建立方向盘项目初始版本

scripts/build_open_encoder_option.py

@@ -0,0 +1,116 @@
+"""Concept test only: 50mm mounting with open slots, corners flat on motor."""
+from pathlib import Path
+import time, math, traceback
+import FreeCAD as A, FreeCADGui as G, Part, Import
+from pivy import coin
+R=Path(__file__).resolve().parent.parent
+O=R/'models'/'profile_mount_check'
+V=A.Vector
+
+def cyl(r,h,x,y,z): return Part.makeCylinder(r,h,V(x,y,z))
+def add(doc,name,label,sh,color,trans=0):
+    o=doc.addObject('PartDesign::Feature',name); o.Label=label; o.Shape=sh
+    o.ViewObject.ShapeColor=color; o.ViewObject.LineColor=(.1,.1,.1); o.ViewObject.Transparency=trans
+    return o
+
+try:
+    old=A.openDocument(str(O/'Direct.FCStd'))
+    keep=['Motor','Holder','Magnet','PCB','Chip']+['PCBHead%d'%i for i in range(1,4)]+['Corner%d'%i for i in range(4)]+['Rail%d'%i for i in range(2)]+['MountM4_%d'%i for i in range(1,5)]
+    shapes={n:old.getObject(n).Shape.copy() for n in keep}
+    orig=old.getObject('Bracket').Shape.copy()
+    shims=[old.getObject('Shim%d'%i).Shape.copy() for i in range(4)]
+    A.closeDocument(old.Name)
+    doc=A.newDocument('OpenSlot50')
+    colors={'Motor':(.32,.34,.37),'Holder':(.98,.55,.10),'Magnet':(.8,.8,.8),'PCB':(.04,.65,.19),'Chip':(.1,.1,.1)}
+    objects={}
+    for n in keep:
+        color=colors.get(n,(.84,.47,.13) if n.startswith('Corner') else (.55,.56,.60) if n.startswith('Rail') else (.8,.8,.8))
+        objects[n]=add(doc,n,n,shapes[n],color,70 if n=='Motor' else 20 if n.startswith('Corner') else 0)
+    pts=[]
+    for i in range(4):
+        a=math.radians(45+90*i);pts.append((25*math.cos(a),25*math.sin(a)))
+    # Existing foot top is z=2.5 with 0.5 shim. Increase clamping surface to 3.5;
+    # subtract motor-side angle brackets, keeping them directly on motor.
+    bracket=orig
+    for x,y in pts:
+        bracket=bracket.fuse(cyl(4.5,1,x,y,2.5))
+    # Add 0.2mm plan clearance to each metal foot and 0.2mm above it.
+    cutters=[]
+    for i in range(4):
+        bb=shapes['Corner%d'%i].BoundBox
+        cutters.append(Part.makeBox(bb.XLength+.4,bb.YLength+.4,3.22,V(bb.XMin-.2,bb.YMin-.2,-.01)))
+    for cutter in cutters: bracket=bracket.cut(cutter)
+    # Four slots open in the same -Y direction; existing Ø4.4 clearance continues.
+    for x,y in pts:
+        slot=Part.makeBox(4.4,6,3.7,V(x-2.2,y-6,-.05)).fuse(cyl(2.2,3.7,x,y,-.05))
+        bracket=bracket.cut(slot)
+        for j in range(4):
+            shims[j]=shims[j].cut(slot)
+    for j in range(4):
+        for cutter in cutters: shims[j]=shims[j].cut(cutter)
+    bracket=bracket.removeSplitter()
+    if bracket.isNull() or not bracket.isValid() or len(bracket.Solids)!=1:raise RuntimeError('support not a single solid')
+    blue=add(doc,'OpenBracket','PCD50 4 open slots - concept',bracket,(.12,.43,.88))
+    for i,sh in enumerate(shims):
+        sh=sh.removeSplitter()
+        if sh.isNull() or not sh.isValid():raise RuntimeError('shim invalid %d'%i)
+        add(doc,'SlottedShim%d'%i,'Open 0.5mm shim - concept',sh,(.65,.7,.75))
+    heads=[];shafts=[]
+    for i,(x,y) in enumerate(pts):
+        head=cyl(3.5,3,x,y,3.5);shaft=cyl(1.95,8.5,x,y,-5)
+        heads.append(add(doc,'EncoderHead%d'%i,'M4 head Ø7 x 3 - assumed',head,(.8,.8,.8)))
+        shafts.append(add(doc,'EncoderShaft%d'%i,'M4 shaft Ø3.9 - assumed',shaft,(.8,.8,.8)))
+    doc.recompute()
+    corners=[objects['Corner%d'%i] for i in range(4)]
+    rails=[objects['Rail%d'%i] for i in range(2)]
+    moving=[blue]+[doc.getObject('SlottedShim%d'%i) for i in range(4)]+heads+shafts
+    checks=[]
+    for o in moving:
+        for c in corners+rails:
+            if not o.Shape.BoundBox.intersect(c.Shape.BoundBox):continue
+            vol=o.Shape.common(c.Shape).Volume
+            if vol>.0001:checks.append('%s vs %s %.6f mm3'%(o.Name,c.Name,vol))
+    for o in shafts:
+        for c in [blue]+[doc.getObject('SlottedShim%d'%i) for i in range(4)]:
+            if not o.Shape.BoundBox.intersect(c.Shape.BoundBox): continue
+            vol=o.Shape.common(c.Shape).Volume
+            if vol>.0001: checks.append('%s vs %s %.6f mm3'%(o.Name,c.Name,vol))
+    # Effective supporting material under each head immediately below the top.
+    areas=[]
+    for x,y in pts:
+        # Planar sampling avoids degenerate thin-cylinder OCC intersections.
+        count=0; step=.1
+        for ix in range(-35,36):
+            for iy in range(-35,36):
+                dx=ix*step;dy=iy*step
+                if dx*dx+dy*dy<=3.5*3.5 and bracket.isInside(V(x+dx,y+dy,3.49),1e-7,True):count+=1
+        areas.append(count*step*step)
+    # Kinematic slide of support from y=+5 to its assembled position: only a
+    # quick volume test of support vs angles + shafts, not a tool/hand check.
+    slide=[]
+    for n in range(11):
+        dy=5.0-n*.5; moved=bracket.copy();moved.translate(V(0,dy,0));hits=[]
+        for c in corners+rails+shafts:
+            if moved.BoundBox.intersect(c.Shape.BoundBox):
+                v=moved.common(c.Shape).Volume
+                if v>.0001:hits.append('%s %.4f'%(c.Name,v))
+        slide.append('dy=%.1f: %s'%(dy,', '.join(hits) if hits else 'no sampled volume overlap'))
+    report=['CONCEPT ONLY; corners are flush to motor; no spacer under PCD76 corners.',
+            'Support feet 0.5..3.5mm; shim 0.5mm; screw head 7mm dia x 3mm assumed; 0.2mm corner clearance.',
+            'PCD50 screw slots open toward -Y; all four are parallel.',
+            'Only 0.05mm theoretical slot-end clearance in motor corner as original direct check.',
+            'Intersections of support/shims/screw envelope with corners and rails:']+(checks or ['none in checked pairs'])
+    report+=['Approx material area under 7mm screw head using 0.1mm sampled grid (mm2): '+', '.join('%.3f'%x for x in areas),'Sampled lateral slide +Y to 0:']+slide
+    (O/'OpenSlot50_check.txt').write_text('\n'.join(report)+'\n',encoding='utf8')
+    view=G.activeDocument().activeView()
+    def render(kind,name):
+        if kind=='rear':view.viewTop()
+        else:view.getCameraNode().orientation.setValue(coin.SbRotation(.880476,.115917,-.279848,-.364705))
+        G.updateGui();time.sleep(.5);view.fitAll();G.updateGui();time.sleep(.5);view.saveImage(str(O/name),1600,1200,'White')
+    render('rear','OpenSlot50_rear.png');render('axon','OpenSlot50_axon.png')
+    doc.recompute();doc.saveAs(str(O/'OpenSlot50.FCStd'))
+    Import.export([o for o in doc.Objects if hasattr(o,'Shape')],str(O/'OpenSlot50.step'))
+    (O/'OPEN_SLOT_DONE.txt').write_text('ok\n',encoding='utf8')
+except Exception:
+    (O/'OPEN_SLOT_ERROR.txt').write_text(traceback.format_exc(),encoding='utf8')
+    raise