initial
This commit is contained in:
Christian Anetzberger
417
_jobs/bb50fd78018d/stepanalyser.py
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417
_jobs/bb50fd78018d/stepanalyser.py
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#!/usr/bin/env python3
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# -*- coding: utf-8 -*-
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"""
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Internal STEP sheet metal analyser
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- Input: ./test.step
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- Unfold with K-factor = 0.5
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- Auto-detect thickness if not provided
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- Export:
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- flat.dxf
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- result.json
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- debug_last.FCStd
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"""
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import os
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import sys
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import json
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import argparse
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import traceback
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from datetime import datetime
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# -----------------------------
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# Configuration
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# -----------------------------
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K_FACTOR = 0.5
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K_STANDARD = "ansi"
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DENSITY_KG_M3 = {
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"alu": 2700.0,
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"aluminum": 2700.0,
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"stainless": 8000.0,
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"edelstahl": 8000.0,
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"copper": 8960.0,
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"kupfer": 8960.0,
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}
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# -----------------------------
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# Helpers
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# -----------------------------
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def mm2_to_m2(x):
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return x / 1_000_000.0
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def mm_to_m(x):
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return x / 1000.0
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def pick_main_object(doc):
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candidates = []
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for obj in doc.Objects:
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if hasattr(obj, "Shape") and obj.Shape:
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try:
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if obj.Shape.Solids:
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candidates.append((float(obj.Shape.Volume), obj))
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except Exception:
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pass
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if not candidates:
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raise RuntimeError("No solid object found in STEP.")
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candidates.sort(key=lambda x: x[0], reverse=True)
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return candidates[0][1]
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def pick_root_face_index(shape):
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planar = []
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all_faces = []
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for i, face in enumerate(shape.Faces, start=1):
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try:
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area = float(face.Area)
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except Exception:
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area = 0.0
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all_faces.append((area, i, face))
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try:
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surf = face.Surface
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if surf and "plane" in surf.__class__.__name__.lower():
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planar.append((area, i, face))
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except Exception:
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pass
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if planar:
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planar.sort(key=lambda x: x[0], reverse=True)
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return planar[0][1], True
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all_faces.sort(key=lambda x: x[0], reverse=True)
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return all_faces[0][1], False
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def compute_bbox_mm(shape):
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bb = shape.BoundBox
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return float(bb.XLength), float(bb.YLength)
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def estimate_thickness_mm_from_solid(part_obj, max_faces=60):
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"""
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Robust thickness estimation for sheet-metal solids:
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- Collect planar faces
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- Cluster by (normalized) face normal direction
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- For each cluster, compute plane offsets d = n·p for face points
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- Thickness candidates are small positive differences between distinct d values
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- Fallback: use distToShape on representative face pairs
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Returns thickness in mm or None.
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"""
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import math
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import Part
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shape = part_obj.Shape
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# --- helpers ---
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def vec_to_tuple(v):
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return (float(v.x), float(v.y), float(v.z))
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def norm(v):
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l = math.sqrt(v.x*v.x + v.y*v.y + v.z*v.z)
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if l <= 1e-12:
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return None
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return v.multiply(1.0 / l)
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def canonical_normal(n):
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"""
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Make the normal direction canonical so +n and -n map consistently:
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Flip so the first significant component is positive.
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"""
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# convert to tuple for easier checks
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x, y, z = float(n.x), float(n.y), float(n.z)
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# find first component with magnitude > eps
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eps = 1e-9
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if abs(x) > eps:
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if x < 0: return n.multiply(-1)
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elif abs(y) > eps:
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if y < 0: return n.multiply(-1)
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elif abs(z) > eps:
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if z < 0: return n.multiply(-1)
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return n
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def angle_close(n1, n2, cos_tol):
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# cos(angle) = n1·n2
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return (n1.dot(n2) >= cos_tol)
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def face_midpoint(face):
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u0, u1, v0, v1 = face.ParameterRange
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return face.valueAt((u0+u1)*0.5, (v0+v1)*0.5), face.normalAt((u0+u1)*0.5, (v0+v1)*0.5)
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# --- collect planar faces ---
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planar = []
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for face in shape.Faces:
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try:
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surf = face.Surface
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if not (surf and "plane" in surf.__class__.__name__.lower()):
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continue
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area = float(face.Area)
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if area < 1.0: # mm², ignore tiny faces
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continue
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p, n = face_midpoint(face)
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n = norm(n)
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if n is None:
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continue
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n = canonical_normal(n)
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d = float(n.dot(p)) # plane offset for n·x = d
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planar.append((area, face, n, d))
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except Exception:
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continue
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if not planar:
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return None
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planar.sort(key=lambda x: x[0], reverse=True)
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planar = planar[:max_faces]
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# --- cluster by normal direction ---
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# Tolerance: within ~2 degrees
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cos_tol = math.cos(math.radians(2.0))
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clusters = [] # each: {"n": normal, "faces": [(area, face, d), ...]}
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for area, face, n, d in planar:
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placed = False
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for c in clusters:
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if angle_close(n, c["n"], cos_tol):
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c["faces"].append((area, face, d))
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placed = True
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break
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if not placed:
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clusters.append({"n": n, "faces": [(area, face, d)]})
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# --- build thickness candidates from d-values inside each cluster ---
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# For a sheet, same-normal planes occur at (outer) and (inner) offsets,
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# so distinct d-values differ ~thickness.
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candidates = []
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def add_candidate(val):
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if 0.05 <= val <= 20.0: # mm range guard (tune if needed)
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candidates.append(val)
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for c in clusters:
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ds = [d for _a, _f, d in c["faces"]]
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if len(ds) < 2:
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continue
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ds.sort()
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# unique d-values with binning (0.01 mm)
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uniq = []
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for d in ds:
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b = round(d / 0.01) * 0.01
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if not uniq or abs(b - uniq[-1]) > 1e-9:
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uniq.append(b)
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if len(uniq) < 2:
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continue
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# candidate: smallest positive gap between uniq planes
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# Often thickness is the smallest meaningful separation.
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for i in range(1, len(uniq)):
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gap = abs(uniq[i] - uniq[i-1])
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add_candidate(gap)
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# --- if candidates exist, pick most frequent bin (mode-ish) ---
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def pick_mode(vals, bin_size=0.01):
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bins = {}
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for x in vals:
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b = round(x / bin_size) * bin_size
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bins.setdefault(b, []).append(x)
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best_bin = max(bins.items(), key=lambda kv: len(kv[1]))[0]
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bucket = sorted(bins[best_bin])
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return bucket[len(bucket)//2]
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if candidates:
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return pick_mode(candidates, 0.01)
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# --- Fallback: distToShape between face pairs in same normal cluster ---
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# Slower but can rescue cases where d-values are too noisy.
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# We try only top clusters and top faces.
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try:
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for c in clusters[:6]:
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faces = sorted(c["faces"], key=lambda t: t[0], reverse=True)[:8]
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# compare each face to others in same cluster; minimal non-zero distance tends to thickness
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for i in range(len(faces)):
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fi = faces[i][1]
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for j in range(i+1, len(faces)):
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fj = faces[j][1]
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dist = fi.distToShape(fj)[0] # returns (dist, pts, info)
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if dist and dist > 0.05 and dist <= 20.0:
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candidates.append(float(dist))
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if candidates:
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return pick_mode(candidates, 0.01)
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except Exception:
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pass
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return None
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# -----------------------------
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# Main
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# -----------------------------
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def main():
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parser = argparse.ArgumentParser()
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parser.add_argument("--material", required=True, help="alu | stainless | copper")
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parser.add_argument("--thickness-mm", required=False, type=float, default=None,
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help="Optional sheet thickness in mm (auto-detect if omitted)")
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args = parser.parse_args()
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material_key = args.material.strip().lower()
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if material_key not in DENSITY_KG_M3:
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raise SystemExit(f"Unknown material '{args.material}'")
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density = DENSITY_KG_M3[material_key]
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cwd = os.getcwd()
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step_path = os.path.join(cwd, "03341791-01_01.step")
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out_dxf = os.path.join(cwd, "03341791-01_01.dxf")
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out_json = os.path.join(cwd, "03341791-01_01-result.json")
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out_fcstd = os.path.join(cwd, "debug_last.FCStd")
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print("=== STEPANALYSER START ===", flush=True)
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print("Material:", material_key, "Density:", density, flush=True)
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if not os.path.exists(step_path):
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raise SystemExit("STEP File not found not found in working directory")
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import FreeCAD as App
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import Import
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import importDXF
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try:
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import SheetMetalNewUnfolder
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from SheetMetalNewUnfolder import BendAllowanceCalculator
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HAS_V2 = True
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except Exception:
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HAS_V2 = False
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try:
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import SheetMetalUnfolder
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HAS_V1 = True
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except Exception:
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HAS_V1 = False
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if not HAS_V1 and not HAS_V2:
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raise SystemExit("No SheetMetal unfolder available")
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doc = App.newDocument("StepAnalyser")
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warnings = []
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try:
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Import.insert(step_path, doc.Name)
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doc.recompute()
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part_obj = pick_main_object(doc)
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face_idx, planar = pick_root_face_index(part_obj.Shape)
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base_face = f"Face{face_idx}"
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thickness_mm = args.thickness_mm
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if thickness_mm is None:
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print("Auto-detecting thickness...", flush=True)
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thickness_mm = estimate_thickness_mm_from_solid(part_obj)
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if thickness_mm is None:
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raise RuntimeError("Could not auto-detect thickness")
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print(f"Detected thickness: {thickness_mm:.3f} mm", flush=True)
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unfolded_shape = None
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sketches = []
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if HAS_V2:
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try:
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bac = BendAllowanceCalculator.from_single_value(K_FACTOR, K_STANDARD)
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sel_face, unfolded_shape, bend_lines, root_normal = \
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SheetMetalNewUnfolder.getUnfold(bac, part_obj, base_face)
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sketches = SheetMetalNewUnfolder.getUnfoldSketches(
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"Unfold", sel_face, unfolded_shape, bend_lines,
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root_normal, [], False, "#000080", "#c00000", "#ff5733"
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)
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except Exception:
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warnings.append("V2 unfold failed")
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if unfolded_shape is None and HAS_V1:
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ktable = {1: K_FACTOR}
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unfolded_shape, foldComp, norm, *_ = \
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SheetMetalUnfolder.getUnfold(ktable, part_obj, base_face, K_STANDARD)
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sketches = SheetMetalUnfolder.getUnfoldSketches(
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"Unfold", unfolded_shape, foldComp.Edges,
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norm, [], False, "#000080",
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bendSketchColor="#ff5733", internalSketchColor="#c00000"
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)
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if unfolded_shape is None or not sketches:
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raise RuntimeError("Unfold failed")
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importDXF.export(sketches, out_dxf)
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bbox_w, bbox_h = compute_bbox_mm(unfolded_shape)
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area_bbox_mm2 = bbox_w * bbox_h
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area_net_mm2 = float(unfolded_shape.Area)
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t_m = mm_to_m(thickness_mm)
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area_bbox_m2 = mm2_to_m2(area_bbox_mm2)
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area_net_m2 = mm2_to_m2(area_net_mm2)
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mass_bbox_kg = area_bbox_m2 * t_m * density
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mass_net_kg = area_net_m2 * t_m * density
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result = {
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"ok": True,
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"timestamp": datetime.now().isoformat(timespec="seconds"),
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"input": {
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"material": material_key,
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"density_kg_m3": density,
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"thickness_mm": thickness_mm,
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"k_factor": K_FACTOR
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},
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"flat": {
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"bbox_mm": {"width": bbox_w, "height": bbox_h},
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"area_bbox_mm2": area_bbox_mm2,
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"area_net_mm2": area_net_mm2
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},
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"weight": {
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"bbox_kg": mass_bbox_kg,
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"net_kg": mass_net_kg
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},
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"warnings": warnings
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}
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with open(out_json, "w") as f:
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json.dump(result, f, indent=2)
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doc.saveAs(out_fcstd)
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print("OK: flat.dxf + result.json written", flush=True)
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except Exception as e:
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try:
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doc.saveAs(out_fcstd)
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except Exception:
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pass
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err = {
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"ok": False,
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"error": str(e),
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"traceback": traceback.format_exc()
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}
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with open(out_json, "w") as f:
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json.dump(err, f, indent=2)
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print("ERROR:", e, flush=True)
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print(traceback.format_exc(), flush=True)
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os._exit(1)
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os._exit(0)
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if __name__ == "__main__":
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main()
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Reference in New Issue
Block a user