""" 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)