cbb
79c1265202
新增 screw_mesh.py 螺丝网格划分模块与 strength_check.py 强度校核逻辑，arm_model.py 同步集成网格生成与校核流程；viewer_tpl.html、web/index.html 与 web/机器人手臂3D查看器.html 更新查看器模板以支持新数据展示；docs/bom.json 与 docs/travel_detail.json 调整 BOM 清单与行程参数；docs/print_settings.md 新增打印设置说明，新增螺丝采购清单 HTML；补充大量定位图与验证截图。
1306 lines
59 KiB
Python
1306 lines
59 KiB
Python
# -*- coding: utf-8 -*-
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"""机器人手臂深度圆角优化版 V2：彻底消除所有棱角
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针对用户反馈的三大问题区域进行深度优化：
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1. 蓝色零件（P04肩叉）顶部方形突起 → 全圆角处理
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2. 绿色/青色零件（P05/P08）底部和侧面棱角 → Loft外轮廓圆角
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3. 所有连接处的尖锐过渡 → 大圆角平滑过渡
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4. 橙色零件（P06/P07）所有方形边缘 → 完整圆角系统
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"""
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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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import cadquery as cq
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import arm_build as AB
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from armcore import (M, C, cyl, box, ring, place, trs, bb, bbox_str, solids_of, OUT, WEB, DOCS)
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from arm_build import (Joint, add, bx, Ycyl, Ybox, Yplate, prism, dogbone, sector,
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FLANGE_Z, COVER_Z, HUB_FACE_Z, CLAMP_SPAN, HUB_M2_CLOCK,
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BORE_R, CB_R, PCB_W, D2R, T, R, PARTS)
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import human_layout as HL
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from OCP.BRepAlgoAPI import BRepAlgoAPI_Common
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from human_layout import (HUB, PLATE_T, R_MOT, Z_TIP, Z_WR, Z_EI, Z_SH, Z_RL, Z_R1,
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Z_R3, Z_HUB3, Z_EL, Z_R6, Z_HUB6,
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Z_R4, Z_CAP, Z_M6, Z_CHEST0, Z_CHEST1, X_J1_HUB, X_ARM, L1,
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X_FORK_GAP,
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Y_AXIS, Y_HUB, Y_REAR, Y_COVER, Y_H, Y_R_IN, Y_R_OUT,
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Y_M6, Y_CHEST, X_CHEST, FOOT_H)
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VERSION = os.environ.get("ARMVER", "v2")
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ITER = int(os.environ.get("ARMITER", "3"))
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AB.VERSION = VERSION
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AB.ITER = ITER
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Y_MID = Y_AXIS
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BOSS = COVER_Z + 0.2
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DISC_R = 40.0
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SLEEVE_R = 35.0
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# 深度圆角优化参数
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CLEARANCE_GAP = 2.0 # 关节间隙 2.0mm
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FILLET_TINY = 1.5 # 微小圆角（螺孔边缘）
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FILLET_SMALL = 3.0 # 小圆角（功能面）
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FILLET_MEDIUM = 6.0 # 中圆角（结构过渡）
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FILLET_LARGE = 10.0 # 大圆角（主要轮廓）
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FILLET_XLARGE = 15.0 # 超大圆角（视觉主导区域）
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CHAMFER_EDGE = 2.0 # 边缘倒角
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def Xcyl(r, x0, x1, py, pz):
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return place(place(cyl(r, 0.0, x1 - x0, 0.0, 0.0), R(90, 0, 1, 0)), T(x0, py, pz))
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def Xplate(pts_yz, x0, x1):
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prof = [(-p[1], p[0]) for p in pts_yz]
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return place(place(prism(prof, 0.0, x1 - x0), R(90, 0, 1, 0)), T(x0, 0.0, 0.0))
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def XB(a0, a1, y0, y1, z0, z1):
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return bx(X_ARM + a0, X_ARM + a1, y0, y1, z0, z1)
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def make_direct_hub(shape, j, r_disc=35.0, z_out=74.0):
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"""优化直连法兰：增加导向倒角"""
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disc = cyl(r_disc, 56.5, z_out)
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boss = cyl(17.8, 54.942, 56.5)
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chamfer_cone = cyl(18.5, 54.5, 54.942)
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shape = shape.fuse(j.L(disc)).fuse(j.L(boss)).cut(j.L(chamfer_cone))
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shape = shape.cut(j.L(cyl(3.5, 54.0, z_out + 30.0)))
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for a in AB.HUB_M2_CLOCK:
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u = AB.M["m2_bcd"] / 2.0 * math.cos(a * AB.D2R)
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v = AB.M["m2_bcd"] / 2.0 * math.sin(a * AB.D2R)
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th = cyl(1.4, 54.0, 58.0, u, v)
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cb = cyl(2.8, 58.0, z_out + 40.0, u, v)
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shape = shape.cut(j.L(th)).cut(j.L(cb))
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return shape
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# ========== 躯干部分 ==========
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# ========== 躯干/测试台架部分 (后置防倾翻高刚性机架) ==========
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X_COL = -115.0
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Y_COL = Y_AXIS # 128.0
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def p_chest():
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"""P01_胸腔支撑立柱 (High-Rigidity Box Mast Tower - 后置台架立柱):
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1. 66x66mm 封闭中空厚壁箱型柱（壁厚 11mm，内腔 44x44），中心在 (-115.0, 128.0)，位于手臂正后方；
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2. 顶部接收 P03 48x48x15mm 榫头插槽与 4x M5 安装螺栓；
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3. 底部 50x50x12mm 阶梯榫头插入 P02 榫座：环形台肩(66->50)面承载轴向力，槽壁全周承载剪切；
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4. 前向开设两组大圆角走线工艺窗口（Z=60~150mm 与 Z=330~420mm）；
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5. 外棱角全部采用 R=6mm 圆角。
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"""
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z_bot = 22.0
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z_top = Z_CHEST1 # 470.0
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col = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_bot))
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.rect(66.0, 66.0)
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.extrude(z_top - z_bot)
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.edges("|Z").fillet(6.0)).val()
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s = cq.Shape(col.wrapped)
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cav = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_bot + 10.0))
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.rect(44.0, 44.0)
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.extrude(z_top - z_bot + 1.0)
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.edges("|Z").fillet(4.0)).val()
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s = s.cut(cav)
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# 底部阶梯榫头：插入 P02 榫座后环形台肩坐实，轴向力走面压而非 M5 螺纹
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tenon = (cq.Workplane("XY", origin=(X_COL, Y_COL, 10.0))
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.rect(50.0, 50.0).extrude(z_bot - 10.0)
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.edges("|Z").fillet(4.0)).val()
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s = s.fuse(tenon)
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# 底部 M5 夹紧孔（贯通榫头）：X 向非对称 (−20/+16) 与榫座孔位配对防反装/防转 90°
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for xx in (X_COL - 20.0, X_COL + 16.0):
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for yy in (Y_COL - 18.0, Y_COL + 18.0):
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s = s.cut(cyl(2.75, 9.99, z_bot + 15.0, xx, yy))
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for xx in (X_COL - 21.0, X_COL + 21.0):
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for yy in (Y_COL - 21.0, Y_COL + 21.0):
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s = s.cut(cyl(2.75, z_top - 20.0, z_top + 0.01, xx, yy))
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w_bot = (cq.Workplane("YZ", origin=(X_COL + 33.5, Y_COL, 105.0))
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.rect(34.0, 70.0)
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.extrude(-20.0)).val()
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s = s.cut(w_bot)
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w_top = (cq.Workplane("YZ", origin=(X_COL + 33.5, Y_COL, 375.0))
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.rect(34.0, 70.0)
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.extrude(-20.0)).val()
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s = s.cut(w_top)
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return s
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def split_p01_poka_yoke(p01):
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"""拆分 P01 为 A/B/C 三段（严格适配 200x200mm 打印机，竖直免支撑打印）：
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带 16mm 阶梯互锁榫卯（外套筒壁 3.6 + 公榫壁 6.9，内腔收窄 51->44 换取双厚壁，
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单边配合间隙 0.5）、非对称 M4 横向对锁穿钉孔（物理防反装防呆）、以及本体 3D 凹刻朝向标识。
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"""
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z_bot = 22.0
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z_s1 = 172.0
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z_s2 = 321.0
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z_top = 470.0
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h_lap = 16.0
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# 非对称对锁孔位（相对立柱中心偏心 -16mm 与 +22mm，偏心差 6mm，反装无法穿入螺栓）
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xx_bolts = (X_COL - 16.0, X_COL + 22.0)
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# --- P01_A (下段) ---
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cut_above_s1 = bx(X_COL - 50.0, X_COL + 50.0, Y_COL - 50.0, Y_COL + 50.0, z_s1, z_top + 10.0)
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p01_a_base = p01.cut(cut_above_s1)
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tongue1_outer = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s1))
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.rect(57.8, 57.8).extrude(h_lap)
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.edges("|Z").fillet(3.4).edges(">Z").chamfer(1.5)).val()
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tongue1_cav = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s1 - 1.0))
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.rect(44.0, 44.0).extrude(h_lap + 2.0)).val()
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tongue1 = cq.Shape(tongue1_outer.wrapped).cut(tongue1_cav)
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p01_a = p01_a_base.fuse(tongue1)
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z_bolt1 = z_s1 + h_lap / 2.0 # 180.0
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for xx in xx_bolts:
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p01_a = p01_a.cut(Ycyl(2.2, Y_COL - 40.0, Y_COL + 40.0, xx, z_bolt1))
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# Engrave the front (-Y) flat face, reading VERTICALLY bottom-to-top along
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# the column (user request): local +X = world +Z, local +Y = world -X, so
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# the trailing "▶" glyph renders pointing world-up (+Z).
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front_label_plane_a = cq.Plane(
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origin=(X_COL, Y_COL - 33.0, 120.0),
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xDir=(0, 0, 1), normal=(0, -1, 0),
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)
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label_a = (cq.Workplane(front_label_plane_a)
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.text("P01-A TOP ▶", 9.0, -0.8)).val()
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p01_a = p01_a.cut(cq.Shape(label_a.wrapped))
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# --- P01_B (中段) ---
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cut_below_s1 = bx(X_COL - 50.0, X_COL + 50.0, Y_COL - 50.0, Y_COL + 50.0, z_bot - 14.0, z_s1)
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cut_above_s2 = bx(X_COL - 50.0, X_COL + 50.0, Y_COL - 50.0, Y_COL + 50.0, z_s2, z_top + 10.0)
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p01_b_base = p01.cut(cut_below_s1).cut(cut_above_s2)
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pocket1 = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s1 - 0.1))
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.rect(58.8, 58.8).extrude(h_lap + 0.6).edges("|Z").fillet(3.9)).val()
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p01_b_base = p01_b_base.cut(pocket1)
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tongue2_outer = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s2))
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.rect(57.8, 57.8).extrude(h_lap)
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.edges("|Z").fillet(3.4).edges(">Z").chamfer(1.5)).val()
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tongue2_cav = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s2 - 1.0))
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.rect(44.0, 44.0).extrude(h_lap + 2.0)).val()
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tongue2 = cq.Shape(tongue2_outer.wrapped).cut(tongue2_cav)
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p01_b = p01_b_base.fuse(tongue2)
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z_bolt2 = z_s2 + h_lap / 2.0 # 329.0
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for xx in xx_bolts:
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p01_b = p01_b.cut(Ycyl(2.2, Y_COL - 40.0, Y_COL + 40.0, xx, z_bolt1))
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p01_b = p01_b.cut(Ycyl(2.2, Y_COL - 40.0, Y_COL + 40.0, xx, z_bolt2))
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front_label_plane_b = cq.Plane(
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origin=(X_COL, Y_COL - 33.0, 240.0),
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xDir=(0, 0, 1), normal=(0, -1, 0),
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)
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label_b = (cq.Workplane(front_label_plane_b)
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.text("P01-B TOP ▶", 9.0, -0.8)).val()
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p01_b = p01_b.cut(cq.Shape(label_b.wrapped))
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# --- P01_C (上段) ---
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cut_below_s2 = bx(X_COL - 50.0, X_COL + 50.0, Y_COL - 50.0, Y_COL + 50.0, z_bot - 14.0, z_s2)
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p01_c_base = p01.cut(cut_below_s2)
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pocket2 = (cq.Workplane("XY", origin=(X_COL, Y_COL, z_s2 - 0.1))
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.rect(58.8, 58.8).extrude(h_lap + 0.6).edges("|Z").fillet(3.9)).val()
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p01_c = p01_c_base.cut(pocket2)
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for xx in xx_bolts:
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p01_c = p01_c.cut(Ycyl(2.2, Y_COL - 40.0, Y_COL + 40.0, xx, z_bolt2))
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front_label_plane_c = cq.Plane(
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origin=(X_COL, Y_COL - 33.0, 390.0),
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xDir=(0, 0, 1), normal=(0, -1, 0),
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)
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label_c = (cq.Workplane(front_label_plane_c)
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.text("P01-C TOP ▶", 9.0, -0.8)).val()
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p01_c = p01_c.cut(cq.Shape(label_c.wrapped))
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return p01_a, p01_b, p01_c
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def make_p02_poka_yoke():
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"""将 P02 拆分为三件模块化组件（均严格 <= 195x190mm，适配 200x200mm 打印床）：
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1. P02_Center (底座中核心): 195x190x70mm，完整容纳立柱套筒与前后三角斜撑筋，核心应力区无接缝；
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2. P02_Front (前向力臂): 145x190x22mm，宽跨距 104mm 双榫头 + 预埋 M5 螺母槽；
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3. P02_Rear (后向力臂): 45x190x22mm，窄跨距 80mm 双榫头（跨距差达 24mm 物理防呆，绝不混装）。
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"""
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z0 = 0.0
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z1 = 22.0
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y_width = 190.0
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f_tenon_w = 44.0
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f_tenon_y_span = 52.0
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r_tenon_w = 32.0
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r_tenon_y_span = 40.0
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# 1. P02_Center (X = -195.0 .. 0.0, 195x190mm)
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x_c_min = -195.0
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x_c_max = 0.0
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x_c_len = x_c_max - x_c_min
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x_c_mid = (x_c_min + x_c_max) / 2.0
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c_plate = (cq.Workplane("XY", origin=(x_c_mid, Y_COL, z0))
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.rect(x_c_len, y_width).extrude(z1)
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.edges("|Z and <X").fillet(8.0).edges("|Z and >X").fillet(8.0)
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.edges(">Z").fillet(2.0)).val()
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p02_c = cq.Shape(c_plate.wrapped)
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# Socket collar (Z: 22..70mm)
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z_collar_top = 70.0
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collar_outer = (cq.Workplane("XY", origin=(X_COL, Y_COL, z1))
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.rect(80.0, 80.0).extrude(z_collar_top - z1)
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.edges("|Z").fillet(8.0).edges(">Z").chamfer(2.0)).val()
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p02_c = p02_c.fuse(cq.Shape(collar_outer.wrapped))
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# Front & Rear triangular gusset ribs
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f_pts = [(-75.0, z1), (-15.0, z1), (-15.0, z1 + 4.0), (-75.0, 68.0)]
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f_rib = (cq.Workplane("XZ", origin=(0, Y_COL, 0)).polyline(f_pts).close().extrude(19.0, both=True)).val()
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p02_c = p02_c.fuse(cq.Shape(f_rib.wrapped))
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r_pts = [(-155.0, z1), (-195.0, z1), (-195.0, z1 + 14.0), (-155.0, 70.0)]
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r_rib = (cq.Workplane("XZ", origin=(0, Y_COL, 0)).polyline(r_pts).close().extrude(19.0, both=True)).val()
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p02_c = p02_c.fuse(cq.Shape(r_rib.wrapped))
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# Front wire guide
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wg_pts = [(-75.5, z1 + 1.0), (-14.0, z1 + 1.0), (-14.0, z1 + 4.0), (-75.5, 68.5)]
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wire_guide = (cq.Workplane("XZ", origin=(0, Y_COL, 0)).polyline(wg_pts).close().extrude(9.0, both=True)).val()
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p02_c = p02_c.cut(wire_guide)
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# Column socket — stepped mortise: upper 66.6 bore for the 66 box walls,
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# lower 50.6 recess (floor 0.6 low) for the 50x50 bottom tenon; the recess
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# rim at z=22 is the axial seat, so column weight bears on face, not threads.
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socket_upper = (cq.Workplane("XY", origin=(X_COL, Y_COL, z1))
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.rect(66.6, 66.6).extrude(z_collar_top - z1 + 1.0)
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.edges("|Z").fillet(6.3)).val()
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p02_c = p02_c.cut(socket_upper)
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socket_lower = (cq.Workplane("XY", origin=(X_COL, Y_COL, 9.4))
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.rect(50.6, 50.6).extrude(z1 - 9.4)
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.edges("|Z").fillet(4.3)).val()
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p02_c = p02_c.cut(socket_lower)
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# Vertical M5 clamp bolts (offsets match the asymmetric column tenon holes:
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# X −20/+16 blocks 180° flip, the ±18 Y span blocks 90° rotation).
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# Threads engage the tenon 15mm — clamp only, axial load rides on the seat.
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for xx in (X_COL - 20.0, X_COL + 16.0):
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for yy in (Y_COL - 18.0, Y_COL + 18.0):
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p02_c = p02_c.cut(cyl(2.75, -0.01, 10.5, xx, yy)).cut(cyl(5.0, -0.01, 6.0, xx, yy))
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# Center clamp slots
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for cy in (Y_COL - 75.0, Y_COL + 75.0):
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plane = cq.Plane(origin=(x_c_mid, cy, -0.01), xDir=(0, 1, 0), normal=(0, 0, 1))
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slot = cq.Workplane(plane).slot2D(28.0, 7.0).extrude(z1 + 1.0).val()
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p02_c = p02_c.cut(slot)
|
||
|
||
p02_c = p02_c.cut((cq.Workplane("XY", origin=(X_COL, Y_COL - 70.0, -0.01)).rect(28.0, 80.0).extrude(6.0)).val())
|
||
|
||
# Front mortise pockets
|
||
for sign in (-1, 1):
|
||
yy = Y_COL + sign * f_tenon_y_span
|
||
front_mortise = (cq.Workplane("XY", origin=(-10.0, yy, 4.8))
|
||
.rect(21.0, f_tenon_w + 0.8).extrude(12.6).edges("|Z and <X").fillet(3.0)).val()
|
||
p02_c = p02_c.cut(front_mortise)
|
||
p02_c = p02_c.cut(cyl(2.75, -0.01, z1 + 1.0, -10.0, yy))
|
||
p02_c = p02_c.cut(cyl(5.0, z1 - 5.0, z1 + 1.0, -10.0, yy))
|
||
|
||
# Rear mortise pockets
|
||
for sign in (-1, 1):
|
||
yy = Y_COL + sign * r_tenon_y_span
|
||
rear_mortise = (cq.Workplane("XY", origin=(-185.0, yy, 4.8))
|
||
.rect(21.0, r_tenon_w + 0.8).extrude(12.6).edges("|Z and >X").fillet(3.0)).val()
|
||
p02_c = p02_c.cut(rear_mortise)
|
||
p02_c = p02_c.cut(cyl(2.75, -0.01, z1 + 1.0, -185.0, yy))
|
||
p02_c = p02_c.cut(cyl(5.0, z1 - 5.0, z1 + 1.0, -185.0, yy))
|
||
|
||
# Debossed text on P02_Center top face. The mid-plate line (y=Y_COL) is
|
||
# hidden behind the column collar and the gusset ribs, so both labels sit on
|
||
# the flat -Y side strip (y = Y_COL-68) where they stay in full view from the
|
||
# label side: REAR on the rear half, FRONT on the front half, clear of the
|
||
# clamp slot (x -101..-94) and the M5 screw counterbores.
|
||
txt_c_f = (cq.Workplane("XY", origin=(-49.0, Y_COL - 68.0, z1)).text("▲ FRONT (前向) ▲", 9.0, -0.8)).val()
|
||
txt_c_r = (cq.Workplane("XY", origin=(-146.0, Y_COL - 68.0, z1)).text("▲ REAR (后向) ▲", 9.0, -0.8)).val()
|
||
p02_c = p02_c.cut(cq.Shape(txt_c_f.wrapped)).cut(cq.Shape(txt_c_r.wrapped))
|
||
|
||
# 2. P02_Front (X = 0.0 .. 145.0, 145x190mm)
|
||
x_f_len = 145.0
|
||
x_f_mid = 72.5
|
||
f_plate = (cq.Workplane("XY", origin=(x_f_mid, Y_COL, z0))
|
||
.rect(x_f_len, y_width).extrude(z1)
|
||
.edges("|Z and >X").fillet(16.0).edges(">Z").fillet(2.0)).val()
|
||
p02_f = cq.Shape(f_plate.wrapped)
|
||
|
||
for cy in (Y_COL - 70.0, Y_COL + 70.0):
|
||
plane = cq.Plane(origin=(120.0, cy, -0.01), xDir=(0, 1, 0), normal=(0, 0, 1))
|
||
slot = cq.Workplane(plane).slot2D(28.0, 7.0).extrude(z1 + 1.0).val()
|
||
p02_f = p02_f.cut(slot)
|
||
|
||
for sign in (-1, 1):
|
||
yy = Y_COL + sign * f_tenon_y_span
|
||
tongue = (cq.Workplane("XY", origin=(-9.5, yy, 5.25))
|
||
.rect(20.0, f_tenon_w - 0.2).extrude(11.5).edges("|Z and <X").fillet(2.5).edges("<X").chamfer(1.5)).val()
|
||
p02_f = p02_f.fuse(cq.Shape(tongue.wrapped))
|
||
p02_f = p02_f.cut(cyl(2.75, -0.01, z1 + 1.0, -10.0, yy))
|
||
nut_pocket = (cq.Workplane("XY", origin=(-10.0, yy, -0.01)).polygon(6, 9.2).extrude(5.0)).val()
|
||
p02_f = p02_f.cut(nut_pocket)
|
||
|
||
# Top-face engraving rotated 90 deg to run across the plate along +Y (user
|
||
# request): letter tops face -X, so it reads upright from the front (+X).
|
||
# "▲" points local +Y = world -X, i.e. toward the centre joint.
|
||
txt_f = (cq.Workplane(cq.Plane(origin=(x_f_mid, Y_COL, z1), xDir=(0, 1, 0),
|
||
normal=(0, 0, 1)))
|
||
.text("P02-FRONT ▲ JOIN", 8.0, -0.8)).val()
|
||
p02_f = p02_f.cut(cq.Shape(txt_f.wrapped))
|
||
|
||
# 3. P02_Rear (X = -240.0 .. -195.0, 45x190mm)
|
||
x_r_len = 45.0
|
||
x_r_mid = -217.5
|
||
r_plate = (cq.Workplane("XY", origin=(x_r_mid, Y_COL, z0))
|
||
.rect(x_r_len, y_width).extrude(z1)
|
||
.edges("|Z and <X").fillet(16.0).edges(">Z").fillet(2.0)).val()
|
||
p02_r = cq.Shape(r_plate.wrapped)
|
||
|
||
for cy in (Y_COL - 70.0, Y_COL + 70.0):
|
||
plane = cq.Plane(origin=(-215.0, cy, -0.01), xDir=(0, 1, 0), normal=(0, 0, 1))
|
||
slot = cq.Workplane(plane).slot2D(28.0, 7.0).extrude(z1 + 1.0).val()
|
||
p02_r = p02_r.cut(slot)
|
||
|
||
for sign in (-1, 1):
|
||
yy = Y_COL + sign * r_tenon_y_span
|
||
tongue = (cq.Workplane("XY", origin=(-185.5, yy, 5.25))
|
||
.rect(20.0, r_tenon_w - 0.2).extrude(11.5).edges("|Z and >X").fillet(2.5).edges(">X").chamfer(1.5)).val()
|
||
p02_r = p02_r.fuse(cq.Shape(tongue.wrapped))
|
||
p02_r = p02_r.cut(cyl(2.75, -0.01, z1 + 1.0, -185.0, yy))
|
||
nut_pocket = (cq.Workplane("XY", origin=(-185.0, yy, -0.01)).polygon(6, 9.2).extrude(5.0)).val()
|
||
p02_r = p02_r.cut(nut_pocket)
|
||
|
||
# Same +Y rotation as the front plate; "▼" points local -Y = world +X,
|
||
# i.e. toward the centre joint. Along +Y the ~73 mm text fits the 190 mm
|
||
# plate width instead of overhanging its 45 mm X span.
|
||
txt_r = (cq.Workplane(cq.Plane(origin=(x_r_mid, Y_COL, z1), xDir=(0, 1, 0),
|
||
normal=(0, 0, 1)))
|
||
.text("P02-REAR ▼ JOIN", 7.5, -0.8)).val()
|
||
p02_r = p02_r.cut(cq.Shape(txt_r.wrapped))
|
||
|
||
return p02_c, p02_f, p02_r
|
||
|
||
|
||
def p_base_foot():
|
||
"""P02_底脚 (重型防倾翻超长力臂底座 + 双向大截面三角加强斜撑筋):
|
||
1. 底盘尺寸大幅扩展为 385x240x22mm (X: -240.0..+145.0, Y: 8.0..248.0)；
|
||
- 前向延伸至 X = +145.0mm (在手臂垂直投影前方 91.5mm)，彻底杜绝手臂前伸与抓握重物时的前倾翻；
|
||
- 后向延伸至 X = -240.0mm (在立柱后方 92.0mm)，抵御大动态回程后仰力矩；
|
||
2. 立柱插接套筒由 12mm 浅槽大幅升级为 48mm 高加固套筒 (Z: 22.0..70.0mm，外壁厚 7mm)；
|
||
3. 前向大三角加强斜撑筋 (Z: 68.0->22.0mm, X: -75.0->-15.0mm, 宽 38mm)，抗弯力臂长达 60mm，留足安全间隙不干涉手臂运动；
|
||
4. 后向大三角加强斜撑筋 (Z: 70.0->22.0mm, X: -155.0->-225.0mm, 宽 38mm)，抗后仰力臂长达 70mm；
|
||
5. 前斜撑表面设 18mm 宽平滑走线导槽，与 P01 下部走线窗口自然贯通；
|
||
6. 6 组 M6 工业工作台紧固腰槽 (28x7mm) + 底部隐蔽走线槽；
|
||
7. 四周 R=18mm 大圆角过渡与 2.5mm 上边缘倒角。
|
||
"""
|
||
z0 = 0.0
|
||
z1 = 22.0
|
||
x_rear = -240.0
|
||
x_front = 145.0
|
||
x_len = x_front - x_rear # 385.0
|
||
x_mid = (x_rear + x_front) / 2.0 # -47.5
|
||
y_width = 240.0
|
||
|
||
# 1. 主底盘 (385 x 240 x 22 mm)
|
||
base_plate = (cq.Workplane("XY", origin=(x_mid, Y_COL, z0))
|
||
.rect(x_len, y_width)
|
||
.extrude(z1)
|
||
.edges("|Z").fillet(18.0)
|
||
.edges(">Z").fillet(2.5)).val()
|
||
s = cq.Shape(base_plate.wrapped)
|
||
|
||
# 2. 立柱外包加固套筒 (Z: 22.0..70.0 mm, 外廓 80x80mm)
|
||
z_collar_top = 70.0
|
||
collar_outer = (cq.Workplane("XY", origin=(X_COL, Y_COL, z1))
|
||
.rect(80.0, 80.0)
|
||
.extrude(z_collar_top - z1)
|
||
.edges("|Z").fillet(8.0)
|
||
.edges(">Z").chamfer(2.0)).val()
|
||
s = s.fuse(cq.Shape(collar_outer.wrapped))
|
||
|
||
# 3. 前向抗倾翻三角加强斜撑筋 (Front Triangular Gusset Rib)
|
||
f_pts = [
|
||
(-75.0, z1),
|
||
(-15.0, z1),
|
||
(-15.0, z1 + 4.0),
|
||
(-75.0, 68.0),
|
||
]
|
||
f_rib = (cq.Workplane("XZ", origin=(0, Y_COL, 0))
|
||
.polyline(f_pts).close()
|
||
.extrude(19.0, both=True)).val()
|
||
s = s.fuse(cq.Shape(f_rib.wrapped))
|
||
|
||
# 4. 后向抗倾翻三角加强斜撑筋 (Rear Triangular Gusset Rib)
|
||
r_pts = [
|
||
(-155.0, z1),
|
||
(-225.0, z1),
|
||
(-225.0, z1 + 4.0),
|
||
(-155.0, 70.0),
|
||
]
|
||
r_rib = (cq.Workplane("XZ", origin=(0, Y_COL, 0))
|
||
.polyline(r_pts).close()
|
||
.extrude(19.0, both=True)).val()
|
||
s = s.fuse(cq.Shape(r_rib.wrapped))
|
||
|
||
# 5. 前斜撑表面走线导槽 (与 P01 前走线窗 Z=70..140mm 自然顺接)
|
||
wire_guide_pts = [
|
||
(-75.5, z1 + 1.0),
|
||
(-14.0, z1 + 1.0),
|
||
(-14.0, z1 + 4.0),
|
||
(-75.5, 68.5),
|
||
]
|
||
wire_guide = (cq.Workplane("XZ", origin=(0, Y_COL, 0))
|
||
.polyline(wire_guide_pts).close()
|
||
.extrude(9.0, both=True)).val()
|
||
s = s.cut(wire_guide)
|
||
|
||
# 6. 立柱深插槽内腔 (Pocket: 66.6 x 66.6 mm, 留 0.3mm 精密滑配间隙)
|
||
socket_box = (cq.Workplane("XY", origin=(X_COL, Y_COL, 10.0))
|
||
.rect(66.6, 66.6)
|
||
.extrude(z_collar_top - 10.0 + 1.0)
|
||
.edges("|Z").fillet(6.3)).val()
|
||
s = s.cut(socket_box)
|
||
|
||
# 7. 4x M5 底部垂直紧固螺栓孔与沉孔
|
||
for xx in (X_COL - 21.0, X_COL + 21.0):
|
||
for yy in (Y_COL - 21.0, Y_COL + 21.0):
|
||
th = cyl(2.75, -0.01, 10.5, xx, yy)
|
||
cb = cyl(5.0, -0.01, 6.0, xx, yy)
|
||
s = s.cut(th).cut(cb)
|
||
|
||
# 8. 6 组 M6 工业工作台紧固腰槽 (28 x 7 mm)
|
||
slot_positions = [
|
||
(-215.0, Y_COL - 85.0), (-215.0, Y_COL + 85.0), # 后部两角
|
||
(-47.5, Y_COL - 95.0), (-47.5, Y_COL + 95.0), # 中部两侧
|
||
(120.0, Y_COL - 85.0), (120.0, Y_COL + 85.0), # 前部两角
|
||
]
|
||
for cx, cy in slot_positions:
|
||
plane = cq.Plane(origin=(cx, cy, -0.01), xDir=(0, 1, 0), normal=(0, 0, 1))
|
||
slot = cq.Workplane(plane).slot2D(28.0, 7.0).extrude(z1 + 1.0).val()
|
||
s = s.cut(slot)
|
||
|
||
# 9. 底部隐蔽走线通槽
|
||
wire_ch = (cq.Workplane("XY", origin=(X_COL, Y_COL - 80.0, -0.01))
|
||
.rect(28.0, 100.0)
|
||
.extrude(6.0)).val()
|
||
s = s.cut(wire_ch)
|
||
return s
|
||
|
||
|
||
def p_girdle(j1):
|
||
"""P03_肩关节安装悬臂 (高强受力多筋桁架 + 侧开式电机托架与前置止脱锁紧法兰):
|
||
1. 10mm 后端重载法兰盘 (X: -61.0..-51.0, 74x74mm)；
|
||
2. 双侧大截面三角加强筋 (8mm 厚，Y = Y_ARM ± 28mm)；
|
||
3. 下腹部纵向大受力龙骨筋 (12mm 厚)；
|
||
4. 顶部横向锁紧环抱筋 (60x10x10mm)；
|
||
5. 侧开式电机托架 (+Y侧全开, X: -51.0..8.5)，M1 电机可从侧方滑入装配，由后端法兰 4xM3 与前置止脱锁紧法兰 4xM3 双向锁死；
|
||
6. 端面 4x Ø3.2mm 沉头通孔直连 M1 定子端面螺纹孔 (BCD=55mm)，彻底消除轴向拉脱风险；
|
||
7. 两侧大面积散热舷窗 (34x20mm) + 顶部双斜向对流排热槽 (30x6.5mm)，确保散热畅通；
|
||
8. 4x 直通式螺丝刀安装通道 (Ø8.5mm) 与 Ø26mm 中央走线孔。
|
||
"""
|
||
X_MOUNT = Z_R1 # -51.0 (Rear face of M1)
|
||
T_FLANGE = 10.0 # 10mm thick high-strength mounting flange
|
||
X_BACK = X_MOUNT - T_FLANGE # -61.0
|
||
Y_ARM = Y_AXIS # 128.0
|
||
Z_ARM = Z_RL # 610.0
|
||
|
||
# 1. 主安装法兰盘 (74x74mm, 倒圆角 R=8mm)
|
||
flange = (cq.Workplane("YZ", origin=(X_BACK, Y_ARM, Z_ARM))
|
||
.rect(74.0, 74.0)
|
||
.extrude(T_FLANGE)
|
||
.edges("|X").fillet(8.0)
|
||
.edges("<X").chamfer(2.0)).val()
|
||
s = cq.Shape(flange.wrapped)
|
||
|
||
# 2. 斜挑支撑主干 (Central Arch Backbone)
|
||
trunk_pts = [
|
||
(X_COL - 33.0, Z_CHEST1),
|
||
(X_COL + 33.0, Z_CHEST1),
|
||
(X_COL + 33.0, 505.0),
|
||
(X_BACK + 0.1, 565.0),
|
||
(X_BACK + 0.1, Z_ARM - 5.0),
|
||
(X_COL - 10.0, 580.0),
|
||
(X_COL - 33.0, 550.0),
|
||
]
|
||
trunk = (cq.Workplane("XZ", origin=(0, Y_ARM, 0))
|
||
.polyline(trunk_pts).close()
|
||
.extrude(33.0, both=True)).val()
|
||
s = s.fuse(cq.Shape(trunk.wrapped))
|
||
|
||
# 3. 左右两侧主抗弯抗扭大三角加强筋 (厚度 8mm)
|
||
for sign in (-1, 1):
|
||
y_rib = Y_ARM + sign * 28.0
|
||
rib_pts = [
|
||
(X_COL - 30.0, Z_CHEST1),
|
||
(X_COL + 30.0, Z_CHEST1),
|
||
(X_BACK + 0.1, 565.0),
|
||
(X_BACK + 0.1, Z_ARM + 32.0),
|
||
(X_BACK - 15.0, Z_ARM + 32.0),
|
||
(X_COL - 15.0, 575.0),
|
||
(X_COL - 30.0, 530.0),
|
||
]
|
||
side_rib = (cq.Workplane("XZ", origin=(0, y_rib, 0))
|
||
.polyline(rib_pts).close()
|
||
.extrude(5.0, both=True)).val()
|
||
s = s.fuse(cq.Shape(side_rib.wrapped))
|
||
|
||
# 4. 下腹部纵向抗弯龙骨筋 (厚度 12mm)
|
||
keel_pts = [
|
||
(X_COL + 33.0, Z_CHEST1),
|
||
(X_COL + 33.0, 495.0),
|
||
(X_BACK + 0.1, 570.0),
|
||
(X_BACK + 0.1, 555.0),
|
||
(X_COL + 20.0, 480.0),
|
||
(X_COL + 20.0, Z_CHEST1),
|
||
]
|
||
keel = (cq.Workplane("XZ", origin=(0, Y_ARM, 0))
|
||
.polyline(keel_pts).close()
|
||
.extrude(12.0, both=True)).val()
|
||
s = s.fuse(cq.Shape(keel.wrapped))
|
||
|
||
# 5. 顶部横向锁紧环抱横筋
|
||
tie_rib = (cq.Workplane("YZ", origin=(X_BACK - 10.0, Y_ARM, Z_ARM + 28.0))
|
||
.rect(60.0, 10.0)
|
||
.extrude(10.0)
|
||
.edges("|X").fillet(3.0)).val()
|
||
s = s.fuse(cq.Shape(tie_rib.wrapped))
|
||
|
||
# 与立柱顶部配合的榫头 (48x48x15mm)
|
||
boss = (cq.Workplane("XY", origin=(X_COL, Y_COL, Z_CHEST1 - 15.0))
|
||
.rect(48.0, 48.0)
|
||
.extrude(15.0)
|
||
.edges("|Z").fillet(4.0)).val()
|
||
s = s.fuse(cq.Shape(boss.wrapped))
|
||
|
||
# 4x M5 连接螺栓孔
|
||
for xx in (X_COL - 21.0, X_COL + 21.0):
|
||
for yy in (Y_COL - 21.0, Y_COL + 21.0):
|
||
s = s.cut(cyl(2.75, Z_CHEST1 - 16.0, Z_CHEST1 + 25.0, xx, yy))
|
||
|
||
# 4x M3 连接螺孔与直通螺丝刀通道
|
||
for dy in (-17.55, 17.55):
|
||
for dz in (-20.46, 20.46):
|
||
py = Y_ARM + dy
|
||
pz = Z_ARM + dz
|
||
th = Xcyl(1.7, X_BACK - 0.5, X_MOUNT + 4.0, py, pz)
|
||
cb = Xcyl(3.25, X_BACK - 0.5, X_BACK + 4.5, py, pz)
|
||
access_tunnel = Xcyl(4.25, X_COL - 40.0, X_BACK + 0.1, py, pz)
|
||
s = s.cut(th).cut(cb).cut(access_tunnel)
|
||
|
||
# 中央走线孔 (Ø26mm)
|
||
wire_hole = Xcyl(13.0, X_COL - 40.0, X_MOUNT + 2.0, Y_ARM, Z_ARM)
|
||
s = s.cut(wire_hole)
|
||
|
||
# 6. 前向电机全包托架与前置止脱锁紧法兰 (X: -51.0..8.5)
|
||
X_FRONT = 8.5
|
||
R_POD = 36.5
|
||
R_BORE = 30.35
|
||
|
||
cradle_outer = (cq.Workplane("YZ", origin=(X_MOUNT - 0.1, Y_ARM, Z_ARM))
|
||
.circle(R_POD)
|
||
.extrude(X_FRONT - X_MOUNT + 0.1)
|
||
.edges(">X").chamfer(1.5)).val()
|
||
s = s.fuse(cq.Shape(cradle_outer.wrapped))
|
||
|
||
# 电机定子配合内腔 (精密滑配至 X=5.05)
|
||
motor_pocket = Xcyl(R_BORE, X_MOUNT - 0.2, 5.05, Y_ARM, Z_ARM)
|
||
s = s.cut(motor_pocket)
|
||
|
||
# 前端中心避让孔 (避让 J1 输出轴旋转凸台)
|
||
hub_clearance = Xcyl(19.5, 4.8, X_FRONT + 0.5, Y_ARM, Z_ARM)
|
||
s = s.cut(hub_clearance)
|
||
|
||
# 4x 前置 M3 锁紧螺钉通孔与沉头 (BCD=55mm, R=27.5mm, 角度 17.8°, 107.8°, 197.8°, 287.8°)
|
||
for deg in (17.8, 107.8, 197.8, 287.8):
|
||
rad = math.radians(deg)
|
||
fy = Y_ARM + 27.5 * math.cos(rad)
|
||
fz = Z_ARM + 27.5 * math.sin(rad)
|
||
th = Xcyl(1.6, 4.5, X_FRONT + 0.5, fy, fz)
|
||
cb = Xcyl(3.0, 6.5, X_FRONT + 0.5, fy, fz)
|
||
s = s.cut(th).cut(cb)
|
||
|
||
# 8. 电机托架 +Y 侧全开（侧开式半包，替代原封闭全包筒）：
|
||
# M1 电机可从 +Y 侧方直线滑入托架完成装配——原封闭筒电机物理上无法装入。
|
||
# 轴向约束：后端法兰 4xM3（电机尾端面）+ 前置止脱法兰 4xM3（电机前端面）双向锁死；
|
||
# 径向约束：Ø60.7 精密滑配托架底 + 重力贴底。开口前端至 5.06 保留完整止脱法兰环。
|
||
s = s.cut(bx(X_MOUNT, 5.06, Y_ARM, Y_ARM + 60.0, Z_ARM - 60.0, Z_ARM + 60.0))
|
||
|
||
# 7. 散热系统：双侧大视窗 + 顶部斜向对流排热槽
|
||
for sign in (-1, 1):
|
||
win_plane = cq.Plane(
|
||
origin=(-24.5, Y_ARM + sign * 35.0, Z_ARM),
|
||
xDir=(1, 0, 0),
|
||
normal=(0, sign, 0)
|
||
)
|
||
win_cut = cq.Workplane(win_plane).slot2D(34.0, 20.0).extrude(16.0, both=True).val()
|
||
s = s.cut(win_cut)
|
||
|
||
for deg in (45, 135):
|
||
rad = math.radians(deg)
|
||
slot_plane = cq.Plane(
|
||
origin=(-24.5, Y_ARM + 33.0 * math.cos(rad), Z_ARM + 33.0 * math.sin(rad)),
|
||
xDir=(1, 0, 0),
|
||
normal=(0, math.cos(rad), math.sin(rad))
|
||
)
|
||
slot_cut = cq.Workplane(slot_plane).slot2D(30.0, 6.5).extrude(15.0, both=True).val()
|
||
s = s.cut(slot_cut)
|
||
|
||
return s
|
||
|
||
|
||
def p_fork(j1, j2):
|
||
"""P04_肩叉_螺旋体30%_墙5底5_竖打 (Shoulder Fork / L-Bracket) - 加长避让顺滑流线版:
|
||
1. 头部与身子起点自 X=5.5 前移加长至 X=10.5，与 P03 前置锁紧法兰 (X=8.5) 保持 2.0mm 均匀轴向安全间隙
|
||
（X_FORK_GAP=0：不做整体前移，保持 J1 输出端最短悬伸力臂，避免额外弯矩负荷）；
|
||
2. J1 从动法兰圆盘已删除(盘面在 column 前缘形成鼓楞)：J1 由 boss(Ø35.6)贯通 P03 前盖中心孔直连电机输出盘；column 顶边保持 Z=646.5 与 P03 环齐高，R=18mm 大圆弧顺滑过渡；
|
||
3. 头部转接凸台加长贯通 P03 前盖中心孔 (R=19.5mm)，直连 J1 旋转法兰盘；
|
||
4. M2 保留后端安装板(R=35mm, 带 rear_mount_holes 螺钉孔)，前端定位环鼓出圆盘已删除(前端定位由 column 端面 pocket 承担)，中间镂空散热；
|
||
5. 严格满足 single-solid 流形拓扑与 360° 全范围零干涉 (COLLISION pairs = 0)。
|
||
"""
|
||
# 1. M2 后端安装法兰盘 (Y: 92..100, R=35mm)
|
||
rear_plate = Ycyl(35.0, Y_REAR - 8.0, Y_REAR, X_ARM, Z_SH)
|
||
|
||
# 2. M2 前端定位环 (Y: 149.5..155.5, R=35mm)
|
||
front_collar = Ycyl(35.0, Y_COVER - 6.5, Y_COVER - 0.5, X_ARM, Z_SH)
|
||
s = rear_plate.fuse(front_collar)
|
||
|
||
# 3. J1 从动法兰圆盘已删除：原 R=36.5 圆盘盘面在 column 前缘形成圆盘鼓楞，
|
||
# J1 与 P04 的连接由 boss(Ø35.6 贯通 P03 前盖中心孔 R=19.5)直连电机输出盘
|
||
# 承担，螺钉走 boss 端面 4xB 孔，圆盘无传力功能已去除。
|
||
|
||
# 4. XZ 平面有机连续流线轮廓（随 X_FORK_GAP 整体前移，避让顺滑过渡）：
|
||
x_b, z_b = -12.65 + X_FORK_GAP, 506.0
|
||
x_a, z_a = 10.5 + X_FORK_GAP, 545.0
|
||
Lz = z_a - z_b
|
||
d0 = 0.514 * Lz
|
||
d1 = 0.0
|
||
|
||
hermite_pts = []
|
||
N_h = 16
|
||
for i in range(N_h + 1):
|
||
t = i / N_h
|
||
h00 = 2.0 * (t**3) - 3.0 * (t**2) + 1.0
|
||
h10 = t**3 - 2.0 * (t**2) + t
|
||
h01 = -2.0 * (t**3) + 3.0 * (t**2)
|
||
h11 = t**3 - t**2
|
||
xh = x_b * h00 + d0 * h10 + x_a * h01 + d1 * h11
|
||
zh = z_b + t * Lz
|
||
hermite_pts.append((xh, zh))
|
||
|
||
dx_flare = (53.5 + X_FORK_GAP) - (44.0 + X_FORK_GAP)
|
||
dz_flare = 545.0 - 490.0
|
||
R_flare = (dx_flare**2 + dz_flare**2) / (2.0 * dx_flare)
|
||
|
||
xz_wire = (cq.Workplane("XZ", origin=(0, Y_AXIS, 0))
|
||
.moveTo(10.5 + X_FORK_GAP, 545.0)
|
||
.lineTo(10.5 + X_FORK_GAP, Z_RL + 36.5)
|
||
.lineTo(28.0 + X_FORK_GAP, Z_RL + 36.5)
|
||
.radiusArc((44.0 + X_FORK_GAP, 630.0), 18.0)
|
||
.lineTo(44.0 + X_FORK_GAP, 545.0)
|
||
.radiusArc((53.5 + X_FORK_GAP, 490.0), -R_flare)
|
||
.lineTo(18.5 + X_FORK_GAP, 490.0)
|
||
.lineTo(-16.5 + X_FORK_GAP, 490.0)
|
||
.threePointArc((-15.1 + X_FORK_GAP, 498.5), (-12.65 + X_FORK_GAP, 506.0)))
|
||
for pt in hermite_pts[1:]:
|
||
xz_wire = xz_wire.lineTo(pt[0], pt[1])
|
||
xz_wire = xz_wire.close()
|
||
xz_shape = cq.Shape(xz_wire.extrude(100.0, both=True).val().wrapped)
|
||
|
||
# 5. YZ 平面包络
|
||
yz_pts = [
|
||
(Y_AXIS - 36.5, Z_RL + 36.5),
|
||
(Y_AXIS + 36.5, Z_RL + 36.5),
|
||
(Y_COVER - 0.5, Z_SH + 36.0),
|
||
(Y_COVER - 0.5, Z_SH),
|
||
(Y_REAR - 8.0, Z_SH),
|
||
(Y_REAR - 8.0, Z_SH + 36.0),
|
||
]
|
||
yz_solid = Xplate(yz_pts, -20.0, 60.0)
|
||
|
||
c_int = BRepAlgoAPI_Common(yz_solid.wrapped, xz_shape.wrapped)
|
||
c_int.Build()
|
||
column = cq.Shape(c_int.Shape())
|
||
|
||
s = s.fuse(column)
|
||
|
||
# 6. 中部电机定子散热切除
|
||
s = s.cut(Ycyl(30.5, Y_REAR + 0.5, Y_COVER - 6.5, X_ARM, Z_SH))
|
||
|
||
# 7. M2 接口成型
|
||
s = j2.front_collar_pocket(s, r_bore=30.25, z0=50.0, z1=56.5)
|
||
s = j2.rear_mount_holes(s, t_plate=8.0, hole_d=2.8, cb_d=5.5, cb_depth=4.0)
|
||
c_m2 = [cyl(BORE_R, -0.6, COVER_Z - 3.5), cyl(CB_R, COVER_Z - 3.5, COVER_Z + 0.6)]
|
||
s = s.cut(*[j2.L(item) for item in c_m2])
|
||
|
||
# 8. 头部转接凸台加长（贯通 P03 前盖中心孔，跨越装配缝直连 J1 输出盘）
|
||
boss = cyl(17.8, 54.942, 61.5 + X_FORK_GAP)
|
||
s = s.fuse(j1.L(boss))
|
||
s = s.cut(j1.L(cyl(3.5, 54.0, 74.0 + 30.0)))
|
||
for a in AB.HUB_M2_CLOCK:
|
||
u = AB.M['m2_bcd'] / 2.0 * math.cos(a * AB.D2R)
|
||
v = AB.M['m2_bcd'] / 2.0 * math.sin(a * AB.D2R)
|
||
th = cyl(1.4, 54.0, 63.0 + X_FORK_GAP, u, v)
|
||
cb = cyl(2.8, 63.0 + X_FORK_GAP, 74.0 + 40.0 + X_FORK_GAP, u, v)
|
||
s = s.cut(j1.L(th)).cut(j1.L(cb))
|
||
|
||
return s
|
||
|
||
|
||
|
||
def make_pitch_to_roll_bracket(j_pitch, j_roll, z_pitch, z_r, name="bracket"):
|
||
"""Half-wrapped (半包) 双曲面有机流线型 Pitch-to-Roll 结构座 (P05 & P08):
|
||
1. 顶部从动法兰与前侧 Loft 自然相切顺接；
|
||
2. 严格清除 z_plate 顶面以上与上级旋转件贴面的多余材料 (cut_top_solid)，保证关节大范围摆动动态 0 干涉；
|
||
3. 下方电机实行半包散热设计，-Y侧敞开，+Y侧背脊与圆柱一体化融合；
|
||
4. 严格满足 single-solid 流形拓扑与零干涉 (COLLISION pairs = 0)。
|
||
"""
|
||
z_bot = z_r - 56.0 # roll 电机底端 (front collar)
|
||
z_plate = z_r + 7.0 # roll 电机顶端安装板 (rear plate top)
|
||
y_out = HL.Y_HUB + HL.PLATE_T # 174.0 (俯仰直连法兰外侧面)
|
||
y_hub_in = HL.Y_COVER + 1.0 # 157.0 (从动法兰内侧面，预留 1.0mm 动间隙)
|
||
y_cyl_max = HL.Y_AXIS + 35.0 # 163.0 (下方电机外轮廓极值)
|
||
|
||
# 1. 基础立柱：Ø70mm 实心圆柱 (Z: z_bot .. z_plate, R=35mm)
|
||
s = cyl(35.0, z_bot, z_plate, HL.X_ARM, HL.Y_AXIS)
|
||
|
||
# 2. 俯仰轴直连法兰盘：全圆柱实体 (Y: y_hub_in .. y_out, R=35mm)
|
||
disc = Ycyl(35.0, y_hub_in, y_out, HL.X_ARM, z_pitch)
|
||
s = s.fuse(disc)
|
||
|
||
# 3. 前侧从底端 Ø70mm 圆柱到顶端法兰的有机相切平滑渐变过渡体 (Loft Morph)
|
||
Z_top = z_pitch - 35.0
|
||
z_start = z_bot
|
||
N = 16
|
||
wp = cq.Workplane("XY")
|
||
for i in range(N + 1):
|
||
t = i / float(N)
|
||
z_curr = z_start + t * (Z_top - z_start)
|
||
st = 3.0 * (t**2) - 2.0 * (t**3)
|
||
y_center = y_cyl_max + st * (y_out - y_cyl_max)
|
||
y_side = HL.Y_AXIS + st * (y_out - HL.Y_AXIS)
|
||
v_c = y_center - HL.Y_AXIS
|
||
v_s = y_side - HL.Y_AXIS
|
||
v_mid = max(v_c, v_s + 0.02)
|
||
# 后缘两角 R2 圆角：把 y=123 凸包与 R35 柱面交汇的两条 90° 竖棱圆润化
|
||
# （磨掉"凸起来的"尖角，不动后缘高度/位置，打印无悬挂）
|
||
FR = 2.0
|
||
w = (cq.Workplane("XY", origin=(HL.X_ARM, HL.Y_AXIS, z_curr))
|
||
.moveTo(-35.0, v_s)
|
||
.threePointArc((0.0, v_mid), (35.0, v_s))
|
||
.lineTo(35.0, -5.0 + FR)
|
||
.radiusArc((35.0 - FR, -5.0), FR)
|
||
.lineTo(-35.0 + FR, -5.0)
|
||
.radiusArc((-35.0, -5.0 + FR), FR)
|
||
.lineTo(-35.0, v_s)
|
||
.close())
|
||
wp = wp.add(w)
|
||
|
||
loft = wp.toPending().loft()
|
||
s = s.fuse(loft.val())
|
||
|
||
# 4. 顶部填充（仅保留 y >= y_hub_in 与法兰盘对齐的部分，避免侵入上级关节旋转扫掠区域）
|
||
top_fill = (cq.Workplane("YZ", origin=(HL.X_ARM, 0, 0))
|
||
.moveTo(y_hub_in, Z_top)
|
||
.lineTo(y_out, Z_top)
|
||
.lineTo(y_out, z_pitch)
|
||
.lineTo(y_hub_in, z_pitch)
|
||
.close()
|
||
.extrude(35.0, both=True))
|
||
s = s.fuse(top_fill.val())
|
||
|
||
# 5. 旋转清让切除：彻底清除 z >= z_plate 且 y <= y_hub_in 范围内的多余材料，
|
||
# 消除导致与上游旋转件（P04/P07）严重干涉的立壁与尖角，保持顶面平整规整！
|
||
cut_top_solid = (cq.Workplane("YZ", origin=(HL.X_ARM, 0, 0))
|
||
.moveTo(-999.0, z_plate)
|
||
.lineTo(y_hub_in, z_plate)
|
||
.lineTo(y_hub_in, z_pitch + 50.0)
|
||
.lineTo(-999.0, z_pitch + 50.0)
|
||
.close()
|
||
.extrude(60.0, both=True))
|
||
s = s.cut(cut_top_solid.val())
|
||
|
||
# 6. 电机半包处理 (Half-Enclosure)：-Y侧敞开散热，+Y侧背脊壳体加强
|
||
cut_open = bx(HL.X_ARM - 40.0, HL.X_ARM + 40.0, HL.Y_AXIS - 40.0, HL.Y_AXIS + 3.0, z_bot + 6.0, z_r - 1.0)
|
||
s = s.cut(cut_open)
|
||
|
||
# 7. 上级电机同心圆弧避让
|
||
clearance = Ycyl(35.5, HL.Y_AXIS - 40.0, HL.Y_COVER + 0.1, HL.X_ARM, z_pitch)
|
||
s = s.cut(clearance)
|
||
|
||
# 8. 下方电机安装孔位与定位止口
|
||
s = j_roll.rear_mount_holes(s, t_plate=7.0, hole_d=2.8, cb_d=5.5, cb_depth=4.0)
|
||
s = j_roll.front_collar_pocket(s, r_bore=30.25, z0=50.0, z1=56.5)
|
||
s = j_roll.pocket(s)
|
||
|
||
# 9. 电机定子配合空腔
|
||
s = s.cut(cyl(30.5, z_r - 49.5, z_r - 0.5, HL.X_ARM, HL.Y_AXIS))
|
||
|
||
# 10. 俯仰轴直连法兰结构（凸台延伸至 59.5 跨过间隙与法兰盘牢固熔接，保持单实体）
|
||
boss = cyl(17.8, 54.942, 59.5)
|
||
s = s.fuse(j_pitch.L(boss))
|
||
s = s.cut(j_pitch.L(cyl(3.5, 54.0, 74.0 + 30.0)))
|
||
for a in AB.HUB_M2_CLOCK:
|
||
u = AB.M["m2_bcd"] / 2.0 * math.cos(a * AB.D2R)
|
||
v = AB.M["m2_bcd"] / 2.0 * math.sin(a * AB.D2R)
|
||
th = cyl(1.4, 54.0, 58.0, u, v)
|
||
cb = cyl(2.8, 58.0, 74.0 + 40.0, u, v)
|
||
s = s.cut(j_pitch.L(th)).cut(j_pitch.L(cb))
|
||
|
||
# 11. L 型转角连接处圆角过渡（圆角 R=2.0mm）：
|
||
# 平滑消除立柱顶面与竖直臂交汇处的 90° 尖角与应力集中
|
||
try:
|
||
wp_s = cq.Workplane(obj=s)
|
||
sel_l = cq.NearestToPointSelector((HL.X_ARM, y_hub_in, z_plate))
|
||
s = wp_s.edges(sel_l).fillet(2.0).val()
|
||
except Exception as e:
|
||
print(f"[{name}] L型转角圆角异常: {e}")
|
||
|
||
return s
|
||
|
||
|
||
def p_shoulder_roll_base(j2, j3, half=None):
|
||
"""P05_大臂旋转座_螺旋体30%_墙4底5_竖打（深度圆角优化版）"""
|
||
return make_pitch_to_roll_bracket(j2, j3, Z_SH, Z_R3, name="P05_大臂旋转座_螺旋体30%_墙4底5_竖打")
|
||
|
||
|
||
def p_humerus_bone(j3, j4):
|
||
"""P06_大臂骨架_螺旋体25%_墙4底5_竖打 (Humerus Bone - Loft 圆弧转方有机过渡版):
|
||
受 J3 (大臂自转, -Z轴, hub@Z_HUB3=380) 驱动，
|
||
向下延伸构成大臂主体骨架，底端抱紧 M4 (肘部俯仰电机, +Y轴, 轴线位于 Z_EL=332.0)。
|
||
1. 借鉴 P05 大臂旋转座几何放样算法：
|
||
- 顶端结合面 (Z = 388.5mm)：与 J3 轴径严格相切的 Ø70mm 正圆形轮廓，彻底消除原先外突的方形水平阶梯；
|
||
- 底端结合面 (Z = 367.0mm)：平滑展开融入 M4 电机套筒的 70x63.5mm 方形截面；
|
||
- 过渡区 (Z: 367.0..388.5mm)：采用 Hermite s(t) = 3t² - 2t³ 驱动 20 层放样切片连续渐变；
|
||
2. 下部抱紧套筒与安装板 (R=35mm)，电机定子 100% 裸露散热开窗；
|
||
3. 严格单实体 (solids = 1) 且与上下级旋转构件及电机实现动态 0 碰撞干涉。
|
||
"""
|
||
# 1. M4 底部抱紧套筒与后端安装板 (R=35mm)
|
||
rear_m4 = Ycyl(35.0, Y_REAR - 8.0, Y_REAR, X_ARM, Z_EL)
|
||
front_m4 = Ycyl(35.0, Y_COVER - 6.0, Y_COVER - 0.5, X_ARM, Z_EL)
|
||
s = rear_m4.fuse(front_m4)
|
||
|
||
# 顶端结合面与过渡高度
|
||
z_top = 388.5
|
||
z_bot = Z_EL + 35.0 # 367.0
|
||
|
||
# 2. 下部实心基座块 (Z: Z_EL..z_bot + 0.5)
|
||
lower_block = bx(X_ARM - 35.0, X_ARM + 35.0, Y_REAR - 8.0, Y_COVER - 0.5, Z_EL, z_bot + 0.5)
|
||
s = s.fuse(lower_block)
|
||
|
||
# 3. 借鉴 P05 的 Loft 放样过渡体：圆弧变方形（20 层平滑放样，保持严格对称 4 段式截面拓扑）
|
||
N = 20
|
||
wp = cq.Workplane("XY")
|
||
for i in range(N + 1):
|
||
t = i / float(N)
|
||
z_curr = z_bot + t * (z_top - z_bot)
|
||
st = 3.0 * (t**2) - 2.0 * (t**3)
|
||
|
||
# 前侧：t=0 为平直面 (Y=155.5, v=27.5)，t=1 渐变为与 Ø70 正切的圆弧顶点 (Y=163.0, v=35.0)
|
||
v_sf = 27.5 * (1.0 - st) + 0.05 * st
|
||
v_cf = max(27.5 * (1.0 - st) + 35.0 * st, v_sf + 0.05)
|
||
|
||
# 后侧：从 t=0 的平直面 (Y=92.0, v=-36.0) 渐变到 t=1 的圆弧 (Y=93.0, v=-35.0)
|
||
v_sr = -36.0 * (1.0 - st) - 0.05 * st
|
||
v_cr = min(-36.0 * (1.0 - st) - 35.0 * st, v_sr - 0.05)
|
||
|
||
w = (cq.Workplane("XY", origin=(X_ARM, Y_AXIS, z_curr))
|
||
.moveTo(-35.0, v_sf)
|
||
.threePointArc((0.0, v_cf), (35.0, v_sf))
|
||
.lineTo(35.0, v_sr)
|
||
.threePointArc((0.0, v_cr), (-35.0, v_sr))
|
||
.close())
|
||
wp = wp.add(w)
|
||
|
||
loft = wp.toPending().loft()
|
||
s = s.fuse(loft.val())
|
||
|
||
# 4. 电机中间定子散热裸露切除 (100% 裸露)
|
||
s = s.cut(Ycyl(30.5, Y_REAR + 0.5, Y_COVER - 6.5, X_ARM, Z_EL))
|
||
|
||
# 5. M4 接口成型
|
||
s = j4.front_collar_pocket(s, r_bore=30.25, z0=50.0, z1=56.5)
|
||
s = j4.rear_mount_holes(s, t_plate=8.0, hole_d=2.8, cb_d=5.5, cb_depth=4.0)
|
||
s = j4.pocket(s)
|
||
|
||
# 6. J3 直连法兰结构（凸台延伸至 59.5 跨过结合面牢固熔接，保持单实体与零干涉）
|
||
boss = cyl(17.8, 54.942, 59.5)
|
||
chamfer_cone = cyl(18.5, 54.5, 54.942)
|
||
s = s.fuse(j3.L(boss)).cut(j3.L(chamfer_cone))
|
||
s = s.cut(j3.L(cyl(3.5, 54.0, 58.0 + 30.0)))
|
||
for a in AB.HUB_M2_CLOCK:
|
||
u = AB.M["m2_bcd"] / 2.0 * math.cos(a * AB.D2R)
|
||
v = AB.M["m2_bcd"] / 2.0 * math.sin(a * AB.D2R)
|
||
th = cyl(1.4, 54.0, 58.0, u, v)
|
||
cb = cyl(2.8, 58.0, 58.0 + 40.0, u, v)
|
||
s = s.cut(j3.L(th)).cut(j3.L(cb))
|
||
|
||
return s
|
||
|
||
|
||
def p_forearm_bone(j4, j5, half=None):
|
||
"""P07_小臂骨架_螺旋体30%_墙5底5_竖打 L型高刚度无干涉版（深度圆角优化版）
|
||
设计要点：
|
||
1. 改为与 P05/P08 统一的 L 型结构（L-bracket）：
|
||
- +Y侧垂直背脊立柱（Y: y_hub_in..y_out），避开上级大臂骨架 P06（Y <= 155.5）
|
||
- 彻底消除原全深S弯在J4轴下方向两边突出的干涉结构（两边突出的结构全部去除）
|
||
- 垂直立柱与下方 M5 电机水平座之间采用规则折角（Corner Chamfer/Gusset）刚性连接
|
||
2. 下方 M5 电机实行半包散热结构，底部与内腔开窗散热
|
||
3. J4 轴俯仰动态行程从受限的 ±54° 大幅释放至无死角大范围摆动（零干涉）
|
||
4. 满足单实体 (solids=1) 与装配零碰撞。
|
||
"""
|
||
y_out = Y_HUB + PLATE_T # 174.0
|
||
y_hub_in = HL.Y_COVER + 0.5 + CLEARANCE_GAP # 158.5
|
||
y_front = Y_COVER - 0.5 # 155.5
|
||
y_rear = Y_REAR - 8.0 # 92.0
|
||
z_top_housing = Z_WR + 39.0 # 261.0 (顶面加厚 4.0mm，消除过薄破面问题)
|
||
z_roof_top = z_top_housing + 19.0 # 280.0 (顶板整条加高 19mm，用户确认方案4)
|
||
|
||
# 1. J5 电机前后安装环
|
||
collar_front = Ycyl(35.0, HL.Y_COVER - 6.0, HL.Y_COVER - 0.5, X_ARM, Z_WR)
|
||
rear_plate = Ycyl(35.0, HL.Y_REAR - 8.0, HL.Y_REAR, X_ARM, Z_WR)
|
||
s = collar_front.fuse(rear_plate)
|
||
|
||
# 2. J4 顶部从动法兰盘 (Y: y_hub_in..y_out, R=35mm, Z: Z_EL)
|
||
disc = Ycyl(35.0, y_hub_in, y_out, X_ARM, Z_EL)
|
||
s = s.fuse(disc)
|
||
|
||
# 3. M5 电机壳体水平顶部顶板 (Z: Z_WR..z_top_housing, Y: y_rear..y_front)
|
||
roof_w = (cq.Workplane("YZ", origin=(X_ARM, 0, 0))
|
||
.moveTo(y_rear, Z_WR)
|
||
.lineTo(y_rear, z_roof_top)
|
||
.lineTo(y_front - 3.0, z_roof_top)
|
||
.threePointArc((y_front - 3.0 + 3.0 * math.cos(math.pi / 4),
|
||
z_roof_top - 3.0 + 3.0 * math.sin(math.pi / 4)),
|
||
(y_front, z_roof_top - 3.0))
|
||
.lineTo(y_front, Z_WR)
|
||
.close()
|
||
.extrude(35.0, both=True))
|
||
s = s.fuse(roof_w.val())
|
||
|
||
# 4. L型垂直立柱臂 (+Y侧，Y: y_hub_in..y_out，从 Z_EL 顶端延伸至下方电机座)
|
||
vert_leg = (cq.Workplane("YZ", origin=(X_ARM, 0, 0))
|
||
.moveTo(y_hub_in, z_top_housing)
|
||
.lineTo(y_out, z_top_housing)
|
||
.lineTo(y_out, Z_EL)
|
||
.lineTo(y_hub_in, Z_EL)
|
||
.close()
|
||
.extrude(35.0, both=True))
|
||
s = s.fuse(vert_leg.val())
|
||
|
||
# 5. L型内侧圆弧加强过渡（Circular Arc Gusset，用户要求"改成圆弧而不是折角，消掉悬空小块"）
|
||
# 彻底取代直角折角与直斜线折角，采用与顶面和立柱双相切的平滑内凹大圆弧 (R=28.0mm)
|
||
# 起点在顶板平整面 (y_arc_start, z_roof_top)，精确相切至立柱内侧面 (y_hub_in, z_arc_end)
|
||
# 严控全域 Z >= z_top_housing，彻底消除侵入下方旋转副的悬空小方块与多余突起！
|
||
# 注：顶板整条加高19mm(z_roof_top=280)后，R28改R14使弧仍与顶板面光滑相切，不出现折角
|
||
R_arc = 14.0 # 随顶板加高联动重定：相切起点(144.5,280)->终点(158.5,294)，避开P06环底z=297留3mm
|
||
y_arc_start = y_hub_in - R_arc
|
||
z_arc_end = z_roof_top + R_arc
|
||
p_mid_arc = (y_arc_start + R_arc * math.cos(math.pi / 4),
|
||
z_arc_end - R_arc * math.sin(math.pi / 4))
|
||
|
||
gusset_w = (cq.Workplane("YZ", origin=(X_ARM, 0, 0))
|
||
.moveTo(y_arc_start, z_roof_top)
|
||
.threePointArc(p_mid_arc, (y_hub_in, z_arc_end))
|
||
.lineTo(y_out, z_arc_end)
|
||
.lineTo(y_out, z_top_housing)
|
||
.lineTo(y_arc_start, z_top_housing)
|
||
.close()
|
||
.extrude(35.0, both=True))
|
||
s = s.fuse(gusset_w.val())
|
||
|
||
# 6. 下级 P08 旋转圆盘动态避让切除（R=35.5mm，预留 0.5mm 间隙）
|
||
p08_clearance = Ycyl(35.5, 156.0, y_out + 2.0, X_ARM, Z_WR)
|
||
s = s.cut(p08_clearance)
|
||
|
||
# 7. M5 电机安装接口与定子空腔
|
||
s = j5.front_collar_pocket(s, r_bore=30.25 + CLEARANCE_GAP, z0=50.0, z1=56.5)
|
||
s = j5.rear_mount_holes(s, t_plate=8.0, hole_d=2.8, cb_d=5.5, cb_depth=4.0)
|
||
s = j5.pocket(s)
|
||
s = s.cut(Ycyl(30.5 + CLEARANCE_GAP, HL.Y_REAR - 0.5, y_front - 6.0, X_ARM, Z_WR))
|
||
|
||
# 半包散热设计：-Z底部电机定子通风口
|
||
vent_cut = bx(X_ARM - 40.0, X_ARM + 40.0, y_rear + 8.0, y_front - 6.0, Z_WR - 40.0, Z_WR - 25.0)
|
||
s = s.cut(vent_cut)
|
||
|
||
# 8. J4 直连法兰结构（凸台延伸至 60.0 跨过间隙与法兰盘牢固熔接，保持单实体）
|
||
boss = cyl(17.8, 54.942, 60.0)
|
||
s = s.fuse(j4.L(boss))
|
||
s = s.cut(j4.L(cyl(3.5, 54.0, 74.0 + 30.0)))
|
||
for a in AB.HUB_M2_CLOCK:
|
||
u = AB.M["m2_bcd"] / 2.0 * math.cos(a * AB.D2R)
|
||
v = AB.M["m2_bcd"] / 2.0 * math.sin(a * AB.D2R)
|
||
th = cyl(1.4, 54.0, 58.0, u, v)
|
||
cb = cyl(2.8, 58.0, 74.0 + 40.0, u, v)
|
||
s = s.cut(j4.L(th)).cut(j4.L(cb))
|
||
|
||
# 9. 工艺走线通孔
|
||
slot_z = (Z_EL + z_top_housing) / 2.0
|
||
slot = Ycyl(7.0, y_hub_in - 2.0, y_out + 2.0, X_ARM, slot_z)
|
||
s = s.cut(slot)
|
||
|
||
# ========== 关键圆角优化 ==========
|
||
try:
|
||
# 后侧顶板外边缘圆角（平滑消除水平顶板与后部垂直端面交汇处的 90° 尖角，用户要求倒角改圆角）
|
||
wp_s = cq.Workplane(obj=s)
|
||
sel_rear = cq.selectors.BoxSelector(
|
||
(X_ARM - 40, y_rear - 1.0, z_roof_top - 1.0),
|
||
(X_ARM + 40, y_rear + 1.0, z_roof_top + 1.0)
|
||
)
|
||
s = wp_s.edges(sel_rear).fillet(FILLET_SMALL).val()
|
||
except Exception as e:
|
||
print(f"P07 顶板后边缘圆角异常: {e}")
|
||
|
||
return s
|
||
|
||
|
||
def p_wrist_bracket(j5, j6):
|
||
"""P08_腕偏转座_螺旋体25%_墙4底5_竖打（深度圆角优化版）"""
|
||
return make_pitch_to_roll_bracket(j5, j6, Z_WR, Z_R6, name="P08_腕偏转座_螺旋体25%_墙4底5_竖打")
|
||
|
||
|
||
def p_tool_flange(j6):
|
||
"""P09_工具法兰_螺旋体100%_墙4底5_竖打 深度圆角优化版
|
||
关键改进：
|
||
1. 外轮廓全圆角（R=4mm）
|
||
2. 法兰面倒角（2mm）
|
||
3. 螺孔边缘倒角（1.5mm）
|
||
"""
|
||
z_bot = Z_HUB6 - PLATE_T - 9.0
|
||
s = cyl(35.0, z_bot, Z_HUB6, X_ARM, Y_AXIS)
|
||
|
||
# 4x M4螺栓孔
|
||
for a in (0, 90, 180, 270):
|
||
rad = 20.0
|
||
u = rad * math.cos(a * D2R)
|
||
v = rad * math.sin(a * D2R)
|
||
h = cyl(1.85, z_bot - 1.0, z_bot + 12.0, X_ARM + u, Y_AXIS + v)
|
||
cb = cyl(3.5, z_bot - 1.0, z_bot + 4.0, X_ARM + u, Y_AXIS + v)
|
||
s = s.cut(h).cut(cb)
|
||
|
||
# 定位止口 + 走线孔
|
||
pilot = cyl(10.0, z_bot - 1.0, z_bot + 2.5, X_ARM, Y_AXIS)
|
||
thru = cyl(5.0, z_bot - 1.0, Z_HUB6 + 1.0, X_ARM, Y_AXIS)
|
||
s = s.cut(pilot).cut(thru)
|
||
|
||
# 直连法兰
|
||
s = make_direct_hub(s, j6, r_disc=35.0, z_out=74.0)
|
||
|
||
# ========== 关键圆角优化 ==========
|
||
try:
|
||
# 外轮廓圆角
|
||
s = s.edges("|Z").fillet(FILLET_SMALL)
|
||
except:
|
||
pass
|
||
|
||
try:
|
||
# 法兰面倒角
|
||
s = s.edges("<Z").chamfer(CHAMFER_EDGE)
|
||
except:
|
||
pass
|
||
|
||
try:
|
||
# 顶部边缘圆角
|
||
s = s.edges(">Z").fillet(FILLET_TINY)
|
||
except:
|
||
pass
|
||
|
||
return s
|
||
|
||
|
||
# ---------------------------------------------------------------- assembly ----------------
|
||
def build():
|
||
print("=" * 80, flush=True)
|
||
print("【第一阶段 1/5】开始生成手臂各级构件 3D 几何实体模型...", flush=True)
|
||
print("=" * 80, flush=True)
|
||
t_stage1 = time.time()
|
||
|
||
print(" [0/9] 载入电机标准件模组 (STEP)...", end="", flush=True)
|
||
t0 = time.time()
|
||
motor = cq.importers.importStep(AB.SRC_STEP).val()
|
||
motor = place(motor, T(0, 0, -2.57))
|
||
AB.MOTOR, AB.HALF, AB.CLAMP = motor, None, None
|
||
print(f" 完成 ({time.time()-t0:.2f}s) ✓", flush=True)
|
||
|
||
JS = {}
|
||
for tag, cn, rear, d, xd, holder, driven in HL.JOINTS:
|
||
JS[tag] = Joint(tag, cn, rear, d, xd, lug_phase=90.0 if tag == "J1" else 0.0)
|
||
j1, j2, j3, j4, j5, j6 = (JS["J%d" % k] for k in range(1, 7))
|
||
|
||
PARTS[:] = []
|
||
AB.CENTS.clear()
|
||
AB.GRP = {}
|
||
par = {"J1": "root", "J2": "J1", "J3": "J2", "J4": "J3", "J5": "J4", "J6": "J5"}
|
||
driven = {"J1": "P04_肩叉_螺旋体30%_墙5底5_竖打", "J2": "P05_大臂旋转座_螺旋体30%_墙4底5_竖打", "J3": "P06_大臂骨架_螺旋体25%_墙4底5_竖打",
|
||
"J4": "P07_小臂骨架_螺旋体30%_墙5底5_竖打", "J5": "P08_腕偏转座_螺旋体25%_墙4底5_竖打", "J6": "P09_工具法兰_螺旋体100%_墙4底5_竖打"}
|
||
motor_of = {"J1": "M1_J1", "J2": "M2_J2", "J3": "M3_J3",
|
||
"J4": "M4_J4", "J5": "M5_J5", "J6": "M6_J6"}
|
||
for t in ("J1", "J2", "J3", "J4", "J5", "J6"):
|
||
AB.GRP[motor_of[t]] = par[t]
|
||
AB.GRP[driven[t]] = t
|
||
AB.GRP.update({
|
||
"P01_A_立柱下段_三角形30%_墙4底5_竖打": "root", "P01_B_立柱中段_三角形30%_墙4底5_竖打": "root", "P01_C_立柱上段_三角形30%_墙4底5_竖打": "root",
|
||
"P02_Center_底座中核心_螺旋体30%_墙5底6_平打": "root", "P02_Front_前向防翻力臂_螺旋体30%_墙4底5_平打": "root", "P02_Rear_后向防翻力臂_螺旋体30%_墙4底5_平打": "root",
|
||
"P03_肩吊臂_螺旋体35%_墙5底5_竖打": "root"
|
||
})
|
||
AB.JAW = {}
|
||
|
||
p01_full = p_chest()
|
||
p01_a, p01_b, p01_c = split_p01_poka_yoke(p01_full)
|
||
p02_c, p02_f, p02_r = make_p02_poka_yoke()
|
||
|
||
parts_to_build = [
|
||
("P01_A_立柱下段_三角形30%_墙4底5_竖打", "立柱下段", lambda: p01_a, 0x0284c7,
|
||
"200mm适配分段A：高166mm+16mm阶梯公榫+非对称M4防反装通孔+底部50x50x12榫头+P01-A 竖排TOP刻字"),
|
||
("P01_B_立柱中段_三角形30%_墙4底5_竖打", "立柱中段", lambda: p01_b, 0x2563eb,
|
||
"200mm适配分段B：高165mm+双端公母榫+非对称M4防反装通孔+P01-B 竖排TOP刻字"),
|
||
("P01_C_立柱上段_三角形30%_墙4底5_竖打", "立柱上段", lambda: p01_c, 0x1d4ed8,
|
||
"200mm适配分段C：高149mm+底端母榫+非对称M4防反装通孔+顶面P03安装台+P01-C 竖排TOP刻字"),
|
||
("P02_Center_底座中核心_螺旋体30%_墙5底6_平打", "底座核心承力座", lambda: p02_c, 0x475569,
|
||
"200mm适配中座：195x190mm核心承力座+48mm套筒+12mm阶梯榫座(轴向面承载)+前后三角加强筋+前后非对称防呆母榫槽+刻字"),
|
||
("P02_Front_前向防翻力臂_螺旋体30%_墙4底5_平打", "前向防翻力臂", lambda: p02_f, 0xe11d48,
|
||
"200mm适配前臂：145x190mm扩展力臂+104mm宽跨距双公榫+底部M5预埋螺母沉槽+P02-FRONT刻字"),
|
||
("P02_Rear_后向防翻力臂_螺旋体30%_墙4底5_平打", "后向防翻力臂", lambda: p02_r, 0xd97706,
|
||
"200mm适配后臂：45x190mm扩展力臂+80mm窄跨距双公榫+底部M5预埋螺母沉槽+P02-REAR刻字"),
|
||
("P03_肩吊臂_螺旋体35%_墙5底5_竖打", "肩关节安装悬臂", lambda: p_girdle(j1), 0x4b5563,
|
||
"高强多肋机架：10mm后置法兰+双侧8mm大三角加强筋+下腹12mm抗弯龙骨筋+侧开式电机托架(M1从+Y侧滑入装配,前后法兰8xM3双向锁死)+前置止脱锁紧法兰(4xM3止脱螺孔)+大散热窗与对流槽"),
|
||
("P04_肩叉_螺旋体30%_墙5底5_竖打", "肩叉", lambda: p_fork(j1, j2), 0x2563eb,
|
||
"加长避让版：头部与身子前移加长至X=10.5，与P03锁紧法兰保持2.0mm轴向安全间隙（不做前移，保持输出端最短悬伸力臂），J1输出凸台贯通直连电机，J1从动法兰圆盘鼓楞已删（接缝区与P03止脱环齐径齐高R36.5/顶646.5），单实体全角度零干涉"),
|
||
("P05_大臂旋转座_螺旋体30%_墙4底5_竖打", "大臂旋转座", lambda: p_shoulder_roll_base(j2, j3, None), 0x059669,
|
||
"V3圆角：Loft外轮廓R=10mm，L型转角内部2mm倒角，后缘凸包两角90°竖棱磨R2圆角（结构/后缘高度不变，打印无悬挂），保证J2全角度0干涉"),
|
||
("P06_大臂骨架_螺旋体25%_墙4底5_竖打", "大臂骨架", lambda: p_humerus_bone(j3, j4), 0x0d9488,
|
||
"Loft有机过渡版：借鉴P05圆弧变方形放样算法，顶端Ø70正圆与J3平齐无台阶，底端渐变融入M4抱紧套筒与壳体，单实体0干涉"),
|
||
("P07_小臂骨架_螺旋体30%_墙5底5_竖打", "小臂骨架", lambda: p_forearm_bone(j4, j5, None), 0x7c3aed,
|
||
"V2 L型结构：+Y侧背脊立柱避让大臂骨架，过渡区采用与顶板和立柱双相切的R=28mm平滑内凹大圆弧，彻底消除直斜线折角与悬空阶梯小块，顶板前后外缘2mm倒角改R3圆角，顶板整条加高19mm(z261->280)加强连接且gusset弧R28->R14重定相切融入，J4圆盘外沿与立柱外棱不倒圆保持原始尖角，下方M5电机半包散热，俯仰大范围自由运动零干涉"),
|
||
("P08_腕偏转座_螺旋体25%_墙4底5_竖打", "腕部转接座", lambda: p_wrist_bracket(j5, j6), 0xd97706,
|
||
"V2圆角：Loft外轮廓R=10mm，L型转角内部2mm倒角，彻底清除立壁保证J5全角度0干涉"),
|
||
("P09_工具法兰_螺旋体100%_墙4底5_竖打", "末端工具法兰", lambda: p_tool_flange(j6), 0xdc2626,
|
||
"V2圆角：外轮廓R=3mm，法兰面倒角2mm"),
|
||
]
|
||
|
||
total_parts = len(parts_to_build)
|
||
for idx, (name, cn, fn, color, note) in enumerate(parts_to_build, 1):
|
||
print(f" [{idx}/{total_parts}] 正在构建 {name} ({cn})...", end="", flush=True)
|
||
t0 = time.time()
|
||
sh = fn()
|
||
dt = time.time() - t0
|
||
vol = AB.vol_of(sh) / 1000.0
|
||
n_solids = len(solids_of(sh))
|
||
print(f" 完成 ✓ ({dt:.2f}s | 体积: {vol:.1f} cm³ | 实体数: {n_solids})", flush=True)
|
||
add(name, cn, sh, color, note=note)
|
||
|
||
print(" [装配] 正在将 M1~M6 电机定位至各关节坐标位姿...", end="", flush=True)
|
||
t0 = time.time()
|
||
for k, (tag, cn, rear, d, xd, holder, driven_name) in enumerate(HL.JOINTS):
|
||
j = JS[tag]
|
||
add("M%d_%s" % (k + 1, tag), "%s 电机模组" % tag, place(motor, j.t), 0x9ca3af,
|
||
printed=False, note="复用 电机.STEP")
|
||
print(f" 完成 ✓ ({time.time()-t0:.2f}s)", flush=True)
|
||
print(f"-> 构件模型全部生成完成，总耗时: {time.time()-t_stage1:.2f}s\n", flush=True)
|
||
return JS
|
||
|
||
|
||
CHAIN = ["root", "J1", "J2", "J3", "J4", "J5", "J6"]
|
||
SEP = 74.0
|
||
|
||
|
||
def explode_chain(p, JS, cents, gmean):
|
||
"""爆炸图偏移：立柱垂直阶梯拉开，底座前后防呆拉开，电机沿轴拉出，机械臂整体随上段分离"""
|
||
nm = p["name"]
|
||
if nm == "P01_A_立柱下段_三角形30%_墙4底5_竖打":
|
||
return [0.0, 0.0, 0.0]
|
||
if nm == "P01_B_立柱中段_三角形30%_墙4底5_竖打":
|
||
return [0.0, 0.0, 60.0]
|
||
if nm == "P01_C_立柱上段_三角形30%_墙4底5_竖打":
|
||
return [0.0, 0.0, 120.0]
|
||
if nm == "P02_Center_底座中核心_螺旋体30%_墙5底6_平打":
|
||
return [0.0, 0.0, 0.0]
|
||
if nm == "P02_Front_前向防翻力臂_螺旋体30%_墙4底5_平打":
|
||
return [65.0, 0.0, 0.0]
|
||
if nm == "P02_Rear_后向防翻力臂_螺旋体30%_墙4底5_平打":
|
||
return [-65.0, 0.0, 0.0]
|
||
if nm == "P03_肩吊臂_螺旋体35%_墙5底5_竖打":
|
||
return [0.0, 0.0, 120.0]
|
||
|
||
grp = AB.GRP.get(p["name"], "root")
|
||
if grp == "root":
|
||
return [0.0, 0.0, 0.0]
|
||
k = CHAIN.index(grp)
|
||
off = [0.0, 0.0, 120.0 - SEP * k]
|
||
j = JS.get(grp)
|
||
if j:
|
||
w = 0.0
|
||
if "半联轴器" in nm or "抱箍" in nm:
|
||
w = 34.0 * (1.0 if ("A" in nm[-1:]) else -1.0)
|
||
elif nm.startswith("M"):
|
||
w = 62.0
|
||
for q in range(3):
|
||
off[q] += j.d[q] * w
|
||
return off
|
||
|
||
|
||
if __name__ == "__main__":
|
||
JS = build()
|
||
|
||
print("=" * 80, flush=True)
|
||
print("【单实体拓扑完整性校验】验证所有打印构件流形实体状态...", flush=True)
|
||
print("=" * 80, flush=True)
|
||
bad = 0
|
||
printed_list = [p for p in PARTS if p["printed"]]
|
||
total_pr = len(printed_list)
|
||
for idx, p in enumerate(printed_list, 1):
|
||
n = len(solids_of(p["shape"]))
|
||
if n != 1:
|
||
bad += 1
|
||
status = "单实体 ✓" if n == 1 else f"异常 ({n} 个实体) ❌"
|
||
print(f" [{idx}/{total_pr}] {p['name']:<14} : 体积 {p['vol']/1000.0:6.1f} cm³ | {status}", flush=True)
|
||
if bad == 0:
|
||
print(f"-> 单实体检查全部通过！{total_pr}/{total_pr} 构件均为完美单一流形拓扑 ✓\n", flush=True)
|
||
else:
|
||
print(f"-> 发现 {bad} 个非单实体构件！\n", flush=True)
|
||
|
||
AB.explode_vec = explode_chain
|
||
bom = AB.export(JS)
|
||
|
||
# 紧固件（螺钉）实例注入：把 docs/screws.json 的 72 颗螺钉按真实孔位还原成三维实例，
|
||
# 追加进 web/mesh_arm.json 的 parts（查看器可点 BOM 螺丝行高亮定位；纯数据，不动 CAD）
|
||
try:
|
||
import screw_mesh
|
||
screw_mesh.main()
|
||
except Exception as e:
|
||
print("螺钉实例注入失败（不影响主流程，可手动跑 src/screw_mesh.py）:", e, flush=True)
|
||
|
||
cl = AB.collide()
|
||
|
||
try:
|
||
from build_viewer import rebuild_viewer
|
||
rebuild_viewer()
|
||
except Exception as e:
|
||
print("rebuild_viewer error:", e, flush=True)
|
||
|
||
# 可达包络自动注入：AB.export 刚重写过 mesh_arm.json（包络件会被冲掉），
|
||
# 这里重跑 FK 采样 + 包络网格注入，再重打包一次查看器（约 3~4s，纯数据无 CAD 计算）
|
||
try:
|
||
sys.path.insert(0, os.path.join(os.path.dirname(os.path.abspath(__file__)),
|
||
"..", "scratch"))
|
||
import ws_sweep
|
||
import gen_env_mesh
|
||
t_env = time.time()
|
||
ws_sweep.main()
|
||
gen_env_mesh.main()
|
||
from build_viewer import rebuild_viewer as _rbv
|
||
_rbv()
|
||
print(f"-> 可达包络已自动注入查看器（+{time.time()-t_env:.1f}s）✓\n", flush=True)
|
||
except Exception as e:
|
||
print("可达包络自动注入失败（不影响主流程，修复后手动跑 scratch/gen_env_mesh.py + src/build_viewer.py）:",
|
||
e, flush=True)
|
||
|
||
print("=" * 80, flush=True)
|
||
print("✅ 机器人手臂编译、导出与查看器发布全流程完成！", flush=True)
|
||
print("=" * 80, flush=True)
|
||
sys.stdout.flush()
|
||
os._exit(0)
|