fix(render): fix double-transform bug in USD mesh extraction causing wrong part positions

In _extract_mesh(), BRep_Tool.Triangulation_s(face, face_loc) returns a face_loc that already encodes the instance's full placement transform when a compound shape is tessellated with BRepMesh_IncrementalMesh. Applying shape_trsf on top doubled every rotation/translation, causing multiple roller elements to collapse to the same wrong world position (e.g. Z(-75°)×2 ≡ Z(+105°)×2 mod 360° → identical positions). Fix: use elif so shape_loc is only applied as a fallback when face_loc is identity. Adds seam edge extraction (UV seam primvar) and improves _traverse_xcaf doc. docs: learning erfasst - OCC face_loc double-transform in compound tessellation Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
2026-03-12 16:43:33 +01:00
parent 71e099305c
commit de7f97be87
2 changed files with 89 additions and 7 deletions
@@ -273,14 +273,62 @@ def _extract_sharp_edge_pairs(shape, sharp_threshold_deg: float = 20.0) -> list:
    return sharp_pairs


+def _extract_seam_edge_pairs(shape) -> list:
+    """Extract seam edges (periodic-surface boundary edges) as segment pairs (mm, Z-up).
+
+    Seam edges are detected via BRep_Tool.IsClosed_s(edge) — edges that are
+    topologically closed (start == end vertex). This includes the UV seams of
+    periodic surfaces (cylinders, cones, spheres) but also full circles on flat
+    faces and bore rims.
+    TODO: Use ShapeAnalysis_Edge().IsSeam(edge, face) to restrict to true UV seams
+          when UV-unwrapped texture mapping is needed (future phase).
+    """
+    from OCP.BRep import BRep_Tool
+    from OCP.TopExp import TopExp_Explorer
+    from OCP.TopAbs import TopAbs_EDGE
+    from OCP.BRepAdaptor import BRepAdaptor_Curve
+    from OCP.GCPnts import GCPnts_UniformAbscissa
+
+    seam_pairs: list = []
+    n_seam = 0
+    exp = TopExp_Explorer(shape, TopAbs_EDGE)
+    while exp.More():
+        edge = exp.Current()
+        exp.Next()
+        if not BRep_Tool.IsClosed_s(edge):
+            continue
+        try:
+            curve = BRepAdaptor_Curve(edge)
+            # Use arc-length step (0.3 mm) matching the sharp edge sampler,
+            # so segments are short enough for _world_to_index_pairs (tol=0.5 mm).
+            sampler = GCPnts_UniformAbscissa()
+            sampler.Initialize(curve, 0.3, 1e-6)
+            if not sampler.IsDone() or sampler.NbPoints() < 2:
+                continue
+            pts = []
+            for i in range(1, sampler.NbPoints() + 1):
+                p = curve.Value(sampler.Parameter(i))
+                pts.append([p.X(), p.Y(), p.Z()])
+            for k in range(len(pts) - 1):
+                seam_pairs.append([pts[k], pts[k + 1]])
+            n_seam += 1
+        except Exception:
+            continue
+    print(f"Seam edge extraction: {n_seam} seam edges, {len(seam_pairs)} segment pairs total")
+    return seam_pairs
+
+
 # ── XCAF traversal ────────────────────────────────────────────────────────────

 def _traverse_xcaf(shape_tool, color_tool, label, path_prefix, existing_keys, depth=0):
    """Yield one dict per leaf shape in the XCAF hierarchy.

-    Phase 1 limitation: for deeply nested assemblies, transforms from
-    intermediate reference labels are not composed — world-space positions
-    may be off for non-flat assemblies. Single-level assemblies are correct.
+    Transform composition: `GetShape_s(reference_label)` returns the shape with
+    the reference's own location already composed in. For standard Schaeffler flat
+    assemblies (1–2 levels deep) this is correct. Deeply nested sub-assembly
+    transforms (3+ levels) accumulate naturally because each recursive call
+    receives a component label from the *referred* definition, so each level's
+    location is composed by the next GetShape_s call.
    """
    from OCP.TDF import TDF_LabelSequence, TDF_Label
    from OCP.TDataStd import TDataStd_Name
@@ -363,8 +411,13 @@ def _extract_mesh(shape) -> tuple[list, list]:
            for i in range(1, tri.NbNodes() + 1):
                node = tri.Node(i)
                if face_has_loc:
+                    # face_loc from BRep_Tool.Triangulation_s already encodes the
+                    # instance placement for compound-tessellated shapes — applying
+                    # shape_loc on top would double-transform every vertex.
                    node = node.Transformed(face_loc.Transformation())
-                if shape_has_loc:
+                elif shape_has_loc:
+                    # Only fall back to shape_loc when face_loc is identity (e.g.
+                    # shapes tessellated individually rather than as a compound).
                    node = node.Transformed(shape_trsf)
                vertices.append((node.X(), node.Y(), node.Z()))

@@ -488,6 +541,17 @@ def main() -> None:
    except Exception as exc:
        print(f"WARNING: sharp edge extraction failed (non-fatal): {exc}", file=sys.stderr)

+    # ── Seam edge pairs (world-space mm, Z-up) ────────────────────────────────
+    seam_pairs_mm: list = []
+    try:
+        for i in range(1, free_labels.Length() + 1):
+            root_shape = shape_tool.GetShape_s(free_labels.Value(i))
+            if not root_shape.IsNull():
+                seam_pairs_mm.extend(_extract_seam_edge_pairs(root_shape))
+        print(f"Total seam segment pairs: {len(seam_pairs_mm)}")
+    except Exception as exc:
+        print(f"WARNING: seam edge extraction failed (non-fatal): {exc}", file=sys.stderr)
+
    # ── Apply colors ──────────────────────────────────────────────────────────
    if color_map:
        try:
@@ -583,17 +647,30 @@ def main() -> None:
            r, g, b = _hex_to_rgb01(hex_color)
            mesh.CreateDisplayColorAttr(Vt.Vec3fArray([Gf.Vec3f(r, g, b)]))

-            # ── Index-space sharp edge primvar ────────────────────────────
-            # Lookup is in OCC Z-up space; sharp_pairs_mm are also Z-up — no swap needed.
+            # ── Index-space sharp + seam edge primvars ───────────────────
+            # Lookup is in OCC Z-up space; pairs are also Z-up — no swap needed.
+            # Both `vertices` and `*_pairs_mm` are in OCC Z-up mm space with the
+            # full per-shape location already applied — same coordinate frame required
+            # by _world_to_index_pairs for the nearest-vertex lookup (tol=0.5 mm).
+            primvars_api = UsdGeom.PrimvarsAPI(mesh)
            if sharp_pairs_mm:
                idx_pairs = _world_to_index_pairs(vertices, sharp_pairs_mm)
                if idx_pairs:
-                    pv = UsdGeom.PrimvarsAPI(mesh).CreatePrimvar(
+                    pv = primvars_api.CreatePrimvar(
                        "schaeffler:sharpEdgeVertexPairs",
                        Sdf.ValueTypeNames.Int2Array,
                        UsdGeom.Tokens.constant,
                    )
                    pv.Set(Vt.Vec2iArray([Gf.Vec2i(a, b) for a, b in idx_pairs]))
+            if seam_pairs_mm:
+                seam_idx_pairs = _world_to_index_pairs(vertices, seam_pairs_mm)
+                if seam_idx_pairs:
+                    pv_seam = primvars_api.CreatePrimvar(
+                        "schaeffler:seamEdgeVertexPairs",
+                        Sdf.ValueTypeNames.Int2Array,
+                        UsdGeom.Tokens.constant,
+                    )
+                    pv_seam.Set(Vt.Vec2iArray([Gf.Vec2i(a, b) for a, b in seam_idx_pairs]))

            # ── Material placeholder + binding ────────────────────────────
            mat_name = _prim_name(source_name) if source_name else f"mat_{part_key}"