the motors as envelopes: fast to intersect fb.motor_model.cache_clear() try: asm = fb.assembly(*phi, with_bought=with_bought) finally: if real: fb.gmi.STEP_FRAMES[fb.MOTOR] = real fb.motor_model.cache_clear() for n, (s, kind) in asm.items(): if s is None or n == 'wheel_cable': continue sl = s.translate((0, yo, 0)) out[f'L.{n}'] = sl out[f'R.{n}'] = sl.rotate((0, 0, 0), (0, 0, 1), 180) return out # ------------------------------------------------------------------------------------------- the power plate and bus bars def plate_uv(x, y): import body_layout as bl return (x - bl.PLATE_X[0], bl.PLATE_Y[1] - y) def place_plate(shape): """Flat part (u, v, 0..t) -> robot, its underside (part z = t after the turn) on the standoffs.""" import body_layout as bl z_top = bp.z_tray_top() + bl.PLATE_H + bp.STOCK['5052-0.100']['t'] return shape.rotate((0, 0, 0), (1, 0, 0), 180).translate((bl.PLATE_X[0], bl.PLATE_Y[1], z_top)) PLATE_STANDOFFS = [(44.0, -96.0), (47.0, 80.0), (145.0, -88.0), (145.0, 80.0)] # clear of the pallet; 8 mm (flat) from the tray's front bend def power_plate_part(mounts=None) -> bs.SheetPart: """The power plate (5052-H32 0.100 in, flat): the P0 power skid. Four printed posts to the tray; a notch round the front-right deck post; PEM nuts and holes for every part on it and under it (mounts['plate']).""" import body_layout as bl W, H = bl.PLATE_X[1] - bl.PLATE_X[0], bl.PLATE_Y[1] - bl.PLATE_Y[0] px, py = bp.POSTS[1] nx0 = px - bp.POST_W / 2 - 3.0 ny1 = py + bp.POST_W / 2 + 3.0 un, vn = nx0 - bl.PLATE_X[0], bl.PLATE_Y[1] - ny1 # the notch's corner (part u, v): x >= nx0 and y <= ny1 go outline = [(0.0, 0.0), (W, 0.0), (W, vn), (un, vn), (un, H), (0.0, H)] feats = [bs.Feature('hole', 'base', plate_uv(x, y), 5.5, note='M5 x 10 ISO 7380 down into the post\'s insert') for x, y in PLATE_STANDOFFS] feats += _mount_features((mounts or {}).get('plate', []), plate_uv) return bs.SheetPart('power_plate', '5052-0.100', W, H, features=feats, outline=outline, note='flat; the whole P0 power skid on one plate; deburr; PEM nuts per the order sheet') BUS_L, BUS_W = 110.0, 20.0 BUS_HOLES = [10.0, 32.5, 55.0, 77.5, 100.0] # along the bar: M6 clearance (the input, then the branches) BUS_INS_H = 16.0 # the insulator: the M6 nut's pocket and the screw's tip both in plastic BUS_FLOOR = 3.5 # plastic left under the deepest screw tip: the VESCs' M5 x 8 tips stand # 1.5 mm up through the plate in 2.5 mm pockets under it, 1 mm of PA6-CF apart BUS_NUT = {'af': 10.0, 'h': 6.0, 'key': 'nut_m6_nyloc'} # DIN 985 M6 nyloc (McMaster 94645A205): 10 mm A/F, 6 mm tall BUS_SCREW = {'d': 6.0, 'length': 16.0, 'key': 'screw_m6x16'} # ISO 4762 M6 x 16 (91290A667), through the lugs and the bar def bus_bar_part() -> bs.SheetPart: """A bus bar: C110 copper 0.125 in, 110 x 20, five Ø6.4 holes for the lugs' M6 screws and two Ø3.4 for the M3 screws that hold it to its insulator. One part for + and -. Each lug stack is an M6 x 16 socket head down through the lug(s) and the bar into a nyloc nut held in a hex pocket of the insulator: SendCutSend taps no part under 1 in wide (its app, 2026-10-27), and three threads of copper are a poor hold for a lug's torque anyway.""" feats = [bs.Feature('hole', 'base', (u, BUS_W / 2), 6.4, note='M6 clearance: the lug screw into the insulator\'s nut') for u in BUS_HOLES] feats += [bs.Feature('hole', 'base', (u, BUS_W / 2), 3.4, note='M3 x 8 down into the insulator\'s inserts') for u in BUS_INS] return bs.SheetPart('bus_bar', 'C110-0.125', BUS_L, BUS_W, features=feats, qty=2, note='C110 copper, cut only: five Ø6.4 holes for the lugs\' M6 screws, two Ø3.4 for the M3 screws into the ' 'printed insulator; deburr; + and - are the same part') BUS_INS = (21.25, 88.75) def bus_insulator(): """The printed PETG block a bus bar sits on (not PA6-CF: carbon fibre conducts and the plate is bonded to the - bus): 110 x 20 x BUS_INS_H, four M3 heat-set inserts (94459A140, Ø4.0 x 6.5: two from above for the bar, two from below for the plate's screws, offset so they never meet) and, under each of the bar's five holes, a hex pocket for the lug screw's nyloc nut (it cannot turn) with the screw's tip hole below it. The bar's potential never reaches the plate: every screw ends in plastic, BUS_FLOOR above the plate (an M6 x 16 through one 1 mm lug and the bar ends 0.7 mm above that floor; a tap with no lug gets no screw).""" H = BUS_INS_H s = box(0.0, BUS_L, 0.0, BUS_W, 0.0, H).edges('|Z').fillet(2.0) for u in BUS_INS: s = s.cut(cyl_z(2.0, H - 6.5, H + 0.1, u, BUS_W / 2)) # M3 insert from above (the bar) for u in (BUS_INS[0] + 22.5, BUS_INS[1] - 22.5): s = s.cut(cyl_z(2.0, -0.1, 6.5, u, BUS_W / 2)) # M3 insert from below (the plate) for u in BUS_HOLES: s = s.cut(hexagon_z(BUS_NUT['af'] + 0.3, H - BUS_NUT['h'] - 0.3, H + 0.1, u, BUS_W / 2)) # the nut, held s = s.cut(cyl_z(3.3, BUS_FLOOR, H - BUS_NUT['h'], u, BUS_W / 2)) # the screw's tip: BUS_FLOOR of plastic stays for u, v in bus_insulator_reliefs(): # the VESCs' flange screws come 3.5 mm up through the plate under it s = s.cut(cyl_z(4.5, -0.1, 2.5, u, v)) return s @functools.lru_cache(maxsize=1) def bus_insulator_reliefs(): """Where the VESCs' flange screws' tips stand under either insulator (its own frame): one part for both, so the pockets of both.""" import body_layout as bl items = bl.layout()['items'] out = set() for bx, by in bl.BUS_XY: for it in ('plate_vesc_r', 'plate_vesc_l'): for x, y in bl.vesc_holes(bl._get(items, it)): if bx - 4 < x < bx + BUS_L + 4 and by - 4 < y < by + BUS_W + 4: out.add((round(x - bx, 2), round(y - by, 2))) return sorted(out)