Basically working gradual overhang speed

CURA-11966

Author: wawanbreton

doc/gradual_overhang_speed.svg

@@ -62,7 +62,7 @@ class LayerPlan : public NoCopy
 public:
     struct OverhangMask
     {
-        Shape mask;
+        Shape supported_region;
         Ratio speed_ratio;
     };
 
@@ -121,8 +121,8 @@ class LayerPlan : public NoCopy
     Comb* comb_;
     coord_t comb_move_inside_distance_; //!< Whenever using the minimum boundary for combing it tries to move the coordinates inside by this distance after calculating the combing.
     Shape bridge_wall_mask_; //!< The regions of a layer part that are not supported, used for bridging
-    std::vector<OverhangMask>
-        overhang_masks_; //!< The regions of a layer part where the walls overhang, calculated for multiple overhang angles. The latter is the most overhanging.
+    std::vector<OverhangMask> overhang_masks_; //!< The regions of a layer part where the walls overhang, calculated for multiple overhang angles. The latter is the most
+                                               //!< overhanging. For a visual explanation of the result, see doc/gradual_overhang_speed.svg
     Shape seam_overhang_mask_; //!< The regions of a layer part where the walls overhang, specifically as defined for the seam
     Shape roofing_mask_; //!< The regions of a layer part where the walls are exposed to the air
 
@@ -400,6 +400,17 @@ class LayerPlan : public NoCopy
         const double fan_speed = GCodePathConfig::FAN_SPEED_DEFAULT,
         const bool travel_to_z = true);
 
+    void addExtrusionMoveWithGradualOverhang(
+        const Point3LL& p,
+        const GCodePathConfig& config,
+        const SpaceFillType space_fill_type,
+        const Ratio& flow = 1.0_r,
+        const Ratio width_factor = 1.0_r,
+        const bool spiralize = false,
+        const Ratio speed_factor = 1.0_r,
+        const double fan_speed = GCodePathConfig::FAN_SPEED_DEFAULT,
+        const bool travel_to_z = true);
+
     /*!
      * Add polygon to the gcode starting at vertex \p startIdx
      * \param polygon The polygon
@@ -1007,13 +1018,6 @@ class LayerPlan : public NoCopy
      * \return The distance from the start of the current wall line to the first bridge segment
      */
     coord_t computeDistanceToBridgeStart(const ExtrusionLine& wall, const size_t current_index, const coord_t min_bridge_line_len) const;
-
-    /*!
-     * \brief Calculates whether the given segment is to be treated as overhanging
-     * \param p0 The start point of the segment
-     * \param p1 The end point of the segment
-     */
-    bool segmentIsOnOverhang(const Point3LL& p0, const Point3LL& p1) const;
 };
 
 } // namespace cura

include/LayerPlan.h

@@ -256,6 +256,14 @@ class Shape : public LinesSet<Polygon>
      */
     void simplify(ClipperLib::PolyFillType fill_type = ClipperLib::pftEvenOdd);
 
+    /*!
+     * Calculates the intersections between the given segment and all the segments of the shape
+     * @param start The start position of the segment
+     * @param end The end position of the segment
+     * @return The parameters of the intersections on the segment (intersection = start + t * (end - start)), unsorted
+     */
+    std::vector<float> intersectionsWithSegment(const Point2LL& start, const Point2LL& end) const;
+
 #ifdef BUILD_TESTS
     /*!
      * @brief Import the polygon from a WKT string

include/geometry/Shape.h

@@ -3080,36 +3080,61 @@ bool FffGcodeWriter::processInsets(
             gcode_layer.setBridgeWallMask(Shape());
         }
 
-        const auto get_overhang_region = [&](const AngleDegrees overhang_angle) -> Shape
+        const Shape fully_supported_region = outlines_below.offset(-half_outer_wall_width);
+        const Shape part_print_region = part.outline.offset(-half_outer_wall_width);
+
+        const auto get_supported_region = [&fully_supported_region, &layer_height](const AngleDegrees& overhang_angle) -> Shape
         {
             // the overhang mask is set to the area of the current part's outline minus the region that is considered to be supported
             // the supported region is made up of those areas that really are supported by either model or support on the layer below
             // expanded to take into account the overhang angle, the greater the overhang angle, the larger the supported area is
             // considered to be
-            const coord_t overhang_width = layer_height * std::tan(overhang_angle / (180 / std::numbers::pi));
-            return part.outline.offset(-half_outer_wall_width).difference(outlines_below.offset(10 + overhang_width - half_outer_wall_width)).offset(10);
+            const coord_t overhang_width = layer_height * std::tan(AngleRadians(overhang_angle));
+            return fully_supported_region.offset(overhang_width + 10);
         };
 
-        // Build overhang masks for all the overhang speeds
+#warning remove SVG writing
+        SVG svg(fmt::format("/tmp/overhang_mask_{}.svg", gcode_layer.getLayerNr().value), storage.getMachineBorder(), 0.001);
+        svg.writePolygons(part.outline, SVG::Color::BLACK, 0.01);
+
+        // Build supported regions for all the overhang speeds. For a visual explanation of the result, see doc/gradual_overhang_speed.svg
         std::vector<LayerPlan::OverhangMask> overhang_masks;
         const auto overhang_speed_factors = mesh.settings.get<std::vector<Ratio>>("wall_overhang_speed_factors");
         const size_t overhang_angles_count = overhang_speed_factors.size();
-        if (overhang_angles_count > 0)
+        const auto wall_overhang_angle = mesh.settings.get<AngleDegrees>("wall_overhang_angle");
+        if (overhang_angles_count > 0 && wall_overhang_angle < 90.0)
         {
-            const auto wall_overhang_angle = mesh.settings.get<AngleDegrees>("wall_overhang_angle");
-            if (wall_overhang_angle < 90.0)
+            const AngleDegrees overhang_step = (90.0 - wall_overhang_angle) / static_cast<double>(overhang_angles_count);
+            for (size_t angle_index = 0; angle_index < overhang_angles_count; ++angle_index)
             {
-                const AngleDegrees overhang_step = (90.0 - wall_overhang_angle) / static_cast<double>(overhang_angles_count);
-                for (size_t angle_index = 0; angle_index < overhang_angles_count; ++angle_index)
-                {
-                    const AngleDegrees actual_wall_overhang_angle = wall_overhang_angle + static_cast<double>(angle_index) * overhang_step;
-                    overhang_masks.emplace_back(get_overhang_region(actual_wall_overhang_angle), overhang_speed_factors[angle_index]);
-                }
+                const AngleDegrees actual_wall_overhang_angle = wall_overhang_angle + static_cast<double>(angle_index) * overhang_step;
+                const Ratio speed_factor = angle_index == 0 ? 1.0_r : overhang_speed_factors[angle_index - 1];
+
+                overhang_masks.emplace_back(get_supported_region(actual_wall_overhang_angle), speed_factor);
+            }
+
+            // Add an empty region, which actually means everything and should be ignored anyway
+            overhang_masks.emplace_back(Shape(), overhang_speed_factors.back());
+
+            for (const auto& region : overhang_masks)
+            {
+                svg.writePolygons(region.supported_region, SVG::Color::RAINBOW, 0.01);
             }
         }
         gcode_layer.setOverhangMasks(overhang_masks);
 
-        gcode_layer.setSeamOverhangMask(get_overhang_region(mesh.settings.get<AngleDegrees>("seam_overhang_angle")));
+        // the seam overhang mask is set to the area of the current part's outline minus the region that is considered to be supported,
+        // which will then be empty if everything is considered supported i.r.t. the angle
+        const AngleDegrees seam_overhang_angle = mesh.settings.get<AngleDegrees>("seam_overhang_angle");
+        if (seam_overhang_angle < 90.0)
+        {
+            const Shape supported_region_seam = get_supported_region(seam_overhang_angle);
+            gcode_layer.setSeamOverhangMask(part_print_region.difference(supported_region_seam).offset(10));
+        }
+        else
+        {
+            gcode_layer.setSeamOverhangMask(Shape());
+        }
 
         const auto roofing_mask_fn = [&]() -> Shape
         {

src/FffGcodeWriter.cpp

@@ -558,6 +558,124 @@ void LayerPlan::addExtrusionMove(
     last_planned_position_ = p.toPoint2LL();
 }
 
+void LayerPlan::addExtrusionMoveWithGradualOverhang(
+    const Point3LL& p,
+    const GCodePathConfig& config,
+    const SpaceFillType space_fill_type,
+    const Ratio& flow,
+    const Ratio width_factor,
+    const bool spiralize,
+    const Ratio speed_factor,
+    const double fan_speed,
+    const bool travel_to_z)
+{
+    const auto add_extrusion_move = [&](const Point3LL& target, const Ratio& overhang_speed_factor = 1.0_r)
+    {
+        addExtrusionMove(target, config, space_fill_type, flow, width_factor, spiralize, speed_factor * overhang_speed_factor, fan_speed, travel_to_z);
+    };
+
+    if (overhang_masks_.empty() || ! last_planned_position_.has_value())
+    {
+        // Unable to apply gradual overhanging (probably just disabled), just add the basic extrusion move
+        add_extrusion_move(p);
+        return;
+    }
+
+    // First, find the speed region where the segment starts
+    const Point2LL start = last_planned_position_.value();
+    size_t actual_speed_region_index = overhang_masks_.size() - 1; // Default to last region, which is infinity and beyond
+    for (const auto& [index, overhang_region] : overhang_masks_ | ranges::views::drop_last(1) | ranges::views::enumerate)
+    {
+        if (overhang_region.supported_region.inside(start, true))
+        {
+            actual_speed_region_index = index;
+            break;
+        }
+    }
+
+    // Pre-calculate the intersections of the segment with all regions (except last one, you cannot intersect an infinite plane)
+    const Point2LL end = p.toPoint2LL();
+    const Point2LL vector = end - start;
+    std::vector<std::vector<float>> speed_regions_intersections;
+    speed_regions_intersections.reserve(overhang_masks_.size() - 1);
+    for (const OverhangMask& overhang_region : overhang_masks_ | ranges::views::drop_last(1))
+    {
+        std::vector<float> intersections = overhang_region.supported_region.intersectionsWithSegment(start, end);
+        ranges::sort(intersections);
+        speed_regions_intersections.push_back(intersections);
+        if (! intersections.empty())
+        {
+            spdlog::debug("coucou");
+        }
+    }
+
+    const auto remove_previous_intersections = [&speed_regions_intersections](const float current_intersection)
+    {
+        for (std::vector<float>& intersections : speed_regions_intersections)
+        {
+            auto iterator = ranges::find_if(
+                intersections,
+                [&current_intersection](const float next_intersection)
+                {
+                    return next_intersection > current_intersection;
+                });
+
+            intersections.erase(intersections.begin(), iterator);
+        }
+    };
+
+    // Now move along segment and split it where we cross speed regions
+    while (true)
+    {
+        // First, see if we cross either the border or our current region (go out) or the border of the inner region (go in)
+        auto get_first_intersection = [](const std::vector<float>* intersections) -> std::optional<float>
+        {
+            return intersections != nullptr && ! intersections->empty() ? std::make_optional(intersections->front()) : std::nullopt;
+        };
+
+        std::vector<float>* intersections_current_region
+            = actual_speed_region_index < speed_regions_intersections.size() ? &speed_regions_intersections[actual_speed_region_index] : nullptr;
+        const std::optional<float> first_intersection_current_region = get_first_intersection(intersections_current_region);
+
+        std::vector<float>* intersections_inner_region = actual_speed_region_index > 0 ? &speed_regions_intersections[actual_speed_region_index - 1] : nullptr;
+        const std::optional<float> first_intersection_inner_region = get_first_intersection(intersections_inner_region);
+
+        if (first_intersection_current_region.has_value() || first_intersection_inner_region.has_value())
+        {
+            float intersection_parameter;
+            size_t next_speed_region_index;
+
+            if (first_intersection_current_region.has_value()
+                && (! first_intersection_inner_region.has_value() || first_intersection_inner_region.value() > first_intersection_current_region.value()))
+            {
+                // We crossed the border of the current region, which means we are getting out of it to an outer region
+                intersection_parameter = first_intersection_current_region.value();
+                next_speed_region_index = actual_speed_region_index + 1;
+            }
+            else
+            {
+                // We crossed the border of the inner region, which means we are getting inside of it
+                intersection_parameter = first_intersection_inner_region.value();
+                next_speed_region_index = actual_speed_region_index - 1;
+            }
+
+            // Move to intersection at current region speed
+            const Point2LL split_position = start + vector * intersection_parameter;
+            add_extrusion_move(split_position, overhang_masks_[actual_speed_region_index].speed_ratio);
+
+            // Prepare for next move in different region
+            actual_speed_region_index = next_speed_region_index;
+            remove_previous_intersections(intersection_parameter);
+        }
+        else
+        {
+            // We cross no border, which means we can reach the end of the segment within the current speed region, so we are done
+            add_extrusion_move(p, overhang_masks_[actual_speed_region_index].speed_ratio);
+            return;
+        }
+    }
+}
+
 template<class PathType>
 void LayerPlan::addWipeTravel(const PathAdapter<PathType>& path, const coord_t wipe_distance, const bool backwards, const size_t start_index, const Point2LL& last_path_position)
 {
@@ -732,8 +850,6 @@ void LayerPlan::addWallLine(
 
     const coord_t min_bridge_line_len = settings.get<coord_t>("bridge_wall_min_length");
     const Ratio bridge_wall_coast = settings.get<Ratio>("bridge_wall_coast");
-    const Ratio overhang_speed_factor = settings.get<Ratio>("wall_overhang_speed_factor");
-    const auto overhang_speed_factors = settings.get<std::vector<int>>("wall_overhang_speed_factors");
 
     Point3LL cur_point = p0;
 
@@ -799,14 +915,14 @@ void LayerPlan::addWallLine(
                 else
                 {
                     // no coasting required, just normal segment using non-bridge config
-                    addExtrusionMove(
+                    addExtrusionMoveWithGradualOverhang(
                         segment_end,
                         default_config,
                         SpaceFillType::Polygons,
                         segment_flow,
                         width_factor,
                         spiralize,
-                        segmentIsOnOverhang(p0, p1) ? overhang_speed_factor : speed_factor,
+                        speed_factor,
                         GCodePathConfig::FAN_SPEED_DEFAULT,
                         travel_to_z);
                 }
@@ -816,14 +932,14 @@ void LayerPlan::addWallLine(
             else
             {
                 // no coasting required, just normal segment using non-bridge config
-                addExtrusionMove(
+                addExtrusionMoveWithGradualOverhang(
                     segment_end,
                     default_config,
                     SpaceFillType::Polygons,
                     segment_flow,
                     width_factor,
                     spiralize,
-                    segmentIsOnOverhang(p0, p1) ? overhang_speed_factor : speed_factor,
+                    speed_factor,
                     GCodePathConfig::FAN_SPEED_DEFAULT,
                     travel_to_z);
             }
@@ -921,14 +1037,14 @@ void LayerPlan::addWallLine(
     else if (bridge_wall_mask_.empty())
     {
         // no bridges required
-        addExtrusionMove(
+        addExtrusionMoveWithGradualOverhang(
             p1,
             default_config,
             SpaceFillType::Polygons,
             flow,
             width_factor,
             spiralize,
-            segmentIsOnOverhang(p0, p1) ? overhang_speed_factor : speed_factor,
+            speed_factor,
             GCodePathConfig::FAN_SPEED_DEFAULT,
             travel_to_z);
     }
@@ -1948,15 +2064,6 @@ void LayerPlan::addLinesInGivenOrder(
     }
 }
 
-bool LayerPlan::segmentIsOnOverhang(const Point3LL& p0, const Point3LL& p1) const
-{
-    // const OpenPolyline segment{ p0.toPoint2LL(), p1.toPoint2LL() };
-    // const OpenLinesSet intersected_lines = overhang_mask_.intersection(OpenLinesSet{ segment });
-    // return ! intersected_lines.empty() && (static_cast<double>(intersected_lines.length()) / segment.length()) > 0.5;
-
-    return false;
-}
-
 void LayerPlan::sendLineTo(const GCodePath& path, const Point3LL& position, const double extrude_speed)
 {
     Application::getInstance().communication_->sendLineTo(

src/LayerPlan.cpp

@@ -890,6 +890,25 @@ void Shape::simplify(ClipperLib::PolyFillType fill_type)
     }
 }
 
+std::vector<float> Shape::intersectionsWithSegment(const Point2LL& start, const Point2LL& end) const
+{
+    std::vector<float> result;
+
+    for (const Polygon& polygon : getLines())
+    {
+        for (auto iterator = polygon.beginSegments(); iterator != polygon.endSegments(); ++iterator)
+        {
+            float t, u;
+            if (LinearAlg2D::segmentSegmentIntersection(start, end, (*iterator).start, (*iterator).end, t, u))
+            {
+                result.push_back(t);
+            }
+        }
+    }
+
+    return result;
+}
+
 void Shape::ensureManifold()
 {
     std::vector<Point2LL> duplicate_locations;