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src/main/java/com/ffii/core/utils/BrotherPrinterUtil.kt

@@ -5,58 +5,51 @@ import org.apache.pdfbox.rendering.PDFRenderer
 import java.awt.image.BufferedImage
 import java.io.ByteArrayOutputStream
 import java.io.File
-import java.io.OutputStream
 import java.net.Socket
-import javax.imageio.ImageIO
+import org.slf4j.LoggerFactory
 
 class BrotherPrinterUtil {
 
     companion object {
+        private const val SOCKET_TIMEOUT_MS = 120_000  // 2 min for large jobs; Brother may be slow to accept
+        private const val BROTHER_DPI = 200           // Lower DPI = smaller job; some Brother models buffer better at 200
+
+        private val log = LoggerFactory.getLogger(BrotherPrinterUtil::class.java)
+
         /**
-         * //Usage 
-         * BrotherPrinterUtil.printToBrother(
-                pdfFile = File("document.pdf"),
-                printerIp = "192.168.1.50",
-                printQty = 1
-            )
-
-         * Sends a PDF to a Brother DCP-1610W by rendering it to a PCL-compatible format.
+         * Sends a PDF to a Brother (e.g. DCP-1610W) by rendering to PCL raster over port 9100.
+         * Uses socket timeout and flush-per-page so the printer has time to accept data.
          */
         fun printToBrother(pdfFile: File, printerIp: String, printerPort: Int = 9100, printQty: Int = 1) {
-            if (!pdfFile.exists()) throw IllegalArgumentException("File not found.")
+            if (!pdfFile.exists()) throw IllegalArgumentException("File not found: ${pdfFile.absolutePath}")
 
-            println("DEBUG: PDF file size: ${pdfFile.length()} bytes")
+            log.info("Brother print: file=${pdfFile.name} size=${pdfFile.length()} ip=$printerIp port=$printerPort copies=$printQty")
 
             PDDocument.load(pdfFile).use { document ->
                 val renderer = PDFRenderer(document)
-
                 val totalPages = document.numberOfPages
-                repeat(printQty) { copyIndex ->
-                    println("DEBUG: Printing copy ${copyIndex + 1} of $printQty")
-                }
 
                 Socket(printerIp, printerPort).use { socket ->
+                    socket.soTimeout = SOCKET_TIMEOUT_MS
                     val os = socket.getOutputStream()
-                    
-                    // 1. Start PJL Job
+
+                    // 1. PJL header (optional; some Brother prefer minimal PJL)
                     os.write(getPjlHeader(printQty))
+                    os.flush()
 
-                    // 2. Render each page as a 300 DPI image
-                    for (pageIndex in 0 until document.numberOfPages) {
-                        val image = renderer.renderImageWithDPI(pageIndex, 300f, org.apache.pdfbox.rendering.ImageType.BINARY)
-                        
-                        // 3. Convert Image to PCL Raster Data
-                        val pclData = convertImageToPcl(image)
-                        os.write(pclData)
-                        
-                        // Form Feed (Move to next page)
-                        os.write("\u000C".toByteArray()) 
+                    repeat(printQty) { copyIndex ->
+                        for (pageIndex in 0 until totalPages) {
+                            val image = renderer.renderImageWithDPI(pageIndex, BROTHER_DPI.toFloat(), org.apache.pdfbox.rendering.ImageType.BINARY)
+                            val pclData = convertImageToPcl(image, BROTHER_DPI)
+                            os.write(pclData)
+                            os.write("\u000C".toByteArray(Charsets.US_ASCII))  // Form feed
+                            os.flush()  // Flush per page so Brother receives incrementally
+                        }
                     }
 
-                    // 4. End Job
                     os.write("\u001B%-12345X".toByteArray(Charsets.US_ASCII))
                     os.flush()
-                    println("DEBUG: Print job sent to printer")
+                    log.info("Brother print job sent successfully")
                 }
             }
         }
@@ -64,24 +57,25 @@ class BrotherPrinterUtil {
         private fun getPjlHeader(qty: Int): ByteArray {
             val pjl = StringBuilder()
             pjl.append("\u001B%-12345X@PJL\r\n")
-            pjl.append("@PJL SET COPIES=$qty\r\n")
-            pjl.append("@PJL ENTER LANGUAGE=PCL\r\n") // Tell printer to expect PCL graphics, not PDF
+            pjl.append("@PJL SET COPIES=1\r\n")  // We send copies in app; some Brother ignore COPIES or mis-handle it
+            pjl.append("@PJL ENTER LANGUAGE=PCL\r\n")
             return pjl.toString().toByteArray(Charsets.US_ASCII)
         }
 
         /**
-         * Converts a BufferedImage into PCL Level 3/5 Raster Graphics.
-         * This is the "magic" that allows a budget printer to print a PDF.
+         * Converts a BufferedImage into PCL raster graphics for Brother.
+         * Uses given DPI (e.g. 200) to keep job size smaller for printers with limited buffer.
          */
-        private fun convertImageToPcl(image: BufferedImage): ByteArray {
+        private fun convertImageToPcl(image: BufferedImage, dpi: Int): ByteArray {
             val out = ByteArrayOutputStream()
             val width = image.width
             val height = image.height
 
-            // PCL: Start Graphics at 300 DPI
-            out.write("\u001B*t300R".toByteArray()) 
-            // PCL: Start Raster Graphics
-            out.write("\u001B*r1A".toByteArray()) 
+            // PCL reset (Brother often needs clean state)
+            out.write("\u001BE".toByteArray(Charsets.US_ASCII))       // Esc E = reset
+            // PCL: Set resolution and start raster
+            out.write("\u001B*t${dpi}R".toByteArray(Charsets.US_ASCII))
+            out.write("\u001B*r1A".toByteArray(Charsets.US_ASCII)) 
 
             for (y in 0 until height) {
                 val rowBytes = (width + 7) / 8