def _make_neg(what):
"""makes a negative shape to be cut out of the parent walls"""
# this copies some logic in the eachpoint() function so that we can use each() which is safer
base_plane = self.plane
base = base_plane.location
if isinstance(what, (cq.Vector, cq.Shape)):
loc = base.inverse * cq.Location(base_plane, what.Center())
elif isinstance(what, cq.Sketch):
loc = base.inverse * cq.Location(base_plane, what._faces.Center())
else:
loc = what
# fastener threaded holes
# TODO: mark these holes as "M3-0.5 threaded" in the engineering drawing
fhs = CQ().pushPoints(fhps).circle(fix_scr.tap_hole_diameters["Soft"] /
2).extrude(-wall_depth +
pt_fix_wall_buffer)
nwp = CQ().add(through_face)
through = nwp.wires().toPending().extrude(-wall_depth)
nwp2 = CQ().add(recess_face)
recess = nwp2.wires().toPending().extrude(-part_thickness)
neg = recess.union(through).union(fhs)
return neg.findSolid().moved(base * loc)
def _make_pt(what):
"""build a passthrough component"""
# this copies some logic in the eachpoint() function so that we can use each() which is safer
base_plane = self.plane
base = base_plane.location
if isinstance(what, (cq.Vector, cq.Shape)):
loc = base.inverse * cq.Location(base_plane, what.Center())
elif isinstance(what, cq.Sketch):
loc = base.inverse * cq.Location(base_plane, what._faces.Center())
else:
loc = what
hardware = cadquery.Assembly()
passthrough = CQ().add(passthrough_face)
passthrough = passthrough.wires().toPending().extrude(
-part_thickness) # extrude the bulk
slotd = pcbt + 2 * min_gap
passthrough = passthrough.workplane(
centerOption="ProjectedOrigin").slot2D(
length=board_width + slotd / 2, diameter=slotd,
angle=0).cutThruAll() # cut the pcb slot
# TODO: retool some geometry because this cutout could possibly interfere with the oring gland for thick PCBs
# cut the oring groove
cq.Workplane.mk_groove = groovy.mk_groove
oring_path = o_face.outerWire().translate((0, 0, -part_thickness))
passthrough = passthrough.faces("<<Z").workplane(
**u.copo).add(oring_path).toPending().mk_groove(ring_cs=oring_cs,
hardware=hardware)
# cut the fastening screw holes
passthrough = passthrough.faces(">Z").workplane(
**u.copo,
origin=(0, 0,
0)).pushPoints(fhps).clearanceHole(fix_scr,
fit="Close",
baseAssembly=hardware)
# add the support towers
in_post_length = wall_depth + board_inner_depth
passthrough = passthrough.faces(">Z").workplane(
**u.copo, origin=(0, 0, 0)).sketch().push(sbpts).rect(
*support_block).finalize().extrude(-in_post_length)
passthrough = passthrough.faces(">Z").workplane(
**u.copo, origin=(0, 0, 0)).sketch().push(sbpts).rect(
*support_block).finalize().extrude(board_outer_depth)
# mount holes
pcb_center_z = ((board_outer_depth) -
(wall_depth + board_inner_depth)) / 2
passthrough = passthrough.faces("+Y").faces(">>Z").workplane(
**u.copo, origin=(0, 0, pcb_center_z)).rarray(
board_width - 2 * pt_pcb_mount_hole_offset[1],
board_inner_depth + board_outer_depth + wall_depth -
2 * pt_pcb_mount_hole_offset[0], 2,
2).clearanceHole(pcb_scr, fit="Close", counterSunk=False)
passthrough = passthrough.edges("<<Z or >>Z").edges("|Y").fillet(
pcb_corner)
passthrough = passthrough.edges(
"<<Z[-1] or <<Z[-2] or <<Z[-3] or >>Z[-1] or >>Z[-2] or >>Z[-3]"
).chamfer(0.5)
if hw_asy is not None:
hw_asy.add(hardware, loc=base * loc)
return passthrough.findSolid().moved(base * loc)
def make_oringer(
self: cq.Workplane,
board_width: float = 84.12,
board_inner_depth: float = 9.271,
board_outer_depth: float = 9.271,
part_thickness: float = 0,
wall_depth: float = 0,
screw="M3-0.5",
pt_asy: cadquery.Assembly = None,
pcb_asy: cadquery.Assembly = None,
hw_asy: cadquery.Assembly = None,
) -> cq.Workplane:
logger = logging.getLogger(__name__)
if wall_depth == 0: # if depth is not given do our best to find it
wall_depth = u.find_length(self, along="normal", bb_method=False)
if part_thickness == 0: # if thickness is not given, use half the wall thickness
part_thickness = wall_depth / 2
pcbt = 1.6 # pcb thickness
washert = 0.5 # washer thickness
screw_nominal_d = 3
screw_head_nominal_d = 6
# header specific for making the pin0 holes, probably doesn't belong here, but it's too convenient...
non_notch_side_chunk_width = 0.381 # is 0.15 in
non_chunk_con_width = 8.89 # is 0.35 in
pin0_offsetx = non_chunk_con_width / 2 + non_notch_side_chunk_width + 2.54 / 2
pin0_offsety_25 = 2.54 * (25 - 1) / 2
pin0_offsety_20 = 2.54 * (20 - 1) / 2
pin0_holed = 1
p0pts = [
] # the pin pin 1 points for the two connectors (for checking the correctness of the PCB designs)
p0pts.append((pin0_offsety_25, pin0_offsetx))
p0pts.append((-pin0_offsety_20 + 2.5 * 2.54, -(wall_depth + pin0_offsetx)))
block_width = 7
block_height_nominal = 6
support_block = (block_width, block_height_nominal - washert
) # actual support block (leaves room for washer)
pcb_corner = 2
pt_pcb_mount_hole_offset = (4.445, block_width / 2) # from corners
pcb_scr_len = 12 # SHP-M3-12-V2-A2, round(block_height_nominal + pcbt + 4)
pt_fix_scr_len = 10 # SHK-M3-10-V2-A2, round(wall_depth * 0.8)
pt_fix_wall_buffer = 1 # amount of wall to leave behind the threaded screw hole
fix_scr = CounterSunkScrew(size=screw,
fastener_type="iso14581",
length=pt_fix_scr_len)
pcb_scr = PanHeadScrew(size=screw,
fastener_type="iso14583",
length=pcb_scr_len)
# washer = CheeseHeadWasher(size=screw, fastener_type="iso7092")
# nylock nut = HNN-M3-A2
oring_cs = 1 # oring thickness
min_radius = oring_cs * 3 # min inner bend radius
min_wall = 0.8 # walls should not be mfg'd thinner than this
min_gap = 0.25 # cutting tolerances prevent smaller gaps between things
gland_width = groovy.get_gland_width(oring_cs)
# effective_gland_width = (round(gland_width * 100) + 1) / 100 # rounded up to the nearest 0.01mm
# logger.info(f"Using {effective_gland_width=}")
# some important radii for construction to ensure we don't overbend the o-ring
minr1 = min_radius - min_wall
minr2 = min_radius + min_wall + gland_width
# actual support block centers
sbpts = []
sbx = board_width / 2 - block_width / 2
sby = ((-pcbt / 2 - washert) + (-pcbt / 2 - block_height_nominal)) / 2
sbpts.append((sbx, sby))
sbpts.append((-sbx, sby))
in_off = minr1 * 2**-0.5 - min_gap * 2**0.5 / 2 # exact inward offset to get min_gap spacing with minr1 fillets
ffo = minr1 * (1 - 2**-0.5) + min_gap * (2**0.5 / 2)
co_tw = minr1 * 2 + min_gap # width of the thin part of the cutout (so that the cutting tool can easily fit)
max_slot_y = ffo + pcbt + block_height_nominal + ffo # width at the slot at its max
if co_tw > max_slot_y:
co_tw = max_slot_y
scy = -pcbt / 2 - block_height_nominal + in_off # y coordinate for the inner, small radius circle
scx = board_width / 2 - block_width + in_off # small, inner circle x value
tcy = pcbt / 2 - in_off # top circles center y value
tcx = board_width / 2 - in_off # top circles center c values
tcpts = [] # top circle points
tcpts.append((tcx, tcy))
tcpts.append((-tcx, tcy))
ocpts1 = [] # outer circle points for positive x
ocpts1.append((tcx, tcy))
ocpts1.append((tcx, scy))
ocpts2 = [] # outer circle points for negative x
ocpts2.append((-tcx, tcy))
ocpts2.append((-tcx, scy))
bcpts1 = [] # bottom circle points for positive x
bcpts1.append((tcx, scy))
bcpts1.append((scx, scy))
bcpts2 = [] # bottom circle points for negative x
bcpts2.append((-tcx, scy))
bcpts2.append((-scx, scy))
icpts1 = [] # inner circle points for positive x
icpts1.append((scx, scy))
icpts1.append((scx, tcy))
icpts2 = [] # inner circle points for negative x
icpts2.append((-scx, scy))
icpts2.append((-scx, tcy))
swp = CQ().sketch()
# need support block shapes to fill in gaps
swp.push(sbpts).rect(*support_block)
# the fillets at the bottom collide and should be unified with a circle, but the ones at the sides don't
if (2 * minr1 > 2 * ffo + block_width) and (2 * minr1 < max_slot_y):
scx = board_width / 2 - block_width / 2 # new center point for circles
tcpts = [] # top circle points
tcpts.append((scx, tcy))
tcpts.append((-scx, tcy))
ocpts1 = [] # outer circle points for positive x
ocpts1.append((scx, tcy))
ocpts1.append((scx, scy))
ocpts2 = [] # outer circle points for negative x
ocpts2.append((-scx, tcy))
ocpts2.append((-scx, scy))
# make the right circle hull
swp.push(ocpts1).circle(
minr1, mode="c",
tag="c").reset().edges(tag="c").hull().clean().reset()
# make the left circle hull
swp.push(ocpts2).circle(
minr1, mode="c",
tag="d").reset().edges(tag="d").hull().clean().reset()
# the fillets at the side collide and should be unified with a circle
elif 2 * minr1 >= max_slot_y:
cpts = [] # center points for new circles
scy = (pcbt / 2 + (-pcbt / 2 - block_height_nominal)) / 2
tcpts = [] # top circle points
tcpts.append((tcx, scy))
tcpts.append((-tcx, scy))
# normal case, no fillets collide
else:
# make the right outer circle hull
swp.push(ocpts1).circle(
minr1, mode="c",
tag="c").reset().edges(tag="c").hull().clean().reset()
# make the left outer circle hull
swp.push(ocpts2).circle(
minr1, mode="c",
tag="d").reset().edges(tag="d").hull().clean().reset()
# make the right bottom circle hull
swp.push(bcpts1).circle(
minr1, mode="c",
tag="e").reset().edges(tag="e").hull().clean().reset()
# make the left bottom circle hull
swp.push(bcpts2).circle(
minr1, mode="c",
tag="f").reset().edges(tag="f").hull().clean().reset()
bcy = pcbt / 2 + ffo - (co_tw + minr2
) # y coordinate for the large radius circle
# make the top circle hull
swp.push(tcpts).circle(
minr1, mode="c",
tag="g").reset().edges(tag="g").hull().clean().reset()
# do all the big circle stuff only if the outer fillets haven't merged
if not (2 * minr1 > max_slot_y):
o = scy - bcy # opposite triangle side length (along y)
h = minr2 + minr1 # hypotenuse
if o < 0: # the circles have moved apart: big one above small one (and the trig breaks)
a = h
elif o > h: # the circles have moved apart (and the trig breaks)
a = h # adjacent (along x)
else:
a = h * math.cos(math.asin(o / h))
# a = o/math.tan(math.asin(o/h)) # adjacent (along x)
bcx = scx - a # big circle x
# bcy = pcbt/2+ffo-(co_tw+minr2)
bcpts = []
bcpts.append((-bcx, bcy))
bcpts.append((bcx, bcy))
swp.push([(-scx, scy), (scx, scy)]).circle(minr1).clean().reset()
if o < 0: # the circles have moved apart: big one above small one
scy = bcy
if 2 * minr1 < 2 * ffo + block_width: # the bottom fillets haven't merged
# make the left inner circle hull
swp.push(icpts1).circle(
minr1, mode="c",
tag="h").reset().edges(tag="h").hull().clean().reset()
# make the right inner circle hull
swp.push(icpts2).circle(
minr1, mode="c",
tag="i").reset().edges(tag="i").hull().clean().reset()
swp.polygon([(-bcx, bcy), (bcx, bcy), (scx, scy), (scx, 0), (-scx, 0),
(-scx, scy), (-bcx, bcy)]).clean().reset()
swp.push(bcpts).circle(
minr2, mode="s").clean().reset() # cut away the large circles
swp.push([(0, bcy)]).rect(
2 * bcx, minr2 * 2,
mode="s").clean().reset() # cut away the space between the circles
through_face = swp.finalize().extrude(-1).faces(
">>Z").val() # get just the face for the through cut
swp = swp.wires().offset(min_wall + gland_width /
2).clean().reset() # inner edge of ogland
o_face = swp.finalize().extrude(-1).faces(
">>Z").val() # get just the face for the oring path wire
# passthrough face
pfw = min_wall + gland_width + min_wall + ffo + board_width + ffo + min_wall + gland_width + min_wall # passthrough face width
pfha = min_wall + gland_width + min_wall + screw_nominal_d + (
screw_head_nominal_d / 2 - screw_nominal_d /
2) + min_wall # passthrough face height above cutout top edge
pfhb1 = co_tw + min_wall + gland_width + min_wall + screw_nominal_d + (
screw_head_nominal_d / 2 - screw_nominal_d /
2) + min_wall # passthrough face height below cutout top edge
pfhb2 = ffo + pcbt + block_height_nominal + ffo + min_wall + gland_width + min_wall # passthrough face height below cutout top edge if limited by support block clearance
if pfhb2 > pfhb1: # if the part below the support blocks would be lower, use that to determine the face height
pfhb = pfhb2
else:
pfhb = pfhb1
pfha_pcb = pfha + pcbt / 2 + ffo # passthrough face height above PCB middle
pfh = pfha + pfhb # passthrough face height
pfx = 0
pfy = -pfh / 2 + pfha_pcb
pf_ctr = (pfx, pfy) # passthrough face center
pfdim = (pfw, pfh) # passthrough face dims
pf_fillets = 5 # fillets to corners of passthrough face
pfwp = CQ().sketch() # make passthrough face sketch workplane
pfwp = pfwp.push([pf_ctr]).rect(*pfdim).reset()
pfwp = pfwp.vertices().fillet(pf_fillets).clean().reset()
# swp = swp.wires().offset(gland_width / 2 + min_wall).clean().reset() # edge of passthrough part
# + screw_nominal_d + (screw_head_nominal_d / 2 - screw_nominal_d / 2) + min_wall
passthrough_face = pfwp.finalize().extrude(-1).faces(
">>Z").val() # get just the face for the passthrough part
pfwp = pfwp.wires().offset(min_gap).clean().reset() # edge of recess_cut
recess_face = pfwp.finalize().extrude(-1).faces(
">>Z").val() # get just the face for the recess
# fastening screw hole points
fhps = []
fhps.append(((board_width - 2 * block_width / 2) / 2,
pcbt / 2 + ffo + min_wall + gland_width + min_wall +
fix_scr.clearance_hole_diameters["Close"] / 2))
fhps.append((-(board_width - 2 * block_width / 2) / 2,
pcbt / 2 + ffo + min_wall + gland_width + min_wall +
fix_scr.clearance_hole_diameters["Close"] / 2))
fhps.append((bcx, pcbt / 2 + ffo - co_tw - min_wall - gland_width -
min_wall - fix_scr.clearance_hole_diameters["Close"] / 2))
fhps.append((-bcx, pcbt / 2 + ffo - co_tw - min_wall - gland_width -
min_wall - fix_scr.clearance_hole_diameters["Close"] / 2))
def _make_pcb(what):
"""build the actual passthrough PCB"""
# this copies some logic in the eachpoint() function so that we can use each() which is safer
base_plane = self.plane
base = base_plane.location
if isinstance(what, (cq.Vector, cq.Shape)):
loc = base.inverse * cq.Location(base_plane, what.Center())
elif isinstance(what, cq.Sketch):
loc = base.inverse * cq.Location(base_plane, what._faces.Center())
else:
loc = what
pcb = CQ().workplane(offset=-wall_depth - board_inner_depth)
pcb = pcb.rect(board_width,
pcbt).extrude(until=board_inner_depth + wall_depth +
board_outer_depth)
pcb = pcb.edges("|Y").fillet(pcb_corner)
# put in screws with holes
hardware = cadquery.Assembly()
pcb = pcb.faces(">Y").workplane(**u.cobb).rarray(
board_width - 2 * block_width / 2, board_inner_depth +
board_outer_depth + wall_depth - 2 * pt_pcb_mount_hole_offset[0],
2, 2).clearanceHole(pcb_scr,
fit="Close",
counterSunk=False,
baseAssembly=hardware)
if hw_asy is not None:
hw_asy.add(hardware, loc=base * loc)
# put in pin0 holes
pcb = pcb.faces(">Y").workplane(**u.copo,
origin=(0, 0,
0)).pushPoints(p0pts).circle(
pin0_holed /
2).cutThruAll()
return pcb.findSolid().moved(base * loc)
def _make_pt(what):
"""build a passthrough component"""
# this copies some logic in the eachpoint() function so that we can use each() which is safer
base_plane = self.plane
base = base_plane.location
if isinstance(what, (cq.Vector, cq.Shape)):
loc = base.inverse * cq.Location(base_plane, what.Center())
elif isinstance(what, cq.Sketch):
loc = base.inverse * cq.Location(base_plane, what._faces.Center())
else:
loc = what
hardware = cadquery.Assembly()
passthrough = CQ().add(passthrough_face)
passthrough = passthrough.wires().toPending().extrude(
-part_thickness) # extrude the bulk
slotd = pcbt + 2 * min_gap
passthrough = passthrough.workplane(
centerOption="ProjectedOrigin").slot2D(
length=board_width + slotd / 2, diameter=slotd,
angle=0).cutThruAll() # cut the pcb slot
# TODO: retool some geometry because this cutout could possibly interfere with the oring gland for thick PCBs
# cut the oring groove
cq.Workplane.mk_groove = groovy.mk_groove
oring_path = o_face.outerWire().translate((0, 0, -part_thickness))
passthrough = passthrough.faces("<<Z").workplane(
**u.copo).add(oring_path).toPending().mk_groove(ring_cs=oring_cs,
hardware=hardware)
# cut the fastening screw holes
passthrough = passthrough.faces(">Z").workplane(
**u.copo,
origin=(0, 0,
0)).pushPoints(fhps).clearanceHole(fix_scr,
fit="Close",
baseAssembly=hardware)
# add the support towers
in_post_length = wall_depth + board_inner_depth
passthrough = passthrough.faces(">Z").workplane(
**u.copo, origin=(0, 0, 0)).sketch().push(sbpts).rect(
*support_block).finalize().extrude(-in_post_length)
passthrough = passthrough.faces(">Z").workplane(
**u.copo, origin=(0, 0, 0)).sketch().push(sbpts).rect(
*support_block).finalize().extrude(board_outer_depth)
# mount holes
pcb_center_z = ((board_outer_depth) -
(wall_depth + board_inner_depth)) / 2
passthrough = passthrough.faces("+Y").faces(">>Z").workplane(
**u.copo, origin=(0, 0, pcb_center_z)).rarray(
board_width - 2 * pt_pcb_mount_hole_offset[1],
board_inner_depth + board_outer_depth + wall_depth -
2 * pt_pcb_mount_hole_offset[0], 2,
2).clearanceHole(pcb_scr, fit="Close", counterSunk=False)
passthrough = passthrough.edges("<<Z or >>Z").edges("|Y").fillet(
pcb_corner)
passthrough = passthrough.edges(
"<<Z[-1] or <<Z[-2] or <<Z[-3] or >>Z[-1] or >>Z[-2] or >>Z[-3]"
).chamfer(0.5)
if hw_asy is not None:
hw_asy.add(hardware, loc=base * loc)
return passthrough.findSolid().moved(base * loc)
def _make_neg(what):
"""makes a negative shape to be cut out of the parent walls"""
# this copies some logic in the eachpoint() function so that we can use each() which is safer
base_plane = self.plane
base = base_plane.location
if isinstance(what, (cq.Vector, cq.Shape)):
loc = base.inverse * cq.Location(base_plane, what.Center())
elif isinstance(what, cq.Sketch):
loc = base.inverse * cq.Location(base_plane, what._faces.Center())
else:
loc = what
# fastener threaded holes
# TODO: mark these holes as "M3-0.5 threaded" in the engineering drawing
fhs = CQ().pushPoints(fhps).circle(fix_scr.tap_hole_diameters["Soft"] /
2).extrude(-wall_depth +
pt_fix_wall_buffer)
nwp = CQ().add(through_face)
through = nwp.wires().toPending().extrude(-wall_depth)
nwp2 = CQ().add(recess_face)
recess = nwp2.wires().toPending().extrude(-part_thickness)
neg = recess.union(through).union(fhs)
return neg.findSolid().moved(base * loc)
rslt = self.each(_make_neg,
useLocalCoordinates=False,
combine="cut",
clean=True)
# pass out the passthrough geometry
if pt_asy is not None:
passthroughs = self.each(_make_pt,
useLocalCoordinates=False,
combine=False).vals()
for i, passthrough in enumerate(passthroughs):
pt_asy.add(passthrough.Solids()[0], name=f"passthrough {i}")
# pass out the pcb geometry
if pcb_asy is not None:
# pcbs = self.eachpoint(lambda loc: _make_pcb().moved(loc), useLocalCoordinates=True, combine=False).vals()
pcbs = self.each(_make_pcb, useLocalCoordinates=False,
combine=False).vals()
for i, pcb in enumerate(pcbs):
pcb_asy.add(pcb.Solids()[0], name=f"pcb {i}")
return rslt