jyvikoandClaude Opus 5.5
9a508571fd
2 commits, squashed; the originals stay reachable from tag archive/merge-main-develop. -b1326e48djyviko: brep: an edge on a line, circle or ellipse carries the NURBS form SMLib holds it as -6adba90e2jyviko: solidcraft-smlib: circle edges on their NURBS form, SMLib's trims kept on them (fork deec9cb) Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_01DtL5M41G8Nua7HvuFPZkmJ
516 lines
22 KiB
Rust
516 lines
22 KiB
Rust
//! Continuity diagnostics across the seams between a body's faces: do the two faces that meet
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//! at an edge share a curve (G0), a tangent plane (G1) and a curvature (G2)?
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//!
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//! The stations are taken on the edge itself — the curve both faces are supposed to share — so
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//! the numbers describe the B-rep and not a tessellation: each station is projected onto each
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//! face's own surface, and the two projections are compared. The gap is the distance between
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//! them (G0); the normal angle is the angle between the faces' outward normals there (G1); the
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//! curvature jump is the difference of their normal curvatures in the normal section square to
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//! the edge, from the second fundamental form of each surface (G2). A rolling-ball fillet is
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//! tangent to the faces it joins but is not curvature continuous: where it meets a plane its
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//! seam reads 0° and 1 / radius, which no chord tolerance would reveal.
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//!
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//! [`crate::smooth_edges`] decides whether a join needs a *display* line; this module measures
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//! the join, and backs the engine's `inspect.continuity`.
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use serde::Serialize;
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use solidcraft_geom::Vec3;
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use solidcraft_geom::brep::{self as b, eval::CurveEval, eval::SurfaceEval};
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use crate::body::Body;
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use crate::{KernelError, Result};
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/// Bodies with more edges than this are refused rather than sampled for minutes.
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const MAX_EDGES: usize = 4096;
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/// Most faces a body may have and still be analysed.
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const MAX_FACES: usize = 50_000;
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/// Stations one call may take over all its edges; edges past the budget are left out and
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/// counted in [`ContinuityReport::skipped`].
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const MAX_STATIONS: usize = 200_000;
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/// Most edges one pick list may name (the full list always fits the station budget).
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const MAX_PICKS: usize = 512;
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/// Samples used to find the edge nearest a picked point (as in `surfaces::edge_near`).
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const PICK_SAMPLES: usize = 32;
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/// Least and most stations along one edge (`inspect.continuity`'s `samples`): three are the two
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/// ends and the middle.
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pub const MIN_SAMPLES: usize = 3;
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pub const MAX_SAMPLES: usize = 257;
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/// How an edge is picked: a point on (or near) it, or its index in the display mesh's edge
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/// order ([`Body::edges`]), which is what a viewport pick carries.
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#[derive(Clone, Copy, Debug, PartialEq)]
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pub enum EdgePick {
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Point(Vec3),
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Index(usize),
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}
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/// What counts as continuous across a seam.
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#[derive(Clone, Copy, Debug, PartialEq)]
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pub struct ContinuityTolerances {
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/// Largest position gap that still counts as coincident (G0), mm.
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pub gap_mm: f64,
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/// Largest angle between the faces' normals that still counts as tangent (G1), degrees.
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pub angle_deg: f64,
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/// Largest curvature jump that still counts as curvature continuous (G2), 1/mm.
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pub curvature_per_mm: f64,
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}
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/// The worst value of one metric along an edge, with where it was found.
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#[derive(Clone, Copy, Debug, Serialize)]
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pub struct SeamWorst {
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pub value: f64,
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/// The station that gave the worst value, in the body's coordinates.
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pub at: Vec3,
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/// How far along the edge it is: 0 at the edge's start, 1 at its end.
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pub edge_fraction: f64,
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}
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/// Which test a seam fails, from the best continuity to the worst: [`SeamVerdict::Smooth`] is
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/// within every tolerance (G2 or better), then a tangent seam whose curvature jumps (G1), then
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/// a visible crease (G0 only), and finally faces that do not meet at all.
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#[derive(Clone, Copy, Debug, PartialEq, Eq, PartialOrd, Ord, Serialize)]
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#[serde(rename_all = "snake_case")]
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pub enum SeamVerdict {
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Smooth,
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CurvatureJump,
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Sharp,
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Gap,
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}
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/// One edge's diagnostics: the worst of each metric along it, and where.
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#[derive(Clone, Debug, Serialize)]
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pub struct SeamReport {
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/// Index in the display mesh's edge order ([`Body::edges`]).
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pub edge: usize,
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/// Length of the edge, mm.
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pub length: f64,
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/// Stations the values were taken at.
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pub samples: usize,
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pub gap_mm: SeamWorst,
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pub normal_angle_deg: SeamWorst,
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pub curvature_jump_per_mm: SeamWorst,
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/// What the tolerances make of the seam.
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pub verdict: SeamVerdict,
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/// The stations in order: what a viewport shades.
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pub points: Vec<Vec3>,
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}
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/// The seam diagnostics of one body.
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#[derive(Clone, Debug, Serialize)]
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pub struct ContinuityReport {
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pub seams: Vec<SeamReport>,
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/// Edges left out: not a seam between two faces (an open boundary, or a periodic face's own
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/// seam, which is one face meeting itself), or past the station budget.
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pub skipped: usize,
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/// Edges that could not be sampled at all: no station of theirs projected onto both faces.
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pub unmeasured: usize,
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}
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/// The edge indices `picks` mean, in display-mesh order and without repeats. A point pick takes
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/// the edge nearest it (within the distance the kernel re-finds an edge from); an index pick
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/// must be an existing index. An empty list means every two-sided seam of the body, and a pick
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/// of an edge that is not a seam between two faces is refused, not guessed at.
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pub fn pick_edges(body: &Body, picks: &[EdgePick]) -> Result<Vec<usize>> {
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body.require_brep("continuity")?;
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if picks.len() > MAX_PICKS {
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return Err(KernelError::Invalid(format!("pick at most {MAX_PICKS} edges")));
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}
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crate::guard("continuity picks", || {
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let Topology { record, adjacent, .. } = topology(body)?;
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if picks.is_empty() {
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return Ok((0..record.edges.len()).filter(|i| two_sided(&adjacent, *i)).collect());
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}
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let reach = body.size() * 0.05 + 1e-6;
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let mut out: Vec<usize> = Vec::new();
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for pick in picks {
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let index = match *pick {
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EdgePick::Index(index) => index,
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EdgePick::Point(p) => nearest_edge(&record.edges, p, reach)?,
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};
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if !two_sided(&adjacent, index) {
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return Err(KernelError::Invalid(format!("edge {index} of this body is not a seam between two faces")));
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}
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if !out.contains(&index) {
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out.push(index);
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}
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}
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out.sort_unstable();
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Ok(out)
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})
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}
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/// Sample the two-sided seams `edges` of `body` (indices in display-mesh order; empty: every
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/// one of them) at `samples` stations along each edge's own parameter, the ends included, with
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/// the tolerances the seams are judged against.
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pub fn seam_diagnostics(body: &Body, edges: &[usize], samples: usize, tolerances: ContinuityTolerances) -> Result<ContinuityReport> {
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body.require_brep("continuity")?;
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if !(MIN_SAMPLES..=MAX_SAMPLES).contains(&samples) {
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return Err(KernelError::Invalid(format!("`samples` must be {MIN_SAMPLES}…{MAX_SAMPLES}")));
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}
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for (name, value) in [("gap", tolerances.gap_mm), ("angle", tolerances.angle_deg), ("curvature", tolerances.curvature_per_mm)] {
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// A range test also throws out NaN (both comparisons are false).
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if !(0.0..1e9).contains(&value) {
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return Err(KernelError::Invalid(format!("the {name} tolerance must be a finite number, 0 or more")));
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}
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}
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crate::guard("continuity", || measure(body, edges, samples, tolerances))
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}
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/// The body's record with, per edge, the faces it bounds (each once: a periodic face's own seam
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/// bounds one), and per face whether its surface's natural normal points out of the material;
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/// refused past the caps.
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struct Topology {
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record: b::Brep,
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adjacent: Vec<Vec<usize>>,
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outward: Vec<bool>,
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}
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fn topology(body: &Body) -> Result<Topology> {
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let record = crate::native::brep_record(body)?;
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if record.faces.len() > MAX_FACES {
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return Err(KernelError::TooLarge(format!("the body has more than {MAX_FACES} faces")));
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}
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if record.edges.len() > MAX_EDGES {
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return Err(KernelError::TooLarge(format!("the body has more than {MAX_EDGES} edges")));
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}
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let adjacent = record
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.edges
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.iter()
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.map(|e| {
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let mut faces: Vec<usize> = e.uses.iter().map(|u| u.face as usize).collect();
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faces.sort_unstable();
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faces.dedup();
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faces
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})
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.collect();
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// A face's side in the first shell that uses it (canonical order walks faces that way).
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let mut outward: Vec<Option<bool>> = vec![None; record.faces.len()];
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for shell in &record.shells {
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if let b::Shell::Faces { faces, .. } = shell {
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for f in faces {
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if let Some(slot) = outward.get_mut(f.face as usize) {
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slot.get_or_insert(f.forward);
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}
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}
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}
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}
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let outward = outward.into_iter().map(|o| o.unwrap_or(true)).collect();
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Ok(Topology { record, adjacent, outward })
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}
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/// Is the edge at `index` shared by (exactly) two faces of the body?
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fn two_sided(adjacent: &[Vec<usize>], index: usize) -> bool {
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adjacent.get(index).is_some_and(|faces| faces.len() == 2)
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}
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/// The index of the edge whose curve comes nearest `p`, within `reach`.
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fn nearest_edge(edges: &[b::Edge], p: Vec3, reach: f64) -> Result<usize> {
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let mut best: Option<(f64, usize)> = None;
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for (index, edge) in edges.iter().enumerate() {
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let Ok(curve) = CurveEval::new(edge.parameters()) else { continue };
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let [t0, t1] = edge.interval;
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for k in 0..=PICK_SAMPLES {
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let Some(q) = curve.point(t0 + (t1 - t0) * k as f64 / PICK_SAMPLES as f64) else { continue };
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let d = q.dist(p);
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if d.is_finite() && best.is_none_or(|(bd, _)| d < bd) {
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best = Some((d, index));
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}
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}
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}
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match best {
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Some((d, index)) if d <= reach => Ok(index),
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_ => Err(KernelError::Invalid(format!("no edge of the body is within {reach:.3} mm of ({}, {}, {})", p.x, p.y, p.z))),
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}
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}
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fn measure(body: &Body, edges: &[usize], samples: usize, tolerances: ContinuityTolerances) -> Result<ContinuityReport> {
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let Topology { record, adjacent, outward } = topology(body)?;
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let mut selected: Vec<usize> = Vec::new();
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let mut skipped = 0usize;
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if edges.is_empty() {
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for index in 0..record.edges.len() {
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if two_sided(&adjacent, index) {
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selected.push(index);
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} else {
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skipped += 1;
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}
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}
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} else {
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selected.extend(edges.iter().copied());
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selected.sort_unstable();
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selected.dedup();
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for &index in &selected {
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if index >= record.edges.len() {
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return Err(KernelError::Invalid(format!("the body has no edge {index}")));
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}
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if !two_sided(&adjacent, index) {
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return Err(KernelError::Invalid(format!("edge {index} of this body is not a seam between two faces")));
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}
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}
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}
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let face = |i: usize| -> Option<FaceSurface> {
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let f = record.faces.get(i)?;
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FaceSurface::new(f.parameters(), outward.get(i).copied().unwrap_or(true))
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};
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let mut seams = Vec::new();
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let mut unmeasured = 0usize;
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let mut budget = MAX_STATIONS;
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for index in selected {
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let Some([first, second]) = adjacent.get(index).and_then(|f| <[usize; 2]>::try_from(f.as_slice()).ok()) else { continue };
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let Some(edge) = record.edges.get(index) else { continue };
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// Every edge costs `samples` stations; a run out of budget stops cleanly.
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if budget < samples {
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skipped += 1;
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continue;
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}
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budget -= samples;
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let report = match (face(first), face(second), CurveEval::new(edge.parameters())) {
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(Some(a), Some(b), Ok(curve)) => seam(index, &curve, edge.interval, a, b, samples, tolerances),
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_ => None,
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};
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match report {
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Some(report) => seams.push(report),
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None => unmeasured += 1,
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}
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}
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Ok(ContinuityReport { seams, skipped, unmeasured })
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}
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/// One edge's worst gap, normal angle and curvature jump.
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fn seam(
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index: usize,
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curve: &CurveEval,
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[t0, t1]: [f64; 2],
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mut on_a: FaceSurface,
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mut on_b: FaceSurface,
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samples: usize,
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tolerances: ContinuityTolerances,
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) -> Option<SeamReport> {
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// The station fractions: 0 at the edge's start, 1 at its end.
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let steps = samples.checked_sub(1)?;
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let fraction = |k: usize| k as f64 / steps as f64;
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let mut gap = None;
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let mut angle = None;
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let mut jump = None;
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let mut points = Vec::with_capacity(samples);
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for k in 0..samples {
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let f = fraction(k);
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let Some((at, tangent)) = curve.derivs(t0 + (t1 - t0) * f) else { continue };
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if !at.is_finite() {
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continue;
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}
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// Both projections and both curvatures, or the station says nothing.
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let (Some((qa, na, uv_a)), Some((qb, nb, uv_b))) = (on_a.project(at), on_b.project(at)) else { continue };
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let Some(tangent) = tangent.normalized() else { continue };
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// The normal sections square to the seam: one direction per face, in its tangent plane.
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let (Some(ka), Some(kb)) = (on_a.normal_curvature(uv_a, na, across(na, tangent)), on_b.normal_curvature(uv_b, nb, across(nb, tangent)))
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else {
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continue;
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};
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// The faces' outward normals agree on a smooth seam; where they are opposed (a knife
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// edge) the curvatures are compared in one frame, since bending away from one face is
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// bending towards the other.
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let signed = if na.dot(nb) < 0.0 { ka + kb } else { ka - kb };
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points.push(at);
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keep(&mut gap, qa.dist(qb), at, f);
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keep(&mut angle, na.dot(nb).clamp(-1.0, 1.0).acos().to_degrees(), at, f);
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keep(&mut jump, signed.abs(), at, f);
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}
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let (gap, angle, jump) = (gap?, angle?, jump?);
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let verdict = if gap.value > tolerances.gap_mm {
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SeamVerdict::Gap
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} else if angle.value > tolerances.angle_deg {
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SeamVerdict::Sharp
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} else if jump.value > tolerances.curvature_per_mm {
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SeamVerdict::CurvatureJump
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} else {
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SeamVerdict::Smooth
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};
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let length = points.windows(2).map(|w| w.first().zip(w.get(1)).map_or(0.0, |(a, b)| a.dist(*b))).sum();
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Some(SeamReport {
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edge: index,
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length,
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samples: points.len(),
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gap_mm: gap,
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normal_angle_deg: angle,
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curvature_jump_per_mm: jump,
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verdict,
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points,
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})
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}
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/// The direction in which a face's curvature is read at a seam: across the edge, square to it,
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/// inside the face's tangent plane (a zero vector where the edge runs along the normal, which
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/// leaves that station unmeasured).
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fn across(normal: Vec3, tangent: Vec3) -> Vec3 {
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normal.cross(tangent)
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}
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/// Keep the largest value seen, with where it was found.
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fn keep(worst: &mut Option<SeamWorst>, value: f64, at: Vec3, edge_fraction: f64) {
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if value.is_finite() && worst.is_none_or(|w| value > w.value) {
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*worst = Some(SeamWorst { value, at, edge_fraction });
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}
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}
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/// A face's surface, kept over the stations of one edge so each search can start at the last
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/// answer (stations run along the edge, so the parameters move smoothly).
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struct FaceSurface {
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surface: SurfaceEval,
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/// +1 where the natural normal points out of the material, −1 where it points in.
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side: f64,
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hint: Option<[f64; 2]>,
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}
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impl FaceSurface {
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fn new(surface: &b::Surface, outward: bool) -> Option<Self> {
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Some(Self { surface: SurfaceEval::new(surface).ok()?, side: if outward { 1.0 } else { -1.0 }, hint: None })
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}
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/// The nearest point of the surface to `p`, the outward unit normal there and the
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/// parameters. `None` where the search or the normal is unusable.
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fn project(&mut self, p: Vec3) -> Option<(Vec3, Vec3, [f64; 2])> {
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let uv = self.surface.project(p, self.hint, f64::INFINITY).or_else(|| self.surface.project(p, None, f64::INFINITY))?;
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let (q, su, sv) = self.surface.derivs(uv[0], uv[1])?;
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if !q.is_finite() {
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return None;
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}
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let normal = (su.cross(sv) * self.side).normalized()?;
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self.hint = Some(uv);
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Some((q, normal, uv))
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}
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/// The normal curvature of the face at `uv` along `direction` (a unit vector of its tangent
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/// plane), from the second fundamental form. A surface point `r(u, v)` with unit normal `n`
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/// crossed that way has curvature `κ = n · r''` of the curve whose tangent there is
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/// `direction`: a plane reads 0 and a cylinder of radius `R`, across its axis, −1 / R
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/// (bending towards its axis). `None` at a degenerate parameter point (a cone's apex), where
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/// the surface has no curvature.
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fn normal_curvature(&self, uv: [f64; 2], normal: Vec3, direction: Vec3) -> Option<f64> {
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let (_, ru, rv) = self.surface.derivs(uv[0], uv[1])?;
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let (ruu, ruv, rvv) = self.surface.second(uv[0], uv[1])?;
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let (ru_len, rv_len) = (ru.len(), rv.len());
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if !(ru_len > 0.0 && rv_len > 0.0) {
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return None;
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}
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// Solve the direction in the unit basis (r_u / |r_u|, r_v / |r_v|): the curve then runs
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// its parameters at du/ds = α / |r_u| and dv/ds = β / |r_v|, and
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// `r'' = r_uu (du/ds)² + 2 r_uv (du/ds)(dv/ds) + r_vv (dv/ds)²`.
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let cos = (ru.dot(rv) / (ru_len * rv_len)).clamp(-1.0, 1.0);
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let sin2 = 1.0 - cos * cos;
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if !(sin2 > 1e-12) {
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return None;
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}
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let (cu, cv) = (direction.dot(ru) / ru_len, direction.dot(rv) / rv_len);
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||
let (du, dv) = ((cu - cv * cos) / sin2 / ru_len, (cv - cu * cos) / sin2 / rv_len);
|
||
if !(du.is_finite() && dv.is_finite()) {
|
||
return None;
|
||
}
|
||
// `direction` is a unit vector: divide by the speed the parameters imply (they only miss
|
||
// it by rounding), so κ does not depend on how the surface is parameterized.
|
||
let speed = (ru * du + rv * dv).len();
|
||
if !(speed > 1e-6) {
|
||
return None;
|
||
}
|
||
let second = normal.dot(ruu * (du * du) + ruv * (2.0 * du * dv) + rvv * (dv * dv));
|
||
(second / (speed * speed)).is_finite().then_some(second / (speed * speed))
|
||
}
|
||
}
|
||
|
||
#[cfg(test)]
|
||
#[allow(clippy::unwrap_used)]
|
||
mod tests {
|
||
use super::*;
|
||
use solidcraft_geom::Plane;
|
||
|
||
fn tolerances() -> ContinuityTolerances {
|
||
ContinuityTolerances { gap_mm: 1e-3, angle_deg: 1.0, curvature_per_mm: 0.01 }
|
||
}
|
||
|
||
fn box_body() -> Body {
|
||
crate::box_solid(Vec3::new(0.0, 0.0, 0.0), Vec3::new(10.0, 10.0, 10.0)).unwrap()
|
||
}
|
||
|
||
fn report(body: &Body) -> ContinuityReport {
|
||
seam_diagnostics(body, &[], 33, tolerances()).unwrap()
|
||
}
|
||
|
||
#[test]
|
||
fn a_box_edge_is_a_gap_free_right_angle() {
|
||
let body = box_body();
|
||
let r = report(&body);
|
||
assert_eq!(r.seams.len(), 12, "a box has twelve edges");
|
||
assert_eq!(r.skipped, 0);
|
||
for seam in &r.seams {
|
||
assert!(seam.gap_mm.value < 1e-6, "gap {}", seam.gap_mm.value);
|
||
assert!((seam.normal_angle_deg.value - 90.0).abs() < 1e-9, "angle {}", seam.normal_angle_deg.value);
|
||
assert!(seam.curvature_jump_per_mm.value < 1e-9, "jump {}", seam.curvature_jump_per_mm.value);
|
||
assert_eq!(seam.verdict, SeamVerdict::Sharp);
|
||
assert_eq!(seam.samples, 33);
|
||
assert!((seam.length - 10.0).abs() < 1e-9);
|
||
}
|
||
}
|
||
|
||
#[test]
|
||
fn a_fillet_seam_is_tangent_with_the_fillets_curvature_jump() {
|
||
let body = box_body();
|
||
let rounded = crate::fillet(&body, &[Vec3::new(10.0, 10.0, 5.0)], 4.0).unwrap();
|
||
let r = report(&rounded);
|
||
// The rounded edge is replaced by the blend face: two tangent seams along it, the two
|
||
// arcs where the blend meets the ends of the edge, and the box's other eleven edges.
|
||
assert_eq!(r.seams.len(), 15);
|
||
let tangent: Vec<&SeamReport> = r.seams.iter().filter(|s| s.normal_angle_deg.value < 0.01).collect();
|
||
assert_eq!(tangent.len(), 2, "the fillet meets its two neighbours tangentially");
|
||
for seam in &tangent {
|
||
assert!(seam.gap_mm.value < 1e-6);
|
||
assert!(seam.curvature_jump_per_mm.value.is_finite());
|
||
assert!((seam.curvature_jump_per_mm.value - 0.25).abs() < 1e-6, "1 / radius, got {}", seam.curvature_jump_per_mm.value);
|
||
assert_eq!(seam.verdict, SeamVerdict::CurvatureJump);
|
||
}
|
||
assert_eq!(r.seams.iter().filter(|s| s.verdict == SeamVerdict::Sharp).count(), 13);
|
||
}
|
||
|
||
#[test]
|
||
fn a_line_tangent_into_an_arc_reports_one_over_its_radius() {
|
||
use solidcraft_geom::{Loop2, Region2, Seg2, Vec2};
|
||
let v = |x: f64, y: f64| Vec2::new(x, y);
|
||
let outer = Loop2 {
|
||
segs: vec![
|
||
Seg2::Arc { center: v(10.0, 0.0), radius: 5.0, start: -std::f64::consts::FRAC_PI_2, sweep: std::f64::consts::PI },
|
||
Seg2::Line { a: v(10.0, 5.0), b: v(-10.0, 5.0) },
|
||
Seg2::Arc { center: v(-10.0, 0.0), radius: 5.0, start: std::f64::consts::FRAC_PI_2, sweep: std::f64::consts::PI },
|
||
Seg2::Line { a: v(-10.0, -5.0), b: v(10.0, -5.0) },
|
||
],
|
||
};
|
||
let body = crate::extrude(&Plane::XY, &[Region2 { outer, holes: vec![] }], 0.0, 3.0).unwrap().remove(0);
|
||
let r = report(&body);
|
||
let joins: Vec<&SeamReport> = r.seams.iter().filter(|s| s.normal_angle_deg.value < 0.01).collect();
|
||
assert_eq!(joins.len(), 4, "a slot has four line-to-arc joins");
|
||
for seam in joins {
|
||
assert!(
|
||
seam.curvature_jump_per_mm.value > 0.19 && seam.curvature_jump_per_mm.value < 0.21,
|
||
"1 / 5, got {}",
|
||
seam.curvature_jump_per_mm.value
|
||
);
|
||
}
|
||
}
|
||
|
||
#[test]
|
||
fn picks_refuse_what_is_not_there() {
|
||
let body = box_body();
|
||
let all = pick_edges(&body, &[]).unwrap();
|
||
assert_eq!(all.len(), 12);
|
||
// The edge up the corner at (0, 0), beside a point in the middle of a face.
|
||
let picked = pick_edges(&body, &[EdgePick::Point(Vec3::new(0.0, 0.0, 5.0)), EdgePick::Index(all[0])]).unwrap();
|
||
assert_eq!(picked.len(), 2);
|
||
assert!(pick_edges(&body, &[EdgePick::Index(999)]).is_err());
|
||
assert!(pick_edges(&body, &[EdgePick::Point(Vec3::new(0.0, 5.0, 5.0))]).is_err(), "a point on a face is not on an edge");
|
||
assert!(pick_edges(&body, &[EdgePick::Point(Vec3::new(500.0, 0.0, 0.0))]).is_err());
|
||
assert!(seam_diagnostics(&body, &[], 2, tolerances()).is_err());
|
||
assert!(seam_diagnostics(&body, &[], 258, tolerances()).is_err());
|
||
assert!(seam_diagnostics(&body, &[], 33, ContinuityTolerances { gap_mm: f64::NAN, ..tolerances() }).is_err());
|
||
assert!(seam_diagnostics(&body, &[999], 33, tolerances()).is_err());
|
||
}
|
||
}
|