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
401
src/model.js
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401
src/model.js
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import { ocRef } from './oc.js';
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export function create3DModel(positions, config) {
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const oc = ocRef.instance;
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if (!oc || positions.length === 0) return null;
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const {
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cellSize,
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spacing,
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height,
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terminalDiameter,
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terminalDepth,
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coverThickness,
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ledgeWidth,
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roundedCorners,
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bmsHoles,
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useTabs,
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useFullCircles,
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filletBms,
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} = config;
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const r = cellSize / 2;
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const minX = Math.min(...positions.map(p => p[0])) - r - spacing;
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const minY = Math.min(...positions.map(p => p[1])) - r - spacing;
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const maxX = Math.max(...positions.map(p => p[0])) + r + spacing;
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const maxY = Math.max(...positions.map(p => p[1])) + r + spacing;
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const centerX = (minX + maxX) / 2;
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const centerY = (minY + maxY) / 2;
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const adjusted = positions.map(([x, y]) => [x - centerX, y - centerY]);
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const width = maxX - minX;
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const length = maxY - minY;
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const perfStart = performance.now();
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let perfLast = perfStart;
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const logTime = (label) => {
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const now = performance.now();
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perfLast = now;
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};
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const boxMaker = new oc.BRepPrimAPI_MakeBox(width, length, height);
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let base = boxMaker.Shape();
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const translation = new oc.gp_Trsf();
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translation.SetTranslation(new oc.gp_Vec(-width / 2, -length / 2, 0));
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const transform = new oc.BRepBuilderAPI_Transform(base, translation, false);
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base = transform.Shape();
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if (roundedCorners) {
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try {
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const cornerRadius = 5.0;
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const forEachEdge = (shape, callback) => {
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const edgeHashes = {};
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let edgeIndex = 0;
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const anExplorer = new oc.TopExp_Explorer(shape, oc.TopAbs_EDGE);
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for (anExplorer.Init(shape, oc.TopAbs_EDGE); anExplorer.More(); anExplorer.Next()) {
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const edge = oc.TopoDS.prototype.Edge(anExplorer.Current());
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const edgeHash = edge.HashCode(100000000);
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if (!edgeHashes.hasOwnProperty(edgeHash)) {
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edgeHashes[edgeHash] = edgeIndex;
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callback(edgeIndex++, edge);
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}
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}
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return edgeHashes;
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};
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const verticalEdgeIndices = [];
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forEachEdge(base, (index, edge) => {
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try {
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const bbox = new oc.Bnd_Box();
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oc.BRepBndLib.prototype.Add(edge, bbox, false);
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const bboxMin = bbox.CornerMin();
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const bboxMax = bbox.CornerMax();
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const dx = Math.abs(bboxMax.X() - bboxMin.X());
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const dy = Math.abs(bboxMax.Y() - bboxMin.Y());
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const dz = Math.abs(bboxMax.Z() - bboxMin.Z());
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if (dx < 1.0 && dy < 1.0 && dz > height * 0.8) {
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verticalEdgeIndices.push(index);
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}
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} catch (e) { /* ignore */ }
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});
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if (verticalEdgeIndices.length > 0) {
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const mkFillet = new oc.BRepFilletAPI_MakeFillet(base);
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let edgeCount = 0;
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forEachEdge(base, (index, edge) => {
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if (verticalEdgeIndices.includes(index)) {
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try {
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mkFillet.Add(cornerRadius, edge);
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edgeCount++;
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} catch (e) {
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console.error(` Failed to add edge ${index}:`, e.message);
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}
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}
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});
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if (edgeCount > 0) {
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base = new oc.TopoDS_Solid(mkFillet.Shape());
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console.log(' Applied rounded corners');
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logTime('Rounded corners');
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}
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} else {
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console.log(' No vertical edges found to fillet');
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}
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} catch (e) {
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console.error(' Fillet operation failed:', e.message);
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console.log(' Continuing without rounded corners');
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}
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}
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// Build cell hole cutters.
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// When a ledge is requested (ledgeWidth > 0 || coverThickness > 0) we use a
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// two-step bore so the ledge ring stays part of the base body:
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// • outer bore (radius r) from z=coverThickness to z=height
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// • inner bore (radius r - ledgeWidth) from z=0 to z=height
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const hasLedge = (ledgeWidth > 0 || coverThickness > 0);
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if (!hasLedge) {
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const cutters = adjusted.map(([x, y]) => {
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const ax = new oc.gp_Ax2(new oc.gp_Pnt(x, y, 0), oc.gp.prototype.DZ());
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return new oc.BRepPrimAPI_MakeCylinder(ax, r, height).Shape();
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});
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let allCutters = cutters[0];
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for (let i = 1; i < cutters.length; i++) {
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allCutters = new oc.BRepAlgoAPI_Fuse(allCutters, cutters[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, allCutters).Shape();
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} else {
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const outerZ = coverThickness;
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const outerH = height - coverThickness;
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const innerR = Math.max(0.1, r - ledgeWidth);
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const outerCutters = adjusted.map(([x, y]) => {
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const ax = new oc.gp_Ax2(new oc.gp_Pnt(x, y, outerZ), oc.gp.prototype.DZ());
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return new oc.BRepPrimAPI_MakeCylinder(ax, r, outerH).Shape();
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});
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let allOuter = outerCutters[0];
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for (let i = 1; i < outerCutters.length; i++) {
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allOuter = new oc.BRepAlgoAPI_Fuse(allOuter, outerCutters[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, allOuter).Shape();
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const innerCutters = adjusted.map(([x, y]) => {
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const ax = new oc.gp_Ax2(new oc.gp_Pnt(x, y, 0), oc.gp.prototype.DZ());
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return new oc.BRepPrimAPI_MakeCylinder(ax, innerR, height).Shape();
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});
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let allInner = innerCutters[0];
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for (let i = 1; i < innerCutters.length; i++) {
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allInner = new oc.BRepAlgoAPI_Fuse(allInner, innerCutters[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, allInner).Shape();
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}
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console.log(' Cell holes cut' + (hasLedge ? ' (with integrated ledge)' : ''));
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logTime('Cell holes');
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if (bmsHoles) {
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const holeDiameter = config.bmsHoleDiameter || 4.0;
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let holeYTop, holeYBottom;
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if (useFullCircles) {
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holeYTop = null;
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holeYBottom = null;
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} else {
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holeYTop = length / 2;
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holeYBottom = -length / 2;
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}
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const rows = {};
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adjusted.forEach(([x, y]) => {
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const yKey = Math.round(y * 1000);
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if (!rows[yKey]) rows[yKey] = [];
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rows[yKey].push([x, y]);
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});
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const rowKeys = Object.keys(rows).map(k => parseInt(k)).sort((a, b) => b - a);
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const topYKey = rowKeys[0];
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const bottomYKey = rowKeys[rowKeys.length - 1];
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if (useFullCircles) {
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const topCellY = rows[topYKey][0][1];
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const bottomCellY = rows[bottomYKey][0][1];
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const wallTop = length / 2;
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const wallBottom = -length / 2;
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const solveEquilateral3D = (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;
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let 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 Bx = x1 + r * Math.cos(alpha);
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const By = cellY + r * Math.sin(alpha);
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const d = xMid - Bx;
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const h = (By - 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); }
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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 + r * Math.sin(alpha);
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return (wallY + 2 * By) / 3;
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};
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holeYTop = solveEquilateral3D(wallTop, topCellY, rows[topYKey][0][0], rows[topYKey][1][0]);
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holeYBottom = solveEquilateral3D(wallBottom, bottomCellY, rows[bottomYKey][0][0], rows[bottomYKey][1][0]);
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}
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const topRow = rows[topYKey].sort((a, b) => a[0] - b[0]);
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const bottomRow = rows[bottomYKey].sort((a, b) => a[0] - b[0]);
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const topHoles = [];
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for (let i = 0; i < topRow.length - 1; i++) {
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const xMid = (topRow[i][0] + topRow[i + 1][0]) / 2;
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topHoles.push([xMid, holeYTop]);
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}
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const bottomHoles = [];
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for (let i = 0; i < bottomRow.length - 1; i++) {
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const xMid = (bottomRow[i][0] + bottomRow[i + 1][0]) / 2;
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bottomHoles.push([xMid, holeYBottom]);
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}
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const allBmsHoles = [...topHoles, ...bottomHoles];
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if (useTabs) {
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const slotWidth = config.tabWidth || holeDiameter;
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const slotInset = config.tabDepth || 1.0;
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const topEdgeY = length / 2;
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const bottomEdgeY = -length / 2;
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const allSlots = [];
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topHoles.forEach(([xPos]) => {
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const slotBox = new oc.BRepPrimAPI_MakeBox(slotWidth, slotInset, height);
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const slot = slotBox.Shape();
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const trans = new oc.gp_Trsf();
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trans.SetTranslation(new oc.gp_Vec(xPos - slotWidth / 2, topEdgeY - slotInset, 0));
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const slotTransform = new oc.BRepBuilderAPI_Transform(slot, trans, false);
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allSlots.push(slotTransform.Shape());
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});
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bottomHoles.forEach(([xPos]) => {
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const slotBox = new oc.BRepPrimAPI_MakeBox(slotWidth, slotInset, height);
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const slot = slotBox.Shape();
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const trans = new oc.gp_Trsf();
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trans.SetTranslation(new oc.gp_Vec(xPos - slotWidth / 2, bottomEdgeY, 0));
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const slotTransform = new oc.BRepBuilderAPI_Transform(slot, trans, false);
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allSlots.push(slotTransform.Shape());
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});
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if (allSlots.length > 0) {
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if (allSlots.length === 1) {
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base = new oc.BRepAlgoAPI_Cut(base, allSlots[0]).Shape();
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} else {
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let compound = allSlots[0];
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for (let i = 1; i < allSlots.length; i++) {
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compound = new oc.BRepAlgoAPI_Fuse(compound, allSlots[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, compound).Shape();
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}
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}
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logTime('Edge tabs');
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} else {
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if (allBmsHoles.length <= 10) {
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allBmsHoles.forEach(([x, y]) => {
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const cylinderAxis = new oc.gp_Ax2(new oc.gp_Pnt(x, y, 0), oc.gp.prototype.DZ());
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const cylinder = new oc.BRepPrimAPI_MakeCylinder(cylinderAxis, holeDiameter / 2, height).Shape();
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base = new oc.BRepAlgoAPI_Cut(base, cylinder).Shape();
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});
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} else {
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const bmsCylinders = allBmsHoles.map(([x, y]) => {
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const cylinderAxis = new oc.gp_Ax2(new oc.gp_Pnt(x, y, 0), oc.gp.prototype.DZ());
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return new oc.BRepPrimAPI_MakeCylinder(cylinderAxis, holeDiameter / 2, height).Shape();
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});
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let compound = bmsCylinders[0];
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for (let i = 1; i < bmsCylinders.length; i++) {
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compound = new oc.BRepAlgoAPI_Fuse(compound, bmsCylinders[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, compound).Shape();
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}
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logTime('BMS holes');
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if (filletBms && allBmsHoles.length > 0) {
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try {
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console.log(' Filleting BMS hole edges...');
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const bmsFilletRadius = 0.5;
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const forEachEdge = (shape, callback) => {
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const edgeHashes = {};
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let edgeIndex = 0;
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const anExplorer = new oc.TopExp_Explorer(shape, oc.TopAbs_EDGE);
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for (anExplorer.Init(shape, oc.TopAbs_EDGE); anExplorer.More(); anExplorer.Next()) {
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const edge = oc.TopoDS.prototype.Edge(anExplorer.Current());
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const edgeHash = edge.HashCode(100000000);
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if (!edgeHashes.hasOwnProperty(edgeHash)) {
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edgeHashes[edgeHash] = edgeIndex;
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callback(edgeIndex++, edge);
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}
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}
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return edgeHashes;
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};
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const bmsEdgeIndices = [];
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forEachEdge(base, (index, edge) => {
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try {
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const bbox = new oc.Bnd_Box();
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oc.BRepBndLib.prototype.Add(edge, bbox, false);
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const bboxMin = bbox.CornerMin();
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const bboxMax = bbox.CornerMax();
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const centerX = (bboxMin.X() + bboxMax.X()) / 2;
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const centerY = (bboxMin.Y() + bboxMax.Y()) / 2;
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const centerZ = (bboxMin.Z() + bboxMax.Z()) / 2;
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for (const [holeX, holeY] of allBmsHoles) {
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const distXY = Math.hypot(centerX - holeX, centerY - holeY);
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const isNearHole = distXY < holeDiameter;
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const isAtTopOrBottom = Math.abs(centerZ - 0) < 1.0 || Math.abs(centerZ - height) < 1.0;
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if (isNearHole && isAtTopOrBottom) {
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bmsEdgeIndices.push(index);
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break;
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}
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}
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} catch (e) { /* ignore */ }
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});
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if (bmsEdgeIndices.length > 0) {
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const mkFillet = new oc.BRepFilletAPI_MakeFillet(base);
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let edgeCount = 0;
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forEachEdge(base, (index, edge) => {
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if (bmsEdgeIndices.includes(index)) {
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try {
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mkFillet.Add(bmsFilletRadius, edge);
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edgeCount++;
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} catch (e) {
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console.error(` Failed to add BMS edge ${index}`);
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}
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}
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});
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if (edgeCount > 0) {
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base = new oc.TopoDS_Solid(mkFillet.Shape());
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console.log(` Applied ${bmsFilletRadius}mm fillet to ${edgeCount} BMS hole edges`);
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}
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}
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} catch (e) {
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console.error(' BMS fillet failed:', e.message);
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console.log(' Continuing without BMS filleting');
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}
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}
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}
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}
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if (adjusted.length <= 10) {
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adjusted.forEach(([x, y]) => {
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const cylinderAxis = new oc.gp_Ax2(new oc.gp_Pnt(x, y, height - terminalDepth), oc.gp.prototype.DZ());
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const cylinder = new oc.BRepPrimAPI_MakeCylinder(cylinderAxis, terminalDiameter / 2, terminalDepth).Shape();
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base = new oc.BRepAlgoAPI_Cut(base, cylinder).Shape();
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});
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} else {
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const terminals = adjusted.map(([x, y]) => {
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const cylinderAxis = new oc.gp_Ax2(new oc.gp_Pnt(x, y, height - terminalDepth), oc.gp.prototype.DZ());
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return new oc.BRepPrimAPI_MakeCylinder(cylinderAxis, terminalDiameter / 2, terminalDepth).Shape();
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});
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const batchSize = 30;
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const batches = [];
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for (let i = 0; i < terminals.length; i += batchSize) {
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const end = Math.min(i + batchSize, terminals.length);
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let batch = terminals[i];
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for (let j = i + 1; j < end; j++) {
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batch = new oc.BRepAlgoAPI_Fuse(batch, terminals[j]).Shape();
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}
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batches.push(batch);
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}
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let allTerminals = batches[0];
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for (let i = 1; i < batches.length; i++) {
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allTerminals = new oc.BRepAlgoAPI_Fuse(allTerminals, batches[i]).Shape();
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}
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base = new oc.BRepAlgoAPI_Cut(base, allTerminals).Shape();
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}
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console.log(' Terminal recesses cut');
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logTime('Terminal recesses');
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if (hasLedge) {
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console.log(' Ledge integrated into cell holes');
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}
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logTime('Ledge rings');
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logTime('TOTAL GENERATION');
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return base;
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}
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