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