Merge pull request #92 from jhbruhn/fix/colormatchtolerance

fix: implement validation of color palette number matches using color…

src/components/ProgressMonitor/ProgressMonitor.tsx

@@ -71,12 +71,12 @@ export function ProgressMonitor() {
   const isMaskTraceComplete =
     machineStatus === MachineStatus.MASK_TRACE_COMPLETE;
 
-  // Use PEN stitch count as fallback when machine reports 0 total stitches
-  const totalStitches = patternInfo
-    ? patternInfo.totalStitches === 0 && displayPattern?.penStitches
-      ? displayPattern.penStitches.stitches.length
-      : patternInfo.totalStitches
-    : 0;
+  // Use our own PEN stitch count as the source of truth for total stitches.
+  // The machine's patternInfo.totalStitches uses a different counting method than
+  // currentStitch (e.g. excludes lock stitches), so it can't be used as the max.
+  const totalStitches = displayPattern?.penStitches
+    ? displayPattern.penStitches.stitches.length
+    : (patternInfo?.totalStitches ?? 0);
 
   // Use adjustedStitchIndex (from step control) when available, otherwise machine-reported
   const currentStitch =
@@ -156,8 +156,10 @@ export function ProgressMonitor() {
             totalStitches={totalStitches}
             lastRolledBackError={lastRolledBackError}
             colorBlocks={colorBlocks}
-            onAdjustPosition={adjustStitchPosition}
-            onSetPosition={setStitchPosition}
+            onAdjustPosition={(offset) =>
+              adjustStitchPosition(offset, totalStitches)
+            }
+            onSetPosition={(index) => setStitchPosition(index, totalStitches)}
           />
         )}
 

src/stores/useMachineStore.ts

@@ -65,8 +65,8 @@ interface MachineState {
   startSewing: () => Promise<void>;
   resumeSewing: () => Promise<void>;
   deletePattern: () => Promise<void>;
-  setStitchPosition: (index: number) => Promise<void>;
-  adjustStitchPosition: (offset: number) => Promise<void>;
+  setStitchPosition: (index: number, maxStitches?: number) => Promise<void>;
+  adjustStitchPosition: (offset: number, maxStitches?: number) => Promise<void>;
 
   // Initialization
   initialize: () => void;
@@ -338,11 +338,11 @@ export const useMachineStore = create<MachineState>((set, get) => ({
   },
 
   // Set stitch position to an absolute index
-  setStitchPosition: async (index: number) => {
+  setStitchPosition: async (index: number, maxStitches?: number) => {
     const { isConnected, service, patternInfo } = get();
     if (!isConnected) return;
 
-    const totalStitches = patternInfo?.totalStitches || 0;
+    const totalStitches = maxStitches ?? patternInfo?.totalStitches ?? 0;
     const clamped = Math.max(0, Math.min(index, totalStitches));
 
     try {
@@ -359,11 +359,11 @@ export const useMachineStore = create<MachineState>((set, get) => ({
   },
 
   // Adjust stitch position by a relative offset
-  adjustStitchPosition: async (offset: number) => {
+  adjustStitchPosition: async (offset: number, maxStitches?: number) => {
     const { sewingProgress, adjustedStitchIndex } = get();
     const currentIndex =
       adjustedStitchIndex ?? sewingProgress?.currentStitch ?? 0;
-    await get().setStitchPosition(currentIndex + offset);
+    await get().setStitchPosition(currentIndex + offset, maxStitches);
   },
 
   // Handle automatic stitch rollback for thread errors

src/utils/brotherColors.ts

@@ -57,6 +57,12 @@ export interface ThreadColorInfo {
 // Type-safe Brother color data
 const brotherColors = brotherColorData as BrotherColor[];
 
+// Maximum RGB Euclidean distance to accept a catalog number match.
+// PES catalog numbers from pystitch use a different numbering scheme than our
+// Brother color database, so a catalog hit can resolve to the wrong color.
+// A match is only trusted if the database entry's RGB is within this distance.
+const CATALOG_COLOR_MATCH_THRESHOLD = 50;
+
 /**
  * Convert RGB values to hex color string
  */
@@ -266,25 +272,32 @@ export function enhanceThreadWithBrotherColor(
 ): ThreadColorInfo {
   const { matchByRGB = true } = options;
 
-  // First, try to match by catalog number
-  if (thread.catalogNumber) {
-    const brotherInfo = mapThreadCode(thread.catalogNumber);
-    if (brotherInfo) {
-      // Found a Brother color match by catalog number - use Brother data
-      return brotherInfo;
-    }
-  }
-
-  // Second, try exact RGB matching if enabled (replicates BrotherColor.FromColor logic)
   const cleanHex = thread.hex.replace("#", "");
   const r = parseInt(cleanHex.slice(0, 2), 16);
   const g = parseInt(cleanHex.slice(2, 4), 16);
   const b = parseInt(cleanHex.slice(4, 6), 16);
 
+  // First, try to match by catalog number — but only accept the match if the
+  // catalog entry's RGB is close to the thread's actual color. PES catalog
+  // numbers from pystitch use a different numbering scheme than our Brother
+  // color database, so a catalog hit can be the wrong color entirely.
+  if (thread.catalogNumber) {
+    const brotherInfo = mapThreadCode(thread.catalogNumber);
+    if (brotherInfo?.rgb) {
+      const dr = brotherInfo.rgb.r - r;
+      const dg = brotherInfo.rgb.g - g;
+      const db = brotherInfo.rgb.b - b;
+      const distance = Math.sqrt(dr * dr + dg * dg + db * db);
+      if (distance <= CATALOG_COLOR_MATCH_THRESHOLD) {
+        return brotherInfo;
+      }
+    }
+  }
+
+  // Try exact RGB matching (replicates BrotherColor.FromColor logic)
   if (matchByRGB) {
     const brotherColor = findBrotherColorByRGB(r, g, b);
     if (brotherColor) {
-      // Found exact RGB match - use Brother data
       return brotherColorToThreadInfo(brotherColor);
     }
   }