建立方向盘项目初始版本
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132
scripts/build_square_open_encoder.py
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132
scripts/build_square_open_encoder.py
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"""Concept test only: 50mm mounting with open slots, corners flat on motor."""
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from pathlib import Path
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import time, math, traceback
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import FreeCAD as A, FreeCADGui as G, Part, Import
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from pivy import coin
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R=Path(__file__).resolve().parent.parent
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O=R/'models'/'square_encoder_concept'
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O.mkdir(parents=True,exist_ok=True)
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V=A.Vector
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def cyl(r,h,x,y,z): return Part.makeCylinder(r,h,V(x,y,z))
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def add(doc,name,label,sh,color,trans=0):
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o=doc.addObject('PartDesign::Feature',name); o.Label=label; o.Shape=sh
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o.ViewObject.ShapeColor=color; o.ViewObject.LineColor=(.1,.1,.1); o.ViewObject.Transparency=trans
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return o
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try:
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old=A.openDocument(str(R/'models'/'profile_mount_check'/'Direct.FCStd'))
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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)]
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shapes={n:old.getObject(n).Shape.copy() for n in keep}
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orig=old.getObject('Bracket').Shape.copy()
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shims=[old.getObject('Shim%d'%i).Shape.copy() for i in range(4)]
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A.closeDocument(old.Name)
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doc=A.newDocument('SquareOpen50')
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colors={'Motor':(.32,.34,.37),'Holder':(.98,.55,.10),'Magnet':(.8,.8,.8),'PCB':(.04,.65,.19),'Chip':(.1,.1,.1)}
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objects={}
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for n in keep:
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color=colors.get(n,(.84,.47,.13) if n.startswith('Corner') else (.55,.56,.60) if n.startswith('Rail') else (.8,.8,.8))
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objects[n]=add(doc,n,n,shapes[n],color,70 if n=='Motor' else 20 if n.startswith('Corner') else 0)
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pts=[]
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for i in range(4):
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a=math.radians(45+90*i);pts.append((25*math.cos(a),25*math.sin(a)))
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# Existing foot top is z=2.5 with 0.5 shim. Increase clamping surface to 3.5;
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# subtract motor-side angle brackets, keeping them directly on motor.
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# Blue square outline in user's sketch: retain PCB ring's original height
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# and pilot bosses while replacing the outer envelope with a 45mm frame.
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square=Part.makeBox(45,45,3.2,V(-22.5,-22.5,10.9)).cut(cyl(16.8,3.22,0,0,10.89))
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bracket=orig.fuse(square)
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for x,y in pts:
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bracket=bracket.fuse(cyl(4.5,1,x,y,2.5))
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# Add 0.2mm plan clearance to each metal foot and 0.2mm above it.
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cutters=[]
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for i in range(4):
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bb=shapes['Corner%d'%i].BoundBox
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cutters.append(Part.makeBox(bb.XLength+.4,bb.YLength+.4,3.22,V(bb.XMin-.2,bb.YMin-.2,-.01)))
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for cutter in cutters: bracket=bracket.cut(cutter)
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# Four axial through slots each open outward toward the nearest side.
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# Remove a larger opening in the upper frame for M4 head/tool access.
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for x,y in pts:
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start = x if x>0 else x-10
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slot=Part.makeBox(10,4.4,3.7,V(start,y-2.2,-.05)).fuse(cyl(2.2,3.7,x,y,-.05))
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upp=Part.makeBox(10,7.4,11,V(start,y-3.7,3.5)).fuse(cyl(3.7,11,x,y,3.5))
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bracket=bracket.cut(slot)
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bracket=bracket.cut(upp)
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for j in range(4):
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shims[j]=shims[j].cut(slot)
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for j in range(4):
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for cutter in cutters: shims[j]=shims[j].cut(cutter)
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bracket=bracket.removeSplitter()
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if bracket.isNull() or not bracket.isValid() or len(bracket.Solids)!=1:raise RuntimeError('support not a single solid')
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blue=add(doc,'OpenBracket','Square PCD50 frame with outward open slots - concept',bracket,(.12,.43,.88))
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for i,sh in enumerate(shims):
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sh=sh.removeSplitter()
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if sh.isNull() or not sh.isValid():raise RuntimeError('shim invalid %d'%i)
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add(doc,'SlottedShim%d'%i,'Open 0.5mm shim - concept',sh,(.65,.7,.75))
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heads=[];shafts=[]
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for i,(x,y) in enumerate(pts):
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head=cyl(3.5,3,x,y,3.5);shaft=cyl(1.95,8.5,x,y,-5)
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heads.append(add(doc,'EncoderHead%d'%i,'M4 head Ø7 x 3 - assumed',head,(.8,.8,.8)))
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shafts.append(add(doc,'EncoderShaft%d'%i,'M4 shaft Ø3.9 - assumed',shaft,(.8,.8,.8)))
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doc.recompute()
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corners=[objects['Corner%d'%i] for i in range(4)]
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rails=[objects['Rail%d'%i] for i in range(2)]
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moving=[blue]+[doc.getObject('SlottedShim%d'%i) for i in range(4)]+heads+shafts
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checks=[]
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for o in moving:
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for c in corners+rails:
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if not o.Shape.BoundBox.intersect(c.Shape.BoundBox):continue
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vol=o.Shape.common(c.Shape).Volume
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if vol>.0001:checks.append('%s vs %s %.6f mm3'%(o.Name,c.Name,vol))
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for o in shafts:
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for c in [blue]+[doc.getObject('SlottedShim%d'%i) for i in range(4)]:
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if not o.Shape.BoundBox.intersect(c.Shape.BoundBox): continue
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vol=o.Shape.common(c.Shape).Volume
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if vol>.0001: checks.append('%s vs %s %.6f mm3'%(o.Name,c.Name,vol))
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# Effective supporting material under each head immediately below the top.
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areas=[]
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for x,y in pts:
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# Planar sampling avoids degenerate thin-cylinder OCC intersections.
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count=0; step=.1
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for ix in range(-35,36):
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for iy in range(-35,36):
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dx=ix*step;dy=iy*step
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if dx*dx+dy*dy<=3.5*3.5 and bracket.isInside(V(x+dx,y+dy,3.49),1e-7,True):count+=1
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areas.append(count*step*step)
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# Kinematic slide of support from y=+5 to its assembled position: only a
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# quick volume test of support vs angles + shafts, not a tool/hand check.
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slide=[]
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for n in range(11):
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dy=5.0-n*.5; moved=bracket.copy();moved.translate(V(0,dy,0));hits=[]
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for c in corners+rails+shafts:
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if moved.BoundBox.intersect(c.Shape.BoundBox):
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v=moved.common(c.Shape).Volume
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if v>.0001:hits.append('%s %.4f'%(c.Name,v))
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slide.append('dy=%.1f: %s'%(dy,', '.join(hits) if hits else 'no sampled volume overlap'))
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report=['CONCEPT ONLY; corners are flush to motor; no spacer under PCD76 corners.',
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'Support feet 0.5..3.5mm; shim 0.5mm; screw head 7mm dia x 3mm assumed; 0.2mm corner clearance.',
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'PCD50 screw slots open sideways outward; 45mm square frame from sketch.',
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'Only 0.05mm theoretical slot-end clearance in motor corner as original direct check.',
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'Intersections of support/shims/screw envelope with corners and rails:']+(checks or ['none in checked pairs'])
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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
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(O/'SquareOpen50_check.txt').write_text('\n'.join(report)+'\n',encoding='utf8')
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view=G.activeDocument().activeView()
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def render(kind,name):
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if kind=='rear':view.viewTop()
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else:view.getCameraNode().orientation.setValue(coin.SbRotation(.880476,.115917,-.279848,-.364705))
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G.updateGui();time.sleep(.5);view.fitAll();G.updateGui();time.sleep(.5);view.saveImage(str(O/name),1600,1200,'White')
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render('rear','SquareOpen50_rear.png');render('axon','SquareOpen50_axon.png')
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states={o.Name:o.ViewObject.Visibility for o in doc.Objects if hasattr(o,'Shape')}
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for o in doc.Objects:
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if hasattr(o,'Shape'):o.ViewObject.Visibility=False
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blue.ViewObject.Visibility=True
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render('rear','SquareOpen50_bracket.png')
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for o in doc.Objects:
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if hasattr(o,'Shape'):o.ViewObject.Visibility=states[o.Name]
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render('axon','SquareOpen50_axon.png')
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doc.recompute();doc.saveAs(str(O/'SquareOpen50.FCStd'))
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Import.export([o for o in doc.Objects if hasattr(o,'Shape')],str(O/'SquareOpen50.step'))
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(O/'SQUARE_DONE.txt').write_text('ok\n',encoding='utf8')
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except Exception:
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(O/'SQUARE_ERROR.txt').write_text(traceback.format_exc(),encoding='utf8')
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raise
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