OpenNest/OpenNest.Benchmark/NestValidator.cs

using System.Collections.Generic;
using System.Linq;
using OpenNest.Converters;
using OpenNest.Engine.Jobs;
using OpenNest.Geometry;
using OpenNest.Math;

namespace OpenNest.Benchmark
{
    public class ValidationResult
    {
        public bool Valid => Violations.Count == 0;
        public List<string> Violations { get; } = new();
    }

    /// <summary>
    /// Validates a (possibly multi-plate) placed layout against the benchmark
    /// rules: on every plate, every part must lie within that plate's work
    /// area and every pair of parts must be at least PartSpacing apart; across
    /// all plates combined, no drawing may have more parts placed than
    /// requested (the quantity limit is a property of the whole order, not of
    /// any one plate). Geometry checks work on arbitrary (concave, holed)
    /// polygons by reusing the same world-space extraction Part.Intersects
    /// uses internally, so no engine gets an advantage or penalty from shape
    /// complexity.
    /// </summary>
    public static class NestValidator
    {
        /// <summary>
        /// requirements maps each materialized part's BaseDrawing (by reference - materialized
        /// Drawing instances are freshly reconstructed per NestResultMaterializer.Materialize, so
        /// identity must never be inferred from Name, which is only incidentally seeded from the
        /// originating NestJobPart id) to its original quantity limit and display name.
        /// </summary>
        public static ValidationResult Validate(
            List<(Plate Plate, List<Part> Parts)> plateRuns,
            IReadOnlyDictionary<Drawing, (string Name, int Quantity)> requirements
        )
        {
            var result = new ValidationResult();
            var allParts = plateRuns.SelectMany(pr => pr.Parts).ToList();

            if (allParts.Count == 0)
                return result;

            ValidateQuantities(allParts, requirements, result);

            foreach (var (plate, parts) in plateRuns)
            {
                if (parts.Count == 0)
                    continue;

                ValidateBounds(parts, plate, requirements, result);
                ValidateAreaBudget(parts, plate, result);
                ValidateSpacing(parts, plate.PartSpacing, requirements, result);
            }

            return result;
        }

        /// <summary>
        /// Checks what the materialized layout cannot show: every sheet must be
        /// one of the job's own stock entries (an engine may not invent a sheet
        /// size or loosen its spacing/edge settings, which the layout checks
        /// would otherwise trust), finite stock may not be overdrawn, and every
        /// placement's rotation must satisfy its part's RotationPolicy.
        /// </summary>
        public static void ValidateAgainstJob(
            NestJob job,
            NestJobResult jobResult,
            IReadOnlyDictionary<string, string> displayNames,
            ValidationResult result
        )
        {
            var stockById = job.Plates.ToDictionary(s => s.Id);
            var partsById = job.Parts.ToDictionary(p => p.Id);
            var sheetsUsed = new Dictionary<string, int>();

            foreach (var sheet in jobResult.Plates)
            {
                if (
                    !stockById.TryGetValue(sheet.Stock.Id, out var stock)
                    || !SameSettings(stock, sheet.Stock)
                )
                {
                    result.Violations.Add(
                        $"Plate {sheet.PlateIndex} uses stock '{sheet.Stock.Id}' ({sheet.Stock.Size}) that does not match any stock offered by the job"
                    );
                    continue;
                }

                sheetsUsed[stock.Id] = sheetsUsed.GetValueOrDefault(stock.Id) + 1;
            }

            foreach (var (stockId, used) in sheetsUsed)
            {
                var available = stockById[stockId].Quantity;

                if (available.HasValue && used > available.Value)
                {
                    result.Violations.Add(
                        $"Used {used} sheet(s) of stock '{stockId}' but only {available.Value} are available"
                    );
                }
            }

            foreach (var sheet in jobResult.Plates)
            {
                foreach (var placement in sheet.Placements)
                {
                    if (!partsById.TryGetValue(placement.PartId, out var part))
                        continue; // reported by ValidateQuantities

                    if (!part.Rotation.Allows(placement.Rotation))
                    {
                        var name = displayNames.TryGetValue(part.Id, out var n) ? n : part.Id;
                        result.Violations.Add(
                            $"'{name}' placed at {Angle.ToDegrees(placement.Rotation):F3}° on plate {sheet.PlateIndex}, "
                                + $"outside its rotation constraint ({Describe(part.Rotation)})"
                        );
                    }
                }
            }
        }

        private static bool SameSettings(NestPlateStock expected, NestPlateStock actual) =>
            ReferenceEquals(expected, actual)
            || (
                expected.Size.Equals(actual.Size)
                && expected.PartSpacing.IsEqualTo(actual.PartSpacing)
                && expected.EdgeSpacing.Left.IsEqualTo(actual.EdgeSpacing.Left)
                && expected.EdgeSpacing.Right.IsEqualTo(actual.EdgeSpacing.Right)
                && expected.EdgeSpacing.Top.IsEqualTo(actual.EdgeSpacing.Top)
                && expected.EdgeSpacing.Bottom.IsEqualTo(actual.EdgeSpacing.Bottom)
                && expected.Quadrant == actual.Quadrant
            );

        private static string Describe(RotationPolicy policy) =>
            policy.Kind switch
            {
                RotationPolicyKind.Fixed => $"fixed at {Angle.ToDegrees(policy.Start):F3}°",
                RotationPolicyKind.BoundedSweep =>
                    $"{Angle.ToDegrees(policy.Start):F3}° to {Angle.ToDegrees(policy.End):F3}° in {Angle.ToDegrees(policy.Step):F3}° steps",
                _ => "any",
            };

        private static void ValidateQuantities(
            List<Part> parts,
            IReadOnlyDictionary<Drawing, (string Name, int Quantity)> requirements,
            ValidationResult result
        )
        {
            var placedCounts = parts
                .GroupBy<Part, Drawing>(p => p.BaseDrawing, ReferenceEqualityComparer.Instance)
                .ToDictionary(g => g.Key, g => g.Count());

            foreach (var (drawing, placed) in placedCounts)
            {
                if (!requirements.TryGetValue(drawing, out var requirement))
                {
                    result.Violations.Add(
                        $"Placed drawing '{drawing.Name}' which was not requested for this job"
                    );
                    continue;
                }

                if (placed > requirement.Quantity)
                {
                    result.Violations.Add(
                        $"'{requirement.Name}': placed {placed} across all plates but only {requirement.Quantity} were requested"
                    );
                }
            }
        }

        private static void ValidateBounds(
            List<Part> parts,
            Plate plate,
            IReadOnlyDictionary<Drawing, (string Name, int Quantity)> requirements,
            ValidationResult result
        )
        {
            var workArea = plate.WorkArea();

            foreach (var part in parts)
            {
                var bb = part.BoundingBox;

                var outLeft = bb.Left < workArea.X - Tolerance.Epsilon;
                var outBottom = bb.Bottom < workArea.Y - Tolerance.Epsilon;
                var outRight = bb.Right > workArea.Right + Tolerance.Epsilon;
                var outTop = bb.Top > workArea.Top + Tolerance.Epsilon;

                if (outLeft || outBottom || outRight || outTop)
                {
                    result.Violations.Add(
                        $"'{DisplayName(part, requirements)}' at ({part.Location.X:F2},{part.Location.Y:F2}) falls outside the work area "
                            + $"of a {plate.Size} plate"
                    );
                }
            }
        }

        /// <summary>
        /// Hard mathematical backstop: non-overlapping parts confined to the
        /// work area can never have a combined area greater than the work
        /// area itself. This catches overlap that the polygon-based
        /// ValidateSpacing check can miss - Collision.HasOverlap (and
        /// Part.Intersects, which uses the same algorithm) has been observed
        /// to return false negatives on real, complex production geometry, so
        /// this check does not depend on it.
        /// </summary>
        private static void ValidateAreaBudget(
            List<Part> parts,
            Plate plate,
            ValidationResult result
        )
        {
            var workArea = plate.WorkArea();
            var budget = workArea.Width * workArea.Length;
            var placedArea = parts.Sum(p => p.BaseDrawing.Area);

            if (placedArea > budget + Tolerance.Epsilon)
            {
                result.Violations.Add(
                    $"Combined placed area ({placedArea:F2}) on a {plate.Size} plate exceeds its work area ({budget:F2}) - "
                        + "parts must overlap even though the polygon overlap check did not flag a pair"
                );
            }
        }

        /// <summary>
        /// Every pair of parts must be at least <paramref name="spacing"/> apart.
        /// Each part's material is inflated by the spacing (perimeter offset
        /// outward, holes shrunk inward) and tested against the other part's raw
        /// material, with holes subtracted on both sides - so a small part
        /// nested inside another part's cutout (part-in-part) is legal as long as
        /// it clears the cutout's edge by the spacing. Pairs are pruned with an
        /// X-sorted sweep over bounding boxes so only neighbours reach the
        /// polygon clipper.
        /// </summary>
        private static void ValidateSpacing(
            List<Part> parts,
            double spacing,
            IReadOnlyDictionary<Drawing, (string Name, int Quantity)> requirements,
            ValidationResult result
        )
        {
            var raw = new PartOutline[parts.Count];
            var inflated = new PartOutline[parts.Count];

            for (var i = 0; i < parts.Count; i++)
            {
                raw[i] = Outline(parts[i], 0);
                inflated[i] = spacing > Tolerance.Epsilon ? Outline(parts[i], spacing) : raw[i];
            }

            var order = Enumerable
                .Range(0, parts.Count)
                .Where(i => raw[i] != null && inflated[i] != null)
                .OrderBy(i => raw[i].Perimeter.BoundingBox.Left)
                .ToList();

            for (var a = 0; a < order.Count; a++)
            {
                var i = order[a];
                var reach = inflated[i].Perimeter.BoundingBox;

                for (var b = a + 1; b < order.Count; b++)
                {
                    var j = order[b];
                    var other = raw[j].Perimeter.BoundingBox;

                    // Sorted by Left, so nothing further along can reach part i either.
                    if (other.Left > reach.Right + Tolerance.Epsilon)
                        break;

                    if (!BoxesTouch(reach, other))
                        continue;

                    // Inflating one side by the full spacing covers both cases: part j
                    // inside part i's (shrunk) cutout, or part i's inflated outline
                    // inside part j's raw cutout.
                    if (
                        Collision.HasOverlap(
                            inflated[i].Perimeter,
                            raw[j].Perimeter,
                            inflated[i].Holes,
                            raw[j].Holes
                        )
                    )
                    {
                        result.Violations.Add(
                            $"'{DisplayName(parts[i], requirements)}' and '{DisplayName(parts[j], requirements)}' are closer than the required spacing ({spacing:F3})"
                        );
                    }
                }
            }
        }

        private static bool BoxesTouch(Box a, Box b) =>
            a.Left <= b.Right + Tolerance.Epsilon
            && b.Left <= a.Right + Tolerance.Epsilon
            && a.Bottom <= b.Top + Tolerance.Epsilon
            && b.Bottom <= a.Top + Tolerance.Epsilon;

        /// <summary>Friendly name for a violation message, falling back to the materialized
        /// Drawing's own Name (the raw partId string) if this part wasn't in requirements at all -
        /// that mismatch is already reported by ValidateQuantities, so this is display-only.</summary>
        private static string DisplayName(
            Part part,
            IReadOnlyDictionary<Drawing, (string Name, int Quantity)> requirements
        ) =>
            requirements.TryGetValue(part.BaseDrawing, out var requirement)
                ? requirement.Name
                : part.BaseDrawing.Name;

        private const double OutlineTolerance = 0.01;

        private sealed class PartOutline
        {
            public Polygon Perimeter { get; init; }
            public List<Polygon> Holes { get; init; }
        }

        /// <summary>
        /// Extracts a part's material as world-space polygons - the perimeter and
        /// its cutouts - grown by <paramref name="inflateBy"/> (perimeter offset
        /// outward, cutouts offset inward, in one Clipper region offset). A cutout
        /// that closes up under the offset is dropped, which treats it as solid:
        /// conservative, since it has no room for another part at the required
        /// spacing anyway. Arcs are flattened conservatively (perimeter arcs
        /// circumscribed, cutout arcs inscribed) but nothing is padded, so a layout
        /// exactly at the spacing passes; the only leniency is the round-join chord
        /// error at convex corners (OutlineTolerance / 10).
        /// part.Program is already rotated; only a Location offset is needed.
        /// </summary>
        private static PartOutline Outline(Part part, double inflateBy)
        {
            var entities = ConvertProgram
                .ToGeometry(part.Program)
                .Where(e => e.Layer != SpecialLayers.Rapid)
                .ToList();

            if (entities.Count == 0)
                return null;

            var profile = new ShapeProfile(entities);

            if (profile.Perimeter == null)
                return null;

            // Adaptive tolerance instead of Shape.ToPolygon()'s default (up to 1000
            // segments per arc) - arc-heavy real parts otherwise produce thousands
            // of vertices, which is needlessly slow for a spacing check.
            var region = ClipperBridge.OffsetForValidation(
                profile,
                inflateBy > Tolerance.Epsilon ? inflateBy : 0,
                OutlineTolerance
            );

            var perimeter = region.LargestOuter();

            if (perimeter == null)
                return null;

            ToWorld(perimeter, part.Location);

            foreach (var hole in region.Holes)
                ToWorld(hole, part.Location);

            return new PartOutline { Perimeter = perimeter, Holes = region.Holes };
        }

        private static void ToWorld(Polygon polygon, Vector location)
        {
            polygon.Offset(location);
            polygon.UpdateBounds();
        }
    }
}