fix: Cincinnati post processor arc feedrate, G89 spacing, pallet exchange, and preamble

- Add radius-based arc feedrate calculation (Variables/Percentages modes) with configurable radius ranges (#123/#124/#125 or inline expressions) - Fix arc distance in SpeedClassifier using actual arc length instead of chord length (full circles previously computed as zero) - Fix G89 P spacing: P now adjacent to filename per CL-707 manual syntax - Add lead-out feedrate support (#129) and arc lead-in feedrate (#127) - Fix pallet exchange: StartAndEnd emits M50 in preamble + last sheet only - Add G121 Smart Rapids emission when UseSmartRapids is enabled - Add G90 absolute mode to main program preamble alongside G20/G21 Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
2026-03-30 09:33:50 -04:00
parent 722f758e94
commit 3d4204db7b
10 changed files with 515 additions and 22 deletions
--- a/OpenNest.Tests/Cincinnati/CincinnatiFeatureWriterTests.cs
+++ b/OpenNest.Tests/Cincinnati/CincinnatiFeatureWriterTests.cs
@@ -297,7 +297,7 @@ public class CincinnatiFeatureWriterTests
        ctx.SheetDiagonal = 30.0;
        var output = WriteFeature(config, ctx);

-        Assert.Contains("G89 P MILD10", output);
+        Assert.Contains("G89 PMILD10", output);
    }

    [Fact]
@@ -470,6 +470,123 @@ public class CincinnatiFeatureWriterTests
        Assert.True(m131Idx < m47Idx, "M131 should come before M47");
    }

+    [Fact]
+    public void LeadoutFeedrate_UsesVariable129()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        var codes = new List<ICode>
+        {
+            new RapidMove(1.0, 1.0),
+            new LinearMove(2.0, 1.0) { Layer = LayerType.Leadout }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F#129", output);
+    }
+
+    [Fact]
+    public void ArcLeadin_UsesVariable127()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        var codes = new List<ICode>
+        {
+            new RapidMove(10.0, 20.0),
+            new ArcMove(new Vector(12.0, 20.0), new Vector(11.0, 20.0), RotationType.CCW) { Layer = LayerType.Leadin }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F#127", output);
+    }
+
+    [Fact]
+    public void ArcFeedrate_VariablesMode_UsesRadiusRangeVariable()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        config.ArcFeedrate = ArcFeedrateMode.Variables;
+        // Arc with radius 0.5 (center at 10.5, 20; start at 10, 20) → R=0.5 → #124 (R ≤ 0.750)
+        var codes = new List<ICode>
+        {
+            new RapidMove(10.0, 20.0),
+            new ArcMove(new Vector(11.0, 20.0), new Vector(10.5, 20.0), RotationType.CW) { Layer = LayerType.Cut }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F#124", output);
+    }
+
+    [Fact]
+    public void ArcFeedrate_PercentagesMode_UsesInlineExpression()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        config.ArcFeedrate = ArcFeedrateMode.Percentages;
+        // Arc with radius 0.1 (≤ 0.125) → 25%
+        var codes = new List<ICode>
+        {
+            new RapidMove(10.0, 20.0),
+            new ArcMove(new Vector(10.2, 20.0), new Vector(10.1, 20.0), RotationType.CW) { Layer = LayerType.Cut }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F[#148*0.25]", output);
+    }
+
+    [Fact]
+    public void ArcFeedrate_LargeRadius_UsesProcessFeedrate()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        config.ArcFeedrate = ArcFeedrateMode.Variables;
+        // Arc with radius 10 (> 4.500) → falls through to #148
+        var codes = new List<ICode>
+        {
+            new RapidMove(0.0, 0.0),
+            new ArcMove(new Vector(20.0, 0.0), new Vector(10.0, 0.0), RotationType.CCW) { Layer = LayerType.Cut }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F#148", output);
+    }
+
+    [Fact]
+    public void ArcFeedrate_NoneMode_UsesProcessFeedrateForNonCircle()
+    {
+        var config = DefaultConfig();
+        config.KerfCompensation = KerfMode.PreApplied;
+        config.ArcFeedrate = ArcFeedrateMode.None;
+        // Small radius arc but mode is None → process feedrate
+        var codes = new List<ICode>
+        {
+            new RapidMove(10.0, 20.0),
+            new ArcMove(new Vector(10.2, 20.0), new Vector(10.1, 20.0), RotationType.CW) { Layer = LayerType.Cut }
+        };
+        var ctx = SimpleContext(codes);
+        var output = WriteFeature(config, ctx);
+
+        Assert.Contains("F#148", output);
+    }
+
+    [Fact]
+    public void G89_PAdjacentToFilename()
+    {
+        var config = DefaultConfig();
+        var ctx = SimpleContext();
+        ctx.LibraryFile = "MS135N2.lib";
+        var output = WriteFeature(config, ctx);
+
+        // P must be directly adjacent to filename, no space
+        Assert.Contains("G89 PMS135N2.lib", output);
+        Assert.DoesNotContain("G89 P MS135N2.lib", output);
+    }
+
    private static int CountOccurrences(string text, string pattern)
    {
        var count = 0;
--- a/OpenNest.Tests/Cincinnati/CincinnatiPostProcessorTests.cs
+++ b/OpenNest.Tests/Cincinnati/CincinnatiPostProcessorTests.cs
@@ -43,6 +43,74 @@ public class CincinnatiPostProcessorTests
        Assert.Contains("M99", output);
    }

+    [Fact]
+    public void Post_EmitsLeadOutVariable()
+    {
+        var nest = CreateTestNest();
+        var config = new CincinnatiPostConfig { PostedAccuracy = 4 };
+        var post = new CincinnatiPostProcessor(config);
+
+        using var ms = new MemoryStream();
+        post.Post(nest, ms);
+
+        var output = Encoding.UTF8.GetString(ms.ToArray());
+        Assert.Contains("#129=", output);
+    }
+
+    [Fact]
+    public void Post_WithArcFeedrateVariables_EmitsRangeVariables()
+    {
+        var nest = CreateTestNest();
+        var config = new CincinnatiPostConfig
+        {
+            PostedAccuracy = 4,
+            ArcFeedrate = ArcFeedrateMode.Variables
+        };
+        var post = new CincinnatiPostProcessor(config);
+
+        using var ms = new MemoryStream();
+        post.Post(nest, ms);
+
+        var output = Encoding.UTF8.GetString(ms.ToArray());
+        Assert.Contains("#123=", output);
+        Assert.Contains("#124=", output);
+        Assert.Contains("#125=", output);
+    }
+
+    [Fact]
+    public void Post_WithArcFeedrateNone_OmitsRangeVariables()
+    {
+        var nest = CreateTestNest();
+        var config = new CincinnatiPostConfig
+        {
+            PostedAccuracy = 4,
+            ArcFeedrate = ArcFeedrateMode.None
+        };
+        var post = new CincinnatiPostProcessor(config);
+
+        using var ms = new MemoryStream();
+        post.Post(nest, ms);
+
+        var output = Encoding.UTF8.GetString(ms.ToArray());
+        Assert.DoesNotContain("#123=", output);
+        Assert.DoesNotContain("#124=", output);
+        Assert.DoesNotContain("#125=", output);
+    }
+
+    [Fact]
+    public void Post_EmitsG90InPreamble()
+    {
+        var nest = CreateTestNest();
+        var config = new CincinnatiPostConfig { PostedAccuracy = 4 };
+        var post = new CincinnatiPostProcessor(config);
+
+        using var ms = new MemoryStream();
+        post.Post(nest, ms);
+
+        var output = Encoding.UTF8.GetString(ms.ToArray());
+        Assert.Contains("G20 G90", output);
+    }
+
    [Fact]
    public void Post_ImplementsIPostProcessor()
    {
--- a/OpenNest.Tests/Cincinnati/CincinnatiPreambleWriterTests.cs
+++ b/OpenNest.Tests/Cincinnati/CincinnatiPreambleWriterTests.cs
@@ -24,9 +24,9 @@ public class CincinnatiPreambleWriterTests
        var output = sb.ToString();
        Assert.Contains("( NEST TestNest )", output);
        Assert.Contains("( CONFIGURATION - CL940 )", output);
-        Assert.Contains("G20", output);
+        Assert.Contains("G20 G90", output);
        Assert.Contains("M42", output);
-        Assert.Contains("G89 P MS135N2PANEL.lib", output);
+        Assert.Contains("G89 PMS135N2PANEL.lib", output);
        Assert.Contains("M98 P100 (Variable Declaration)", output);
        Assert.Contains("GOTO1 (GOTO SHEET NUMBER)", output);
        Assert.Contains("N1 M98 P101 (SHEET 1)", output);
@@ -44,7 +44,72 @@ public class CincinnatiPreambleWriterTests

        writer.WriteMainProgram(sw, "Test", "", 1, "");

-        Assert.Contains("G21", sb.ToString());
+        Assert.Contains("G21 G90", sb.ToString());
+    }
+
+    [Fact]
+    public void WriteMainProgram_EmitsG90WithUnits()
+    {
+        var config = new CincinnatiPostConfig { PostedUnits = Units.Inches };
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var writer = new CincinnatiPreambleWriter(config);
+
+        writer.WriteMainProgram(sw, "Test", "", 1, "");
+
+        Assert.Contains("G20 G90", sb.ToString());
+    }
+
+    [Fact]
+    public void WriteMainProgram_EmitsG121_WhenSmartRapidsEnabled()
+    {
+        var config = new CincinnatiPostConfig { UseSmartRapids = true };
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var writer = new CincinnatiPreambleWriter(config);
+
+        writer.WriteMainProgram(sw, "Test", "", 1, "");
+
+        Assert.Contains("G121 (SMART RAPIDS)", sb.ToString());
+    }
+
+    [Fact]
+    public void WriteMainProgram_OmitsG121_WhenSmartRapidsDisabled()
+    {
+        var config = new CincinnatiPostConfig { UseSmartRapids = false };
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var writer = new CincinnatiPreambleWriter(config);
+
+        writer.WriteMainProgram(sw, "Test", "", 1, "");
+
+        Assert.DoesNotContain("G121", sb.ToString());
+    }
+
+    [Fact]
+    public void WriteMainProgram_EmitsM50_WhenStartAndEnd()
+    {
+        var config = new CincinnatiPostConfig { PalletExchange = PalletMode.StartAndEnd };
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var writer = new CincinnatiPreambleWriter(config);
+
+        writer.WriteMainProgram(sw, "Test", "", 1, "");
+
+        Assert.Contains("M50", sb.ToString());
+    }
+
+    [Fact]
+    public void WriteMainProgram_OmitsM50_WhenEndOfSheet()
+    {
+        var config = new CincinnatiPostConfig { PalletExchange = PalletMode.EndOfSheet };
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var writer = new CincinnatiPreambleWriter(config);
+
+        writer.WriteMainProgram(sw, "Test", "", 1, "");
+
+        Assert.DoesNotContain("M50", sb.ToString());
    }

    [Fact]
--- a/OpenNest.Tests/Cincinnati/CincinnatiSheetWriterTests.cs
+++ b/OpenNest.Tests/Cincinnati/CincinnatiSheetWriterTests.cs
@@ -32,7 +32,7 @@ public class CincinnatiSheetWriterTests
        Assert.Contains("#110=", output);
        Assert.Contains("#111=", output);
        Assert.Contains("G92 X#5021 Y#5022", output);
-        Assert.Contains("G89 P MS135N2PANEL.lib", output);
+        Assert.Contains("G89 PMS135N2PANEL.lib", output);
        Assert.Contains("M99", output);
    }

@@ -137,9 +137,110 @@ public class CincinnatiSheetWriterTests
        Assert.True(g85Idx < g84Idx, "G85 (etch) should come before G84 (cut)");

        // Etch uses etch library
-        Assert.Contains("G89 P EtchN2.lib", output);
+        Assert.Contains("G89 PEtchN2.lib", output);
        // Cut uses cut library
-        Assert.Contains("G89 P MS250O2.lib", output);
+        Assert.Contains("G89 PMS250O2.lib", output);
+    }
+
+    [Fact]
+    public void WriteSheet_StartAndEnd_NoM50OnNonLastSheet()
+    {
+        var config = new CincinnatiPostConfig
+        {
+            PalletExchange = PalletMode.StartAndEnd,
+            PostedAccuracy = 4
+        };
+        var plate = new Plate(48.0, 96.0);
+        plate.Parts.Add(new Part(new Drawing("TestPart", CreateSimpleProgram())));
+
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var sheetWriter = new CincinnatiSheetWriter(config, new ProgramVariableManager());
+
+        sheetWriter.Write(sw, plate, "TestNest", 1, 101, "", "", isLastSheet: false);
+
+        var output = sb.ToString();
+        Assert.DoesNotContain("M50", output);
+    }
+
+    [Fact]
+    public void WriteSheet_StartAndEnd_M50OnLastSheet()
+    {
+        var config = new CincinnatiPostConfig
+        {
+            PalletExchange = PalletMode.StartAndEnd,
+            PostedAccuracy = 4
+        };
+        var plate = new Plate(48.0, 96.0);
+        plate.Parts.Add(new Part(new Drawing("TestPart", CreateSimpleProgram())));
+
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var sheetWriter = new CincinnatiSheetWriter(config, new ProgramVariableManager());
+
+        sheetWriter.Write(sw, plate, "TestNest", 1, 101, "", "", isLastSheet: true);
+
+        var output = sb.ToString();
+        Assert.Contains("M50", output);
+    }
+
+    [Fact]
+    public void WriteSheet_EndOfSheet_AlwaysEmitsM50()
+    {
+        var config = new CincinnatiPostConfig
+        {
+            PalletExchange = PalletMode.EndOfSheet,
+            PostedAccuracy = 4
+        };
+        var plate = new Plate(48.0, 96.0);
+        plate.Parts.Add(new Part(new Drawing("TestPart", CreateSimpleProgram())));
+
+        var sb = new StringBuilder();
+        using var sw = new StringWriter(sb);
+        var sheetWriter = new CincinnatiSheetWriter(config, new ProgramVariableManager());
+
+        sheetWriter.Write(sw, plate, "TestNest", 1, 101, "", "", isLastSheet: false);
+
+        var output = sb.ToString();
+        Assert.Contains("M50", output);
+    }
+
+    [Fact]
+    public void ComputeArcLength_FullCircle_Returns2PiR()
+    {
+        var start = new Vector(10.0, 20.0);
+        var arc = new ArcMove(new Vector(10.0, 20.0), new Vector(15.0, 20.0), RotationType.CW);
+        var length = FeatureUtils.ComputeArcLength(start, arc);
+
+        // Radius = 5, full circle = 2 * PI * 5 ≈ 31.416
+        Assert.Equal(2.0 * System.Math.PI * 5.0, length, 4);
+    }
+
+    [Fact]
+    public void ComputeArcLength_Semicircle_ReturnsPiR()
+    {
+        // Semicircle from (0,0) to (10,0) with center at (5,0), CCW → goes through (5,5)
+        var start = new Vector(0.0, 0.0);
+        var arc = new ArcMove(new Vector(10.0, 0.0), new Vector(5.0, 0.0), RotationType.CCW);
+        var length = FeatureUtils.ComputeArcLength(start, arc);
+
+        // Radius = 5, semicircle = PI * 5 ≈ 15.708
+        Assert.Equal(System.Math.PI * 5.0, length, 4);
+    }
+
+    [Fact]
+    public void ComputeCutDistance_WithArcs_UsesArcLengthNotChord()
+    {
+        // Full circle: chord = 0 but arc length = 2πr
+        var codes = new List<ICode>
+        {
+            new RapidMove(10.0, 20.0),
+            new ArcMove(new Vector(10.0, 20.0), new Vector(15.0, 20.0), RotationType.CW) { Layer = LayerType.Cut }
+        };
+        var distance = FeatureUtils.ComputeCutDistance(codes);
+
+        // Full circle with R=5 → 2πr ≈ 31.416
+        Assert.True(distance > 30.0, $"Expected arc length > 30 but got {distance}");
    }

    [Fact]