Manual mode previously offered only Auto De-rotate (rotation from known
scan angles) plus keyboard nudging, so every angle's translation had to
be found entirely by eye — fine for a small correction, unworkable for
the tens-of-mm scatter a real many-angle scan can have between angles
before any translation search runs at all.
Add an "Auto Cross-Correlate (vs Reference)" action that, for every
non-reference angle, sets rotation to the known analytic angle (same as
Auto De-rotate) and translation to the FFT-phase-correlation best fit
against angle #0 (always the reference/ground truth). This is meant to
land every angle's outline roughly stacked on the others so keyboard
nudging only has to make small corrections afterward, per the intended
workflow: cross-correlate first, then nudge.
Exposes two tunable options, since real data may correlate better one
way than the other: "Correlate on" (raw CH4 signal, minus its own
minimum -- the default, robust to a shared threshold not suiting every
angle's real signal level -- or the thresholded binary mask), and
"Search margin" (how far a shift the phase correlation searches before
wraparound bias becomes a risk).
Runs on a background thread (new CrossCorrelateWorker in
sras_workers.py) since correlating many high-resolution angles can take
long enough to visibly freeze the dialog otherwise.
The underlying per-angle correlation math is factored out of
compute_angle_alignment's Step 2 into a new, reusable
correlate_translation_mm, so the existing automatic Fusion -> Angle
Alignment action and the new manual button now share one implementation
instead of two copies of the same phase-correlation logic.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
The dialog was seeding rotation_deg/shift_mm from self._alignment_result
whenever it was non-None, with no way to tell whether that result came
from a user's own manual Save or from the automatic Fusion -> Angle
Alignment run. The automatic path's translation comes from FFT phase
correlation - the exact thing manual mode exists to work around - so
opening Manual Alignment after running the automatic pass silently
inherited its unreliable shifts on top of the (correct) analytic
rotation, reproducing the same scattered-scan symptom under a "manual"
label.
Manual mode should always start from identity (each angle's centroid
already coincides with every other's, per the prior pivot fix) unless
the user previously used this same dialog to save their own deliberate
translation - which is exactly what the sidecar file already records.
Seed exclusively from load_manual_alignment() and drop the
self._alignment_result branch entirely; the automatic result is never
an appropriate seed for a manual editing session.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
The pivot was still derived from the binary CH4 >= dc_threshold_mv mask,
so a threshold that happens to leave a real angle's mask empty (signal
levels vary scan to scan across a many-angle acquisition) silently fell
back to the raw scan-window bbox center — reproducing the exact "aligned
to the scan window, not the sample" scatter the centroid pivot exists to
fix, without any visible error.
Replace the binary-mask centroid with an intensity-weighted centroid of
the continuous CH4 signal, which is always well-defined regardless of the
RF-mask threshold in effect. The threshold still controls what the manual
dialog's overlay and CH1 masking show; it no longer has any bearing on
where alignment pivots.
Also bump the sidecar schema version: a file saved before today's pivot
and rotation-sign fixes stores numbers for a since-corrected transform, so
loading it unchanged would reintroduce the same scatter. Old sidecars are
now treated as absent rather than silently reused.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Rotation was pivoting on each angle's raw scan-window bbox center, which
ties alignment to wherever the window happened to sit in microscope/global
XY space rather than to the sample itself, leaving a residual orbital drift
between angles. Pivot on each angle's own CH4-threshold mask centroid
instead (its own sample footprint), for both the automatic phase-
correlation path and the manual dialog's Auto De-rotate/live preview.
Also negate the rotation used everywhere (_theta_deg): the GR stage's
reported angle increases in the opposite rotational sense from this
module's CCW math convention, so de-rotating by the raw angles_deg delta
was making misalignment worse rather than better.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Automatic alignment's phase-correlation translation search is unreliable, so
add a Fusion -> Manual Alignment dialog: every angle's CH4 threshold mask
overlaid at once with distinct colors/opacity, a selector for the active
angle, arrow keys to nudge translation and Q/E to nudge rotation, an Auto
De-rotate button that snaps to the known scan angle, and Save/Clear
controls backed by a JSON sidecar that's restored automatically on reload.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Three defects found by testing the parallel paths end to end.
Nested parallelism was unbounded. DcPrecomputeWorker and the alignment
driver both parallelise over angles, and each angle's compute_dc_image
then parallelised over rows again: 14 x 14 threads, and — worse — every
angle sized its chunk against the *whole* memory budget, so worst-case
live buffers were ~13.9 GB against a 1 GB budget. Capping the inner
worker count alone does not fix it; the chunk is still sized against the
full budget. plan_angle_level now hands each angle both max_workers=1
and its share of the budget, which bounds the real file at 1002 MB.
Chunk planning could not produce concurrency at all. _plan_chunks sized
chunk_rows first, and _chunk_rows_for spends whatever budget it is given
— so a single chunk consumed the lot and budget//chunk_bytes came back
as one worker. It now picks the worker count first and sizes the chunk to
it, giving 7-16 workers on the real file instead of 1.
Cancellation was too coarse to shut down. stop() was only checked between
angles, and one angle of the real scan is ~40 s, so closing the window
sat through it and returned with threads still running. should_stop is
now polled per row chunk and closeEvent signals every worker before
waiting: close went from 4.0 s with two live threads to 1.04 s with both
finished. A cancelled ComputeWorker emits None so a half-filled image is
never cached.
Also: BatchCacheWorker no longer reports every file as failed when the
process pool itself dies (unguarded __main__, frozen build, sandbox) —
it retries those files in-process. Batches below 512 MB skip the pool
entirely, since interpreter startup would otherwise make small jobs
slower. cache_file rejects an unknown mode instead of silently treating
it as "fft".
Measured on the real 496 GB scan, angle 3, 32 rows:
DC 2.94s -> 0.75s RF 6.10s -> 1.99s peak RSS 1.40 -> 1.93 GB
Batch convert, 24 files / 1 GB: 4.03s -> 2.36s.
Memory budget defaults to 1024 MB (SRAS_MEM_BUDGET_MB), the measured knee.
Testing: tools/test_refactor.py (70 checks: cache round-trip and block
carry-forward, partial-cache handling, parallel-vs-serial identity,
no-mask path, ROI mask vs full-grid, v2/v3/v4 parsing, sras_average
round-trip incl. remainder handling) and tools/test_gui.py (46 checks
driving the real widgets and workers headlessly). check_equivalence.py
still reports all 167 outputs identical to ed0eba4.
Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Thomas Ales