建立方向盘项目初始版本

models/kfl_same_flange_100/DONE.txt

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+ok

models/kfl_same_flange_100/geometry_check.txt

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+CONCEPT ONLY; NOT ASSEMBLY FIT VALIDATION.
+Both flanges: disc OD57 thickness4, 6x PCD48 5.5 clearance; hub OD30 protrudes 20 from the base. Mirrored.
+Shaft nominal 12 x 100; z=-158.0..-58.0; motor hub z=-70..-50; motor insertion 12mm assumed.
+Wheel hub z=-176..-156, front plate z=-180..-176; hub engagement 2.0 mm; plate bore overlap 0.0 mm (this is not extra key engagement).
+Bearing positions, 50mm switch envelope and cam as previous shifted design; rear/front hub clearance to simplified outer bearing 0.5mm nominal.
+KFL approximate 48 bolt pitch and 14.5 inner width, housing/protrusion guessed; 8mm plate 30.2 hole guessed; no real module shape, its 47mm hole is an assumption.
+Wheel70 is real STEP, mirror/phase0, rear face in contact with front flange disc, PCD48 hole centers align nominally; bolt direction, washer and tool clearances not checked.
+Real converter/70 STEP hole OD4.234, fastener M4 feasible only with washers and actual size checks; M5 cannot pass nominally; hole intersections/phase and actual hardware must be checked.
+Shaft endpoint keys not modeled; front hub insertion alone does not establish permissible torque. Actual axial gap, M3 nut, alignments, float bearing arrangement, switch/fan/angles, bolt heads, tool accessibility, and fit/strength not verified.
+Checked positive-volume intersections of listed pairs only:
+Plate0 / KFLHousing0 = 0.000000 mm3
+Plate1 / KFLHousing1 = 0.000000 mm3
+Plate0 / KFLInner0 = 0.000000 mm3
+Plate1 / KFLInner1 = 0.000000 mm3
+SwitchEnvelope / CamUpper = 0.000000 mm3
+SwitchEnvelope / CamLower = 0.000000 mm3
+SwitchEnvelope / CamHardware0 = 0.000000 mm3
+SwitchEnvelope / CamHardware1 = 0.000000 mm3
+SwitchEnvelope / CamHardware2 = 0.000000 mm3
+SwitchEnvelope / CamHardware3 = 0.000000 mm3
+MotorFlange / Shaft = 0.000000 mm3
+WheelHub / Shaft = 0.000000 mm3
+WheelHub / 70Adapter = 0.000000 mm3
+Plate0 / Plate1 = 0.000000 mm3
+MotorFlange / RearBearing = 0.000000 mm3
+MotorFlange / RearInner = 0.000000 mm3
+MotorFlange / RearPlate = 0.000000 mm3
+WheelHub / FrontBearing = 0.000000 mm3
+WheelHub / FrontInner = 0.000000 mm3
+WheelHub / FrontPlate = 0.000000 mm3
+MotorFlange / Conversion = 0.000000 mm3
+Wheel bolt path 0: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Wheel bolt path 1: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Wheel bolt path 2: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Wheel bolt path 3: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Wheel bolt path 4: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Wheel bolt path 5: shaft probe / flange 0.00000000 / 70plate 0.00000000 mm3
+Motor bolt path 0: probe / flange 0.00000000 / converter 0.00000000 mm3
+Motor bolt path 1: probe / flange 0.00000000 / converter 0.00000000 mm3
+Motor bolt path 2: probe / flange 0.00000000 / converter 0.00000000 mm3
+Motor bolt path 3: probe / flange 0.00000000 / converter 0.00000000 mm3
+Motor bolt path 4: probe / flange 0.00000000 / converter 0.00000000 mm3
+Motor bolt path 5: probe / flange 0.00000000 / converter 0.00000000 mm3

models/kfl_same_flange_100/示意说明.md

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+# 两端相同法兰：100 mm 轴总装比较
+
+本次只用于用户讨论布局，不是 CNC 或打印定稿。`两端相同法兰_装配示意.png` 为两种轴长的示意，`Assembly.FCStd`、`Assembly.step` 是 100 mm 版本；`../kfl_same_flange_120/` 为保持相同布局、仅改用 120 mm 轴的对比模型。
+
+电机与方向盘两端法兰完全相同：底盘 Ø57 × 4 mm、六孔 PCD48、M5 通孔示意 Ø5.5 mm；凸台 Ø30 × 20 mm，20 mm 假设从底盘外表面起算，整体 24 mm，轴孔按 Ø12.4 示意。两端凸台都朝向轴承。方向盘侧法兰盘面与既有 70 转接板贴合，PCD48 六孔名义对齐。所用 70 转接板、原小转换盘为项目现有 STEP；电机前端和两盘相对位置仍依旧模型假设。
+
+本布局：轴尾 z=-58，电机侧法兰凸台 z=-70..-50，因此只假设 12 mm 轴处于电机侧凸台中；方向盘侧法兰凸台 z=-176..-156。轴为 100 mm 时其前端 z=-158，进入方向盘侧凸台区仅 2 mm；轴为 120 mm 时前端 z=-178，凸台区内为 20 mm，并额外穿入法兰底板孔 2 mm。端面的键槽、前后实际键长、强度未建模，不代表实际可用插入深度。短轴在这一个布局下显然不适合直接夹持，但其他开关错位、轴承朝向等方案尚未穷尽，不能由此证明 100 mm 一定不行。
+
+两只 KFL001 反装于 8 mm 铝板，夹耳与板面贴合，中央凸起穿过板。两端法兰与简化轴承外壳之间按 0.5 mm 名义间隙布置，未验证工具、转动或公差。参照 KFL001 厂商标称孔距48mm、内圈宽14.5mm；凸起外径29mm和铝板孔径30.2mm是未实测的示意假设。不可用于加工。
+
+绿色透明框为灯光开关50mm轴向包络占位，不是实物外形，内部Ø47孔只是示意。50mm包含偏轴接线插座，轴套20mm位于框内，未重复计长。白色回正件、运动轨迹、固定机构、线缆均未建模；不能以示意孔认为凸块能转或回正。
+
+几何检查选定了板与简化轴承、两法兰与简化轴承/板、轴套与假定开关包络、真实转接板与法兰。方向盘端与电机端各6处PCD48孔使用Ø2mm贯穿探针测试都无实体重叠；但实际螺丝、螺母、垫圈、安装方向和工具未检查。两块既有转接盘 STEP 的外圈孔约Ø4.234 mm，与新法兰的M5通孔不是同一孔径；现有盘不能直接穿M5螺钉，M4和合适垫圈也需实物检查和强度校核。
+
+电机中心M3贯穿螺杆与螺母、法兰轴孔深度、轴承顶丝、轴端键槽、调角器、风扇和方向盘外形均未完整建模；轴承对中、轴向定位及浮动、强度与全部实物间隙未验证，不可直接用于采购定长、CNC或打印。