建立方向盘项目初始版本

models/kfl_plate_adjust_concept/DONE.txt

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+ok

models/kfl_plate_adjust_concept/checks_status.txt

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+INTERSECTIONS FOUND: []

models/kfl_plate_adjust_concept/geometry_check.txt

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+CONCEPT ONLY: NOT FOR CNC OR PRINT.
+Prior shaft 12x150, 60mm switch envelope, mirrored KFL and known motor assembly retained.
+8 mm plates: 140x86 envelope; central hole OD30.2 assumed, KFL holes OD7 at +/-24 (48mm pitch).
+KMT catalogue A0=16, A1=5.5, A=11.5: inner extends 10.5mm and housing 6mm from flange mounting plane. Housing projection OD29 assumed; not catalog-confirmed.
+Minimum nominal clearance between centre and KFL bolt holes: 24-15.1-3.5=5.4 mm; not a strength calculation.
+Whole plate height adjusts via 9.5x5.5 long slot in angle leg; initial bolt is 1mm off slot centre, nominal offsets -2 to +1mm. Plate to rail has 4mm nominal gap.
+Whole plate left/right adjusts via 9.5x5.5 slots on plates, crossing each slotted angle leg, about +/-2mm subject to fit.
+Axial positioning via sliding T-nuts in the 2020 profile. Brackets 20x20x18x3, 9.5x5.5 slot / 5.5 round as assumed stock.
+M5 head/nut envelopes include 10mm board washers; round-hole rail fasteners use low-profile 9.5mm head, no washer; T nuts, shape and actual extrusion grooves need review.
+Centre hole and bearing projection are assumptions: do NOT assume bearing moves in plate opening.
+Slots geometry offers horizontal +/-2mm, vertical -2..+1mm, but assembled shaft, flange and small gaps constrain safe motion. Loosen and check continuously; do not force alignment.
+KFL shape, fastener head/nut access, actual motor, electrical wiring, switch shape, stator etc not validated.
+Bearing locating/floating and structural strength remain unresolved.
+Positive-volume intersection checks in cubic mm:
+Plate0/KFLHousing0: 0.000000
+Plate0/KFLInner0: 0.000000
+Plate0/corner00: 0.000000
+boardfast00/corner: 0.000000
+boardfast00/plate: 0.000000
+railfast00/corner: 0.000000
+boardfast00/railfast: 0.000000
+boardfast00/rail: 0.000000
+railfast00/plate: 0.000000
+corner00/Motor: 0.000000
+boardfast00/Motor: 0.000000
+railfast00/Motor: 0.000000
+corner00/SwitchEnvelope: 0.000000
+boardfast00/SwitchEnvelope: 0.000000
+railfast00/SwitchEnvelope: 0.000000
+corner00/MotorFlange: 0.000000
+boardfast00/MotorFlange: 0.000000
+railfast00/MotorFlange: 0.000000
+corner00/WheelHub: 0.000000
+boardfast00/WheelHub: 0.000000
+railfast00/WheelHub: 0.000000
+corner00/Wheel70: 0.000000
+boardfast00/Wheel70: 0.000000
+railfast00/Wheel70: 0.000000
+corner00/ownRail: 0.000000
+Plate0/corner01: 0.000000
+boardfast01/corner: 0.000000
+boardfast01/plate: 0.000000
+railfast01/corner: 0.000000
+boardfast01/railfast: 0.000000
+boardfast01/rail: 0.000000
+railfast01/plate: 0.000000
+corner01/Motor: 0.000000
+boardfast01/Motor: 0.000000
+railfast01/Motor: 0.000000
+corner01/SwitchEnvelope: 0.000000
+boardfast01/SwitchEnvelope: 0.000000
+railfast01/SwitchEnvelope: 0.000000
+corner01/MotorFlange: 0.000000
+boardfast01/MotorFlange: 0.000000
+railfast01/MotorFlange: 0.000000
+corner01/WheelHub: 0.000000
+boardfast01/WheelHub: 0.000000
+railfast01/WheelHub: 0.000000
+corner01/Wheel70: 0.000000
+boardfast01/Wheel70: 0.000000
+railfast01/Wheel70: 0.000000
+corner01/ownRail: 0.000000
+Plate1/KFLHousing1: 0.000000
+Plate1/KFLInner1: 0.000000
+Plate1/corner10: 0.000000
+boardfast10/corner: 0.000000
+boardfast10/plate: 0.000000
+railfast10/corner: 0.000000
+boardfast10/railfast: 0.000000
+boardfast10/rail: 0.000000
+railfast10/plate: 0.000000
+corner10/Motor: 0.000000
+boardfast10/Motor: 0.000000
+railfast10/Motor: 0.000000
+corner10/SwitchEnvelope: 0.000000
+boardfast10/SwitchEnvelope: 0.000000
+railfast10/SwitchEnvelope: 0.000000
+corner10/MotorFlange: 0.000000
+boardfast10/MotorFlange: 0.000000
+railfast10/MotorFlange: 0.000000
+corner10/WheelHub: 0.000000
+boardfast10/WheelHub: 0.000000
+railfast10/WheelHub: 0.000000
+corner10/Wheel70: 0.000000
+boardfast10/Wheel70: 0.000000
+railfast10/Wheel70: 0.000000
+corner10/ownRail: 0.000000
+Plate1/corner11: 0.000000
+boardfast11/corner: 0.000000
+boardfast11/plate: 0.000000
+railfast11/corner: 0.000000
+boardfast11/railfast: 0.000000
+boardfast11/rail: 0.000000
+railfast11/plate: 0.000000
+corner11/Motor: 0.000000
+boardfast11/Motor: 0.000000
+railfast11/Motor: 0.000000
+corner11/SwitchEnvelope: 0.000000
+boardfast11/SwitchEnvelope: 0.000000
+railfast11/SwitchEnvelope: 0.000000
+corner11/MotorFlange: 0.000000
+boardfast11/MotorFlange: 0.000000
+railfast11/MotorFlange: 0.000000
+corner11/WheelHub: 0.000000
+boardfast11/WheelHub: 0.000000
+railfast11/WheelHub: 0.000000
+corner11/Wheel70: 0.000000
+boardfast11/Wheel70: 0.000000
+railfast11/Wheel70: 0.000000
+corner11/ownRail: 0.000000
+KFLHousing0/MotorFlange: 0.000000
+KFLHousing0/CamShaft: 0.000000
+KFLHousing0/SwitchEnvelope: 0.000000
+KFLInner0/MotorFlange: 0.000000
+KFLInner0/CamShaft: 0.000000
+KFLInner0/SwitchEnvelope: 0.000000
+KFLFastEnd00/MotorFlange: 0.000000
+KFLFastEnd00/WheelHub: 0.000000
+KFLFastEnd00/SwitchEnvelope: 0.000000
+KFLFastEnd01/MotorFlange: 0.000000
+KFLFastEnd01/WheelHub: 0.000000
+KFLFastEnd01/SwitchEnvelope: 0.000000
+KFLHousing1/WheelHub: 0.000000
+KFLHousing1/CamShaft: 0.000000
+KFLHousing1/SwitchEnvelope: 0.000000
+KFLInner1/WheelHub: 0.000000
+KFLInner1/CamShaft: 0.000000
+KFLInner1/SwitchEnvelope: 0.000000
+KFLFastEnd10/MotorFlange: 0.000000
+KFLFastEnd10/WheelHub: 0.000000
+KFLFastEnd10/SwitchEnvelope: 0.000000
+KFLFastEnd11/MotorFlange: 0.000000
+KFLFastEnd11/WheelHub: 0.000000
+KFLFastEnd11/SwitchEnvelope: 0.000000
+M5 hardware clearance over candidate vertical travel (cubic mm intersection and mm minimum separation):
+BoardFast00 dy=-2.0 intersection=0.000000 distance=0.300000
+BoardFast00 dy=+0.0 intersection=0.000000 distance=1.952562
+BoardFast00 dy=+1.0 intersection=0.000000 distance=2.795085
+BoardFast01 dy=-2.0 intersection=0.000000 distance=0.300000
+BoardFast01 dy=+0.0 intersection=0.000000 distance=1.952562
+BoardFast01 dy=+1.0 intersection=0.000000 distance=2.795085
+BoardFast10 dy=-2.0 intersection=0.000000 distance=0.300000
+BoardFast10 dy=+0.0 intersection=0.000000 distance=1.952562
+BoardFast10 dy=+1.0 intersection=0.000000 distance=2.795085
+BoardFast11 dy=-2.0 intersection=0.000000 distance=0.300000
+BoardFast11 dy=+0.0 intersection=0.000000 distance=1.952562
+BoardFast11 dy=+1.0 intersection=0.000000 distance=2.795085
+Combined adjustment corners (plate dx/dy and M5s relative bracket; no mounted shaft or surrounding structure included):
+corner=0 dx=-2.0 dy=-2.0 max_intersection=0.000000
+corner=0 dx=-2.0 dy=+0.0 max_intersection=0.000000
+corner=0 dx=-2.0 dy=+1.0 max_intersection=0.000000
+corner=0 dx=+0.0 dy=-2.0 max_intersection=0.000000
+corner=0 dx=+0.0 dy=+0.0 max_intersection=0.000000
+corner=0 dx=+0.0 dy=+1.0 max_intersection=0.000000
+corner=0 dx=+2.0 dy=-2.0 max_intersection=0.000000
+corner=0 dx=+2.0 dy=+0.0 max_intersection=0.000000
+corner=0 dx=+2.0 dy=+1.0 max_intersection=0.000000
+corner=1 dx=-2.0 dy=-2.0 max_intersection=0.000000
+corner=1 dx=-2.0 dy=+0.0 max_intersection=0.000000
+corner=1 dx=-2.0 dy=+1.0 max_intersection=0.000000
+corner=1 dx=+0.0 dy=-2.0 max_intersection=0.000000
+corner=1 dx=+0.0 dy=+0.0 max_intersection=0.000000
+corner=1 dx=+0.0 dy=+1.0 max_intersection=0.000000
+corner=1 dx=+2.0 dy=-2.0 max_intersection=0.000000
+corner=1 dx=+2.0 dy=+0.0 max_intersection=0.000000
+corner=1 dx=+2.0 dy=+1.0 max_intersection=0.000000
+corner=2 dx=-2.0 dy=-2.0 max_intersection=0.000000
+corner=2 dx=-2.0 dy=+0.0 max_intersection=0.000000
+corner=2 dx=-2.0 dy=+1.0 max_intersection=0.000000
+corner=2 dx=+0.0 dy=-2.0 max_intersection=0.000000
+corner=2 dx=+0.0 dy=+0.0 max_intersection=0.000000
+corner=2 dx=+0.0 dy=+1.0 max_intersection=0.000000
+corner=2 dx=+2.0 dy=-2.0 max_intersection=0.000000
+corner=2 dx=+2.0 dy=+0.0 max_intersection=0.000000
+corner=2 dx=+2.0 dy=+1.0 max_intersection=0.000000
+corner=3 dx=-2.0 dy=-2.0 max_intersection=0.000000
+corner=3 dx=-2.0 dy=+0.0 max_intersection=0.000000
+corner=3 dx=-2.0 dy=+1.0 max_intersection=0.000000
+corner=3 dx=+0.0 dy=-2.0 max_intersection=0.000000
+corner=3 dx=+0.0 dy=+0.0 max_intersection=0.000000
+corner=3 dx=+0.0 dy=+1.0 max_intersection=0.000000
+corner=3 dx=+2.0 dy=-2.0 max_intersection=0.000000
+corner=3 dx=+2.0 dy=+0.0 max_intersection=0.000000
+corner=3 dx=+2.0 dy=+1.0 max_intersection=0.000000
+Nominal simplified axial clearances (mm): rear housing/flange 0.500000; rear inner/flange 2.000000; front housing/flange 0.500000; front inner/flange 2.000000.
+KFL inner axial centre distance 104.5mm, switch envelope to inner end gaps rear15.5mm front14.5mm; computed from nominal adjusted model.

models/kfl_plate_adjust_concept/示意说明.md

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+# KFL001 反装 8 mm 铝板及可调角码：装配概念
+
+这是用于讨论的概念装配，不是可送 CNC 的图。图片为 `KFL反装铝板_3D装配示意.png`，模型为 `Assembly.FCStd` 和 `Assembly.step`，`geometry_check.txt` 是限定实体对的干涉记录。
+
+## 结构及目前假设
+
+- 复用原 12 × 150 mm 轴、60 mm 开关包络、电机、两端相同法兰和 2020 布置。两只 KFL001 反向安装，安装耳与铝板平面接触，中间凸起伸入铝板孔；轴承和铝板一起调整，不能将轴承在孔里单独移动几毫米。依 KMT KFL001 目录，安装耳厚 5.5 mm、总轴向高 16 mm、壳体总高 11.5 mm，示意凸起自安装耳贴合面起壳体 6 mm、内圈 10.5 mm。具体厂家及真实突起直径仍需核对。[KMT 目录](https://www.e-kmt.com/wp-content/themes/dc_e-kmt/img/download/dl02.pdf)
+- 两块板各 8 mm 厚，示意 140 × 86 mm；板中心孔 Ø30.2、KFL 凸起 Ø29 都是原示意尺寸，不是厂家实测，不可用于开孔。按该示意孔径和两只 Ø7 mm 安装孔、48 mm 孔距，孔之间最近净材料约 5.4 mm，不能据此确认承载能力或足够的轴承/垫圈承压面积。
+- 每板两端各用一只 2020 角码连接下方型材；按用户提供的 20 × 20 × 18 mm、厚 3 mm 角码示意，椭圆腿在铝板侧并沿竖向，圆孔腿在型材侧。椭圆孔示意 9.5 × 5.5 mm（槽宽未实测），圆孔示意 Ø5.5；这些值需与实物核对。
+- 两个板侧安装孔为横向 9.5 × 5.5 mm 槽，与对应角码竖向椭圆槽交叉，同一颗 M5 螺丝调两方向。螺丝基准偏离角码椭圆槽中心 1 mm：在单独零件几何下，左右约 ±2 mm、上约 1 mm、下约 2 mm；板下缘与型材上表面名义留 4 mm。实际可用行程受螺杆、槽尺寸、工艺及干涉限制。
+- 板侧 M5 螺丝、螺母是圆形包络，在两连接面加 Ø10 × 1 mm 平垫圈；型材圆孔侧为了避开板侧螺丝，使用 Ø9.5 × 2.75 mm 低头 M5 螺钉示意，不加垫圈。低头螺丝、槽宽与实际 2020 T 螺母是否匹配需核对；KFL M6 头、螺母也只有圆形包络，工具和型号未模拟。
+- 2020 型材使用实体外形占位，没有实际槽形；T 螺母示意在实体型材内，属于预留位置，不代表已验证实体配合或槽内装得下。2020 示意纵梁长度增加以覆盖前板，不能据此切割。
+
+## 调整方法
+
+1. 各只 KFL 按其法兰耳固定在对应板上，确认凸起进入孔且内圈、顶丝等运动部件与板孔有余量。不得假定 Ø29/Ø30.2 可用于实物加工。
+2. 松开铝板与角码之间的 M5 螺丝，使用角码竖槽调高度、板横槽调左右，两方向由同一颗螺丝夹紧；前后距离通过型材 T 螺母沿槽移动。三方向作用于整块板和轴承，不是改变轴承与板的相对位置。
+3. 约左右 ±2 mm、上 1 mm／下 2 mm 是按所列槽和螺丝的几何示意，不是安装后的保证行程。向下 2 mm 时同侧两个螺丝包络间只剩 0.3 mm 名义距离。安装轴、法兰等以后还会受约 0.5 mm 示意法兰/轴承座间隙和其他实物约束。必须在松开相应连接并确认间隙的状态下微调，不可强行推动轴或靠紧螺栓拉直；调整并紧固后再次测同轴和检查旋转阻力。
+4. 角度调节器应带动电机、两根新型材、轴承板和开关支架整体倾斜；角度调节器本身、开关固定件和真实线路未建模。两只轴承的轴向定位／浮动方式未解决，不能简单依靠两端顶丝均锁紧或一端顶丝留松。
+
+## 检查局限
+
+所列板、KFL 假设外形、角码、M5 螺杆及其头部、示意垫圈与指定对象之间的正体积交叉为零；交叉槽左右 -2/0/+2 mm 与高度 -2/0/+1 mm 的组合几何检查，同角码两颗 M5 螺丝包络无交叉（未含装配轴对行程的限制）。KMT 轴向示意后两只轴承内圈中心距约 104.5 mm，60 mm 开关包络距内圈端面后约 15.5 mm、前约 14.5 mm；两轴承座与法兰示意轴向间隙各约 0.5 mm。模型不包含真实型材槽、完整扳手、真实 KFL 突起与顶丝、轴承座受力、真实开关和线束、前后法兰误差或工作时变形。轴承、孔、长槽、五金、公差、装配路径及连接强度须另作校核和实物试装。