Support calculations seem to be working. Tested quite a bit. The new reprap.properties.dist file contains quite good settings for using PLA to support itself.

git-svn-id: https://reprap.svn.sourceforge.net/svnroot/reprap@3513 cb376a5e-1013-0410-a455-b6b1f9ac8223
author: adrian-bowyer <adrian-bowyer@cb376a5e-1013-0410-a455-b6b1f9ac8223> 2010-02-18 23:17:36 +0000
committer: adrian-bowyer <adrian-bowyer@cb376a5e-1013-0410-a455-b6b1f9ac8223> 2010-02-18 23:17:36 +0000
commit: 55648ab782d8dc4fcf9382a52a6768f26fecf632 (patch)
tree: 7ee1bb318d0a1cd82b643ccc49b5822c8ea12321
parent: c5b909fa0e6cffa2a9c87f531510c35108bb5e52 (diff)
download: reprap-backup-55648ab782d8dc4fcf9382a52a6768f26fecf632.tar.gz
reprap-backup-55648ab782d8dc4fcf9382a52a6768f26fecf632.zip
4 files changed, 115 insertions, 117 deletions
diff --git a/trunk/reprap/host/lib/reprap.properties.dist b/trunk/reprap/host/lib/reprap.properties.dist
index 07673156..beae0733 100644
--- a/trunk/reprap/host/lib/reprap.properties.dist
+++ b/trunk/reprap/host/lib/reprap.properties.dist
@@ -1,5 +1,5 @@
 #RepRap machine parameters. See http://objects.reprap.org/wiki/Java_Software_Preferences_File
-#Mon Jan 25 23:53:16 GMT 2010
+#Thu Feb 18 23:12:22 GMT 2010
 AxisCount=3
 BackColourB(0..1)=0.9
 BackColourG(0..1)=0.9
@@ -10,10 +10,8 @@ BoundFactor=3.0
 CommsDebug=false
 Debug=false
 DisplaySimulation=false
-DumpX(mm)=120
+DumpX(mm)=130
 DumpY(mm)=5
-FinishX(mm)=10
-FinishY(mm)=190
 Extruder0_Address=0
 Extruder0_AngleSpeedFactor(0..1)=0.5
 Extruder0_AngleSpeedLength(mm)=-1
@@ -94,13 +92,13 @@ Extruder1_ColourG(0..1)=0.6
 Extruder1_ColourR(0..1)=0.9
 Extruder1_CoolingPeriod(s)=0.1
 Extruder1_EvenHatchDirection(degrees)=45
-Extruder1_ExtrudeRatio(0..)=1
+Extruder1_ExtrudeRatio(0..)=0.6
 Extruder1_ExtrusionBroadWidth(mm)=2.0
 Extruder1_ExtrusionDelayForLayer(ms)=600
 Extruder1_ExtrusionDelayForPolygon(ms)=500
 Extruder1_ExtrusionFoundationWidth(mm)=2
 Extruder1_ExtrusionHeight(mm)=0.3
-Extruder1_ExtrusionInfillWidth(mm)=1.0
+Extruder1_ExtrusionInfillWidth(mm)=2.5
 Extruder1_ExtrusionLastFoundationWidth(mm)=1
 Extruder1_ExtrusionOverRun(mm)=3
 Extruder1_ExtrusionPWM(0..1)=-1
@@ -168,7 +166,7 @@ Extruder2_ExtrusionDelayForLayer(ms)=600
 Extruder2_ExtrusionDelayForPolygon(ms)=500
 Extruder2_ExtrusionFoundationWidth(mm)=2
 Extruder2_ExtrusionHeight(mm)=0.3
-Extruder2_ExtrusionInfillWidth(mm)=2
+Extruder2_ExtrusionInfillWidth(mm)=1.5
 Extruder2_ExtrusionLastFoundationWidth(mm)=2
 Extruder2_ExtrusionOverRun(mm)=0
 Extruder2_ExtrusionPWM(0..1)=-1
@@ -226,31 +224,32 @@ Extruder3_ArcCompensationFactor(0..)=8
 Extruder3_ArcShortSides(0..)=1
 Extruder3_Beta(K)=550.0
 Extruder3_Capacitor(F)=0.000003
-Extruder3_ColourB(0..1)=0.4
+Extruder3_ColourB(0..1)=0.5
 Extruder3_ColourG(0..1)=0.5
-Extruder3_ColourR(0..1)=0.6
+Extruder3_ColourR(0..1)=0.3
 Extruder3_CoolingPeriod(s)=0.1
-Extruder3_EvenHatchDirection(degrees)=-45
-Extruder3_ExtrudeRatio(0..)=-1.0
-Extruder3_ExtrusionBroadWidth(mm)=2.0
-Extruder3_ExtrusionDelayForLayer(ms)=300
-Extruder3_ExtrusionDelayForPolygon(ms)=200
+Extruder3_EvenHatchDirection(degrees)=45
+Extruder3_ExtrudeRatio(0..)=1
+Extruder3_ExtrusionBroadWidth(mm)=6
+Extruder3_ExtrusionDelayForLayer(ms)=600
+Extruder3_ExtrusionDelayForPolygon(ms)=500
 Extruder3_ExtrusionFoundationWidth(mm)=2
-Extruder3_ExtrusionHeight(mm)=0.4
-Extruder3_ExtrusionInfillWidth(mm)=0.5
+Extruder3_ExtrusionHeight(mm)=0.3
+Extruder3_ExtrusionInfillWidth(mm)=1.5
 Extruder3_ExtrusionLastFoundationWidth(mm)=2
-Extruder3_ExtrusionOverRun(mm)=-1
+Extruder3_ExtrusionOverRun(mm)=0
+Extruder3_ExtrusionPWM(0..1)=-1
 Extruder3_ExtrusionSize(mm)=0.7
-Extruder3_ExtrusionSpeed(mm/minute)=-1
+Extruder3_ExtrusionSpeed(mm/minute)=3000
 Extruder3_ExtrusionTemp(C)=0
 Extruder3_FastXYFeedrate(mm/minute)=3000.0
 Extruder3_InFillMaterialType(name)=null
-Extruder3_IncrementedStart=true
+Extruder3_IncrementedStart=false
 Extruder3_InfillOverlap(mm)=0.2
 Extruder3_InfillSpeed(0..1)=1
-Extruder3_LowerFineLayers(0...)=2
+Extruder3_LowerFineLayers(0...)=0
 Extruder3_MaterialType(name)=Paste
-Extruder3_MaxAcceleration(mm/minute/minute)=-1
+Extruder3_MaxAcceleration(mm/minute/minute)=1200000.0
 Extruder3_MaxSpeed(0..255)=255
 Extruder3_MinimumZClearance(mm)=-1
 Extruder3_NozzleClearTime(s)=10
@@ -262,34 +261,38 @@ Extruder3_NozzleWipeFreq=1
 Extruder3_NozzleWipeStrokeX(mm)=0
 Extruder3_NozzleWipeStrokeY(mm)=10
 Extruder3_NumberOfShells(0..N)=1
-Extruder3_OddHatchDirection(degrees)=45
+Extruder3_OddHatchDirection(degrees)=-45
 Extruder3_OffsetX(mm)=0
 Extruder3_OffsetY(mm)=0
 Extruder3_OffsetZ(mm)=0
 Extruder3_OutlineSpeed(0..1)=0.9
 Extruder3_PauseBetweenSegments=false
+Extruder3_Purge(ms)=10000
 Extruder3_RandomStart=false
-Extruder3_Reverse(ms)=0
+Extruder3_Reverse(ms)=400
 Extruder3_Rz(ohms)=4837
 Extruder3_SeparationFraction(0..1)=0.8
-Extruder3_SeparationSpeed(mm/minute)=3000
+Extruder3_SeparationOutlineSpeed(0..1)=1
+Extruder3_SeparationSpeed(mm/minute)=2500
 Extruder3_ShortLength(mm)=-1
 Extruder3_ShortSpeed(0..1)=1
 Extruder3_SlowXYFeedrate(mm/minute)=1500.0
 Extruder3_SupportMaterialType(name)=null
-Extruder3_UpperFineLayers(0...)=2
+Extruder3_UpperFineLayers(0...)=0
 Extruder3_ValveDelayForLayer(ms)=200
 Extruder3_ValveDelayForPolygon(ms)=200
-Extruder3_ValveOverRun(mm)=-1
+Extruder3_ValveOverRun(mm)=2
 Extruder3_ValvePulseTime(ms)=500
 Extruder3_hb(C)=20
 Extruder3_hm(C/pwr)=0.86
 Extruder3_t0(0..255)=0
 FastSpeed(-1..255)=240
+FinishX(mm)=10
+FinishY(mm)=190
 FiveD=true
 FoundationLayers=0
 FrontFactor=0.001
-GCodeUseSerial=true
+GCodeUseSerial=false
 IdleZAxis=true
 InterLayerCooling=true
 MachineColourB(0..1)=0.3
@@ -304,7 +307,7 @@ MouseTranslationFactor=50
 MouseZoomFactor=50
 MovementSpeedZ(0..255)=240
 NumberOfExtruders=3
-PathOptimise=false
+PathOptimise=true
 Port(name)=/dev/ttyUSB0
 RadiusFactor=0.7
 RememberWindowPosition=false
diff --git a/trunk/reprap/host/src/org/reprap/geometry/LayerRules.java b/trunk/reprap/host/src/org/reprap/geometry/LayerRules.java
index 9049026b..2db81109 100644
--- a/trunk/reprap/host/src/org/reprap/geometry/LayerRules.java
+++ b/trunk/reprap/host/src/org/reprap/geometry/LayerRules.java
@@ -161,14 +161,8 @@ public class LayerRules
 			}
 		}
 		
-		//layerRecord = new RrCSGPolygonList[fineLayers+1];
 		recordNumber = new int[fineLayers+1];
 		layerPointer = 0;
-//		for(int i = 0; i < layerRecord.length; i++)
-//		{
-//			layerRecord[i] = null;
-//			recordNumber[i] = -1;
-//		}
 	}
 	
 	public RrRectangle getBox()
@@ -176,42 +170,20 @@ public class LayerRules
 		return bBox;
 	}
 	
-//	public void recordThisLayer(RrCSGPolygonList pl)
-//	{
-//		//if(layerRecord[layerPointer] != null)
-//		//	layerRecord[layerPointer].destroy();
-//		layerRecord[layerPointer] = pl;
-//		recordNumber[layerPointer] = machineLayer;
-//		layerPointer++;
-//		if(layerPointer >= layerRecord.length)
-//			layerPointer = 0;
-//	}
-	
-	/**
-	 * Return the layer i above where we are 
-	 * @param i
-	 * @return
-	 */
-//	public RrCSGPolygonList getLayerAbove(int i)
-//	{
-//		int lp = layerPointer - i;
-//		if(lp < 0)
-//			return layerRecord[layerRecord.length + lp];
-//		else
-//			return layerRecord[lp];
-//	}
-	
 	public boolean getTopDown() { return topDown; }
 	
 	public void setPrinter(Printer p) { printer = p; }
 	public Printer getPrinter() { return printer; }
 	
-	//public void setModelZ(double mz) { modelZ = mz; }
 	public double getModelZ() { return modelZ; }
 	
+	public double getModelZ(int layer) 
+	{
+		return zStep*layer; 
+	}
+	
 	public double getMachineZ() { return machineZ; }
 	
-	//private void setModelLayer(int ml) { modelLayer = ml; }
 	public int getModelLayer() { return modelLayer; }
 	
 	public int getModelLayerMax() { return modelLayerMax; }
@@ -300,27 +272,7 @@ public class LayerRules
 	public double getHatchWidth(Extruder e)
 	{
 		if(getMachineLayer() < getFoundationLayers())
-		{
-			//if(getMachineLayer() == getFoundationLayers() - 2)
-				//return e.getExtrusionFoundationWidth()*0.5;
-
-			
 			return e.getExtrusionFoundationWidth();
-		}
-		
-		
-//		String inFillName = e.getBroadInfillMaterial();
-//		
-//		// If this stuff's infill is not called "null"...
-//		
-//		if(!inFillName.contentEquals("null"))
-//		{
-//			if(modelLayer+1 > e.getLowerFineLayers() && modelLayer+1 <= modelLayerMax - e.getUpperFineLayers())
-//			{
-//				Extruder inFillExtruder = printer.getExtruders()[GenericExtruder.getNumberFromMaterial(inFillName)];
-//				return inFillExtruder.getExtrusionInfillWidth();
-//			}
-//		}
 		
 		return e.getExtrusionInfillWidth();
 	}
@@ -389,21 +341,10 @@ public class LayerRules
 		}
 		addToStep = 0;
 		stepMachine(e);
-		
-//		// modelLayer < 0 when we're building foundations
-//		if(modelLayer < 0)
-//		{
-//			modelLayer = 0;
-//			modelZ = 0;
-//		}
 	}
 	
 	public void setFractionDone()
 	{
-//		double f = machineZ/machineZMax;
-//		if(topDown)
-//			f = 1 - f;
-		
 		// Set -ve to force the system to query the layer rules
 		
 		org.reprap.gui.botConsole.BotConsoleFrame.getBotConsoleFrame().setFractionDone(-1);
diff --git a/trunk/reprap/host/src/org/reprap/geometry/polygons/AllSTLsToBuild.java b/trunk/reprap/host/src/org/reprap/geometry/polygons/AllSTLsToBuild.java
index 67e09699..08b2b162 100644
--- a/trunk/reprap/host/src/org/reprap/geometry/polygons/AllSTLsToBuild.java
+++ b/trunk/reprap/host/src/org/reprap/geometry/polygons/AllSTLsToBuild.java
@@ -546,7 +546,7 @@ public class AllSTLsToBuild
 		// from doesn't matter.
 		
 		int layer = layerConditions.getMachineLayer();
-		BooleanGridList thisLayer = slice(stl, layerConditions);
+		BooleanGridList thisLayer = slice(stl, layerConditions.getModelLayer(), layerConditions);
 		
 		BooleanGrid unionOfThisLayer;
 		Attributes a;
@@ -567,36 +567,37 @@ public class AllSTLsToBuild
 		
 		BooleanGridList allThis = new BooleanGridList();
 		allThis.add(unionOfThisLayer);
-		allThis = allThis.offset(layerConditions, true, -1);
+		allThis = allThis.offset(layerConditions, true, -3);  // -3 is a bit of a hack...
 		
 		if(allThis.size() > 0)
 			unionOfThisLayer = allThis.get(0);
 		else
 			unionOfThisLayer = BooleanGrid.nullBooleanGrid();
 
-		// Now we subtract the union of this layer from all the stuff requiring support in the layer above.
+		// Get the layer above and union it with this layer.  That's what needs
+		// support on the next layer down.
 		
 		BooleanGridList previousSupport = cache.getSupport(layer+1, stl);
+		cache.setSupport(BooleanGridList.unions(previousSupport, thisLayer), layer, stl);
+		
+		// Now we subtract the union of this layer from all the stuff requiring support in the layer above.
 		
 		BooleanGridList support = new BooleanGridList();
+	
 		if(previousSupport != null)
 		{
 			for(int i = 0; i < previousSupport.size(); i++)
 			{
 				BooleanGrid above = previousSupport.get(i);
 				a = above.attribute();
-				if(!a.getExtruder().getSupportMaterial().equalsIgnoreCase("null"))
+				if(a.getExtruder().getSupportExtruder() != null)
 					support.add(BooleanGrid.difference(above, unionOfThisLayer, a));
 			}
+			support = support.unionDuplicates();
 		}
 		
-		// Copy the support material as we are about to change its attributes
-		// to that of the support for each of its components, and we want
-		// the original material in the cache.
-		
-		BooleanGridList toCache = new BooleanGridList(support);
-		toCache = BooleanGridList.unions(toCache, thisLayer);
-		cache.setSupport(toCache, layer, stl);
+		// Now force the attributes of the support pattern to be the support extruders
+		// for all the materials in it.
 		
 		for(int i = 0; i < support.size(); i++)
 		{
@@ -609,6 +610,7 @@ public class AllSTLsToBuild
 			support.get(i).forceAttribute(new Attributes(e.getMaterial(), null, null, e.getAppearance()));
 		}
 		
+		// Finally compute the support hatch.
 		
 		return support.hatch(layerConditions, false, null);
 	}
@@ -629,13 +631,15 @@ public class AllSTLsToBuild
 		// Where are we and what does the current slice look like?
 		
 		int layer = layerConditions.getMachineLayer();
-		BooleanGridList slice = slice(stl, layerConditions);
+		BooleanGridList slice = slice(stl, layerConditions.getModelLayer(), layerConditions);
 
 		// If we are solid but the slices around us weren't, we need some fine infill as
 		// we are (at least partly) surface
 		
-		BooleanGridList previousSlices = cache.getSlice(layer+1, stl);
-		previousSlices = BooleanGridList.intersections(cache.getSlice(layer+2, stl), previousSlices);
+		BooleanGridList adjacentSlices = slice(stl, layer+1, layerConditions);
+		adjacentSlices = BooleanGridList.intersections(slice(stl, layer+2, layerConditions), adjacentSlices);
+		adjacentSlices = BooleanGridList.intersections(slice(stl, layer-1, layerConditions), adjacentSlices);
+		adjacentSlices = BooleanGridList.intersections(slice(stl, layer-2, layerConditions), adjacentSlices);
 		BooleanGridList insides = null;
 		
 		// The insides are the bits that aren't surface.
@@ -644,10 +648,10 @@ public class AllSTLsToBuild
 		// ensure that they go a little way into the inside infill.
 		
 		BooleanGridList outsides = slice;
-		if(previousSlices != null && layerConditions.getModelLayer() > 1)
+		if(adjacentSlices != null && layerConditions.getModelLayer() > 1)
 		{
-			insides = BooleanGridList.intersections(slice, previousSlices);
-			outsides = BooleanGridList.differences(slice, previousSlices);
+			insides = BooleanGridList.intersections(slice, adjacentSlices);
+			outsides = BooleanGridList.differences(slice, adjacentSlices);
 			outsides = outsides.offset(layerConditions, false, -1);
 			outsides = BooleanGridList.intersections(outsides, slice);
 		}
@@ -688,7 +692,7 @@ public class AllSTLsToBuild
 		
 		// The shapes to outline.
 		
-		BooleanGridList slice = slice(stl, layerConditions);
+		BooleanGridList slice = slice(stl, layerConditions.getModelLayer(), layerConditions);
 		
 		RrPolygonList borderPolygons;
 		
@@ -741,7 +745,7 @@ public class AllSTLsToBuild
 	 * @param extruders
 	 * @return
 	 */
-	private BooleanGridList slice(int stl, LayerRules layerRules)
+	private BooleanGridList slice(int stl, int layer, LayerRules layerRules)
 	{
 		if(!frozen)
 		{
@@ -749,9 +753,11 @@ public class AllSTLsToBuild
 			freeze();
 		}
 		
+		if(layer < 0)
+			return new BooleanGridList();
+		
 		// Is the result in the cache?  If so, just use that.
 		
-		int layer = layerRules.getMachineLayer();
 		BooleanGridList result = cache.getSlice(layer, stl);
 		if(result != null)
 			return result;
@@ -765,7 +771,7 @@ public class AllSTLsToBuild
 		
 		// Probably...
 		
-		double z = layerRules.getModelZ() + layerRules.getZStep()*0.5;
+		double z = layerRules.getModelZ(layer) + layerRules.getZStep()*0.5;
 		Extruder[] extruders = layerRules.getPrinter().getExtruders();
 		result = new BooleanGridList();
 		RrCSG csgp = null;
diff --git a/trunk/reprap/host/src/org/reprap/geometry/polygons/BooleanGridList.java b/trunk/reprap/host/src/org/reprap/geometry/polygons/BooleanGridList.java
index 5f1dadf0..e565e3cb 100644
--- a/trunk/reprap/host/src/org/reprap/geometry/polygons/BooleanGridList.java
+++ b/trunk/reprap/host/src/org/reprap/geometry/polygons/BooleanGridList.java
@@ -206,6 +206,49 @@ public class BooleanGridList
 			return result;
 		}
 		
+		/**
+		 * Run through the list, unioning entries in it that share the same material so that
+		 * the result has just one entry per material.
+		 */
+		public BooleanGridList unionDuplicates()
+		{
+			BooleanGridList result = new BooleanGridList();
+
+			if(size() <= 0)
+				return result;
+			
+			if(size() == 1)
+				return this;
+
+			boolean[] usedUp = new boolean[size()];
+			for(int i = 0; i < usedUp.length; i++)
+				usedUp[i] = false;
+
+			for(int i = 0; i < size() - 1; i++)
+			{
+				if(!usedUp[i])
+				{
+					BooleanGrid union = get(i);
+					int iExId = union.attribute().getExtruder().getID();
+					for(int j = i+1; j < size(); j++)
+					{
+						if(!usedUp[j])
+						{
+							BooleanGrid jg = get(j);
+							if(iExId == jg.attribute().getExtruder().getID())
+							{
+								union = BooleanGrid.union(union, jg);
+								usedUp[j] = true;
+							}
+						}
+					}
+					result.add(union);
+				}
+			}
+
+			return result;
+		}
+		
 		
 		/**
 		 * Return a list of unions between the entries in a and b.
@@ -220,6 +263,8 @@ public class BooleanGridList
 		{
 			BooleanGridList result = new BooleanGridList();
 			
+			if(a == b)
+				return a;
 			if(a == null)
 				return b;
 			if(a.size() <= 0)
@@ -255,7 +300,7 @@ public class BooleanGridList
 				if(!bMatched[i])
 					result.add(b.get(i));
 			
-			return result;
+			return result.unionDuplicates();
 		}
 		
 		/**
@@ -270,7 +315,8 @@ public class BooleanGridList
 		public static BooleanGridList intersections(BooleanGridList a, BooleanGridList b)
 		{
 			BooleanGridList result = new BooleanGridList();
-			
+			if(a == b)
+				return a;
 			if(a == null || b == null)
 				return result;
 			if(a.size() <= 0  || b.size() <= 0)
@@ -288,7 +334,7 @@ public class BooleanGridList
 					}
 				}
 			}
-			return result;
+			return result.unionDuplicates();
 		}
 		
 		
@@ -305,6 +351,8 @@ public class BooleanGridList
 		{
 			BooleanGridList result = new BooleanGridList();
 			
+			if(a == b)
+				return result;
 			if(a == null)
 				return result;
 			if(a.size() <= 0)
@@ -331,7 +379,7 @@ public class BooleanGridList
 					result.add(abg);
 					
 			}
-			return result;
+			return result.unionDuplicates();
 		}
author	adrian-bowyer <adrian-bowyer@cb376a5e-1013-0410-a455-b6b1f9ac8223>	2010-02-18 23:17:36 +0000
committer	adrian-bowyer <adrian-bowyer@cb376a5e-1013-0410-a455-b6b1f9ac8223>	2010-02-18 23:17:36 +0000
commit	55648ab782d8dc4fcf9382a52a6768f26fecf632 (patch)
tree	7ee1bb318d0a1cd82b643ccc49b5822c8ea12321
parent	c5b909fa0e6cffa2a9c87f531510c35108bb5e52 (diff)
download	reprap-backup-55648ab782d8dc4fcf9382a52a6768f26fecf632.tar.gz reprap-backup-55648ab782d8dc4fcf9382a52a6768f26fecf632.zip