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fix: add overlap safety check and diagnostics to FillGrid Step 2

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FillGrid had no overlap check after perpendicular tiling of the row
pattern (Step 2), unlike Step 1 which had one. When geometry-aware
FindPatternCopyDistance underestimated row spacing, overlapping parts
were returned unchecked.

Changes:
- Make FillLinear.HasOverlappingParts shape-aware (bbox pre-filter +
  Part.Intersects) instead of bbox-only, preventing false positives on
  interlocking pairs while catching real overlaps
- Add missing overlap safety check after Step 2 perpendicular tiling
  with bbox fallback
- Add diagnostic Debug.WriteLine logging when overlap fallback triggers,
  including engine label, step, direction, work area, spacing, pattern
  details, and overlapping part locations/rotations for reproduction
- Add FillLinear.Label property set at all callsites for log traceability
- Refactor LinearFillStrategy and ExtentsFillStrategy to use shared
  FillHelpers.BestOverAngles helper for angle-sweep logic

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
AJ Isaacs
2026-03-28 22:08:38 -04:00
parent 1c2b569ff4
commit 953429dae9
9 changed files with 133 additions and 67 deletions
Download Patch File Download Diff File Expand all files Collapse all files

2
OpenNest.Engine/DefaultNestEngine.cs
View File

@@ -94,7 +94,7 @@ namespace OpenNest
// Multi-part group: linear pattern fill only.
PhaseResults.Clear();
var engine = new FillLinear(workArea, Plate.PartSpacing);
var engine = new FillLinear(workArea, Plate.PartSpacing) { Label = "GroupPattern" };
var angles = RotationAnalysis.FindHullEdgeAngles(groupParts);
var best = FillHelpers.FillPattern(engine, groupParts, angles, workArea, Comparer);
PhaseResults.Add(new PhaseResult(NestPhase.Linear, best?.Count ?? 0, 0));

63
OpenNest.Engine/Fill/FillLinear.cs
View File

@@ -1,6 +1,7 @@
using OpenNest.Geometry;
using OpenNest.Math;
using System.Collections.Generic;
using System.Diagnostics;
using System.Threading.Tasks;
namespace OpenNest.Engine.Fill
@@ -19,6 +20,11 @@ namespace OpenNest.Engine.Fill
public double HalfSpacing => PartSpacing / 2;
/// <summary>
/// Diagnostic label set by callers to identify the engine/context in overlap logs.
/// </summary>
public string Label { get; set; }
private static Vector MakeOffset(NestDirection direction, double distance)
{
return direction == NestDirection.Horizontal
@@ -323,7 +329,7 @@ namespace OpenNest.Engine.Fill
return result;
}
private static bool HasOverlappingParts(List<Part> parts)
private static bool HasOverlappingParts(List<Part> parts, out int overlapA, out int overlapB)
{
for (var i = 0; i < parts.Count; i++)
{
@@ -338,11 +344,20 @@ namespace OpenNest.Engine.Fill
var overlapY = System.Math.Min(b1.Top, b2.Top)
- System.Math.Max(b1.Bottom, b2.Bottom);
if (overlapX > Tolerance.Epsilon && overlapY > Tolerance.Epsilon)
if (overlapX <= Tolerance.Epsilon || overlapY <= Tolerance.Epsilon)
continue;
if (parts[i].Intersects(parts[j], out _))
{
overlapA = i;
overlapB = j;
return true;
}
}
}
overlapA = -1;
overlapB = -1;
return false;
}
@@ -384,10 +399,9 @@ namespace OpenNest.Engine.Fill
var row = new List<Part>(pattern.Parts);
row.AddRange(TilePattern(pattern, direction, boundaries));
// Safety: if geometry-aware spacing produced overlapping parts,
// fall back to bbox-based spacing for this axis.
if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
if (pattern.Parts.Count > 1 && HasOverlappingParts(row, out var a1, out var b1))
{
LogOverlap("Step1-Primary", direction, pattern, row, a1, b1);
row = new List<Part>(pattern.Parts);
row.AddRange(TilePatternBbox(pattern, direction));
}
@@ -397,8 +411,9 @@ namespace OpenNest.Engine.Fill
{
row.AddRange(TilePattern(pattern, perpAxis, boundaries));
if (pattern.Parts.Count > 1 && HasOverlappingParts(row))
if (pattern.Parts.Count > 1 && HasOverlappingParts(row, out var a2, out var b2))
{
LogOverlap("Step1-PerpOnly", perpAxis, pattern, row, a2, b2);
row = new List<Part>(pattern.Parts);
row.AddRange(TilePatternBbox(pattern, perpAxis));
}
@@ -415,9 +430,45 @@ namespace OpenNest.Engine.Fill
var gridResult = new List<Part>(rowPattern.Parts);
gridResult.AddRange(TilePattern(rowPattern, perpAxis, rowBoundaries));
if (HasOverlappingParts(gridResult, out var a3, out var b3))
{
LogOverlap("Step2-Perp", perpAxis, rowPattern, gridResult, a3, b3);
gridResult = new List<Part>(rowPattern.Parts);
gridResult.AddRange(TilePatternBbox(rowPattern, perpAxis));
}
return gridResult;
}
private void LogOverlap(string step, NestDirection tilingDir,
Pattern pattern, List<Part> parts, int idxA, int idxB)
{
var pa = parts[idxA];
var pb = parts[idxB];
var ba = pa.BoundingBox;
var bb = pb.BoundingBox;
Debug.WriteLine($"[FillLinear] OVERLAP FALLBACK ({Label ?? "unknown"})");
Debug.WriteLine($" Step: {step}, TilingDir: {tilingDir}");
Debug.WriteLine($" WorkArea: ({WorkArea.X:F4},{WorkArea.Y:F4}) {WorkArea.Width:F4}x{WorkArea.Length:F4}, Spacing: {PartSpacing}");
Debug.WriteLine($" Pattern: {pattern.Parts.Count} parts, bbox {pattern.BoundingBox.Width:F4}x{pattern.BoundingBox.Length:F4}");
Debug.WriteLine($" Total parts after tiling: {parts.Count}");
Debug.WriteLine($" Overlapping pair [{idxA}] vs [{idxB}]:");
Debug.WriteLine($" [{idxA}]: drawing={pa.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(pa.Rotation):F2}° " +
$"loc=({pa.Location.X:F4},{pa.Location.Y:F4}) bbox=({ba.Left:F4},{ba.Bottom:F4})-({ba.Right:F4},{ba.Top:F4})");
Debug.WriteLine($" [{idxB}]: drawing={pb.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(pb.Rotation):F2}° " +
$"loc=({pb.Location.X:F4},{pb.Location.Y:F4}) bbox=({bb.Left:F4},{bb.Bottom:F4})-({bb.Right:F4},{bb.Top:F4})");
// Log all pattern seed parts for reproduction
Debug.WriteLine($" Pattern seed parts:");
for (var i = 0; i < pattern.Parts.Count; i++)
{
var p = pattern.Parts[i];
Debug.WriteLine($" [{i}]: drawing={p.BaseDrawing?.Name ?? "?"} rot={Angle.ToDegrees(p.Rotation):F2}° " +
$"loc=({p.Location.X:F4},{p.Location.Y:F4}) bbox={p.BoundingBox.Width:F4}x{p.BoundingBox.Length:F4}");
}
}
/// <summary>
/// Fills a single row of identical parts along one axis using geometry-aware spacing.
/// </summary>

4
OpenNest.Engine/Fill/PairFiller.cs
View File

@@ -195,7 +195,7 @@ namespace OpenNest.Engine.Fill
if (pattern.Parts.Count == 0)
continue;
var engine = new FillLinear(workArea, partSpacing);
var engine = new FillLinear(workArea, partSpacing) { Label = "Pairs" };
foreach (var dir in new[] { NestDirection.Horizontal, NestDirection.Vertical })
{
if (!dedup.TryAdd(pattern.BoundingBox, workArea, dir))
@@ -321,7 +321,7 @@ namespace OpenNest.Engine.Fill
return cachedResult;
}
var filler = new FillLinear(remnantBox, partSpacing);
var filler = new FillLinear(remnantBox, partSpacing) { Label = "Pairs-Remnant" };
List<Part> parts = null;
foreach (var angle in new[] { 0.0, Angle.HalfPI })

8
OpenNest.Engine/Fill/StripeFiller.cs
View File

@@ -121,7 +121,7 @@ public class StripeFiller
if (!_dedup.TryAdd(rotatedPattern.BoundingBox, workArea, primaryAxis))
return null;
var stripeEngine = new FillLinear(stripeBox, spacing);
var stripeEngine = new FillLinear(stripeBox, spacing) { Label = "Stripe" };
var stripeParts = stripeEngine.Fill(rotatedPattern, primaryAxis);
if (stripeParts == null || stripeParts.Count == 0)
@@ -136,7 +136,7 @@ public class StripeFiller
stripePattern.Parts.AddRange(stripeParts);
stripePattern.UpdateBounds();
var gridEngine = new FillLinear(workArea, spacing);
var gridEngine = new FillLinear(workArea, spacing) { Label = "Stripe-Grid" };
var gridParts = gridEngine.Fill(stripePattern, perpAxis);
if (gridParts == null || gridParts.Count == 0)
@@ -244,7 +244,7 @@ public class StripeFiller
return cachedResult;
}
var filler = new FillLinear(remnantBox, spacing);
var filler = new FillLinear(remnantBox, spacing) { Label = "Stripe-Remnant" };
List<Part> best = null;
foreach (var angle in new[] { 0.0, Angle.HalfPI })
@@ -396,7 +396,7 @@ public class StripeFiller
var stripeBox = axis == NestDirection.Horizontal
? new Box(0, 0, sheetSpan, perpDim)
: new Box(0, 0, perpDim, sheetSpan);
var engine = new FillLinear(stripeBox, spacing);
var engine = new FillLinear(stripeBox, spacing) { Label = "Stripe-EstimateRow" };
var filled = engine.Fill(rotated, axis);
var n = filled?.Count ?? 0;

20
OpenNest.Engine/Strategies/ExtentsFillStrategy.cs
View File

@@ -20,22 +20,10 @@ namespace OpenNest.Engine.Strategies
var angles = new[] { bestRotation, bestRotation + Angle.HalfPI };
List<Part> best = null;
var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
foreach (var angle in angles)
{
context.Token.ThrowIfCancellationRequested();
var result = filler.Fill(context.Item.Drawing, angle,
context.PlateNumber, context.Token, context.Progress);
if (result != null && result.Count > 0)
{
if (best == null || comparer.IsBetter(result, best, context.WorkArea))
best = result;
}
}
return best ?? new List<Part>();
return FillHelpers.BestOverAngles(context, angles,
angle => filler.Fill(context.Item.Drawing, angle,
context.PlateNumber, context.Token, context.Progress),
NestPhase.Extents, "Extents");
}
}
}

43
OpenNest.Engine/Strategies/FillHelpers.cs
View File

@@ -110,6 +110,49 @@ namespace OpenNest.Engine.Strategies
return fallback ?? new List<Part>();
}
/// <summary>
/// Sweeps a list of angles, calling fillAtAngle for each, and returns
/// the best result according to the context's comparer. Handles
/// cancellation and progress reporting.
/// </summary>
public static List<Part> BestOverAngles(
FillContext context,
IReadOnlyList<double> angles,
Func<double, List<Part>> fillAtAngle,
NestPhase phase,
string phaseLabel)
{
var workArea = context.WorkArea;
var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
List<Part> best = null;
for (var i = 0; i < angles.Count; i++)
{
context.Token.ThrowIfCancellationRequested();
var angle = angles[i];
var result = fillAtAngle(angle);
var angleDeg = Angle.ToDegrees(angle);
if (result != null && result.Count > 0)
{
if (best == null || comparer.IsBetter(result, best, workArea))
best = result;
}
NestEngineBase.ReportProgress(context.Progress, new ProgressReport
{
Phase = phase,
PlateNumber = context.PlateNumber,
Parts = best,
WorkArea = workArea,
Description = $"{phaseLabel}: {i + 1}/{angles.Count} angles, {angleDeg:F0}° best = {best?.Count ?? 0} parts",
});
}
return best ?? new List<Part>();
}
/// <summary>
/// Checks if any pair of parts geometrically overlap. Uses bounding box
/// pre-filtering for performance, then falls back to shape intersection.

53
OpenNest.Engine/Strategies/LinearFillStrategy.cs
View File

@@ -19,45 +19,28 @@ namespace OpenNest.Engine.Strategies
var workArea = context.WorkArea;
var comparer = context.Policy?.Comparer ?? new DefaultFillComparer();
var preferred = context.Policy?.PreferredDirection;
List<Part> best = null;
for (var ai = 0; ai < angles.Count; ai++)
{
context.Token.ThrowIfCancellationRequested();
var angle = angles[ai];
var engine = new FillLinear(workArea, context.Plate.PartSpacing);
var result = FillHelpers.FillWithDirectionPreference(
dir => engine.Fill(context.Item.Drawing, angle, dir),
preferred, comparer, workArea);
var angleDeg = Angle.ToDegrees(angle);
if (result != null && result.Count > 0)
return FillHelpers.BestOverAngles(context, angles,
angle =>
{
context.AngleResults.Add(new AngleResult
var engine = new FillLinear(workArea, context.Plate.PartSpacing) { Label = "Linear" };
var result = FillHelpers.FillWithDirectionPreference(
dir => engine.Fill(context.Item.Drawing, angle, dir),
preferred, comparer, workArea);
if (result != null && result.Count > 0)
{
AngleDeg = angleDeg,
Direction = preferred ?? NestDirection.Horizontal,
PartCount = result.Count
});
context.AngleResults.Add(new AngleResult
{
AngleDeg = Angle.ToDegrees(angle),
Direction = preferred ?? NestDirection.Horizontal,
PartCount = result.Count
});
}
if (best == null || comparer.IsBetter(result, best, workArea))
best = result;
}
NestEngineBase.ReportProgress(context.Progress, new ProgressReport
{
Phase = NestPhase.Linear,
PlateNumber = context.PlateNumber,
Parts = best,
WorkArea = workArea,
Description = $"Linear: {ai + 1}/{angles.Count} angles, {angleDeg:F0}° best = {best?.Count ?? 0} parts",
});
}
return best ?? new List<Part>();
return result;
},
NestPhase.Linear, "Linear");
}
}
}

1
OpenNest.Tests/StrategyOverlapTests.cs
View File

@@ -107,4 +107,5 @@ public class StrategyOverlapTests
Assert.Empty(failures);
}
}

6
OpenNest/Forms/PatternTileForm.cs
View File

@@ -220,7 +220,7 @@ namespace OpenNest.Forms
return;
var workArea = new Box(0, 0, plateSize.Length, plateSize.Width);
var filler = new FillLinear(workArea, PartSpacing);
var filler = new FillLinear(workArea, PartSpacing) { Label = "PatternTile-H" };
var hParts = filler.Fill(pattern, NestDirection.Horizontal);
foreach (var part in hParts)
@@ -228,7 +228,7 @@ namespace OpenNest.Forms
hLabel.Text = $"Horizontal — {hParts.Count} parts";
hPreview.ZoomToFit();
var vFiller = new FillLinear(workArea, PartSpacing);
var vFiller = new FillLinear(workArea, PartSpacing) { Label = "PatternTile-V" };
var vParts = vFiller.Fill(pattern, NestDirection.Vertical);
foreach (var part in vParts)
vPreview.Plate.Parts.Add(part);
@@ -328,7 +328,7 @@ namespace OpenNest.Forms
if (pattern == null)
return;
var filler = new FillLinear(new Box(0, 0, plateSize.Length, plateSize.Width), PartSpacing);
var filler = new FillLinear(new Box(0, 0, plateSize.Length, plateSize.Width), PartSpacing) { Label = "PatternTile-Apply" };
var tiledParts = filler.Fill(pattern, applyDirection);
Result = new PatternTileResult