建立方向盘项目初始版本
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186
models/kfl_plate_adjust_concept/geometry_check.txt
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186
models/kfl_plate_adjust_concept/geometry_check.txt
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CONCEPT ONLY: NOT FOR CNC OR PRINT.
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Prior shaft 12x150, 60mm switch envelope, mirrored KFL and known motor assembly retained.
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8 mm plates: 140x86 envelope; central hole OD30.2 assumed, KFL holes OD7 at +/-24 (48mm pitch).
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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.
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Minimum nominal clearance between centre and KFL bolt holes: 24-15.1-3.5=5.4 mm; not a strength calculation.
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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.
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Whole plate left/right adjusts via 9.5x5.5 slots on plates, crossing each slotted angle leg, about +/-2mm subject to fit.
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Axial positioning via sliding T-nuts in the 2020 profile. Brackets 20x20x18x3, 9.5x5.5 slot / 5.5 round as assumed stock.
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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.
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Centre hole and bearing projection are assumptions: do NOT assume bearing moves in plate opening.
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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.
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KFL shape, fastener head/nut access, actual motor, electrical wiring, switch shape, stator etc not validated.
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Bearing locating/floating and structural strength remain unresolved.
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Positive-volume intersection checks in cubic mm:
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Plate0/KFLHousing0: 0.000000
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Plate0/KFLInner0: 0.000000
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Plate0/corner00: 0.000000
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boardfast00/corner: 0.000000
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boardfast00/plate: 0.000000
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railfast00/corner: 0.000000
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boardfast00/railfast: 0.000000
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boardfast00/rail: 0.000000
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railfast00/plate: 0.000000
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corner00/Motor: 0.000000
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boardfast00/Motor: 0.000000
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railfast00/Motor: 0.000000
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corner00/SwitchEnvelope: 0.000000
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boardfast00/SwitchEnvelope: 0.000000
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railfast00/SwitchEnvelope: 0.000000
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corner00/MotorFlange: 0.000000
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boardfast00/MotorFlange: 0.000000
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railfast00/MotorFlange: 0.000000
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corner00/WheelHub: 0.000000
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boardfast00/WheelHub: 0.000000
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railfast00/WheelHub: 0.000000
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corner00/Wheel70: 0.000000
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boardfast00/Wheel70: 0.000000
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railfast00/Wheel70: 0.000000
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corner00/ownRail: 0.000000
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Plate0/corner01: 0.000000
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boardfast01/corner: 0.000000
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boardfast01/plate: 0.000000
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railfast01/corner: 0.000000
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boardfast01/railfast: 0.000000
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boardfast01/rail: 0.000000
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railfast01/plate: 0.000000
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corner01/Motor: 0.000000
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boardfast01/Motor: 0.000000
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railfast01/Motor: 0.000000
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corner01/SwitchEnvelope: 0.000000
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boardfast01/SwitchEnvelope: 0.000000
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railfast01/SwitchEnvelope: 0.000000
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corner01/MotorFlange: 0.000000
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boardfast01/MotorFlange: 0.000000
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railfast01/MotorFlange: 0.000000
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corner01/WheelHub: 0.000000
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boardfast01/WheelHub: 0.000000
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railfast01/WheelHub: 0.000000
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corner01/Wheel70: 0.000000
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boardfast01/Wheel70: 0.000000
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railfast01/Wheel70: 0.000000
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corner01/ownRail: 0.000000
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Plate1/KFLHousing1: 0.000000
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Plate1/KFLInner1: 0.000000
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Plate1/corner10: 0.000000
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boardfast10/corner: 0.000000
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boardfast10/plate: 0.000000
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railfast10/corner: 0.000000
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boardfast10/railfast: 0.000000
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boardfast10/rail: 0.000000
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railfast10/plate: 0.000000
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corner10/Motor: 0.000000
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boardfast10/Motor: 0.000000
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railfast10/Motor: 0.000000
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corner10/SwitchEnvelope: 0.000000
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boardfast10/SwitchEnvelope: 0.000000
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railfast10/SwitchEnvelope: 0.000000
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corner10/MotorFlange: 0.000000
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boardfast10/MotorFlange: 0.000000
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railfast10/MotorFlange: 0.000000
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corner10/WheelHub: 0.000000
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boardfast10/WheelHub: 0.000000
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railfast10/WheelHub: 0.000000
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corner10/Wheel70: 0.000000
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boardfast10/Wheel70: 0.000000
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railfast10/Wheel70: 0.000000
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corner10/ownRail: 0.000000
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Plate1/corner11: 0.000000
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boardfast11/corner: 0.000000
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boardfast11/plate: 0.000000
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railfast11/corner: 0.000000
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boardfast11/railfast: 0.000000
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boardfast11/rail: 0.000000
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railfast11/plate: 0.000000
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corner11/Motor: 0.000000
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boardfast11/Motor: 0.000000
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railfast11/Motor: 0.000000
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corner11/SwitchEnvelope: 0.000000
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boardfast11/SwitchEnvelope: 0.000000
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railfast11/SwitchEnvelope: 0.000000
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corner11/MotorFlange: 0.000000
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boardfast11/MotorFlange: 0.000000
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railfast11/MotorFlange: 0.000000
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corner11/WheelHub: 0.000000
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boardfast11/WheelHub: 0.000000
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railfast11/WheelHub: 0.000000
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corner11/Wheel70: 0.000000
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boardfast11/Wheel70: 0.000000
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railfast11/Wheel70: 0.000000
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corner11/ownRail: 0.000000
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KFLHousing0/MotorFlange: 0.000000
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KFLHousing0/CamShaft: 0.000000
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KFLHousing0/SwitchEnvelope: 0.000000
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KFLInner0/MotorFlange: 0.000000
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KFLInner0/CamShaft: 0.000000
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KFLInner0/SwitchEnvelope: 0.000000
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KFLFastEnd00/MotorFlange: 0.000000
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KFLFastEnd00/WheelHub: 0.000000
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KFLFastEnd00/SwitchEnvelope: 0.000000
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KFLFastEnd01/MotorFlange: 0.000000
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KFLFastEnd01/WheelHub: 0.000000
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KFLFastEnd01/SwitchEnvelope: 0.000000
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KFLHousing1/WheelHub: 0.000000
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KFLHousing1/CamShaft: 0.000000
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KFLHousing1/SwitchEnvelope: 0.000000
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KFLInner1/WheelHub: 0.000000
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KFLInner1/CamShaft: 0.000000
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KFLInner1/SwitchEnvelope: 0.000000
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KFLFastEnd10/MotorFlange: 0.000000
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KFLFastEnd10/WheelHub: 0.000000
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KFLFastEnd10/SwitchEnvelope: 0.000000
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KFLFastEnd11/MotorFlange: 0.000000
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KFLFastEnd11/WheelHub: 0.000000
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KFLFastEnd11/SwitchEnvelope: 0.000000
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M5 hardware clearance over candidate vertical travel (cubic mm intersection and mm minimum separation):
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BoardFast00 dy=-2.0 intersection=0.000000 distance=0.300000
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BoardFast00 dy=+0.0 intersection=0.000000 distance=1.952562
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BoardFast00 dy=+1.0 intersection=0.000000 distance=2.795085
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BoardFast01 dy=-2.0 intersection=0.000000 distance=0.300000
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BoardFast01 dy=+0.0 intersection=0.000000 distance=1.952562
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BoardFast01 dy=+1.0 intersection=0.000000 distance=2.795085
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BoardFast10 dy=-2.0 intersection=0.000000 distance=0.300000
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BoardFast10 dy=+0.0 intersection=0.000000 distance=1.952562
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BoardFast10 dy=+1.0 intersection=0.000000 distance=2.795085
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BoardFast11 dy=-2.0 intersection=0.000000 distance=0.300000
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BoardFast11 dy=+0.0 intersection=0.000000 distance=1.952562
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BoardFast11 dy=+1.0 intersection=0.000000 distance=2.795085
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Combined adjustment corners (plate dx/dy and M5s relative bracket; no mounted shaft or surrounding structure included):
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corner=0 dx=-2.0 dy=-2.0 max_intersection=0.000000
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corner=0 dx=-2.0 dy=+0.0 max_intersection=0.000000
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corner=0 dx=-2.0 dy=+1.0 max_intersection=0.000000
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corner=0 dx=+0.0 dy=-2.0 max_intersection=0.000000
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corner=0 dx=+0.0 dy=+0.0 max_intersection=0.000000
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corner=0 dx=+0.0 dy=+1.0 max_intersection=0.000000
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corner=0 dx=+2.0 dy=-2.0 max_intersection=0.000000
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corner=0 dx=+2.0 dy=+0.0 max_intersection=0.000000
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corner=0 dx=+2.0 dy=+1.0 max_intersection=0.000000
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corner=1 dx=-2.0 dy=-2.0 max_intersection=0.000000
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corner=1 dx=-2.0 dy=+0.0 max_intersection=0.000000
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corner=1 dx=-2.0 dy=+1.0 max_intersection=0.000000
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corner=1 dx=+0.0 dy=-2.0 max_intersection=0.000000
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corner=1 dx=+0.0 dy=+0.0 max_intersection=0.000000
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corner=1 dx=+0.0 dy=+1.0 max_intersection=0.000000
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corner=1 dx=+2.0 dy=-2.0 max_intersection=0.000000
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corner=1 dx=+2.0 dy=+0.0 max_intersection=0.000000
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corner=1 dx=+2.0 dy=+1.0 max_intersection=0.000000
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corner=2 dx=-2.0 dy=-2.0 max_intersection=0.000000
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corner=2 dx=-2.0 dy=+0.0 max_intersection=0.000000
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corner=2 dx=-2.0 dy=+1.0 max_intersection=0.000000
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corner=2 dx=+0.0 dy=-2.0 max_intersection=0.000000
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corner=2 dx=+0.0 dy=+0.0 max_intersection=0.000000
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corner=2 dx=+0.0 dy=+1.0 max_intersection=0.000000
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corner=2 dx=+2.0 dy=-2.0 max_intersection=0.000000
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corner=2 dx=+2.0 dy=+0.0 max_intersection=0.000000
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corner=2 dx=+2.0 dy=+1.0 max_intersection=0.000000
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corner=3 dx=-2.0 dy=-2.0 max_intersection=0.000000
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corner=3 dx=-2.0 dy=+0.0 max_intersection=0.000000
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corner=3 dx=-2.0 dy=+1.0 max_intersection=0.000000
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corner=3 dx=+0.0 dy=-2.0 max_intersection=0.000000
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corner=3 dx=+0.0 dy=+0.0 max_intersection=0.000000
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corner=3 dx=+0.0 dy=+1.0 max_intersection=0.000000
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corner=3 dx=+2.0 dy=-2.0 max_intersection=0.000000
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corner=3 dx=+2.0 dy=+0.0 max_intersection=0.000000
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corner=3 dx=+2.0 dy=+1.0 max_intersection=0.000000
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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.
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KFL inner axial centre distance 104.5mm, switch envelope to inner end gaps rear15.5mm front14.5mm; computed from nominal adjusted model.
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