建立方向盘项目初始版本

scripts/build_pcd50_open_pillar.py

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+"""PCD50 3/4-open pillar print trial. Run through FreeCAD GUI macro."""
+from pathlib import Path
+import math, time, traceback
+import FreeCAD as A, FreeCADGui as G, Part, Mesh, Import
+from pivy import coin
+
+R=Path(__file__).resolve().parent.parent
+O=R/'models'/'pcd50_open_pillar_v1'; O.mkdir(parents=True,exist_ok=True)
+V=A.Vector
+def cy(r,h,x=0,y=0,z=0): return Part.makeCylinder(r,h,V(x,y,z))
+def item(d,n,label,s,c,trans=0):
+ o=d.addObject('PartDesign::Feature',n);o.Label=label;o.Shape=s
+ o.ViewObject.ShapeColor=c;o.ViewObject.LineColor=(.1,.1,.1);o.ViewObject.Transparency=trans;return o
+def check(n,s):
+ if s.isNull() or not s.isValid() or len(s.Solids)!=1 or s.Volume<=0:raise RuntimeError('Invalid solid: '+n)
+def wedge(x,y,z,h):
+ # A 90 degree sector points 22.5 degrees from the outward X direction toward
+ # the nearby corner; mirrored independently for all four quadrants.
+ sx=1 if x>0 else -1;sy=1 if y>0 else -1
+ points=[V(x,y,z)]
+ for i in range(19):
+  a=math.radians(-22.5+90.0*i/18.0)
+  points.append(V(x+sx*20*math.cos(a),y+sy*20*math.sin(a),z))
+ points.append(points[0])
+ return Part.Face(Part.Wire(Part.makePolygon(points).Edges)).extrude(V(0,0,h))
+try:
+ src=A.openDocument(str(R/'models'/'pcd50_pillar_concept'/'PCD50_Pillar_Assembly.FCStd'))
+ names=['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)]+['Mount76_%d'%i for i in range(4)]+['Washer76_%d'%i for i in range(4)]+['Head50_%d'%i for i in range(4)]+['Shaft50_%d'%i for i in range(4)]
+ sh={n:src.getObject(n).Shape.copy() for n in names}; old=src.getObject('PillarBracket').Shape.copy()
+ A.closeDocument(src.Name)
+ pts=[(25*math.cos(math.radians(45+90*i)),25*math.sin(math.radians(45+90*i))) for i in range(4)]
+ # Retain the already-verified closed-hole 49mm panel and PCB mounting pads.
+ bracket=old.common(Part.makeBox(120,120,3.2,V(-60,-60,10.9)))
+ for x,y in pts:
+  col=cy(6,10.4,x,y,.5).cut(cy(2.2,10.42,x,y,.49)).cut(wedge(x,y,.49,10.42))
+  check('column',col);bracket=bracket.fuse(col)
+ bracket=bracket.removeSplitter();check('bracket',bracket)
+ def shim(x,y,thick,z):
+  return cy(6,thick,x,y,z).cut(cy(2.2,thick+.02,x,y,z-.01)).cut(wedge(x,y,z-.01,thick+.02)).removeSplitter()
+ shims=[shim(x,y,.5,0) for x,y in pts]
+ for i,s in enumerate(shims):check('shim'+str(i),s)
+ # Printable placement: panel flat on bed, open columns upwards.
+ parts=A.newDocument('PCD50OpenPillarParts')
+ orient=bracket.copy();orient.translate(V(0,0,-14.1));orient.rotate(V(),V(1,0,0),180)
+ neutral05=shim(10,10,.5,0);neutral05.translate(V(-10,-10,0))
+ neutral10=shim(10,10,1,0);neutral10.translate(V(-10,-10,0))
+ outparts=[item(parts,'EncoderBracket','PCD50 open pillar bracket',orient,(.1,.42,.85)),item(parts,'Shim05','0.5mm C shim; rotate to opening',neutral05,(.7,.7,.7)),item(parts,'Shim10','1mm C shim; rotate to opening',neutral10,(.7,.7,.7))]
+ parts.recompute();meshlog=[]
+ for o in outparts:
+  check(o.Name,o.Shape);Mesh.export([o],str(O/(o.Name+'.stl')));Import.export([o],str(O/(o.Name+'.step')))
+  m=Mesh.Mesh(str(O/(o.Name+'.stl')));meshlog.append('%s solid=%s triangles=%d volume=%.5f zmin=%.5f'%(o.Name,m.isSolid(),m.CountFacets,m.Volume,m.BoundBox.ZMin))
+  if not m.isSolid() or m.Volume<=0 or abs(m.BoundBox.ZMin)>.001:raise RuntimeError('bad mesh '+o.Name)
+ (O/'mesh_check.txt').write_text('\n'.join(meshlog)+'\n',encoding='utf8')
+ parts.saveAs(str(O/'PrintParts.FCStd'));A.closeDocument(parts.Name)
+ # Real assembled orientation, from existing motor and hardware geometry.
+ d=A.newDocument('PCD50OpenPillarAssembly'); colors={'Motor':(.32,.34,.37),'Holder':(.98,.55,.1),'Magnet':(.8,.8,.8),'PCB':(.04,.65,.19),'Chip':(.1,.1,.1)}
+ objs={}
+ for n in names:
+  col=colors.get(n,(.84,.47,.13) if n.startswith('Corner') else (.55,.56,.60) if n.startswith('Rail') else (.8,.8,.8))
+  objs[n]=item(d,n,n,sh[n],col,70 if n=='Motor' else 20 if n.startswith('Corner') else 0)
+ b=item(d,'OpenPillarBracket','four open pillars - print trial',bracket,(.12,.43,.88))
+ shimobjs=[item(d,'AdjustShim%d'%i,'0.5mm C shim',s,(.7,.7,.75)) for i,s in enumerate(shims)]
+ d.recompute();hits=[]
+ # Test all printed parts and all motor screws against every other object;
+ # intended mating contact is only a shared zero-volume face.
+ allparts=[o for o in d.Objects if hasattr(o,'Shape')];focus=[b]+shimobjs
+ for a in focus:
+  for c in allparts:
+   if a.Name==c.Name:continue
+   if not a.Shape.BoundBox.intersect(c.Shape.BoundBox):continue
+   vol=a.Shape.common(c.Shape).Volume
+   if vol>.001:hits.append('%s / %s %.6fmm3'%(a.Name,c.Name,vol))
+ # Motor-side nominal separation of every pillar from every corner.
+ distances=[]
+ for i,(x,y) in enumerate(pts):
+  part=bracket.common(cy(6.01,10.39,x,y,.5))
+  dmin=min(part.distToShape(sh['Corner%d'%j])[0] for j in range(4))
+  distances.append(dmin)
+ # Clearance for an axial 7.5mm diameter tool above each head.
+ access=[]
+ for i,(x,y) in enumerate(pts):
+  tool=cy(3.75,20,x,y,17.11);h=[]
+  for n in ['Corner%d'%j for j in range(4)]+['Rail%d'%j for j in range(2)]:
+   v=tool.common(sh[n]).Volume
+   if v>.001:h.append(n+':%.4f'%v)
+  access.append('tool%d: %s'%(i,', '.join(h) if h else 'no checked obstruction'))
+ # Verify top panel material lies under screw head and bores stay open.
+ heads=[]
+ for x,y in pts:
+  count=0;step=.2
+  for ix in range(-18,19):
+   for iy in range(-18,19):
+    dx,dy=ix*step,iy*step
+    if dx*dx+dy*dy<=3.5**2 and bracket.isInside(V(x+dx,y+dy,14.09),1e-7,True):count+=1
+  heads.append(count*step*step)
+ report=['50 PCD; 76 corners flush against motor, 2.5mm outboard in 9.5x5.5 slot (width assumed).',
+ '3/4 open pillars outer diameter 12mm, M4 bore 4.4mm; nominal radial wall away from opening 3.8mm.',
+ 'Each 90 degree opening faces 22.5 degrees from outward X toward its respective nearby 76mm corner.',
+ 'PCB and magnet positions retain nominal 1mm gap with 0.5mm C shims.',
+ 'M4x20 bolt without a head washer: nominal motor engagement 5.9mm; actual thread depth unknown.',
+ 'minimum pillar/corner distances mm: '+', '.join('%.4f'%x for x in distances),
+ 'Estimated material under 7mm head by sampling mm2: '+', '.join('%.2f'%x for x in heads),
+ 'Positive volume intersections >0.001mm3 for support and shims:']+(hits or ['none in checked pairs'])+['Tool clearance, 7.5mm cylinder:']+access
+ (O/'geometry_check.txt').write_text('\n'.join(report)+'\n',encoding='utf8')
+ if hits: raise RuntimeError('Interference in print trial: '+', '.join(hits))
+ view=G.activeDocument().activeView();G.activateWorkbench('PartWorkbench')
+ def render(kind,path):
+  if kind=='rear':view.viewTop()
+  else:
+   view.viewAxonometric();G.updateGui();time.sleep(.5)
+   view.getCameraNode().orientation.setValue(coin.SbRotation(.880476,.115917,-.279848,-.364705))
+  G.updateGui();time.sleep(.7);view.fitAll();G.updateGui();time.sleep(.7);view.saveImage(str(O/path),1600,1200,'White')
+ render('rear','rear.png');render('axon','assembly.png')
+ state={o.Name:o.ViewObject.Visibility for o in d.Objects if hasattr(o,'Shape')}
+ for o in d.Objects:
+  if hasattr(o,'Shape'):o.ViewObject.Visibility=False
+ b.ViewObject.Visibility=True;render('axon','bracket.png')
+ # Cutting one half through two bores makes the head-bearing face and slots visible.
+ b.ViewObject.Visibility=False
+ sec=bracket.cut(Part.makeBox(120,60,25,V(-60,-60-25/math.sqrt(2),0))).removeSplitter()
+ so=item(d,'SectionPreview','section preview only',sec,(.12,.43,.88));d.recompute();render('axon','section.png');d.removeObject(so.Name)
+ for o in d.Objects:
+  if hasattr(o,'Shape'):o.ViewObject.Visibility=state.get(o.Name,True)
+ render('axon','assembly.png');d.recompute();d.saveAs(str(O/'Assembly.FCStd'))
+ Import.export([o for o in d.Objects if hasattr(o,'Shape')],str(O/'Assembly.step'))
+ (O/'DONE.txt').write_text('ok\n',encoding='utf8')
+except Exception:
+ (O/'ERROR.txt').write_text(traceback.format_exc(),encoding='utf8');raise