reducers/backend/src/physical_validators/base.py

from __future__ import annotations

import math
from dataclasses import dataclass
from typing import Any, Protocol

from ..models import (
    AssemblySnapshot,
    ComponentManifest,
    PhysicalRelation,
    ReducerInstance,
    ValidationCheck,
)


@dataclass(frozen=True)
class PhysicalValidationContext:
    instance: ReducerInstance
    snapshot: AssemblySnapshot

    def component(self, component_id: str) -> ComponentManifest | None:
        return self.snapshot.manifest.components.get(component_id)

    def component_exists(self, component_id: str) -> bool:
        return (
            component_id in self.snapshot.manifest.components
            and component_id in self.snapshot.components_from_model
        )

    def placement_origin(self, component_id: str) -> list[float] | None:
        origin = self.snapshot.component_placements.get(component_id, {}).get("origin")
        if origin is None:
            component = self.component(component_id)
            if component is None:
                return None
            origin = component.center_xyz_mm
        return [float(value) for value in origin]


class PhysicalRelationValidator(Protocol):
    relation_type: str

    def validate(
        self,
        context: PhysicalValidationContext,
        relation: PhysicalRelation,
        checks: list[ValidationCheck],
    ) -> None:
        ...


def add_check(
    checks: list[ValidationCheck],
    *,
    section: str,
    code: str,
    passed: bool,
    message: str,
    actual: Any | None = None,
    expected: Any | None = None,
) -> None:
    checks.append(
        ValidationCheck(
            section=section,
            code=code,
            passed=bool(passed),
            message=message,
            actual=actual,
            expected=expected,
        )
    )


def relation_code(relation: PhysicalRelation, suffix: str) -> str:
    return f"industrial.{relation.relation_type}.{relation.relation_id}.{suffix}"


def xy_distance(a: list[float], b: list[float]) -> float:
    return math.hypot(a[0] - b[0], a[1] - b[1])


def xy_radius(origin: list[float]) -> float:
    return math.hypot(origin[0], origin[1])


def planet_bore_diameter_mm(context: PhysicalValidationContext) -> float:
    derived = context.instance.derived
    return 2.0 * (max(0.6, min(2.0, derived.planet_pitch_radius_mm * 0.22)) + 0.25)


def relation_manifest_constraints(
    context: PhysicalValidationContext,
    relation: PhysicalRelation,
) -> list[Any]:
    pair = {relation.source_component_id, relation.target_component_id}
    matches = []
    for constraint in context.snapshot.manifest.constraints:
        if constraint.relation_id == relation.relation_id or constraint.constraint_id == relation.relation_id:
            matches.append(constraint)
            continue
        if constraint.relation_type != relation.relation_type:
            continue
        if {constraint.component_a, constraint.component_b} == pair:
            matches.append(constraint)
    return matches


def constraint_id_in_model(context: PhysicalValidationContext, constraint_id: str, relation_type: str) -> bool:
    if relation_type == "bearing_revolute":
        return constraint_id in context.snapshot.revolute_constraints
    if relation_type in {"rigid", "bolted", "press_fit", "slip_fit", "axial_retention", "bearing_support", "coaxial", "keyed"}:
        return constraint_id in context.snapshot.fixed_constraints
    return False


def add_common_relation_checks(
    context: PhysicalValidationContext,
    relation: PhysicalRelation,
    checks: list[ValidationCheck],
    *,
    extra_components: list[str] | None = None,
) -> list[Any]:
    component_ids = [relation.source_component_id, relation.target_component_id] + list(extra_components or [])
    missing = [component_id for component_id in component_ids if not context.component_exists(component_id)]
    add_check(
        checks,
        section="assembly",
        code=relation_code(relation, "component_exists"),
        passed=not missing,
        message="all physical relation components exist in manifest and model",
        actual=missing,
        expected=[],
    )

    matches = relation_manifest_constraints(context, relation)
    add_check(
        checks,
        section="assembly",
        code=relation_code(relation, "manifest_relation_exists"),
        passed=bool(matches),
        message="physical relation is represented in the assembly manifest",
        actual=[match.constraint_id for match in matches],
        expected=relation.relation_id,
    )

    model_or_semantic = any(
        match.source == "formula_semantic"
        or match.cad_constraint_kind is None
        or constraint_id_in_model(context, match.constraint_id, relation.relation_type)
        for match in matches
    )
    add_check(
        checks,
        section="assembly",
        code=relation_code(relation, "model_constraint_or_semantic_exists"),
        passed=model_or_semantic,
        message="physical relation has a real CAD constraint or explicit formula semantic manifest entry",
        actual=[
            {
                "constraint_id": match.constraint_id,
                "source": match.source,
                "cad_constraint_kind": match.cad_constraint_kind,
            }
            for match in matches
        ],
        expected="simplecadapi constraint or formula_semantic",
    )
    return matches


class BasePhysicalRelationValidator:
    relation_type: str

    def validate(
        self,
        context: PhysicalValidationContext,
        relation: PhysicalRelation,
        checks: list[ValidationCheck],
    ) -> None:
        add_common_relation_checks(context, relation, checks)