AJ Isaacs
a2f7219db3
G-code output was concatenated without spaces (e.g. N1005G0X1.4375Y-0.6562). Now emits standard spacing (N1005 G0 X1.4375 Y-0.6562) across all motion commands, line numbers, kerf comp, feedrates, M-codes, and comments. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
337 lines
12 KiB
C#
337 lines
12 KiB
C#
using System;
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using System.Collections.Generic;
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using System.IO;
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using System.Linq;
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using System.Text;
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using OpenNest.CNC;
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using OpenNest.Geometry;
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namespace OpenNest.Posts.Cincinnati;
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/// <summary>
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/// Emits one Cincinnati-format sheet subprogram per plate.
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/// Supports two modes: inline features (default) or M98 sub-program calls per part.
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/// </summary>
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public sealed class CincinnatiSheetWriter
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{
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private readonly CincinnatiPostConfig _config;
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private readonly ProgramVariableManager _vars;
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private readonly CoordinateFormatter _fmt;
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private readonly CincinnatiFeatureWriter _featureWriter;
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public CincinnatiSheetWriter(CincinnatiPostConfig config, ProgramVariableManager vars)
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{
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_config = config;
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_vars = vars;
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_fmt = new CoordinateFormatter(config.PostedAccuracy);
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_featureWriter = new CincinnatiFeatureWriter(config);
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}
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/// <summary>
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/// Writes a complete sheet subprogram for the given plate.
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/// </summary>
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/// <param name="cutLibrary">Resolved G89 library file for cut operations.</param>
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/// <param name="etchLibrary">Resolved G89 library file for etch operations.</param>
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/// <param name="partSubprograms">
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/// Optional mapping of (drawingId, rotationKey) to sub-program number.
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/// When provided, non-cutoff parts are emitted as M98 calls instead of inline features.
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/// </param>
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public void Write(TextWriter w, Plate plate, string nestName, int sheetIndex, int subNumber,
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string cutLibrary, string etchLibrary,
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Dictionary<(int, long), int> partSubprograms = null)
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{
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if (plate.Parts.Count == 0)
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return;
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var width = plate.Size.Width;
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var length = plate.Size.Length;
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var sheetDiagonal = System.Math.Sqrt(width * width + length * length);
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var varDeclSub = _config.VariableDeclarationSubprogram;
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var partCount = plate.Parts.Count(p => !p.BaseDrawing.IsCutOff);
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// 1. Sheet header
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w.WriteLine("(*****************************************************)");
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w.WriteLine($"( START OF {nestName}.{sheetIndex:D3} )");
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w.WriteLine($":{subNumber}");
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w.WriteLine($"( Sheet {sheetIndex} )");
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w.WriteLine($"( Layout {sheetIndex} )");
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w.WriteLine($"( SHEET NAME = {_fmt.FormatCoord(length)} X {_fmt.FormatCoord(width)} )");
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w.WriteLine($"( Total parts on sheet = {partCount} )");
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w.WriteLine($"#{_config.SheetWidthVariable}={_fmt.FormatCoord(width)} (SHEET WIDTH FOR CUTOFFS)");
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w.WriteLine($"#{_config.SheetLengthVariable}={_fmt.FormatCoord(length)} (SHEET LENGTH FOR CUTOFFS)");
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// 2. Coordinate setup
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w.WriteLine("M42");
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w.WriteLine("N10000");
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w.WriteLine("G92 X#5021 Y#5022");
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if (!string.IsNullOrEmpty(cutLibrary))
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w.WriteLine($"G89 P {cutLibrary}");
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w.WriteLine($"M98 P{varDeclSub} (Variable Declaration)");
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w.WriteLine("G90");
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w.WriteLine("M47");
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if (!string.IsNullOrEmpty(cutLibrary))
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w.WriteLine($"G89 P {cutLibrary}");
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w.WriteLine("GOTO1( Goto Feature )");
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// 3. Order parts: non-cutoff sorted by Bottom then Left, cutoffs last
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var nonCutoffParts = plate.Parts
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.Where(p => !p.BaseDrawing.IsCutOff)
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.OrderBy(p => p.Bottom)
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.ThenBy(p => p.Left)
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.ToList();
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var cutoffParts = plate.Parts
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.Where(p => p.BaseDrawing.IsCutOff)
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.ToList();
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var allParts = nonCutoffParts.Concat(cutoffParts).ToList();
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// 4. Emit parts
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if (partSubprograms != null)
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WritePartsWithSubprograms(w, allParts, cutLibrary, etchLibrary, sheetDiagonal, partSubprograms);
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else
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WritePartsInline(w, allParts, cutLibrary, etchLibrary, sheetDiagonal);
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// 5. Footer
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w.WriteLine("M42");
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w.WriteLine("G0 X0 Y0");
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if (_config.PalletExchange != PalletMode.None)
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w.WriteLine($"N{sheetIndex + 1} M50");
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w.WriteLine($"M99 (END OF {nestName}.{sheetIndex:D3})");
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}
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private void WritePartsWithSubprograms(TextWriter w, List<Part> allParts,
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string cutLibrary, string etchLibrary, double sheetDiagonal,
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Dictionary<(int, long), int> partSubprograms)
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{
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var lastPartName = "";
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var featureIndex = 0;
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for (var p = 0; p < allParts.Count; p++)
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{
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var part = allParts[p];
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var partName = part.BaseDrawing.Name;
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var isNewPart = partName != lastPartName;
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var isSafetyHeadraise = isNewPart && lastPartName != "";
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var isLastPart = p == allParts.Count - 1;
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var key = CincinnatiPartSubprogramWriter.SubprogramKey(part);
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partSubprograms.TryGetValue(key, out var subNum);
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var hasSubprogram = !part.BaseDrawing.IsCutOff && subNum != 0;
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if (hasSubprogram)
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{
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WriteSubprogramCall(w, part, subNum, featureIndex, partName,
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isSafetyHeadraise, isLastPart);
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featureIndex++;
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}
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else
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{
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// Inline features for cutoffs or parts without sub-programs
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var features = SplitAndOrderFeatures(part);
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for (var f = 0; f < features.Count; f++)
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{
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var (codes, isEtch) = features[f];
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var featureNumber = featureIndex == 0
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? _config.FeatureLineNumberStart
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: 1000 + featureIndex + 1;
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var isLastFeature = isLastPart && f == features.Count - 1;
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var cutDistance = ComputeCutDistance(codes);
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var ctx = new FeatureContext
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{
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Codes = codes,
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FeatureNumber = featureNumber,
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PartName = partName,
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IsFirstFeatureOfPart = isNewPart && f == 0,
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IsLastFeatureOnSheet = isLastFeature,
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IsSafetyHeadraise = isSafetyHeadraise && f == 0,
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IsExteriorFeature = false,
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IsEtch = isEtch,
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LibraryFile = isEtch ? etchLibrary : cutLibrary,
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CutDistance = cutDistance,
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SheetDiagonal = sheetDiagonal
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};
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_featureWriter.Write(w, ctx);
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featureIndex++;
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}
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}
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lastPartName = partName;
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}
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}
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private void WriteSubprogramCall(TextWriter w, Part part, int subNum,
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int featureIndex, string partName, bool isSafetyHeadraise, bool isLastPart)
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{
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// Safety headraise before rapid to new part
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if (isSafetyHeadraise && _config.SafetyHeadraiseDistance.HasValue)
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w.WriteLine($"M47 P{_config.SafetyHeadraiseDistance.Value} (Safety Headraise)");
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// Rapid to part position (bounding box lower-left)
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var featureNumber = featureIndex == 0
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? _config.FeatureLineNumberStart
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: 1000 + featureIndex + 1;
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var sb = new StringBuilder();
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if (_config.UseLineNumbers)
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sb.Append($"N{featureNumber} ");
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sb.Append($"G0 X{_fmt.FormatCoord(part.Left)} Y{_fmt.FormatCoord(part.Bottom)}");
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w.WriteLine(sb.ToString());
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// Part name comment
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w.WriteLine(CoordinateFormatter.Comment($"PART: {partName}"));
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// Set local coordinate system at part position
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w.WriteLine("G92 X0 Y0");
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// Call part sub-program
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w.WriteLine($"M98 P{subNum} ({partName})");
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// Restore sheet coordinate system
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w.WriteLine($"G92 X{_fmt.FormatCoord(part.Left)} Y{_fmt.FormatCoord(part.Bottom)}");
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// Head raise (unless last part on sheet)
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if (!isLastPart)
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w.WriteLine("M47");
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}
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private void WritePartsInline(TextWriter w, List<Part> allParts,
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string cutLibrary, string etchLibrary, double sheetDiagonal)
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{
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// Split and classify features, ordering etch before cut per part
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var features = new List<(Part part, List<ICode> codes, bool isEtch)>();
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foreach (var part in allParts)
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{
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var partFeatures = SplitAndOrderFeatures(part);
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foreach (var (codes, isEtch) in partFeatures)
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features.Add((part, codes, isEtch));
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}
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// Emit features
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var lastPartName = "";
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for (var i = 0; i < features.Count; i++)
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{
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var (part, codes, isEtch) = features[i];
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var partName = part.BaseDrawing.Name;
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var isFirstFeatureOfPart = partName != lastPartName;
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var isSafetyHeadraise = partName != lastPartName && lastPartName != "";
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var isLastFeature = i == features.Count - 1;
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var featureNumber = i == 0
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? _config.FeatureLineNumberStart
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: 1000 + i + 1;
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var cutDistance = ComputeCutDistance(codes);
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var ctx = new FeatureContext
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{
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Codes = codes,
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FeatureNumber = featureNumber,
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PartName = partName,
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IsFirstFeatureOfPart = isFirstFeatureOfPart,
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IsLastFeatureOnSheet = isLastFeature,
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IsSafetyHeadraise = isSafetyHeadraise,
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IsExteriorFeature = false,
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IsEtch = isEtch,
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LibraryFile = isEtch ? etchLibrary : cutLibrary,
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CutDistance = cutDistance,
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SheetDiagonal = sheetDiagonal
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};
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_featureWriter.Write(w, ctx);
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lastPartName = partName;
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}
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}
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/// <summary>
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/// Splits a part's program into features (by rapids), classifies each as etch or cut,
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/// and orders etch features before cut features.
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/// </summary>
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public static List<(List<ICode> codes, bool isEtch)> SplitAndOrderFeatures(Part part)
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{
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var etchFeatures = new List<List<ICode>>();
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var cutFeatures = new List<List<ICode>>();
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List<ICode> current = null;
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foreach (var code in part.Program.Codes)
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{
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if (code is RapidMove)
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{
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if (current != null)
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ClassifyAndAdd(current, etchFeatures, cutFeatures);
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current = new List<ICode> { code };
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}
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else
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{
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current ??= new List<ICode>();
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current.Add(code);
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}
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}
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if (current != null && current.Count > 0)
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ClassifyAndAdd(current, etchFeatures, cutFeatures);
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// Etch features first, then cut features
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var result = new List<(List<ICode>, bool)>();
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foreach (var f in etchFeatures)
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result.Add((f, true));
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foreach (var f in cutFeatures)
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result.Add((f, false));
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return result;
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}
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private static void ClassifyAndAdd(List<ICode> codes,
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List<List<ICode>> etchFeatures, List<List<ICode>> cutFeatures)
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{
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if (IsFeatureEtch(codes))
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etchFeatures.Add(codes);
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else
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cutFeatures.Add(codes);
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}
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/// <summary>
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/// A feature is etch if any non-rapid move has LayerType.Scribe.
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/// </summary>
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public static bool IsFeatureEtch(List<ICode> codes)
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{
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foreach (var code in codes)
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{
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if (code is LinearMove linear && linear.Layer == LayerType.Scribe)
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return true;
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if (code is ArcMove arc && arc.Layer == LayerType.Scribe)
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return true;
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}
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return false;
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}
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private static double ComputeCutDistance(List<ICode> codes)
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{
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var distance = 0.0;
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var currentPos = Vector.Zero;
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foreach (var code in codes)
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{
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if (code is RapidMove rapid)
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{
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currentPos = rapid.EndPoint;
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}
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else if (code is LinearMove linear)
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{
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distance += currentPos.DistanceTo(linear.EndPoint);
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currentPos = linear.EndPoint;
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}
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else if (code is ArcMove arc)
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{
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distance += currentPos.DistanceTo(arc.EndPoint);
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currentPos = arc.EndPoint;
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}
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}
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return distance;
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}
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}
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