autonomous-mower

#!/usr/bin/env python3
# SPDX-License-Identifier: MIT
"""Generate docs/PRINT-QUEUE.md from cad/stl/ — per-part solid volume, filament
estimate, and a sensible print order. Pure stdlib.

Volume = divergence theorem over the STL mesh (exact for closed meshes).
Filament grams = solid volume x 1.24 g/cm3 (PETG) x a 0.55 effective-density
factor (3-4 walls + 25-40% infill on chunky brackets). It's an ESTIMATE for
planning spools — the slicer's number wins.
Run:  python3 scripts/print_queue.py
"""
import csv
import os
import struct

ROOT = os.path.join(os.path.dirname(os.path.abspath(__file__)), "..")
STL = os.path.join(ROOT, "cad", "stl")
OUT = os.path.join(ROOT, "docs", "PRINT-QUEUE.md")

DENSITY = 1.24          # g/cm3 PETG (ASA ~1.07 — scale accordingly)
EFFECTIVE = 0.55        # walls+infill vs solid
GRAMS_PER_HOUR = 18.0   # ~0.4mm nozzle, 0.2mm layers, moderate speeds — planning number

GROUPS = [
    ("Weekend 1 — brain box + safety (bench-build first)",
     ["equipment_plate", "upper_shelf", "box_foot", "relay_box", "relay_lid",
      "estop_pedestal_a", "estop_pedestal_b", "estop_face", "badge"]),
    ("Weekend 2 — steering (the actuator kit)",
     ["lapbar_yoke_bottom", "lapbar_yoke_top", "rail_anchor_bottom", "rail_anchor_top",
      "throttle_servo_bracket"]),
    ("Weekend 3 — sensors (masts + mounts)",
     ["gps_clamp_a", "gps_clamp_b", "gps_top_plate", "lidar_base_a", "lidar_base_b",
      "lidar_mast_lower", "lidar_mast_upper", "lidar_top_plate", "camera_base", "camera_cradle"]),
    ("Phase 3 — attachment hardware (print when the attachments land)",
     ["boom_base_plate", "blower_cradle_top", "blower_cradle_bottom", "trimmer_motor_plate",
      "duct_adapter", "dump_clevis", "tpms_cradle", "sprayer_ctrl_mount"]),
    ("Weekend 4 — overhead sonar + on-unit screen",
     ["sonar_collar_a", "sonar_collar_b", "display_hood_l", "display_hood_r",
      "display_brace", "display_yoke"]),
    ("Upgrade — dual-antenna RTK heading (moving baseline)",
     ["baseline_tee", "baseline_ant_plate"]),
]
QTY = {"dump_clevis": 2, "display_brace": 2, "baseline_ant_plate": 2}

def stl_volume_mm3(path):
    with open(path, "rb") as f:
        head = f.read(80)
        if head[:5] == b"solid" and b"facet" in head + f.read(200):
            f.seek(0)
            return _ascii_volume(f)
        f.seek(80)
        n = struct.unpack("<I", f.read(4))[0]
        vol = 0.0
        for _ in range(n):
            f.read(12)
            v = [struct.unpack("<3f", f.read(12)) for _ in range(3)]
            f.read(2)
            vol += _signed_tetra(v)
        return abs(vol)

def _ascii_volume(f):
    vol, tri = 0.0, []
    for line in f.read().decode(errors="ignore").splitlines():
        s = line.split()
        if len(s) >= 4 and s[0] == "vertex":
            tri.append(tuple(float(x) for x in s[1:4]))
            if len(tri) == 3:
                vol += _signed_tetra(tri)
                tri = []
    return abs(vol)

def _signed_tetra(v):
    (ax, ay, az), (bx, by, bz), (cx, cy, cz) = v
    return (ax * (by * cz - bz * cy) - ay * (bx * cz - bz * cx)
            + az * (bx * cy - by * cx)) / 6.0

def main():
    rows = {}
    with open(os.path.join(STL, "MANIFEST.csv")) as f:
        for r in csv.DictReader(f):
            rows[r["part"].replace("PRINT_", "")] = r

    lines = [f"# Print queue — {sum(len(p) for _, p in GROUPS)} parts in build order",
             "",
             "Generated by `scripts/print_queue.py` from the real STLs. Grams are a",
             f"planning estimate (solid volume × {DENSITY} g/cm³ PETG × {EFFECTIVE} walls+infill",
             "factor) — **the slicer's number wins**. Print the brim-baked files in",
             "`cad/stl/brim/` and do NOT add a slicer brim on top.",
             ""]
    total_g = total_h = 0.0
    for title, parts in GROUPS:
        lines += [f"## {title}", "",
                  "| Part | Qty | Bounding box (mm) | ~grams | ~hours |",
                  "|---|---|---|---|---|"]
        for name in parts:
            r = rows.get(name)
            if not r:
                lines.append(f"| {name} | — | MISSING FROM MANIFEST | — | — |")
                continue
            qty = QTY.get(name, 1)
            vol = stl_volume_mm3(os.path.join(ROOT, r["stl"] if os.path.isabs(r["stl"])
                                              else os.path.join("cad", r["stl"])))
            g = vol / 1000.0 * DENSITY * EFFECTIVE * qty
            h = g / GRAMS_PER_HOUR
            total_g += g; total_h += h
            bbox = f'{r["bbox_x"]} × {r["bbox_y"]} × {r["bbox_z"]}'
            lines.append(f"| {name} | {qty} | {bbox} | {g:.0f} g | {h:.1f} h |")
        lines.append("")
    lines += [f"**Totals: ≈ {total_g:.0f} g (~{total_g/1000:.1f} kg spool budget) · ≈ {total_h:.0f} printer-hours** "
              f"(mostly unattended; batch small parts per plate).", ""]
    with open(OUT, "w") as f:
        f.write("\n".join(lines))
    print(f"wrote {OUT}  (≈{total_g:.0f} g, ≈{total_h:.0f} h)")

if __name__ == "__main__":
    main()