pa calib: print flow value and acceleration (#7178)

* pa calib: print flow value and acceleration

Print flow value and acceleration for PA pattern calibration.
This should help keep track during adaptive PA calibration.

* pa pattern: fix legent section too wide in some cases

Rework pa pattern legent generation to correctly estimate
width of the legend section.

Current flow value now has variable length which is a longest of
PA value and the acceleration for a given test.

Few examples:
1. PA value are 4 characters:        0.04
   Acceleratioion 3 chars:           400
   Flow value will be 4 chars long:  7.98, or 11.3

2. PA:      0.018
   Accel:   1000
   Flow:    12.35, or 6.345

3. PA:      0.04
   Accel:   15000
   Flow:    34.34, or 4.567

Rework number-to-string conversion flow to correctly round values at
given precision.

src/libslic3r/calib.cpp

@@ -46,13 +46,20 @@ double CalibPressureAdvance::e_per_mm(
     return line_flow.mm3_per_mm() * print_flow_ratio / filament_area ;
 }
 
-std::string CalibPressureAdvance::convert_number_to_string(double num) const
+std::string CalibPressureAdvance::convert_number_to_string(double num, unsigned int precision) const
 {
-    auto sNumber = std::to_string(num);
+    std::ostringstream stream;
-    sNumber.erase(sNumber.find_last_not_of('0') + 1, std::string::npos);
-    sNumber.erase(sNumber.find_last_not_of('.') + 1, std::string::npos);
 
-    return sNumber;
+    if (precision) {
+        /* if number is > 1000 then there are no way we'll fit fractional part into 5 glyphs, so
+         * in this case we keep full precision.
+         * Otherwise we reduce precision by 1 to accomodate decimal separator */
+        stream << std::setprecision(num >= 1000 ? precision : precision - 1);
+    }
+
+    stream << num;
+
+    return stream.str();
 }
 
 std::string CalibPressureAdvance::draw_digit(
@@ -201,12 +208,12 @@ std::string CalibPressureAdvance::draw_number(double
                                               double                              speed,
                                               GCodeWriter                        &writer)
 {
-    auto              sNumber = convert_number_to_string(value);
+    auto              sNumber = convert_number_to_string(value, m_number_len);
     std::stringstream gcode;
     gcode << writer.set_speed(speed);
 
     for (std::string::size_type i = 0; i < sNumber.length(); ++i) {
-        if (i > m_max_number_len) {
+        if (i >= m_number_len) {
             break;
         }
         switch (mode) {
@@ -537,6 +544,18 @@ CalibPressureAdvancePattern::CalibPressureAdvancePattern(
     this->m_draw_digit_mode = DrawDigitMode::Bottom_To_Top;
 
     refresh_setup(config, is_bbl_machine, model, origin);
+}
+
+double CalibPressureAdvancePattern::flow_val() const
+{
+    double flow_mult = m_config.option<ConfigOptionFloats>("filament_flow_ratio")->get_at(0);
+    double nozzle_diameter = m_config.option<ConfigOptionFloats>("nozzle_diameter")->get_at(0);
+    double line_width = m_config.get_abs_value("line_width", nozzle_diameter);
+    double layer_height = m_config.get_abs_value("layer_height");
+    double speed = m_config.opt_float("outer_wall_speed");
+    Flow pattern_line = Flow(line_width, layer_height, m_config.option<ConfigOptionFloats>("nozzle_diameter")->get_at(0));
+
+    return speed * pattern_line.mm3_per_mm() * flow_mult;
 };
 
 void CalibPressureAdvancePattern::generate_custom_gcodes(const DynamicPrintConfig &config,
@@ -564,7 +583,7 @@ void CalibPressureAdvancePattern::generate_custom_gcodes(const DynamicPrintConfi
     draw_box_opt_args.is_filled      = true;
     draw_box_opt_args.num_perimeters = wall_count();
     gcode << draw_box(m_writer, m_starting_point.x(), m_starting_point.y() + frame_size_y() + line_spacing_first_layer(),
-                      glyph_tab_max_x() - m_starting_point.x(),
+                      print_size_x(),
                       max_numbering_height() + line_spacing_first_layer() + m_glyph_padding_vertical * 2, draw_box_opt_args);
 
     std::vector<CustomGCode::Item> gcode_items;
@@ -593,6 +612,8 @@ void CalibPressureAdvancePattern::generate_custom_gcodes(const DynamicPrintConfi
 
         // line numbering
         if (i == 1) {
+            m_number_len = max_numbering_length();
+
             gcode << m_writer.set_pressure_advance(m_params.start);
 
             double number_e_per_mm = e_per_mm(line_width(), height_layer(),
@@ -606,6 +627,18 @@ void CalibPressureAdvancePattern::generate_custom_gcodes(const DynamicPrintConfi
                                      m_params.start + (j * m_params.step), m_draw_digit_mode, line_width(), number_e_per_mm,
                                      speed_first_layer(), m_writer);
             }
+
+            // flow value
+            int line_num = num_patterns + 2;
+            gcode << draw_number(glyph_start_x(line_num), m_starting_point.y() + frame_size_y() + m_glyph_padding_vertical + line_width(),
+                                 flow_val(), m_draw_digit_mode, line_width(), number_e_per_mm,
+                                 speed_first_layer(), m_writer);
+
+            // acceleration
+            line_num = num_patterns + 4;
+            gcode << draw_number(glyph_start_x(line_num), m_starting_point.y() + frame_size_y() + m_glyph_padding_vertical + line_width(),
+                                 m_config.opt_float("default_acceleration"), m_draw_digit_mode, line_width(), number_e_per_mm,
+                                 speed_first_layer(), m_writer);
         }
 
 
@@ -790,7 +823,7 @@ double CalibPressureAdvancePattern::glyph_tab_max_x() const
            (glyph_length_x() - line_width() / 2) + padding;
 }
 
-double CalibPressureAdvancePattern::max_numbering_height() const
+size_t CalibPressureAdvancePattern::max_numbering_length() const
 {
     std::string::size_type most_characters = 0;
     const int              num_patterns    = get_num_patterns();
@@ -804,9 +837,18 @@ double CalibPressureAdvancePattern::max_numbering_height() const
         }
     }
 
-    most_characters = std::min(most_characters, m_max_number_len);
+    std::string sAccel = convert_number_to_string(m_config.opt_float("default_acceleration"));
+    most_characters = std::max(most_characters, sAccel.length());
 
-    return (most_characters * m_digit_segment_len) + ((most_characters - 1) * m_digit_gap_len);
+    /* don't actually check flow value: we'll print as many fractional digits as fits */
+
+    return std::min(most_characters, m_max_number_len);
+}
+
+double CalibPressureAdvancePattern::max_numbering_height() const
+{
+    std::string::size_type num_characters = max_numbering_length();
+    return (num_characters * m_digit_segment_len) + ((num_characters - 1) * m_digit_gap_len);
 }
 
 double CalibPressureAdvancePattern::pattern_shift() const

src/libslic3r/calib.hpp

@@ -155,7 +155,7 @@ protected:
     double e_per_mm(double line_width, double layer_height, float nozzle_diameter, float filament_diameter, float print_flow_ratio) const;
     double speed_adjust(int speed) const { return speed * 60; };
 
-    std::string convert_number_to_string(double num) const;
+    std::string convert_number_to_string(double num, unsigned precision = 0) const;
     double      number_spacing() const { return m_digit_segment_len + m_digit_gap_len; };
     std::string draw_digit(double                              startx,
                            double                              starty,
@@ -188,6 +188,7 @@ protected:
     const double                 m_digit_segment_len{2};
     const double                 m_digit_gap_len{1};
     const std::string::size_type m_max_number_len{5};
+    std::string::size_type       m_number_len{m_max_number_len}; /* Current length of number labels */
 };
 
 class CalibPressureAdvanceLine : public CalibPressureAdvance
@@ -255,6 +256,7 @@ public:
     double print_size_x() const { return object_size_x() + pattern_shift(); };
     double print_size_y() const { return object_size_y(); };
     double max_layer_z() const { return height_first_layer() + ((m_num_layers - 1) * height_layer()); };
+    double flow_val() const;
 
     void generate_custom_gcodes(const DynamicPrintConfig &config, bool is_bbl_machine, Model &model, const Vec3d &origin);
 
@@ -296,6 +298,7 @@ private:
     double glyph_length_x() const;
     double glyph_tab_max_x() const;
     double max_numbering_height() const;
+    size_t max_numbering_length() const;
 
     double pattern_shift() const;