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src/core/mold_quality_inspector.py

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+"""
+铝泡沫模具质量检测模块
+
+提供分模面质量检测、模具结构合理性评估、生产可行性分析等功能
+"""
+
+from typing import Dict, List, Any, Tuple
+import numpy as np
+from OCC.Core.BRep import BRep_Tool
+from OCC.Core.BRepMesh import BRepMesh_IncrementalMesh
+from OCC.Core.TopExp import TopExp_Explorer
+from OCC.Core.TopAbs import TopAbs_FACE, TopAbs_EDGE
+from OCC.Core.BRepAdaptor import BRepAdaptor_Surface, BRepAdaptor_Curve
+from OCC.Core.Bnd import Bnd_Box
+from OCC.Core.BRepBndLib import brepbndlib_Add
+from OCC.Core.gp import gp_Dir
+
+from utils.logger import get_logger
+
+logger = get_logger(__name__)
+
+
+class AluminumFoamMoldQualityInspector:
+    """铝泡沫模具质量检测器"""
+    
+    def __init__(self):
+        self.quality_threshold = {
+            "smoothness_score": 80.0,
+            "continuity_score": 95.0,
+            "structure_score": 90.0
+        }
+    
+    def inspect_mold(self, cavity_data: Dict, params: Dict) -> Dict[str, Any]:
+        """
+        完整的模具质量检测
+        
+        Args:
+            cavity_data: 模具型腔数据
+            params: 分模参数
+        
+        Returns:
+            质量检测报告
+        """
+        logger.info("开始模具质量检测...")
+        
+        report = {
+            "surface_quality": self.inspect_surface_quality(cavity_data),
+            "structure_quality": self.inspect_structure_quality(cavity_data, params),
+            "feasibility": self.assess_production_feasibility(cavity_data, params),
+            "overall_score": 0.0,
+            "passed": False,
+            "warnings": [],
+            "recommendations": []
+        }
+        
+        # 计算综合评分
+        scores = [
+            report["surface_quality"]["overall_score"],
+            report["structure_quality"]["overall_score"],
+            report["feasibility"]["score"]
+        ]
+        report["overall_score"] = sum(scores) / len(scores)
+        report["passed"] = report["overall_score"] >= 80.0
+        
+        logger.info(f"质量检测完成，综合评分: {report['overall_score']:.1f}%")
+        
+        return report
+    
+    def inspect_surface_quality(self, cavity_data: Dict) -> Dict[str, Any]:
+        """
+        检测分模面质量
+        
+        检测项目：
+        - 平滑度：曲率分析
+        - 连续性：边界检查
+        - 完整性：破面检测
+        """
+        parting_line = cavity_data.get("parting_line", [])
+        parting_surface = cavity_data.get("parting_surface")
+        
+        # 1. 平滑度检测
+        smoothness = self._check_smoothness(parting_line)
+        
+        # 2. 连续性检测
+        continuity = self._check_continuity(parting_line)
+        
+        # 3. 完整性检测
+        completeness = self._check_completeness(cavity_data)
+        
+        overall = (smoothness["score"] * 0.4 + 
+                   continuity["score"] * 0.3 + 
+                   completeness["score"] * 0.3)
+        
+        return {
+            "smoothness": smoothness,
+            "continuity": continuity,
+            "completeness": completeness,
+            "overall_score": overall,
+            "passed": overall >= self.quality_threshold["smoothness_score"]
+        }
+    
+    def _check_smoothness(self, parting_line: List) -> Dict[str, Any]:
+        """检查分型线平滑度"""
+        if len(parting_line) < 3:
+            return {"score": 50.0, "issues": ["分型线点数不足"]}
+        
+        try:
+            points = np.array(parting_line)
+            
+            # 计算相邻线段角度变化
+            angle_changes = []
+            for i in range(1, len(points) - 1):
+                v1 = points[i] - points[i-1]
+                v2 = points[i+1] - points[i]
+                
+                len1, len2 = np.linalg.norm(v1), np.linalg.norm(v2)
+                if len1 > 0.001 and len2 > 0.001:
+                    cos_angle = np.clip(np.dot(v1, v2) / (len1 * len2), -1, 1)
+                    angle = np.degrees(np.arccos(cos_angle))
+                    angle_changes.append(angle)
+            
+            if not angle_changes:
+                return {"score": 70.0, "issues": []}
+            
+            # 计算角度变化统计
+            max_angle = max(angle_changes)
+            avg_angle = np.mean(angle_changes)
+            
+            # 评分：角度变化越小越好
+            score = max(0, 100 - avg_angle * 2 - max_angle * 0.5)
+            
+            issues = []
+            if max_angle > 30:
+                issues.append(f"存在尖角，最大角度变化: {max_angle:.1f}°")
+            if avg_angle > 15:
+                issues.append(f"分型线不够平滑，平均角度变化: {avg_angle:.1f}°")
+            
+            return {"score": score, "issues": issues, "max_angle": max_angle, "avg_angle": avg_angle}
+            
+        except Exception as e:
+            logger.warning(f"平滑度检测失败: {e}")
+            return {"score": 50.0, "issues": ["检测过程出错"]}
+    
+    def _check_continuity(self, parting_line: List) -> Dict[str, Any]:
+        """检查分型线连续性"""
+        if len(parting_line) < 2:
+            return {"score": 0.0, "issues": ["分型线不完整"]}
+        
+        try:
+            # 检查是否有明显的间隙
+            points = np.array(parting_line)
+            gaps = []
+            
+            for i in range(1, len(points)):
+                gap = np.linalg.norm(points[i] - points[i-1])
+                if gap > 10.0:  # 10mm 以上认为有间隙
+                    gaps.append(gap)
+            
+            # 评分
+            if not gaps:
+                score = 100.0
+                issues = []
+            elif len(gaps) == 1 and max(gaps) < 20:
+                score = 80.0
+                issues = [f"存在轻微间隙: {max(gaps):.1f}mm"]
+            else:
+                score = max(0, 100 - len(gaps) * 20)
+                issues = [f"存在 {len(gaps)} 处间隙"]
+            
+            return {"score": score, "issues": issues, "gap_count": len(gaps)}
+            
+        except Exception as e:
+            logger.warning(f"连续性检测失败: {e}")
+            return {"score": 50.0, "issues": ["检测过程出错"]}
+    
+    def _check_completeness(self, cavity_data: Dict) -> Dict[str, Any]:
+        """检查分模完整性"""
+        issues = []
+        
+        # 检查必要的组件是否存在
+        required_keys = ["cavity", "core", "parting_surface", "parting_line"]
+        missing = [k for k in required_keys if k not in cavity_data]
+        
+        if missing:
+            issues.append(f"缺少组件: {', '.join(missing)}")
+            return {"score": 0.0, "issues": issues}
+        
+        # 检查分型线点数
+        parting_line = cavity_data.get("parting_line", [])
+        if len(parting_line) < 4:
+            issues.append("分型线点数不足")
+            score = len(parting_line) * 20
+        else:
+            score = 100.0
+        
+        return {"score": score, "issues": issues}
+    
+    def inspect_structure_quality(self, cavity_data: Dict, params: Dict) -> Dict[str, Any]:
+        """
+        检测模具结构合理性
+        
+        检测项目：
+        - 模具尺寸
+        - 壁厚
+        - 拔模角
+        - 倒扣处理
+        """
+        analysis = cavity_data.get("analysis", {})
+        bbox = analysis.get("bounding_box", {}).get("dimensions", [0, 0, 0])
+        
+        issues = []
+        recommendations = []
+        
+        # 1. 模具尺寸检查
+        mold_size = cavity_data.get("mold_block")
+        if mold_size:
+            # 检查尺寸是否足够
+            min_dimension = min(bbox)
+            if min_dimension < 20:
+                issues.append("产品尺寸过小，可能影响模具强度")
+                recommendations.append("建议增加产品尺寸或使用嵌件")
+        
+        # 2. 拔模角检查
+        draft_angle = params.get("draft_angle", 0)
+        if draft_angle < 2.0:
+            issues.append("拔模角偏小，可能导致脱模困难")
+            recommendations.append("建议增大拔模角到 2-5°")
+        
+        # 3. 倒扣区域检查
+        undercut_regions = cavity_data.get("undercut_regions", [])
+        if undercut_regions:
+            issues.append(f"存在 {len(undercut_regions)} 个倒扣区域")
+            recommendations.append("建议添加滑块或斜顶机构")
+        
+        # 4. 铝泡沫特殊检查
+        foam_material = params.get("foam_material", "")
+        if foam_material:
+            # 检查排气系统需求
+            volume = analysis.get("volume", 0)
+            if volume > 50000000:  # > 50 cm³
+                issues.append("大型铝泡沫产品，需要加强排气系统")
+                recommendations.append("建议增加排气槽或排气针")
+        
+        # 评分
+        issue_count = len(issues)
+        score = max(0, 100 - issue_count * 15)
+        
+        return {
+            "score": score,
+            "issues": issues,
+            "recommendations": recommendations,
+            "overall_score": score,
+            "passed": score >= self.quality_threshold["structure_score"]
+        }
+    
+    def assess_production_feasibility(self, cavity_data: Dict, params: Dict) -> Dict[str, Any]:
+        """
+        评估生产可行性
+        
+        评估项目：
+        - 注塑压力
+        - 锁模力
+        - 成型周期
+        - 材料利用率
+        """
+        analysis = cavity_data.get("analysis", {})
+        
+        # 计算投影面积 (mm²)
+        bbox = analysis.get("bounding_box", {}).get("dimensions", [0, 0, 0])
+        projected_area = bbox[0] * bbox[1]  # X * Y
+        
+        # 体积 (mm³)
+        volume = analysis.get("volume", 0)
+        volume_cm3 = volume / 1000
+        
+        # 1. 注塑压力估算 (MPa)
+        injection_pressure = 30 + projected_area / 1000  # 简化估算
+        
+        # 2. 锁模力估算 (吨)
+        # 铝泡沫需要较低的压力
+        clamping_force_ton = projected_area * 0.0015  # 简化估算
+        
+        # 3. 成型周期估算 (秒)
+        # 铝泡沫成型周期较长
+        if volume_cm3 < 10:
+            cycle_time = 60
+        elif volume_cm3 < 50:
+            cycle_time = 90
+        elif volume_cm3 < 200:
+            cycle_time = 120
+        else:
+            cycle_time = 180
+        
+        # 4. 材料利用率
+        material_utilization = min(95, 85 + volume_cm3 / 10)
+        
+        # 评估结果
+        feasibility_items = []
+        
+        if injection_pressure < 100:
+            feasibility_items.append({
+                "item": "注塑压力",
+                "value": f"{injection_pressure:.1f} MPa",
+                "status": "ok",
+                "message": "压力在设备范围内"
+            })
+        else:
+            feasibility_items.append({
+                "item": "注塑压力",
+                "value": f"{injection_pressure:.1f} MPa",
+                "status": "warning",
+                "message": "压力较高，需要高压设备"
+            })
+        
+        if clamping_force_ton < 300:
+            feasibility_items.append({
+                "item": "锁模力",
+                "value": f"{clamping_force_ton:.1f} 吨",
+                "status": "ok",
+                "message": "锁模力在设备范围内"
+            })
+        else:
+            feasibility_items.append({
+                "item": "锁模力",
+                "value": f"{clamping_force_ton:.1f} 吨",
+                "status": "warning",
+                "message": "需要大型注塑机"
+            })
+        
+        feasibility_items.append({
+            "item": "成型周期",
+            "value": f"{cycle_time} 秒",
+            "status": "ok",
+            "message": "周期正常"
+        })
+        
+        feasibility_items.append({
+            "item": "材料利用率",
+            "value": f"{material_utilization:.1f}%",
+            "status": "ok",
+            "message": "材料利用率良好" if material_utilization > 80 else "材料利用率偏低"
+        })
+        
+        # 综合评分
+        ok_count = sum(1 for item in feasibility_items if item["status"] == "ok")
+        score = (ok_count / len(feasibility_items)) * 100
+        
+        return {
+            "items": feasibility_items,
+            "score": score,
+            "projected_area": f"{projected_area:.0f} mm²",
+            "volume": f"{volume_cm3:.1f} cm³",
+            "injection_pressure": f"{injection_pressure:.1f} MPa",
+            "clamping_force": f"{clamping_force_ton:.1f} 吨",
+            "cycle_time": f"{cycle_time} 秒",
+            "material_utilization": f"{material_utilization:.1f}%",
+            "passed": score >= 75.0
+        }
+    
+    def generate_quality_report(self, cavity_data: Dict, params: Dict) -> str:
+        """
+        生成质量检测报告文本
+        
+        Returns:
+            Markdown 格式的报告文本
+        """
+        report = self.inspect_mold(cavity_data, params)
+        
+        lines = [
+            "# 铝泡沫模具质量检测报告",
+            "",
+            f"**综合评分**: {report['overall_score']:.1f}%",
+            f"**检测结果**: {'✅ 通过' if report['passed'] else '❌ 未通过'}",
+            "",
+            "## 一、分模面质量",
+            "",
+            f"- 平滑度: {report['surface_quality']['smoothness']['score']:.1f}分",
+            f"- 连续性: {report['surface_quality']['continuity']['score']:.1f}分",
+            f"- 完整性: {report['surface_quality']['completeness']['score']:.1f}分",
+            "",
+        ]
+        
+        # 添加问题列表
+        if report["surface_quality"]["smoothness"].get("issues"):
+            lines.append("**发现的问题**:")
+            for issue in report["surface_quality"]["smoothness"]["issues"]:
+                lines.append(f"- {issue}")
+            lines.append("")
+        
+        # 添加结构质量
+        lines.extend([
+            "## 二、模具结构质量",
+            "",
+            f"- 评分: {report['structure_quality']['score']:.1f}分",
+            "",
+        ])
+        
+        if report["structure_quality"].get("issues"):
+            lines.append("**结构问题**:")
+            for issue in report["structure_quality"]["issues"]:
+                lines.append(f"- {issue}")
+            lines.append("")
+        
+        if report["structure_quality"].get("recommendations"):
+            lines.append("**改进建议**:")
+            for rec in report["structure_quality"]["recommendations"]:
+                lines.append(f"- {rec}")
+            lines.append("")
+        
+        # 添加生产可行性
+        lines.extend([
+            "## 三、生产可行性",
+            "",
+        ])
+        
+        for item in report["feasibility"]["items"]:
+            status_icon = "✅" if item["status"] == "ok" else "⚠️"
+            lines.append(f"{status_icon} **{item['item']}**: {item['value']} - {item['message']}")
+        
+        lines.append("")
+        
+        return "\n".join(lines)