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fix(diagnostics): keep tiny clamps beyond coarse chords in the overlap check

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Check Overlaps dismissed a tiny clamp by the part's coarse material bounds
before the fine tolerance-free test ran, but that material is inscribed at
the 0.001 chord tolerance: real material in the sliver beyond a convex arc
(a short arc cap, a rotated crescent) lay outside those bounds and the clamp
read as clear. For clamps below the tolerance the bounds are widened by the
chord tolerance before rejecting.

PM 407f5eb7-329f-41e4-947e-64ad52aa4034 (review s6-delta3-review.md)
This commit is contained in:
aj committed 2026-10-13 18:15:50 -04:00
1 parent f2cc471a33
commit c57e0ded83
2 files changed
+31 -2
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OpenNest.Core/Diagnostics/PlateOverlapAnalyzer.cs
+5 -2
View File
@@ -270,8 +270,11 @@ public static class PlateOverlapAnalyzer
{
cancellationToken.ThrowIfCancellationRequested();
var zone = clamp.Bounds;
if (partBounds.Right <= zone.Left || zone.Right <= partBounds.Left
|| partBounds.Top <= zone.Bottom || zone.Top <= partBounds.Bottom)
// The prepared material is inscribed at ChordTolerance, so real material can
// reach that far past its bounds; a tiny clamp there must still be checked.
var reach = KeepOutOverlap.NeedsToleranceFreeTest(zone) ? ChordTolerance : 0;
if (partBounds.Right + reach <= zone.Left || zone.Right <= partBounds.Left - reach
|| partBounds.Top + reach <= zone.Bottom || zone.Top <= partBounds.Bottom - reach)
continue;
try
{
OpenNest.Tests/Diagnostics/PlateOverlapAnalyzerClampZoneTests.cs
+26
View File
@@ -282,6 +282,32 @@ public class PlateOverlapAnalyzerClampZoneTests
Assert.NotEmpty(report.ClampFindings);
}
// Delta review 3: a tiny clamp in the sliver beyond a convex arc's 0.001 chords must not
// be dismissed by the coarse material bounds before the fine check runs.
[Fact]
public void TinyClampBeyondCoarseChordsIsReported()
{
const double r = 0.01, half = 0.04;
var dx = r * System.Math.Sin(half);
var cy = 20 - r * System.Math.Cos(half);
var program = new Program();
program.MoveTo(0, 0);
program.LineTo(20, 0);
program.LineTo(20, 20);
program.LineTo(10 + dx, 20);
program.ArcTo(10 - dx, 20, 10, cy, RotationType.CCW);
program.LineTo(0, 20);
program.LineTo(0, 0);
// Witness (10, 20.000002) is inside the arc (radius 0.009994 < 0.01) and the zone.
var zone = new ClampZone("tiny", new Box(9.999995, 20.000001199840007, 1e-5, 1e-5));
var report = PlateOverlapAnalyzer.Analyze(PlateOverlapAnalyzer.Capture(
new List<Part> { new(new Drawing("cap", program), new Vector(0, 0)) }, new[] { zone }));
Assert.True(report.IsComplete, string.Join("; ", report.Issues.Select(issue => issue.Message)));
Assert.NotEmpty(report.ClampFindings);
}
private static string Describe(PlateOverlapReport report) =>
string.Join(";", report.Pairs.Select(p => $"{p.PartAId}/{p.PartBId}:{p.Area:R}"))
+ "|"