Merge branch 'vb_dev250_cooling' into dev_250

src/libslic3r/GCode/CoolingBuffer.cpp

@@ -54,6 +54,9 @@ struct CoolingLine
         TYPE_WIPE               = 1 << 9,
         TYPE_G4                 = 1 << 10,
         TYPE_G92                = 1 << 11,
+        // Would be TYPE_ADJUSTABLE, but the block of G-code lines has zero extrusion length, thus the block
+        // cannot have its speed adjusted. This should not happen (sic!).
+        TYPE_ADJUSTABLE_EMPTY   = 1 << 12,
     };
 
     CoolingLine(unsigned int type, size_t  line_start, size_t  line_end) :
@@ -136,6 +139,7 @@ struct PerExtruderAdjustments
                 assert(line.time_max >= 0.f && line.time_max < FLT_MAX);
                 line.slowdown = true;
                 line.time     = line.time_max;
+                assert(line.time > 0);
                 line.feedrate = line.length / line.time;
             }
             time_total += line.time;
@@ -151,6 +155,7 @@ struct PerExtruderAdjustments
             if (line.adjustable(slowdown_external_perimeters)) {
                 line.slowdown = true;
                 line.time     = std::min(line.time_max, line.time * factor);
+                assert(line.time > 0);
                 line.feedrate = line.length / line.time;
             }
             time_total += line.time;
@@ -182,9 +187,11 @@ struct PerExtruderAdjustments
         assert(this->min_print_speed < min_feedrate + EPSILON);
         for (size_t i = 0; i < n_lines_adjustable; ++ i) {
             const CoolingLine &line = lines[i];
-            if (line.feedrate > min_feedrate)
+            if (line.feedrate > min_feedrate) {
+                assert(min_feedrate > 0);
                 time_stretch += line.time * (line.feedrate / min_feedrate - 1.f);
             }
+        }
         return time_stretch;
     }
 
@@ -196,6 +203,7 @@ struct PerExtruderAdjustments
         for (size_t i = 0; i < n_lines_adjustable; ++ i) {
             CoolingLine &line = lines[i];
             if (line.feedrate > min_feedrate) {
+                assert(min_feedrate > 0);
                 line.time *= std::max(1.f, line.feedrate / min_feedrate);
                 line.feedrate = min_feedrate;
                 line.slowdown = true;
@@ -250,7 +258,7 @@ float new_feedrate_to_reach_time_stretch(
             }
         }
         assert(denom > 0);
-        if (denom < 0)
+        if (denom <= 0)
             return min_feedrate;
         new_feedrate = nomin / denom;
         assert(new_feedrate > min_feedrate - EPSILON);
@@ -404,11 +412,16 @@ std::vector<PerExtruderAdjustments> CoolingBuffer::parse_layer_gcode(const std::
                 }
                 line.feedrate = new_pos[4];
                 assert((line.type & CoolingLine::TYPE_ADJUSTABLE) == 0 || line.feedrate > 0.f);
-                if (line.length > 0)
+                if (line.length > 0) {
+                    assert(line.feedrate > 0);
                     line.time = line.length / line.feedrate;
+                    assert(line.time > 0);
+                }
                 line.time_max = line.time;
-                if ((line.type & CoolingLine::TYPE_ADJUSTABLE) || active_speed_modifier != size_t(-1))
+                if ((line.type & CoolingLine::TYPE_ADJUSTABLE) || active_speed_modifier != size_t(-1)) {
+                    assert(adjustment->min_print_speed >= 0);
                     line.time_max = (adjustment->min_print_speed == 0.f) ? FLT_MAX : std::max(line.time, line.length / adjustment->min_print_speed);
+                }
                 if (active_speed_modifier < adjustment->lines.size() && (line.type & CoolingLine::TYPE_G1)) {
                     // Inside the ";_EXTRUDE_SET_SPEED" blocks, there must not be a G1 Fxx entry.
                     assert((line.type & CoolingLine::TYPE_HAS_F) == 0);
@@ -428,7 +441,23 @@ std::vector<PerExtruderAdjustments> CoolingBuffer::parse_layer_gcode(const std::
             }
             current_pos = std::move(new_pos);
         } else if (boost::starts_with(sline, ";_EXTRUDE_END")) {
+            // Closing a block of non-zero length extrusion moves.
             line.type = CoolingLine::TYPE_EXTRUDE_END;
+            if (active_speed_modifier != size_t(-1)) {
+                assert(active_speed_modifier < adjustment->lines.size());
+                CoolingLine &sm = adjustment->lines[active_speed_modifier];
+                // There should be at least some extrusion move inside the adjustment block.
+                // However if the block has no extrusion (which is wrong), fix it for the cooling buffer to work.
+                assert(sm.length > 0);
+                assert(sm.time > 0);
+                if (sm.time <= 0) {
+                    // Likely a zero length extrusion, it should not be emitted, however the zero extrusions should not confuse firmware either.
+                    // Prohibit time adjustment of a block of zero length extrusions by the cooling buffer.
+                    sm.type &= ~CoolingLine::TYPE_ADJUSTABLE;
+                    // But the start / end comment shall be removed.
+                    sm.type |= CoolingLine::TYPE_ADJUSTABLE_EMPTY;
+                }
+            }
             active_speed_modifier = size_t(-1);
         } else if (boost::starts_with(sline, m_toolchange_prefix)) {
             unsigned int new_extruder = (unsigned int)atoi(sline.c_str() + m_toolchange_prefix.size());
@@ -568,6 +597,7 @@ static inline void extruder_range_slow_down_non_proportional(
                 float time_adjustable = 0.f;
                 for (auto it = adj; it != by_min_print_speed.end(); ++ it)
                     time_adjustable += (*it)->adjustable_time(true);
+                assert(time_adjustable > 0);
                 float rate = (time_adjustable + time_stretch) / time_adjustable;
                 for (auto it = adj; it != by_min_print_speed.end(); ++ it)
                     (*it)->slow_down_proportional(rate, true);
@@ -762,7 +792,7 @@ std::string CoolingBuffer::apply_layer_cooldown(
                 new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_config.gcode_comments, m_fan_speed);
         } else if (line->type & CoolingLine::TYPE_EXTRUDE_END) {
             // Just remove this comment.
-        } else if (line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE | CoolingLine::TYPE_HAS_F)) {
+        } else if (line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_ADJUSTABLE_EMPTY | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE | CoolingLine::TYPE_HAS_F)) {
             // Find the start of a comment, or roll to the end of line.
             const char *end = line_start;
             for (; end < line_end && *end != ';'; ++ end);
@@ -777,7 +807,7 @@ std::string CoolingBuffer::apply_layer_cooldown(
             new_feedrate = line->slowdown ? int(floor(60. * line->feedrate + 0.5)) : atoi(fpos);
             if (new_feedrate == current_feedrate) {
                 // No need to change the F value.
-                if ((line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE)) || line->length == 0.)
+                if ((line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_ADJUSTABLE_EMPTY | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE)) || line->length == 0.)
                     // Feedrate does not change and this line does not move the print head. Skip the complete G-code line including the G-code comment.
                     end = line_end;
                 else
@@ -822,7 +852,7 @@ std::string CoolingBuffer::apply_layer_cooldown(
             }
             // Process the rest of the line.
             if (end < line_end) {
-                if (line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE)) {
+                if (line->type & (CoolingLine::TYPE_ADJUSTABLE | CoolingLine::TYPE_ADJUSTABLE_EMPTY | CoolingLine::TYPE_EXTERNAL_PERIMETER | CoolingLine::TYPE_WIPE)) {
                     // Process comments, remove ";_EXTRUDE_SET_SPEED", ";_EXTERNAL_PERIMETER", ";_WIPE"
                     std::string comment(end, line_end);
                     boost::replace_all(comment, ";_EXTRUDE_SET_SPEED", "");

src/libslic3r/Polyline.cpp

@@ -132,37 +132,38 @@ template void Polyline::simplify_by_visibility<ExPolygonCollection>(const ExPoly
 
 void Polyline::split_at(const Point &point, Polyline* p1, Polyline* p2) const
 {
-    if (this->points.empty()) return;
+    if (this->size() < 2) {
-    
+        *p1 = *this;
-    // find the line to split at
+        p2->clear();
-    size_t line_idx = 0;
+        return;
-    Point p = this->first_point();
-    double min = (p - point).cast<double>().norm();
-    Lines lines = this->lines();
-    for (Lines::const_iterator line = lines.begin(); line != lines.end(); ++line) {
-        Point p_tmp = point.projection_onto(*line);
-        if ((p_tmp - point).cast<double>().norm() < min) {
-	        p = p_tmp;
-	        min = (p - point).cast<double>().norm();
-	        line_idx = line - lines.begin();
-        }
     }
 
-    // create first half
+    if (this->points.front() == point) {
-    p1->points.clear();
+        *p1 = { point };
-    for (Lines::const_iterator line = lines.begin(); line != lines.begin() + line_idx + 1; ++line)
+        *p2 = *this;
-        if (line->a != p) 
-            p1->points.push_back(line->a);
-    // we add point instead of p because they might differ because of numerical issues
-    // and caller might want to rely on point belonging to result polylines
-    p1->points.push_back(point);
-    
-    // create second half
-    p2->points.clear();
-    p2->points.push_back(point);
-    for (Lines::const_iterator line = lines.begin() + line_idx; line != lines.end(); ++line) {
-        p2->points.push_back(line->b);
     }
+
+    auto  min_dist2    = std::numeric_limits<double>::max();
+    auto  min_point_it = this->points.cbegin();
+    Point prev         = this->points.front();
+    for (auto it = this->points.cbegin() + 1; it != this->points.cend(); ++ it) {
+        Point proj = point.projection_onto(Line(prev, *it));
+        auto  d2 = (proj - point).cast<double>().squaredNorm();
+        if (d2 < min_dist2) {
+	        min_dist2    = d2;
+	        min_point_it = it;
+        }
+        prev = *it;
+    }
+
+    p1->points.assign(this->points.cbegin(), min_point_it);
+    if (p1->points.back() != point)
+        p1->points.emplace_back(point);
+    
+    p2->points = { point };
+    if (*min_point_it == point)
+        ++ min_point_it;
+    p2->points.insert(p2->points.end(), min_point_it, this->points.cend());
 }
 
 bool Polyline::is_straight() const