x

src/api/routes.py

@@ -12,6 +12,9 @@ from core.geometry_analyzer import GeometryAnalyzer
 from utils.file_handler import FileHandler
 from utils.html_generator import HTMLGenerator
 from services.storage_integration_rustfs import StorageIntegrationService
+from services.redis_task_manager import redis_task_manager
+from services.processing_service import processing_service
+from services.task_query_service import TaskQueryService
 from database.database import get_db_session
 from utils.logger import get_logger
 from sqlalchemy.ext.asyncio import AsyncSession
@@ -58,10 +61,12 @@ tasks = {}
 @router.get("/health")
 @router.post("/health")
 async def health():
+    task_count = await redis_task_manager.get_task_count()
     return {
         "status": "healthy",
         "pythonocc": True,
-        "total_tasks": len(tasks)
+        "total_tasks": task_count,
+        "redis_connected": redis_task_manager.is_connected,
     }
 
 
@@ -97,8 +102,8 @@ async def upload_stp(
     # 创建处理任务记录
     await storage_service.create_processing_task(db_session, task_id, stp_file.id)
 
-    # 创建内存任务记录
-    tasks[task_id] = create_task_info(
+    # 创建任务记录（Redis 为主，内存为兼容回退）
+    task_info = create_task_info(
         task_id=task_id,
         status=ProcessingStatus.PROCESSING,
         filename=file.filename,
@@ -106,9 +111,14 @@ async def upload_stp(
         file_size=file_size,
         upload_time=str(datetime.now())
     )
+    await redis_task_manager.set_task(task_id, task_info)
+    tasks[task_id] = task_info
 
-    # 后台处理（包含数据库存储）
-    background_tasks.add_task(process_file_with_storage, task_id, file_path, stp_file.id, db_session, material)
+    # 后台处理（统一走 ProcessingService，使用独立数据库会话）
+    background_tasks.add_task(
+        processing_service.process_file_with_storage,
+        task_id, file_path, stp_file.id, material
+    )
 
     return {
         "task_id": task_id,
@@ -134,99 +144,12 @@ async def get_status(task_id: str, db_session: AsyncSession = Depends(get_db_ses
     结构与内存任务保持尽量一致，便于前端集中展示总结性信息。
     """
     try:
-        # 1. 内存任务（进行中的任务）
+        task_view = await TaskQueryService.get_task_view(db_session, task_id)
+        if task_view is None:
+            # 兼容老的仅内存任务
             if task_id in tasks:
-            task = tasks[task_id]
-            logger.info(f"返回内存任务状态：{task_id} - {task['status']}")
-            logger.info(f"内存任务 analysis_result: {task.get('analysis_result', 'None')}")
-            logger.info(f"内存任务 html_file: {task.get('html_file', 'None')}")
-            return task
-
-        # 2. 持久化任务（已完成/失败，或服务重启后的任务）
-        from sqlalchemy import select
-        from models.database import ProcessingTask, STPFile, GeometryData, MeshData, MoldCavityData
-        storage_service = StorageIntegrationService()
-
-        # 查询任务和文件元数据
-        result = await db_session.execute(
-            select(ProcessingTask, STPFile)
-            .join(STPFile, ProcessingTask.stp_file_id == STPFile.id)
-            .where(ProcessingTask.task_id == task_id)
-        )
-        row = result.first()
-        if not row:
+                return tasks[task_id]
             raise HTTPException(404, "任务不存在")
-
-        processing_task, stp_file = row
-
-        # 从 RustFS 取几何 / 型腔 / 网格详细 JSON（小量数据，便于前端展示汇总）
-        try:
-            file_with_data = await storage_service.get_stp_file_with_data(
-                db_session, stp_file_id=stp_file.id
-            )
-        except Exception as e:
-            logger.error(f"获取文件数据失败: {e}")
-            file_with_data = {}
-
-        geometry_json: Optional[Dict[str, Any]] = None
-        if file_with_data.get("geometry_data"):
-            geo_raw = file_with_data["geometry_data"]
-            if isinstance(geo_raw, dict):
-                if "geometry_data" in geo_raw:
-                    geometry_json = geo_raw["geometry_data"]
-                else:
-                    geometry_json = geo_raw
-
-        cavity_json: Optional[Dict[str, Any]] = file_with_data.get("mold_cavity_data")
-        features_json: List[Dict[str, Any]] = file_with_data.get("features", [])
-        recommendations_json: List[Dict[str, Any]] = file_with_data.get("recommendations", [])
-
-        # 组装网格摘要
-        mesh_summary = None
-        mesh_record = await db_session.execute(
-            select(MeshData).where(MeshData.stp_file_id == stp_file.id)
-        )
-        mesh_record = mesh_record.scalar_one_or_none()
-        if mesh_record:
-            mesh_summary = {
-                "vertex_count": mesh_record.vertex_count,
-                "face_count": mesh_record.face_count,
-                "point_count": mesh_record.point_count,
-                "quality": mesh_record.quality,
-            }
-
-        # 构造与内存任务兼容的任务视图
-        task_view = {
-            "task_id": processing_task.task_id,
-            "status": processing_task.status,
-            "filename": stp_file.original_filename if stp_file else "",
-            "file_path": stp_file.file_path or "",
-            "file_size": stp_file.file_size if stp_file else 0,
-            "upload_time": processing_task.created_time.isoformat()
-            if processing_task.created_time
-            else "",
-            "completed_at": processing_task.completed_time.isoformat()
-            if processing_task.completed_time
-            else "",
-            "geometry_data": geometry_json,
-            "key_info": cavity_json,
-            "cavity_data": cavity_json,
-            "mesh_summary": mesh_summary,
-            "analysis_result": {
-                "geometry_data": geometry_json,
-                "detected_features": features_json,
-                "design_recommendations": recommendations_json,
-                "quality_metrics": {
-                    "volume_utilization": file_with_data.get("analysis_metrics", {}).get("volume_utilization", 0),
-                    "topology_complexity": file_with_data.get("analysis_metrics", {}).get("topology_complexity", 0),
-                    "wall_uniformity": file_with_data.get("analysis_metrics", {}).get("wall_uniformity", 0)
-                },
-                "analysis_summary": file_with_data.get("analysis_metrics", {}).get("analysis_summary", "分析完成")
-            } if geometry_json or features_json or recommendations_json else None,
-            "error": processing_task.error_message or stp_file.error_message or None,
-        }
-
-        logger.info(f"返回持久化任务状态: {task_id} - {processing_task.status}")
         return task_view
     except HTTPException:
         raise
@@ -239,9 +162,12 @@ async def get_status(task_id: str, db_session: AsyncSession = Depends(get_db_ses
 @router.post("/debug/tasks")
 async def debug_tasks():
     """调试接口：查看所有任务"""
+    all_tasks = await redis_task_manager.get_all_tasks()
     return {
-        "total_tasks": len(tasks),
-        "tasks": tasks
+        "total_tasks": len(all_tasks),
+        "tasks": all_tasks,
+        "redis_connected": redis_task_manager.is_connected,
+        "memory_fallback_tasks": len(tasks),
     }
 
 

src/core/aluminum_foam_mold.py

@@ -28,6 +28,7 @@ from OCC.Core.BRepGProp import brepgprop
 from models.schemas import create_mold_cavity_data, create_mold_key_info
 from utils.logger import get_logger
 from core.base_mold_generator import BaseMoldGenerator
+from core.side_action_designer import SideActionDesigner
 
 logger = get_logger(__name__)
 
@@ -102,6 +103,7 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
         self.cavity_count = 1
         self.parting_precision = 0.1
         self.cavity_match_rate = 95.0
+        self.side_action_designer = SideActionDesigner()
 
     def set_foam_material(self, material: str):
         """设置铝泡沫材料"""
@@ -147,8 +149,17 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
             parting_result = self._detect_parting_surfaces(product_shape, analysis)
             primary_parting_surface = parting_result["primary_surface"]
             primary_parting_line = parting_result["primary_line"]
+            primary_parting_direction = parting_result["primary_direction"]
 
-            undercut_regions = self._detect_undercut_regions(product_shape, primary_parting_surface)
+            side_action_result = self.side_action_designer.analyze_and_design(
+                shape=product_shape,
+                parting_direction=primary_parting_direction,
+                mold_size=self._calculate_mold_size(analysis),
+                parting_surface=primary_parting_surface,
+            )
+            undercut_regions = self._build_undercut_regions(
+                side_action_result.get("undercut_analysis", {})
+            )
 
             scaled_shape = self._apply_shrinkage_compensation(product_shape)
 
@@ -170,6 +181,7 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
                 "mold_block": mold_block,
                 "analysis": analysis,
                 "undercut_regions": undercut_regions,
+                "side_actions": side_action_result,
                 "parting_surfaces": parting_result,
                 "material": self.foam_material,
                 "shrinkage_applied": self.shrinkage_rate,
@@ -224,6 +236,7 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
             },
             "quality_checks": {
                 "undercut_regions": cavity_data.get("undercut_regions", []),
+                "side_actions": cavity_data.get("side_actions", {}),
                 "parting_line_smoothness": self._assess_parting_line_smoothness(
                     cavity_data.get("parting_line", [])
                 )
@@ -265,6 +278,7 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
             "quality_considerations": {
                 "undercut_count": len(cavity_data.get("undercut_regions", [])),
                 "undercut_regions": cavity_data.get("undercut_regions", []),
+                "side_action_summary": cavity_data.get("side_actions", {}).get("summary", {}),
                 "sink_mark_risk": self._identify_sink_mark_risk(analysis),
                 "warpage_risk": self._assess_warpage_risk(analysis),
                 "venting_requirement": self._assess_venting_requirement(analysis)
@@ -278,130 +292,27 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
     def _analyze_product_geometry(self, shape: Any) -> Dict[str, Any]:
         """分析产品几何属性（扩展基类版本，增加法向量统计）"""
         result = super()._analyze_product_geometry(shape)
-        result["normal_statistics"] = self._analyze_face_normals(shape)
+        result["normal_statistics"] = self._analyze_parting_direction(shape)
         return result
 
     def _split_cavity_core(self, shape: Any, parting_surface: Any) -> Tuple[Any, Any]:
         """分离型腔和型芯（铝泡沫使用更大余量）"""
         return super()._split_cavity_core(shape, parting_surface, margin=25)
 
-    def _analyze_face_normals(self, shape: Any) -> Dict[str, Any]:
-        """
-        改进的法向量分析 - 使用高斯权重和多点采样
-        """
-        face_normals = []
-        face_centers = []
-        face_areas = []
-
-        explorer = TopExp_Explorer(shape, TopAbs_FACE)
-
-        while explorer.More():
-            face = TopoDS_Face(explorer.Current())
-            try:
-                surface = BRepAdaptor_Surface(face)
-
-                u_min, u_max = surface.FirstUParameter(), surface.LastUParameter()
-                v_min, v_max = surface.FirstVParameter(), surface.LastVParameter()
-
-                sample_points = 4
-                normal_sum = np.array([0.0, 0.0, 0.0])
-
-                for i in range(sample_points):
-                    for j in range(sample_points):
-                        u = u_min + (u_max - u_min) * i / (sample_points - 1) if sample_points > 1 else (u_min + u_max) / 2
-                        v = v_min + (v_max - v_min) * j / (sample_points - 1) if sample_points > 1 else (v_min + v_max) / 2
-
-                        if surface.GetType() == 0:
-                            normal = surface.Plane().Position().Direction()
-                            normal_sum += np.array([normal.X(), normal.Y(), normal.Z()])
-                            break
-                    if surface.GetType() == 0:
-                        break
-
-                bbox = Bnd_Box()
-                brepbndlib_Add(face, bbox)
-                center = bbox.Center()
-
-                face_props = GProp_GProps()
-                brepgprop.SurfaceProperties(face, face_props)
-                area = face_props.Mass()
-
-                length = np.linalg.norm(normal_sum)
-                if length > 0.001:
-                    normal_sum /= length
-
-                face_normals.append(normal_sum)
-                face_centers.append([center.X(), center.Y(), center.Z()])
-                face_areas.append(area)
-
-            except Exception as e:
-                logger.debug(f"面分析失败: {e}")
-
-            explorer.Next()
-
-        if not face_normals:
-            return {
-                "primary_direction": [0, 0, 1],
-                "confidence": 0.5,
-                "face_count": 0
-            }
-
-        total_area = sum(face_areas)
-        weighted_normal = np.array([0.0, 0.0, 0.0])
-
-        for i, normal in enumerate(face_normals):
-            weight = face_areas[i] / total_area if total_area > 0 else 1.0 / len(face_normals)
-            weighted_normal += normal * weight
-
-        length = np.linalg.norm(weighted_normal)
-        if length > 0.001:
-            weighted_normal /= length
-
-        dot_products = []
-        for normal in face_normals:
-            dot = np.dot(normal, weighted_normal)
-            dot_products.append(abs(dot))
-
-        confidence = np.mean(dot_products) if dot_products else 0.5
-
-        return {
-            "primary_direction": weighted_normal.tolist(),
-            "confidence": float(confidence),
-            "face_count": len(face_normals),
-            "normal_distribution": face_normals
-        }
-
     def _detect_parting_surfaces(self, shape: Any, analysis: Dict) -> Dict[str, Any]:
         """
         检测分型面（支持多分型面）
         """
-        if self.ai_parting_detector is not None:
-            try:
-                ai_result = self.ai_parting_detector.detect(shape, analysis)
-                if ai_result:
-                    return self._create_parting_surface_from_ai(ai_result, analysis, shape)
-            except Exception as e:
-                logger.warning(f"AI 分型面检测失败: {e}")
+        primary_parting = self._detect_primary_parting(shape, analysis)
+        parting_surface = primary_parting["surface"]
+        parting_line = self.optimize_parting_line(primary_parting["line"])
+        primary_direction = primary_parting["direction"]
 
-        normal_stats = analysis.get("normal_statistics", {})
-        primary_direction = normal_stats.get("primary_direction", [0, 0, 1])
+        additional_surfaces = []
 
         bbox = analysis["bounding_box"]
         center = bbox["center"]
 
-        dir_obj = gp_Dir(primary_direction[0], primary_direction[1], primary_direction[2])
-        parting_plane = gp_Pln(gp_Pnt(center[0], center[1], center[2]), dir_obj)
-
-        try:
-            parting_surface = BRepBuilderAPI_MakeFace(parting_plane).Face()
-        except Exception:
-            parting_plane = gp_Pln(gp_Pnt(0, 0, center[2]), gp_Dir(0, 0, 1))
-            parting_surface = BRepBuilderAPI_MakeFace(parting_plane).Face()
-
-        parting_line = self._calculate_parting_line(shape, parting_surface)
-
-        additional_surfaces = []
-
         dims = bbox["dimensions"]
         max_dim = max(dims)
         min_dim = min(dims)
@@ -422,59 +333,29 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
             "primary_surface": parting_surface,
             "primary_line": parting_line,
             "primary_direction": primary_direction,
-            "confidence": normal_stats.get("confidence", 0.5),
+            "confidence": primary_parting["confidence"],
+            "method": primary_parting["method"],
             "additional_surfaces": additional_surfaces,
             "surface_count": 1 + len(additional_surfaces)
         }
 
-    def _detect_undercut_regions(self, shape: Any, parting_surface: Any) -> List[Dict]:
-        """
-        检测倒扣区域
-        """
-        undercut_regions = []
+    def _build_undercut_regions(self, undercut_analysis: Dict[str, Any]) -> List[Dict[str, Any]]:
+        """将侧向机构分析结果转换为兼容旧结构的倒扣区域列表。"""
+        undercut_faces = undercut_analysis.get("undercut_faces", [])
+        regions = []
 
-        try:
-            surface = BRepAdaptor_Surface(parting_surface)
-            parting_normal = surface.Plane().Position().Direction()
-
-            explorer = TopExp_Explorer(shape, TopAbs_FACE)
-
-            while explorer.More():
-                face = TopoDS_Face(explorer.Current())
-
-                try:
-                    face_surface = BRepAdaptor_Surface(face)
-
-                    if face_surface.GetType() == 0:
-                        face_normal = face_surface.Plane().Position().Direction()
-
-                        dot = (face_normal.X() * parting_normal.X() +
-                               face_normal.Y() * parting_normal.Y() +
-                               face_normal.Z() * parting_normal.Z())
-
-                        if dot < -0.7:
-                            bbox = Bnd_Box()
-                            brepbndlib_Add(face, bbox)
-                            center = bbox.Center()
-
-                            if center.Z() < 0:
-                                undercut_regions.append({
+        for face in undercut_faces:
+            regions.append({
                 "type": "negative_draft",
-                                    "location": [center.X(), center.Y(), center.Z()],
-                                    "severity": abs(dot)
+                "location": face.get("center", [0, 0, 0]),
+                "severity": face.get("severity", "medium"),
+                "area": face.get("area", 0),
+                "is_outer": face.get("is_outer", False),
+                "face_index": face.get("face_index"),
             })
 
-                except Exception as e:
-                    logger.debug(f"倒扣检测失败: {e}")
-
-                explorer.Next()
-
-            logger.info(f"检测到 {len(undercut_regions)} 个倒扣区域")
-
-        except Exception as e:
-            logger.warning(f"倒扣区域检测异常: {e}")
-
-        return undercut_regions
+        logger.info(f"转换得到 {len(regions)} 个兼容倒扣区域")
+        return regions
 
     def _smooth_parting_line(self, parting_line: List[List[float]]) -> List[List[float]]:
         """
@@ -561,22 +442,12 @@ class AluminumFoamMoldGenerator(BaseMoldGenerator):
 
     def _extract_parting_surface_geometry(self, surface: Any) -> Dict[str, Any]:
         """提取分型面几何数据"""
-        try:
-            adaptor = BRepAdaptor_Surface(surface)
-            normal = adaptor.Plane().Position().Direction()
-
+        metadata = self._extract_plane_metadata(surface)
         return {
             "type": "plane",
-                "normal": [normal.X(), normal.Y(), normal.Z()],
-                "origin": [0, 0, 0],
-                "bounds": {"u_range": [-200, 200], "v_range": [-200, 200]}
-            }
-        except Exception:
-            return {
-                "type": "plane",
-                "normal": [0, 0, 1],
-                "origin": [0, 0, 0],
-                "bounds": {"u_range": [-200, 200], "v_range": [-200, 200]}
+            "normal": metadata["normal"],
+            "origin": metadata["origin"],
+            "bounds": metadata["bounds"],
         }
 
     def _create_parting_surface_from_ai(self, ai_result: Dict, analysis: Dict,

src/core/base_mold_generator.py

@@ -224,6 +224,180 @@ class BaseMoldGenerator:
             logger.error(f"产品几何分析失败: {e}")
             raise
 
+    def _analyze_parting_direction(self, shape: Any) -> Dict[str, Any]:
+        """
+        分析主分型方向。
+
+        使用面积加权的面法向统计，作为普通模具与铝泡沫模具的统一几何回退。
+        """
+        face_normals = []
+        face_areas = []
+        explorer = TopExp_Explorer(shape, TopAbs_FACE)
+
+        while explorer.More():
+            face = TopoDS_Face(explorer.Current())
+            explorer.Next()
+
+            try:
+                normal = self._get_face_normal(face)
+                if normal is None:
+                    continue
+
+                face_props = GProp_GProps()
+                brepgprop.SurfaceProperties(face, face_props)
+                area = max(float(face_props.Mass()), 1e-6)
+
+                face_normals.append(np.array([normal.X(), normal.Y(), normal.Z()], dtype=np.float64))
+                face_areas.append(area)
+            except Exception as e:
+                logger.debug(f"分型方向面分析失败: {e}")
+
+        if not face_normals:
+            return {
+                "primary_direction": [0.0, 0.0, 1.0],
+                "confidence": 0.5,
+                "face_count": 0,
+            }
+
+        normals = np.array(face_normals, dtype=np.float64)
+        areas = np.array(face_areas, dtype=np.float64)
+        total_area = float(areas.sum())
+        if total_area > 1e-6:
+            weights = areas / total_area
+            weighted_normal = np.sum(normals * weights[:, np.newaxis], axis=0)
+        else:
+            weighted_normal = np.mean(normals, axis=0)
+
+        norm = np.linalg.norm(weighted_normal)
+        if norm > 1e-6:
+            weighted_normal /= norm
+        else:
+            weighted_normal = np.array([0.0, 0.0, 1.0], dtype=np.float64)
+
+        confidence = float(np.mean(np.abs(np.dot(normals, weighted_normal))))
+
+        return {
+            "primary_direction": weighted_normal.tolist(),
+            "confidence": confidence,
+            "face_count": len(face_normals),
+            "normal_distribution": normals.tolist(),
+        }
+
+    def _create_parting_surface_from_direction(
+        self,
+        shape: Any,
+        analysis: Dict[str, Any],
+        direction: Any,
+        extension: float = 10.0,
+    ) -> Any:
+        """按给定方向创建覆盖产品边界的分型面。"""
+        bbox = analysis.get("bounding_box", {})
+        center = bbox.get("center", [0.0, 0.0, 0.0])
+        dims = bbox.get("dimensions", [100.0, 100.0, 100.0])
+
+        dir_obj = self._normalize_direction(direction)
+        plane = gp_Pln(gp_Pnt(center[0], center[1], center[2]), dir_obj)
+
+        span = max(max(dims), 1.0) + extension * 2
+        try:
+            return BRepBuilderAPI_MakeFace(plane, -span, span, -span, span).Face()
+        except Exception:
+            return BRepBuilderAPI_MakeFace(plane).Face()
+
+    def _normalize_direction(self, direction: Any) -> gp_Dir:
+        """归一化分型方向，异常时回退到 Z 轴。"""
+        try:
+            if isinstance(direction, gp_Dir):
+                return direction
+
+            if isinstance(direction, np.ndarray):
+                values = direction.tolist()
+            else:
+                values = list(direction)
+
+            if len(values) < 3:
+                raise ValueError("direction 维度不足")
+
+            vec = np.array(values[:3], dtype=np.float64)
+            norm = np.linalg.norm(vec)
+            if norm <= 1e-6:
+                raise ValueError("direction 长度为 0")
+
+            vec /= norm
+            return gp_Dir(float(vec[0]), float(vec[1]), float(vec[2]))
+        except Exception:
+            return gp_Dir(0, 0, 1)
+
+    def _detect_primary_parting(self, shape: Any, analysis: Dict[str, Any]) -> Dict[str, Any]:
+        """
+        统一主分型面检测。
+
+        返回统一结构，便于子类按需追加多分型面、倒扣与平滑逻辑。
+        """
+        if self.ai_parting_detector is not None:
+            try:
+                ai_result = self.ai_parting_detector.detect(shape, analysis)
+                if ai_result:
+                    parting_surface = self._create_parting_surface_from_direction(
+                        shape,
+                        analysis,
+                        ai_result.get("normal", [0, 0, 1]),
+                    )
+                    parting_line = ai_result.get("parting_line") or self._calculate_parting_line(shape, parting_surface)
+                    return {
+                        "surface": parting_surface,
+                        "line": parting_line,
+                        "direction": ai_result.get("normal", [0, 0, 1]),
+                        "confidence": ai_result.get("confidence", 0.8),
+                        "method": ai_result.get("method", "ai"),
+                    }
+            except Exception as e:
+                logger.warning(f"AI 分型面检测失败，回退到几何方法：{e}")
+
+        normal_stats = self._analyze_parting_direction(shape)
+        parting_surface = self._create_parting_surface_from_direction(
+            shape,
+            analysis,
+            normal_stats.get("primary_direction", [0, 0, 1]),
+        )
+        parting_line = self._calculate_parting_line(shape, parting_surface)
+
+        return {
+            "surface": parting_surface,
+            "line": parting_line,
+            "direction": normal_stats.get("primary_direction", [0, 0, 1]),
+            "confidence": normal_stats.get("confidence", 0.5),
+            "method": "geometric",
+        }
+
+    def _extract_plane_metadata(self, surface: Any, analysis: Optional[Dict[str, Any]] = None) -> Dict[str, Any]:
+        """提取分型面法向、原点和参数范围。"""
+        default_origin = [0.0, 0.0, 0.0]
+        if analysis:
+            default_origin = analysis.get("bounding_box", {}).get("center", default_origin)
+
+        try:
+            adaptor = BRepAdaptor_Surface(surface)
+            plane = adaptor.Plane()
+            origin = plane.Location()
+            normal = plane.Axis().Direction()
+
+            return {
+                "normal": [float(normal.X()), float(normal.Y()), float(normal.Z())],
+                "origin": [float(origin.X()), float(origin.Y()), float(origin.Z())],
+                "bounds": {
+                    "u_range": [float(adaptor.FirstUParameter()), float(adaptor.LastUParameter())],
+                    "v_range": [float(adaptor.FirstVParameter()), float(adaptor.LastVParameter())],
+                },
+            }
+        except Exception as e:
+            logger.warning(f"分型面几何提取失败，使用默认值: {e}")
+            return {
+                "normal": [0.0, 0.0, 1.0],
+                "origin": [float(default_origin[0]), float(default_origin[1]), float(default_origin[2])],
+                "bounds": {"u_range": [-200.0, 200.0], "v_range": [-200.0, 200.0]},
+            }
+
     def _split_cavity_core(self, shape: Any, parting_surface: Any, margin: int = 20) -> Tuple[Any, Any]:
         """
         分离型腔和型芯

src/core/mold_generator.py

@@ -12,6 +12,7 @@ from OCC.Core.BRepBndLib import brepbndlib_Add
 from models.schemas import create_mold_cavity_data, create_mold_key_info
 from utils.logger import get_logger
 from core.base_mold_generator import BaseMoldGenerator
+from core.side_action_designer import SideActionDesigner
 
 logger = get_logger(__name__)
 
@@ -36,6 +37,7 @@ class MoldCavityGenerator(BaseMoldGenerator):
 
         self.parting_line_tolerance = 0.1
         self.max_draft_angle = 5.0
+        self.side_action_designer = SideActionDesigner()
 
     def set_material(self, material: str):
         """设置产品材料"""
@@ -62,8 +64,19 @@ class MoldCavityGenerator(BaseMoldGenerator):
         try:
             analysis = self._analyze_product_geometry(product_shape)
 
-            parting_surface, parting_line = self._detect_parting_surface(
-                product_shape, analysis
+            parting_result = self._detect_primary_parting(product_shape, analysis)
+            parting_surface = parting_result["surface"]
+            parting_line = self.optimize_parting_line(parting_result["line"])
+            parting_direction = parting_result["direction"]
+
+            side_action_result = self.side_action_designer.analyze_and_design(
+                shape=product_shape,
+                parting_direction=parting_direction,
+                mold_size=self._calculate_mold_size(analysis),
+                parting_surface=parting_surface,
+            )
+            undercut_regions = self._build_undercut_regions(
+                side_action_result.get("undercut_analysis", {})
             )
 
             scaled_shape = self._apply_shrinkage_compensation(product_shape)
@@ -79,7 +92,9 @@ class MoldCavityGenerator(BaseMoldGenerator):
                 "core": core,
                 "parting_surface": parting_surface,
                 "parting_line": parting_line,
-                "analysis": analysis
+                "analysis": analysis,
+                "undercut_regions": undercut_regions,
+                "side_actions": side_action_result,
             }
 
         except Exception as e:
@@ -124,6 +139,10 @@ class MoldCavityGenerator(BaseMoldGenerator):
                 "core": core_geometry
             },
             "parting_surface": parting_geometry,
+            "quality_checks": {
+                "undercut_regions": cavity_data.get("undercut_regions", []),
+                "side_actions": cavity_data.get("side_actions", {}),
+            },
             "manufacturing_info": {
                 "estimated_mold_size": self._calculate_mold_size(analysis),
                 "estimated_clamping_force": self._calculate_clamping_force(analysis),
@@ -165,6 +184,8 @@ class MoldCavityGenerator(BaseMoldGenerator):
                 "recommended_injection_pressure": "80-120 MPa"
             },
             "quality_considerations": {
+                "undercut_count": len(cavity_data.get("undercut_regions", [])),
+                "side_action_summary": cavity_data.get("side_actions", {}).get("summary", {}),
                 "potential_weld_lines": self._identify_weld_line_risk(analysis),
                 "sink_mark_areas": self._identify_sink_mark_risk(analysis),
                 "warpage_risk": self._assess_warpage_risk(analysis)
@@ -184,26 +205,13 @@ class MoldCavityGenerator(BaseMoldGenerator):
         2. 基于法向量分析的几何方法
         3. 简化方法（基于边界框）
         """
-        if self.ai_parting_detector is not None:
         try:
-                logger.info("使用 AI 模型检测分型面")
-                ai_result = self.ai_parting_detector.detect(shape, analysis)
-                if ai_result:
-                    return self._create_parting_surface_from_ai(ai_result, analysis, shape)
-            except Exception as e:
-                logger.warning(f"AI 分型面检测失败，回退到几何方法：{e}")
-
-        try:
-            logger.info("使用法向量分析检测分型面")
-            optimal_direction = self._analyze_face_normals(shape)
-            parting_plane = self._create_optimal_parting_plane(
-                shape, analysis, optimal_direction
+            parting_result = self._detect_primary_parting(shape, analysis)
+            logger.info(
+                f"使用 {parting_result['method']} 方法检测分型面，"
+                f"置信度={parting_result['confidence']:.3f}"
             )
-            parting_surface = BRepBuilderAPI_MakeFace(parting_plane).Face()
-
-            parting_line = self._calculate_parting_line(shape, parting_surface)
-
-            return parting_surface, parting_line
+            return parting_result["surface"], self.optimize_parting_line(parting_result["line"])
 
         except Exception as e:
             logger.warning(f"法向量分析失败，使用简化方法：{e}")
@@ -211,6 +219,24 @@ class MoldCavityGenerator(BaseMoldGenerator):
         logger.info("使用简化方法检测分型面")
         return self._simple_parting_surface(shape, analysis)
 
+    def _build_undercut_regions(self, undercut_analysis: Dict[str, Any]) -> List[Dict[str, Any]]:
+        """将侧向机构分析结果转换为兼容旧结构的倒扣区域列表。"""
+        undercut_faces = undercut_analysis.get("undercut_faces", [])
+        regions = []
+
+        for face in undercut_faces:
+            regions.append({
+                "type": "negative_draft",
+                "location": face.get("center", [0, 0, 0]),
+                "severity": face.get("severity", "medium"),
+                "area": face.get("area", 0),
+                "is_outer": face.get("is_outer", False),
+                "face_index": face.get("face_index"),
+            })
+
+        logger.info(f"转换得到 {len(regions)} 个兼容倒扣区域")
+        return regions
+
     def _analyze_face_normals(self, shape: Any) -> gp_Dir:
         """
         分析产品表面的法向量分布，找出最优分型方向
@@ -335,27 +361,13 @@ class MoldCavityGenerator(BaseMoldGenerator):
 
     def _extract_parting_surface_geometry(self, surface: Any) -> Dict[str, Any]:
         """提取分型面几何数据"""
-        try:
-            adaptor = BRepAdaptor_Surface(surface)
-            u_min, u_max = adaptor.FirstUParameter(), adaptor.LastUParameter()
-            v_min, v_max = adaptor.FirstVParameter(), adaptor.LastVParameter()
-
-            bounds = {
-                "u_range": [float(u_min), float(u_max)],
-                "v_range": [float(v_min), float(v_max)]
-            }
-        except Exception as e:
-            logger.warning(f"分型面边界提取失败，使用默认值: {e}")
-            bounds = {
-                "u_range": [-200, 200],
-                "v_range": [-200, 200]
-            }
+        metadata = self._extract_plane_metadata(surface)
 
         return {
             "type": "plane",
-            "normal": [0, 0, 1],
-            "origin": [0, 0, 0],
-            "bounds": bounds
+            "normal": metadata["normal"],
+            "origin": metadata["origin"],
+            "bounds": metadata["bounds"],
         }
 
     def _calculate_mold_size(self, analysis: Dict) -> Dict[str, float]:

src/services/calculation_service.py

@@ -221,6 +221,23 @@ class CalculationService:
                 if key in mold_cavities:
                     detailed_cavity_json["mold_cavities"][key] = mold_cavities[key]
 
+        # 合并分模附加信息，保持普通模具与铝泡沫模具输出结构一致
+        if cavity_mesh_data:
+            if cavity_mesh_data.get("parting_surface"):
+                detailed_cavity_json["parting_surface"] = cavity_mesh_data["parting_surface"]
+
+            quality_checks = cavity_mesh_data.get("quality_checks", {})
+            if quality_checks:
+                detailed_cavity_json["quality_checks"] = quality_checks
+
+            undercut_regions = quality_checks.get("undercut_regions")
+            if undercut_regions:
+                detailed_cavity_json["undercut_regions"] = undercut_regions
+
+            side_actions = quality_checks.get("side_actions")
+            if side_actions:
+                detailed_cavity_json["side_actions"] = side_actions
+
         # 添加型腔关键信息
         detailed_cavity_json["mold_cavities"]["cavity_key_info"] = {
             "geometric_characteristics": {
@@ -231,6 +248,8 @@ class CalculationService:
                 "projected_area": f"{projected_area_cm2:.2f} cm²",
             },
             "quality_considerations": {
+                "undercut_count": len(detailed_cavity_json.get("undercut_regions", [])),
+                "side_action_summary": detailed_cavity_json.get("side_actions", {}).get("summary", {}),
                 "potential_weld_lines": "center" if cavity_count > 1 else "minimal",
                 "sink_mark_areas": "thick_sections" if wall["wall_thickness_max"] > 4 else "minimal",
                 "warpage_risk": "medium" if wall["wall_thickness_max"] > 5 else "low",