148 lines
8.3 KiB
Python
148 lines
8.3 KiB
Python
"""PCD50 square-open bracket, with PCD76 corner slots offset 2 mm.
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Concept assembly only. Rebuild via rebuild_pcd50_fit_concept.FCMacro.
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"""
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from pathlib import Path
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import math, time, 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'/'pcd50_fit_concept'; O.mkdir(parents=True,exist_ok=True)
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V=A.Vector
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def cy(r,h,x,y,z): return Part.makeCylinder(r,h,V(x,y,z))
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def add(doc,n,label,s,c,t=0):
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o=doc.addObject('PartDesign::Feature',n); o.Label=label; o.Shape=s
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o.ViewObject.ShapeColor=c;o.ViewObject.LineColor=(.1,.1,.1);o.ViewObject.Transparency=t
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return o
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try:
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src=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)]
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shapes={n:src.getObject(n).Shape.copy() for n in keep}
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orig=src.getObject('Bracket').Shape.copy()
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shims=[src.getObject('Shim%d'%i).Shape.copy() for i in range(4)]
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A.closeDocument(src.Name)
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# The old Direct model moved each bracket 2.75mm outwards. Inwards by
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# 0.75mm makes the new shift 2.00mm, leaving nominal slot clearance.
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for n in ['Corner%d'%i for i in range(4)]+['Rail%d'%i for i in range(2)]:
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s=shapes[n]; cx=(s.BoundBox.XMin+s.BoundBox.XMax)/2
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s.translate(V(-.75 if cx>0 else .75,0,0))
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doc=A.newDocument('PCD50_Fit_2mm'); objs={}
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colors={'Motor':(.32,.34,.37),'Holder':(.98,.55,.1),'Magnet':(.8,.8,.8),'PCB':(.04,.65,.19),'Chip':(.1,.1,.1)}
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for n,s in shapes.items():
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c=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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objs[n]=add(doc,n,n,s,c,70 if n=='Motor' else 20 if n.startswith('Corner') else 0)
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pts=[(25*math.cos(math.radians(45+90*i)),25*math.sin(math.radians(45+90*i))) for i in range(4)]
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# A 49mm frame leaves about 2.7mm beside the 8.2mm tool opening.
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# Its outer corners are notched to permit PCD76 fastening tool access.
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square=Part.makeBox(49,49,3.2,V(-24.5,-24.5,10.9)).cut(cy(16.8,3.22,0,0,10.89))
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p76=38/math.sqrt(2)
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for sx in (-1,1):
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for sy in (-1,1):
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square=square.cut(cy(5.2,3.24,sx*p76,sy*p76,10.88))
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bracket=orig.fuse(square)
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for x,y in pts:bracket=bracket.fuse(cy(4.5,1,x,y,2.5))
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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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# Outward opening towards left/right per user sketch, with upper 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(cy(2.2,3.7,x,y,-.05))
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upper=Part.makeBox(10,8.2,11,V(start,y-4.1,3.5)).fuse(cy(4.1,11,x,y,3.5))
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bracket=bracket.cut(slot).cut(upper)
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for j in range(4):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('invalid bracket')
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b=add(doc,'OpenBracket','PCD50 square frame, outward open - concept',bracket,(.12,.43,.88))
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shimobjs=[]
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for i,s in enumerate(shims):
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s=s.removeSplitter()
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if s.isNull() or not s.isValid() or len(s.Solids)!=1:raise RuntimeError('invalid shim %d'%i)
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shimobjs.append(add(doc,'Shim50_%d'%i,'0.5mm open adjustment shim - concept',s,(.70,.70,.75)))
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heads=[];shafts=[];mount76=[];washers76=[]
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for i,(x,y) in enumerate(pts):
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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)))
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shafts.append(add(doc,'Shaft50_%d'%i,'M4x8 50 screw shank Ø4 concept',cy(2,8,x,y,-4.5),(.8,.8,.8)))
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p=38/math.sqrt(2)
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for sx in (-1,1):
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for sy in (-1,1):
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x,y=sx*p,sy*p
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w=cy(5,.8,x,y,3).cut(cy(2.15,.82,x,y,2.99)).removeSplitter()
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washers76.append(add(doc,'Washer76_%d'%len(washers76),'M4 washer Ø10 x 0.8 assumed',w,(.75,.75,.77)))
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s=cy(2,8,x,y,-4.2).fuse(cy(3.5,2.5,x,y,3.8)).removeSplitter()
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mount76.append(add(doc,'Mount76_%d'%len(mount76),'M4 76 shank Ø4 head Ø7 concept',s,(.8,.8,.8)))
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doc.recompute(); corners=[objs['Corner%d'%i] for i in range(4)]; rails=[objs['Rail%d'%i] for i in range(2)]
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pairs=[]
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for a in [b]+shimobjs+heads+shafts:
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for c in corners+rails:pairs.append((a,c))
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for a in shafts:
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for c in [b]+shimobjs:pairs.append((a,c))
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for a in mount76:
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for c in corners+rails+[b]+shimobjs+heads+shafts:pairs.append((a,c))
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for a in washers76:
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for c in corners+rails+[b]+shimobjs+heads+shafts+mount76:pairs.append((a,c))
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for a in [b]+shimobjs+heads+shafts:
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for n in ['Motor','Holder','Magnet','PCB','Chip']+['PCBHead%d'%i for i in range(1,4)]:pairs.append((a,objs[n]))
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errors=[]
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for a,c in pairs:
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if not a.Shape.BoundBox.intersect(c.Shape.BoundBox):continue
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vol=a.Shape.common(c.Shape).Volume
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if vol>.001:errors.append('%s / %s %.6fmm3'%(a.Name,c.Name,vol))
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# Record tool clearance against corner/support for four assumed 7.5mm
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# axial screwdriver envelopes. Start above the modelled screw heads.
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access=[]
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for i,(x,y) in enumerate(pts):
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tool=cy(3.75,20,x,y,6.51); hits=[]
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for o in [b]+corners+rails:
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if tool.BoundBox.intersect(o.Shape.BoundBox):
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v=tool.common(o.Shape).Volume
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if v>.001:hits.append('%s %.4f'%(o.Name,v))
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access.append('50 head %d: %s'%(i,', '.join(hits) if hits else 'clear (model envelope only)'))
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for sx in (-1,1):
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for sy in (-1,1):
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x,y=sx*p,sy*p; tool=cy(3.75,20,x,y,6.31); hits=[]
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for o in [b]+corners+rails:
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if tool.BoundBox.intersect(o.Shape.BoundBox):
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v=tool.common(o.Shape).Volume
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if v>.001:hits.append('%s %.4f'%(o.Name,v))
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access.append('76 head %+.0f,%+.0f: %s'%(sx,sy,', '.join(hits) if hits else 'clear (model envelope only)'))
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areas=[]
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for x,y in pts:
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count=0; step=.2
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for ix in range(-18,19):
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for iy in range(-18,19):
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dx,dy=ix*step,iy*step
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if dx*dx+dy*dy<=3.5**2 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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report=['Concept only. PCD50 and PCD76 phase 45 deg assumed; 4x M4 Ø4.',
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'PCD76 slot 9.5 x 5.5 assumed; angle brackets remain flush and shifted 2.00mm outwards.',
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'Nominal M4 versus slot-end clearance: 0.75mm. 50 head Ø7 x 3 assumed.',
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'76 washer Ø10x0.8 assumed; M4x8 gives nominal 4.2mm engagement, motor hole depth unknown.',
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'0.5mm shim; 50 foot top 3.5mm; original PCB and magnet position unchanged.',
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'Detected positive volumes >0.001mm3:']+(errors or ['none in checked pairs'])
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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)]
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(O/'geometry_check.txt').write_text('\n'.join(report)+'\n',encoding='utf-8')
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G.activateWorkbench('PartWorkbench');view=G.activeDocument().activeView()
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def render(top,path):
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if top:view.viewTop()
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else:
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view.viewAxonometric();G.updateGui();time.sleep(.5)
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view.getCameraNode().orientation.setValue(coin.SbRotation(.880476,.115917,-.279848,-.364705))
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G.updateGui();time.sleep(.7);view.fitAll();G.updateGui();time.sleep(.7);G.updateGui();view.saveImage(str(O/path),1600,1200,'White')
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render(True,'rear.png');render(False,'assembly.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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b.ViewObject.Visibility=True;render(True,'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(False,'assembly.png');doc.recompute();doc.saveAs(str(O/'PCD50_Assembly.FCStd'))
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Import.export([o for o in doc.Objects if hasattr(o,'Shape')],str(O/'PCD50_Assembly.step'))
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(O/'DONE.txt').write_text('ok\n',encoding='utf-8')
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except Exception:
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(O/'ERROR.txt').write_text(traceback.format_exc(),encoding='utf-8');raise
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