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Fixes problems in autoleveler with scaling between metric and imperia…
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…l units (#2273)

* Replaced the setting for handling units with the global preferred unit setting
* Show the color difference for high and low based on the min/max value of the probed values
* Fixed problems with unit scaling between imperial and metric. Now uses the units from the positions instead of and explicit one.
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@breiler
breiler authored Aug 11, 2023
1 parent 837d81d commit 2543f82
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Showing 14 changed files with 846 additions and 1,162 deletions.
106 changes: 48 additions & 58 deletions ugs-core/src/com/willwinder/universalgcodesender/gcode/processors/MeshLeveler.java
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Original file line number Diff line number Diff line change
Expand Up @@ -28,6 +28,7 @@ This file is part of Universal Gcode Sender (UGS).
import com.willwinder.universalgcodesender.model.Position;
import com.willwinder.universalgcodesender.model.UnitUtils;
import com.willwinder.universalgcodesender.model.UnitUtils.Units;

import java.util.Collections;
import java.util.List;

Expand All @@ -37,36 +38,46 @@ This file is part of Universal Gcode Sender (UGS).
* @author wwinder
*/
public class MeshLeveler implements CommandProcessor {
final private double materialSurfaceHeight;
final private Position[][] surfaceMesh;
final private Position lowerLeft;
final private int xLen, yLen;
final private double resolution;

private Units units;

public final static String ERROR_MESH_SHAPE= "Surface mesh must be a rectangular 2D array.";
public final static String ERROR_MESH_SHAPE = "Surface mesh must be a rectangular 2D array.";
public final static String ERROR_NOT_ENOUGH_SAMPLES = "Need at least 2 samples along each axis.";
public final static String ERROR_X_ALIGNMENT = "Unaligned x coordinate in surface grid.";
public final static String ERROR_Y_ALIGNMENT = "Unaligned y coordinate in surface grid.";
public final static String ERROR_Y_ASCENTION = "Found a y coordinate that isn't ascending.";
public final static String ERROR_X_ASCENTION = "Found a x coordinate that isn't ascending.";

public final static String ERROR_UNEXPECTED_ARC = "The mesh leveler cannot process arcs. Enable the arc expander.";
public final static String ERROR_MISSING_POINT_DATA = "Internal parser error: missing data. ";
final private double materialSurfaceHeightMM;
final private Position[][] surfaceMesh;
final private Position lowerLeft;
final private int xLen, yLen;
final private double resolution;
private Units surfaceMeshUnits;

/**
* @param materialSurfaceHeightMM Z height used in offset.
* @param surfaceMesh 2D array in the format Position[x][y]
* @param surfaceMesh 2D array in the format Position[x][y]
*/
public MeshLeveler(double materialSurfaceHeightMM, Position[][] surfaceMesh, Units units) {
public MeshLeveler(double materialSurfaceHeightMM, Position[][] surfaceMesh) {
if (surfaceMesh == null) {
throw new IllegalArgumentException("Surface mesh is required.");
}

// Validate that points form a rectangular 2D array.
this.materialSurfaceHeightMM = materialSurfaceHeightMM;
this.yLen = surfaceMesh[0].length;
this.xLen = surfaceMesh.length;

validateMesh(surfaceMesh);
this.surfaceMesh = surfaceMesh;
this.surfaceMeshUnits = surfaceMesh[0][0].getUnits();
this.resolution = Math.max(
surfaceMesh[1][0].x - surfaceMesh[0][0].x,
surfaceMesh[0][1].y - surfaceMesh[0][0].y);

this.lowerLeft = surfaceMesh[0][0];
}

private void validateMesh(Position[][] surfaceMesh) {
// Validate that points form a rectangular 2D array.
for (Position[] arr : surfaceMesh) {
if (arr.length != yLen) {
throw new IllegalArgumentException(ERROR_MESH_SHAPE);
Expand All @@ -84,11 +95,11 @@ public MeshLeveler(double materialSurfaceHeightMM, Position[][] surfaceMesh, Uni
double yCoord = surfaceMesh[xIdx][0].y;
for (int yIdx = 0; yIdx < yLen; yIdx++) {
if (surfaceMesh[xIdx][yIdx].x != xCoord) {
String err = "@ " + xIdx + ", " + yIdx + ": ("+xCoord+" != "+surfaceMesh[xIdx][yIdx].x+")";
String err = "@ " + xIdx + ", " + yIdx + ": (" + xCoord + " != " + surfaceMesh[xIdx][yIdx].x + ")";
throw new IllegalArgumentException(ERROR_X_ALIGNMENT + err);
}
if (yCoord > surfaceMesh[xIdx][yIdx].y) {
String err = "@ " + xIdx + ", " + yIdx + ": ("+yCoord+" !<= "+surfaceMesh[xIdx][yIdx].y+")";
String err = "@ " + xIdx + ", " + yIdx + ": (" + yCoord + " !<= " + surfaceMesh[xIdx][yIdx].y + ")";
throw new IllegalArgumentException(ERROR_Y_ASCENTION + err);
}
yCoord = surfaceMesh[xIdx][yIdx].y;
Expand All @@ -101,32 +112,23 @@ public MeshLeveler(double materialSurfaceHeightMM, Position[][] surfaceMesh, Uni
double yCoord = surfaceMesh[0][yIdx].y;
for (int xIdx = 0; xIdx < xLen; xIdx++) {
if (surfaceMesh[xIdx][yIdx].y != yCoord) {
String err = "@ " + xIdx + ", " + yIdx + ": ("+yCoord+" != "+surfaceMesh[xIdx][yIdx].y+")";
String err = "@ " + xIdx + ", " + yIdx + ": (" + yCoord + " != " + surfaceMesh[xIdx][yIdx].y + ")";
throw new IllegalArgumentException(ERROR_Y_ALIGNMENT + err);
}
if (xCoord > surfaceMesh[xIdx][yIdx].x) {
String err = "@ " + xIdx + ", " + yIdx + ": ("+xCoord+" !<= "+surfaceMesh[xIdx][yIdx].x+")";
String err = "@ " + xIdx + ", " + yIdx + ": (" + xCoord + " !<= " + surfaceMesh[xIdx][yIdx].x + ")";
throw new IllegalArgumentException(ERROR_X_ASCENTION + err);
}
xCoord = surfaceMesh[xIdx][yIdx].x;
}
}

this.units = units;
this.materialSurfaceHeight = materialSurfaceHeightMM;
this.surfaceMesh = surfaceMesh;
this.resolution = Math.max(
surfaceMesh[1][0].x-surfaceMesh[0][0].x,
surfaceMesh[0][1].y-surfaceMesh[0][0].y);

this.lowerLeft = surfaceMesh[0][0];
}

private boolean ensureJustLines(List<GcodeMeta> commands) throws GcodeParserException {
if (commands == null) return false;
boolean hasLine = false;
for (GcodeMeta command : commands) {
switch(command.code) {
switch (command.code) {
case G0:
case G1:
hasLine = true;
Expand Down Expand Up @@ -163,26 +165,28 @@ public List<String> processCommand(final String commandString, GcodeState state)

// Get offset relative to the expected surface height.
// Visualizer normalizes everything to MM but probe mesh might be INCH
double probeScaleFactor = UnitUtils.scaleUnits(UnitUtils.Units.MM, this.units);
double zScaleFactor = UnitUtils.scaleUnits(UnitUtils.Units.MM, state.isMetric ? Units.MM : Units.INCH);

double zPointOffset;
if (state.inAbsoluteMode) {
zPointOffset = surfaceHeightAt(end.x, end.y, zScaleFactor) - (this.materialSurfaceHeight / probeScaleFactor);
Position position = end.getPositionIn(surfaceMeshUnits);
double materialSurfaceHeight = this.materialSurfaceHeightMM * UnitUtils.scaleUnits(Units.MM, surfaceMeshUnits);
zPointOffset = (surfaceHeightAt(position.x, position.y) - materialSurfaceHeight) * UnitUtils.scaleUnits(surfaceMeshUnits, end.getUnits());
} else {
// TODO: If the first move in the gcode file is relative it won't properly take the materialSurfaceHeight
// into account. To fix the CommandProcessor needs to inject an adjustment before that first relative move
// happens. Until that happens the user must make sure the materialSurfaceHeight is zero.

// In relative mode we only need to adjust by the z delta between the starting and ending point
zPointOffset = surfaceHeightAt(end.x, end.y, zScaleFactor) - surfaceHeightAt(start.x, start.y, zScaleFactor);
Position startPositionInMeshUnits = start.getPositionIn(surfaceMeshUnits);
double startHeight = surfaceHeightAt(startPositionInMeshUnits.x, startPositionInMeshUnits.y);
Position endPositionInMeshUnits = end.getPositionIn(surfaceMeshUnits);
double endHeight = surfaceHeightAt(endPositionInMeshUnits.x, endPositionInMeshUnits.y);
zPointOffset = (endHeight - startHeight) * UnitUtils.scaleUnits(surfaceMeshUnits, end.getUnits());
}
zPointOffset *= zScaleFactor;

// Update z coordinate.
double newZ = end.getZ() + zPointOffset;

PartialPosition.Builder overrideZ = PartialPosition.builder(units);
PartialPosition.Builder overrideZ = PartialPosition.builder(end.getUnits());
if (command.state.inAbsoluteMode) {
overrideZ.setZ(newZ);
} else {
Expand All @@ -195,13 +199,7 @@ public List<String> processCommand(final String commandString, GcodeState state)
return adjustedCommands.build();
}

protected Position[][] findBoundingArea(double x, double y) throws GcodeParserException {
/*
if (x < this.lowerLeft.x || x > this.upperRight.x || y < this.lowerLeft.y || y > this.upperRight.y) {
throw new GcodeParserException("Coordinate out of bounds.");
}
*/

protected Position[][] findBoundingArea(double x, double y) {
double xOffset = x - this.lowerLeft.x;
double yOffset = y - this.lowerLeft.y;

Expand All @@ -214,43 +212,35 @@ protected Position[][] findBoundingArea(double x, double y) throws GcodeParserEx
xIdx = Math.max(xIdx, 0);
yIdx = Math.max(yIdx, 0);

return new Position[][] {
{this.surfaceMesh[xIdx ][yIdx], this.surfaceMesh[xIdx ][yIdx+1]},
{this.surfaceMesh[xIdx+1][yIdx], this.surfaceMesh[xIdx+1][yIdx+1]}
return new Position[][]{
{this.surfaceMesh[xIdx][yIdx], this.surfaceMesh[xIdx][yIdx + 1]},
{this.surfaceMesh[xIdx + 1][yIdx], this.surfaceMesh[xIdx + 1][yIdx + 1]}
};
}

/**
* Get the surface height from the mesh and returns it in the surface mesh units.
* <p>
* Bilinear interpolation:
* http://supercomputingblog.com/graphics/coding-bilinear-interpolation/
*/
protected double surfaceHeightAt(double unscaledX, double unscaledY, double zScaleFactor) throws GcodeParserException {
double x = unscaledX / zScaleFactor;
double y = unscaledY / zScaleFactor;
protected double surfaceHeightAt(double x, double y) {
Position[][] q = findBoundingArea(x, y);

Position Q11 = q[0][0];
Position Q21 = q[1][0];
Position Q12 = q[0][1];
Position Q22 = q[1][1];

/*
// This check doesn't work properly because I chose to clamp bounds
if (Q11.x > x || Q12.x > x || Q21.x < x || Q22.x < x ||
Q12.y < y || Q22.y < y || Q11.y > y || Q21.y > y) {
throw new GcodeParserException("Problem detected getting surface height. Please submit file to github for analysis.");
}
*/

double x1 = Q11.x;
double x2 = Q21.x;
double y1 = Q11.y;
double y2 = Q12.y;

double R1 = ((x2 - x)/(x2 - x1)) * Q11.z + ((x - x1)/(x2 - x1)) * Q21.z;
double R2 = ((x2 - x)/(x2 - x1)) * Q12.z + ((x - x1)/(x2 - x1)) * Q22.z;
double R1 = ((x2 - x) / (x2 - x1)) * Q11.z + ((x - x1) / (x2 - x1)) * Q21.z;
double R2 = ((x2 - x) / (x2 - x1)) * Q12.z + ((x - x1) / (x2 - x1)) * Q22.z;

return ((y2 - y)/(y2 - y1)) * R1 + ((y - y1)/(y2 - y1)) * R2;
return ((y2 - y) / (y2 - y1)) * R1 + ((y - y1) / (y2 - y1)) * R2;
}

@Override
Expand Down
2 changes: 1 addition & 1 deletion ugs-core/src/com/willwinder/universalgcodesender/gcode/processors/TranslateProcessor.java
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Original file line number Diff line number Diff line change
Expand Up @@ -101,7 +101,7 @@ private List<String> translateCoordinates(String command, GcodeState state) thro

Position end = gcodeMeta.point.point()
.getPositionIn(currentUnits);
end.add(offset.getPositionIn(currentUnits));
end = end.add(offset.getPositionIn(currentUnits));

String adjustedCommand = GcodePreprocessorUtils.generateLineFromPoints(
gcodeMeta.code, start, end, gcodeMeta.state.inAbsoluteMode, null);
Expand Down
5 changes: 5 additions & 0 deletions ugs-core/src/com/willwinder/universalgcodesender/model/Position.java
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Original file line number Diff line number Diff line change
Expand Up @@ -188,4 +188,9 @@ public Position rotate(Position center, double radians) {
z,
units);
}

public Position add(Position position) {
Position p = position.getPositionIn(units);
return new Position(x + p.x, y + p.y, z + p.z, a + p.a, b + p.b, c + p.c, units);
}
}
12 changes: 12 additions & 0 deletions ugs-core/src/com/willwinder/universalgcodesender/utils/Settings.java
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Original file line number Diff line number Diff line change
Expand Up @@ -557,8 +557,20 @@ public static class AutoLevelSettings {
// Setting window
public double autoLevelProbeZeroHeight = 0;
public Position autoLevelProbeOffset = new Position(0, 0, 0, Units.MM);

/**
* How long the arcs segments should be expanded in millimeters
*/
public double autoLevelArcSliceLength = 0.01;

/**
* The fast probe scan rate in mm/min
*/
public double probeScanFeedRate = 1000;

/**
* Probe speed in mm/min
*/
public double probeSpeed = 10;

// Main window
Expand Down
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