Initial commit: cell holder generator + busbar builder
- 3D printable cell holder with STEP export (grid/honeycomb/vertical layouts) - Configurable BMS holes (half circles, full circles, edge tabs) - Busbar builder: click cells to define busbars, auto-routed with bend fallback - Compound STEP export bundles holder + busbars - OpenCascade.js (wasm) vendored for 3D modeling
This commit is contained in:
Maxim
495
src/app.js
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495
src/app.js
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@@ -0,0 +1,495 @@
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import { canvasState } from './state.js';
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import { showStatus, showLoading } from './ui.js';
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import { ocRef, initOC } from './oc.js';
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import {
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generateGridLayout,
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generateHoneycombLayout,
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generateVerticalHoneycombLayout,
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getCachedPositions,
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} from './layouts.js';
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import { drawPreview, clearCanvas } from './preview.js';
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import { create3DModel } from './model.js';
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import { downloadSTEP } from './step-export.js';
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import { busbarStore } from './busbars.js';
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import { computeBusbarGeometry } from './busbar-geometry.js';
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import { drawBusbarsOverlay } from './busbar-preview.js';
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import { build3DBusbar } from './busbar-model.js';
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import { renderBusbarList } from './busbar-ui.js';
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let lastComputedGeometries = [];
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export function getLastBusbarGeometries() {
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return lastComputedGeometries;
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}
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export function updatePreview(resetView = false) {
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if (resetView) {
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canvasState.zoom = 1.0;
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canvasState.panX = 0;
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canvasState.panY = 0;
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}
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const stats = document.getElementById('previewStats');
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const setStats = (text, color) => {
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stats.textContent = text;
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stats.style.color = color;
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};
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try {
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const xDim = parseFloat(document.getElementById('xDim').value);
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const yDim = parseFloat(document.getElementById('yDim').value);
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const spacing = parseFloat(document.getElementById('spacing').value);
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const cellSize = parseFloat(document.getElementById('cellSize').value);
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const layoutType = document.getElementById('layoutType').value;
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const ledgeWidth = parseFloat(document.getElementById('ledgeWidth').value) || 0;
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const bmsHoleDiameter = parseFloat(document.getElementById('bmsHoleDiameter').value) || 4.0;
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const coverThickness = parseFloat(document.getElementById('coverThickness').value);
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if (!xDim || !yDim || !spacing || !cellSize) {
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setStats('Configure settings to see preview', '#94a3b8');
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return;
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}
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if (ledgeWidth > 0 && ledgeWidth >= cellSize) {
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setStats(`Ledge width (${ledgeWidth}mm) must be less than cell diameter (${cellSize}mm)!`, '#ef4444');
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clearCanvas();
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return;
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}
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const minPackSize = cellSize + spacing * 2;
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if (xDim < minPackSize || yDim < minPackSize) {
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setStats(`Pack too small! Minimum: ${minPackSize.toFixed(1)}×${minPackSize.toFixed(1)} mm`, '#ef4444');
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clearCanvas();
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return;
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}
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if (cellSize > xDim || cellSize > yDim) {
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setStats(`Cell diameter (${cellSize}mm) larger than pack dimensions!`, '#ef4444');
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clearCanvas();
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return;
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}
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if (spacing < 0) {
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setStats(`Cell spacing cannot be negative!`, '#ef4444');
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clearCanvas();
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return;
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}
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const positions = getCachedPositions(xDim, yDim, spacing, cellSize, layoutType);
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if (!positions || positions.length === 0) {
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setStats(`No cells fit! Increase pack size or decrease cell size/spacing`, '#ef4444');
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clearCanvas();
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return;
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}
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const bmsHolesType = document.getElementById('bmsHolesType').value;
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const bmsHoles = bmsHolesType !== 'off';
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if (bmsHoles) {
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if (bmsHoleDiameter > cellSize) {
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setStats(`BMS hole (${bmsHoleDiameter}mm) larger than cell (${cellSize}mm)! Reduce hole size.`, '#ef4444');
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clearCanvas();
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return;
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}
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const cellRadius = cellSize / 2;
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const bmsHoleRadius = bmsHoleDiameter / 2;
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const r = cellRadius;
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const minY = Math.min(...positions.map(p => p[1]));
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const maxY = Math.max(...positions.map(p => p[1]));
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const packMaxY = maxY + r + spacing;
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const packMinY = minY - r - spacing;
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const rows = {};
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for (const [x, y] of positions) {
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const key = Math.round(y * 1000);
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if (!rows[key]) rows[key] = [];
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rows[key].push([x, y]);
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}
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const rowKeys = Object.keys(rows).map(Number).sort((a, b) => a - b);
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const topYKey = rowKeys[rowKeys.length - 1];
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const bottomYKey = rowKeys[0];
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rows[topYKey].sort((a, b) => a[0] - b[0]);
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rows[bottomYKey].sort((a, b) => a[0] - b[0]);
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const topEdge = packMaxY;
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const bottomEdge = packMinY;
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for (let i = 0; i < rows[topYKey].length - 1; i++) {
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const bmsX = (rows[topYKey][i][0] + rows[topYKey][i + 1][0]) / 2;
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const bmsY = topEdge;
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for (const [cellX, cellY] of positions) {
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const distance = Math.hypot(bmsX - cellX, bmsY - cellY);
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const minDistance = bmsHoleRadius + cellRadius;
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if (distance < minDistance) {
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const maxDiameter = (distance - cellRadius) * 2;
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setStats(`BMS hole overlaps cells! Max diameter: ${maxDiameter.toFixed(1)}mm`, '#ef4444');
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canvasState.currentPositions = [];
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clearCanvas();
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return;
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}
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}
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}
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for (let i = 0; i < rows[bottomYKey].length - 1; i++) {
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const bmsX = (rows[bottomYKey][i][0] + rows[bottomYKey][i + 1][0]) / 2;
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const bmsY = bottomEdge;
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for (const [cellX, cellY] of positions) {
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const distance = Math.hypot(bmsX - cellX, bmsY - cellY);
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const minDistance = bmsHoleRadius + cellRadius;
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if (distance < minDistance) {
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setStats(`BMS hole overlaps cells! Reduce hole diameter.`, '#ef4444');
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canvasState.currentPositions = [];
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clearCanvas();
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return;
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}
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}
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}
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}
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if (coverThickness > cellSize / 2) {
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setStats(`Cover thickness (${coverThickness}mm) very large for cell size (${cellSize}mm)`, '#f59e0b');
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}
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if (spacing < 0.5 && spacing > 0) {
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setStats(`Spacing < 0.5mm may be difficult to 3D print`, '#f59e0b');
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}
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if (positions.length < 2) {
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setStats(`Only ${positions.length} cell fits. Increase pack size for practical holder.`, '#f59e0b');
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} else {
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stats.style.color = '#10b981';
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}
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drawPreview(positions, cellSize);
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const cellRadius = cellSize / 2;
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const busbarPadRadius = Math.max(cellRadius - ledgeWidth, 1.0);
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const busbarKeepoutRadius = 4.0;
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lastComputedGeometries = busbarStore.list.map(bb =>
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computeBusbarGeometry(bb.cellIndices, positions, cellRadius, busbarPadRadius, spacing, busbarKeepoutRadius)
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);
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drawBusbarsOverlay(busbarStore.list, lastComputedGeometries, positions, cellSize, busbarPadRadius, spacing, busbarStore.activeId);
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const blockedByBusbarId = {};
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busbarStore.list.forEach((bb, i) => {
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const g = lastComputedGeometries[i];
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if (g && g.blocked) blockedByBusbarId[bb.id] = g.blocked.reason;
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});
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renderBusbarList(blockedByBusbarId);
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const minX = Math.min(...positions.map(p => p[0]));
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const minY = Math.min(...positions.map(p => p[1]));
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const maxX = Math.max(...positions.map(p => p[0]));
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const maxY = Math.max(...positions.map(p => p[1]));
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const actualWidth = maxX - minX + cellSize + spacing * 2;
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const actualHeight = maxY - minY + cellSize + spacing * 2;
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if (positions.length >= 2) {
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stats.textContent = `${positions.length} cells • ${actualWidth.toFixed(0)}×${actualHeight.toFixed(0)} mm`;
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}
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} catch (error) {
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console.error('Preview error:', error);
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setStats('Error: ' + error.message, '#ef4444');
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}
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}
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export async function generateLayout() {
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const layoutType = document.getElementById('layoutType').value;
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if (!ocRef.initialized) {
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showStatus('3D engine not ready. Please wait...', 'error');
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await initOC();
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if (!ocRef.initialized) return;
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}
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showLoading(true, 'Generating 3D Model', 'Please be patient...');
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await new Promise(resolve => setTimeout(resolve, 50));
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try {
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const xDim = parseFloat(document.getElementById('xDim').value);
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const yDim = parseFloat(document.getElementById('yDim').value);
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const spacing = parseFloat(document.getElementById('spacing').value);
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const cellSize = parseFloat(document.getElementById('cellSize').value);
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const ledgeWidth = parseFloat(document.getElementById('ledgeWidth').value) || 0;
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const bmsHoleDiameter = parseFloat(document.getElementById('bmsHoleDiameter').value) || 4.0;
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const coverThickness = parseFloat(document.getElementById('coverThickness').value);
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const cellRadius = cellSize / 2;
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const bmsHoleRadius = bmsHoleDiameter / 2;
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if (ledgeWidth > 0 && ledgeWidth >= cellSize) {
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showStatus(`Ledge width (${ledgeWidth}mm) must be less than cell diameter (${cellSize}mm)!`, 'error');
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showLoading(false);
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return;
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}
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const minPackSize = cellSize + spacing * 2;
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if (xDim < minPackSize || yDim < minPackSize) {
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showStatus(`Pack too small! Minimum size: ${minPackSize.toFixed(1)}×${minPackSize.toFixed(1)} mm`, 'error');
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showLoading(false);
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return;
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}
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if (cellSize > xDim || cellSize > yDim) {
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showStatus('Cell diameter is larger than pack dimensions!', 'error');
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showLoading(false);
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return;
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}
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if (spacing < 0) {
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showStatus('Cell spacing cannot be negative!', 'error');
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showLoading(false);
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return;
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}
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const height = parseFloat(document.getElementById('height').value);
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const terminalDiameter = 8.0;
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const terminalDepth = 1.0;
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const roundedCorners = document.getElementById('roundedCorners').checked;
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const bmsHolesType = document.getElementById('bmsHolesType').value;
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const bmsHoles = bmsHolesType !== 'off';
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const useTabs = bmsHolesType === 'tabs';
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const useFullCircles = bmsHolesType === 'fullcircles';
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const filletBms = false;
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const circleHoleOffset = false;
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let positions;
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let layoutName;
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switch (layoutType) {
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case 'grid':
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positions = generateGridLayout(xDim, yDim, spacing, cellSize);
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layoutName = 'Grid Layout';
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break;
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case 'honeycomb':
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positions = generateHoneycombLayout(xDim, yDim, spacing, cellSize);
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layoutName = 'Honeycomb Layout';
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break;
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case 'vertical':
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positions = generateVerticalHoneycombLayout(xDim, yDim, spacing, cellSize);
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layoutName = 'Vertical Honeycomb';
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break;
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default:
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showStatus('Invalid layout type', 'error');
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return;
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}
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if (bmsHoles && useFullCircles) {
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const solveEquilateralY = (wallY, cellY, x1, x2) => {
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const xMid = (x1 + x2) / 2;
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const flip = cellY < wallY ? -1 : 1;
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let lo = flip > 0 ? -Math.PI / 2 : 0, hi = flip > 0 ? 0 : Math.PI / 2;
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for (let i = 0; i < 80; i++) {
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const alpha = (lo + hi) / 2;
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const d = xMid - (x1 + cellRadius * Math.cos(alpha));
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const h = (cellY + cellRadius * Math.sin(alpha) - wallY) * flip;
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const diff = h - d * Math.sqrt(3);
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if (Math.abs(diff) < 1e-8) break;
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if (diff < 0) { flip > 0 ? (lo = alpha) : (hi = alpha); } else { flip > 0 ? (hi = alpha) : (lo = alpha); }
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}
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const alpha = (lo + hi) / 2;
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const By = cellY + cellRadius * Math.sin(alpha);
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return (wallY + 2 * By) / 3;
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};
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const minY = Math.min(...positions.map(p => p[1]));
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const maxY = Math.max(...positions.map(p => p[1]));
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const packMinY = minY - cellRadius - spacing;
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const packMaxY = maxY + cellRadius + spacing;
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const rows = {};
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for (const [x, y] of positions) {
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const key = Math.round(y * 1000);
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if (!rows[key]) rows[key] = [];
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rows[key].push([x, y]);
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}
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const rowKeys = Object.keys(rows).map(Number).sort((a, b) => a - b);
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const visualTopKey = rowKeys[0];
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const visualBotKey = rowKeys[rowKeys.length - 1];
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rows[visualTopKey].sort((a, b) => a[0] - b[0]);
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rows[visualBotKey].sort((a, b) => a[0] - b[0]);
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const holePositions = [];
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for (let i = 0; i < rows[visualTopKey].length - 1; i++) {
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const x1 = rows[visualTopKey][i][0], x2 = rows[visualTopKey][i + 1][0];
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const adjY = rows[visualTopKey][i][1];
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holePositions.push({ hx: (x1 + x2) / 2, hy: solveEquilateralY(packMinY, adjY, x1, x2) });
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}
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for (let i = 0; i < rows[visualBotKey].length - 1; i++) {
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const x1 = rows[visualBotKey][i][0], x2 = rows[visualBotKey][i + 1][0];
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const adjY = rows[visualBotKey][i][1];
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holePositions.push({ hx: (x1 + x2) / 2, hy: solveEquilateralY(packMaxY, adjY, x1, x2) });
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}
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for (const { hx, hy } of holePositions) {
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let minDist = Infinity;
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for (const [cx, cy] of positions) {
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const dist = Math.hypot(hx - cx, hy - cy);
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if (dist < minDist) minDist = dist;
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}
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if (minDist < bmsHoleRadius + cellRadius) {
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const maxAllowed = (minDist - cellRadius) * 2;
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showStatus(`BMS hole too large, overlaps cell! Max diameter: ${maxAllowed.toFixed(2)}mm`, 'error');
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showLoading(false);
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return;
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}
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}
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} else if (bmsHoles) {
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const minY = Math.min(...positions.map(p => p[1]));
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const maxY = Math.max(...positions.map(p => p[1]));
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const r = cellSize / 2;
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const packMinY = minY - r - spacing;
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const packMaxY = maxY + r + spacing;
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const rows = {};
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for (const [x, y] of positions) {
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const key = Math.round(y * 1000);
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if (!rows[key]) rows[key] = [];
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rows[key].push([x, y]);
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}
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const rowKeys = Object.keys(rows).map(Number).sort((a, b) => a - b);
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const topYKey = rowKeys[rowKeys.length - 1];
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const bottomYKey = rowKeys[0];
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rows[topYKey].sort((a, b) => a[0] - b[0]);
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rows[bottomYKey].sort((a, b) => a[0] - b[0]);
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const topY = rows[topYKey][0][1];
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const bottomY = rows[bottomYKey][0][1];
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let topEdge, bottomEdge;
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if (circleHoleOffset) {
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const offsetDistance = bmsHoleRadius + 1.0;
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topEdge = topY + cellRadius + offsetDistance;
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bottomEdge = bottomY - cellRadius - offsetDistance;
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} else {
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topEdge = packMaxY;
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bottomEdge = packMinY;
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}
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for (let i = 0; i < rows[topYKey].length - 1; i++) {
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const bmsX = (rows[topYKey][i][0] + rows[topYKey][i + 1][0]) / 2;
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const bmsY = topEdge;
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const adjacentCell1 = [rows[topYKey][i][0], rows[topYKey][i][1]];
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const adjacentCell2 = [rows[topYKey][i + 1][0], rows[topYKey][i + 1][1]];
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for (const [cellX, cellY] of positions) {
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if ((cellX === adjacentCell1[0] && cellY === adjacentCell1[1]) ||
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(cellX === adjacentCell2[0] && cellY === adjacentCell2[1])) continue;
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const distance = Math.hypot(bmsX - cellX, bmsY - cellY);
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if (distance < bmsHoleRadius + cellRadius + ledgeWidth) {
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showStatus(`BMS hole (${bmsHoleDiameter}mm) collides with cell ledges! Reduce BMS hole size or increase spacing.`, 'error');
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showLoading(false);
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return;
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}
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}
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}
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for (let i = 0; i < rows[bottomYKey].length - 1; i++) {
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const bmsX = (rows[bottomYKey][i][0] + rows[bottomYKey][i + 1][0]) / 2;
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const bmsY = bottomEdge;
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const adjacentCell1 = [rows[bottomYKey][i][0], rows[bottomYKey][i][1]];
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const adjacentCell2 = [rows[bottomYKey][i + 1][0], rows[bottomYKey][i + 1][1]];
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for (const [cellX, cellY] of positions) {
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if ((cellX === adjacentCell1[0] && cellY === adjacentCell1[1]) ||
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(cellX === adjacentCell2[0] && cellY === adjacentCell2[1])) continue;
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const distance = Math.hypot(bmsX - cellX, bmsY - cellY);
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if (distance < bmsHoleRadius + cellRadius + ledgeWidth) {
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showStatus(`BMS hole (${bmsHoleDiameter}mm) collides with cell ledges! Reduce BMS hole size or increase spacing.`, 'error');
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showLoading(false);
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return;
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}
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}
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||||
}
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||||
}
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||||
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||||
const tabWidth = parseFloat(document.getElementById('tabWidth').value) || 4.0;
|
||||
const tabDepth = parseFloat(document.getElementById('tabDepth').value) || 1.0;
|
||||
|
||||
const config = {
|
||||
cellSize, spacing, height, terminalDiameter, terminalDepth,
|
||||
coverThickness, roundedCorners, bmsHoles, ledgeWidth,
|
||||
filletBms, circleHoleOffset, useTabs, useFullCircles, bmsHoleDiameter,
|
||||
tabWidth, tabDepth,
|
||||
};
|
||||
|
||||
const holderShape = create3DModel(positions, config);
|
||||
|
||||
if (!holderShape) {
|
||||
showStatus('Failed to create 3D model', 'error');
|
||||
return;
|
||||
}
|
||||
|
||||
const busbarPadRadius = Math.max(cellRadius - ledgeWidth, 1.0);
|
||||
const busbarKeepoutRadius = terminalDiameter / 2;
|
||||
const busbarGeometries = busbarStore.list.map(bb =>
|
||||
computeBusbarGeometry(bb.cellIndices, positions, cellRadius, busbarPadRadius, spacing, busbarKeepoutRadius)
|
||||
);
|
||||
|
||||
for (let i = 0; i < busbarStore.list.length; i++) {
|
||||
const bb = busbarStore.list[i];
|
||||
const geom = busbarGeometries[i];
|
||||
if (geom.blocked) {
|
||||
showStatus(`${bb.name}: ${geom.blocked.reason} — cannot export`, 'error');
|
||||
showLoading(false);
|
||||
return;
|
||||
}
|
||||
}
|
||||
|
||||
const holderCenterX = (Math.min(...positions.map(p => p[0])) + Math.max(...positions.map(p => p[0]))) / 2;
|
||||
const holderCenterY = (Math.min(...positions.map(p => p[1])) + Math.max(...positions.map(p => p[1]))) / 2;
|
||||
const centeredPositions = positions.map(([x, y]) => [x - holderCenterX, y - holderCenterY]);
|
||||
|
||||
const busbarShapes = [];
|
||||
for (let i = 0; i < busbarStore.list.length; i++) {
|
||||
const bb = busbarStore.list[i];
|
||||
if (bb.cellIndices.length === 0) continue;
|
||||
const shape = build3DBusbar(busbarGeometries[i], centeredPositions, busbarPadRadius, height, bb.thickness);
|
||||
if (shape) busbarShapes.push(shape);
|
||||
}
|
||||
|
||||
const oc = ocRef.instance;
|
||||
let exportShape = holderShape;
|
||||
if (busbarShapes.length > 0) {
|
||||
const compound = new oc.TopoDS_Compound();
|
||||
const builder = new oc.BRep_Builder();
|
||||
builder.MakeCompound(compound);
|
||||
builder.Add(compound, holderShape);
|
||||
for (const s of busbarShapes) builder.Add(compound, s);
|
||||
exportShape = compound;
|
||||
}
|
||||
|
||||
const filename = `${layoutType}_layout.step`;
|
||||
downloadSTEP(exportShape, filename);
|
||||
|
||||
const holeType = useTabs ? 'edge tabs' :
|
||||
(circleHoleOffset ? 'circle offset' : 'semicircle offset');
|
||||
const filletMsg = (filletBms && !useTabs) ? ' with filleted holes' : '';
|
||||
const busbarMsg = busbarShapes.length > 0 ? ` + ${busbarShapes.length} busbar${busbarShapes.length === 1 ? '' : 's'}` : '';
|
||||
|
||||
showStatus(
|
||||
`${layoutName} generated with ${positions.length} cells (${holeType}${filletMsg})${busbarMsg}`,
|
||||
'success'
|
||||
);
|
||||
} catch (error) {
|
||||
console.error('Generation error:', error);
|
||||
showStatus('Error: ' + error.message, 'error');
|
||||
} finally {
|
||||
showLoading(false);
|
||||
}
|
||||
}
|
||||
Reference in New Issue
Block a user