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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/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++)