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547ac30 | 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 | """Canonical hole-cycle physics approximation, independent of training targets.
One Hole Processing Expert for G17/Z and G19/X; physical axis retained only for
machine-energy accounting. New synthetic metadata is NOT suitable for G-code-only
production deployments unless corresponding tool/stock data are available.
This is NOT a LinuxCNC runtime simulator.
"""
from __future__ import annotations
import math,re,json
import numpy as np
from hole_constants import MAT,TOOL,move_time
from hole_energy_hardware import components_by_row
RE=re.compile(r'([A-Z])\s*([-+]?(?:\d+(?:\.\d*)?|\.\d+))',re.I)
OPS=['drilling','boring','reaming','tapping']
CODE={'G81':46,'G82':47,'G83':48,'G84':49,'G85':50,'G89':51,'G80':52,'G0':1,'G4':5,'M3':40,'M5':41,'M8':42,'M9':43,'M2':44,'STATE':45}
def simulate_program(rows, feature_dim=42, accel_nominal=590, rapid_nominal=5700):
profile=json.loads(rows[0]['initial_profile']);op=profile.get('operation',rows[0].get('operation','drilling'))
if op not in OPS: raise ValueError(op)
orient='horizontal' if any(re.search(r'\bG19\b',r['gcode']) for r in rows) else 'vertical'
# Geometric stock/tool descriptors from simulated machine metadata. These are
# optional input data (not tool-wear sensor feedback); no target is read here.
diameter=float(profile.get('hidden_diameter_mm',0.0));pilot=float(profile.get('hidden_pilot_diameter_mm',0.0))
depth=float(profile.get('hole_depth_mm',0.0));pitch=float(profile.get('pitch_mm',0.0))
form=bool(profile.get('tap_form',False));material=profile.get('hidden_work_material','AL6061')
tool=profile.get('hidden_tool_material','CARBIDE');density,se,_=MAT.get(material,MAT['AL6061'])
tool_power=TOOL.get(tool,TOOL['CARBIDE'])[0]
area=math.pi/4*max(0,diameter*diameter-pilot*pilot)
if op=='tapping':
area=0 if form else math.pi*diameter*pitch*.11
area=max(0,area)
# Energy teacher uses operation-specific friction/contact. No hidden wear or
# hidden motor gain is supplied to this baseline; they remain unpredictable.
contact_area=math.pi*diameter*pitch*.25 if op=='tapping' else math.pi/4*max(0,diameter**2-pilot**2)
contact_geometry={'drilling':1.,'boring':.78,'reaming':1.42,'tapping':2.4 if form else 1.7}[op]
feed=600.;rpm=0.;on=False;cool=False;axispos=5.;crosspos=(12.,12.);cycle=None;cycle_peck=4.5;cycle_dwell=0.3
out_codes=[];out_feats=[];out_prior=[];out_mass=[];total_energy=0.
running_total_distance=0.;running_cutvol=0.;running_motion=0.
running_power_components=np.zeros(8,np.float64)
ax='X' if orient=='horizontal' else 'Z';cross=('Y','Z') if orient=='horizontal' else ('X','Y')
for ir,row in enumerate(rows):
gc=row['gcode'].strip().upper(); pairs=[(k,float(v)) for k,v in RE.findall(gc)]; w=dict(pairs)
gv=[int(v) for k,v in pairs if k=='G'];mv=[int(v) for k,v in pairs if k=='M']
previous_cycle=cycle
for g in gv:
if g in (81,82,83,84,85,89):cycle='G'+str(g)
if g==80:cycle=None
if 'F' in w:feed=w['F']
if cycle and any(g in (81,82,83,84,85,89) for g in gv):
cycle_peck=float(w.get('Q',cycle_peck));cycle_dwell=float(w.get('P',cycle_dwell))
if 'S' in w:rpm=w['S']
for m in mv:
if m in (3,4):on=True
elif m==5:on=False
elif m==8:cool=True
elif m==9:cool=False
code=('G'+str(gv[0])) if gv else ('M'+str(mv[0]) if mv else ('STATE'))
dt=0.;volume=0.;axial_distance=0.;lateral_distance=0.;is_cycle=False;dwell=0.;rapid_distance=0.
if 4 in gv:dt=max(0.,w.get('P',0.))
if 0 in gv:
new_axis=w.get(ax,axispos)
new_cross=(w.get(cross[0],crosspos[0]),w.get(cross[1],crosspos[1]))
axial_distance=abs(new_axis-axispos);lateral_distance=math.dist(crosspos,new_cross)
rapid_distance=math.hypot(axial_distance,lateral_distance)
dt=move_time(rapid_distance,rapid_nominal/60,accel_nominal)
axispos=new_axis;crosspos=new_cross
# A canned-cycle command OR a positional-only line while a cycle is modal.
if cycle and (int(cycle[1:]) in gv or (not gv and not mv and any(k in w for k in cross))):
nc=(w.get(cross[0],crosspos[0]),w.get(cross[1],crosspos[1]))
lateral_distance=math.dist(crosspos,nc);crosspos=nc
axial_distance=depth+2.
speed=max(feed/60,0.01)
dt=move_time(lateral_distance,rapid_nominal/60,accel_nominal)+move_time(axial_distance,speed,accel_nominal)
dt+=move_time(axial_distance,speed if cycle in ('G85','G89','G84') else rapid_nominal/60,accel_nominal)
if cycle=='G83':
q=max(.1,cycle_peck)
dt+=.55*(max(1,math.ceil(depth/q))-1)*depth/max(speed,.1)
if cycle in ('G82','G84','G89'):
dwell=cycle_dwell
dt+=dwell
if cycle=='G84': dt+=.27+.035*depth
volume=area*depth;is_cycle=True;code=cycle
energy=0.
if dt>0:
base_w=58.+18*(orient=='horizontal')+22.
spindle_w=(48+rpm*.022+rpm*rpm*1e-6) if on else 0.
aux_w=(82. if cool else 0.)
motion_dist=lateral_distance+axial_distance if is_cycle else rapid_distance
speed_motion=motion_dist/max(dt,1e-8)
motion_w=(.4*speed_motion+.012*speed_motion**2) if motion_dist else 0.
# Form tapping consumes contact work EVEN when zero chips are produced.
vol_for_contact=contact_area*depth if (is_cycle and op=='tapping') else volume
cutting_J=se*tool_power*vol_for_contact*contact_geometry if is_cycle else 0.
power_comp=np.asarray([base_w*dt,0.,motion_w*dt*.5,motion_w*dt*.5,0.,spindle_w*dt,cutting_J,aux_w*dt],float)/3600.
running_power_components+=power_comp
energy=float(power_comp.sum())
running_motion+=dt if (rapid_distance or is_cycle) else 0.
running_total_distance+=motion_dist
running_cutvol+=volume
vec=np.zeros(feature_dim,np.float32)
# Canonical axial/lateral motion ONLY. No raw X/Y/Z positions, signs,
# physical orientation, or direction indicators leak into Hole Expert.
fields=[math.log1p(axial_distance+lateral_distance),math.log1p(max(feed/60,0)),math.log1p(max(rpm,0)),
math.log1p(max(diameter,0)),math.log1p(max(depth,0)),math.log1p(axial_distance),
math.log1p(lateral_distance),math.log1p(abs(depth)),float(is_cycle),
float(code in ('G81','G82','G83')),float(code in ('G84','G85','G89')),
float(code=='G0'),math.log1p(max(volume,0)),float(on),float(cool),float(is_cycle),
float(code=='G0'),float(code in ('G81','G82','G83')),float(code=='G83'),
float(op=='boring'),float(op=='reaming'),math.log1p(max(feed,0)),math.log1p(dt),
float(dwell>0),math.log1p(len(rows)),math.log1p(max(pitch,0)),
float(form),math.log1p(max(pilot,0)),math.log1p(max(area,0)),math.log1p(max(contact_area,0))]
vec[:len(fields)]=fields
vec[37]=1.
# These 2 are density and machine speed, which prior architecture uses.
# They are not raw X/Z coordinates. For the hole canonical invariance
# test, physical orientation affects only the hardware energy baseline.
vec[40]=density*1000
vec[41]=math.log1p(rapid_nominal)
out_codes.append(CODE.get(code, CODE['STATE']))
out_feats.append(vec)
out_prior.append([dt,0.,volume*density]);out_mass.append(volume*density)
# Corrected job-level, twelve-component electromechanical energy prior.
# Here out_prior durations are G-code-only approximate time predictions.
# The inference-stage prior is recomputed with the trained time prediction.
_,raw=components_by_row(rows,np.asarray(out_prior)[:,0],teacher=False)
return (np.asarray(out_codes,np.int64),np.asarray(out_feats,np.float32),np.asarray(out_prior,np.float32),
np.asarray(out_mass,np.float64),raw)
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