接入ai

2026-08-14 10:26:28 +08:00
parent f051146486
commit 7d12459a32
44 changed files with 900211 additions and 15295 deletions
@@ -51,7 +51,7 @@ def scale_from_motor(
    reducer_axial_allowance_mm: float = 42.0,
    min_radial_scale: float = 0.45,
    max_radial_scale: float = 1.50,
-    min_axial_scale: float = 0.55,
+    min_axial_scale: float = 0.42,
    max_axial_scale: float = 1.80,
 ) -> HousingScale:
    target_inner_radius = motor_radial_diameter_mm / 2.0 + radial_clearance_mm
@@ -0,0 +1,255 @@
+from pathlib import Path
+import math
+
+import cadquery as cq
+
+
+AXIS = cq.Vector(0.0, 1.0, 0.0)
+
+
+def _point_on_xz(radius: float, angle_degrees: float, y: float) -> cq.Vector:
+    angle = math.radians(angle_degrees)
+    return cq.Vector(radius * math.cos(angle), y, radius * math.sin(angle))
+
+
+def _cylinder(radius: float, y0: float, length: float, x: float = 0.0, z: float = 0.0):
+    return cq.Solid.makeCylinder(radius, length, cq.Vector(x, y0, z), AXIS)
+
+
+def _ring(outer_radius: float, inner_radius: float, y0: float, length: float):
+    return _cylinder(outer_radius, y0, length).cut(_cylinder(inner_radius, y0, length))
+
+
+def _conical_ring(
+    outer_start: float,
+    outer_end: float,
+    inner_start: float,
+    inner_end: float,
+    y0: float,
+    length: float,
+):
+    outer = cq.Solid.makeCone(outer_start, outer_end, length, cq.Vector(0.0, y0, 0.0), AXIS)
+    inner = cq.Solid.makeCone(inner_start, inner_end, length, cq.Vector(0.0, y0, 0.0), AXIS)
+    return outer.cut(inner)
+
+
+def _sector_cut(angle_center: float, angle_width: float, y0: float, length: float, radius: float = 100.0):
+    start = math.radians(angle_center - angle_width / 2.0)
+    end = math.radians(angle_center + angle_width / 2.0)
+    points = [
+        (0.0, 0.0),
+        (radius * math.cos(start), radius * math.sin(start)),
+        (radius * math.cos(end), radius * math.sin(end)),
+    ]
+    plane = cq.Plane(origin=(0.0, y0, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, 1.0, 0.0))
+    return cq.Workplane(plane).polyline(points).close().extrude(length).val()
+
+
+def _annular_sector_cut(
+    angle_center: float,
+    angle_width: float,
+    inner_radius: float,
+    outer_radius: float,
+    y0: float,
+    length: float,
+    profile_fillet_radius: float = 0.0,
+    axial_fillet_radius: float = 0.0,
+):
+    start = math.radians(angle_center - angle_width / 2.0)
+    middle = math.radians(angle_center)
+    end = math.radians(angle_center + angle_width / 2.0)
+    inner_start = (inner_radius * math.cos(start), inner_radius * math.sin(start))
+    inner_middle = (inner_radius * math.cos(middle), inner_radius * math.sin(middle))
+    inner_end = (inner_radius * math.cos(end), inner_radius * math.sin(end))
+    outer_start = (outer_radius * math.cos(start), outer_radius * math.sin(start))
+    outer_middle = (outer_radius * math.cos(middle), outer_radius * math.sin(middle))
+    outer_end = (outer_radius * math.cos(end), outer_radius * math.sin(end))
+    plane = cq.Plane(origin=(0.0, y0, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, 1.0, 0.0))
+    cutter = (
+        cq.Workplane(plane)
+        .moveTo(*inner_start)
+        .lineTo(*outer_start)
+        .threePointArc(outer_middle, outer_end)
+        .lineTo(*inner_end)
+        .threePointArc(inner_middle, inner_start)
+        .close()
+        .extrude(length)
+    )
+    if profile_fillet_radius > 0.0:
+        # Round the corners of the annular profile (fillet axes parallel to Y).
+        cutter = cutter.edges("|Y").fillet(profile_fillet_radius)
+    if axial_fillet_radius > 0.0:
+        # Round only the straight radial edges at the two axial ends.  This
+        # produces the R10/R5/R2 window run-outs present in the source STEP.
+        end_edges = [
+            edge
+            for edge in cutter.edges("%LINE").vals()
+            if abs(edge.Center().y - y0) < 1.0e-6
+            or abs(edge.Center().y - (y0 + length)) < 1.0e-6
+        ]
+        cutter = cutter.newObject(end_edges).fillet(axial_fillet_radius)
+    return cutter.val()
+
+
+def _radial_bar(angle_degrees: float, y0: float, length: float, inner_radius: float, outer_radius: float, width: float):
+    radial_length = outer_radius - inner_radius
+    bar = (
+        cq.Workplane("XY")
+        .box(radial_length, length, width)
+        .translate(((inner_radius + outer_radius) / 2.0, y0 + length / 2.0, 0.0))
+    )
+    return bar.rotate((0.0, 0.0, 0.0), (0.0, 1.0, 0.0), -angle_degrees).val()
+
+
+def _rounded_radial_slot(angle_degrees: float, y0: float, length: float):
+    """A 40 mm wide radial window with R2 corners in its axial section."""
+    plane = cq.Plane(
+        origin=(40.0, y0 + length / 2.0, 0.0),
+        xDir=(0.0, 1.0, 0.0),
+        normal=(1.0, 0.0, 0.0),
+    )
+    slot = (
+        cq.Workplane(plane)
+        .rect(length - 4.0, 36.0)
+        .offset2D(2.0)
+        .extrude(42.0)
+        .rotate((0.0, 0.0, 0.0), (0.0, 1.0, 0.0), -angle_degrees)
+    )
+    return slot.val()
+
+
+def _support_blend(angle_degrees: float, mirrored: bool):
+    """One of the six R2 blends between the R64 and R29.2 support arcs."""
+    sharp = (-62.80715975198, 12.298808230444)
+    inner_tangent = (-62.1855700706093, 15.131254904777)
+    lobe_tangent = (-63.6707499640005, 16.8512614004542)
+    inner_center = (0.0, 0.0)
+    blend_center = (-61.6824120316291, 17.0669284278203)
+    lobe_center = (-34.6410161514, 20.0)
+
+    def transform(point):
+        x, z = point
+        if mirrored:
+            axis = math.radians(150.0)
+            ux, uz = math.cos(axis), math.sin(axis)
+            projection = x * ux + z * uz
+            x, z = 2.0 * projection * ux - x, 2.0 * projection * uz - z
+        angle = math.radians(angle_degrees)
+        return (
+            x * math.cos(angle) - z * math.sin(angle),
+            x * math.sin(angle) + z * math.cos(angle),
+        )
+
+    def arc_middle(center, start, end, radius):
+        ux = (start[0] - center[0]) / radius + (end[0] - center[0]) / radius
+        uz = (start[1] - center[1]) / radius + (end[1] - center[1]) / radius
+        scale = radius / math.hypot(ux, uz)
+        return center[0] + ux * scale, center[1] + uz * scale
+
+    points = [transform(point) for point in (sharp, inner_tangent, lobe_tangent)]
+    centers = [transform(point) for point in (inner_center, blend_center, lobe_center)]
+    plane = cq.Plane(origin=(0.0, 90.2, 0.0), xDir=(1.0, 0.0, 0.0), normal=(0.0, -1.0, 0.0))
+    return (
+        cq.Workplane(plane)
+        .moveTo(*points[0])
+        .threePointArc(arc_middle(centers[0], points[0], points[1], 64.0), points[1])
+        .threePointArc(arc_middle(centers[1], points[1], points[2], 2.0), points[2])
+        .threePointArc(arc_middle(centers[2], points[2], points[0], 29.2), points[0])
+        .close()
+        .extrude(10.0)
+        .val()
+    )
+
+
+def build():
+    # Front cylindrical shell and its smaller continuation.
+    part = cq.Workplane(obj=_ring(79.4, 74.4, -10.0, 22.0))
+    part = part.union(_ring(78.4, 74.4, 12.0, 43.2))
+
+    # Nine radial R2 holes through the front lip, spaced every 40 degrees.
+    for angle in (90.0, 50.0, 10.0, -30.0, -70.0, -110.0, -150.0, -190.0, -230.0):
+        start = _point_on_xz(72.0, angle, -5.0)
+        direction = _point_on_xz(1.0, angle, 0.0)
+        direction = cq.Vector(direction.x, 0.0, direction.z)
+        part = part.cut(cq.Solid.makeCylinder(2.0, 10.0, start, direction))
+
+    # Six long ventilation windows, 40-degree openings with 20-degree ribs.
+    for center in (-110.0, -50.0, 10.0, 70.0, 130.0, 190.0):
+        part = part.cut(
+            _annular_sector_cut(center, 40.0, 70.0, 82.0, 12.0, 40.0, axial_fillet_radius=10.0)
+        )
+
+    # Taper from the large front shell to the narrower middle shell.
+    part = part.union(_conical_ring(78.4, 73.2, 74.4, 69.2, 55.2, 20.0))
+    part = part.union(_ring(73.2, 60.0, 75.2, 5.0))
+
+    # Three small axial holes in the first shoulder ring.
+    for angle in (30.0, 150.0, 270.0):
+        p = _point_on_xz(64.0, angle, 75.2)
+        part = part.cut(cq.Solid.makeCylinder(2.0, 5.0, p, AXIS))
+
+    # Three-lobed support plate: a disk with three large circular openings.
+    support = cq.Workplane(obj=_ring(73.2, 64.0, 80.2, 10.0))
+    for x, z in ((34.6410161514, 20.0), (-34.6410161514, 20.0), (0.0, -40.0)):
+        support = support.cut(_cylinder(29.2, 80.2, 10.0, x, z))
+    part = part.union(support)
+
+    # Thin middle shell and its second, angularly shifted six-window pattern.
+    part = part.union(_ring(73.2, 69.2, 90.2, 30.0))
+    for center in (-150.0, -90.0, -30.0, 30.0, 90.0, 150.0):
+        part = part.cut(
+            _annular_sector_cut(center, 40.0, 65.0, 76.0, 90.2, 20.0, axial_fillet_radius=5.0)
+        )
+
+    # Rear shell is one continuous 2:7 taper.  Its inner cavity changes from
+    # a steep R69.2 -> R63.6 cone to the matching shallow taper at Y=125.8.
+    taper_outer = cq.Solid.makeCone(
+        73.2, 64.91428571428571, 29.0, cq.Vector(0.0, 120.2, 0.0), AXIS
+    )
+    taper_inner_a = cq.Solid.makeCone(69.2, 63.6, 5.6, cq.Vector(0.0, 120.2, 0.0), AXIS)
+    taper_inner_b = cq.Solid.makeCone(63.6, 59.2, 15.4, cq.Vector(0.0, 125.8, 0.0), AXIS)
+    part = part.union(taper_outer.cut(taper_inner_a).cut(taper_inner_b))
+    hub = cq.Workplane(obj=_ring(38.0, 26.0, 129.2, 4.0)).union(
+        _ring(38.0, 30.0, 133.2, 16.0)
+    )
+    part = part.union(hub)
+
+    # Stop 0.0001 mm before the coincident rear-plate face so OpenCascade
+    # keeps the six ribs in one valid solid.
+    for center in (30.0, 90.0, 150.0, 210.0, 270.0, 330.0):
+        part = part.cut(_rounded_radial_slot(center, 131.2, 9.9999))
+
+    # Central bore through the solid rear plate, then its six fan windows.
+    part = part.cut(_cylinder(30.0, 141.2, 8.0))
+    for center in (45.0, 105.0, 165.0, 225.0, 285.0, 345.0):
+        cutter = _annular_sector_cut(
+            center, 30.0, 38.0, 59.2, 141.2, 8.0, profile_fillet_radius=2.0
+        )
+        part = part.cut(cutter)
+
+    # These holes pass through both the end plate and the previously added hub.
+    for angle in (-90.0, -30.0, 30.0, 90.0, 150.0, 210.0):
+        p = _point_on_xz(34.0, angle, 141.2)
+        part = part.cut(cq.Solid.makeCylinder(1.81198, 8.0, p, AXIS))
+
+    # Add the small support blends last so they cannot interfere with fusing
+    # the face-connected rear shell and end plate.
+    for mirrored in (False, True):
+        for angle in (0.0, 120.0, 240.0):
+            part = part.union(_support_blend(angle, mirrored))
+
+    # Remove only the six 0.0001 mm run-out residuals after the complete part
+    # is connected.  This reaches the exact Y=141.2 boundary without causing
+    # the earlier coincident-face split into six solids.
+    for center in (30.0, 90.0, 150.0, 210.0, 270.0, 330.0):
+        full_slot = _rounded_radial_slot(center, 131.2, 10.0)
+        stable_slot = _rounded_radial_slot(center, 131.2, 9.9999)
+        part = part.cut(full_slot.cut(stable_slot))
+
+    return part
+
+
+if __name__ == "__main__":
+    output = Path(__file__).resolve().with_name("外壳框架.step")
+    cq.exporters.export(build(), str(output))
+    print(output)
@@ -0,0 +1,6 @@
+{
+  "platform_id": "actuator_v2_fixed_platform",
+  "motor_step": "../motors/3500_motor_part2_standard.step",
+  "housing_step": "../housings/actuator_v2_knee_abd_main_case_2.step",
+  "reference_assembly_step": "../references/actuator_v2_knee_abd_reference.step"
+}
@@ -1,14 +1,14 @@
 {
  "module_type": "planetary_joint_module",
-  "motor_step": "../../assets/motors/3500_motor_part2.step",
-  "housing_step": "../../assets/housings/generated_housing_baseline.step",
-  "reducer_requirement": "../reducers/simple_2k_h/simple_2kh_industrial_ratio_7p5_spur.json",
+  "platform_profile": "../../assets/platforms/actuator_v2_fixed_platform.json",
+  "reducer_requirement": "../reducers/simple_2k_h/simple_2kh_industrial_ratio_7p5_spur_compact.json",
  "placement_policy": "infer_then_write_editable_json",
  "motor_to_reducer_relation": "motor_output_to_sun_keyed_input",
  "housing_relation": "ring_fixed_to_housing",
  "joint_output": "carrier_output_shaft",
-  "output_extension_mm": 8.0,
-  "coupling_clearance_mm": 1.0,
+  "motor_placement_policy": "external_flush_input_end",
+  "output_extension_mm": 2.0,
+  "coupling_clearance_mm": 0.5,
  "input_shaft_insertion_depth_mm": 4.0,
  "motor_output_side": "axis_max",
  "axis_angle_tolerance_deg": 0.5,
@@ -1,15 +1,15 @@
 {
  "module_type": "planetary_joint_module",
-  "motor_step": "../../assets/motors/3500_motor_part2.step",
-  "housing_step": "../../assets/housings/generated_housing_baseline.step",
-  "reducer_requirement": "../reducers/simple_2k_h_cascade/simple_2kh_cascade_ratio_9_spur.json",
+  "platform_profile": "../../assets/platforms/actuator_v2_fixed_platform.json",
+  "reducer_requirement": "../reducers/simple_2k_h_cascade/simple_2kh_cascade_ratio_9_spur_compact.json",
  "placement_policy": "infer_then_write_editable_json",
  "motor_to_reducer_relation": "motor_output_to_s1_sun_input",
  "housing_relation": "stage_rings_fixed_to_housing",
  "joint_output": "s2_carrier_output",
+  "motor_placement_policy": "external_flush_input_end",
  "output_extension_mm": 2.0,
  "coupling_clearance_mm": 0.5,
-  "input_shaft_insertion_depth_mm": 1.0,
+  "input_shaft_insertion_depth_mm": 4.0,
  "motor_output_side": "axis_max",
  "axis_angle_tolerance_deg": 0.5,
  "axis_distance_tolerance_mm": 0.25,
@@ -0,0 +1,26 @@
+{
+  "target_ratio": 7.5,
+  "ratio_tolerance": 0.01,
+  "topology_family": "simple_2k_h",
+  "detail_level": "industrial_core",
+  "input": "sun",
+  "fixed": "ring",
+  "output": "carrier",
+  "tooth_form": "spur",
+  "planet_count_candidates": [3],
+  "module_candidates_mm": [0.3],
+  "pressure_angle_deg": 20.0,
+  "face_width_mm": 6.0,
+  "backlash_mm": 0.03,
+  "addendum_coeff": 1.0,
+  "clearance_coeff": 0.25,
+  "ring_rim_thickness_mm": 1.5,
+  "constraints": {
+    "max_outer_diameter_mm": 60.0,
+    "min_planet_neighbor_clearance_mm": 0.3,
+    "min_sun_teeth": 20,
+    "max_sun_teeth": 20,
+    "min_planet_teeth": 55,
+    "max_planet_teeth": 55
+  }
+}
@@ -0,0 +1,44 @@
+{
+  "target_ratio": 9.0,
+  "ratio_tolerance": 0.000001,
+  "topology_family": "simple_2k_h_cascade",
+  "tooth_form": "spur",
+  "planet_count_candidates": [3],
+  "module_candidates_mm": [0.5],
+  "pressure_angle_deg": 20.0,
+  "face_width_mm": 6.0,
+  "backlash_mm": 0.03,
+  "addendum_coeff": 1.0,
+  "clearance_coeff": 0.25,
+  "ring_rim_thickness_mm": 2.5,
+  "constraints": {
+    "max_outer_diameter_mm": 100.0,
+    "min_planet_neighbor_clearance_mm": 0.3,
+    "min_sun_teeth": 36,
+    "max_sun_teeth": 36,
+    "min_planet_teeth": 18,
+    "max_planet_teeth": 18
+  },
+  "stages": [
+    {
+      "stage_id": "s1",
+      "input": "sun",
+      "fixed": "ring",
+      "output": "carrier",
+      "planet_count_candidates": [3],
+      "module_candidates_mm": [0.5]
+    },
+    {
+      "stage_id": "s2",
+      "input": "sun",
+      "fixed": "ring",
+      "output": "carrier",
+      "planet_count_candidates": [3],
+      "module_candidates_mm": [0.5]
+    }
+  ],
+  "cascade": {
+    "coupling_policy": "stage_output_to_next_stage_input",
+    "stage_gap_mm": 2.0
+  }
+}