diff --git a/crates/engine/src/tests.rs b/crates/engine/src/tests.rs index c39a5148..a1b92233 100644 --- a/crates/engine/src/tests.rs +++ b/crates/engine/src/tests.rs @@ -317,6 +317,7 @@ mod mirror_planes; #[cfg(not(target_arch = "wasm32"))] mod native_cad_import; mod path_scope; +mod pleat_join; mod primitive_points; mod rim_cut; mod robustness; diff --git a/crates/engine/src/tests/fixtures/battery-tpu-case-v2.solidcraft b/crates/engine/src/tests/fixtures/battery-tpu-case-v2.solidcraft new file mode 100644 index 00000000..198e620d --- /dev/null +++ b/crates/engine/src/tests/fixtures/battery-tpu-case-v2.solidcraft @@ -0,0 +1,2501 @@ +{ + "format": "solidcraft/21", + "name": "Battery TPU Case v2", + "units": "mm", + "params": [ + { + "name": "batt_w", + "expr": "290 mm", + "unit": "mm", + "comment": "Battery flat top/bottom width", + "model": false + }, + { + "name": "batt_bulge", + "expr": "10 mm", + "unit": "mm", + "comment": "Side bulge past the top/bottom corners", + "model": false + }, + { + "name": "batt_h", + "expr": "92 mm", + "unit": "mm", + "comment": "Battery height", + "model": false + }, + { + "name": "peak_left", + "expr": "27 mm", + "unit": "mm", + "comment": "Height of the left side's widest point", + "model": false + }, + { + "name": "peak_right", + "expr": "batt_h - peak_left", + "unit": "mm", + "comment": "Height of the right side's widest point", + "model": false + }, + { + "name": "batt_len", + "expr": "198 mm", + "unit": "mm", + "comment": "Battery length", + "model": false + }, + { + "name": "tab_w", + "expr": "15 mm", + "unit": "mm", + "comment": "Connector tab width", + "model": false + }, + { + "name": "tab_depth", + "expr": "5.5 mm", + "unit": "mm", + "comment": "Connector tab protrusion", + "model": false + }, + { + "name": "ramp_len", + "expr": "35 mm", + "unit": "mm", + "comment": "Ramp from tab back to the wall", + "model": false + }, + { + "name": "ramp_blend_wall", + "expr": "80 mm", + "unit": "mm", + "comment": "Blend radius ramp to wall", + "model": false + }, + { + "name": "ramp_blend_tab", + "expr": "40 mm", + "unit": "mm", + "comment": "Blend radius tab to ramp", + "model": false + }, + { + "name": "wall", + "expr": "2.5 mm", + "unit": "mm", + "comment": "TPU wall thickness", + "model": false + }, + { + "name": "r_big", + "expr": "5 mm", + "unit": "mm", + "comment": "Fillet on the 4 long edges", + "model": false + }, + { + "name": "r_small", + "expr": "1 mm", + "unit": "mm", + "comment": "Fillet on all other edges", + "model": false + }, + { + "name": "clear", + "expr": "1 mm", + "unit": "mm", + "comment": "Tool overshoot", + "model": false + }, + { + "name": "pleat_top", + "expr": "batt_h - 2 * r_small", + "unit": "mm", + "comment": "Height where the pleat fades out", + "model": false + }, + { + "name": "d1", + "expr": "batt_w", + "unit": "mm", + "model": true + }, + { + "name": "d2", + "expr": "batt_w", + "unit": "mm", + "model": true + }, + { + "name": "d3", + "expr": "batt_h", + "unit": "mm", + "model": 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b/crates/engine/src/tests/pleat_join.rs new file mode 100644 index 00000000..9ddaeaa5 --- /dev/null +++ b/crates/engine/src/tests/pleat_join.rs @@ -0,0 +1,47 @@ +//! #1490: the owner's shelled battery case (`battery-tpu-case-v2.solidcraft`, format 21, saved +//! at `wall = 2.5 mm`) with a pleat loft joined into a window in one end wall. The loft stands on +//! the case's open rim and its end strips lie in the wall's inner face. At walls of 2.4–2.6 mm +//! the join failed with "no result": every exact route was refused, and the last resort's +//! nudge failed both ways about its one screw axis. The other screws are now tried too. + +use std::path::Path; + +use serde_json::json; + +use super::run; +use crate::Session; + +fn open() -> Session { + let path = Path::new(env!("CARGO_MANIFEST_DIR")).join("src/tests/fixtures/battery-tpu-case-v2.solidcraft"); + let mut s = Session::default(); + run(&mut s, "doc.open", json!({"path": path.to_string_lossy()})); + s +} + +fn errors(s: &Session) -> Vec<(String, String)> { + s.model.results.iter().filter_map(|r| Some((r.name.clone(), r.error.clone()?))).collect() +} + +fn case_volume(s: &mut Session) -> f64 { + let m = run(s, "inspect.measure", json!({"bodies": ["Case"]})); + m["total"]["volume_mm3"].as_f64().unwrap() +} + +/// The design rebuilds as saved, and at 2.4 and 2.6 mm, with both pleats and every round; the +/// case grows with the wall between them. +#[test] +fn the_pleats_join_at_every_wall_from_2_4_to_2_6_mm() { + let mut s = open(); + assert_eq!(errors(&s), Vec::new(), "as saved, at 2.5 mm"); + let at = case_volume(&mut s); + let mut volumes = Vec::new(); + for wall in ["2.4 mm", "2.6 mm"] { + run(&mut s, "parameters.change", json!({"name": "wall", "expression": wall})); + assert_eq!(errors(&s), Vec::new(), "at {wall}"); + volumes.push(case_volume(&mut s)); + } + // About 14.8 cm³ of wall per tenth of a millimetre here. + let (thin, thick) = (volumes[0], volumes[1]); + assert!(thin < at && at < thick, "{thin} < {at} < {thick}"); + assert!(((at - thin) - (thick - at)).abs() < 0.01 * (thick - thin), "{thin} {at} {thick}"); +} diff --git a/crates/kernel/src/ops.rs b/crates/kernel/src/ops.rs index 102b6e98..0afa9ee2 100644 --- a/crates/kernel/src/ops.rs +++ b/crates/kernel/src/ops.rs @@ -903,14 +903,15 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result> { if !APART.with(|c| c.get()) { APART.with(|c| c.set(true)); let c = b.solid.vertex_iter().fold(Vec3::ZERO, |acc, v| acc + from_p3(v.point())) * (1.0 / b.solid.vertex_iter().count().max(1) as f64); - let translation = Vec3::new(0.61, -0.37, 0.71) * (size * 2e-6); - let nudge = |sign: f64| { + let translation = |screw: usize| SCREWS.get(screw).map_or(Vec3::ZERO, |s| Vec3::new(s.0[0], s.0[1], s.0[2]) * (size * 2e-6)); + let nudge = |screw: usize, sign: f64| { + let axis = SCREWS.get(screw).map_or(Vec3::Z, |s| Vec3::new(s.1[0], s.1[1], s.1[2])); capture_boolean_diagnostics(|| { - transform(b, translation * sign, c, Vec3::new(0.27, 0.83, -0.49), 2e-6 * sign) - .and_then(|nb| Ok(boolean(a, &nb, op)?.map(|r| nudged(r, &nb, &counts)))) + transform(b, translation(screw) * sign, c, axis, 2e-6 * sign).and_then(|nb| Ok(boolean(a, &nb, op)?.map(|r| nudged(r, &nb, &counts)))) }) }; - let (mut r, mut diagnostics) = nudge(1.0); + let mut used = 0; + let (mut r, mut diagnostics) = nudge(used, 1.0); // A nudge that pushes a face into a curved face it only touched (a cut whose end lies // tangent to a round side) leaves a sliver of that face behind, a fraction of a // millimetre wide, which later features (a shell, a fillet) can't work with. The @@ -923,7 +924,7 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result> { }; let made = slivers.is_none_or(|n| n > 0 && n > sliver_faces(a, size).saturating_add(sliver_faces(b, size))); if !matches!(r, Ok(None)) && made { - let (r2, diagnostics2) = nudge(-1.0); + let (r2, diagnostics2) = nudge(used, -1.0); if let Ok(Some(body)) = &r2 && slivers.is_none_or(|n| sliver_faces(body, size) < n) && check(body).0 @@ -931,6 +932,26 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result> { (r, diagnostics) = (r2, diagnostics2); } } + // Neither way worked: the screw can turn the tool along a seam it lies in (a loft + // standing in the rim of a shelled case with its ends in the wall's inner face, #1490). + // The other screws are tried in turn, and the first result that checks is taken. + let works = |r: &Result>| match r { + Ok(None) => true, + Ok(Some(body)) => check(body).0, + Err(_) => false, + }; + if !works(&r) { + 'screws: for screw in 1..SCREWS.len() { + for sign in [1.0, -1.0] { + let (r2, diagnostics2) = nudge(screw, sign); + if matches!(&r2, Ok(Some(body)) if check(body).0) { + (r, diagnostics, used) = (r2, diagnostics2, screw); + break 'screws; + } + } + } + } + let translation = translation(used); APART.with(|c| c.set(false)); match r { Ok(Some(body)) => { @@ -972,6 +993,12 @@ fn boolean_whole(a: &Body, b: &Body, op: BoolOp) -> Result> { } } +/// The screw motions a tool is nudged by as a last resort: (direction of the move, axis of the +/// turn), each tried both ways. The first is the one every nudge used before #1490; the others +/// are asked only when it fails both ways. +const SCREWS: [([f64; 3], [f64; 3]); 3] = + [([0.61, -0.37, 0.71], [0.27, 0.83, -0.49]), ([-0.42, 0.68, 0.6], [0.77, -0.18, 0.61]), ([0.31, 0.52, -0.79], [-0.58, 0.41, 0.70])]; + /// Faces of `b` narrower than 1/200 of `size` (twice their area over their boundary's /// length): the slivers a nudged tool leaves where it was pushed into a face it touched. fn sliver_faces(b: &Body, size: f64) -> usize { diff --git a/tests/robustness/goldens.json b/tests/robustness/goldens.json index 0728e06e..cc943915 100644 --- a/tests/robustness/goldens.json +++ b/tests/robustness/goldens.json @@ -64,7 +64,7 @@ "60": {"area":3443.328607,"bodies":1,"edges":39,"error":null,"faces":15,"outcome":"ok","rejected":0,"shells":1,"steps":["revolved section","cut sphere"],"unsupported":0,"volume":11779.204543}, "61": {"area":5020.413153,"bodies":1,"edges":36,"error":"boolean Cut: the operation failed: no result","faces":15,"outcome":"failed","rejected":0,"shells":1,"steps":["extruded profile","cut cylinder","shell","rectangular pattern"],"unsupported":0,"volume":4906.628538}, "62": {"area":8771.003732,"bodies":1,"edges":60,"error":null,"faces":23,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","cut cylinder","circular pattern","cut box","cut box","join cylinder"],"unsupported":2,"volume":40107.001728}, - "63": {"area":3060.37707,"bodies":1,"edges":57,"error":"boolean Union: implausible result volume ","faces":21,"outcome":"failed","rejected":1,"shells":1,"steps":["revolved section","join box","cut cylinder","hole","cut cylinder","join box"],"unsupported":0,"volume":6534.395036}, + "63": {"area":3198.797259,"bodies":1,"edges":84,"error":null,"faces":30,"outcome":"ok","rejected":1,"shells":1,"steps":["revolved section","join box","cut cylinder","hole","cut cylinder","join box","fillet"],"unsupported":0,"volume":7075.892751}, "64": {"area":4088.335645,"bodies":1,"edges":36,"error":null,"faces":14,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","fillet","join cylinder"],"unsupported":0,"volume":8495.220295}, "65": {"area":8442.175249,"bodies":1,"edges":33,"error":null,"faces":13,"outcome":"ok","rejected":0,"shells":1,"steps":["box","cut cylinder","fillet","rectangular pattern","circular pattern","circular pattern","fillet","cut box"],"unsupported":0,"volume":45117.305023}, "66": {"area":9222.76638,"bodies":1,"edges":99,"error":null,"faces":37,"outcome":"ok","rejected":0,"shells":1,"steps":["extruded profile","join box","join box","join box","cut sphere","cut box"],"unsupported":1,"volume":35217.203139}, @@ -122,6 +122,7 @@ {"reason":"#391 after merging main with #1213: seed 41 now reaches its second fillet (built since #1213), and the end-snap fix again drops a sliver edge the cuts left (94 to 93 edges); its steps, outcome, faces and shells are unchanged, volume moves by 0.005 mm³ (5185.215737 to 5185.221068) and area by 0.0014 mm²","seeds":[41]}, {"reason":"the chamfer bug is on main too, see #1390","seeds":[57]}, {"reason":"#1390: a chamfer of a convex edge that would grow the part is refused (TooLarge). Seed 57's 0.5 mm chamfer on the sphere cut's rim, which grew the part since #391 reordered its steps, is now refused, so the run goes on to its later steps and ends ok (16017.21 mm³, 24 faces)","seeds":[57]}, - {"reason":"seed 15 now cuts around a sealed void","seeds":[15]} + {"reason":"seed 15 now cuts around a sealed void","seeds":[15]}, + {"reason":"#1490: when the last-resort nudge fails both ways, two more screw axes are tried; seed 63's final box join (its face 0.00005 mm off the half-ring's cut face) now builds instead of being refused with an implausible volume, and the design goes on to its fillet","seeds":[63]} ] }