grid-apps-cmms/src/mode/cam/prepare.js

734 lines
29 KiB
JavaScript

/** Copyright Stewart Allen <sa@grid.space> -- All Rights Reserved */
"use strict";
(function() {
let KIRI = self.kiri,
BASE = self.base,
POLY = BASE.polygons,
UTIL = BASE.util,
CAM = KIRI.driver.CAM,
PRO = CAM.process,
newPoint = BASE.newPoint;
/**
* DRIVER PRINT CONTRACT
*
* @param {Object} print state object
* @param {Function} update incremental callback
* @param {Number} [index] into widget array
* @param {Object} [firstPoint] starting point
*/
CAM.prepare = function(widgets, settings, update) {
const count = widgets.length;
const weight = 1/count;
const print = self.worker.print = KIRI.newPrint(settings, widgets);
print.output = [];
let point;
widgets.forEach((widget, index) => {
point = prepEach(widget, settings, print, point, progress => {
update((index * weight + progress * weight) * 0.5, "prepare");
});
});
print.render = KIRI.driver.FDM.prepareRender(print.output, (progress, layer) => {
update(0.5 + progress * 0.5, "render", layer);
}, {
thin: true,
print: 0,
move: 0x557799,
speed: false,
moves: true,
other: "moving",
action: "milling"
});
return print.render;
};
function prepEach(widget, settings, print, firstPoint, update) {
let device = settings.device,
process = settings.process,
stock = settings.stock,
outer = settings.bounds,
outerz = outer.max.z,
slices = widget.slices,
hasStock = stock.x && stock.y && stock.z && process.camStockOn,
startCenter = process.outputOriginCenter,
alignTop = settings.controller.alignTop,
zclear = (process.camZClearance || 1),
zmax_outer = hasStock ? stock.z + zclear : outerz + zclear,
ztOff = hasStock ? process.camZTopOffset : 0,
bounds = widget.getBoundingBox(),
boundsz = bounds.max.z + ztOff,
zadd = hasStock ? stock.z - boundsz : alignTop ? outerz - boundsz : 0,
zmax = outerz + zclear,
wmpos = widget.mesh.position,
wmx = wmpos.x,
wmy = wmpos.y,
originx = startCenter ? 0 : hasStock ? -stock.x / 2 : bounds.min.x,
originy = startCenter ? 0 : hasStock ? -stock.y / 2 : bounds.min.y,
origin = newPoint(originx + wmx, originy + wmy, zmax),
output = print.output,
easeDown = process.camEaseDown,
depthFirst = process.camDepthFirst,
tolerance = 0,
drillDown = 0,
drillLift = 0,
drillDwell = 0,
newOutput = print.output || [],
layerOut = [],
printPoint,
isNewMode,
tool,
toolType,
toolDiam,
toolDiamMove,
feedRate,
plungeRate,
lastTool,
lastMode,
lastPoint,
nextIsMove = true,
synthPlunge = false,
spindle = 0,
spindleMax = device.spindleMax,
addOutput = print.addOutput,
tip2tipEmit = print.tip2tipEmit,
poly2polyEmit = print.poly2polyEmit,
maxToolDiam = widget.maxToolDiam,
terrain = widget.terrain ? widget.terrain.map(data => {
return {
z: data.z,
tops: data.tops,
};
}) : zmax;
function newLayer() {
if (layerOut.length < 2) {
return;
}
newOutput.push(layerOut);
layerOut = [];
layerOut.spindle = spindle;
}
// non-zero means contouring
function setTolerance(dist) {
tolerance = dist;
}
function setPrintPoint(point) {
printPoint = point;
}
function setSpindle(speed) {
spindle = Math.min(speed, spindleMax);
}
function setTool(toolID, feed, plunge) {
if (toolID !== lastTool) {
tool = new CAM.Tool(settings, toolID);
toolType = tool.getType();
toolDiam = tool.fluteDiameter();
toolDiamMove = toolType === 'endmill' ? toolDiam : tolerance * 2;
lastTool = toolID;
}
feedRate = feed;
plungeRate = plunge;
}
function setDrill(down, lift, dwell) {
drillDown = down;
drillLift = lift;
drillDwell = dwell;
}
function emitDrills(polys) {
polys = polys.slice();
for (;;) {
let closestDist = Infinity,
closestI,
closest = null,
dist;
for (let i=0; i<polys.length; i++) {
if (!polys[i]) continue;
if ((dist = polys[i].first().distTo2D(printPoint)) < closestDist) {
closestDist = dist;
closest = polys[i];
closestI = i;
}
}
if (!closest) return;
polys[closestI] = null;
printPoint = closest.first();
emitDrill(closest, drillDown, drillLift, drillDwell);
}
// TODO emit in next-closest-order
// polys.forEach(function(poly) {
// emitDrill(poly, drillDown, drillLift, drillDwell);
// });
}
function emitDrill(poly, down, lift, dwell) {
let remain = poly.first().z - poly.last().z,
points = [],
point = poly.first();
for (;;) {
if (remain > down * 2) {
points.push(point.clone());
point.z -= down;
remain -= down;
} else if (remain < down) {
points.push(point.clone());
point.z -= remain;
points.push(point.clone());
break;
} else {
points.push(point.clone());
point.z -= remain / 2;
points.push(point.clone());
point.z -= remain / 2;
points.push(point.clone());
break;
}
}
camOut(point.clone().setZ(zmax));
points.forEach(function(point, index) {
camOut(point, 1);
if (index > 0 && index < points.length - 1) {
if (dwell) camDwell(dwell);
if (lift) camOut(point.clone().setZ(point.z + lift), 0);
}
})
camOut(point.clone().setZ(zmax));
newLayer();
}
/**
* @param {Point} point
* @param {number} emit (0=move, !0=filament emit/laser on/cut mode)
* @param {number} [speed] speed
* @param {number} [tool] tool
*/
function layerPush(point, emit, speed, tool) {
layerOut.mode = lastMode;
addOutput(layerOut, point, emit, speed, tool);
return point;
}
function camDwell(time) {
layerPush(
null,
0,
time,
tool.getNumber()
);
}
function camOut(point, cut) {
point = point.clone();
point.x += wmx;
point.y += wmy;
point.z += zadd;
if (nextIsMove) {
cut = 0;
nextIsMove = false;
}
let rate = feedRate;
// before first point, move cutting head to point above it
// then set that new point as the lastPoint
if (!lastPoint) {
let above = point.clone().setZ(zmax + zadd + ztOff);
lastPoint = layerPush(above, 0, 0, tool.getNumber());
}
// measure deltas to last point in XY and Z
let deltaXY = lastPoint.distTo2D(point),
deltaZ = point.z - lastPoint.z,
absDeltaZ = Math.abs(deltaZ),
isMove = !cut;
// drop points too close together
if (deltaXY < 0.001 && point.z === lastPoint.z) {
// console.trace(["drop dup",lastPoint,point]);
return;
}
// convert short planar moves to cuts in some cases
if (isMove && deltaXY <= toolDiamMove) {
let iscontour = tolerance > 0;
let isflat = absDeltaZ < 0.001;
// restrict this to contouring
if (isflat || (iscontour && absDeltaZ <= tolerance)) {
cut = 1;
isMove = false;
} else if (deltaZ <= -tolerance) {
// move over before descending
layerPush(point.clone().setZ(lastPoint.z), 0, 0, tool.getNumber());
// new pos for plunge calc
deltaXY = 0;
}
} else if (isMove) {
// for longer moves, check the terrain to see if we need to go up and over
const bigXY = (deltaXY > toolDiamMove);
const bigZ = (deltaZ > toolDiam/2 && deltaXY > tolerance);
const midZ = (absDeltaZ >= tolerance);
if ((bigXY || bigZ) && (isMove || midZ)) {
let maxz = getZClearPath(
terrain,
lastPoint.x - wmx,
lastPoint.y - wmy,
point.x - wmx,
point.y - wmy,
Math.max(point.z, lastPoint.z),
zadd,
maxToolDiam/2,
zclear
) + ztOff,
mustGoUp = Math.max(maxz - point.z, maxz - lastPoint.z) >= tolerance,
clearz = maxz;
// up if any point between higher than start/outline, go up
if (mustGoUp) {
if (bigXY) {
clearz += zclear;
}
layerPush(lastPoint.clone().setZ(clearz), 0, 0, tool.getNumber());
}
// move to point above target point
if (mustGoUp || point.z < maxz) {
layerPush(point.clone().setZ(clearz), 0, 0, tool.getNumber());
// new pos for plunge calc
deltaXY = 0;
}
}
}
// synth new plunge rate
if (synthPlunge && deltaZ <= -tolerance) {
let threshold = Math.min(deltaXY / 2, absDeltaZ),
modifier = threshold / absDeltaZ;
if (threshold && modifier && deltaXY > tolerance) {
// use modifier to speed up long XY move plunge rates
rate = Math.round(plungeRate + ((feedRate - plungeRate) * modifier));
} else {
rate = plungeRate;
}
}
// todo synthesize move speed from feed / plunge accordingly
layerOut.spindle = spindle;
lastPoint = layerPush(
point,
cut ? 1 : 0,
rate,
tool.getNumber()
);
}
// coming from a previous widget, use previous last point
lastPoint = firstPoint;
// make top start offset configurable
printPoint = firstPoint || origin;
// accumulated data for depth-first optimiztions
let depthData = {
rough: [],
outline: [],
roughDiam: 0,
outlineDiam: 0,
contourx: [],
contoury: [],
trace: [],
drill: [],
layer: 0,
};
let ops = {
setTool,
setDrill,
setSpindle,
setPrintPoint,
printPoint,
newLayer,
camOut,
polyEmit,
poly2polyEmit,
depthRoughPath,
depthOutlinePath,
emitDrills,
emitTrace
};
let opSum = 0;
let opTot = widget.camops.map(op => op.weight()).reduce((a,v) => a + v);
for (let op of widget.camops) {
setTolerance(0);
nextIsMove = true;
let weight = op.weight();
op.prepare(ops, (progress, message) => {
onupdate((opSum + (progress * weight)) / opTot, message || op.type());
});
opSum += weight;
}
// todo first move into positon
if (false) slices.forEach(function(slice, sliceIndex) {
depthData.layer++;
isNewMode = slice.camMode != lastMode;
lastMode = slice.camMode;
// force move at start of each slice
nextIsMove = true;
if (isNewMode) depthData.layer = 0;
switch (slice.camMode) {
case PRO.LEVEL:
setTool(process.camRoughTool, process.camRoughSpeed, process.camRoughPlunge);
spindle = Math.min(spindleMax, process.camRoughSpindle);
const level = [];
slice.camLines.forEach(function (poly) {
level.push(poly);
if (poly.inner) {
poly.inner.forEach(function(inner) {
level.push(inner);
})
}
});
// set winding specified in output
POLY.setWinding(level, process.camConventional, false);
printPoint = poly2polyEmit(level, printPoint, function(poly, index, count) {
poly.forEachPoint(function(point, pidx, points, offset) {
camOut(point.clone(), offset !== 0);
}, true, index);
});
newLayer();
break;
case PRO.ROUGH:
case PRO.OUTLINE:
let dir = process.camConventional;
if (slice.camMode === PRO.ROUGH) {
setTool(process.camRoughTool, process.camRoughSpeed, process.camRoughPlunge);
spindle = Math.min(spindleMax, process.camRoughSpindle);
depthData.roughDiam = toolDiam;
} else {
setTool(process.camOutlineTool, process.camOutlineSpeed, process.camOutlinePlunge);
spindle = Math.min(spindleMax, process.camOutlineSpindle);
depthData.outlineDiam = toolDiam;
if (!process.camOutlinePocket) {
dir = !dir;
}
}
let polys = [], t = [], c = [];
POLY.flatten(slice.camLines).forEach(function (poly) {
let child = poly.parent;
if (depthFirst) { poly = poly.clone(); poly.parent = child ? 1 : 0 }
if (child) c.push(poly); else t.push(poly);
poly.layer = depthData.layer;
polys.push(poly);
});
// set cut direction on outer polys
POLY.setWinding(t, dir);
// set cut direction on inner polys
POLY.setWinding(c, !dir);
if (depthFirst) {
(slice.camMode === PRO.ROUGH ? depthData.rough : depthData.outline).append(polys);
// polys.xout(`prep ${slice.z}`);
} else {
printPoint = poly2polyEmit(polys, printPoint, function(poly, index, count) {
poly.forEachPoint(function(point, pidx, points, offset) {
camOut(point.clone(), offset !== 0);
}, poly.isClosed(), index);
});
newLayer();
}
break;
case PRO.CONTOUR_X:
case PRO.CONTOUR_Y:
if (isNewMode || !printPoint) {
// force start at lower left corner
printPoint = newPoint(bounds.min.x,bounds.min.y,zmax);
}
setTool(process.camContourTool, process.camContourSpeed, process.camFastFeedZ);
spindle = Math.min(spindleMax, process.camContourSpindle);
depthData.outlineDiam = toolDiam;
// todo find closest next trace/trace-point
{
let polys = [], poly, emit;
slice.camLines.forEach(function (poly) {
if (depthFirst) poly = poly.clone(true);
polys.push({first:poly.first(), last:poly.last(), poly:poly});
});
if (depthFirst) {
(slice.camMode === PRO.CONTOUR_X ? depthData.contourx : depthData.contoury).appendAll(polys);
} else {
printPoint = tip2tipEmit(polys, printPoint, function(el, point, count) {
poly = el.poly;
if (poly.last() === point) {
poly.reverse();
}
poly.forEachPoint(function(point, pidx) {
camOut(point.clone(), pidx > 0);
}, false);
// return lastPoint;
});
newLayer();
}
}
break;
case PRO.TRACE:
if (depthFirst) {
depthData.trace.push(slice);
break;
} else {
emitTrace(slice);
}
break;
case PRO.DRILL:
setTool(process.camDrillTool, process.camDrillDownSpeed, process.camDrillDownSpeed);
depthData.drill.appendAll(slice.camLines);
break;
}
update(sliceIndex / slices.length);
});
function emitTrace(slice) {
let { tool, speed, plunge, path } = slice.camTrace;
setTool(tool, speed, plunge);
let traceTool = new CAM.Tool(settings, tool);
let traceToolDiam = traceTool.fluteDiameter();
slice.camLines.forEach(poly => {
poly.forEachPoint(function(point, pidx) {
camOut(point.clone(), pidx > 0);
}, !poly.open);
});
newLayer();
}
function polyEmit(poly, index, count, fromPoint) {
let last = null;
if (easeDown && poly.isClosed()) {
last = poly.forEachPointEaseDown(function(point, offset) {
camOut(point.clone(), offset > 0);
}, fromPoint);
} else {
poly.forEachPoint(function(point, pidx, points, offset) {
last = point;
camOut(point.clone(), offset !== 0);
}, poly.isClosed(), index);
}
newLayer();
return last;
}
function depthRoughPath(start, depth, levels, tops, emitter, fit) {
let level = levels[depth];
if (!level) {
return start;
}
let ltops = tops[depth];
let fitted = fit ? ltops.filter(poly => poly.isInside(fit)) : ltops;
fitted.filter(top => !top.level_emit).forEach(top => {
top.level_emit = true;
let inside = level.filter(poly => poly.isInside(top));
start = poly2polyEmit(inside, start, emitter, { mark: "emark" });
start = depthRoughPath(start, depth + 1, levels, tops, emitter, top);
});
return start;
}
function depthOutlinePath(start, depth, levels, radius, emitter, clr) {
let bottm = depth < levels.length - 1 ? levels[levels.length - 1] : null;
let above = levels[depth-1];
let level = levels[depth];
if (!level) {
return start;
}
if (above) {
level = level.filter(lp => {
const conf = above.filter(ap => !ap.level_emit && lp.isNear(ap, radius, true));
return conf.length === 0;
});
}
// const thru = []; // match thru polys
level = level.filter(lp => {
if (lp.level_emit) {
return false;
}
// if (bottm && !clr) {
// const tm = bottm.filter(bp => lp.isEquivalent(bp));
// thru.appendAll(tm);
// return tm.length === 0;
// }
return true;
});
// omit polys that match bottom level polys unless level above is cleared
start = poly2polyEmit(level, start, (poly, index, count, fromPoint) => {
poly.level_emit = true;
fromPoint = polyEmit(poly, index, count, fromPoint);
fromPoint = depthOutlinePath(fromPoint, depth + 1, levels, radius, emitter, clr);
return fromPoint;
}, {weight: true});
return start;
}
// act on accumulated layer data
if (false && depthFirst) {
// roughing depth first
if (depthData.rough.length > 0) {
lastMode = PRO.ROUGH;
setTool(process.camRoughTool, process.camRoughSpeed, process.camRoughPlunge);
spindle = Math.min(spindleMax, process.camRoughSpindle);
let tops = depthData.rough.map(level => {
return POLY.nest(level.filter(poly => poly.depth === 0).clone());
});
printPoint = depthRoughPath(printPoint, 0, depthData.rough, tops, polyEmit);
}
// outline depth first
if (depthData.outline.length > 0) {
// depthData.outline.xout('depth');
lastMode = PRO.OUTLINE;
setTool(process.camOutlineTool, process.camOutlineSpeed, process.camOutlinePlunge);
spindle = Math.min(spindleMax, process.camOutlineSpindle);
let flatLevels = depthData.outline.map(level => {
return POLY.flatten(level.clone(true), [], true).filter(p => !(p.depth = 0));
}).filter(l => l.length > 0);
// flatLevels.xout('flat');
// start with the smallest polygon on the top
printPoint = flatLevels[0]
// .filter(l => l.length > 0)[0]
.sort((a,b) => { return a.area() - b.area() })[0]
.average();
printPoint = depthOutlinePath(printPoint, 0, flatLevels, toolDiam, polyEmit, false);
printPoint = depthOutlinePath(printPoint, 0, flatLevels, toolDiam, polyEmit, true);
}
// two modes for deferred outlining: x then y or combined
if (contour && contourCurves) {
lastMode = PRO.CONTOUR_X;
setTool(process.camContourTool, process.camContourSpeed, process.camContourPlunge);
spindle = Math.min(spindleMax, process.camContourSpindle);
// combined deferred contour x and y outlining
let contourxy = [].appendAll(depthData.contourx).appendAll(depthData.contoury);
printPoint = tip2tipEmit(contourxy, printPoint, function(el, point, count) {
let poly = el.poly;
if (poly.last() === point) {
poly.reverse();
}
poly.forEachPoint(function(point, pidx) {
camOut(point.clone(), pidx > 0);
}, false);
newLayer();
return lastPoint;
});
} else if (contour) {
setTool(process.camContourTool, process.camContourSpeed, process.camContourPlunge);
spindle = Math.min(spindleMax, process.camContourSpindle);
// deferred contour x outlining
if (depthData.contourx.length > 0) {
lastMode = PRO.CONTOUR_X;
// force start at lower left corner
// printPoint = newPoint(bounds.min.x,bounds.min.y,zmax);
printPoint = tip2tipEmit(depthData.contourx, printPoint, function(el, point, count) {
let poly = el.poly;
if (poly.last() === point) poly.reverse();
poly.forEachPoint(function(point, pidx) {
camOut(point.clone(), pidx > 0);
}, false);
newLayer();
return lastPoint;
});
}
// deferred contour y outlining
if (depthData.contoury.length > 0) {
lastMode = PRO.CONTOUR_Y;
// force start at lower left corner
printPoint = tip2tipEmit(depthData.contoury, printPoint, function(el, point, count) {
let poly = el.poly;
if (poly.last() === point) poly.reverse();
poly.forEachPoint(function(point, pidx) {
camOut(point.clone(), pidx > 0);
}, false);
newLayer();
return lastPoint;
});
}
}
depthData.trace.forEach(slice => {
emitTrace(slice);
});
}
// drilling is always depth first, and always output last (change?)
if (false && depthData.drill.length > 0) {
lastMode = PRO.DRILL;
setTool(process.camDrillTool, process.camDrillDownSpeed, process.camDrillDownSpeed);
emitDrills(depthData.drill);
}
// last layer/move is to zmax
// injected into the last layer generated
if (lastPoint)
addOutput(newOutput[newOutput.length-1], printPoint = lastPoint.clone().setZ(zmax_outer), 0, 0, tool.getNumber());
// replace output single flattened layer with all points
print.output = newOutput;
return printPoint;
};
/**
* return tool Z clearance height for a line segment movement path
*/
function getZClearPath(terrain, x1, y1, x2, y2, z, zadd, off, over) {
if (terrain > 0) {
return terrain + zadd + over;
}
let maxz = z;
let check = [];
for (let i=0; i<terrain.length; i++) {
let data = terrain[i];
check.push(data);
if (data.z + zadd < z) {
break;
}
}
check.reverse();
for (let i=0; i<check.length; i++) {
let data = check[i];
let p1 = newPoint(x1, y1);
let p2 = newPoint(x2, y2);
let int = data.tops.map(p => p.intersections(p1, p2, true)).flat();
if (int.length) {
maxz = Math.max(maxz, data.z + zadd + over);
continue;
}
let s1 = p1.slopeTo(p2).toUnit().normal();
let s2 = p2.slopeTo(p1).toUnit().normal();
let pa = p1.projectOnSlope(s1, off);
let pb = p2.projectOnSlope(s1, off);
int = data.tops.map(p => p.intersections(pa, pb, true)).flat();
if (int.length) {
maxz = Math.max(maxz, data.z + zadd + over);
continue;
}
pa = p1.projectOnSlope(s2, off);
pb = p2.projectOnSlope(s2, off);
int = data.tops.map(p => p.intersections(pa, pb, true)).flat();
if (int.length) {
maxz = Math.max(maxz, data.z + zadd + over);
continue;
}
}
return maxz;
}
})();