Fix Python unicode logging issues. Add sin approximation to inverse processor. Fix log levels and progress output. Add firmware compensation statistics.

6 files changed, 48 insertions, 62 deletions

diff --git a/ArcWelder/arc_welder.cpp b/ArcWelder/arc_welder.cpp
index 981eeec..9fe02d0 100644
--- a/ArcWelder/arc_welder.cpp
+++ b/ArcWelder/arc_welder.cpp
@@ -205,7 +205,7 @@ arc_welder_results results;
 	bool continue_processing = true;
 	
 	p_logger_->log(logger_type_, DEBUG, "Configuring progress updates.");
-	int read_lines_before_clock_check = 5000;
+	int read_lines_before_clock_check = 1000;
 	double next_update_time = get_next_update_time();
 	const clock_t start_clock = clock();
 	p_logger_->log(logger_type_, DEBUG, "Getting source file size.");
@@ -247,6 +247,8 @@ arc_welder_results results;
 	
 	parsed_command cmd;
 	// Communicate every second
+	p_logger_->log(logger_type_, DEBUG, "Sending initial progress update.");
+	continue_processing = on_progress_(get_progress_(static_cast<long>(gcodeFile.tellg()), static_cast<double>(start_clock)));
 	p_logger_->log(logger_type_, DEBUG, "Processing source file.");
 	while (std::getline(gcodeFile, line) && continue_processing)
 	{
@@ -278,7 +280,7 @@ arc_welder_results results;
 		process_gcode(cmd, false, false);
 
 		// Only continue to process if we've found a command and either a progress_callback_ is supplied, or debug loggin is enabled.
-		if (has_gcode && (progress_callback_ != NULL || info_logging_enabled_))
+		if (has_gcode)
 		{
 			if ((lines_processed_ % read_lines_before_clock_check) == 0 && next_update_time < clock())
 			{
@@ -302,12 +304,12 @@ arc_welder_results results;
 	p_logger_->log(logger_type_, DEBUG, "Fetching the final progress struct.");
 
 	arc_welder_progress final_progress = get_progress_(static_cast<long>(file_size_), static_cast<double>(start_clock));
-	if (progress_callback_ != NULL || info_logging_enabled_)
+	if (debug_logging_enabled_)
 	{
-		// Sending final progress update message
-		p_logger_->log(logger_type_, VERBOSE, "Sending final progress update message.");
-		on_progress_(arc_welder_progress(final_progress));
+		p_logger_->log(logger_type_, DEBUG, "Sending final progress update message.");
 	}
+	on_progress_(arc_welder_progress(final_progress));
+	
 	p_logger_->log(logger_type_, DEBUG, "Processing complete, closing source and target file.");
 	output_file_.close();
 	gcodeFile.close();
@@ -355,7 +357,7 @@ arc_welder_progress arc_welder::get_progress_(long source_file_position, double
 		progress.compression_ratio = (static_cast<float>(source_file_position) / static_cast<float>(progress.target_file_size));
 		progress.compression_percent = (1.0 - (static_cast<float>(progress.target_file_size) / static_cast<float>(source_file_position))) * 100.0f;
 	}
-
+	progress.num_firmware_compensations = current_arc_.get_num_firmware_compensations();
 	progress.segment_statistics = segment_statistics_;
 	return progress;
 	
diff --git a/ArcWelder/arc_welder.h b/ArcWelder/arc_welder.h
index 22cf4b6..0e6bb81 100644
--- a/ArcWelder/arc_welder.h
+++ b/ArcWelder/arc_welder.h
@@ -352,6 +352,7 @@ struct arc_welder_progress {
 		lines_processed = 0;
 		points_compressed = 0;
 		arcs_created = 0;
+		num_firmware_compensations = 0;
 		source_file_size = 0;
 		source_file_position = 0;
 		target_file_size = 0;
@@ -365,6 +366,7 @@ struct arc_welder_progress {
 	int lines_processed;
 	int points_compressed;
 	int arcs_created;
+	int num_firmware_compensations;
 	double compression_ratio;
 	double compression_percent;
 	long source_file_position;
@@ -381,6 +383,7 @@ struct arc_welder_progress {
 		stream << ", current_file_line: " << lines_processed;
 		stream << ", points_compressed: " << points_compressed;
 		stream << ", arcs_created: " << arcs_created;
+		stream << ", num_firmware_compensations: " << num_firmware_compensations;
 		stream << ", compression_ratio: " << compression_ratio;
 		stream << ", size_reduction: " << compression_percent << "% ";
 		return stream.str();
diff --git a/ArcWelder/segmented_arc.cpp b/ArcWelder/segmented_arc.cpp
index bd4b964..9f02049 100644
--- a/ArcWelder/segmented_arc.cpp
+++ b/ArcWelder/segmented_arc.cpp
@@ -36,6 +36,7 @@ segmented_arc::segmented_arc() : segmented_shape(DEFAULT_MIN_SEGMENTS, DEFAULT_M
   max_radius_mm_ = DEFAULT_MAX_RADIUS_MM;
   min_arc_segments_ = DEFAULT_MIN_ARC_SEGMENTS,
   allow_3d_arcs_ = DEFAULT_allow_3d_arcs;
+  num_firmware_compensations_ = 0;
 }
 
 segmented_arc::segmented_arc(
@@ -64,6 +65,7 @@ segmented_arc::segmented_arc(
     min_arc_segments_ = 0;
   }
   allow_3d_arcs_ = allow_3d_arcs;
+  num_firmware_compensations_ = 0;
 }
 
 segmented_arc::~segmented_arc()
@@ -98,6 +100,11 @@ int segmented_arc::get_min_arc_segments() const
   return min_arc_segments_;
 }
 
+int segmented_arc::get_num_firmware_compensations() const
+{
+  return num_firmware_compensations_;
+}
+
 double segmented_arc::get_mm_per_arc_segment() const
 {
   return mm_per_arc_segment_;
@@ -149,15 +156,6 @@ bool segmented_arc::try_add_point(point p, double e_relative)
     point_added = true;
     points_.push_back(p);
     original_shape_length_ += distance;
-    if (points_.count() == get_min_segments())
-    {
-      if (!arc::try_create_arc(points_, current_arc_, original_shape_length_, max_radius_mm_, resolution_mm_, path_tolerance_percent_, min_arc_segments_, mm_per_arc_segment_, xyz_precision_, allow_3d_arcs_))
-      {
-        point_added = false;
-        points_.pop_back();
-        original_shape_length_ -= distance;
-      }
-    }
   }
   else
   {
@@ -214,11 +212,30 @@ bool segmented_arc::try_add_point_internal_(point p, double pd)
 
   if (arc::try_create_arc(points_, current_arc_, original_shape_length_, max_radius_mm_, resolution_mm_, path_tolerance_percent_, min_arc_segments_, mm_per_arc_segment_, xyz_precision_, allow_3d_arcs_))
   {
-    if (!is_shape())
+    // See how many arcs will be interpolated
+    bool firmware_corrected = false;
+    if (min_arc_segments_ > 0 && mm_per_arc_segment_ > 0)
     {
-      set_is_shape(true);
+      double circumference = 2.0 * PI_DOUBLE * current_arc_.radius;
+      int num_segments = (int)std::floor(circumference / min_arc_segments_);
+      if (num_segments < min_arc_segments_) {
+        //num_segments = (int)std::ceil(circumference/approximate_length) * (int)std::ceil(approximate_length / mm_per_arc_segment);
+        num_segments = (int)std::floor(circumference / original_shape_length_);
+        if (num_segments < min_arc_segments_) {
+          firmware_corrected = true;
+          num_firmware_compensations_++; 
+        }
+      }
+    }
+
+    if (!firmware_corrected)
+    {
+      if (!is_shape())
+      {
+        set_is_shape(true);
+      }
+      return true;
     }
-    return true;
   }
   // Can't create the arc.  Remove the point and remove the previous segment length.
   points_.pop_back();
diff --git a/ArcWelder/segmented_arc.h b/ArcWelder/segmented_arc.h
index 10ad7f0..a51cbbd 100644
--- a/ArcWelder/segmented_arc.h
+++ b/ArcWelder/segmented_arc.h
@@ -56,6 +56,7 @@ public:
 	double get_max_radius() const;
 	int get_min_arc_segments() const;
 	double get_mm_per_arc_segment() const;
+	int get_num_firmware_compensations() const;
 
 private:
 	bool try_add_point_internal_(point p, double pd);
@@ -67,6 +68,7 @@ private:
 	double max_radius_mm_;
 	int min_arc_segments_;
 	double mm_per_arc_segment_;
+	int num_firmware_compensations_;
 	bool allow_3d_arcs_;
 };															
 
diff --git a/ArcWelder/segmented_shape.cpp b/ArcWelder/segmented_shape.cpp
index 945c912..d9041eb 100644
--- a/ArcWelder/segmented_shape.cpp
+++ b/ArcWelder/segmented_shape.cpp
@@ -332,8 +332,6 @@ bool arc::try_create_arc(
   double approximate_length,
   double resolution,
   double path_tolerance_percent,
-  int min_arc_segments,
-  double mm_per_arc_segment,
   bool allow_3d_arcs)
 {
   double polar_start_theta = c.get_polar_radians(start_point);
@@ -439,20 +437,6 @@ bool arc::try_create_arc(
     angle_radians *= -1.0;
   }
 
-  // See how many arcs will be interpolated
-  if (min_arc_segments > 0 && mm_per_arc_segment > 0)
-  {
-    double circumference = 2.0*PI_DOUBLE*c.radius;
-    int num_segments = (int)std::ceil(circumference/mm_per_arc_segment);
-    if (num_segments < min_arc_segments) {
-      // We might be able to salvage this.  See if there would be enough segments if we use an arc of the current size
-      num_segments = (int)std::ceil(circumference / arc_length);
-      if (num_segments < min_arc_segments) {
-        return false;
-      }
-    }
-  }
-
   target_arc.center.x = c.center.x;
   target_arc.center.y = c.center.y;
   target_arc.center.z = c.center.z;
@@ -469,20 +453,6 @@ bool arc::try_create_arc(
 }
 
 bool arc::try_create_arc(
-  const circle& c,
-  const array_list<point>& points,
-  arc& target_arc,
-  double approximate_length,
-  double resolution,
-  double path_tolerance_percent,
-  int min_arc_segments,
-  double mm_per_arc_segment,
-  bool allow_3d_arcs)
-{
-  int mid_point_index = ((points.count() - 2) / 2) + 1;
-  return arc::try_create_arc(c, points[0], points[mid_point_index], points[points.count() - 1], target_arc, approximate_length, resolution, path_tolerance_percent, min_arc_segments, mm_per_arc_segment, allow_3d_arcs);
-}
-bool arc::try_create_arc(
   const array_list<point>& points,
   arc& target_arc,
   double approximate_length,
@@ -497,11 +467,14 @@ bool arc::try_create_arc(
   circle test_circle;
   if (circle::try_create_circle(points, max_radius_mm, resolution_mm, xyz_precision, allow_3d_arcs, false, test_circle))
   {
+    // We could save a bit of processing power and do our firmware compensation here, but we won't be able to track statistics for this easily.
+    // moved check to segmented_arc.cpp
     int mid_point_index = ((points.count() - 2) / 2) + 1;
-    return arc::try_create_arc(test_circle, points[0], points[mid_point_index], points[points.count() - 1], target_arc, approximate_length, resolution_mm, path_tolerance_percent, min_arc_segments, mm_per_arc_segment, allow_3d_arcs);
+    return arc::try_create_arc(test_circle, points[0], points[mid_point_index], points[points.count() - 1], target_arc, approximate_length, resolution_mm, path_tolerance_percent, allow_3d_arcs);
   }
   return false;
 }
+
 #pragma endregion
 
 segmented_shape::segmented_shape(int min_segments, int max_segments, double resolution_mm, double path_tolerance_percnet) : points_(max_segments)
diff --git a/ArcWelder/segmented_shape.h b/ArcWelder/segmented_shape.h
index 7e57c54..eda6a7c 100644
--- a/ArcWelder/segmented_shape.h
+++ b/ArcWelder/segmented_shape.h
@@ -163,19 +163,8 @@ struct arc : circle
 		double approximate_length,
 		double resolution = DEFAULT_RESOLUTION_MM, 
 		double path_tolerance_percent = ARC_LENGTH_PERCENT_TOLERANCE_DEFAULT,
-		int min_arc_segments = DEFAULT_MIN_ARC_SEGMENTS,
-		double mm_per_arc_segment = DEFAULT_MM_PER_ARC_SEGMENT,
-		bool allow_3d_arcs = DEFAULT_allow_3d_arcs);
-	static bool try_create_arc(
-		const circle& c, 
-		const array_list<point>& points, 
-		arc& target_arc, 
-		double approximate_length,
-		double resolution = DEFAULT_RESOLUTION_MM, 
-		double path_tolerance_percent = ARC_LENGTH_PERCENT_TOLERANCE_DEFAULT,
-		int min_arc_segments = DEFAULT_MIN_ARC_SEGMENTS,
-		double mm_per_arc_segment = DEFAULT_MM_PER_ARC_SEGMENT,
 		bool allow_3d_arcs = DEFAULT_allow_3d_arcs);
+
 	static bool try_create_arc(
 		const array_list<point>& points, 
 		arc& target_arc,