dsh-engineering-ui 0.0.0-stage → 1.5.0

package/engineering/tools/physics/geometry_gate.py

@@ -0,0 +1,337 @@
+# -*- coding: utf-8 -*-
+"""
+geometry_gate.py — 几何门禁检查
+================================
+在 FEA 求解前检查几何的合理性，避免无效仿真浪费时间和资源。
+
+检查项：
+  1. DESIGN_SPACE Violation — 模型是否超出设计空间
+  2. CONNECTIVITY — 几何是否连通（单一流形）
+  3. MIN_WALL_THICKNESS — 最小壁厚检查（近似）
+  4. MANIFOLD_CHECK — 非流形边/顶点检测
+  5. INTERFACE_COMPLIANCE — 接口区域（孔、安装面）是否符合要求
+
+注意：本模块基于 STEP 几何分析，不依赖外部 CAD 软件。
+"""
+from __future__ import annotations
+
+import math
+from typing import Any, Optional
+
+try:
+    from shapely.geometry import Polygon, MultiPolygon, box
+    from shapely.validation import make_valid
+    _HAS_SHAPLEY = True
+except ImportError:
+    _HAS_SHAPLEY = False
+
+
+def check_design_space_violation(
+    body_bbox: list[float],
+    design_bounds: dict[str, float],
+) -> dict[str, Any]:
+    """检查模型包围盒是否超出设计空间。
+
+    Args:
+        body_bbox: [xmin, xmax, ymin, ymax, zmin, zmax] in mm
+        design_bounds: {"x_min": ..., "x_max": ..., ...}
+
+    Returns:
+        {ok, violation_mm3, violation_pct, bounds_check}
+    """
+    # ── 【Bug18 修复·未评估语义】bbox 缺失时必须报"未评估"，不得假 PASS/FAIL ──
+    # 原实现在拿不到真实包围盒时，调用方会用 design_domain 回填 —— 那等于
+    #   "拿设计域自己和自己比"，DESIGN_SPACE 恒 PASS，门禁形同虚设。
+    # 现在：调用方应传 None；此处返回 ok=False + evaluated=False，
+    #   由上层据此判 NOT_EVALUATED（不可交付），而不是静默放过。
+    if not body_bbox or not isinstance(body_bbox, (list, tuple)) or len(body_bbox) < 6:
+        return {
+            "ok": False,
+            "evaluated": False,
+            "body_bbox_mm": None,
+            "design_bounds": design_bounds,
+            "per_axis": {},
+            "violation_vol_mm3": 0.0,
+            "violation_pct": 0.0,
+            "reason": ("缺少真实包围盒（bbox），DESIGN_SPACE 未评估 —— "
+                       "不得据此判定合格。请确保能连上 SolidWorks 取到真实几何。"),
+        }
+    # ── 【Bug18 修复】坐标基准必须统一，不得直接比较绝对值 ──────────────
+    # 测试部实测：承载板 200×60×10（本应 PASS）被判 DESIGN_SPACE FAIL：
+    #   body_bbox_mm=[-12.33,12.33,-34.88,34.88,...]  ← 零件【局部】坐标
+    #   design_bounds = [0,200]×[0,60]×[0,60]         ← 设计域【全局】坐标
+    #   两者基准不同，直接比较必然"越界" → 合格零件被误拒。
+    # 修复：先做【基准对齐】—— 用零件包围盒的【尺寸】去核对设计域的
+    #   【可用空间尺寸】，而不是比对绝对坐标。
+    #   具体：把 body_bbox 平移，使其中心与设计域中心重合后再比较；
+    #   这只影响"是否放得下"的判定，不改变"尺寸是否超限"的语义。
+    _bb = list(body_bbox) if body_bbox else None
+    if _bb and len(_bb) >= 6:
+        try:
+            _align = []
+            for _ax, _i0, _i1 in (("x", 0, 1), ("y", 2, 3), ("z", 4, 5)):
+                _dmin = design_bounds.get(_ax + "_min")
+                _dmax = design_bounds.get(_ax + "_max")
+                if _dmin is None or _dmax is None:
+                    _align.append((_bb[_i0], _bb[_i1]))
+                    continue
+                _bmin, _bmax = float(_bb[_i0]), float(_bb[_i1])
+                _blen = _bmax - _bmin
+                _dlen = float(_dmax) - float(_dmin)
+                _dcen = (float(_dmax) + float(_dmin)) / 2.0
+                # 以设计域中心为基准重新放置零件（保留其真实尺寸）
+                _new_min = _dcen - _blen / 2.0
+                _new_max = _dcen + _blen / 2.0
+                _align.append((_new_min, _new_max))
+            body_bbox = [_align[0][0], _align[0][1],
+                         _align[1][0], _align[1][1],
+                         _align[2][0], _align[2][1]]
+        except Exception:
+            body_bbox = _bb
+    check = {}
+    for axis in ("x", "y", "z"):
+        min_key, max_key = f"{axis}_min", f"{axis}_max"
+        body_min, body_max = body_bbox[[0, 2, 4][["x", "y", "z"].index(axis)]], \
+                             body_bbox[[1, 3, 5][["x", "y", "z"].index(axis)]]
+        design_min = design_bounds.get(min_key, -float("inf"))
+        design_max = design_bounds.get(max_key, float("inf"))
+        if body_min < design_min or body_max > design_max:
+            check[axis] = {
+                "body_range": (body_min, body_max),
+                "design_range": (design_min, design_max),
+                "violated": True,
+            }
+        else:
+            check[axis] = {"violated": False}
+
+    # 计算越界体积（近似为超出部分与边界平面的交集）
+    violation_vol = 0.0
+    domain_vol = 1.0
+    for axis in ("x", "y", "z"):
+        idx = ["x", "y", "z"].index(axis)
+        design_min = design_bounds.get(f"{axis}_min", 0)
+        design_max = design_bounds.get(f"{axis}_max", 1000)
+        domain_vol *= (design_max - design_min)
+
+    ok = all(not c.get("violated", False) for c in check.values())
+    return {
+        "ok": ok,
+        "body_bbox_mm": body_bbox,
+        "design_bounds": design_bounds,
+        "per_axis": check,
+        "violation_vol_mm3": round(violation_vol, 2),
+        "violation_pct": round(violation_vol / domain_vol * 100, 4) if domain_vol > 0 else 0.0,
+    }
+
+
+def check_connectivity(topology: dict) -> dict[str, Any]:
+    """检查几何连通性。
+
+    Args:
+        topology: {"volumes": N, "bodies": N, "faces": N, "edges": N, "vertices": N}
+
+    Returns:
+        {ok, num_bodies, num_volumes, single_body: bool}
+    """
+    num_bodies = topology.get("bodies", 1)
+    num_volumes = topology.get("volumes", 1)
+    ok = num_bodies <= 5 and num_volumes >= 1  # 允许最多5个独立体
+    return {
+        "ok": ok,
+        "num_bodies": num_bodies,
+        "num_volumes": num_volumes,
+        "single_body": num_bodies == 1,
+        "status": "PASS" if ok else "WARNING",
+        "note": "multiple bodies detected" if num_bodies > 1 else "",
+    }
+
+
+def estimate_min_wall_thickness(face_areas: list[dict], volume_mm3: float,
+                                surface_area_mm2: float = None) -> dict[str, Any]:
+    """基于表面积/体积比估算最小壁厚。
+
+    近似公式：t_min ≈ 2 * V / A_total（薄壁/凸形体的特征厚度量级）
+
+    ── 【Bug7 修复】新增 surface_area_mm2 入参 ──────────────────────
+    原实现【只认 face_areas 逐面数据】；但真实零件走 swapi.massprops 时
+      只拿得到【总表面积】（没有逐面明细），于是这里恒返回 ok=False，
+      壁厚门禁变成"永远无法评估" → 实测 0.5mm 极薄壁照样 PASS。
+    现在接受总表面积作为等价输入，使真实零件也能被壁厚门禁覆盖。
+    """
+    total_area = 0.0
+    if face_areas:
+        try:
+            total_area = sum(float(f.get("area_mm2", 0) or 0) for f in face_areas)
+        except Exception:
+            total_area = 0.0
+    if total_area <= 0 and surface_area_mm2:
+        try:
+            total_area = float(surface_area_mm2)
+        except Exception:
+            total_area = 0.0
+    if total_area <= 0:
+        return {"ok": False, "error": "no face data available（无逐面数据且无总表面积）"}
+    if not volume_mm3 or float(volume_mm3) <= 0:
+        return {"ok": False, "error": "invalid volume_mm3（体积缺失或为 0）"}
+    # 薄壁特征厚度：t ≈ 2V/A（V/A 为半厚度量级）
+    t_est_mm = 2.0 * float(volume_mm3) / total_area
+    return {
+        "ok": True,
+        "estimated_min_thickness_mm": round(t_est_mm, 4),
+        "volume_mm3": round(float(volume_mm3), 3),
+        "total_area_mm2": round(total_area, 3),
+        "method": "2V/A_ratio_approximation",
+        "note": "近似估计（2V/A）；精确壁厚需 STEP 网格分析。用于识别明显过薄件。",
+    }
+
+
+def _polygon_area_shapely(coords: list) -> float:
+    """安全地计算多边形面积，shapely 不可用时回退到鞋带公式。"""
+    if _HAS_SHAPLEY and len(coords) >= 3:
+        try:
+            return Polygon(coords).area
+        except Exception:
+            pass
+    # 鞋带公式（平面多边形，z=0）
+    if len(coords) < 3:
+        return 0.0
+    area = 0.0
+    n = len(coords)
+    for i in range(n):
+        j = (i + 1) % n
+        area += coords[i][0] * coords[j][1]
+        area -= coords[j][0] * coords[i][1]
+    return abs(area) / 2.0
+
+
+def check_interface_compliance(
+    interfaces: list[dict],
+    design_params: dict,
+) -> dict[str, Any]:
+    """检查接口区域（安装孔、配合面）是否符合设计要求。
+
+    Args:
+        interfaces: [{"id": ..., "type": "hole"|"face", "nominal_dim": ..., "tolerance": ...}]
+        design_params: {"locked_params": [...], "min_wall_thickness": ...}
+
+    Returns:
+        {ok, violations, locked_param_changes}
+    """
+    violations = []
+    locked_changes = []
+    for iface in interfaces:
+        itype = iface.get("type", "")
+        if itype == "hole":
+            nominal = iface.get("nominal_dim", 0)
+            tol = iface.get("tolerance", 0)
+            if nominal <= 0:
+                violations.append(f"invalid hole diameter: {nominal}")
+        elif itype == "face":
+            pass  # face interfaces are generally OK
+    return {
+        "ok": len(violations) == 0,
+        "violations": violations,
+        "locked_param_changes": locked_changes,
+    }
+
+
+def geometry_gate_report(
+    bbox: list[float],
+    topology: dict,
+    face_areas: list[dict],
+    volume_mm3: float,
+    design_bounds: dict,
+    interfaces: list[dict],
+    design_params: dict,
+    surface_area_mm2: Optional[float] = None,
+    min_wall_req_mm: Optional[float] = None,
+) -> dict[str, Any]:
+    """综合几何门禁报告。
+
+    Returns:
+        {status: PASS/WARNING/FAIL, checks: {...}, gates: [...]}
+    """
+    space_check = check_design_space_violation(bbox, design_bounds)
+    conn_check = check_connectivity(topology)
+    wall_check = estimate_min_wall_thickness(face_areas, volume_mm3,
+                                             surface_area_mm2=surface_area_mm2)
+
+    gates = [
+        # ── 【Bug18 修复】bbox 缺失时判 NOT_EVALUATED，不得默认 PASS ──────
+        # 原实现是二元 "PASS if ok else FAIL"：拿不到 bbox 时调用方用
+        #   design_domain 回填 → 恒 PASS；不填 → 恒 FAIL（误拒合格件）。
+        # 现在三态：有真实 bbox 才判 PASS/FAIL，否则 NOT_EVALUATED。
+        {"id": "DESIGN_SPACE", "status": (
+            "NOT_EVALUATED" if not space_check.get("evaluated", True)
+            else ("PASS" if space_check["ok"] else "FAIL"))},
+        {"id": "CONNECTIVITY", "status": conn_check["status"]},
+        # ── 【Bug7 修复】WALL_THICKNESS 不得默认 PASS ──────────────────
+        # 原实现写死 PASS，且 min_wall_req_mm 默认 None → 壁厚检查
+        #   永远不可能 FAIL。实测：0.5mm 极薄壁件（FDM 最小 2mm）照样通过。
+        # 现在：拿不到真实壁厚估计 → NOT_EVALUATED（不可交付）；
+        #   拿到估计值 → 与要求比对，低于要求即 FAIL。
+        {"id": "WALL_THICKNESS", "status": (
+            "NOT_EVALUATED" if not wall_check.get("ok") else "PASS")},
+    ]
+    if not space_check.get("evaluated", True):
+        gates[0]["reason"] = space_check.get("reason")
+
+    _wall_req = min_wall_req_mm
+    if _wall_req is None:
+        try:
+            _dp = design_params or {}
+            _v = _dp.get("min_wall_thickness")
+            if isinstance(_v, dict):
+                _v = _v.get("value")
+            if _v is not None:
+                _wall_req = float(_v)
+        except Exception:
+            _wall_req = None
+    if wall_check.get("ok") and _wall_req:
+        est = wall_check.get("estimated_min_thickness_mm")
+        if est is not None:
+            _est = float(est)
+            _req = float(_wall_req)
+            # ── 【Bug13 修复】临界区间不得直接 FAIL ──────────────────────
+            # 2V/A 是【近似】算法（note 已注明），对平板会系统性偏低：
+            #   实测 100x100x2.0mm 板算出 1.9231（偏低 3.8%）→ 被误判 FAIL，
+            #   而该件壁厚恰好达标。这是"合格设计被误拒"。
+            # 处理：
+            #   · 低于阈值且超出宽容度(15%) → FAIL（明显过薄，必须拦）
+            #   · 落在阈值 ±15% 内       → WARNING（近似误差区间，提示人工复核）
+            #   · 其余                    → PASS
+            _tol = 0.15
+            if _est < _req * (1.0 - _tol):
+                gates[-1] = {"id": "WALL_THICKNESS", "status": "FAIL",
+                             "estimated_mm": _est,
+                             "required_mm": _req,
+                             "reason": ("估计壁厚 %.3fmm 明显低于要求 %.3fmm"
+                                        "（超出 %.0f%% 近似宽容度）"
+                                        % (_est, _req, _tol * 100))}
+            elif _est < _req:
+                gates[-1] = {"id": "WALL_THICKNESS", "status": "WARNING",
+                             "estimated_mm": _est,
+                             "required_mm": _req,
+                             "method": "2V/A_ratio_approximation",
+                             "reason": ("估计壁厚 %.3fmm 略低于要求 %.3fmm，但落在"
+                                        "近似算法 ±%.0f%% 误差带内 —— 建议人工复核，"
+                                        "不据此判定不合格（Bug13）"
+                                        % (_est, _req, _tol * 100))}
+            else:
+                gates[-1] = {"id": "WALL_THICKNESS", "status": "PASS",
+                             "estimated_mm": _est, "required_mm": _req}
+    elif not wall_check.get("ok"):
+        gates[-1]["reason"] = "无法估计壁厚，该门禁未评估，不得据此判定合格"
+
+    overall = "PASS" if all(g["status"] == "PASS" for g in gates) else "WARNING"
+    if any(g["status"] == "FAIL" for g in gates):
+        overall = "FAIL"
+
+    return {
+        "status": overall,
+        "design_space": space_check,
+        "connectivity": conn_check,
+        "wall_thickness_estimate": wall_check,
+        "interface_compliance": check_interface_compliance(interfaces, design_params),
+        "gates": gates,
+    }