projects:tesla_car:doorhandles
Table of Contents
Tesla Model S door handles
Until about 2017, the Model S door handles suffered two problems. These were:
- Water ingress damaged multiple parts. These were:
- Circuit board with the controller.
- Some wires which protrude at connectors got corrosion directly at the exit with green from copper-like color.
- The axis of the gear at the gear box, which stuck in the plastic housing was corroded.
- Missing grease around the gear, probably because soapy water drained all away.
- Broken wires at a moving switch which was mounted at the arm.
- Non working LED illumination module was probably hammered in by Tesla, which caused cracks in the plastic with water ingress and corrosion as a consequence.
Remedy RR-RH
Original part after taking out:
A solution for the switches was to combine both moving switches in a stationary holder. After designing with FreeCAD, the following came out:
Mylar sheet
One of the objectives is to make the doorhandles water-proof. For this the following material has been tested:
- IASOPET OAN 26μm, Zolltarif PET Folie 39206219, BOPP Folie 39202021 (delivered from the company Strohmeier+Ernst GmbH & Co KG, Pilgerplatt 10, 33378 Rheda-Wiedenbrück, Mr. Gottlieb Ernst, Tlf. 05242-406603, Kunde Nr. 500002)
- Hostaphan RNT/36μm, (Delivered by the company Pütz GmbH + Co. Folien KG, Obere Waldstr. 26 + 26a, 65232 Taunusstein-Wehen, Tlf. Mrs. Manuela Erdmann, Tlf. 06128-964270)
FreeCad
The following script creates the RR_RH part:
#!/usr/bin/python # This script creates a small 3d printable enclosure for two switches # to improve the constuction of a tesla retracting door handle. # # copyright: Marc Nijdam # Date of creation: 05.02.2018 # # To run this independent of an instance of freecad, uncomment following lines. #import sys #sys.path.append("/usr/lib/freecad/lib") #import FreeCAD #import FreeCADGui # Otherwise, copy paste this code into the freecad python console. import WebGui import PartDesignGui import math import Part import os.path # helper functions # sketches a line from a to b on a sketch object: App.getDocument("tesla_RR_RH").some_sketch def sketch_line(pl_obj,a,b): return pl_obj.addGeometry(Part.LineSegment(App.Vector(a[0],a[1]),App.Vector(b[0],b[1])),False) # returns sum of two coordinates def addp(a,b): return ([a[0] + b[0], a[1] + b[1]]) # # coordinate system # ________ # ! \_ # ! ! # ! ! # ^ ! ____! # y !_(o)! # # x > # # creation mode: 0:final shape, 1:3d printable shape print_3d = 1 # parameters: stack hb = 2.0 # height of bottom area hb1 = 4.0 # thickness of base 1 hb_mid = 4.0 # thickness of base_mid # parameters: wall thickness # _____ # ! !##2## # ! !1 3 # ! !##4## # ^ ! ____! # y !_(o)! # # x > tw1 = 1.8 # thickness wall 1 tw2 = 1.0 # thickness wall 2 tw3 = 1.8 # thickness wall 3 tw4 = 1.8 # thickness wall 4 # parameters: switch Panasonic ASQ10410 sw_dim = [5.4, 13.3, 12.3] # switch (W x L x H) sw_area = [13.4, 10.0, hb] # left bottom area where switches are [x,y,z] sw_offset = [2.71, 6.66, 7.25] # offset for switch left bottom front corner sw_rotation = [90, 0, 90] # default rotation angle for importing switch sw_gap = 0.1 # extra margin around switch bc_vpos = 3.2 # bottom corner vertical space # # (switch side view) # # _^_ # ! ! # #####___----- # ! ! # ! ! # ! () {} ! () pin {} hole # !___________! # # # # # left bottom ^ # corner is reference point (0,0) # sw_pin = [2.7, 7.2] # position of pin referenced to left bottom corner pin_d = 3.0 # diameter of side pins at switches pin_p = 1.5 # sideways distance of protruding pin sw_hole = [2.7 + 8.3, 7.2] # position of hole referenced to left bottom corner # # (switches top view) # _..__ _ # [_<>__||_] SW1: Width: 13.3, pin: 2.7, pin > hole: 8.3, rest: 2.3 # ''__.._ # [||__<>_] SW2: Width: 13.3, hole: 2.3, hole > pin : 8.3, rest: 2.7, D_hole-right border = 13.3-2.3 = 11.0 # '' # Total width for reciprocal switch mounting: 2.7 + 11.0 = 13.7mm = sw_pin[0] + (sw_dim[1] - (sw_dim[1] - sw_hole[0])) # = sw_pin[0] + sw_hole[0] # Therefore y dimension of wall 2 to position in sw_area = max(sw_dim[1], sw_pin[0] + sw_hole[0]) sw_fname = "/home/mni/Backup/projects/programming/freecad/tesla_adapter_pieces/asq10410.step" # file obtained from Panasonic # parameters: mounting hole position mnt_pos = [10.0, 5.0] # [x,y] mnt_hole1 = 10.0 # diameter of hole at base 1 mnt_hole2 = 3.0 # diameter of hole at base 2 # parameters: total object size obj_dim = [26.0, 26.0, sw_dim[2] + hb + sw_gap] # maximum dimensions of object # parameters: pipe dimensions w_trench = 2.5 # diameter of trench for cable # parameters: small corner to cut away crn_dim = [3.0, 1.5, obj_dim[2]] # small corner to cut material away crn_c_angle = 88 # ref drawing 9b # Screwhead screw_head_d = 4 # screwhead diameter ### deriving points # # calculations based on choniometrical identities # Using: # w_trench: closest distance between two (parallel) lines PQ and MN # w : closest wall thickness (distance between lines HG and QP, FG and PN, MN and EF) # point F is pivot point # point A, B, C, D, F, I, J, K and L are fixed points. # other points depend on value of w and w_trench. # Point X is in the middle, between point I and L # # Line PS is perpendicular to line MN (drawing is not to scale) # _________________________ # ! B----------------------------------C # ! | | # ! | J---------------------------K | # ! | | | | # ! | | | | # ! | | | | # ! | | | | # ! | | | | # ! | | | | # ! | I------Q X M----S---L T # ! | \ . \ \ | # ! A-----H \ . \ E-----D # ! \ \ . \V W # ! \ \ U \ \ # ! \ \ . \ \ # ! \ P-----.----N \ # ! \ . \ # ! (0) ____________G-----------Z----------F # ! ) # ! _/ # !--------------------- # (Drawing 4 - wall) # # # # # Additionally helper points U, V and W are defined, as well as T # Calculation is based on defining helper line XZ, parallel to SF. # In the middle between points U and W, is point V, which is also # the middle point between points X and F. The line UW is perpendicular # to line XZ. Furthermore, the distance of the line: # UW = 0.5 * w_trench + w # Therefore the distance of points UV is m = 0.5 * UW # With that we can calculate the angles a and b which we use to calculate # the coordinates of the remaining points. # sw_width = max(sw_dim[1], sw_pin[0] + sw_hole[0]) # maximum width (in y-direction) for two reciprocal positioned switches Xmax = min(sw_area[0] + sw_dim[0] * 2 + tw3, obj_dim[0]) # Make sure, wall thickness never exceed maximum object size Ymax = min(sw_area[1] + sw_width + tw2, obj_dim[1]) # Make sure, wall thickness never exceed maximum object size w = max(max(max(tw1,tw2),tw3),tw4) # find the thickest wall as base to create strong walls around the wire trench m = (0.5 * w_trench + w) * 0.5 XV = math.sqrt( ((obj_dim[0] - sw_area[0] - sw_dim[0]) / 2) ** 2 + ((sw_area[1] - bc_vpos) / 2) ** 2) a = math.asin(m/XV) # in radians b = math.asin( (sw_area[1] - bc_vpos) / (XV * 2) ) # in radians wh_trench = w_trench / math.sin(a + b) wh = w / math.sin(a + b) # outer wall pt_a = [sw_area[0] - tw1, sw_area[1] - tw4] # starting point pt_b = [sw_area[0] - tw1, Ymax] pt_c = [Xmax, Ymax] pt_d = [Xmax, sw_area[1] - tw4] pt_f = [obj_dim[0], bc_vpos] pt_x = [sw_area[0] + sw_dim[0], sw_area[1]] pt_e = [obj_dim[0] - (sw_area[1] - tw4 - bc_vpos) / math.tan(a + b), sw_area[1] - tw4] pt_g = addp(pt_f, [ - (2 * wh + wh_trench), 0]) pt_h = [pt_g[0] - (pt_f[0] - pt_e[0]), pt_a[1]] # inner wall pt_i = [sw_area[0], sw_area[1]] pt_j = addp(pt_b, [tw1, -tw2]) pt_k = addp(pt_c, [-tw3, -tw2]) pt_l = addp(pt_d, [-tw3, tw4]) pt_m = addp(pt_x, [wh_trench/2, 0]) pt_n = [pt_m[0] + (sw_area[1] - bc_vpos - w) / math.tan(a + b), bc_vpos + w] pt_p = addp(pt_n, [-wh_trench, 0]) pt_q = addp(pt_m, [-wh_trench, 0]) # Initialization App.newDocument("tesla_RR_RH") App.setActiveDocument("tesla_RR_RH") App.ActiveDocument=App.getDocument("tesla_RR_RH") Gui.ActiveDocument=Gui.getDocument("tesla_RR_RH") App.activeDocument().saveAs("/home/mni/Backup/projects/programming/freecad/tesla_adapter_pieces/rear_right_side6.fcstd") ad = App.getDocument("tesla_RR_RH") gd = Gui.getDocument("tesla_RR_RH") # 0. Create grid (key g, key r), set camera position Gui.activateWorkbench("DraftWorkbench") gd.activeView().setCamera('#Inventor V2.1 ascii \n OrthographicCamera {\n viewportMapping ADJUST_CAMERA \n position 0 0 87 \n orientation 0 0 1 0 \n nearDistance -112.88701 \n farDistance 287.28702 \n aspectRatio 1 \n focalDistance 87 \n height 143.52005 }') # 1. Create sketch for ground object # _____ # !####! # !####! # !####!_____ # ^ !#########! # y !#(o)! # # x > r = mnt_hole1/2.0 q = 8.2 # bottom corner horizontal space a1=-math.asin((mnt_pos[0]-q)/r) # starting angle of arc a2=-math.pi/2 - math.asin((mnt_pos[0]-q)/r) # end angle of arc xa1=mnt_pos[0] + math.sqrt(r ** 2 - (mnt_pos[1]-bc_vpos) ** 2) ya2=mnt_pos[1] - math.sqrt(r ** 2 - (mnt_pos[0]-q) ** 2) Gui.activateWorkbench("PartDesignWorkbench") ad.addObject('PartDesign::Body','sw_housing_RR_RH') ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','base_sketch') ad.base_sketch.Support = (ad.XY_Plane, ['']) ad.base_sketch.MapMode = 'FlatFace' Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('base_sketch') so=ad.base_sketch # sketch object gd.setEdit('base_sketch') sketch_line(so, [0.0, 0.0] , [0.0, obj_dim[1]]) sketch_line(so, [0.0, obj_dim[1]] , [sw_area[0] - tw1, obj_dim[1]]) sketch_line(so, [sw_area[0] - tw1, obj_dim[1]] , [sw_area[0]-tw1, sw_area[1]-tw4]) sketch_line(so, [sw_area[0] - tw1, sw_area[1] - tw4], pt_h) sketch_line(so, pt_h, pt_p) sketch_line(so, pt_p, pt_n) sketch_line(so, pt_n, pt_e) sketch_line(so, pt_e, [obj_dim[0], sw_area[1]-tw4]) sketch_line(so, [obj_dim[0], sw_area[1]-tw4] , [obj_dim[0], bc_vpos]) sketch_line(so, [obj_dim[0], bc_vpos] , [xa1, bc_vpos]) so.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1]),App.Vector(0,0,1), r),a2,a1),False) sketch_line(so, [q, ya2], [q, 0.0]) sketch_line(so, [q, 0.0], [0.0, 0.0]) so.addGeometry(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1]),App.Vector(0,0,1), mnt_hole2/2.0),False) ad.recompute() # ... pad base_sketch Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pad","base") ad.base.Profile = so ad.base.Length = hb1 + hb_mid ad.base.Length2 = 100.000000 ad.base.Type = 0 ad.base.UpToFace = None ad.base.Reversed = 0 ad.base.Midplane = 0 ad.base.Offset = 0.000000 gd.setEdit('base', 0) Gui.Selection.clearSelection() gd.base.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.base.LineColor=gd.sw_housing_RR_RH.LineColor gd.base.PointColor=gd.sw_housing_RR_RH.PointColor gd.base.Transparency=gd.sw_housing_RR_RH.Transparency gd.base.DisplayMode=gd.sw_housing_RR_RH.DisplayMode so.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 2. create maximum size floor under switch area and pad # _____ # ! !##### # ! !##### # ! !##### # ^ ! ____! # y !_(o)! # # x > gd.activeView().viewAxonometric() ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','floorbase') ad.floorbase.Support = (ad.XY_Plane, ['']) ad.floorbase.MapMode = 'FlatFace' Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('floorbase') bs=ad.floorbase gd.setEdit('floorbase') sketch_line(bs, [sw_area[0]-tw1, sw_area[1]-tw4], [sw_area[0]-tw1, obj_dim[1] ]) sketch_line(bs, [sw_area[0]-tw1, obj_dim[1] ], [obj_dim[0] , obj_dim[1] ]) sketch_line(bs, [obj_dim[0] , obj_dim[1] ], [obj_dim[0] , sw_area[1]-tw4]) sketch_line(bs, [obj_dim[0] , sw_area[1]-tw4], pt_e) sketch_line(bs, pt_e, pt_n) sketch_line(bs, pt_n, pt_p) sketch_line(bs, pt_p, pt_h) sketch_line(bs, pt_h, [sw_area[0]-tw1, sw_area[1]-tw4]) ad.recompute() # ... pad main_switchfloor Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pad","main_switchfloor") ad.main_switchfloor.Profile = bs ad.main_switchfloor.Length = hb ad.main_switchfloor.Length2 = 100.000000 ad.main_switchfloor.Type = 0 ad.main_switchfloor.UpToFace = None ad.main_switchfloor.Reversed = 0 ad.main_switchfloor.Midplane = 0 ad.main_switchfloor.Offset = 0.000000 gd.setEdit('main_switchfloor', 0) Gui.Selection.clearSelection() gd.main_switchfloor.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.main_switchfloor.LineColor=gd.sw_housing_RR_RH.LineColor gd.main_switchfloor.PointColor=gd.sw_housing_RR_RH.PointColor gd.main_switchfloor.Transparency=gd.sw_housing_RR_RH.Transparency gd.main_switchfloor.DisplayMode=gd.sw_housing_RR_RH.DisplayMode bs.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 3. Create sketch for switch walls and pad # ref. Drawing 4 - wall ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch_walls_sketch') ad.switch_walls_sketch.Support = (ad.main_switchfloor,["Face14"]) # found by testing... ad.switch_walls_sketch.MapMode = 'FlatFace' gd.setEdit('switch_walls_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('switch_walls_sketch') wsk=ad.switch_walls_sketch # sketch for outside wall: sketch_line(wsk, pt_a, pt_b) sketch_line(wsk, pt_b, pt_c) sketch_line(wsk, pt_c, pt_d) sketch_line(wsk, pt_d, pt_e) sketch_line(wsk, pt_e, pt_f) sketch_line(wsk, pt_f, pt_g) sketch_line(wsk, pt_g, pt_h) sketch_line(wsk, pt_h, pt_a) # sketch for inside wall: sketch_line(wsk, pt_i, pt_j) sketch_line(wsk, pt_j, pt_k) sketch_line(wsk, pt_k, pt_l) sketch_line(wsk, pt_l, pt_m) sketch_line(wsk, pt_m, pt_n) sketch_line(wsk, pt_n, pt_p) sketch_line(wsk, pt_p, pt_q) sketch_line(wsk, pt_q, pt_i) ad.recompute() # ... Pad walls Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pad","switch_walls") ad.switch_walls.Profile = wsk ad.switch_walls.Length = obj_dim[2] - hb ad.switch_walls.Length2 = 100.0 ad.switch_walls.Type = 0 ad.switch_walls.UpToFace = None ad.switch_walls.Reversed = 0 ad.switch_walls.Midplane = 0 ad.switch_walls.UpToFace = None gd.setEdit('switch_walls', 0) Gui.Selection.clearSelection() gd.switch_walls.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.switch_walls.LineColor=gd.sw_housing_RR_RH.LineColor gd.switch_walls.PointColor=gd.sw_housing_RR_RH.PointColor gd.switch_walls.Transparency=gd.sw_housing_RR_RH.Transparency gd.switch_walls.DisplayMode=gd.sw_housing_RR_RH.DisplayMode wsk.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 5. create a maximum 0.8mm fillet for inside bottom edges Gui.activateWorkbench("PartDesignWorkbench") ad.sw_housing_RR_RH.newObject("PartDesign::Fillet","Fillet") ad.Fillet.Radius = min(0.8, w_trench / 4) ad.Fillet.Base = (App.ActiveDocument.switch_walls,["Face26"]) Gui.Selection.clearSelection() gd.hide("switch_walls") ad.recompute() gd.setEdit('Fillet', 0) gd.Fillet.ShapeColor=Gui.ActiveDocument.sw_housing_RR_RH.ShapeColor gd.Fillet.LineColor=Gui.ActiveDocument.sw_housing_RR_RH.LineColor gd.Fillet.PointColor=Gui.ActiveDocument.sw_housing_RR_RH.PointColor gd.Fillet.Transparency=Gui.ActiveDocument.sw_housing_RR_RH.Transparency gd.Fillet.DisplayMode=Gui.ActiveDocument.sw_housing_RR_RH.DisplayMode ad.recompute() gd.resetEdit() # 6. Create sketch for m3 screwhead ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','screwhead_sketch') ad.screwhead_sketch.Support = (ad.Fillet,["Face4"]) # found by testing... ad.screwhead_sketch.MapMode = 'FlatFace' gd.setEdit('screwhead_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('screwhead_sketch') ssk=ad.screwhead_sketch ssk.addGeometry(Part.Circle(App.Vector(mnt_pos[0],mnt_pos[1],0),App.Vector(0,0,1),screw_head_d),False) ad.recompute() # ... create a pocket from top downwards Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","screwhead") ad.screwhead.Profile = ssk ad.screwhead.Length = obj_dim[2]-(hb1+hb_mid) ad.screwhead.Length2 = 100.0 ad.screwhead.Type = 0 ad.screwhead.UpToFace = None ad.screwhead.Reversed = 0 ad.screwhead.Midplane = 0 ad.screwhead.UpToFace = None ad.screwhead.Offset = 0.0 gd.setEdit('screwhead', 0) Gui.Selection.clearSelection() gd.screwhead.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.screwhead.LineColor=gd.sw_housing_RR_RH.LineColor gd.screwhead.PointColor=gd.sw_housing_RR_RH.PointColor gd.screwhead.Transparency=gd.sw_housing_RR_RH.Transparency gd.screwhead.DisplayMode=gd.sw_housing_RR_RH.DisplayMode ssk.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 7. Create sketch for slope ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','slope_sketch') ad.slope_sketch.Support = (ad.screwhead,["Face35"]) # found by testing... ad.slope_sketch.MapMode = 'FlatFace' gd.setEdit('slope_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('slope_sketch') lsk=ad.slope_sketch sketch_line(lsk, [-10.5, hb1 + hb_mid], [-obj_dim[0], hb]) # previous height: sw_pin[2] + hb - pin_d/2 sketch_line(lsk, [-obj_dim[0], hb] , [-obj_dim[0], obj_dim[2]]) sketch_line(lsk, [-obj_dim[0], obj_dim[2]] , [-10.5, obj_dim[2]]) sketch_line(lsk, [-10.5, obj_dim[2]] , [-10.5, hb1 + hb_mid]) ad.recompute() # ... create a pocket for the slope with 11.5mm Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","slope") ad.slope.Profile = lsk ad.slope.Length = sw_area[0] - tw1 ad.slope.Length2 = 100.0 ad.slope.Type = 0 ad.slope.UpToFace = None ad.slope.Reversed = 0 ad.slope.Midplane = 0 ad.slope.UpToFace = None gd.setEdit('slope', 0) Gui.Selection.clearSelection() gd.slope.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.slope.LineColor=gd.sw_housing_RR_RH.LineColor gd.slope.PointColor=gd.sw_housing_RR_RH.PointColor gd.slope.Transparency=gd.sw_housing_RR_RH.Transparency gd.slope.DisplayMode=gd.sw_housing_RR_RH.DisplayMode lsk.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 8. create pockets for switch side pin # #____(2)_____(3) <----- Top of object # \ ! ! # \ ! ! # \ ! ! # \ ! ! # \ !<----->! width corresponds with pin diameter # \ ! ! # \ ! ! # \ (1) 0 (4) <------ Pin center (ref: sw_hole) # \ \ / # \ '-_-' # # pin radius: pin_d / 2 # pin thickness: tw1 - 0.3 # column height: tw1 # column length: sw_dim[2] - sw_pin[2] # column width: pin_d # # Pocket 1 ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch1_pocket_sketch') ad.switch1_pocket_sketch.Support = (ad.slope,["Face5"]) # found by testing... ad.switch1_pocket_sketch.MapMode = 'FlatFace' gd.setEdit('switch1_pocket_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('switch1_pocket_sketch') swp1=ad.switch1_pocket_sketch # all coordinates relative to pin center sp_0 = [sw_area[1] + sw_pin[0] , obj_dim[2] - sw_dim[2] + sw_pin[1]] sp_1 = addp(sp_0, [- pin_d / 2, 0]) sp_2 = [sp_1[0], obj_dim[2]] sp_3 = addp(sp_2, [pin_d, 0]) sp_4 = addp(sp_1, [pin_d, 0]) sketch_line(swp1, sp_1, sp_2) sketch_line(swp1, sp_2, sp_3) sketch_line(swp1, sp_3, sp_4) swp1.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(sp_0[0], sp_0[1]), App.Vector(0,0,1), pin_d / 2), math.pi, 0),False) ad.recompute() # ... create a pocket for the switch side-pin Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","switch1_pocket") ad.switch1_pocket.Profile = swp1 ad.switch1_pocket.Length = tw1 - 0.3 ad.switch1_pocket.Length2 = 100.0 ad.switch1_pocket.Type = 0 ad.switch1_pocket.UpToFace = None ad.switch1_pocket.Reversed = 0 ad.switch1_pocket.Midplane = 0 ad.switch1_pocket.UpToFace = None gd.setEdit('switch1_pocket', 0) Gui.Selection.clearSelection() gd.switch1_pocket.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.switch1_pocket.LineColor=gd.sw_housing_RR_RH.LineColor gd.switch1_pocket.PointColor=gd.sw_housing_RR_RH.PointColor gd.switch1_pocket.Transparency=gd.sw_housing_RR_RH.Transparency gd.switch1_pocket.DisplayMode=gd.sw_housing_RR_RH.DisplayMode swp1.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # Pocket 2 ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','switch2_pocket_sketch') ad.switch2_pocket_sketch.Support = (ad.switch1_pocket,["Face23"]) # found by testing... ad.switch2_pocket_sketch.MapMode = 'FlatFace' gd.setEdit('switch2_pocket_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('switch2_pocket_sketch') swp2=ad.switch2_pocket_sketch # all coordinates relative to pin center sp_0 = [-(sw_area[1] + sw_hole[0]) , obj_dim[2] - sw_dim[2] + sw_pin[1]] sp_1 = addp(sp_0, [- pin_d / 2, 0]) sp_2 = [sp_1[0], obj_dim[2]] sp_3 = addp(sp_2, [pin_d, 0]) sp_4 = addp(sp_1, [pin_d, 0]) sketch_line(swp2, sp_1, sp_2) sketch_line(swp2, sp_2, sp_3) sketch_line(swp2, sp_3, sp_4) swp2.addGeometry(Part.ArcOfCircle(Part.Circle(App.Vector(sp_0[0], sp_0[1]), App.Vector(0,0,1), pin_d / 2), math.pi, 0),False) ad.recompute() # ... create a pocket for the switch side-pin Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","switch2_pocket") ad.switch2_pocket.Profile = swp2 ad.switch2_pocket.Length = tw3 - 0.3 ad.switch2_pocket.Length2 = 100.0 ad.switch2_pocket.Type = 0 ad.switch2_pocket.UpToFace = None ad.switch2_pocket.Reversed = 0 ad.switch2_pocket.Midplane = 0 ad.switch2_pocket.UpToFace = None gd.setEdit('switch2_pocket', 0) Gui.Selection.clearSelection() gd.switch2_pocket.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.switch2_pocket.LineColor=gd.sw_housing_RR_RH.LineColor gd.switch2_pocket.PointColor=gd.sw_housing_RR_RH.PointColor gd.switch2_pocket.Transparency=gd.sw_housing_RR_RH.Transparency gd.switch2_pocket.DisplayMode=gd.sw_housing_RR_RH.DisplayMode swp2.ViewObject.Visibility=False ad.recompute() gd.resetEdit() # 9. cut away small corner # # Coordinate system: # _____ # ! !####X <--- small corner to cut away # ! !# # # ! !## ## # ^ ! __\\_ # -y !_(o)! # +x > # .--- crn_dim[0] # \/ # 2_______1 # ! ! \ # ! ! !_ crn_dim[1] # 3__ c ! ! # ''--__4 / # # (drawing 9b - corner cut) # # Angle c is somewhat smaller # than 90 degrees # # ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','corner_cut_sketch') ad.corner_cut_sketch.Support = (ad.switch2_pocket,["Face39"]) # found by testing... ad.corner_cut_sketch.MapMode = 'FlatFace' gd.setEdit('corner_cut_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('corner_cut_sketch') ccs=ad.corner_cut_sketch cc_1 = [obj_dim[0], -obj_dim[1]] cc_2 = addp(cc_1, [-crn_dim[0], 0]) cc_4 = addp(cc_1, [0 , crn_dim[1]]) cc_3 = addp(cc_4, [-crn_dim[0], -crn_dim[0]/math.tan(crn_c_angle * math.pi / 180)]) sketch_line(ccs, cc_1, cc_2) sketch_line(ccs, cc_2, cc_3) sketch_line(ccs, cc_3, cc_4) sketch_line(ccs, cc_4, cc_1) ad.recompute() gd.resetEdit() # create pocket Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","corner_cut") ad.corner_cut.Profile = ccs ad.corner_cut.Length = obj_dim[2] * 1.5 ad.corner_cut.Length2 = 100.0 ad.corner_cut.Type = 0 ad.corner_cut.UpToFace = None ad.corner_cut.Reversed = 0 ad.corner_cut.Midplane = 0 ad.corner_cut.UpToFace = None gd.setEdit('corner_cut', 0) Gui.Selection.clearSelection() ccs.ViewObject.Visibility=False gd.corner_cut.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.corner_cut.LineColor=gd.sw_housing_RR_RH.LineColor gd.corner_cut.PointColor=gd.sw_housing_RR_RH.PointColor gd.corner_cut.Transparency=gd.sw_housing_RR_RH.Transparency gd.corner_cut.DisplayMode=gd.sw_housing_RR_RH.DisplayMode ad.recompute() gd.resetEdit() # 10. last final operation: create pocket from # circle on bottom face for the print_3d option: # if set, cut out cylinder which cannot be 3d printed r_circle = mnt_hole1/2.0 ad.sw_housing_RR_RH.newObject('Sketcher::SketchObject','cut_sketch') ad.cut_sketch.Support = (ad.corner_cut,["Face38"]) # found by testing... ad.cut_sketch.MapMode = 'FlatFace' gd.setEdit('cut_sketch') Gui.activateWorkbench('SketcherWorkbench') ActiveSketch = ad.getObject('cut_sketch') csk=ad.cut_sketch csk.addGeometry(Part.Circle(App.Vector(mnt_pos[0],-mnt_pos[1],0),App.Vector(0,0,1), r_circle),False) ad.recompute() gd.resetEdit() # create pocket Gui.activateWorkbench('PartDesignWorkbench') ad.sw_housing_RR_RH.newObject("PartDesign::Pocket","baseprt") ad.baseprt.Profile = csk ad.baseprt.Length = hb1 ad.baseprt.Length2 = 100.0 ad.baseprt.Type = 0 ad.baseprt.UpToFace = None ad.baseprt.Reversed = 0 ad.baseprt.Midplane = 0 ad.baseprt.UpToFace = None gd.setEdit('baseprt', 0) Gui.Selection.clearSelection() csk.ViewObject.Visibility=False gd.baseprt.ShapeColor=gd.sw_housing_RR_RH.ShapeColor gd.baseprt.LineColor=gd.sw_housing_RR_RH.LineColor gd.baseprt.PointColor=gd.sw_housing_RR_RH.PointColor gd.baseprt.Transparency=gd.sw_housing_RR_RH.Transparency gd.baseprt.DisplayMode=gd.sw_housing_RR_RH.DisplayMode ad.recompute() gd.resetEdit() # 11. import switches if file is present if os.path.isfile(sw_fname) and print_3d == 1: import ImportGui # import switch1 ImportGui.insert(sw_fname,"tesla_RR_RH") App.activeDocument().Part__Feature.Placement=App.Placement(App.Vector(sw_offset[0] + sw_area[0], sw_offset[1] + sw_area[1], sw_offset[2] + sw_area[2] + sw_gap), App.Rotation(90,0,90), App.Vector(0,0,0)) #import switch2 ImportGui.insert(sw_fname,"tesla_RR_RH") App.activeDocument().Part__Feature001.Placement=App.Placement(App.Vector(sw_offset[0] + sw_area[0] + sw_dim[0], sw_offset[1] + sw_area[1] + (sw_pin[1] - (sw_dim[1] - sw_hole[1])), sw_offset[2] + sw_area[2] + sw_gap), App.Rotation(-90,0,90), App.Vector(0,0,0)) # finished Gui.SendMsgToActiveView("ViewFit") Gui.activeDocument().activeView().viewAxonometric()
projects/tesla_car/doorhandles.txt · Last modified: 2018/09/11 00:50 by admin