OpenNest/OpenNest.Tests/Engine/MultiPlateNesterTests.cs

using OpenNest.Geometry;
using OpenNest.IO;
using System;
using System.Collections.Generic;
using System.IO;
using System.Linq;
using System.Threading;
using Xunit;
using Xunit.Abstractions;

namespace OpenNest.Tests.Engine;

public class MultiPlateNesterTests
{
    private readonly ITestOutputHelper _output;

    public MultiPlateNesterTests(ITestOutputHelper output)
    {
        _output = output;
    }
    private static Drawing MakeDrawing(string name, double width, double length)
    {
        var program = new OpenNest.CNC.Program();
        program.Codes.Add(new OpenNest.CNC.RapidMove(new Vector(0, 0)));
        program.Codes.Add(new OpenNest.CNC.LinearMove(new Vector(width, 0)));
        program.Codes.Add(new OpenNest.CNC.LinearMove(new Vector(width, length)));
        program.Codes.Add(new OpenNest.CNC.LinearMove(new Vector(0, length)));
        program.Codes.Add(new OpenNest.CNC.LinearMove(new Vector(0, 0)));
        var drawing = new Drawing(name, program);
        drawing.UpdateArea();
        return drawing;
    }

    private static NestItem MakeItem(string name, double width, double length, int qty = 1)
    {
        return new NestItem
        {
            Drawing = MakeDrawing(name, width, length),
            Quantity = qty,
        };
    }

    [Fact]
    public void SortByBoundingBoxArea_OrdersLargestFirst()
    {
        var items = new List<NestItem>
        {
            MakeItem("small", 10, 10),
            MakeItem("large", 40, 60),
            MakeItem("medium", 20, 30),
        };

        var sorted = MultiPlateNester.SortItems(items, PartSortOrder.BoundingBoxArea);

        Assert.Equal("large", sorted[0].Drawing.Name);
        Assert.Equal("medium", sorted[1].Drawing.Name);
        Assert.Equal("small", sorted[2].Drawing.Name);
    }

    [Fact]
    public void SortBySize_OrdersByLongestDimension()
    {
        var items = new List<NestItem>
        {
            MakeItem("short-wide", 50, 20),    // longest = 50
            MakeItem("tall-narrow", 10, 80),    // longest = 80
            MakeItem("square", 30, 30),         // longest = 30
        };

        var sorted = MultiPlateNester.SortItems(items, PartSortOrder.Size);

        Assert.Equal("tall-narrow", sorted[0].Drawing.Name);
        Assert.Equal("short-wide", sorted[1].Drawing.Name);
        Assert.Equal("square", sorted[2].Drawing.Name);
    }

    // --- Task 4: Part Classification ---

    [Fact]
    public void Classify_LargePart_WhenWidthExceedsHalfWorkArea()
    {
        var workArea = new Box(0, 0, 96, 48);
        var bb = new Box(0, 0, 50, 20); // width 50 > half of 96 = 48
        var result = MultiPlateNester.Classify(bb, workArea);
        Assert.Equal(PartClass.Large, result);
    }

    [Fact]
    public void Classify_LargePart_WhenLengthExceedsHalfWorkArea()
    {
        var workArea = new Box(0, 0, 96, 48);
        var bb = new Box(0, 0, 20, 30); // length 30 > half of 48 = 24
        var result = MultiPlateNester.Classify(bb, workArea);
        Assert.Equal(PartClass.Large, result);
    }

    [Fact]
    public void Classify_MediumPart_NotLargeButAreaAboveThreshold()
    {
        var workArea = new Box(0, 0, 96, 48);
        // workArea = 4608, 1/9 = 512. bb = 40*15 = 600 > 512
        // 40 < 48 (half of 96), 15 < 24 (half of 48) — not Large
        var bb = new Box(0, 0, 40, 15);
        var result = MultiPlateNester.Classify(bb, workArea);
        Assert.Equal(PartClass.Medium, result);
    }

    [Fact]
    public void Classify_SmallPart()
    {
        var workArea = new Box(0, 0, 96, 48);
        // workArea = 4608, 1/9 = 512. bb = 10*10 = 100 < 512
        var bb = new Box(0, 0, 10, 10);
        var result = MultiPlateNester.Classify(bb, workArea);
        Assert.Equal(PartClass.Small, result);
    }

    // --- Task 5: Scrap Zone Identification ---

    [Fact]
    public void IsScrapRemnant_BothDimensionsBelowThreshold_ReturnsTrue()
    {
        var remnant = new Box(0, 0, 10, 8);
        Assert.True(MultiPlateNester.IsScrapRemnant(remnant, 12.0));
    }

    [Fact]
    public void IsScrapRemnant_OneDimensionAboveThreshold_ReturnsFalse()
    {
        // 11 x 120 — narrow but long, should be preserved
        var remnant = new Box(0, 0, 11, 120);
        Assert.False(MultiPlateNester.IsScrapRemnant(remnant, 12.0));
    }

    [Fact]
    public void IsScrapRemnant_BothDimensionsAboveThreshold_ReturnsFalse()
    {
        var remnant = new Box(0, 0, 20, 30);
        Assert.False(MultiPlateNester.IsScrapRemnant(remnant, 12.0));
    }

    [Fact]
    public void FindRemnants_ScrapOnly_ReturnsOnlyScrapRemnants()
    {
        // 96x48 plate with a 70x40 part placed at origin
        var plate = new Plate(96, 48) { PartSpacing = 0.25 };
        var drawing = MakeDrawing("big", 70, 40);
        var part = new Part(drawing);
        plate.Parts.Add(part);

        var scrap = MultiPlateNester.FindRemnants(plate, 12.0, scrapOnly: true);

        // All returned zones should have both dims < 12
        foreach (var zone in scrap)
        {
            Assert.True(zone.Width < 12.0 && zone.Length < 12.0,
                $"Zone {zone.Width:F1}x{zone.Length:F1} is not scrap — at least one dimension >= 12");
        }
    }

    // --- Task 6: Plate Creation Helper ---

    [Fact]
    public void CreatePlate_UsesTemplateWhenNoOptions()
    {
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing { Left = 1, Right = 1, Top = 1, Bottom = 1 };

        var plate = MultiPlateNester.CreatePlate(template, null, null);

        Assert.Equal(96, plate.Size.Width);
        Assert.Equal(48, plate.Size.Length);
        Assert.Equal(0.25, plate.PartSpacing);
        Assert.Equal(1, plate.Quadrant);
    }

    [Fact]
    public void CreatePlate_PicksSmallestFittingOption()
    {
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing { Left = 1, Right = 1, Top = 1, Bottom = 1 };

        var options = new List<PlateOption>
        {
            new() { Width = 48, Length = 96, Cost = 100 },
            new() { Width = 60, Length = 120, Cost = 200 },
            new() { Width = 72, Length = 144, Cost = 300 },
        };

        // Part needs 50x50 work area — 48x96 (after edge spacing: 46x94) — 46 < 50, doesn't fit.
        // 60x120 (58x118) does fit.
        var minBounds = new Box(0, 0, 50, 50);

        var plate = MultiPlateNester.CreatePlate(template, options, minBounds);

        Assert.Equal(60, plate.Size.Width);
        Assert.Equal(120, plate.Size.Length);
    }

    [Fact]
    public void EvaluateUpgrade_PrefersCheaperOption()
    {
        var currentOption = new PlateOption { Width = 48, Length = 96, Cost = 100 };
        var upgradeOption = new PlateOption { Width = 60, Length = 120, Cost = 160 };
        var newPlateOption = new PlateOption { Width = 48, Length = 96, Cost = 100 };

        // Upgrade cost = 160 - 100 = 60
        // New plate cost with 50% utilization, 50% salvage:
        // remnantFraction = 0.5, salvageCredit = 0.5 * 100 * 0.5 = 25
        // netNewCost = 100 - 25 = 75
        // Upgrade (60) < new plate (75), so upgrade wins
        var decision = MultiPlateNester.EvaluateUpgradeVsNew(
            currentOption, upgradeOption, newPlateOption, 0.5, 0.5);

        Assert.True(decision.ShouldUpgrade);
    }

    // --- Task 7: Main Orchestration ---

    [Fact]
    public void Nest_LargePartsGetOwnPlates()
    {
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing();

        var items = new List<NestItem>
        {
            MakeItem("big1", 80, 40, 1),
            MakeItem("big2", 70, 35, 1),
        };

        var options = new MultiPlateNestOptions { Template = template };

        var result = MultiPlateNester.Nest(items, options);

        // Each large part should be on its own plate.
        Assert.True(result.Plates.Count >= 2,
            $"Expected at least 2 plates, got {result.Plates.Count}");
    }

    [Fact]
    public void Nest_SmallPartsConsolidateOntoSharedPlates()
    {
        // Small parts should be packed together on shared plates rather than
        // each drawing getting its own plate. The consolidation pass fills
        // small parts into remaining space on existing plates.
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing();

        var items = new List<NestItem>
        {
            MakeItem("big", 80, 40, 1),
            MakeItem("tinyA", 5, 5, 3),
            MakeItem("tinyB", 4, 4, 3),
        };

        var options = new MultiPlateNestOptions { Template = template };

        var result = MultiPlateNester.Nest(items, options);

        // Both small drawing types should share space — not each on their own plate.
        // With consolidation, they pack into remaining space alongside the big part.
        Assert.True(result.Plates.Count <= 2,
            $"Expected at most 2 plates (small parts consolidated), got {result.Plates.Count}");
        Assert.Equal(0, result.UnplacedItems.Count);
    }

    [Fact]
    public void Nest_RespectsAllowPlateCreation()
    {
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing();

        var items = new List<NestItem>
        {
            MakeItem("big1", 80, 40, 1),
            MakeItem("big2", 70, 35, 1),
        };

        var options = new MultiPlateNestOptions
        {
            Template = template,
            AllowPlateCreation = false,
        };

        var result = MultiPlateNester.Nest(items, options);

        // No existing plates and no plate creation — nothing can be placed.
        Assert.Empty(result.Plates);
        Assert.Equal(2, result.UnplacedItems.Count);
    }

    [Fact]
    public void Nest_UsesExistingPlates()
    {
        var template = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        template.EdgeSpacing = new Spacing();

        var existingPlate = new Plate(96, 48) { PartSpacing = 0.25, Quadrant = 1 };
        existingPlate.EdgeSpacing = new Spacing();

        // Use a part small enough to be classified as Medium on a 96x48 plate.
        // Plate WorkArea: Width=96, Length=48. Half: 48, 24.
        // Part 24x22: Length=24 (not > 24), Width=22 (not > 48) — not Large.
        // Area = 528 > 4608/9 = 512 — Medium.
        var items = new List<NestItem>
        {
            MakeItem("medium", 24, 22, 1),
        };

        var options = new MultiPlateNestOptions { Template = template };

        var result = MultiPlateNester.Nest(items, options,
            existingPlates: new List<Plate> { existingPlate });

        // Part should be placed on the existing plate, not a new one.
        Assert.Single(result.Plates);
        Assert.False(result.Plates[0].IsNew);
    }

    [Fact]
    public void Nest_RealNestFile_PartFirst()
    {
        var nestPath = @"C:\Users\aisaacs\Desktop\4526 A14 - 0.188 AISI 304.nest";
        if (!File.Exists(nestPath))
        {
            _output.WriteLine("SKIP: nest file not found");
            return;
        }

        var nest = new NestReader(nestPath).Read();
        var template = nest.PlateDefaults.CreateNew();

        _output.WriteLine($"Plate: {template.Size.Width}x{template.Size.Length}, " +
            $"spacing={template.PartSpacing}, edge=({template.EdgeSpacing.Left},{template.EdgeSpacing.Bottom},{template.EdgeSpacing.Right},{template.EdgeSpacing.Top})");

        var wa = template.WorkArea();
        _output.WriteLine($"Work area: {wa.Width:F1}x{wa.Length:F1}");
        _output.WriteLine($"Classification thresholds: Large if dim > {wa.Width / 2:F1} or {wa.Length / 2:F1}, " +
            $"Medium if area > {wa.Width * wa.Length / 9:F0}");
        _output.WriteLine("---");

        var items = new List<NestItem>();
        foreach (var d in nest.Drawings)
        {
            var qty = d.Quantity.Required > 0 ? d.Quantity.Required : d.Quantity.Remaining;
            if (qty <= 0) qty = 1;

            var bb = d.Program.BoundingBox();
            var classification = MultiPlateNester.Classify(bb, wa);

            _output.WriteLine($"  {d.Name,-25} {bb.Width:F1}x{bb.Length:F1} (area={bb.Width * bb.Length:F0})  qty={qty}  class={classification}");

            items.Add(new NestItem
            {
                Drawing = d,
                Quantity = qty,
                StepAngle = d.Constraints.StepAngle,
                RotationStart = d.Constraints.StartAngle,
                RotationEnd = d.Constraints.EndAngle,
            });
        }

        _output.WriteLine("---");
        _output.WriteLine($"Total: {items.Count} drawings, {items.Sum(i => i.Quantity)} parts");

        var plateOptions = new List<PlateOption>
        {
            new() { Width = 48, Length = 96, Cost = 0 },
            new() { Width = 48, Length = 120, Cost = 0 },
            new() { Width = 48, Length = 144, Cost = 0 },
            new() { Width = 60, Length = 96, Cost = 0 },
            new() { Width = 60, Length = 120, Cost = 0 },
            new() { Width = 60, Length = 144, Cost = 0 },
            new() { Width = 72, Length = 96, Cost = 0 },
            new() { Width = 72, Length = 120, Cost = 0 },
            new() { Width = 72, Length = 144, Cost = 0 },
        };

        _output.WriteLine($"Plate options: {string.Join(", ", plateOptions.Select(o => $"{o.Width}x{o.Length}"))}");
        _output.WriteLine("");

        var options = new MultiPlateNestOptions
        {
            Template = template,
            PlateOptions = plateOptions,
        };

        var result = MultiPlateNester.Nest(items, options);

        _output.WriteLine($"=== RESULTS: {result.Plates.Count} plates ===");

        for (var i = 0; i < result.Plates.Count; i++)
        {
            var pr = result.Plates[i];
            var groups = pr.Parts.GroupBy(p => p.BaseDrawing.Name)
                .Select(g => $"{g.Key} x{g.Count()}")
                .ToList();
            _output.WriteLine($"  Plate {i + 1} ({pr.Plate.Size.Width}x{pr.Plate.Size.Length}): " +
                $"{pr.Parts.Count} parts, util={pr.Plate.Utilization():P1}  [{string.Join(", ", groups)}]");
        }

        if (result.UnplacedItems.Count > 0)
        {
            _output.WriteLine($"  Unplaced: {string.Join(", ", result.UnplacedItems.Select(i => $"{i.Drawing.Name} x{i.Quantity}"))}");
        }

        _output.WriteLine($"\nTotal parts placed: {result.Plates.Sum(p => p.Parts.Count)}");
        _output.WriteLine($"Total plates used: {result.Plates.Count}");
    }
}