"""One-piece removable pickup cartridge, plus separate removable print aids.
Assembly datums retained; root and snap flange raised1.1mm per Rev I decision.
"""
from pathlib import Path
import cadquery as cq,numpy as np,trimesh,json,math,hashlib,time
D=Path(__file__).resolve().parent
Z0=148.3;Z1=151.3
def cyl(r,a,b):return cq.Solid.makeCylinder(r,b-a,cq.Vector(0,0,a))
def box(x0,x1,y0,y1,z0,z1):return cq.Solid.makeBox(x1-x0,y1-y0,z1-z0,cq.Vector(x0,y0,z0))
def xz(points,y0,y1):
 w=cq.Wire.makePolygon([cq.Vector(x,y0,z) for x,z in points],close=True)
 return cq.Solid.extrudeLinear(w,[],cq.Vector(0,y1-y0,0))
def revolved(points,a,b):
 w=cq.Wire.makePolygon([cq.Vector(r,0,z) for r,z in points],close=True)
 return cq.Solid.revolve(w,[],b-a,cq.Vector(0,0,0),cq.Vector(0,0,1)).rotate((0,0,0),(0,0,1),a)
def sector(r0,r1,z0,z1,a,b):return revolved([(r0,z0),(r1,z0),(r1,z1),(r0,z1)],a,b)
def info(s):
 b=s.BoundingBox();return {'valid':s.isValid(),'solids':len(s.Solids()),'faces':len(s.Faces()),'volume_mm3':s.Volume(),'bounds_mm':[b.xmin,b.xmax,b.ymin,b.ymax,b.zmin,b.zmax]}
def pose(s):return s.rotate((0,0,0),(1,0,0),180).translate((0,0,Z1))
def load(p):return cq.Compound.makeCompound(cq.importers.importStep(str(p)).vals())
def export(s,name):
 p=D/name;s.exportStep(str(p),write_pcurves=False,precision_mode=1);b=load(p)
 assert b.isValid() and len(b.Solids())==len(s.Solids()),(name,info(b))
 return {**info(b),'sha256':hashlib.sha256(p.read_bytes()).hexdigest()}
def build():
 flange=cyl(22.3,Z0,Z1).cut(cyl(13.4,Z0-.1,Z1+.1))
 slot_angles=[(68,111),(208,251),(338,381)]
 for a,b in slot_angles:
  #1.15mm slot permits the0.9mm geometric entry travel;0.6mm would not.
  flange=flange.cut(sector(19.55,20.7,Z0-.1,Z1+.1,a,b))
  flange=flange.cut(sector(19.55,24,Z0-.1,Z1+.1,b,b+2))
  nub=revolved([(22.1,Z0),(23.3,Z0),(23.3,Z1-1),(22.3,Z1),(22.1,Z1)],b-8,b-.3)
  flange=flange.fuse(nub)
 flange=flange.fuse(sector(22.2,23.3,Z0,Z1,148,152))
 leaves=[];supports=[]
 for a,w,h in [(38,6,12),(180,8,15),(322,6,12)]:
  leaf=box(16.4,17.8,-w/2,w/2,129.2,148.5)
  lip=xz([(16.4,127.8),(17.8,127.8),(17.8,129.3),(14.5,129.3),(14.5,128.6)],-w/2,w/2)
  leaf=leaf.fuse(lip).rotate((0,0,0),(0,0,1),a)
  leaf=leaf.fuse(sector(16.4,20,146.6,148.6,a-h,a+h));leaves.append(leaf)
  #The support begins on the bed inside the flange's bore, then fans out
  #at45degrees beneath the inward flat stop.0.2mm axial breakout gap.
  hw=math.degrees((w-1)/2/16.2)
  supports.append(revolved([(11,Z1),(13.2,Z1),(13.2,132.5),(16.2,129.5),(14.65,129.5),(11,133.15)],a-hw,a+hw))
 body=flange.fuse(*leaves)
 assert body.isValid() and len(body.Solids())==1,info(body)
 return body,cq.Compound.makeCompound(supports)
def run():
 t=time.time();body,supports=build();r={'revision':'I','status':'One additional internal printed cartridge; two exterior shroud parts remain. Hardware fit and spring durability remain untested.',
 'assembly':export(body,'RAMSELE_Pickup_Cartridge.step'),'print_pose':export(pose(body),'RAMSELE_Pickup_Cartridge_Print_Orientation.step'),
 'supports_assembly':export(supports,'Cartridge_Removable_Hook_Supports.step'),'supports_print_pose':export(pose(supports),'Cartridge_Removable_Hook_Supports_Print_Orientation.step')}
 r['dimensions_mm']={'root_annulus_radii':[13.4,22.3],'root_z':[Z0,Z1],'leaf_radii':[16.4,17.8],'leaf_widths':[6,8,6],'leaf_angles':[38,180,322],'guide_z':[146.6,148.6],
 'lower_stop_z':129.3,'lowest_hook_z':127.8,'grip_diameter_assumed':31.5,'grip_height_assumed':10,'grip_free_axial_travel':9.0,'grip_low_z':[129.3,139.3],'grip_high_z':[138.3,148.3],
 'spring_slot_radii':[19.55,20.7],'spring_band_radii':[20.7,22.3],'spring_band_thickness':1.6,'nub_max_radius':23.3,'nub_upper_cam_slope':1,'key_angles':[148,152],'key_radii':[22.2,23.3]}
 r['checks']={}
 r['checks']['full_grip_travel_overlap_mm3']=body.intersect(cyl(15.75,129.3001,148.2999)).Volume()
 assert abs(r['checks']['full_grip_travel_overlap_mm3'])<1e-5
 for name,z,dz in [('lower',129.3,-.1),('upper',138.3,.1)]:
  grip=cyl(15.75,z,z+10);nom=body.intersect(grip).Volume();over=body.intersect(grip.translate((0,0,dz))).Volume()
  r['checks'][name+'_axial_stop']={'nominal_overlap_mm3':nom,'overtravel_0_1mm_overlap_mm3':over}
  assert abs(nom)<1e-5 and over>.1
 r['checks']['support_overlap_mm3']=body.intersect(supports).Volume();assert abs(r['checks']['support_overlap_mm3'])<1e-5
 back=load(D/'RAMSELE_Pickup_Cartridge.step');half=back.intersect(box(-30,30,.1,30,125,155));r['checks']['positive_half_cut_mm3']=half.Volume();assert half.isValid() and half.Volume()>1
 #Export and recheck the small printable part. Zero-area triangles have no
 #surface extent; removing them does not alter any vertex or designed shape.
 posed=pose(body);raw=D/'RAMSELE_Pickup_Cartridge_Print_Orientation_raw.stl';posed.exportStl(str(raw),tolerance=.025,angularTolerance=.08,relative=False)
 m=trimesh.load_mesh(raw,process=True,validate=False);n0=len(m.faces);m.update_faces(m.area_faces>0);m.remove_unreferenced_vertices()
 p=D/'RAMSELE_Pickup_Cartridge_Print_Orientation.stl';p.write_bytes(trimesh.exchange.stl.export_stl(m));m=trimesh.load_mesh(p,process=True,validate=False)
 components=trimesh.graph.connected_components(m.face_adjacency,nodes=np.arange(len(m.faces)),min_len=1)
 assert m.is_watertight and m.is_winding_consistent and m.is_volume and len(components)==1 and abs(m.bounds[0,2])<1e-5
 r['mesh']={'watertight':bool(m.is_watertight),'winding_consistent':bool(m.is_winding_consistent),'positive_volume':bool(m.is_volume),'components':len(components),'zero_area_faces_removed':n0-len(m.faces),'vertex_movement_mm':0.,'bounds_mm':m.bounds.tolist(),'sha256':hashlib.sha256(p.read_bytes()).hexdigest()}
 r['print_orientation']='Upper flange face down: rotate180degrees aroundX, translate+151.3mm Z. Hooks point upward. Three separate, removable supports begin inside the bore atbedZ0 and fan45degrees under hook bearing faces; axial breakout gap0.2mm. Remove them before installing pickup.'
 r['spring_notes']='Snap arms are intentional flexible bands, not rigid supports. Approximate insertion radial movement0.9mm. The1.15mm inward slot replaces an impossible0.6mm requested gap. No material, fatigue, force, or printed-fit validation.'
 r['runtime_s']=time.time()-t;(D/'cartridge_check.json').write_text(json.dumps(r,indent=2)+'\n');print(json.dumps(r,indent=2),flush=True)
if __name__=='__main__':run()