x

src/core/base_mold_generator.py

@@ -398,14 +398,42 @@ class BaseMoldGenerator:
                 core = self._subtract_product_from_plate(b_plate, shape, "B板(回退)")
                 return cavity or a_plate, core or b_plate
 
-            logger.warning("回退方案也失败，使用最简方法")
-            cavity_op = BRepAlgoAPI_Cut(mold_block, shape)
-            cavity = cavity_op.Shape() if cavity_op.IsDone() else mold_block
-            return cavity, shape
+            logger.warning("回退方案也失败，使用最简A/B板切分（避免返回产品本体）")
+            center_z = (zmin + zmax) / 2
+            margin = 20
+            a_plate = BRepPrimAPI_MakeBox(
+                gp_Pnt(xmin - margin, ymin - margin, center_z),
+                gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
+            ).Shape()
+            b_plate = BRepPrimAPI_MakeBox(
+                gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
+                gp_Pnt(xmax + margin, ymax + margin, center_z)
+            ).Shape()
+
+            cavity = self._subtract_product_from_plate(a_plate, shape, "A板(最简)")
+            core = self._subtract_product_from_plate(b_plate, shape, "B板(最简)")
+            return cavity or a_plate, core or b_plate
 
         except Exception as e:
             logger.error(f"分模回退方案失败: {e}")
-            return shape, shape
+            # 最后兜底也返回模具半板，而不是产品本体，避免预览出现“三份产品”
+            try:
+                bbox = Bnd_Box()
+                brepbndlib.Add(shape, bbox)
+                xmin, ymin, zmin, xmax, ymax, zmax = bbox.Get()
+                center_z = (zmin + zmax) / 2
+                margin = 20
+                a_plate = BRepPrimAPI_MakeBox(
+                    gp_Pnt(xmin - margin, ymin - margin, center_z),
+                    gp_Pnt(xmax + margin, ymax + margin, zmax + margin)
+                ).Shape()
+                b_plate = BRepPrimAPI_MakeBox(
+                    gp_Pnt(xmin - margin, ymin - margin, zmin - margin),
+                    gp_Pnt(xmax + margin, ymax + margin, center_z)
+                ).Shape()
+                return a_plate, b_plate
+            except Exception:
+                return shape, shape
 
     def detect_insert_regions(self, shape: Any, analysis: Dict,
                                depth_threshold: float = 30.0,

src/core/multi_scheme_planner.py

@@ -113,6 +113,7 @@ class MultiSchemeMoldPlanner:
         undercut_regions = generator._build_undercut_regions(
             side_action_result.get("undercut_analysis", {})
         )
+        mold_structure = self._determine_mold_structure(analysis, undercut_regions)
 
         scaled_shape = generator._apply_shrinkage_compensation(shape)
         drafted_shape = generator._apply_draft_angles(scaled_shape, parting_surface)
@@ -150,6 +151,9 @@ class MultiSchemeMoldPlanner:
         cavity_data["metadata"]["scheme_reason"] = candidate["reason"]
         cavity_data["metadata"]["scheme_offset_ratio"] = candidate.get("offset_ratio", 0.0)
         cavity_data["metadata"]["scheme_offset_label"] = candidate.get("offset_label", "中面")
+        cavity_data["metadata"]["mold_structure_type"] = mold_structure["mold_structure_type"]
+        cavity_data["metadata"]["core_required"] = mold_structure["core_required"]
+        cavity_data["metadata"]["structure_decision_reason"] = mold_structure["decision_reason"]
 
         return {
             "scheme_id": candidate["scheme_id"],
@@ -161,6 +165,9 @@ class MultiSchemeMoldPlanner:
             "normal_alignment_score": candidate.get("normal_alignment_score"),
             "offset_ratio": candidate.get("offset_ratio", 0.0),
             "offset_label": candidate.get("offset_label", "中面"),
+            "mold_structure_type": mold_structure["mold_structure_type"],
+            "core_required": mold_structure["core_required"],
+            "decision_reason": mold_structure["decision_reason"],
             "parting": {
                 "axis": candidate["axis"],
                 "direction": parting_direction,
@@ -273,3 +280,40 @@ class MultiSchemeMoldPlanner:
             axis: round(value / total * 100, 2)
             for axis, value in stats.items()
         }
+
+    @staticmethod
+    def _determine_mold_structure(analysis: Dict[str, Any], undercut_regions: List[Dict[str, Any]]) -> Dict[str, Any]:
+        """
+        判定是否需要独立模芯。
+        规则为工程启发式：
+        - 实心度高 + 平均厚度占比高 + 无明显倒扣：倾向两板半腔（无独立凸芯）
+        - 否则：采用型腔+模芯结构
+        """
+        dims = analysis.get("bounding_box", {}).get("dimensions", [0.0, 0.0, 0.0])
+        valid_dims = [float(d) for d in dims if float(d) > 1e-6]
+        min_dim = min(valid_dims) if valid_dims else 1.0
+        bbox_volume = 1.0
+        for dim in valid_dims[:3]:
+            bbox_volume *= dim
+        if bbox_volume <= 0:
+            bbox_volume = 1.0
+
+        volume = float(analysis.get("volume", 0.0))
+        surface_area = float(analysis.get("surface_area", 0.0))
+        solid_ratio = max(0.0, min(volume / bbox_volume, 1.0))
+        avg_wall = (2.0 * volume / surface_area) if surface_area > 1e-6 else min_dim
+        wall_ratio = max(0.0, min(avg_wall / max(min_dim, 1e-6), 1.0))
+        undercut_count = len(undercut_regions or [])
+
+        core_required = not (solid_ratio > 0.62 and wall_ratio > 0.38 and undercut_count == 0)
+        mold_structure_type = "cavity_core" if core_required else "two_half_cavity"
+        decision_reason = (
+            f"solid_ratio={solid_ratio:.2f}, wall_ratio={wall_ratio:.2f}, "
+            f"undercut_count={undercut_count}"
+        )
+
+        return {
+            "core_required": core_required,
+            "mold_structure_type": mold_structure_type,
+            "decision_reason": decision_reason,
+        }

src/core/parting_scheme_scorer.py

@@ -1,4 +1,4 @@
-from typing import Dict, Any, List
+from typing import Dict, Any, List, Optional, Tuple
 import re
 
 
@@ -19,8 +19,19 @@ class PartingSchemeScorer:
             )
 
             scored_scheme = dict(scheme)
+            fallback = self._assess_fallback(scored_scheme, score_breakdown)
             scored_scheme["score_breakdown"] = score_breakdown
             scored_scheme["score"] = total_score
+            scored_scheme["is_fallback"] = fallback["is_fallback"]
+            scored_scheme["fallback_reason"] = fallback["fallback_reason"]
+            scored_scheme["dfm_violations"] = self._build_dfm_violations(scored_scheme)
+            scored_scheme["dfm_violation_count"] = len(scored_scheme["dfm_violations"])
+            scored_scheme["confidence_score"] = self._build_confidence_score(
+                total_score,
+                score_breakdown,
+                fallback["is_fallback"],
+                scored_scheme["dfm_violation_count"],
+            )
             scored_scheme["summary"] = self._build_summary(scored_scheme)
             scored.append(scored_scheme)
 
@@ -95,6 +106,98 @@ class PartingSchemeScorer:
             "risk": round(risk, 2),
         }
 
+    def _assess_fallback(self, scheme: Dict[str, Any], score_breakdown: Dict[str, float]) -> Dict[str, Any]:
+        cavity_data = scheme.get("cavity_data", {})
+        mold_cavities = cavity_data.get("mold_cavities", {})
+        cavity_mesh = mold_cavities.get("cavity", {})
+        core_mesh = mold_cavities.get("core", {})
+        core_required = bool(scheme.get("core_required", True))
+
+        cavity_v = int(cavity_mesh.get("vertex_count", 0) or 0)
+        core_v = int(core_mesh.get("vertex_count", 0) or 0)
+        reasons = []
+
+        if cavity_v <= 0:
+            reasons.append("型腔网格为空")
+        if core_required and core_v <= 0:
+            reasons.append("型芯网格为空")
+        if float(score_breakdown.get("manufacturability", 0.0)) < 70.0:
+            reasons.append("可制造性评分偏低")
+
+        return {
+            "is_fallback": len(reasons) > 0,
+            "fallback_reason": "；".join(reasons) if reasons else "",
+        }
+
+    @staticmethod
+    def _build_confidence_score(
+        total_score: float,
+        score_breakdown: Dict[str, float],
+        is_fallback: bool,
+        dfm_violation_count: int = 0,
+    ) -> float:
+        confidence = float(total_score)
+        confidence += (float(score_breakdown.get("manufacturability", 0.0)) - 70.0) * 0.25
+        confidence += (float(score_breakdown.get("parting_quality", 0.0)) - 70.0) * 0.15
+        if is_fallback:
+            confidence -= 18.0
+        confidence -= min(max(dfm_violation_count, 0) * 3.0, 15.0)
+        return round(max(20.0, min(99.0, confidence)), 2)
+
+    def _build_dfm_violations(self, scheme: Dict[str, Any]) -> List[Dict[str, str]]:
+        cavity_data = scheme.get("cavity_data", {})
+        manufacturing_info = cavity_data.get("manufacturing_info", {})
+        key_info = scheme.get("key_info", {})
+        geometric = key_info.get("geometric_characteristics", {})
+        quality = key_info.get("quality_considerations", {})
+        metadata = cavity_data.get("metadata", {})
+
+        violations: List[Dict[str, str]] = []
+
+        wall_min, wall_max = self._parse_wall_range(
+            geometric.get("wall_thickness_range", "")
+        )
+        if wall_min is not None and wall_min < 1.2:
+            violations.append({
+                "rule": "最小壁厚",
+                "level": "high",
+                "message": f"最小壁厚 {wall_min:.2f}mm 偏薄，可能导致短射/强度不足",
+            })
+        if wall_max is not None and wall_max > 6.0:
+            violations.append({
+                "rule": "最大壁厚",
+                "level": "medium",
+                "message": f"最大壁厚 {wall_max:.2f}mm 偏厚，存在缩痕与冷却不均风险",
+            })
+
+        draft_angle = self._parse_first_number(metadata.get("draft_angle"))
+        if draft_angle and draft_angle < 1.0:
+            violations.append({
+                "rule": "拔模角",
+                "level": "medium",
+                "message": f"拔模角 {draft_angle:.2f}° 偏小，脱模阻力较大",
+            })
+
+        warpage = str(quality.get("warpage_risk", "")).lower()
+        if "high" in warpage or "高" in warpage:
+            violations.append({
+                "rule": "翘曲风险",
+                "level": "high",
+                "message": "当前方案翘曲风险高，建议优化壁厚与浇口位置",
+            })
+
+        clamping_force = self._parse_first_number(
+            manufacturing_info.get("estimated_clamping_force")
+        )
+        if clamping_force > 1200:
+            violations.append({
+                "rule": "锁模力",
+                "level": "medium",
+                "message": f"预估锁模力 {clamping_force:.0f} 吨，设备适配窗口较窄",
+            })
+
+        return violations
+
     def _build_summary(self, scheme: Dict[str, Any]) -> str:
         cavity_data = scheme.get("cavity_data", {})
         quality_checks = cavity_data.get("quality_checks", {})
@@ -106,8 +209,10 @@ class PartingSchemeScorer:
         axis = scheme.get("parting", {}).get("axis", "Z")
         offset_label = scheme.get("offset_label", "中面")
         clamping_force = manufacturing_info.get("estimated_clamping_force", "自动计算")
+        structure_type = scheme.get("mold_structure_type", "cavity_core")
+        structure_text = "型腔+模芯" if structure_type == "cavity_core" else "两板半腔(无独立模芯)"
         return (
-            f"{axis} 轴开模，分型面位置 {offset_label}，倒扣 {undercut_count} 处，"
+            f"{axis} 轴开模，结构 {structure_text}，分型面位置 {offset_label}，倒扣 {undercut_count} 处，"
             f"滑块 {slider_count} 组，斜顶 {lifter_count} 组，"
             f"预估锁模力 {clamping_force}"
         )
@@ -127,3 +232,15 @@ class PartingSchemeScorer:
             return 0.0
         matches = re.findall(r"\d+(?:\.\d+)?", str(value))
         return float(matches[0]) if matches else 0.0
+
+    @staticmethod
+    def _parse_wall_range(value: Any) -> Tuple[Optional[float], Optional[float]]:
+        if value is None:
+            return None, None
+        nums = re.findall(r"\d+(?:\.\d+)?", str(value))
+        if not nums:
+            return None, None
+        if len(nums) == 1:
+            v = float(nums[0])
+            return v, v
+        return float(nums[0]), float(nums[1])