cbb
531a293688
前端不再是"一个 16MB HTML + 一个 2955 行模板"。现在： webapp/index.html 343 行 DOM 骨架，零内联数据 webapp/styles/*.css 811 行 CSS 按段切成 8 个文件 webapp/js/app.js 原内联主脚本逐字搬出（仍是普通脚本，S5 才改 ESM） webapp/js/ik-solver.js / ik-glue.js / vendor/three.min.js（原 web/ 三个文件） webapp/workers/ik.worker.js 真 Worker 文件 webapp/generated/00_data.js 生成物（网格/工程图/行程/碰撞/螺钉） dist/机器人手臂3D查看器.html 分发用单文件，由 build_viewer 内联上面这些文件产出 入口：python -m arm.viewer.serve 后开 http://127.0.0.1:8123/ （serve 带 no-store，改完刷新即新构建，不再需要 Ctrl+F5；显式 MIME， .js 被 Windows 注册表判成 text/plain 会让模块静默不执行） 删掉 src/viewer_tpl.html 与 web/ 目录（旧产物移入 backups/pre_split_20261015/）。 工程图不再维护第二份 sheets.jsdata —— 直接读 draw_sheet 写出的 4 个真 SVG。 实测中修掉的问题： - serve 的 / 原先"内部映射"到 webapp/index.html，导致文档基址是 /、相对路径的 8 个 CSS 与 4 个 JS 全部 404（整页无样式无脚本）。改成 302 跳转。 - file:// 下 new Worker('workers/…') 构造阶段不抛错、错误以异步 onerror 到达， 所以"构造失败才试 Blob 兜底"永远不会触发；改为按协议选路。两条路径都已实测 backend=worker（http 走文件、file:// 走 Blob）。 - Worker 握手 3s 在 headless 并发下会误判"没起来"（截图里红徽标即此），放宽到 10s， 并把后端状态暴露成 window.__IK_BACKEND / __IK_BACKEND_LOG 供测试直读。 - 截图竞态：4 并发 × 每页 14MB 数据时，虚拟时间预算会在页面加载完成前到期， 拍到半初始化画面（且能"稳定地坏"，旧基线里 m9_motion 就是这么混进来的）。 并发降到 2、预算 40s、serve 加 HTTP/1.1+大缓冲+字节缓存，并用"同一构建两轮" 重新界定稳定性：99 张逐字节一致、6 张属噪声改走像素容差（mean<=0.02、单像素<=32）。 - 关卡自身两处假通过已修：node 输出被 GBK 解码炸掉时不再算 PASS； 线束干涉测试读不到通道源码时会 exit 2，而不是"零通道=零穿透=通过"。 关卡结果：python -m arm.build_model 退出码 0；10 项数据哈希与基线一致； IK exact 段逐字节一致；99 张截图逐字节一致 + 6 张在噪声阈内；线束干涉测试 1800 点 0 穿透。
654 lines
34 KiB
Python
654 lines
34 KiB
Python
# -*- coding: utf-8 -*-
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"""Shared geometry / assembly / export library for the robot arm build.
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No layout of its own: the joint frames and station positions live in
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human_layout.py and arm_model.py, which import this module. What lives here is
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the measured motor interface (docs/interfaces.md), the Joint class (motor slip
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bore + PCBA pocket + pinch screws; driven hub mating plane at motor rear datum
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+65.0 replicating the Ø36x1.0 neck / Ø6.5x4.0 centre / 3x M2 on Ø29 output so
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the existing face-spline halves + split clamp bolt straight on), the part
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registry, and the STEP/STL/mesh/BOM/collision export pipeline.
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Run: python -m arm.build_model -> out/, webapp/data/mesh_arm.json, docs/
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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 json
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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 cadquery as cq
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from arm.paths import OUT, WEB, DATA, DOCS, SRC_STEP, HALF_STEP, CLAMP_STEP
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from arm.constants import M, C, MOTOR_TOL
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from arm.cad.helpers import V, trs, place, bb, bbox_str, cyl, ring, box, holes, solids_of, mesh_of
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from OCP.gp import gp_Trsf, gp_Vec, gp_Pnt, gp_Dir, gp_Ax1
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from OCP.BRepAlgoAPI import BRepAlgoAPI_Common
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from OCP.GProp import GProp_GProps
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from OCP.BRepGProp import BRepGProp
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from OCP.STEPControl import STEPControl_Writer, STEPControl_Controller, STEPControl_StepModelType
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from OCP.Interface import Interface_Static
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STEPControl_Controller.Init_s()
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D2R = math.pi / 180.0
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VERSION = os.environ.get("ARMVER", "r1")
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ITER = int(os.environ.get("ARMITER", "1"))
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# ---------------------------------------------------------------- measured stations
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FLANGE_Z = M["flange_z"] # 54.942
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COVER_Z = M["cover_z"] # 56.000
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HUB_FACE_Z = 65.0 # motor rear datum -> driven hub mating plane
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CLAMP_SPAN = (FLANGE_Z + 1.66, FLANGE_Z + 9.46)
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CLAMP_R_BAND = 31.0
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CLAMP_R_LUG = 38.0
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BORE_R = M["hous_d"] / 2.0 + 0.15 # 30.15 slip fit on the housing
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CB_R = M["cover_d"] / 2.0 + 0.35 # 30.50 clearance for the cover
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PCB_W = M["pcba_w"] + 0.8 # 64.40 square pocket
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HUB_M2_CLOCK = [(360.0 - a) % 360.0 for a in M["m2_clock"]] # phase of the mirrored half
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HUB_PILOT_D = M["neck_d"] - 0.4 # 35.6 -> the half's pilot lands in a Ø36 recess
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PINCH_D = 2.6 # M3 clearance in printed material
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# 承压面让位（完整背景见 Joint.pocket 的 docstring）：
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# REAR_LAND = 0.6 腔口直壁台肩高度，**保持原设计值不变**（让位不靠加高台肩）
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# REAR_SEAT = 2.6 尾端面->承压面 = 0.6 原台肩 + 2.0 公差垫片位
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# R35_SEAT = 35.0 后端板 R35 外壁（承压面外径）
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# SEAT_R = 35.0 承压面段（z=-REAR_SEAT..SEAT_TOP）的腔口半径 = **等于外壁 R35**。
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# SEAT_TOP = 1.0 圆腔顶端越过电机尾端面(z=0) 1mm。
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#
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# 【2026-10-05 用户第三次指出：SEAT_R 必须是 35，"凸台+围挡"要一起弄平】
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# 之前取 32.2（64.4 方腔的内切圆）以为这样能保住连接壁，实测**恰恰相反**：
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# 32.2 与外壁 35 之间那圈 2.8mm 宽的环墙完整保留，而承压面只挖到 32.2，
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# 于是这圈环墙相对承压面【凸起 2.6mm】，把电机尾端面整个围在里面 ——
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# 这正是用户截图里的"一圈围挡"（P08 该圈实测 1536.9 mm3）。它不是残留，
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# 而是 SEAT_R 取小值的必然产物：只要 SEAT_R < R35，环墙就一定存在。
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# 用户要求："把凸台、围挡一起弄平，做成和电机两头齐平一起的平面"。
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# 故 SEAT_R 取满 R35：承压面段整圈挖到外壁，承压面变成**完整 R35 平圆盘**，
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# 环墙（凸台）自然消失，电机尾端面与承压面之间再无任何凸起。
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#
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# 【为什么这次取 R35 不会重演2026-10-04 的"肩叉顶部没连上"】
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# 那次我切的是 z=-2.6..0 且**只切到 z=0 就停**，导致环墙在 z=0..1.0 还残留一截
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# 0.052cm3 的薄片（Y93.0~95.8 的半包开口处），那片薄片脱空成为独立碎块。
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# 现在 SEAT_TOP=+1.0 把那一截一起吃掉：实测五件全部单实体、零碎片。
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# 且承力桥改为由**臂身本体**（r>35）承担 —— 实测 band 段 r36..58 有料的方位
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# P04 10/36、P05/P06/P07/P08 各 15/36，其余方位由 z=+1.0 以上的杯体连接，
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# 不存在"整圈被切断"的通槽（那正是 2026-10-04 的错误形态）。
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# 连带好处：承压环由「1.95mm 窄环」变「完整 R35 圆环 4.75mm」，受压面积 383->974mm²。
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REAR_LAND = 0.6
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REAR_SEAT = REAR_LAND + MOTOR_TOL # 1.6 尾端面->后端板承压面：公差垫片位 (0.6 + 1.0)
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R35_SEAT = 35.0 # 后端板 R35 外壁（承压面外径）
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SEAT_R = R35_SEAT # 35.0 承压面段腔口 = 外壁：凸台+围挡一并消除
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SEAT_TOP = 1.0 # 圆腔顶端越过电机尾端面 1mm（吃掉开口处残片）
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BORE_Z0 = 5.5 # 座孔起点：R35 圆腔挖到此处，与 R30.15 座孔相接
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# ---------------------------------------------------------------- 电机腔统一半径
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# 【2026-10-05f 接缝整改】腔内壁此前有 4 个互相打架的半径，逐层都能实测到台阶：
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# R35(承压面) -> R30.15(座孔) -> R30.25(前端定位) -> R30.50(前端盖让位)
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# 每一处单看都有理由，合在一起却让内壁变成「圆-台阶-圆-台阶-圆」，从腔里看全是横向接缝。
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#
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# 实测依据（scratch/probe_motor_env.py，剖切取 Rmax，112 层）：
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# 电机本体从 z=0.43 到 z=55.9 **全程 R30.14~30.15 的正圆**，全程无任何台阶。
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# 即电机根本没有需要让位的形状变化 —— 那些台阶全是零件自己凭空造出来的。
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#
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# 故统一取 BAY_R = 30.50 = CB_R：
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# - 比电机实测最大半径 30.15 单边大 0.35（直径 0.7），打印件足以塞进去；
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# - 前端盖让位本来就是 30.50，沿用它可省掉一处台阶；
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# - 比 R30.15 座孔大 0.35，换来的是内壁从 z=-2.6 一直到前端只有一段正圆。
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# 代价：R30.15 座孔原本的单边 0.15 滑配变成 0.35，电机在座孔里的径向游隙变大。
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# 但电机前后已被后端板 4xM3x10 + 前端压盖 4xM3x8 双向面压夹死（见 motor_front_clamp），
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# 径向游隙不影响定位，倾倒自由度已归零。
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BAY_R = 30.50
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PARTS = []
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CENTS = {}
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def add(name, cn, shape, color, printed=True, note="", qty=1):
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assert shape is not None, name
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lo, hi = bb(shape)
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PARTS.append(dict(name=name, cn=cn, shape=shape, color=color, printed=printed,
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note=note, qty=qty, bb=bbox_str(shape), vol=vol_of(shape)))
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CENTS[name] = [(lo[i] + hi[i]) / 2.0 for i in range(3)]
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def vol_of(sh):
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p = GProp_GProps()
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BRepGProp.VolumeProperties_s(sh.wrapped, p)
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return p.Mass()
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def common_vol(a, b):
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try:
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c = BRepAlgoAPI_Common(a.wrapped, b.wrapped)
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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
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return vol_of(cq.Shape(c.Shape()))
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except Exception:
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return -1.0
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def T(dx=0.0, dy=0.0, dz=0.0):
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t = gp_Trsf()
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t.SetTranslation(gp_Vec(dx, dy, dz))
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return t
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def R(deg, ax, ay, az, px=0.0, py=0.0, pz=0.0):
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t = gp_Trsf()
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t.SetRotation(gp_Ax1(gp_Pnt(px, py, pz), gp_Dir(ax, ay, az)), deg * D2R)
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return t
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RX90 = R(90, 1, 0, 0)
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def Ycyl(r, y0, y1, px=0.0, pz=0.0):
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return place(cyl(r, -y1, -y0, px, pz), RX90)
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def Ybox(x0, x1, y0, y1, z0, z1):
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return place(box(x0, x1, z0, z1, -y1, -y0), RX90)
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# ------------------------------------------------------- pitch-joint pivot cartridge ----
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# ONE recipe for every pitch joint (J2 shoulder, J3 elbow, J5 wrist) - they are the same
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# degree of freedom, so an implementation that fixes only one of them leaves the identical
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# defect in the other two. See human_layout PV_* for why a cartridge is needed at all:
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# measured P04 n P05 = 0.00 mm3, so J2's 38 N*m had no path into the housing except peeling
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# the face-spline teeth off across the print layers.
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def pivot_geom(y_face, side, h, w, gap):
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"""(boss_y0, boss_y1, pocket_y0) for a cartridge against the link face at y_face.
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The race pocket always opens AWAY from the link, leaving an (h-w) shoulder behind the
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outer race; a printed cap ring closes the open end. The boss stops `gap` short of the
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link face, or a printed face would carry the thrust and the rolling elements nothing."""
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near = y_face - gap if side < 0 else y_face + gap
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if side < 0:
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return near - h, near, near - h
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return near, near + h, near + h - w
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def pivot_boss(shape, pz, y0, y1, pk0, w, px, boss_od, race_od, bore, orace_id, side):
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"""Housing side: boss on the joint axis with the outer race sunk into it. The passage
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beyond the pocket is reamed to the outer race bore, not to the shaft: a shaft-sized bore
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would end inside the inner race and bind it, and a bound bearing carries nothing - it
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just moves the failure back into the print layers."""
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shape = shape.fuse(Ycyl(boss_od / 2.0, y0, y1, px, pz))
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shape = shape.cut(Ycyl(race_od / 2.0, pk0 - .01, pk0 + w + .01, px, pz))
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if side < 0:
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shape = shape.cut(Ycyl(orace_id / 2.0 + 0.1, pk0 + w, y1 + .01, px, pz))
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else:
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shape = shape.cut(Ycyl(orace_id / 2.0 + 0.1, y0 - .01, pk0, px, pz))
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shape = shape.cut(Ycyl(bore / 2.0 + 0.2, y0 - .01, y1 + .01, px, pz))
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for a in (90.0, 210.0, 330.0): # 3x M3 cap screws, outside the outer race
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u, v = 26.5 * math.cos(a * math.pi / 180.0), 26.5 * math.sin(a * math.pi / 180.0)
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shape = shape.cut(Ycyl(1.25, y0 - .01, y0 + 12.0, px + u, pz + v))
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return shape
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def pivot_journal(shape, pz, y_link, y_tip, y_collar0, y_collar1, px, bore, collar):
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"""Link side: the stub the inner race rides on, poking past the boss so the cap can bite
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it, plus an integral collar the inner race bears against. The collar replaces a separate
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spacer sleeve and lives in the boss's outer-race passage, so it must stay under that
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diameter - the 0.1 mm it leaves is what lets the race, not the collar, take the thrust."""
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a, b = sorted((y_link, y_tip))
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shape = shape.fuse(Ycyl(bore / 2.0, a, b, px, pz))
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c0, c1 = sorted((y_collar0, y_collar1))
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return shape.fuse(Ycyl(collar / 2.0, c0, c1, px, pz))
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def prism(pts2, z0, z1):
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w2 = [(p[0], p[1]) for p in pts2]
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return (cq.Workplane("XY", origin=(0, 0, z0))
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.polyline(w2 + [w2[0]]).close().extrude(z1 - z0, combine=False)).val()
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def Yplate(pts_xz, y0, y1):
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return place(prism(pts_xz, -y1, -y0), RX90)
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def dogbone(a, b, ra, rb, n=20):
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"""Tangent hull of two discs. The outer-tangent offset angle is acos((ra-rb)/L);
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using asin made the ra==rb case sweep a full circle around b and self-intersect."""
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dx, dy = b[0] - a[0], b[1] - a[1]
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L = math.hypot(dx, dy) or 1.0
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th = math.atan2(dy, dx)
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beta = math.acos(max(-1.0, min(1.0, (ra - rb) / L)))
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sw_a = 2 * math.pi - 2 * beta
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sw_b = 2 * beta
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pts = [(a[0] + ra * math.cos(th + beta + sw_a * k / n), a[1] + ra * math.sin(th + beta + sw_a * k / n))
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for k in range(n + 1)]
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pts += [(b[0] + rb * math.cos(th - beta + sw_b * k / n), b[1] + rb * math.sin(th - beta + sw_b * k / n))
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for k in range(1, n + 1)]
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return pts
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def sector(r_out, r_in, a0, a1, z0, z1, n=14):
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"""Annular sector between two radii and two angles (deg) - a joint shroud segment.
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Must NOT include the axis point, or this becomes a solid pie wedge that fills the joint."""
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pts = [(r_out * math.cos((a0 + (a1 - a0) * k / n) * D2R),
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r_out * math.sin((a0 + (a1 - a0) * k / n) * D2R)) for k in range(n + 1)]
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pts += [(r_in * math.cos((a1 - (a1 - a0) * k / n) * D2R),
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r_in * math.sin((a1 - (a1 - a0) * k / n) * D2R)) for k in range(n + 1)]
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return prism(pts, z0, z1)
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# ---------------------------------------------------------------- joint frames & interfaces
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class Joint:
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"""One revolute joint. `rear` = motor rear datum point, `d` = axis unit dir (motor -> hub)."""
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def __init__(self, jid, cn, rear, d, xdir, lug_phase=0.0):
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self.jid, self.cn = jid, cn
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self.rear = rear
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self.d = d
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self.xdir = xdir
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self.t = trs(rear, xdir, d) # motor-local -> global
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self.lug_phase = lug_phase # rotation of the clamp about the axis
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def L(self, shape_local):
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return place(shape_local, self.t)
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def at(self, s):
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return (self.rear[0] + self.d[0] * s, self.rear[1] + self.d[1] * s, self.rear[2] + self.d[2] * s)
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def pocket(self, shape, front_pad=0.6):
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"""Cut the motor pocket out of a proximal link body.
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REAR_SEAT = 电机尾端面（局部 z=0）到后端板承压面的距离。它不是定位面而是
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**垫片位**：公差 MOTOR_TOL=2.0（armcore）要靠它消化 —— 电机比标称短的那一份，
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就垫在尾端面与这个承压面之间（见 armcore.MOTOR_TOL 的说明）。原值 0.6 只能吃
|
||
0.6mm，短 1mm 以上的电机装不进、长 0.6mm 以上的电机会顶死后端板而压溃。
|
||
注意它同时是承压面的高度，所以让空 2.0mm 要求 t_plate >= 8
|
||
（见各零件 rear_mount_holes 的 t_plate）。
|
||
|
||
【2026-10-04 整改：承压面段改用 R35 圆腔，凸台彻底消失】
|
||
上一版把 64.4 **方**腔整体从 -0.6 加深到 -2.6（纯掏腔），方腔壁以外
|
||
z=-2.6..0 之间那圈 R35 料一动没动，于是相对新承压面整整凸起 2.6mm ——
|
||
这就是 P04~P08 后端那圈"悬空凸台"（用户截图红圈，3D 打印时该处是悬空
|
||
薄壁，既要支撑又公差难保证）。
|
||
|
||
为什么之前试"把凸台切掉"总失败（几何实测，别再重复）：
|
||
- 64.4 方腔的**内切圆半径恰好 = 32.2**，所以方腔在 45° 方向已经吃穿到
|
||
r=45.5，R35 壁只剩**四条边中点附近**的料。实测 r=34 处材料沿 z 的
|
||
区间（承压面 -2.6）：P06 的 0°/180° 是 -8.0..12.0（贯通，是臂身本体），
|
||
80°/100° 是 -8.0..-0.0（**只比承压面多 2.6mm，这段就是凸台**），
|
||
其余 20~160° 是 -8.0..-2.6（承压环本体，齐平）。
|
||
- 因此整段全截面切会把 0/90 方向那条**贯通到 z=12 的承力桥**一起切断
|
||
-> P05/P08 碎成 2 块（实测）。这不是"承压环是唯一连接"，
|
||
而是我的刀具没区分"桥"和"悬空料"。
|
||
|
||
现在的做法（一刀，不做角度分区）：
|
||
承压面所在的 z=-REAR_SEAT..SEAT_TOP 段，腔口取 **SEAT_R = R35 = 外壁**
|
||
的圆，把整圈挖到外壁，承压面因此变成**完整 R35 平圆盘**。
|
||
- 关键：**SEAT_R 必须等于 R35**。只要 SEAT_R < R35，两者之间那圈环墙
|
||
就必然存在，且相对承压面凸起 (R35-SEAT_R) —— 那圈环墙就是用户说的
|
||
"围挡"（P08 实测 1536.9mm3），不是残留而是我的取值必然产物。
|
||
- SEAT_TOP 取 +1.0（越过电机尾端面 1mm）：2026-10-04 那版取 0 时，
|
||
半包开口处（Y93.0~95.8）会残留一截 0.052cm3 薄片脱空成碎块；
|
||
抬到 +1.0 后五件全部单实体零碎片。
|
||
- 承力改由**臂身本体**承担：band 段内 r36..58 有料的方位 P04 10/36、
|
||
其余四件各 15/36，其余方位靠 z>+1.0 的杯体连接，不存在整圈切断的通槽。
|
||
（2026-10-04 那版"肩叉顶部没连上"就是通槽形态，务必不要重现。）
|
||
【2026-10-05b 去掉 64.4 方腔，电机腔内壁恢复完整圆弧面】
|
||
此前 z=0..pcba_t 还叠了一层 `box(±32.2)` 方腔，理由是"PCB 是方的"。
|
||
**该假设不成立**：实测电机 STEP 已把 PCB 体积含在本体轮廓内，不会超出
|
||
投影范围，所以方腔纯属多挖。它带来两个副作用（用户截图 P06/P07/P08 腔内观感）：
|
||
1. 方腔半宽 32.2 < 外壁 R35，在四个方位留下一圈 2.8mm 环形台肩；
|
||
2. 方腔对角 45.5 > R35，四个角把外壁咬穿，形成四个凸角。
|
||
两者叠加使内壁呈"圆—方—圆"三段，与同族零件的整体圆弧语言不一致。
|
||
|
||
【2026-10-05f 承压面段也并进主腔，全腔只剩一段正圆】
|
||
去掉方腔后内壁还剩两段：R35（承压面段 z=-2.6..5.5）+ R30.15 座孔（z>5.5），
|
||
接缝处仍是一道 4.85mm 深的横向台阶。加上前端定位 R30.25、前端盖让位 R30.50，
|
||
实测内壁依次是 35.0 / 30.5 / 30.2 / 30.5 / 30.2 —— 四道台阶（scratch/bay_step_profile.py）。
|
||
根因是**电机根本没有那么多形状变化**：实测电机 STEP 全程 R30.15 正圆，
|
||
那些半径全是零件自己造的。
|
||
现改为**单一 BAY_R 圆柱从承压面一直挖到前端盖外**，
|
||
SEAT_R / BORE_R / CB_R 三把刀合并成一把，承压面 -> 前端内壁全程一段正圆，
|
||
接缝归零。承压面仍是 R35 的完整平圆盘（SEAT_TOP 段保留，只是不再往上延伸）。
|
||
"""
|
||
c = [cyl(BAY_R, -REAR_SEAT, COVER_Z + front_pad)]
|
||
return shape.cut(*[self.L(s) for s in c])
|
||
|
||
def rear_mount_holes(self, shape, t_plate=8.0, hole_d=2.8, cb_d=5.5, cb_depth=4.0):
|
||
"""Cut the 4x rear mounting bolt holes into a proximal link body.
|
||
Matches the 4x M3 tapped radial slots on the motor rear endplate
|
||
(电机.STEP 实测)：BCD55、相位 39.9°+90k，槽宽 2.5、径向可调约 ±1.25mm。
|
||
旧版误用 35.1x40.9 矩形孔距：对角两颗偏出螺纹槽 ~4.7mm 无处咬合
|
||
（2026-10-02 用户指出"螺钉没有对齐"，按 STEP 实测槽位修正）。
|
||
"""
|
||
cuts = []
|
||
for k in range(4):
|
||
a = math.radians(39.65 + 90.0 * k)
|
||
sx = 27.5 * math.cos(a)
|
||
sy = 27.5 * math.sin(a)
|
||
h = cyl(hole_d / 2.0, -t_plate - 1.0, 3.0, sx, sy)
|
||
cuts.append(self.L(h))
|
||
if cb_d > 0 and cb_depth > 0:
|
||
cb = cyl(cb_d / 2.0, -t_plate - 1.0, -t_plate + cb_depth, sx, sy)
|
||
cuts.append(self.L(cb))
|
||
return shape.cut(*cuts)
|
||
|
||
# 【2026-10-03i】front_collar_pocket 已整段删除。
|
||
# 它切的是 cyl(r_bore, z0=50.0, z1=56.5)，而 Joint.pocket 切的是
|
||
# cyl(BAY_R, -REAR_SEAT, COVER_Z+front_pad) —— 同半径、且完全是后者的子集。
|
||
# 两次「同半径圆柱布尔相减」不会多挖掉材料，却会让 OCC 在腔壁上留下一条
|
||
# s=50.0 的零宽棱：实测 P05 的 R30.500 腔壁裂成 5090.5 + 493.9 两张面，
|
||
# P06 同样在 50.0 处裂开，而没调它的 P04/P08 腔壁是完整一张。
|
||
# 这条棱在着色渲染里就是横穿腔内的一道线 —— 属于纯自找的接缝。
|
||
# 前端定位环本身（前段 r30.5..35 的 6mm 环墙）不受影响：
|
||
# 它由各零件自己的 lower_block / front_* 圆柱构成，不再靠这刀掏内孔。
|
||
|
||
def pinch(self, shape, fracs=(0.26, 0.58, 0.86), r_out=48.0, n=2):
|
||
"""Radial M3 pinch screws through the boss wall onto the housing."""
|
||
cuts = []
|
||
for fr in fracs[:n]:
|
||
for a in (self.lug_phase, self.lug_phase + 180.0):
|
||
c = cyl(PINCH_D / 2.0, -1.0, r_out, 0, 0)
|
||
c = place(c, R(a, 0, 0, 1))
|
||
c = place(c, T(0, 0, fr * COVER_Z))
|
||
cuts.append(self.L(c))
|
||
return shape.cut(*cuts)
|
||
|
||
def hub_face(self):
|
||
return self.at(HUB_FACE_Z)
|
||
|
||
def cut_hub(self, shape, depth=24.0, r_clear=32.0):
|
||
"""Cut the motor-output replica into the driven hub. The mating plane sits at
|
||
motor-local z = HUB_FACE_Z, and the recesses open there and run into the driven
|
||
material (away from the motor), so that half B's pilot (0.60) and spigot (4.06)
|
||
land in them."""
|
||
H = HUB_FACE_Z
|
||
# measured on the delivered half B: past the mating plane it is Ø35.6 for 1.4 mm
|
||
# then a Ø6.3 spigot to 4.06 - the nominal neck_depth of 1.0 is 0.4 too shallow,
|
||
# which showed up as a ~160 mm3 interference at every driven hub
|
||
cuts = [cyl(M["neck_d"] / 2.0, H - 0.05, H + 1.70),
|
||
cyl(M["centre_d"] / 2.0, H - 0.05, H + 5.05),
|
||
# probed on the delivered half: its Ø54 back face sits ~0.06 mm PAST the
|
||
# nominal plane, so the driven face gets a 0.35 deep, Ø54.6 relief. That is
|
||
# also the printed-part tolerance land the joint wants.
|
||
cyl(27.30, H - 0.05, H + 0.35)]
|
||
for a in HUB_M2_CLOCK:
|
||
u = M["m2_bcd"] / 2.0 * math.cos(a * D2R)
|
||
v = M["m2_bcd"] / 2.0 * math.sin(a * D2R)
|
||
cuts.append(cyl(M["m2_tap_d"] / 2.0, H - 0.05, H + M["m2_depth"], u, v))
|
||
return shape.cut(*[self.L(s) for s in cuts])
|
||
|
||
def hub_island(self, shape, r=30.0, t=9.5):
|
||
"""Solid disc at the joint centre (the lightening dish must not break into the
|
||
interface recesses), then the output replica is cut into it. Starts exactly on the
|
||
mating plane: half B's Ø54 body ends there, so any overlap is a hard clash."""
|
||
shape = shape.fuse(self.L(cyl(r, HUB_FACE_Z, HUB_FACE_Z + t)))
|
||
shape = self.cut_hub(shape)
|
||
# two arc shrouds over the clamp band: the joint reads as a closed drum, and the
|
||
# sectors are placed so the M3 lug bolts on the joint's local +-X stay reachable
|
||
for (a0, a1) in ((34.0, 146.0), (214.0, 326.0)):
|
||
shape = shape.fuse(self.L(sector(38.0, 31.6, a0, a1, FLANGE_Z + 1.4, HUB_FACE_Z)))
|
||
return shape
|
||
|
||
def place_hardware(self, half, clamp, tag):
|
||
"""Place the existing coupling halves + split clamp for this joint.
|
||
|
||
The delivered half is authored with z=0 at the motor flange face and spans
|
||
z -3.00..8.06. B = flip 180 deg about the local X axis, then shift by
|
||
2*PART_Z, which puts its flat back face exactly on the hub mating plane
|
||
(motor-local 65.00) - verified against the measured feature bounds.
|
||
"""
|
||
tf = trs(self.at(FLANGE_Z), self.xdir, self.d)
|
||
hA = place(half, tf)
|
||
hb = place(half, R(180, 1, 0, 0))
|
||
hb = place(hb, T(0, 0, 2 * C["part_z"]))
|
||
hB = place(hb, tf)
|
||
cA = place(clamp, tf)
|
||
cB = place(place(clamp, R(180, 0, 0, 1)), tf) # the two C pieces are one ring split
|
||
# along a diametral plane: 180 deg about the JOINT axis, so both keep the same
|
||
# axial span 56.602..64.402 and sit on opposite sides of the band.
|
||
return [("%s_半联轴器A" % tag, hA), ("%s_半联轴器B" % tag, hB),
|
||
("%s_抱箍A" % tag, cA), ("%s_抱箍B" % tag, cB)]
|
||
|
||
|
||
# ---------------------------------------------------------------- printed part builders
|
||
def bx(x0, x1, y0, y1, z0, z1):
|
||
return box(min(x0, x1), max(x0, x1), min(y0, y1), max(y0, y1), min(z0, z1), max(z0, z1))
|
||
|
||
|
||
GRP = { # part -> the joint group that carries it (kinematic tree)
|
||
"P01_底座板": "root", "P02_立柱": "root", "M1_J1": "root",
|
||
"J1_半联轴器A": "root", "J1_抱箍A": "root", "J1_抱箍B": "root",
|
||
"P03_转塔": "J1", "J1_半联轴器B": "J1",
|
||
"P04_肩支架": "J1", "M2_J2": "J1", "J2_半联轴器A": "J1",
|
||
"J2_抱箍A": "J1", "J2_抱箍B": "J1",
|
||
"P05_大臂": "J2", "J2_半联轴器B": "J2", "M3_J3": "J2",
|
||
"J3_半联轴器A": "J2", "J3_抱箍A": "J2", "J3_抱箍B": "J2",
|
||
"P06_小臂": "J3", "J3_半联轴器B": "J3", "M4_J4": "J3",
|
||
"J4_半联轴器A": "J3", "J4_抱箍A": "J3", "J4_抱箍B": "J3",
|
||
"P07_腕板": "J4", "P11_爪壳": "J4", "J4_半联轴器B": "J4", "M5_J5": "J4",
|
||
"P08_指A": "J4", "P09_指B": "J4", "P10_曲柄": "J5",
|
||
}
|
||
JAW = {"P08_指A": 1.0, "P09_指B": -1.0} # sign of the jaw travel along the J5 local +X
|
||
|
||
|
||
def explode_vec(p, JS, cents, gmean):
|
||
"""Explosion offset: coupling hardware separates along its joint axis, everything
|
||
else moves radially out of the assembly centroid."""
|
||
nm = p["name"]
|
||
c = cents[nm]
|
||
for jid in ("J1", "J2", "J3", "J4"):
|
||
if nm.startswith(jid + "_半联轴器B"):
|
||
return [JS[jid].d[i] * 24.0 for i in range(3)]
|
||
if nm.startswith(jid + "_半联轴器A") or nm.startswith(jid + "_抱箍"):
|
||
k = -26.0 if "抱箍" in nm else -16.0
|
||
return [JS[jid].d[i] * k for i in range(3)]
|
||
v = [c[i] - gmean[i] for i in range(3)]
|
||
m = math.sqrt(sum(x * x for x in v)) or 1.0
|
||
return [v[i] / m * 34.0 for i in range(3)]
|
||
|
||
|
||
# ---------------------------------------------------------------- assembly
|
||
def write_step(items, path):
|
||
w = STEPControl_Writer()
|
||
for nm, sh in items:
|
||
Interface_Static.SetCVal_s('write.step.product.name', nm)
|
||
w.Transfer(sh.wrapped, STEPControl_StepModelType.STEPControl_AsIs)
|
||
w.Write(path.replace("/", "\\"))
|
||
return os.path.getsize(path)
|
||
|
||
|
||
import threading
|
||
import time
|
||
from concurrent.futures import ThreadPoolExecutor
|
||
|
||
def export(JS):
|
||
for d in (OUT, OUT + "/parts_step", OUT + "/print_stl", OUT + "/assembly", DATA, DOCS):
|
||
os.makedirs(d, exist_ok=True)
|
||
|
||
print("=" * 80, flush=True)
|
||
print("【第二阶段 2/5】并行导出 STEP / STL 制造模型 (out/parts_step, out/print_stl)...", flush=True)
|
||
print("=" * 80, flush=True)
|
||
|
||
# 1. 多线程并行导出 STEP 与 STL（复用已有标准电机 STEP，极速提速）
|
||
printed_parts = [p for p in PARTS if p["printed"]]
|
||
total_exp = len(printed_parts)
|
||
done_exp = 0
|
||
exp_lock = threading.Lock()
|
||
|
||
def export_one_part(p):
|
||
nonlocal done_exp
|
||
t0 = time.time()
|
||
fn = "%s/%s.step" % (OUT + "/parts_step", p["name"])
|
||
# 如果是非打印标准已有件且已存在，跳过冗余写盘
|
||
if not p["printed"] and os.path.exists(fn) and os.path.getsize(fn) > 1000:
|
||
pass
|
||
else:
|
||
write_step([(p["name"], p["shape"])], fn)
|
||
if p["printed"]:
|
||
stl = "%s/%s.stl" % (OUT + "/print_stl", p["name"])
|
||
cq.exporters.export(cq.Workplane(obj=p["shape"]), stl, exportType="STL")
|
||
with exp_lock:
|
||
done_exp += 1
|
||
dt = time.time() - t0
|
||
print(f" [文件导出 {done_exp}/{total_exp}] {p['name']}.step / .stl 导出完成 ({dt:.2f}s) ✓", flush=True)
|
||
return p["name"]
|
||
|
||
workers = 1
|
||
with ThreadPoolExecutor(max_workers=workers) as ex:
|
||
list(ex.map(export_one_part, PARTS))
|
||
|
||
print(f"-> 制造模型导出全部完成！已保存在 {OUT}/parts_step 与 {OUT}/print_stl\n", flush=True)
|
||
|
||
# 2. 多线程并行生成网页 3D Mesh
|
||
print("=" * 80, flush=True)
|
||
print("【第三阶段 3/5】多线程并行生成网页 3D 轻量化几何网格 (webapp/data/mesh_arm.json)...", flush=True)
|
||
print("=" * 80, flush=True)
|
||
|
||
done_mesh = 0
|
||
mesh_lock = threading.Lock()
|
||
total_parts = len(PARTS)
|
||
|
||
def mesh_one_part(p):
|
||
nonlocal done_mesh
|
||
t0 = time.time()
|
||
key = "motor" if p["name"].startswith("M") else ("coupl" if "联轴器" in p["name"] or "抱箍" in p["name"] else p["name"])
|
||
defl = 0.85 if p["name"].startswith("M") else (0.20 if key == "coupl" else 0.055)
|
||
v, t = mesh_of(p["shape"], defl)
|
||
with mesh_lock:
|
||
done_mesh += 1
|
||
n_v = len(v) // 3
|
||
n_t = len(t) // 3
|
||
dt = time.time() - t0
|
||
print(f" [网格细分 {done_mesh:2d}/{total_parts}] {p['name']:<14} 顶点: {n_v:5d} | 面片: {n_t:5d} ({dt:.2f}s) ✓", flush=True)
|
||
return (p, v, t)
|
||
|
||
with ThreadPoolExecutor(max_workers=workers) as ex:
|
||
mesh_results = list(ex.map(mesh_one_part, PARTS))
|
||
|
||
parts = []
|
||
for idx, (p, v, t) in enumerate(mesh_results):
|
||
parts.append(dict(name=p["name"], cn=p["cn"], v=v, t=t, color=p["color"],
|
||
printed=p["printed"], vol=round(p["vol"], 0), note=p["note"],
|
||
grp=GRP.get(p["name"], "root"), jaw=JAW.get(p["name"], 0.0),
|
||
ex=[round(x, 1) for x in explode_vec(p, JS, CENTS,
|
||
[sum(CENTS[k][i] for k in CENTS) / float(len(CENTS)) for i in range(3)])
|
||
],
|
||
idx=idx + 1))
|
||
|
||
joints = [dict(id=k, cn=JS[k].cn, rear=JS[k].rear, d=JS[k].d, xdir=JS[k].xdir, hub=JS[k].hub_face())
|
||
for k in JS]
|
||
d3 = lambda a, b: math.sqrt(sum((a[i] - b[i]) ** 2 for i in range(3)))
|
||
json.dump(dict(parts=parts, joints=joints,
|
||
layout=dict(ver=VERSION, it=ITER,
|
||
L1=round(d3(JS["J2"].rear, JS["J4"].rear), 1),
|
||
L2=round(d3(JS["J4"].rear, JS["J5"].rear), 1)),
|
||
measured=dict(M=M, C=C, HUB_FACE_Z=HUB_FACE_Z, CLAMP_SPAN=list(CLAMP_SPAN))),
|
||
open(DATA + "/mesh_arm.json", "w", encoding="utf-8"), ensure_ascii=False)
|
||
bom = [dict(件号=p["name"], 名称=p["cn"], 类型="3D打印" if p["printed"] else "已有/电机",
|
||
数量=1, 体积cm3=round(p["vol"] / 1000.0, 1),
|
||
质量g_PLA=round(p["vol"] * 1.24e-3, 1), 包络=p["bb"], 说明=p["note"]) for p in PARTS]
|
||
json.dump(bom, open(DOCS + "/bom.json", "w", encoding="utf-8"), ensure_ascii=False, indent=1)
|
||
print(f"-> 3D网格与BOM清单已保存至 webapp/data/mesh_arm.json 与 docs/bom.json ✓\n", flush=True)
|
||
return bom
|
||
|
||
|
||
def collide():
|
||
ps = [p for p in PARTS if p["vol"] > 1.0]
|
||
pairs = []
|
||
MOUNT_PAIRS = {
|
||
("P03_肩吊臂_螺旋体35%_墙5底5_竖打", "M1_J1"), ("P04_肩叉_螺旋体30%_墙5底5_竖打", "M1_J1"),
|
||
("P04_肩叉_螺旋体30%_墙5底5_竖打", "M2_J2"), ("P05_大臂旋转座_螺旋体30%_墙4底5_竖打", "M2_J2"),
|
||
("P05_大臂旋转座_螺旋体30%_墙4底5_竖打", "M3_J3"), ("P06_大臂骨架_螺旋体25%_墙4底5_竖打", "M3_J3"),
|
||
("P06_大臂骨架_螺旋体25%_墙4底5_竖打", "M4_J4"), ("P07_小臂骨架_螺旋体30%_墙5底5_竖打", "M4_J4"),
|
||
("P07_小臂骨架_螺旋体30%_墙5底5_竖打", "M5_J5"), ("P08_腕偏转座_螺旋体25%_墙4底5_竖打", "M5_J5"),
|
||
("P08_腕偏转座_螺旋体25%_墙4底5_竖打", "M6_J6"), ("P09_工具法兰_螺旋体30%_墙4底5_竖打", "M6_J6"),
|
||
("P01_A_立柱下段_三角形30%_墙4底5_竖打", "P01_B_立柱中段_三角形30%_墙4底5_竖打"), ("P01_B_立柱中段_三角形30%_墙4底5_竖打", "P01_C_立柱上段_三角形30%_墙4底5_竖打"),
|
||
("P01_A_立柱下段_三角形30%_墙4底5_竖打", "P02_Center_底座中核心_螺旋体30%_墙5底6_平打"),
|
||
("P02_Center_底座中核心_螺旋体30%_墙5底6_平打", "P02_Front_前向防翻力臂_螺旋体30%_墙4底5_平打"),
|
||
("P02_Center_底座中核心_螺旋体30%_墙5底6_平打", "P02_Rear_后向防翻力臂_螺旋体30%_墙4底5_平打"),
|
||
("P01_C_立柱上段_三角形30%_墙4底5_竖打", "P03_肩吊臂_螺旋体35%_墙5底5_竖打"),
|
||
}
|
||
for i in range(len(ps)):
|
||
for j in range(i + 1, len(ps)):
|
||
a, b = ps[i], ps[j]
|
||
if a["name"].startswith("M") and b["name"].startswith("M"):
|
||
continue
|
||
if (a["name"], b["name"]) in MOUNT_PAIRS or (b["name"], a["name"]) in MOUNT_PAIRS:
|
||
continue
|
||
av, bv = bb(a["shape"]), bb(b["shape"])
|
||
if any(av[1][k] < bv[0][k] - 0.05 or bv[1][k] < av[0][k] + 0.05 for k in range(3)):
|
||
continue
|
||
pairs.append((a, b))
|
||
|
||
print("=" * 80, flush=True)
|
||
print(f"【第四阶段 4/5】多线程精确布尔碰撞检测（从 {len(ps)*(len(ps)-1)//2} 对中初筛出 {len(pairs)} 组潜在包络相交对）...", flush=True)
|
||
print("=" * 80, flush=True)
|
||
|
||
done_pair = 0
|
||
pair_lock = threading.Lock()
|
||
|
||
def check_pair(pair):
|
||
nonlocal done_pair
|
||
a, b = pair
|
||
t0 = time.time()
|
||
v = common_vol(a["shape"], b["shape"])
|
||
with pair_lock:
|
||
done_pair += 1
|
||
status = f"干涉 {v:.1f} mm³ ❌" if v > 2.0 else "零干涉 (0.0 mm³) ✓"
|
||
print(f" [干涉检测 {done_pair:2d}/{len(pairs)}] {a['name']:<14} x {b['name']:<14} : {status} ({time.time()-t0:.3f}s)", flush=True)
|
||
if v > 2.0:
|
||
try:
|
||
c = BRepAlgoAPI_Common(a["shape"].wrapped, b["shape"].wrapped)
|
||
c.SetRunParallel(True)
|
||
c.Build()
|
||
cb = cq.Shape(c.Shape())
|
||
lo, hi = bb(cb)
|
||
loc = "@[%.0f %.0f %.0f..%.0f %.0f %.0f]" % (
|
||
lo[0], lo[1], lo[2], hi[0], hi[1], hi[2])
|
||
except Exception:
|
||
loc = "?"
|
||
return (a["name"], b["name"], round(v, 1), loc)
|
||
return None
|
||
|
||
rows = []
|
||
for pair in pairs:
|
||
res = check_pair(pair)
|
||
if res is not None:
|
||
rows.append(res)
|
||
|
||
rows.sort(key=lambda r: -r[2])
|
||
json.dump([r[:3] for r in rows], open(DOCS + "/collision.json", "w", encoding="utf-8"),
|
||
ensure_ascii=False)
|
||
if len(rows) == 0:
|
||
print(f"\n-> 静态碰撞干涉检测通过: 0 对干涉！全部 {len(pairs)} 组接触面对零碰撞！\n", flush=True)
|
||
else:
|
||
print(f"\n-> 发现 {len(rows)} 对干涉！\n", flush=True)
|
||
return rows
|
||
|
||
|
||
def axial_extent(j, shape):
|
||
lo, hi = bb(shape)
|
||
vals = []
|
||
for i in (0, 1):
|
||
for k in range(3):
|
||
p = [lo[0], lo[1], lo[2]]
|
||
p[k] = hi[k] if i else lo[k]
|
||
vals.append(sum((p[q] - j.rear[q]) * j.d[q] for q in range(3)))
|
||
return min(vals), max(vals)
|
||
|
||
|
||
def verify_interfaces(half, clamp, JS):
|
||
"""Numeric self-check of the derived joint stack, before trusting the renders."""
|
||
rows = []
|
||
for k, j in JS.items():
|
||
if k == "J5":
|
||
continue
|
||
parts = dict(j.place_hardware(half, clamp, k))
|
||
a = axial_extent(j, parts["%s_半联轴器A" % k])
|
||
b = axial_extent(j, parts["%s_半联轴器B" % k])
|
||
c = axial_extent(j, parts["%s_抱箍A" % k])
|
||
hub = j.at(HUB_FACE_Z)
|
||
rows.append(dict(jid=k, halfA=[round(x, 3) for x in a], halfB=[round(x, 3) for x in b],
|
||
clamp=[round(x, 3) for x in c], hub_face=round(HUB_FACE_Z, 3),
|
||
spigot_proud=round(b[1] - HUB_FACE_Z, 3),
|
||
clamp_clear=round(c[0] - COVER_Z, 3)))
|
||
return rows
|