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fix: improve arc-tangency fitting and add layered engrave/cut passes for GravographIS

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GeometrySimplifier/ArcFit now fit arcs that pass exactly through run
endpoints while balancing tangency error between trusted and estimated
directions, fixing arcs that previously bulged or broke tangent
continuity at fillet/compound-curve junctions.

GravographIS post processor gains per-layer (engrave/cut) tool passes
via a new GravographISPostConfig, so ENGRAVE/ETCH-tagged geometry runs
as a separate scribe pass with its own feed/depth and an operator
pause before the cut pass (spring-floated spindle needs a tool swap).

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
This commit is contained in:
aj
2026-08-06 23:15:18 -04:00
co-authored by Claude Opus 4.6
parent e493d83899
commit a085339ba9
15 changed files with 1084 additions and 138 deletions
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OpenNest.Tests/Converters/ConvertGeometryLayerTests.cs
+70
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@@ -0,0 +1,70 @@
using System.Linq;
using OpenNest.CNC;
using OpenNest.Converters;
using OpenNest.Geometry;
namespace OpenNest.Tests.Converters;
public class ConvertGeometryLayerTests
{
private static Program ProgramFor(Entity entity)
{
var shape = new Shape();
shape.Entities.Add(entity);
return ConvertGeometry.ToProgram(shape);
}
[Fact]
public void AddLine_EngraveLayer_TagsScribe()
{
var line = new Line(0, 0, 1, 0) { Layer = new Layer("ENGRAVE") };
var pgm = ProgramFor(line);
Assert.All(pgm.Codes.OfType<LinearMove>(), m => Assert.Equal(LayerType.Scribe, m.Layer));
}
[Fact]
public void AddLine_EtchLayer_TagsScribe()
{
var line = new Line(0, 0, 1, 0) { Layer = new Layer("etch") };
var pgm = ProgramFor(line);
Assert.All(pgm.Codes.OfType<LinearMove>(), m => Assert.Equal(LayerType.Scribe, m.Layer));
}
[Fact]
public void AddArc_EngraveLayer_TagsScribe()
{
var arc = new Arc(new Vector(0, 0), 1, 0, System.Math.PI / 2) { Layer = new Layer("ENGRAVE") };
var pgm = ProgramFor(arc);
var arcs = pgm.Codes.OfType<ArcMove>().ToList();
Assert.NotEmpty(arcs);
Assert.All(arcs, m => Assert.Equal(LayerType.Scribe, m.Layer));
}
[Fact]
public void AddCircle_EngraveLayer_TagsScribe()
{
var circle = new Circle(0, 0, 1) { Layer = new Layer("ENGRAVE") };
var pgm = ProgramFor(circle);
var arcs = pgm.Codes.OfType<ArcMove>().ToList();
Assert.NotEmpty(arcs);
Assert.All(arcs, m => Assert.Equal(LayerType.Scribe, m.Layer));
}
[Fact]
public void AddLine_DefaultLayer_StaysCut()
{
var line = new Line(0, 0, 1, 0) { Layer = new Layer("0") };
var pgm = ProgramFor(line);
Assert.All(pgm.Codes.OfType<LinearMove>(), m => Assert.Equal(LayerType.Cut, m.Layer));
}
}
OpenNest.Tests/Geometry/GeometrySimplifierTests.cs
+105
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@@ -131,6 +131,111 @@ public class GeometrySimplifierTests
Assert.IsType<Arc>(result.Entities[6]);
}
[Fact]
public void Analyze_FilletBetweenTangentLines_ArcIsTangentToLines()
{
// A 90-degree fillet (r=0.3, center origin, 270deg..360deg CCW) between two
// long tangent lines, approximated by 8 chords whose interior vertices bulge
// radially outward within tolerance (simulates real DXF tessellation noise).
var r = 0.3;
var deltas = new[] { 0.0, 0.002, 0.003, 0.0035, 0.0035, 0.0035, 0.003, 0.002, 0.0 };
var pts = new List<Vector>();
for (var i = 0; i <= 8; i++)
{
var ang = OpenNest.Math.Angle.ToRadians(270 + 11.25 * i);
var radius = r + deltas[i];
pts.Add(new Vector(radius * System.Math.Cos(ang), radius * System.Math.Sin(ang)));
}
var shape = new Shape();
shape.Entities.Add(new Line(new Vector(-2, -r), pts[0]));
for (var i = 0; i < pts.Count - 1; i++)
shape.Entities.Add(new Line(pts[i], pts[i + 1]));
shape.Entities.Add(new Line(pts[^1], new Vector(r, 2)));
var simplifier = new GeometrySimplifier { Tolerance = 0.004 };
var candidates = simplifier.Analyze(shape);
Assert.Single(candidates);
var arc = candidates[0].FittedArc;
// Arc must pass exactly through the run's boundary vertices (no gaps)
Assert.True(arc.StartPoint().DistanceTo(pts[0]) < 1e-6);
Assert.True(arc.EndPoint().DistanceTo(pts[^1]) < 1e-6);
// Arc must be tangent to the adjacent straight edges at its endpoints
var startDelta = AngleBetweenDeg(ArcTangentAt(arc, arc.StartPoint()), new Vector(1, 0));
var endDelta = AngleBetweenDeg(ArcTangentAt(arc, arc.EndPoint()), new Vector(0, 1));
Assert.True(startDelta < 0.3, $"Arc start not tangent to incoming line: off by {startDelta:F3} deg");
Assert.True(endDelta < 0.3, $"Arc end not tangent to outgoing line: off by {endDelta:F3} deg");
}
[Fact]
public void Analyze_CompoundCurve_AdjacentArcsAreTangentAtJunction()
{
// Two tangent-continuous arcs of different radii (r=0.2 sweeping 60deg, then
// r=0.6 sweeping 40deg), tessellated into chords with slight radial noise.
// The fitted arcs must stay tangent-continuous at their junction.
var c1 = new Vector(0, 0);
var r1 = 0.2;
var deltas1 = new[] { 0.0, 0.001, 0.0005, -0.0005, -0.001, -0.0005, 0.0 };
var pts = new List<Vector>();
for (var i = 0; i <= 6; i++)
{
var ang = OpenNest.Math.Angle.ToRadians(10 * i);
var radius = r1 + deltas1[i];
pts.Add(new Vector(c1.X + radius * System.Math.Cos(ang), c1.Y + radius * System.Math.Sin(ang)));
}
// Second arc center along the junction radius so tangents match at the junction
var junctionAngle = OpenNest.Math.Angle.ToRadians(60);
var u = new Vector(System.Math.Cos(junctionAngle), System.Math.Sin(junctionAngle));
var r2 = 0.6;
var c2 = new Vector(c1.X + u.X * (r1 - r2), c1.Y + u.Y * (r1 - r2));
var deltas2 = new[] { 0.0, 0.001, -0.001, 0.0005, -0.0005, 0.0 };
for (var i = 1; i <= 5; i++)
{
var ang = OpenNest.Math.Angle.ToRadians(60 + 8 * i);
var radius = r2 + deltas2[i];
pts.Add(new Vector(c2.X + radius * System.Math.Cos(ang), c2.Y + radius * System.Math.Sin(ang)));
}
var shape = new Shape();
for (var i = 0; i < pts.Count - 1; i++)
shape.Entities.Add(new Line(pts[i], pts[i + 1]));
var simplifier = new GeometrySimplifier { Tolerance = 0.004 };
var candidates = simplifier.Analyze(shape);
Assert.Equal(2, candidates.Count);
var arcA = candidates[0].FittedArc;
var arcB = candidates[1].FittedArc;
// Arcs must share the junction vertex exactly
Assert.True(arcA.EndPoint().DistanceTo(arcB.StartPoint()) < 1e-6);
// Tangent continuity across the junction
var junctionDelta = AngleBetweenDeg(ArcTangentAt(arcA, arcA.EndPoint()), ArcTangentAt(arcB, arcB.StartPoint()));
Assert.True(junctionDelta < 0.3, $"Tangent break of {junctionDelta:F3} deg at arc-arc junction");
}
private static Vector ArcTangentAt(Arc arc, Vector pt)
{
var ang = System.Math.Atan2(pt.Y - arc.Center.Y, pt.X - arc.Center.X);
return arc.IsReversed
? new Vector(System.Math.Sin(ang), -System.Math.Cos(ang))
: new Vector(-System.Math.Sin(ang), System.Math.Cos(ang));
}
private static double AngleBetweenDeg(Vector v1, Vector v2)
{
var l1 = System.Math.Sqrt(v1.X * v1.X + v1.Y * v1.Y);
var l2 = System.Math.Sqrt(v2.X * v2.X + v2.Y * v2.Y);
var dot = (v1.X * v2.X + v1.Y * v2.Y) / (l1 * l2);
dot = System.Math.Max(-1, System.Math.Min(1, dot));
return System.Math.Acos(dot) * 180.0 / System.Math.PI;
}
[Fact]
public void Apply_DynaPanDxf_NoGapsAfterSimplification()
{
OpenNest.Tests/GravographIS/GravographISPostConfigTests.cs
+51
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@@ -0,0 +1,51 @@
using OpenNest.CNC;
using OpenNest.Posts.GravographIS;
namespace OpenNest.Tests.GravographIS;
public class GravographISPostConfigTests
{
[Fact]
public void Defaults_EngraveBlock_NoPause_FasterFeed()
{
var config = new GravographISPostConfig();
Assert.Equal(10, config.Engrave.FeedMmPerSec);
Assert.False(config.Engrave.PauseBefore);
}
[Fact]
public void Defaults_CutBlock_PausesToChangeTool()
{
var config = new GravographISPostConfig();
Assert.Equal(3, config.Cut.FeedMmPerSec);
Assert.True(config.Cut.PauseBefore);
Assert.Equal("Change tool", config.Cut.PauseMessage);
}
[Theory]
[InlineData(LayerType.Scribe)]
public void ConfigFor_Scribe_ReturnsEngraveBlock(LayerType layer)
{
var config = new GravographISPostConfig();
Assert.Same(config.Engrave, config.ConfigFor(layer));
}
[Theory]
[InlineData(LayerType.Cut)]
[InlineData(LayerType.Leadin)]
[InlineData(LayerType.Leadout)]
public void ConfigFor_CutLayers_ReturnCutBlock(LayerType layer)
{
var config = new GravographISPostConfig();
Assert.Same(config.Cut, config.ConfigFor(layer));
}
[Fact]
public void ConfigFor_Display_ReturnsNull_SoItIsSkipped()
{
var config = new GravographISPostConfig();
Assert.Null(config.ConfigFor(LayerType.Display));
}
}
OpenNest.Tests/GravographIS/GravographISPostProcessorTests.cs
+70
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@@ -0,0 +1,70 @@
using System.Collections.Generic;
using OpenNest.CNC;
using OpenNest.Geometry;
using OpenNest.Posts.GravographIS;
namespace OpenNest.Tests.GravographIS;
public class GravographISPostProcessorTests
{
private static LayeredPolyline Poly(LayerType layer, params Vector[] pts)
=> new LayeredPolyline(new List<Vector>(pts), layer);
[Fact]
public void BuildPasses_EngraveAndCut_OrdersEngraveFirstThenCutWithPause()
{
var post = new GravographISPostProcessor();
var passes = post.BuildPasses(new[]
{
Poly(LayerType.Cut, new Vector(0, 0), new Vector(1, 0)),
Poly(LayerType.Scribe, new Vector(0, 0), new Vector(0, 1)),
});
Assert.Equal(2, passes.Count);
Assert.Equal(post.Config.Engrave.FeedMmPerSec, passes[0].FeedMmPerSec);
Assert.False(passes[0].PauseBefore);
Assert.Equal(post.Config.Cut.FeedMmPerSec, passes[1].FeedMmPerSec);
Assert.True(passes[1].PauseBefore);
Assert.Equal("Change tool", passes[1].PauseMessage);
}
[Fact]
public void BuildPasses_CutOnly_IsSinglePass()
{
var post = new GravographISPostProcessor();
var passes = post.BuildPasses(new[]
{
Poly(LayerType.Cut, new Vector(0, 0), new Vector(1, 0)),
});
Assert.Single(passes);
Assert.Equal(post.Config.Cut.FeedMmPerSec, passes[0].FeedMmPerSec);
}
[Fact]
public void BuildPasses_SkipsDisplayGeometry()
{
var post = new GravographISPostProcessor();
var passes = post.BuildPasses(new[]
{
Poly(LayerType.Display, new Vector(0, 0), new Vector(1, 0)),
Poly(LayerType.Cut, new Vector(0, 0), new Vector(0, 1)),
});
Assert.Single(passes);
Assert.Equal(post.Config.Cut.FeedMmPerSec, passes[0].FeedMmPerSec);
}
[Fact]
public void Config_IsExposedThroughConfigurableInterface()
{
var post = new GravographISPostProcessor(new GravographISPostConfig());
OpenNest.IConfigurablePostProcessor configurable = post;
Assert.Same(post.Config, configurable.Config);
}
}
OpenNest.Tests/GravographIS/GravographISWriterTests.cs
+95
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@@ -178,6 +178,101 @@ public class GravographISWriterTests
Assert.Equal(-GravographISWriter.StepsPerInch, dy);
}
[Fact]
public void Passes_PauseBeforeCut_EmitsPauseSequenceBetweenGroups()
{
var engrave = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(1, 0) } };
var cut = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(0, -1) } };
var passes = new List<GravographPass>
{
new GravographPass { Polylines = engrave, FeedMmPerSec = 10, DepthInches = 0.25 },
new GravographPass { Polylines = cut, FeedMmPerSec = 3, DepthInches = 0.25, PauseBefore = true, PauseMessage = "Hi" },
};
using var ms = new MemoryStream();
new GravographISWriter(new GravographISWriterOptions
{
EnvelopeGuardEnabled = false,
ReturnToOriginAtEnd = false,
}).Write(passes, ms);
var bytes = ms.ToArray();
var mcOff = IndexOf(bytes, 0, (byte)'M', (byte)'C', 0x00, 0x00);
var ouFb = IndexOf(bytes, mcOff, (byte)'O', (byte)'U', 0xFF, 0xFB);
var ouFa = IndexOf(bytes, ouFb, (byte)'O', (byte)'U', 0xFF, 0xFA);
var lbBegin = IndexOf(bytes, ouFa, (byte)'L', (byte)'B', 0x00, 0x00);
var lbMsg = IndexOf(bytes, lbBegin, (byte)'L', (byte)'B', (byte)'H', (byte)'i');
var nr = IndexOf(bytes, lbMsg, (byte)'N', (byte)'R', 0x00, 0x01);
var lbEnd = IndexOf(bytes, nr, (byte)'L', (byte)'B', 0x00, 0x01);
var mcOn = IndexOf(bytes, lbEnd, (byte)'M', (byte)'C', 0x00, 0x01);
Assert.True(mcOff >= 0, "motor-off (MC 0000) not found");
Assert.True(mcOff < ouFb && ouFb < ouFa && ouFa < lbBegin && lbBegin < lbMsg
&& lbMsg < nr && nr < lbEnd && lbEnd < mcOn,
"pause commands out of order");
// Resume sets the cut feed inline (VS 0x0003) after the motor restarts.
var vsCut = IndexOf(bytes, mcOn, (byte)'V', (byte)'S', 0x00, 0x03);
Assert.True(vsCut > mcOn, "cut feed not set after resume");
}
[Fact]
public void Passes_PauseOddMessage_SpacePadsLastPacket()
{
var passes = new List<GravographPass>
{
new GravographPass { Polylines = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(1, 0) } }, FeedMmPerSec = 10 },
new GravographPass { Polylines = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(0, -1) } }, FeedMmPerSec = 3, PauseBefore = true, PauseMessage = "abc" },
};
using var ms = new MemoryStream();
new GravographISWriter(new GravographISWriterOptions { EnvelopeGuardEnabled = false, ReturnToOriginAtEnd = false }).Write(passes, ms);
var bytes = ms.ToArray();
var lbAb = IndexOf(bytes, 0, (byte)'L', (byte)'B', (byte)'a', (byte)'b');
var lbCPad = IndexOf(bytes, lbAb, (byte)'L', (byte)'B', (byte)'c', 0x20);
Assert.True(lbAb >= 0, "first message packet 'ab' not found");
Assert.True(lbCPad > lbAb, "odd packet not space-padded to 'c '");
}
[Fact]
public void Passes_DifferentFeeds_NoPause_EmitsInlineFeedChangeNoMessage()
{
var passes = new List<GravographPass>
{
new GravographPass { Polylines = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(1, 0) } }, FeedMmPerSec = 10 },
new GravographPass { Polylines = new List<IReadOnlyList<Vector>> { new[] { new Vector(0, 0), new Vector(0, -1) } }, FeedMmPerSec = 3, PauseBefore = false },
};
using var ms = new MemoryStream();
new GravographISWriter(new GravographISWriterOptions { EnvelopeGuardEnabled = false, ReturnToOriginAtEnd = false }).Write(passes, ms);
var bytes = ms.ToArray();
Assert.True(IndexOf(bytes, 0, (byte)'V', (byte)'S', 0x00, 0x03) >= 0, "inline cut feed change missing");
Assert.True(IndexOfCmd(bytes, (byte)'L', (byte)'B') < 0, "no LB message expected without a pause");
}
private static int IndexOf(byte[] bytes, int from, byte c0, byte c1, byte hi, byte lo)
{
for (var i = System.Math.Max(0, from); i <= bytes.Length - 6; i++)
{
if (bytes[i] == 0xFF && bytes[i + 1] == 0xFD && bytes[i + 2] == c0 &&
bytes[i + 3] == c1 && bytes[i + 4] == hi && bytes[i + 5] == lo)
return i;
}
return -1;
}
private static int IndexOfCmd(byte[] bytes, byte c0, byte c1)
{
for (var i = 0; i <= bytes.Length - 4; i++)
{
if (bytes[i] == 0xFF && bytes[i + 1] == 0xFD && bytes[i + 2] == c0 && bytes[i + 3] == c1)
return i;
}
return -1;
}
private static void AssertOperand(byte[] bytes, byte c0, byte c1, byte hi, byte lo)
{
for (var i = 0; i < bytes.Length - 5; i++)
OpenNest.Tests/GravographIS/NestPolylineExtractorTests.cs
+41
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@@ -34,4 +34,45 @@ public class NestPolylineExtractorTests
Assert.Equal(new Vector(0.25, 47.75), poly[3]);
Assert.Equal(new Vector(0.25, 46.75), poly[4]);
}
[Fact]
public void ExtractPartLayered_SplitsContinuousChainAtLayerChange()
{
// A single continuous chain (no rapid) that switches from Scribe to Cut
// must be split into two layer-uniform polylines sharing the seam vertex,
// so the post can emit a tool-change pause between engrave and cut.
var program = new Program(Mode.Absolute);
program.Codes.Add(new LinearMove(1, 0) { Layer = LayerType.Scribe });
program.Codes.Add(new LinearMove(2, 0) { Layer = LayerType.Scribe });
program.Codes.Add(new LinearMove(2, 1) { Layer = LayerType.Cut });
program.Codes.Add(new LinearMove(3, 1) { Layer = LayerType.Cut });
var drawing = new Drawing("Mixed", program);
var part = new Part(drawing, new Vector(0, 0));
var polylines = new NestPolylineExtractor().ExtractPartLayered(part);
Assert.Equal(2, polylines.Count);
Assert.Equal(LayerType.Scribe, polylines[0].Layer);
Assert.Equal(new[] { new Vector(0, 0), new Vector(1, 0), new Vector(2, 0) }, polylines[0].Points);
Assert.Equal(LayerType.Cut, polylines[1].Layer);
Assert.Equal(new[] { new Vector(2, 0), new Vector(2, 1), new Vector(3, 1) }, polylines[1].Points);
}
[Fact]
public void ExtractPartLayered_UniformChain_IsSinglePolyline()
{
var program = new Program(Mode.Absolute);
program.Codes.Add(new LinearMove(1, 0));
program.Codes.Add(new LinearMove(1, 1));
var part = new Part(new Drawing("Cut", program), new Vector(0, 0));
var polylines = new NestPolylineExtractor().ExtractPartLayered(part);
Assert.Single(polylines);
Assert.Equal(LayerType.Cut, polylines[0].Layer);
}
}