"""PCD50 square-open bracket, with PCD76 corner slots offset 2 mm. Concept assembly only. Rebuild via rebuild_pcd50_fit_concept.FCMacro. """ from pathlib import Path import math, time, traceback import FreeCAD as A, FreeCADGui as G, Part, Import from pivy import coin R=Path(__file__).resolve().parent.parent O=R/'models'/'pcd50_fit_concept'; O.mkdir(parents=True,exist_ok=True) V=A.Vector def cy(r,h,x,y,z): return Part.makeCylinder(r,h,V(x,y,z)) def add(doc,n,label,s,c,t=0): o=doc.addObject('PartDesign::Feature',n); o.Label=label; o.Shape=s o.ViewObject.ShapeColor=c;o.ViewObject.LineColor=(.1,.1,.1);o.ViewObject.Transparency=t return o try: src=A.openDocument(str(R/'models'/'profile_mount_check'/'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)] shapes={n:src.getObject(n).Shape.copy() for n in keep} orig=src.getObject('Bracket').Shape.copy() shims=[src.getObject('Shim%d'%i).Shape.copy() for i in range(4)] A.closeDocument(src.Name) # The old Direct model moved each bracket 2.75mm outwards. Inwards by # 0.75mm makes the new shift 2.00mm, leaving nominal slot clearance. for n in ['Corner%d'%i for i in range(4)]+['Rail%d'%i for i in range(2)]: s=shapes[n]; cx=(s.BoundBox.XMin+s.BoundBox.XMax)/2 s.translate(V(-.75 if cx>0 else .75,0,0)) doc=A.newDocument('PCD50_Fit_2mm'); objs={} colors={'Motor':(.32,.34,.37),'Holder':(.98,.55,.1),'Magnet':(.8,.8,.8),'PCB':(.04,.65,.19),'Chip':(.1,.1,.1)} for n,s in shapes.items(): c=colors.get(n,(.84,.47,.13) if n.startswith('Corner') else (.55,.56,.60) if n.startswith('Rail') else (.8,.8,.8)) objs[n]=add(doc,n,n,s,c,70 if n=='Motor' else 20 if n.startswith('Corner') else 0) pts=[(25*math.cos(math.radians(45+90*i)),25*math.sin(math.radians(45+90*i))) for i in range(4)] # A 49mm frame leaves about 2.7mm beside the 8.2mm tool opening. # Its outer corners are notched to permit PCD76 fastening tool access. square=Part.makeBox(49,49,3.2,V(-24.5,-24.5,10.9)).cut(cy(16.8,3.22,0,0,10.89)) p76=38/math.sqrt(2) for sx in (-1,1): for sy in (-1,1): square=square.cut(cy(5.2,3.24,sx*p76,sy*p76,10.88)) bracket=orig.fuse(square) for x,y in pts:bracket=bracket.fuse(cy(4.5,1,x,y,2.5)) 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) # Outward opening towards left/right per user sketch, with upper access. for x,y in pts: start=x if x>0 else x-10 slot=Part.makeBox(10,4.4,3.7,V(start,y-2.2,-.05)).fuse(cy(2.2,3.7,x,y,-.05)) upper=Part.makeBox(10,8.2,11,V(start,y-4.1,3.5)).fuse(cy(4.1,11,x,y,3.5)) bracket=bracket.cut(slot).cut(upper) 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('invalid bracket') b=add(doc,'OpenBracket','PCD50 square frame, outward open - concept',bracket,(.12,.43,.88)) shimobjs=[] for i,s in enumerate(shims): s=s.removeSplitter() if s.isNull() or not s.isValid() or len(s.Solids)!=1:raise RuntimeError('invalid shim %d'%i) shimobjs.append(add(doc,'Shim50_%d'%i,'0.5mm open adjustment shim - concept',s,(.70,.70,.75))) heads=[];shafts=[];mount76=[];washers76=[] for i,(x,y) in enumerate(pts): heads.append(add(doc,'Head50_%d'%i,'M4 50 head dia 7, height 3 assumed',cy(3.5,3,x,y,3.5),(.8,.8,.8))) shafts.append(add(doc,'Shaft50_%d'%i,'M4x8 50 screw shank Ø4 concept',cy(2,8,x,y,-4.5),(.8,.8,.8))) p=38/math.sqrt(2) for sx in (-1,1): for sy in (-1,1): x,y=sx*p,sy*p w=cy(5,.8,x,y,3).cut(cy(2.15,.82,x,y,2.99)).removeSplitter() washers76.append(add(doc,'Washer76_%d'%len(washers76),'M4 washer Ø10 x 0.8 assumed',w,(.75,.75,.77))) s=cy(2,8,x,y,-4.2).fuse(cy(3.5,2.5,x,y,3.8)).removeSplitter() mount76.append(add(doc,'Mount76_%d'%len(mount76),'M4 76 shank Ø4 head Ø7 concept',s,(.8,.8,.8))) doc.recompute(); corners=[objs['Corner%d'%i] for i in range(4)]; rails=[objs['Rail%d'%i] for i in range(2)] pairs=[] for a in [b]+shimobjs+heads+shafts: for c in corners+rails:pairs.append((a,c)) for a in shafts: for c in [b]+shimobjs:pairs.append((a,c)) for a in mount76: for c in corners+rails+[b]+shimobjs+heads+shafts:pairs.append((a,c)) for a in washers76: for c in corners+rails+[b]+shimobjs+heads+shafts+mount76:pairs.append((a,c)) for a in [b]+shimobjs+heads+shafts: for n in ['Motor','Holder','Magnet','PCB','Chip']+['PCBHead%d'%i for i in range(1,4)]:pairs.append((a,objs[n])) errors=[] for a,c in pairs: if not a.Shape.BoundBox.intersect(c.Shape.BoundBox):continue vol=a.Shape.common(c.Shape).Volume if vol>.001:errors.append('%s / %s %.6fmm3'%(a.Name,c.Name,vol)) # Record tool clearance against corner/support for four assumed 7.5mm # axial screwdriver envelopes. Start above the modelled screw heads. access=[] for i,(x,y) in enumerate(pts): tool=cy(3.75,20,x,y,6.51); hits=[] for o in [b]+corners+rails: if tool.BoundBox.intersect(o.Shape.BoundBox): v=tool.common(o.Shape).Volume if v>.001:hits.append('%s %.4f'%(o.Name,v)) access.append('50 head %d: %s'%(i,', '.join(hits) if hits else 'clear (model envelope only)')) for sx in (-1,1): for sy in (-1,1): x,y=sx*p,sy*p; tool=cy(3.75,20,x,y,6.31); hits=[] for o in [b]+corners+rails: if tool.BoundBox.intersect(o.Shape.BoundBox): v=tool.common(o.Shape).Volume if v>.001:hits.append('%s %.4f'%(o.Name,v)) access.append('76 head %+.0f,%+.0f: %s'%(sx,sy,', '.join(hits) if hits else 'clear (model envelope only)')) areas=[] 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,3.49),1e-7,True):count+=1 areas.append(count*step*step) report=['Concept only. PCD50 and PCD76 phase 45 deg assumed; 4x M4 Ø4.', 'PCD76 slot 9.5 x 5.5 assumed; angle brackets remain flush and shifted 2.00mm outwards.', 'Nominal M4 versus slot-end clearance: 0.75mm. 50 head Ø7 x 3 assumed.', '76 washer Ø10x0.8 assumed; M4x8 gives nominal 4.2mm engagement, motor hole depth unknown.', '0.5mm shim; 50 foot top 3.5mm; original PCB and magnet position unchanged.', 'Detected positive volumes >0.001mm3:']+(errors or ['none in checked pairs']) report+=['Tool access, Ø7.5 envelope from z6.51:']+access+['Sampled 50 head contact areas, mm2 (not strength): '+', '.join('%.2f'%x for x in areas)] (O/'geometry_check.txt').write_text('\n'.join(report)+'\n',encoding='utf-8') G.activateWorkbench('PartWorkbench');view=G.activeDocument().activeView() def render(top,path): if top: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);G.updateGui();view.saveImage(str(O/path),1600,1200,'White') render(True,'rear.png');render(False,'assembly.png') states={o.Name:o.ViewObject.Visibility for o in doc.Objects if hasattr(o,'Shape')} for o in doc.Objects: if hasattr(o,'Shape'):o.ViewObject.Visibility=False b.ViewObject.Visibility=True;render(True,'bracket.png') for o in doc.Objects: if hasattr(o,'Shape'):o.ViewObject.Visibility=states[o.Name] render(False,'assembly.png');doc.recompute();doc.saveAs(str(O/'PCD50_Assembly.FCStd')) Import.export([o for o in doc.Objects if hasattr(o,'Shape')],str(O/'PCD50_Assembly.step')) (O/'DONE.txt').write_text('ok\n',encoding='utf-8') except Exception: (O/'ERROR.txt').write_text(traceback.format_exc(),encoding='utf-8');raise