建立方向盘项目初始版本

models/encoder_standoff_plate_print/build.FCMacro

@@ -0,0 +1,70 @@
+from pathlib import Path
+import math, json, os, traceback, time
+import FreeCAD as A, FreeCADGui as G, Part, Mesh, MeshPart, Import
+V=A.Vector
+root=Path(r'C:\projects\wheel')
+out=root/'models'/'encoder_standoff_plate_print'
+try:
+    src=A.openDocument(str(root/'models'/'symmetric_corner_18_concept'/'Assembly_对称角码装配_概念.FCStd'))
+    src.recompute()
+    plate=src.getObject('EncoderPlateConcept').Shape.copy()
+    assert plate.isValid() and len(plate.Solids)==1 and plate.Volume>1
+    # 10mm standoff with 1mm shim -> support face at z=11, rear motor z=0.
+    plate.translate(V(0,0,0.1))
+    hit=[]; distances=[]
+    for o in src.Objects:
+        if not hasattr(o,'Shape') or o.Shape.isNull() or not o.ViewObject.Visibility or o.Name=='EncoderPlateConcept': continue
+        if o.Name.startswith(('EncoderHex','EncoderSpacer')): continue
+        v=plate.common(o.Shape).Volume if plate.BoundBox.intersect(o.Shape.BoundBox) else 0
+        if v>0.001: hit.append((o.Name,round(v,6)))
+        if o.Name.startswith(('NewMotorCorner','Rail')):
+            distances.append((o.Name,round(plate.distToShape(o.Shape)[0],5)))
+    # Test panel has four complete M4 clear bores, as in the source design.
+    bore=[]
+    for k in range(4):
+        angle=math.radians(45+90*k)
+        x=25*math.cos(angle);y=10+25*math.sin(angle)
+        probe=Part.makeCylinder(2.19,3.3,V(x,y,10.95))
+        bore.append(round(probe.common(plate).Volume,6))
+    assert max(bore)<1e-5
+    # The old PCB rests against the lower face of this 3.2 mm slab. Verify
+    # each 1.8 mm pilot and surrounding pads match the old original panel.
+    pcb_centres=[(0,13.49),(-11.71,-6.76),(11.71,-6.76)]
+    pcb_probes=[]; pcb_pad=[]
+    for x,y in pcb_centres:
+        y+=10
+        probe=Part.makeCylinder(.89,3.3,V(x,y,10.95))
+        pcb_probes.append(round(probe.common(plate).Volume,6))
+        pad=Part.makeCylinder(3.1,3.2,V(x,y,11))
+        pcb_pad.append(round(pad.common(plate).Volume,6))
+    assert max(pcb_probes)<1e-5 and min(pcb_pad)>50
+    orig=src.getObject('OpenPillarBracket').Shape.common(Part.makeBox(120,120,3.2,V(-60,-60,10.9)))
+    compare=plate.copy();compare.translate(V(0,0,-.1))
+    panel_diff=[orig.cut(compare).Volume,compare.cut(orig).Volume]
+    assert max(panel_diff)<1e-5
+    # Put support face flat on build plate and centre the source motor axis.
+    printed=plate.copy();printed.translate(V(0,-10,-11))
+    assert abs(printed.BoundBox.ZMin)<1e-5
+    doc=A.newDocument('EncoderStandoffPlate')
+    obj=doc.addObject('PartDesign::Feature','EncoderPlate')
+    obj.Label='PCD50 encoder panel - four metal stand-offs'
+    obj.Shape=printed;obj.ViewObject.ShapeColor=(.15,.4,.85)
+    doc.recompute();doc.saveAs(str(out/'EncoderPlate.FCStd'))
+    Import.export([obj],str(out/'EncoderPlate.step'))
+    mesh=MeshPart.meshFromShape(Shape=printed,LinearDeflection=0.05,AngularDeflection=math.radians(15),Relative=False)
+    mesh.write(str(out/'EncoderPlate.stl'))
+    mesh2=Mesh.Mesh(str(out/'EncoderPlate.stl'))
+    assert mesh2.isSolid() and mesh2.Volume>0
+    step=Part.read(str(out/'EncoderPlate.step'))
+    assert step.isValid() and len(step.Solids)==1
+    G.activateWorkbench('PartWorkbench');G.activeDocument().activeView().viewAxonometric();G.updateGui();time.sleep(.6);view=G.activeDocument().activeView();view.fitAll();G.updateGui();time.sleep(.6);view.saveImage(str(out/'EncoderPlate.png'),1400,1000,'White')
+    report={'solid_valid':printed.isValid(),'solids':len(printed.Solids),'volume_mm3':printed.Volume,'dimensions_mm':[printed.BoundBox.XLength,printed.BoundBox.YLength,printed.BoundBox.ZLength],'mesh_closed':mesh2.isSolid(),'mesh_volume_mm3':mesh2.Volume,'bore_probe_intersections_mm3':bore,'pcb_pilot_probe_intersections_mm3':pcb_probes,'pcb_pad_material_mm3':pcb_pad,'original_panel_two_way_difference_mm3':panel_diff,'tested_position':'10 mm standoffs + 1 mm shim, panel bottom at z=11 mm','positive_intersections_mm3':hit,'angle_rail_clearances_mm':distances,'warning':'All geometry and PCB dimensions assumed; tool access and physical assembly unverified.'}
+    (out/'验证.json').write_text(json.dumps(report,ensure_ascii=False,indent=2),encoding='utf8')
+    A.closeDocument(doc.Name)
+    reopened=A.openDocument(str(out/'EncoderPlate.FCStd'));reopened.recompute()
+    assert reopened.getObject('EncoderPlate').Shape.isValid();A.closeDocument(reopened.Name)
+    A.closeDocument(src.Name)
+    (out/'完成.txt').write_text('ok',encoding='utf8')
+except Exception:
+    (out/'错误.txt').write_text(traceback.format_exc(),encoding='utf8')
+os._exit(0)

models/encoder_standoff_plate_print/完成.txt

@@ -0,0 +1 @@
+ok

models/encoder_standoff_plate_print/打印和装配说明.md

@@ -0,0 +1,11 @@
+# MT6826S 编码器支架：金属柱试装版
+
+`EncoderPlate.stl` 为单个整件，打印 1 件；`EncoderPlate.step` 和 `EncoderPlate.FCStd` 为对应模型。支架为 49 × 49 × 3.2 mm 的面板，不带塑料立柱，打印时平面贴平台。PCB 圆孔、三个局部支撑耳、三个直径 1.8 mm 的自攻导孔和 PCD50 四个直径 4.4 mm 的通孔完整保留自原支架；PCB Ø33 mm、三孔位置均为既有图像估算，须按实物试装。导孔可试配 M2 小自攻螺丝，避免拧裂 PCB 或支架，按实际孔深和螺钉头复核。
+
+支架用 **4 根 M4 公母六角金属柱，柱身长 10 mm、对边约 7 mm** 固定到电机的 PCD50 孔。柱身长度不包含公牙。柱体旋入电机之前，必须确认公牙长度、盲孔实际深度和足够有效啮合；M4×8 螺丝规格不能证明电机孔深。顶部另用 4 颗 M4 螺丝和合适平垫，实际长度按面板 3.2 mm、调整垫片及柱内螺纹深度选取，不得顶底。
+
+柱顶和支架之间放 4 片等厚非磁性金属垫片，调整 PCB 到磁铁的距离。开始试装可选每处 1 mm：断电慢转检查磁铁与芯片不能碰擦，再检查编码器角度与磁场状态。减少垫片使间隙变小，增加则变大，四处保持同厚。
+
+以下只是原近似几何推算：PCB 厚按 1.6 mm、芯片凸起 0.8 mm、磁铁表面距电机背面 7.5 mm。若铜柱不额外垫高，板面距电机背面 = 10 + 垫片厚度，名义间隙 = 板面距离 − 1.6 − 0.8 − 7.5 = 垫片厚度 + 0.1 mm。实物 PCB、芯片、磁铁及轴向跳动未测，不能据此保证实际间隙。磁铁座可靠固定并确认同轴后再转动测试。
+
+验证记录见 `验证.json`：STL 为单一闭合网格；STEP 为单实体，FCStd 重新打开后有效；三处 PCB 导孔和四处 M4 孔均做了探针检查，原面板双向实体差为零。以 10 mm 柱加 1 mm 垫片的示意位置检查面板，与装配内可见零件无正体积相交；实际五金、螺丝头、工具、PCB 背面元件、线束、完整工作运动和实物尺寸仍需试装。对边 7 mm 的铜柱与新角码仅按近似模型评估，需实物确认。

models/encoder_standoff_plate_print/验证.json

@@ -0,0 +1,77 @@
+{
+  "solid_valid": true,
+  "solids": 1,
+  "volume_mm3": 4906.512274176155,
+  "dimensions_mm": [
+    49.0,
+    49.0,
+    3.200000000000001
+  ],
+  "mesh_closed": true,
+  "mesh_volume_mm3": 4910.2578125,
+  "bore_probe_intersections_mm3": [
+    0.0,
+    0.0,
+    0.0,
+    0.0
+  ],
+  "pcb_pilot_probe_intersections_mm3": [
+    0.0,
+    0.0,
+    0.0
+  ],
+  "pcb_pad_material_mm3": [
+    88.467249,
+    88.467249,
+    88.467249
+  ],
+  "original_panel_two_way_difference_mm3": [
+    0.0,
+    0.0
+  ],
+  "tested_position": "10 mm standoffs + 1 mm shim, panel bottom at z=11 mm",
+  "positive_intersections_mm3": [],
+  "angle_rail_clearances_mm": [
+    [
+      "Rail0",
+      16.37006
+    ],
+    [
+      "Rail1",
+      16.37006
+    ],
+    [
+      "NewMotorCorner00",
+      9.2
+    ],
+    [
+      "RailWasher00",
+      14.37063
+    ],
+    [
+      "NewMotorCorner01",
+      9.2
+    ],
+    [
+      "RailWasher01",
+      14.37063
+    ],
+    [
+      "NewMotorCorner10",
+      9.2
+    ],
+    [
+      "RailWasher10",
+      14.37063
+    ],
+    [
+      "NewMotorCorner11",
+      9.2
+    ],
+    [
+      "RailWasher11",
+      14.37063
+    ]
+  ],
+  "warning": "All geometry and PCB dimensions assumed; tool access and physical assembly unverified."
+}