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Tommaso BianchiandClaude Opus 5
555af98474
The connector work has lived outside the code since 2026-08-05, in a workspace repo with no
remote. It is the basis of a decision that now shapes the Design tab, so it belongs here.
docs/design/mate-connectors/
DESIGN_MATE_CONNECTORS.md seven CAD systems surveyed; the frame-pair model this kernel
already matches; sections 8b/8c on the glyph, and section 9's
four open decisions (D1-D4) still awaiting Tommaso.
bear.step the male, Onshape 2026-08-05T08:27Z, md5 faf228326ee3f971
BearConnector_Female*.step/.stl, BearConnector_Cutter.step
built by make_female.py FROM the real male B-rep rather than
re-modelled, so the pocket is complementary by construction
including every deliberate asymmetry. Fit measured at exactly
0.2000 mm, zero interference, mated hosts proven coplanar.
BEAR_CONNECTOR_REVIEW.md the symmetry-group result: identity 81/81 edges, mirror-x 0/81,
mirror-y 0/81, rot180Z 0/81, rot90Z 0/81, diagonal 0/81 at
0.1 mm. Trivial group, so every PARTIAL view fixes orientation.
extract_outline.py, simplify_study.py, relief_sheet.py, handedness.py, make_female.py,
trim_female.py, fit_check.py, verify_trimmed.py, coplanar_test.py + their sheets
THE DECISION THIS SUPPORTS (snaporca-x0kd): the mate connector is drawn as a simplified BEAR
FACE by default, with the standard disc + roll quadrant + Z arrow kept behind a preference.
Face orientation is hardwired perception -- a toddler reads a face's roll and verse with no
instruction -- and no abstract glyph earns that. Measured against the alternative: the disc's
gold quadrant+tick falls 89 -> 66 -> 37 -> 20 -> 3 -> 0 lit pixels as the camera drops from
47 deg to edge-on, and is a shapeless blob by 16 deg.
WHAT THE SIMPLIFICATION STUDY SETTLED (snaporca-wi3z), all measured off the real B-rep:
The eyes are load-bearing. Same outline and muzzle with the eyes removed stops reading as
a face at every size. Whatever else goes, they stay.
45 -> 22 outline vertices with no loss of read at 22 / 32 / 48 px; the muzzle reduces to
one filled triangle. Three marks plus a cheek dot.
Drawn FLAT the face fails exactly where the disc fails: in the connector's plane everything
foreshortens by sin(elevation). Rendered as its real relief instead, lit pixels at 32 px go
164 -> 210 at 16 deg and 69 -> 120 at 6 deg, and the snout ridge stands proud as a profile
rather than smearing. The glyph must be a shaded relief, not an outline.
Handedness already reads without any added mark -- 32 to 35 % of lit pixels differ from the
mirror, and re-registering by best whole-pixel translation returns offset (0,0), so it is
real shape asymmetry. But it reads only BY COMPARISON. A dot on one cheek makes it local:
34.5 / 37.0 / 36.4 %, and unlike uneven eyes (42 %) it does not read as a defect.
Tommaso's calls: it stays a bear, and handedness must read.
The scripts were repointed at the co-located male and extract_outline.py re-run from here to
prove it -- same 45 outline points, same three inner wires, same 3829.5 mm2 back plate.
Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
69 lines
3.4 KiB
Python
69 lines
3.4 KiB
Python
# Does the connector pair let two hosts sit COPLANAR, or does it hold them apart?
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#
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# The male's flat back is the plane Y=0 and all its relief rises to +Y. So Y=0 is the natural
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# mating datum: everything the male adds lives on one side of it. The test below builds two dummy
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# host plates that meet on that plane -- one with the male FUSED on, one with the cavity CUT in --
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# and measures whether they touch, interfere, or stand apart.
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#
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# It also emits the artifact that makes this work in practice: a CUTTER solid (the male grown by
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# the clearance) that you subtract from any host. A standalone female block cannot keep two hosts
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# coplanar, because its own floor material stands between them; a cavity can.
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#
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# Run: /snap/bin/freecad.cmd coplanar_test.py
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import os
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import FreeCAD as App
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import Part
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from FreeCAD import Vector
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HERE = os.path.dirname(os.path.abspath(__file__))
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MALE = os.path.join(HERE, "bear.step")
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CLEAR = 0.20
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male = Part.Shape(); male.read(MALE); male = male.Solids[0]
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bb = male.BoundBox
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print(f"male relief: Y {bb.YMin:.3f} .. {bb.YMax:.3f} -> datum plane Y=0, all relief on +Y")
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# the flat back face, and proof it is the whole silhouette sitting on Y=0
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back = max((f for f in male.Faces
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if abs(f.CenterOfMass.y) < 1e-6 and abs(abs(f.normalAt(0, 0).y) - 1) < 1e-6),
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key=lambda f: f.Area)
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print(f"back face : {back.Area:.1f} mm2 on Y=0 -- this is the contact surface")
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# ---- the cutter: the male grown by the clearance, poking 0.2 mm proud so the boolean is clean
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cutter = male.makeOffsetShape(CLEAR, 1e-6, False, False, 0, 2, False).Solids[0]
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cb = cutter.BoundBox
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print(f"cutter : Y {cb.YMin:.3f} .. {cb.YMax:.3f}, {cutter.Volume/1000:.2f} cm3")
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# ---- two dummy hosts meeting on Y = 0
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W, H = 120.0, 100.0
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hostA = Part.makeBox(W, 10.0, H, Vector(-W/2, -10.0, -15.0)) # occupies Y -10..0
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hostB = Part.makeBox(W, 30.0, H, Vector(-W/2, 0.0, -15.0)) # occupies Y 0..30
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partA = hostA.fuse(male) # male stands proud of A's face
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partB = hostB.cut(cutter) # cavity sunk into B from its face
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print(f"\npart A (host + male) : {partA.Volume/1000:.2f} cm3")
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print(f"part B (host - cutter) : {partB.Volume/1000:.2f} cm3")
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# ---- the question ------------------------------------------------------------------
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inter = partA.common(partB)
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iv = inter.Volume if inter.Solids else 0.0
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gap = partA.distToShape(partB)[0]
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print(f"\nRESULT interference A vs B : {iv:.6f} mm3 (0 = they do not collide)")
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print(f"RESULT closest approach : {gap:.4f} mm (0 = the host faces are touching)")
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# are the two host faces actually on the same plane?
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fa = [f for f in partA.Faces if abs(f.CenterOfMass.y) < 1e-9 and abs(abs(f.normalAt(0,0).y)-1) < 1e-6]
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fb = [f for f in partB.Faces if abs(f.CenterOfMass.y) < 1e-9 and abs(abs(f.normalAt(0,0).y)-1) < 1e-6]
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print(f"RESULT A has {len(fa)} face(s) lying exactly on Y=0, total {sum(f.Area for f in fa):.1f} mm2")
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print(f"RESULT B has {len(fb)} face(s) lying exactly on Y=0, total {sum(f.Area for f in fb):.1f} mm2")
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print("RESULT -> the hosts meet on Y=0: COPLANAR" if fa and fb and iv < 1e-3
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else "RESULT -> NOT coplanar")
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doc = App.newDocument("Cutter")
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o = doc.addObject("Part::Feature", "BearConnector_Cutter"); o.Shape = cutter
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doc.recompute()
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Part.export([o], os.path.join(HERE, "BearConnector_Cutter.step"))
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print(f"\nwrote BearConnector_Cutter.step -- subtract this from any host to get the socket")
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