建立方向盘项目初始版本

models/kfl_double_crossbar_concept/DONE.txt

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+ok

models/kfl_double_crossbar_concept/geometry_check.txt

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+CONCEPT ONLY: schematic profile envelopes and simplified hardware; not CNC/manufacturing drawings.
+Two plate sizes 76x80x8; 39 bore assumed, KFL bolt centres 48 and clearance holes 7. Shaft diameter 12 x 150; switch 60 mm envelope.
+Crossbars x -80..80, y -95..-75, z -76..-56 / -207..-187, each beneath longitudinal profiles y -75..-55.
+Four assumed bent metal angles: outer legs 45 x 20, width 18, thickness 3, actual bend radius unspecified; foot round hole diameter 5.5, vertical 9.5 x 5.5 slot Y; plate slot 9.5 x 5.5 X at y=-42.
+Proposed nominal M5 adjustment about +/-2mm each axis; requires testing of all actual washer, shaft, bearing and interference conditions. Each plate washer OD10 at slot lower travel remains within plate edge by nominal 2mm.
+T slots shown as SOLID 2020 ENVELOPES: fastener shanks intentionally enter solid beam; do not treat as interference free, actual T nut and bolt depth must be checked.
+Four standard corner angles join crossbars to long profiles, two per crossbar. Screw access, T nuts, actual slot geometry, bending radii, switch casing and strength unverified.
+Selected static common volume tests mm3; zero volume checks apply ONLY to modeled shapes and those specific pairs:
+CompactPlate0/KFLHousing0=0.00000
+CompactPlate0/KFLInner0=0.00000
+CompactPlate0/Motor=0.00000
+CompactPlate0/MotorFlange=0.00000
+CompactPlate0/WheelHub=0.00000
+CompactPlate0/Wheel70=0.00000
+CompactPlate0/SwitchEnvelope=0.00000
+CompactPlate0/NewRail0=0.00000
+CompactPlate0/NewRail1=0.00000
+CompactPlate0/Crossbeam0=0.00000
+Crossbeam0/NewRail0=0.00000
+Crossbeam0/NewRail1=0.00000
+Crossbeam0/SwitchEnvelope=0.00000
+Crossbeam0/Motor=0.00000
+Crossbeam0/CamShaft=0.00000
+Crossbeam0/CamUpper=0.00000
+Crossbeam0/CamLower=0.00000
+LongAngle00/CompactPlate0=0.00000
+LongAngle00/KFLHousing0=0.00000
+LongAngle00/KFLInner0=0.00000
+LongAngle00/Motor=0.00000
+LongAngle00/MotorFlange=0.00000
+LongAngle00/WheelHub=0.00000
+LongAngle00/Wheel70=0.00000
+LongAngle00/SwitchEnvelope=0.00000
+LongAngle00/Crossbeam0=0.00000
+LongAngle00/NewRail0=0.00000
+LongAngle00/NewRail1=0.00000
+LongAngle00/BoardM5_00=0.00000
+LongAngle00/FootM5_00=0.00000
+LongAngle00/CrossAngle00=0.00000
+CrossAngle00/Crossbeam0=0.00000
+CrossAngle00/NewRail0=0.00000
+CrossAngle00/SwitchEnvelope=0.00000
+CrossAngle00/Motor=0.00000
+CrossAngle00/LongAngle00=0.00000
+CrossAngle00/CrossTopM5_00=0.00000
+CrossAngle00/CrossSideM5_00=0.00000
+BoardM5_00/CompactPlate0=0.00000
+FootM5_00/CrossTopM5_00=0.00000
+LongAngle01/CompactPlate0=0.00000
+LongAngle01/KFLHousing0=0.00000
+LongAngle01/KFLInner0=0.00000
+LongAngle01/Motor=0.00000
+LongAngle01/MotorFlange=0.00000
+LongAngle01/WheelHub=0.00000
+LongAngle01/Wheel70=0.00000
+LongAngle01/SwitchEnvelope=0.00000
+LongAngle01/Crossbeam0=0.00000
+LongAngle01/NewRail0=0.00000
+LongAngle01/NewRail1=0.00000
+LongAngle01/BoardM5_01=0.00000
+LongAngle01/FootM5_01=0.00000
+LongAngle01/CrossAngle01=0.00000
+CrossAngle01/Crossbeam0=0.00000
+CrossAngle01/NewRail1=0.00000
+CrossAngle01/SwitchEnvelope=0.00000
+CrossAngle01/Motor=0.00000
+CrossAngle01/LongAngle01=0.00000
+CrossAngle01/CrossTopM5_01=0.00000
+CrossAngle01/CrossSideM5_01=0.00000
+BoardM5_01/CompactPlate0=0.00000
+FootM5_01/CrossTopM5_01=0.00000
+CompactPlate1/KFLHousing1=0.00000
+CompactPlate1/KFLInner1=0.00000
+CompactPlate1/Motor=0.00000
+CompactPlate1/MotorFlange=0.00000
+CompactPlate1/WheelHub=0.00000
+CompactPlate1/Wheel70=0.00000
+CompactPlate1/SwitchEnvelope=0.00000
+CompactPlate1/NewRail0=0.00000
+CompactPlate1/NewRail1=0.00000
+CompactPlate1/Crossbeam1=0.00000
+Crossbeam1/NewRail0=0.00000
+Crossbeam1/NewRail1=0.00000
+Crossbeam1/SwitchEnvelope=0.00000
+Crossbeam1/Motor=0.00000
+Crossbeam1/CamShaft=0.00000
+Crossbeam1/CamUpper=0.00000
+Crossbeam1/CamLower=0.00000
+LongAngle10/CompactPlate1=0.00000
+LongAngle10/KFLHousing1=0.00000
+LongAngle10/KFLInner1=0.00000
+LongAngle10/Motor=0.00000
+LongAngle10/MotorFlange=0.00000
+LongAngle10/WheelHub=0.00000
+LongAngle10/Wheel70=0.00000
+LongAngle10/SwitchEnvelope=0.00000
+LongAngle10/Crossbeam1=0.00000
+LongAngle10/NewRail0=0.00000
+LongAngle10/NewRail1=0.00000
+LongAngle10/BoardM5_10=0.00000
+LongAngle10/FootM5_10=0.00000
+LongAngle10/CrossAngle10=0.00000
+CrossAngle10/Crossbeam1=0.00000
+CrossAngle10/NewRail0=0.00000
+CrossAngle10/SwitchEnvelope=0.00000
+CrossAngle10/Motor=0.00000
+CrossAngle10/LongAngle10=0.00000
+CrossAngle10/CrossTopM5_10=0.00000
+CrossAngle10/CrossSideM5_10=0.00000
+BoardM5_10/CompactPlate1=0.00000
+FootM5_10/CrossTopM5_10=0.00000
+LongAngle11/CompactPlate1=0.00000
+LongAngle11/KFLHousing1=0.00000
+LongAngle11/KFLInner1=0.00000
+LongAngle11/Motor=0.00000
+LongAngle11/MotorFlange=0.00000
+LongAngle11/WheelHub=0.00000
+LongAngle11/Wheel70=0.00000
+LongAngle11/SwitchEnvelope=0.00000
+LongAngle11/Crossbeam1=0.00000
+LongAngle11/NewRail0=0.00000
+LongAngle11/NewRail1=0.00000
+LongAngle11/BoardM5_11=0.00000
+LongAngle11/FootM5_11=0.00000
+LongAngle11/CrossAngle11=0.00000
+CrossAngle11/Crossbeam1=0.00000
+CrossAngle11/NewRail1=0.00000
+CrossAngle11/SwitchEnvelope=0.00000
+CrossAngle11/Motor=0.00000
+CrossAngle11/LongAngle11=0.00000
+CrossAngle11/CrossTopM5_11=0.00000
+CrossAngle11/CrossSideM5_11=0.00000
+BoardM5_11/CompactPlate1=0.00000
+FootM5_11/CrossTopM5_11=0.00000

models/kfl_double_crossbar_concept/positive_intersections.txt

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+none

models/kfl_double_crossbar_concept/方案说明.md

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+# 双横梁轴承支撑方案（概念）
+
+每块 76 × 80 × 8 mm 铝板下有一根横向 2020 型材，每根横梁跨接原来的两根纵向 2020。每块板通过两只金属加长 L 角码连接其下横梁；每根横梁两端再各用一只普通角码固定到纵梁外侧。两块板共用 4 只加长角码、4 只普通角码。原来的四片平连接条不再使用。
+
+## 尺寸和调整
+
+- 两根横梁均按长 160 mm 示意，实际切长须核对纵梁及端部附件。纵梁假定不变，位于 y = -75 至 -55 mm，横梁在其正下方 y = -95 至 -75 mm。轴承板底边到横梁顶面间距 24 mm。
+- 轴承板中央孔暂按直径 39 mm；轴承固定孔按孔距 48 mm、孔径 7 mm。轴承背部直径 38 mm 和其周边形状为示意，需核对实物突出形状、卡口和轴承尺寸后定稿。
+- 加长角码为示意规格，外形按两腿长 45 × 20 mm、宽 18 mm、厚 3 mm 建模；板侧 9.5 × 5.5 mm 竖槽中心距底边 33 mm，横梁侧直径 5.5 mm 圆孔中心距脚端 10 mm。两腿为连续 L 形，未建模真实折弯圆角，也未查证有完全匹配的商品。
+- 轴承板上每个 9.5 × 5.5 mm 水平槽中心距板底 9 mm；与角码竖槽配合，理论上可横向、竖向各微调约 ±2 mm。调整是相对于角码，实际可用行程须结合孔差、垫片、轴承、相邻螺钉和轴线确认。两根横梁可沿纵梁槽分别前后移动，实际行程受其他部件限制。
+- 每个加长角码板侧用 M5 螺栓、垫圈和螺母穿板，横梁侧用 M5 螺栓与横梁 T 型螺母连接；共 4 组板侧紧固、4 组横梁侧紧固。每只普通角码另需 2 组 M5 螺栓和匹配型材的 T 型螺母，共 8 组。螺栓长度和螺母槽型按实物选，螺栓头及工具空间需试装。
+
+## 模型的边界
+
+保留 150 mm 轴、60 mm 开关空间示意、两只反装轴承、电机及原纵梁。开关实际外形、接线、轴承外形、螺丝工具路径都还需要实测。2020 型材为实心包络，并未建 T 型槽；螺栓进入型材体积的部分仅代表应进入槽内，不能以此认定装配无干涉。角码折弯半径、强度与同轴度也未验证。
+
+`geometry_check.txt` 仅列出所选模型零件在默认位置的静态相交计算，不是全部部件、装配过程或调节范围的无干涉证明。先按实物核对开关位置、轴承与固定件，再确定角码规格和铝板 CNC 图。