建立方向盘项目初始版本

2026-10-29 22:04:55 +08:00
commit 9962cbfbce
834 changed files with 1519203 additions and 0 deletions
--- a/scripts/build_shop_sprues.py
+++ b/scripts/build_shop_sprues.py
@@ -0,0 +1,110 @@
+"""Create two genuinely connected eight-washer sprues for shop review.
+
+Run with the FreeCAD bundled Python. The original single-part files are read
+only; all lengths and placements below are in millimetres.
+"""
+from pathlib import Path
+import hashlib
+import json
+import math
+import shutil
+import zipfile
+
+import FreeCAD as App
+import Part
+import Mesh
+import MeshPart
+
+ROOT = Path(__file__).resolve().parent.parent
+SOURCE = ROOT / 'models' / 'pcd50_open_pillar_v1'
+OUT = ROOT / 'models' / 'print_shop_joined_eight'
+OUT.mkdir(parents=True, exist_ok=True)
+V = App.Vector
+
+# STEP washer geometry is centered on (10,10) in these exported files. These
+# coordinates are explicit because imported STEP and STL placements differ.
+def centered_shape(name):
+    shape = Part.read(str(SOURCE / name))
+    if shape.isNull() or not shape.isValid() or len(shape.Solids) != 1:
+        raise RuntimeError('Invalid source shape ' + name)
+    shape.translate(V(-10,-10,0))
+    return shape
+
+def make_sprue(step_name, doc_name, stem, expected_t):
+    source = centered_shape(step_name)
+    if abs(source.BoundBox.ZLength-expected_t) > 1e-5:
+        raise RuntimeError('Unexpected washer thickness')
+    pads=[]
+    # Left column is rotated so both inward edges are solid. Two columns and
+    # four rows give eight washers with seven straight connecting bars.
+    for col in (0, 1):
+        for row in range(4):
+            pad=source.copy()
+            if col == 0:
+                pad.rotate(V(),V(0,0,1),180)
+            pad.translate(V(24*col,16*row,0))
+            pads.append(pad)
+    # Each bar is constant 1.8 x 1.8 mm. Ends overlap the outer edge by
+    # 0.8 mm on the centerline. The root is sacrificial and needs careful
+    # trimming and smoothing after printing.
+    rods=[]
+    for x in (0,24):
+        for row in range(3):
+            rods.append(Part.makeBox(1.8,5.6,1.8,V(x-.9,16*row+5.2,0)))
+    rods.append(Part.makeBox(13.6,1.8,1.8,V(5.2,-.9,0)))
+    # Quantify the overlap of each end with its two washers. The rod body is
+    # never necked down, but its contact height is limited by the washer.
+    overlaps=[]
+    for col in (0,1):
+        for row in range(3):
+            rod=rods[col*3+row]
+            overlaps.append([rod.common(pads[col*4+row]).Volume,
+                             rod.common(pads[col*4+row+1]).Volume])
+    overlaps.append([rods[6].common(pads[0]).Volume,
+                     rods[6].common(pads[4]).Volume])
+    if any(min(pair) < 0.5 for pair in overlaps):
+        raise RuntimeError('Insufficient rod/pad intersection')
+    combined=pads[0]
+    # All parts touch through each rod, but may not be sequentially connected.
+    # MultiFuse avoids relying on order of the graph during the operation.
+    combined = pads[0].multiFuse(pads[1:]+rods).removeSplitter()
+    if combined.isNull() or not combined.isValid() or len(combined.Solids)!=1:
+        raise RuntimeError('Sprue is not one valid connected solid: '+stem)
+    # Confirm every washer's complete original geometry is retained.
+    for pad in pads:
+        if pad.cut(combined).Volume > 1e-5:
+            raise RuntimeError('Source washer material was removed')
+    bounds=combined.BoundBox
+    doc=App.newDocument(doc_name)
+    o=doc.addObject('Part::Feature','ConnectedSprue');o.Label=stem;o.Shape=combined
+    doc.recompute()
+    doc.saveAs(str(OUT/(stem+'.FCStd')))
+    Part.export([o],str(OUT/(stem+'.step')))
+    mesh=MeshPart.meshFromShape(Shape=combined,LinearDeflection=0.03,
+                                AngularDeflection=0.2,Relative=False)
+    mesh.write(str(OUT/(stem+'.stl')))
+    App.closeDocument(doc.Name)
+    check=Mesh.Mesh(str(OUT/(stem+'.stl')))
+    components=check.getSeparateComponents()
+    if len(components)!=1 or not components[0].isSolid():
+        raise RuntimeError('STL is not one closed connected mesh')
+    return {'file':stem+'.stl','washer_quantity':8,'nominal_washer_thickness_mm':expected_t,
+            'rod_count':len(rods),'rod_width_mm':1.8,'rod_height_mm':1.8,
+            'rod_centerline_radial_overlap_mm':0.8,
+            'rod_end_intersection_volumes_mm3': [[round(v,5) for v in pair] for pair in overlaps],
+            'closed_components':len(components),'closed':True,
+            'bounds_mm':[bounds.XMin,bounds.XMax,bounds.YMin,bounds.YMax,bounds.ZMin,bounds.ZMax],
+            'nominal_washer_volume_mm3':round(source.Volume,5)}
+
+result=[]
+result.append(make_sprue('Shim05.step','WasherSprue05','垫片0.5mm_8个拼件',.5))
+result.append(make_sprue('Shim10.step','WasherSprue10','垫片1.0mm_8个拼件',1.0))
+source=SOURCE/'EncoderBracket.stl'; target=OUT/'编码器支架_单件.stl'
+shutil.copyfile(source,target)
+digest=hashlib.sha256(source.read_bytes()).hexdigest()
+if hashlib.sha256(target.read_bytes()).hexdigest()!=digest: raise RuntimeError('Bracket copy mismatch')
+m=Mesh.Mesh(str(target))
+if len(m.getSeparateComponents())!=1 or not m.isSolid(): raise RuntimeError('Invalid bracket mesh')
+result.insert(0,{'file':target.name,'quantity':1,'closed_components':1,'sha256':digest})
+(OUT/'几何检查.json').write_text(json.dumps(result,ensure_ascii=False,indent=2)+'\n',encoding='utf-8')
+print(json.dumps(result,ensure_ascii=False,indent=2))