OpenNest/OpenNest.Engine/Jobs/ClampRemovalRecovery.cs

using System;
using System.Collections.Generic;
using System.Linq;
using System.Threading;

namespace OpenNest.Engine.Jobs;

/// <summary>
/// D8/D9 last-resort clamp removal for the whole-job pipeline. After a normal clamped solve
/// leaves demand unmet, finds parts that cannot fit anywhere with every clamp in place (C10),
/// computes the fewest clamps whose removal lets each one fit (C11), and re-solves the
/// residual demand on stock variants with those clamps taken off (C12). Never changes the
/// result when nothing is blocked (C10's bit-identical guarantee) and never trades a removal
/// for material savings - it only runs after the ordinary solve could not place a part.
/// </summary>
internal static class ClampRemovalRecovery
{
    /// <summary>A result that replaces the caller's raw solve, and the expanded job it was
    /// validated against (the caller's own stock plus the reduced-clamp variants used).</summary>
    internal sealed record Outcome(NestJob Job, NestJobResult Result);

    /// <summary>
    /// Null when there is nothing to recover: the job is already complete, no offered stock
    /// has any clamp, no remaining part is genuinely clamp-blocked, or removing clamps did
    /// not let anything new fit. Callers keep their original job/result unchanged in every
    /// one of those cases (C10).
    /// </summary>
    internal static Outcome TryRecover(
        NestJob job,
        NestJobResult raw,
        INestingEngine engine,
        CancellationToken token
    )
    {
        ArgumentNullException.ThrowIfNull(job);
        ArgumentNullException.ThrowIfNull(raw);
        ArgumentNullException.ThrowIfNull(engine);

        // Recovery is optional: any failure inside it (a throwing probe or residual solve)
        // keeps the caller's ordinary result instead of discarding it. Cancellation still
        // propagates.
        try
        {
            return Recover(job, raw, engine, token);
        }
        catch (Exception exception) when (exception is not OperationCanceledException)
        {
            token.ThrowIfCancellationRequested();
            return null;
        }
    }

    private static Outcome Recover(NestJob job, NestJobResult raw, INestingEngine engine, CancellationToken token)
    {
        if (raw.Status == NestJobStatus.Complete)
            return null;

        var availableStock = job.Plates.Where(s => s.Quantity != 0).ToList();
        if (!availableStock.Any(CanRemoveClamps))
            return null;

        var partsById = job.Parts.ToDictionary(p => p.Id, StringComparer.Ordinal);
        var remaining = raw.Fulfillment
            .Where(f => f.Unplaced > 0)
            .Select(f => (Part: partsById[f.PartId], Unplaced: f.Unplaced))
            .ToList();
        if (remaining.Count == 0)
            return null;

        token.ThrowIfCancellationRequested();

        // C10: only a part that fits nowhere with every clamp in place is "blocked". One
        // lane's failure is not proof: a part any built-in lane can place clamped is not.
        var lanes = FeasibilityLanes(engine);
        var blocked = remaining
            .Where(x => !lanes.Any(lane => FitsAnywhere(x.Part, availableStock, job.Options, lane, token)))
            .Select(x => x.Part)
            .ToList();
        if (blocked.Count == 0)
            return null;

        // C11: per blocked part, the fewest clamps (smallest contiguous run, nearest the
        // origin on ties) whose removal frees an empty sheet of some offered stock. Parts
        // needing the same removal on the same stock share one variant.
        var groups = new List<RemovalGroup>();
        foreach (var part in blocked)
        {
            token.ThrowIfCancellationRequested();
            var best = BestRemoval(part, availableStock, job.Options, lanes, token);
            if (best == null)
                continue; // Unfit even with every clamp removed: stays unplaced, as today.
            var group = groups.FirstOrDefault(g => g.Removal.Stock.Id == best.Stock.Id);
            if (group == null)
                groups.Add(group = new RemovalGroup(best));
            group.BlockedIds.Add(part.Id);
        }
        if (groups.Count == 0)
            return null;

        // Phase 2, one removal variant at a time, fewest removed clamps first: each variant
        // takes its own blocked parts plus any other unmet demand that is not blocked (freed
        // space may take other parts, C12). A sheet is kept only when it holds a part that
        // needed exactly this removal (C10/C11 per sheet), and every kept sheet comes out of
        // its base stock's remaining physical pool (C12: a finite pool is never exceeded).
        var unmet = remaining.ToDictionary(x => x.Part.Id, x => x.Unplaced, StringComparer.Ordinal);
        var blockedIds = new HashSet<string>(groups.SelectMany(g => g.BlockedIds), StringComparer.Ordinal);
        var pool = availableStock.ToDictionary(
            s => s.Id,
            s => s.Quantity is int q ? q - raw.StockUsage.Where(u => u.StockId == s.Id).Sum(u => u.Used) : (int?)null,
            StringComparer.Ordinal);
        int? platesLeft = job.Options.MaxPlates is int cap ? cap - raw.Plates.Count : null;

        var recovered = new List<(NestPlateStock Variant, string BaseId, List<NestJobPlateResult> Sheets)>();
        foreach (var group in groups.OrderBy(g => g.Removal.RemovedIds.Count))
        {
            token.ThrowIfCancellationRequested();
            var baseId = group.Removal.BaseStockId;
            var available = pool[baseId];
            if (available <= 0 || platesLeft <= 0)
                continue;
            int? sheetCap = (available, platesLeft) switch
            {
                (int a, int p) => System.Math.Min(a, p),
                (int a, null) => a,
                (null, int p) => p,
                _ => null,
            };

            var parts = remaining
                .Where(x => unmet[x.Part.Id] > 0
                    && (group.BlockedIds.Contains(x.Part.Id) || !blockedIds.Contains(x.Part.Id)))
                .Select(x => new NestJobPart(x.Part.Id, x.Part.Geometry, unmet[x.Part.Id], x.Part.Priority, x.Part.Rotation))
                .ToList();
            if (!parts.Any(p => group.BlockedIds.Contains(p.Id)))
                continue;

            var variant = Clone(group.Removal.Stock, group.Removal.Stock.Id, sheetCap, null);
            var options = new NestJobOptions(job.Options.PlacementStrategy, platesLeft,
                job.Options.SalvageRate, job.Options.MinimumSalvageDimension);
            var groupJob = new NestJob(parts, new[] { variant }, options);

            List<NestJobPlateResult> kept = null;
            foreach (var lane in lanes)
            {
                token.ThrowIfCancellationRequested();
                var solved = lane.Solve(groupJob, null, token);
                token.ThrowIfCancellationRequested();
                kept = solved?.Plates
                    .Where(sheet => sheet.Placements.Any(p => group.BlockedIds.Contains(p.PartId)))
                    .Take(sheetCap ?? int.MaxValue)
                    .ToList();
                if (kept is { Count: > 0 })
                    break;
            }
            if (kept is not { Count: > 0 })
                continue;

            foreach (var placement in kept.SelectMany(sheet => sheet.Placements))
                unmet[placement.PartId]--;
            if (pool[baseId] is int left)
                pool[baseId] = left - kept.Count;
            if (platesLeft is int plates)
                platesLeft = plates - kept.Count;
            recovered.Add((group.Removal.Stock, baseId, kept));
        }
        if (recovered.Count == 0)
            return null;

        return Merge(job, raw, recovered);
    }

    private sealed class RemovalGroup(Removal removal)
    {
        public Removal Removal { get; } = removal;
        public HashSet<string> BlockedIds { get; } = new(StringComparer.Ordinal);
    }

    /// <summary>
    /// Engines whose placement of a lone part proves it fits (C10): the caller's own engine,
    /// plus the built-in Irregular (NFP, true material) and Rectangles lanes. Default already
    /// runs both, so it is enough on its own. Phase 2 tries them in this order too.
    /// </summary>
    private static IReadOnlyList<INestingEngine> FeasibilityLanes(INestingEngine engine)
    {
        if (engine is NestingEngines.Default.DefaultNestingEngine)
            return new[] { engine };
        var lanes = new List<INestingEngine> { engine };
        if (engine is not NestingEngines.Irregular.IrregularNestingEngine)
            lanes.Add(new NestingEngines.Irregular.IrregularNestingEngine());
        if (engine is not NestingEngines.Rectangles.RectanglesNestingEngine)
            lanes.Add(new NestingEngines.Rectangles.RectanglesNestingEngine());
        return lanes;
    }

    private sealed record Removal(NestPlateStock Stock, string BaseStockId, IReadOnlyList<string> RemovedIds);

    /// <summary>The (stock, removal) with the fewest removed clamps across every offered
    /// rail-backed stock; ties prefer the stock listed earliest.</summary>
    private static Removal BestRemoval(
        NestJobPart part,
        IReadOnlyList<NestPlateStock> stocks,
        NestJobOptions options,
        IReadOnlyList<INestingEngine> lanes,
        CancellationToken token
    )
    {
        Removal best = null;
        foreach (var stock in stocks)
        {
            if (!CanRemoveClamps(stock))
                continue;
            token.ThrowIfCancellationRequested();
            var found = MinimalRemovalForStock(part, stock, options, lanes, token);
            if (found == null)
                continue;
            if (best == null || found.RemovedIds.Count < best.RemovedIds.Count)
                best = found;
        }
        return best;
    }

    /// <summary>Only clamps resolved from a machine rail can be removed (see
    /// <see cref="NestPlateStock.ClampRail"/>): explicit zones have no clamp to name.</summary>
    private static bool CanRemoveClamps(NestPlateStock stock) =>
        stock.ClampRail != null && stock.ClampZones.Count > 0;

    /// <summary>
    /// Ascending run size, then ascending start index: the first contiguous run of the
    /// stock's own clamp zones, ordered by distance from the origin along the edge, whose
    /// removal lets the part fit alone (in any lane) is both the fewest clamps and, among
    /// ties, the run nearest the origin.
    /// </summary>
    private static Removal MinimalRemovalForStock(
        NestJobPart part,
        NestPlateStock stock,
        NestJobOptions options,
        IReadOnlyList<INestingEngine> lanes,
        CancellationToken token
    )
    {
        // Placement-frame X is signed from the origin, so |centre X| is the distance along
        // the edge in every quadrant.
        var zones = stock.ClampZones
            .OrderBy(z => System.Math.Abs(z.Bounds.X + z.Bounds.Length / 2))
            .ToList();
        for (var run = 1; run <= zones.Count; run++)
        {
            for (var start = 0; start + run <= zones.Count; start++)
            {
                token.ThrowIfCancellationRequested();
                var removedIds = zones.Skip(start).Take(run).Select(z => z.Id).ToList();
                var candidate = Clone(stock, Suffixed(stock.Id, removedIds), null, removedIds);
                if (lanes.Any(lane => FitsAlone(part, candidate, options, lane, token)))
                    return new Removal(candidate, stock.Id, removedIds);
            }
        }
        return null;
    }

    private static bool FitsAlone(
        NestJobPart part,
        NestPlateStock stock,
        NestJobOptions options,
        INestingEngine engine,
        CancellationToken token
    ) => Probe(part, new[] { stock }, options, engine, token);

    private static bool FitsAnywhere(
        NestJobPart part,
        IReadOnlyList<NestPlateStock> stocks,
        NestJobOptions options,
        INestingEngine engine,
        CancellationToken token
    ) => Probe(part, stocks, options, engine, token);

    /// <summary>Whether this part, alone and at quantity one, places on an empty sheet of any
    /// of the given stock entries with the given engine.</summary>
    private static bool Probe(
        NestJobPart part,
        IReadOnlyList<NestPlateStock> stocks,
        NestJobOptions options,
        INestingEngine engine,
        CancellationToken token
    )
    {
        var probePart = new NestJobPart(part.Id, part.Geometry, 1, part.Priority, part.Rotation);
        var probeStock = stocks.Select(s => Unlimited(s)).ToList();
        var probeOptions = new NestJobOptions(options.PlacementStrategy, 1, 0, 0);
        var probeJob = new NestJob(new[] { probePart }, probeStock, probeOptions);
        token.ThrowIfCancellationRequested();
        var result = engine.Solve(probeJob, null, token);
        return result != null && result.Status == NestJobStatus.Complete;
    }

    /// <summary>Same stock with unlimited quantity (feasibility probes never consume real
    /// inventory); id/zones unchanged.</summary>
    private static NestPlateStock Unlimited(NestPlateStock stock) =>
        stock.Quantity == null ? stock : Clone(stock, stock.Id, null, null);

    /// <summary>
    /// A copy of <paramref name="stock"/> with a new id/quantity and, when
    /// <paramref name="removedIds"/> is given, those clamp zones dropped. Built from the
    /// stock's own sheet-frame zones, so the kept zones are bit-identical to the original's.
    /// </summary>
    private static NestPlateStock Clone(
        NestPlateStock stock,
        string id,
        int? quantity,
        IReadOnlyCollection<string> removedIds
    )
    {
        var sheetZones = stock.SheetClampZones
            .Where(z => removedIds == null || !removedIds.Contains(z.Id))
            .ToList();
        return new NestPlateStock(
            id,
            stock.Size,
            quantity,
            stock.PartSpacing,
            stock.EdgeSpacing,
            stock.Quadrant,
            stock.Cost,
            sheetZones
        )
        { ClampRail = stock.ClampRail };
    }

    private static string Suffixed(string stockId, IReadOnlyList<string> removedIds) =>
        $"{stockId}::removed:{string.Join(",", removedIds)}";

    /// <summary>
    /// Combines the ordinary solve with the kept recovery sheets into one result, and the
    /// expanded job it validates against: the caller's stock with each finite base reduced
    /// by the sheets its variants took, plus each variant with exactly the sheets it used
    /// (unlimited when its base is), so the expanded inventory equals the physical one.
    /// Recovery placements get fresh instance indices continuing on from phase 1's.
    /// </summary>
    private static Outcome Merge(
        NestJob job,
        NestJobResult raw,
        IReadOnlyList<(NestPlateStock Variant, string BaseId, List<NestJobPlateResult> Sheets)> recovered
    )
    {
        var placedSoFar = raw.Fulfillment.ToDictionary(f => f.PartId, f => f.Placed, StringComparer.Ordinal);
        var nextPlateIndex = raw.Plates.Count;
        var reindexed = new List<NestJobPlateResult>();
        var variantStock = new List<NestPlateStock>();
        var takenFromBase = new Dictionary<string, int>(StringComparer.Ordinal);
        foreach (var (variant, baseId, sheets) in recovered)
        {
            var baseStock = job.Plates.First(s => s.Id == baseId);
            var used = Clone(variant, variant.Id, baseStock.Quantity == null ? null : sheets.Count, null);
            variantStock.Add(used);
            takenFromBase[baseStock.Id] = takenFromBase.GetValueOrDefault(baseStock.Id) + sheets.Count;
            foreach (var sheet in sheets)
            {
                var placements = new List<NestJobPlacement>(sheet.Placements.Count);
                foreach (var pose in sheet.Placements)
                {
                    var index = placedSoFar.GetValueOrDefault(pose.PartId);
                    placedSoFar[pose.PartId] = index + 1;
                    placements.Add(pose with { InstanceIndex = index });
                }
                reindexed.Add(new NestJobPlateResult(nextPlateIndex++, used, placements));
            }
        }

        var allPlates = raw.Plates.Concat(reindexed).ToList();
        var fulfillment = job.Parts
            .Select(p =>
            {
                var placed = placedSoFar.GetValueOrDefault(p.Id);
                return new PartFulfillment(p.Id, p.Quantity, placed, p.Quantity - placed);
            })
            .ToList();

        var used1 = new Dictionary<string, int>(StringComparer.Ordinal);
        foreach (var u in raw.StockUsage)
            used1[u.StockId] = used1.GetValueOrDefault(u.StockId) + u.Used;

        var expandedStock = job.Plates
            .Select(s => s.Quantity is int q && takenFromBase.TryGetValue(s.Id, out var taken)
                ? Clone(s, s.Id, q - taken, null)
                : s)
            .Concat(variantStock)
            .ToList();
        var stockUsage = expandedStock
            .Select(s =>
            {
                var usedCount = used1.GetValueOrDefault(s.Id) + reindexed.Count(p => p.StockId == s.Id);
                return new StockUsage(s.Id, usedCount, s.Quantity is int q ? q - usedCount : null);
            })
            .ToList();

        var complete = fulfillment.All(f => f.Unplaced == 0);
        var status = complete ? NestJobStatus.Complete : raw.Status;
        var stopReason = complete ? NestJobStopReason.Completed : raw.StopReason;

        var expandedJob = new NestJob(job.Parts, expandedStock, job.Options);
        var result = new NestJobResult(status, stopReason, allPlates, fulfillment, stockUsage);
        return new Outcome(expandedJob, result);
    }
}