alpha version

img2nc.py

+import math
+import numpy as np
+import matplotlib.pyplot as plt
+import cv2
+
+
+def imshow(img, w_max=1200, h_max=700, name="show"):
+    h = img.shape[0]
+    w = img.shape[1]
+    ratio = w / h
+    ratio_max = w_max / h_max
+
+    if ratio >= ratio_max:
+        w_new = w_max
+        h_new = int(h * w_new / w)
+    else:
+        h_new = h_max
+        w_new = int(w * h_new / h)
+    img_show = cv2.resize(img, (w_new, h_new))
+    cv2.imshow(name, img_show)
+
+
+def mill(img_mill, img_keep, dpi, dia_mm, stepover=0.8, once=False):
+    global count
+    img_mill_bin = np.zeros_like(img_mill)
+    img_mill_bin[img_mill >= 127] = 255
+
+    img_keep_bin = np.zeros_like(img_keep)
+    img_keep_bin[img_keep >= 127] = 255
+
+    dpmm = dpi / 25.4
+    dia_px = int(dia_mm * dpmm)
+
+    print(f"Tool: {dia_mm} mm = {dia_px} px")
+    if dia_px < 10:
+        print(f"Warning: tool is only {dia_px} pixels wide")
+
+    k_step = int(dia_mm * 2 * stepover * dpmm)
+    k_tool = int(dia_mm * dpmm)
+
+    kernel_step = cv2.getStructuringElement(cv2.MORPH_ELLIPSE, (k_step, k_step))
+    kernel_tool = cv2.getStructuringElement(cv2.MORPH_ELLIPSE, (k_tool, k_tool))
+
+    done = False
+
+    paths = []
+
+    # mask = cv2.dilate(img_mill_bin, kernel_tool)
+    # mask = cv2.dilate(mask, kernel_tool)
+    img_keep_pad = np.pad(img_keep_bin, pad_width=(k_tool, k_tool), mode="constant", constant_values=0)
+
+    mask = np.copy(img_mill_bin)
+    # cv2.imwrite(f"mask_init_{count:02d}_pre.png", mask)
+    mask = cv2.dilate(mask, kernel_tool)
+    # mask = cv2.dilate(mask, kernel_tool)
+    mask[img_keep_bin > 0] = 0
+    # cv2.imwrite(f"mask_init_{count:02d}.png", mask)
+    # mask[img_keep > 0] = 0
+    mask = np.pad(mask, pad_width=(k_tool, k_tool), mode="constant", constant_values=0)
+
+    h_p, w_p = mask.shape
+
+    edge_px = k_tool
+
+    mask_diff = np.zeros_like(mask)
+    mask_miss = np.zeros_like(mask)
+    mask_next = np.zeros_like(mask)
+
+    i = 0
+    img_miss = np.zeros_like(img_mill_bin)
+
+    while not done:
+        if i == 0:
+            dil = cv2.dilate(img_keep_pad, kernel_tool)
+            mask_next[(mask > 0) & ~(dil > 0)] = 255
+            mask_next_dil = cv2.dilate(mask_next, kernel_tool)
+            missed = (mask > 0) & ~(mask_next_dil > 0)
+            img_miss[missed[edge_px:-edge_px, edge_px:-edge_px]] = 255
+            # ignore pixels that weren't marked to begin with
+            img_miss[img_mill_bin == 0] = 0
+        else:
+            mask_next[:, :] = cv2.erode(mask, kernel_step)
+            mask_diff[~(mask > 0)] = 0
+            mask_diff[mask > 0] = 255
+            mask_diff[mask_next > 0] = 0
+            mask_miss[:, :] = cv2.erode(mask_diff, kernel_tool)
+            contours, hierarchy = cv2.findContours(mask, cv2.RETR_TREE, cv2.CHAIN_APPROX_TC89_KCOS)
+            for c in contours:
+                c_float = c.astype(np.float32)
+                c_mm = np.zeros_like(c_float)
+                c_mm[:, 0, 0] = (c_float[:, 0, 0] - edge_px) / dpmm
+                c_mm[:, 0, 1] = ((h_p - c_float[:, 0, 1]) - edge_px) / dpmm
+                paths.append(c_mm[:, 0, :])
+            if once:
+                done = True
+
+        mask[:, :] = mask_next[:, :]
+        if i > 0:
+            mask[mask_miss > 0] = 255
+
+        i += 1
+
+        if not np.any(mask > 0):
+            done = True
+
+        print(i)
+
+    return paths, img_miss
+
+
+def add_gcode(f, paths, z_down=0.0, z_up=1.0):
+    feedrate_cut = 480.0
+    feedrate_plunge = 240.0
+
+    for p in paths:
+        x = p[0, 0]
+        y = p[0, 1]
+        f.write(f"G0 X{x:.4f} Y{y:.4f}\n")
+        f.write(f"G1 Z{z_down:.4f} F{feedrate_plunge:.4f}\n")
+
+        for c in p:
+            x, y = c[:]
+            f.write(f"G1 X{x:.4f} Y{y:.4f} F{feedrate_cut:.4f}\n")
+
+        x = p[0, 0]
+        y = p[0, 1]
+        f.write(f"G1 X{x:.4f} Y{y:.4f} F{feedrate_cut:.4f}\n")
+        f.write(f"G0 Z{z_up:.4f}\n")
+
+
+def main():
+    filename_copper = "input/Cu.png"
+    filename_edge = "input/Edge.png"
+    filename_out = "result.nc"
+
+    dpi = 1000.0
+
+    img_copper = cv2.imread(filename_copper)
+    img_edge = cv2.imread(filename_edge)
+
+    if len(img_copper.shape) > 2:
+        img_copper = cv2.cvtColor(img_copper, cv2.COLOR_BGR2GRAY)
+
+    if len(img_edge.shape) > 2:
+        img_edge = cv2.cvtColor(img_edge, cv2.COLOR_BGR2GRAY)
+
+    img1 = np.zeros_like(img_edge)
+    img1[(img_edge < 127) | (img_copper > 127)] = 255
+    img1_keep = np.copy(img1)
+    img1_keep[img1_keep >= 127] = 255
+    img1_keep[img1_keep < 127] = 0
+    img1_mill = 255 - img1_keep
+
+    paths1, img_miss1 = mill(img1_mill, img1_keep, 1000, 0.794)
+
+    paths2, img_miss2 = mill(img_miss1, img1_keep, 1000, 0.397)
+
+    img_edge_keep = np.copy(img_edge)
+    img_edge_keep[img_edge_keep >= 127] = 255
+    img_edge_keep[img_edge_keep < 127] = 0
+    img_edge_mill = 255 - img_edge_keep
+    paths3, _ = mill(img_edge_mill, img_edge_keep, dpi, 0.794, once=True)
+
+    f = open(filename_out, "w")
+
+    f.write("%\n")
+    f.write("G17\n")
+    f.write("G21\n")
+    f.write("G40\n")
+    f.write("G49\n")
+    f.write("G54\n")
+    f.write("G80\n")
+    f.write("G90\n")
+    f.write("G94\n")
+    f.write("T4 M06\n")
+    f.write("S16000\n")
+    f.write("G0 Z1\n")
+    f.write("M03\n")
+
+    add_gcode(f, paths2, z_down=-0.12)
+
+    f.write("M05\n")
+    f.write("T3 M06\n")
+    f.write("S16000\n")
+    f.write("G0 Z1\n")
+    f.write("M03\n")
+
+    add_gcode(f, paths1, z_down=-0.12)
+
+    add_gcode(f, paths3, z_down=-0.6)
+    add_gcode(f, paths3, z_down=-1.2)
+    add_gcode(f, paths3, z_down=-1.75)
+
+    f.write("M30\n")
+    f.write("%\n")
+    f.write("M6 T-1\n")
+    f.write("M496.1\n")
+
+    f.close()
+
+    dpmm = dpi / 25.4
+
+    h, w = np.shape(img1_mill)
+    img_show = np.zeros((h, w, 3), dtype=np.uint8)
+    img_show[img1_mill > 0, :] = 150
+    img_show[img_miss2 > 0, :] = 0
+    img_show[img_miss2 > 0, 0] = 255
+
+    plt.figure()
+    plt.imshow(img_show)
+    for c in paths1:
+        plt.plot(c[:, 0] * dpmm,  h-c[:, 1] * dpmm, "b")
+        plt.plot([c[-1, 0] * dpmm, c[0, 0] * dpmm],  [h-c[-1, 1] * dpmm, h-c[0, 1] * dpmm], "b")
+    for c in paths2:
+        plt.plot(c[:, 0] * dpmm,  h-c[:, 1] * dpmm, "g")
+        plt.plot([c[-1, 0] * dpmm, c[0, 0] * dpmm],  [h-c[-1, 1] * dpmm, h-c[0, 1] * dpmm], "g")
+    for c in paths3:
+        plt.plot(c[:, 0] * dpmm,  h-c[:, 1] * dpmm, "b")
+        plt.plot([c[-1, 0] * dpmm, c[0, 0] * dpmm],  [h-c[-1, 1] * dpmm, h-c[0, 1] * dpmm], "b")
+    plt.axis("equal")
+    plt.show()
+
+
+if __name__ == "__main__":
+    main()