"""Primary injection test pin ("tulip") for testing molded case circuit breakers.

One end is a milled hex that slides through the breaker's terminal cover into the set-screw box lug. A short
round neck flows into a tangent "tulip" turned straight onto the square bar, so there is no sharp shoulder where
the pin levers against the lug mouth. Everything behind the tulip is one solid rounded-square section (no round
body, no holes) that the test cable's lug is clamped to with vise-grips. Each pin is made from one square bar of
C18150 or C18200 copper alloy, TH04 temper, left bare.

`size` picks one of seven sizes: the Ampteks traditional hex set (3/16, 7/32, 1/4, 5/16, 3/8, 1/2 in across
flats) plus 5/8 for large frames. Hex lengths clear deep terminal covers. `hex_length` and `overall_length` can
be overridden. Pin axis along +x, hex tip at the origin, a hex corner pointing +z. Dimensions are set in inches;
the model is built in mm.
"""
import math

import cadquery as cq
from steve import Model

size = "5"  # Size
hex_length = 0  # in Hex length override (0 = size default)
overall_length = 0  # in Overall length override (0 = size default)

IN = 25.4
LN = 0.25  # neck length
SIZES = {
    # hex across flats, hex length, square width, corner radius, tulip length, overall length
    "1": dict(AF=3 / 16, Lh=2.00, sq=0.50, rc=0.06, Lf=0.50, L=8.0),
    "2": dict(AF=7 / 32, Lh=2.25, sq=0.50, rc=0.06, Lf=0.50, L=8.0),
    "3": dict(AF=1 / 4, Lh=2.25, sq=0.50, rc=0.06, Lf=0.50, L=8.0),
    "4": dict(AF=5 / 16, Lh=2.50, sq=0.625, rc=0.075, Lf=0.50, L=8.0),
    "5": dict(AF=3 / 8, Lh=3.25, sq=0.75, rc=0.09, Lf=0.50, L=8.5),
    "6": dict(AF=1 / 2, Lh=3.75, sq=1.00, rc=0.125, Lf=0.625, L=9.0),
    "7": dict(AF=5 / 8, Lh=4.00, sq=1.00, rc=0.125, Lf=0.625, L=9.5),
}
s = dict(SIZES[str(size)])
if hex_length:
    if not 1.0 <= hex_length <= 8.0:
        raise ValueError("hex_length must be 0 (size default) or between 1 and 8 in.")
    s["Lh"] = float(hex_length)
if overall_length:
    s["L"] = float(overall_length)
if s["L"] - s["Lh"] - LN - s["Lf"] < 2.0:
    raise ValueError("overall_length must leave at least 2 in of full square behind the tulip.")
if s["L"] > 24.0:
    raise ValueError("overall_length must be at most 24 in.")

AF, Lh, L = s["AF"], s["Lh"], s["L"]
AC = AF / math.cos(math.radians(30))                    # across corners
Dn = math.ceil((AC + 0.01) * 200) / 200                 # neck just over across-corners
h = s["sq"] / 2
Rc = (h - s["rc"]) * math.sqrt(2) + s["rc"]             # radial reach of the rounded corners
x_neck, x_flare = Lh, Lh + LN
x_full = x_flare + s["Lf"]


def u(v):
    return v * IN


# hex prism along +x with a 30 degree chamfered tip
hexp = cq.Workplane("YZ").polygon(6, u(AC)).extrude(u(Lh + 0.02))
r0 = 0.45 * AF
r1 = AC / 2 + 0.02
dx = (r1 - r0) * math.tan(math.radians(30))
lim = (cq.Workplane("XY").polyline([(0, 0), (0, u(r0)), (u(dx), u(r1)), (u(Lh + 0.02), u(r1)), (u(Lh + 0.02), 0)])
       .close().revolve(360, (0, 0, 0), (1, 0, 0)))
hexp = hexp.intersect(lim)

# short round neck
rn = Dn / 2
neck = (cq.Workplane("XY").moveTo(u(x_neck), 0).lineTo(u(x_neck), u(rn)).lineTo(u(x_flare + 0.01), u(rn))
        .lineTo(u(x_flare + 0.01), 0).close().revolve(360, (0, 0, 0), (1, 0, 0)))

# tulip turned onto the square bar: a revolved envelope intersected with the rounded-square prism
Rt = Rc + 0.002
env = (cq.Workplane("XY").moveTo(u(x_flare), 0).lineTo(u(x_flare), u(rn))
       .spline([(u(x_full), u(Rt))], tangents=[(1, 0), (1, 0)], includeCurrent=True)
       .lineTo(u(L), u(Rt)).lineTo(u(L), 0).close().revolve(360, (0, 0, 0), (1, 0, 0)))
sqb = (cq.Workplane("YZ").workplane(offset=u(x_flare)).rect(u(s["sq"]), u(s["sq"])).extrude(u(L - x_flare))
       .edges("|X").fillet(u(s["rc"])))
sqb = sqb.faces(">X").edges().chamfer(u(0.03))
body = sqb.intersect(env)

pin = hexp.union(neck).union(body)
try:
    pin = pin.faces("<X").edges().chamfer(u(0.01))
except Exception:
    pass

model = Model()
model.add("pin", pin.val(), op="new", name=f"Test pin size {size}")
model.material("copper-c15000", bodies=["pin"], finish="machined", color="#c9774e")
result = model.result()