437 lines
18 KiB
Python
437 lines
18 KiB
Python
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# -*- coding: utf-8 -*-
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"""全对全动态行程扫描与碰撞验证（权威版 v2，多进程并行）
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与旧 travel_sweep.py / real_arm_collision_test.py 的区别（旧脚本漏掉了用户实测到的干涉）：
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1. 直接在进程内构建当前模型（arm_model_v2_rounded.build()），杜绝 STEP/网格过期；
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2. 关节轴取自 Joint.rear/.d（human_layout 唯一事实源），与网页查看器逐位一致；
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3. 检查【全部】零件对 —— 包括相邻关节的零件对与电机模组（旧脚本跳过相邻对，
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而 P04xP05 / P07xP08 恰恰在关节贴面处被卡死）；
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4. 单关节双向精扫（粗扫 + 二分）得出真实硬限位；
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5. 组合姿态扫描：每个关节置于其极限，再扫其余关节，收敛出滑块安全范围；
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6. 写 docs/travel.json（查看器滑块范围）+ docs/travel_detail.json（逐对明细）。
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并行化（用户要求）：
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- mp.Pool 每个工作进程独立构建一次模型，角度任务批量分发（imap 保序）；
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- OCCT 布尔运算 SetRunParallel(True)；
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- 预剪枝：按关节轴计算每对零件的轴向/径向区间，区间不相交的零件对在该关节的
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任何角度都不可能碰撞，直接跳过（对单关节扫描是精确安全的）。
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运行：python src/sweep_v2.py [--workers 20] [--step 2] [--combo-step 6]
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[--no-combos] [--joints J2,J4]
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"""
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import json
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import math
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import os
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import sys
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import time
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sys.path.insert(0, os.path.dirname(os.path.abspath(__file__)))
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try:
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sys.stdout.reconfigure(encoding="utf-8")
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except Exception:
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pass
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import multiprocessing as mp
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import arm_build as AB
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import cadquery as cq
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from armcore import place, bb, DOCS
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VOL_MIN = 2.0 # mm3，超过即计为干涉
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CHAIN = ["root", "J1", "J2", "J3", "J4", "J5", "J6"]
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# ---------------------------------------------------------------- 模型与上下文
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def load_model():
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import arm_model_v2_rounded as AM
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JS = AM.build()
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parts = []
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for p in AB.PARTS:
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g = CHAIN.index(AB.GRP.get(p["name"], "root"))
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lo, hi = bb(p["shape"])
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corners = [(x, y, z) for x in (lo[0], hi[0]) for y in (lo[1], hi[1]) for z in (lo[2], hi[2])]
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parts.append(dict(name=p["name"], shape=p["shape"], g=g, c8=corners, box=(lo, hi)))
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joints = {t: (JS[t].rear, JS[t].d) for t in CHAIN[1:]}
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return parts, joints
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def axis_intervals(parts, rear, d):
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"""每个零件沿关节轴的 (轴向区间, 径向最小/最大距离)。要求 d 为坐标轴方向。"""
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out = []
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for p in parts:
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lo, hi = p["box"]
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if abs(d[0]) > 0.5:
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ax = (lo[0] - rear[0], hi[0] - rear[0])
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u = (lo[1], hi[1], rear[1]); v = (lo[2], hi[2], rear[2])
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elif abs(d[1]) > 0.5:
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ax = (lo[1] - rear[1], hi[1] - rear[1])
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u = (lo[0], hi[0], rear[0]); v = (lo[2], hi[2], rear[2])
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else:
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ax = (lo[2] - rear[2], hi[2] - rear[2])
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u = (lo[0], hi[0], rear[0]); v = (lo[1], hi[1], rear[1])
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du = max(u[0] - u[2], 0.0, u[2] - u[1])
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dv = max(v[0] - v[2], 0.0, v[2] - v[1])
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rmin = math.hypot(du, dv)
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rmax = max(math.hypot(a - u[2], b - v[2]) for a in (u[0], u[1]) for b in (v[0], v[1]))
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out.append((ax, rmin, rmax))
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return out
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def make_ctx():
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parts, joints = load_model()
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impossible = {}
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for k in range(1, len(CHAIN)):
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rear, d = joints[CHAIN[k]]
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iv = axis_intervals(parts, rear, d)
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s = set()
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for i in range(len(parts)):
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for j in range(i + 1, len(parts)):
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ga, gb = parts[i]["g"], parts[j]["g"]
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lo, hi = (ga, gb) if ga < gb else (gb, ga)
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if lo == hi or not (lo < k <= hi):
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continue
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ax_i, r_i = iv[i][0], (iv[i][1], iv[i][2])
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ax_j, r_j = iv[j][0], (iv[j][1], iv[j][2])
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if ax_i[1] < ax_j[0] or ax_j[1] < ax_i[0] or \
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r_i[1] < r_j[0] or r_j[1] < r_i[0]:
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s.add((i, j))
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impossible[k] = s
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return dict(parts=parts, joints=joints, impossible=impossible)
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# ---------------------------------------------------------------- 姿态测试
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def accum_trsf(joints, angles_by_idx):
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"""链式累积变换：acc[i] = acc[i-1] ∘ R_i（与查看器嵌套 pivot 完全一致）。"""
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acc = [None] * len(CHAIN)
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for i in range(1, len(CHAIN)):
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ang = angles_by_idx.get(i, 0.0)
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if abs(ang) < 1e-9:
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acc[i] = acc[i - 1]
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continue
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rear, d = joints[CHAIN[i]]
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r = AB.R(ang, d[0], d[1], d[2], rear[0], rear[1], rear[2])
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acc[i] = r if acc[i - 1] is None else acc[i - 1].Multiplied(r)
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return acc
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def xf_c8(c8, t):
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from OCP.gp import gp_Pnt
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gpt = [gp_Pnt(*c).Transformed(t) for c in c8]
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lo = [min(p.X() for p in gpt), min(p.Y() for p in gpt), min(p.Z() for p in gpt)]
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hi = [max(p.X() for p in gpt), max(p.Y() for p in gpt), max(p.Z() for p in gpt)]
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return (lo, hi)
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def common_vol_center(a, b):
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"""交集体积 + 干涉质心；布尔失败返回 (-1, None)。"""
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try:
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from OCP.BRepAlgoAPI import BRepAlgoAPI_Common
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c = BRepAlgoAPI_Common(a.wrapped, b.wrapped)
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c.SetRunParallel(True)
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c.Build()
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if not c.IsDone() or c.Shape().IsNull():
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return 0.0, None
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sh = cq.Shape(c.Shape())
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v = AB.vol_of(sh)
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if v <= VOL_MIN:
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return v, None
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(lo, hi) = bb(sh)
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return v, tuple(round((lo[i] + hi[i]) / 2.0, 1) for i in range(3))
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except Exception:
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return -1.0, None
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def test_posture(ctx, angles_by_idx, want_errors=False):
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"""返回 (violations, errors)：violations = [(na, nb, vol, 干涉质心)]。"""
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parts, joints, impossible = ctx["parts"], ctx["joints"], ctx["impossible"]
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active = [k for k, a in angles_by_idx.items() if abs(a) > 1e-9]
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acc = accum_trsf(joints, angles_by_idx)
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boxes = []
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for p in parts:
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t = acc[p["g"]]
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boxes.append(p["box"] if t is None else xf_c8(p["c8"], t))
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shapes = {}
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viol, errs = [], []
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n = len(parts)
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for i in range(n):
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gi = parts[i]["g"]
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for j in range(i + 1, n):
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gj = parts[j]["g"]
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lo, hi = (gi, gj) if gi < gj else (gj, gi)
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if lo == hi:
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continue
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span = [k for k in active if lo < k <= hi]
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if not span:
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continue
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if len(span) == 1 and (i, j) in impossible[span[0]]:
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continue
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bi, bj = boxes[i], boxes[j]
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if any(bi[1][k] < bj[0][k] - 0.1 or bj[1][k] < bi[0][k] - 0.1 for k in range(3)):
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continue
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si = shapes.get(i)
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if si is None:
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t = acc[gi]
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si = parts[i]["shape"] if t is None else place(parts[i]["shape"], t)
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shapes[i] = si
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sj = shapes.get(j)
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if sj is None:
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t = acc[gj]
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sj = parts[j]["shape"] if t is None else place(parts[j]["shape"], t)
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shapes[j] = sj
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v, center = common_vol_center(si, sj)
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if v < 0:
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errs.append((parts[i]["name"], parts[j]["name"]))
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continue
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if v > VOL_MIN:
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viol.append((parts[i]["name"], parts[j]["name"], round(v, 1), center))
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return (viol, errs) if want_errors else viol
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# ---------------------------------------------------------------- 工作进程
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_CTX = None
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_POOL = None
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_WORKERS = 4
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def _init_worker():
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global _CTX
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_CTX = make_ctx()
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def _task(task):
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angles = {int(k): v for k, v in task["a"].items()}
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return test_posture(_CTX, angles) # imap 保序，无需回传 id
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def get_pool(workers):
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global _POOL, _WORKERS
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_WORKERS = workers
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if _POOL is None and workers > 1:
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_POOL = mp.Pool(workers, initializer=_init_worker)
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return _POOL
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def eval_angles(angles_list, workers, chunk=None):
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"""批量评估姿态列表 [{idx: ang}]，按输入顺序返回 violations 列表。"""
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tasks = [dict(id=i, a={str(k): v for k, v in a.items()}) for i, a in enumerate(angles_list)]
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if workers <= 1:
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ctx = _ctx_single()
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return [test_posture(ctx, a) for a in angles_list]
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pool = get_pool(workers)
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out = [None] * len(tasks)
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cs = chunk or max(1, len(tasks) // (workers * 4) or 1)
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for idx, viol in enumerate(pool.imap(_task, tasks, chunksize=cs)):
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out[idx] = viol
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return out
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def _ctx_single():
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global _CTX
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if _CTX is None:
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_CTX = make_ctx()
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return _CTX
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# ---------------------------------------------------------------- 扫描逻辑
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def bisect(workers, k, a_free, a_jam, tol=0.2):
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while abs(a_jam - a_free) > tol:
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mid = 0.5 * (a_free + a_jam)
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if eval_angles([{k: mid}], workers)[0]:
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a_jam = mid
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else:
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a_free = mid
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return a_free
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def sweep_single(k, step, workers):
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jams = {}
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lo = hi = 0.0
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for sign in (+1, -1):
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angles = [sign * step * i for i in range(1, int(180.0 / step) + 1)]
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stop, a_free = None, 0.0
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B = max(workers * 2, 8)
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for s in range(0, len(angles), B):
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batch = angles[s:s + B]
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results = eval_angles([{k: a} for a in batch], workers)
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for a, viol in zip(batch, results):
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if viol:
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jams[a] = viol
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stop = bisect(workers, k, sign * (a - step), a)
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break
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a_free = a
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if stop is not None:
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break
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if stop is None:
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stop = a_free
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if sign > 0:
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hi = stop
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else:
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lo = stop
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return dict(lo=lo, hi=hi, jams=jams)
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def sweep_combo(k_hold, e_hold, j_sweep, a_lo, a_hi, step, workers):
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jams = {}
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res = {}
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for sign, lim in ((+1, a_hi), (-1, a_lo)):
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angles = [sign * step * i for i in range(1, int(abs(lim) / step) + 1)] if abs(lim) > 1e-6 else []
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stop, a_free = None, 0.0
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B = max(workers * 2, 8)
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for s in range(0, len(angles), B):
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batch = angles[s:s + B]
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results = eval_angles([{k_hold: e_hold, j_sweep: a} for a in batch], workers)
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for a, viol in zip(batch, results):
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if viol:
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jams[a] = viol
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lo_f, hi_j = sign * (a - step), a
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while abs(hi_j - lo_f) > 0.5:
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mid = 0.5 * (lo_f + hi_j)
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if eval_angles([{k_hold: e_hold, j_sweep: mid}], workers)[0]:
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hi_j = mid
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else:
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lo_f = mid
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stop = lo_f
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break
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a_free = a
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if stop is not None:
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break
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if stop is None:
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stop = a_free
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res[sign] = stop
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return res[+1], res[-1], jams
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def main():
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t0 = time.time()
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step, combo_step = 2.0, 6.0
|
|||
|
|
do_combos = "--no-combos" not in sys.argv
|
|||
|
|
want_joints = None
|
|||
|
|
workers = max(1, min(20, (os.cpu_count() or 4) - 2))
|
|||
|
|
for i, a in enumerate(sys.argv):
|
|||
|
|
if a == "--step":
|
|||
|
|
step = float(sys.argv[i + 1])
|
|||
|
|
if a == "--combo-step":
|
|||
|
|
combo_step = float(sys.argv[i + 1])
|
|||
|
|
if a == "--workers":
|
|||
|
|
workers = int(sys.argv[i + 1])
|
|||
|
|
if a == "--joints":
|
|||
|
|
want_joints = set(sys.argv[i + 1].split(","))
|
|||
|
|
|
|||
|
|
print("=" * 78)
|
|||
|
|
print("全对全动态行程扫描 v2 并行版（workers=%d，轴=human_layout，含相邻对与电机）" % workers)
|
|||
|
|
print("=" * 78, flush=True)
|
|||
|
|
if workers > 1:
|
|||
|
|
get_pool(workers) # 启动工作进程（各自并行建模，父进程不重复建模）
|
|||
|
|
# 零位检查
|
|||
|
|
v0 = eval_angles([{}], workers)[0]
|
|||
|
|
print("[零位检查] %s" % ("0 对干涉 ✓" if not v0 else "干涉: %s" % v0), flush=True)
|
|||
|
|
|
|||
|
|
singles = {}
|
|||
|
|
print("\n[单关节硬限位] 粗扫 %.1f° + 二分 0.2°" % step, flush=True)
|
|||
|
|
for k in range(1, len(CHAIN)):
|
|||
|
|
tag = CHAIN[k]
|
|||
|
|
if want_joints and tag not in want_joints:
|
|||
|
|
continue
|
|||
|
|
r = sweep_single(k, step, workers)
|
|||
|
|
singles[tag] = r
|
|||
|
|
jam_s = "; ".join(
|
|||
|
|
"%s%.1f°:%s" % ("+" if a > 0 else "", a,
|
|||
|
|
",".join("%sx%s@%s(%.0f)" % (p, q, c, v) for p, q, v, c in vs[:2]))
|
|||
|
|
for a, vs in sorted(r["jams"].items())[:4])
|
|||
|
|
print(" %-3s lo=%7.2f hi=%7.2f %s [%.0fs]" % (tag, r["lo"], r["hi"],
|
|||
|
|
("卡死: " + jam_s) if jam_s else "整周无干涉 → 360° 连续", time.time() - t0), flush=True)
|
|||
|
|
|
|||
|
|
if want_joints:
|
|||
|
|
json.dump(dict(generated=time.strftime("%Y-%m-%d %H:%M:%S"),
|
|||
|
|
singles={t: dict(lo=round(singles[t]["lo"], 2),
|
|||
|
|
hi=round(singles[t]["hi"], 2),
|
|||
|
|
jams={str(a): v for a, v in singles[t]["jams"].items()})
|
|||
|
|
for t in singles}),
|
|||
|
|
open(DOCS + "/travel_probe.json", "w", encoding="utf-8"),
|
|||
|
|
ensure_ascii=False, indent=1)
|
|||
|
|
print("\n[诊断模式] 明细已写出 docs/travel_probe.json [%.0fs]" % (time.time() - t0))
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
limits = {t: [singles[t]["lo"], singles[t]["hi"]] for t in CHAIN[1:]}
|
|||
|
|
|
|||
|
|
combos_log = []
|
|||
|
|
if do_combos:
|
|||
|
|
print("\n[组合姿态收敛] 保持一个关节于极限，扫其余关节（步长 %.1f°）" % combo_step, flush=True)
|
|||
|
|
for pass_i in range(2):
|
|||
|
|
changed = False
|
|||
|
|
for k in range(1, len(CHAIN)):
|
|||
|
|
tag_k = CHAIN[k]
|
|||
|
|
for e in (limits[tag_k][0], limits[tag_k][1]):
|
|||
|
|
if abs(e) < 5.0:
|
|||
|
|
continue
|
|||
|
|
for j in range(1, len(CHAIN)):
|
|||
|
|
if j == k:
|
|||
|
|
continue
|
|||
|
|
tag_j = CHAIN[j]
|
|||
|
|
lo_j, hi_j = limits[tag_j]
|
|||
|
|
if abs(lo_j) < 5.0 and abs(hi_j) < 5.0:
|
|||
|
|
continue
|
|||
|
|
pos, neg, jams = sweep_combo(k, e, j, lo_j, hi_j, combo_step, workers)
|
|||
|
|
for sign, free, lim in ((+1, pos, hi_j), (-1, neg, lo_j)):
|
|||
|
|
new = free - 1.0
|
|||
|
|
if sign > 0 and new < limits[tag_j][1] - 0.01:
|
|||
|
|
combos_log.append(dict(pass_=pass_i, hold=tag_k, hold_at=e,
|
|||
|
|
swept=tag_j, direction="hi",
|
|||
|
|
old=limits[tag_j][1], new=max(new, 0.0),
|
|||
|
|
jams={str(a): v for a, v in jams.items()}))
|
|||
|
|
limits[tag_j][1] = max(new, 0.0)
|
|||
|
|
changed = True
|
|||
|
|
if sign < 0 and new > limits[tag_j][0] + 0.01:
|
|||
|
|
combos_log.append(dict(pass_=pass_i, hold=tag_k, hold_at=e,
|
|||
|
|
swept=tag_j, direction="lo",
|
|||
|
|
old=limits[tag_j][0], new=min(new, 0.0),
|
|||
|
|
jams={str(a): v for a, v in jams.items()}))
|
|||
|
|
limits[tag_j][0] = min(new, 0.0)
|
|||
|
|
changed = True
|
|||
|
|
print(" hold %s done [%.0fs]" % (tag_k, time.time() - t0), flush=True)
|
|||
|
|
print(" pass %d: %s" % (pass_i + 1,
|
|||
|
|
"收紧 " + str({t: [round(limits[t][0], 1), round(limits[t][1], 1)] for t in CHAIN[1:]}
|
|||
|
|
if changed else "无变化")), flush=True)
|
|||
|
|
if not changed:
|
|||
|
|
break
|
|||
|
|
|
|||
|
|
# 滑块范围 = 单关节验证硬限位（任意单关节推满保证零干涉）。
|
|||
|
|
# 组合折叠约束（某关节保持极限时扫其它关节发现的卡死）只写入明细/报告，
|
|||
|
|
# 不压缩滑块 —— 否则手臂会被静态限位锁死（真实机器人由控制器做避碰）。
|
|||
|
|
final = {}
|
|||
|
|
print("\n[最终滑块范围]（单关节硬限位，含 1° 安全余量）")
|
|||
|
|
for t in CHAIN[1:]:
|
|||
|
|
lo, hi = singles[t]["lo"], singles[t]["hi"]
|
|||
|
|
if lo <= -179.9 and hi >= 179.9:
|
|||
|
|
final[t] = dict(axis=t, lo=-180.0, hi=180.0, continuous=True, zero=0.0,
|
|||
|
|
note="整周无干涉，可 360° 连续旋转（全对全动态扫描验证）")
|
|||
|
|
else:
|
|||
|
|
lo_out = float(math.ceil(lo + 1.0)) if lo < -0.5 else 0.0
|
|||
|
|
hi_out = float(math.floor(hi - 1.0)) if hi > 0.5 else 0.0
|
|||
|
|
final[t] = dict(axis=t, lo=lo_out, hi=hi_out, continuous=False, zero=0.0,
|
|||
|
|
note="正向 +%d° / 反向 %d°，总行程 %d°（全对全动态扫描验证，含相邻件与电机）"
|
|||
|
|
% (hi_out, lo_out, hi_out - lo_out))
|
|||
|
|
print(" %-3s %7.1f .. %7.1f %s" % (t, final[t]["lo"], final[t]["hi"],
|
|||
|
|
"360°连续" if final[t]["continuous"] else ""))
|
|||
|
|
|
|||
|
|
os.makedirs(DOCS, exist_ok=True)
|
|||
|
|
json.dump([final[t] for t in CHAIN[1:]],
|
|||
|
|
open(DOCS + "/travel.json", "w", encoding="utf-8"), ensure_ascii=False, indent=1)
|
|||
|
|
detail = dict(generated=time.strftime("%Y-%m-%d %H:%M:%S"),
|
|||
|
|
vol_min=VOL_MIN, step=step, combo_step=combo_step, workers=workers,
|
|||
|
|
singles={t: dict(lo=round(singles[t]["lo"], 2), hi=round(singles[t]["hi"], 2),
|
|||
|
|
jams={str(a): v for a, v in singles[t]["jams"].items()})
|
|||
|
|
for t in singles},
|
|||
|
|
combos=combos_log,
|
|||
|
|
final=[final[t] for t in CHAIN[1:]])
|
|||
|
|
json.dump(detail, open(DOCS + "/travel_detail.json", "w", encoding="utf-8"),
|
|||
|
|
ensure_ascii=False, indent=1)
|
|||
|
|
print("\n已写出 docs/travel.json（查看器滑块）+ docs/travel_detail.json（明细） [%.0fs]"
|
|||
|
|
% (time.time() - t0))
|
|||
|
|
if _POOL is not None:
|
|||
|
|
_POOL.terminate()
|
|||
|
|
|
|||
|
|
|
|||
|
|
if __name__ == "__main__":
|
|||
|
|
main()
|