pdf2cad/src/pdf2imos/reconstruct/assembler.py

"""Part geometry assembly from orthographic dimension measurements."""
import logging

from pdf2imos.models import (
    DimensionAnnotation,
    DimensionDirection,
    PartGeometry,
    ViewRegion,
    ViewType,
)

logger = logging.getLogger(__name__)


def assemble_part_geometry(
    views: list[ViewRegion],
    dimensions: dict[ViewType, list[DimensionAnnotation]],
    part_name: str = "unknown",
    tolerance_mm: float = 0.5,
) -> PartGeometry | None:
    """Assemble W×H×D dimensions from orthographic views into PartGeometry.

    Args:
        views: ViewRegion list from segment_views()
        dimensions: Dict mapping ViewType → list of DimensionAnnotations for that view
        part_name: Name for the part (from title block)
        tolerance_mm: Cross-validation tolerance in mm

    Returns:
        PartGeometry or None if assembly fails
    """
    if not dimensions:
        logger.error("No dimensions provided for assembly")
        return None

    # Extract dimensions by view
    front_dims = dimensions.get(ViewType.FRONT, [])
    side_dims = dimensions.get(ViewType.SIDE, [])
    top_dims = dimensions.get(ViewType.TOP, [])

    # Fall back: if no view-specific dims, use all dims combined
    all_dims: list[DimensionAnnotation] = []
    for dims in dimensions.values():
        all_dims.extend(dims)

    if not all_dims:
        logger.error("No dimension annotations available")
        return None

    # Extract W, H, D
    width_mm = _extract_dimension(
        front_dims or all_dims, DimensionDirection.HORIZONTAL, "width"
    )
    height_mm = _extract_dimension(
        front_dims or all_dims, DimensionDirection.VERTICAL, "height"
    )

    # For depth: prefer side view horizontal, then top view vertical, then smallest dim
    depth_mm: float | None = None
    if side_dims:
        depth_mm = _extract_dimension(
            side_dims, DimensionDirection.HORIZONTAL, "depth"
        )
        if depth_mm is None:
            depth_mm = _extract_dimension(
                side_dims, DimensionDirection.VERTICAL, "depth"
            )
    elif top_dims:
        depth_mm = _extract_dimension(
            top_dims, DimensionDirection.VERTICAL, "depth"
        )
        # Sanity check: if depth from top view matches height, it's misattributed
        if (
            depth_mm is not None
            and height_mm is not None
            and abs(depth_mm - height_mm) < tolerance_mm
        ):
            logger.debug(
                "Top view depth (%s) matches height — seeking alternative", depth_mm
            )
            depth_mm = _extract_smallest_remaining(
                top_dims, exclude={width_mm, height_mm}
            )

    if depth_mm is None:
        # No dedicated view or sanity check failed: use smallest remaining
        depth_mm = _extract_smallest_remaining(
            all_dims, exclude={width_mm, height_mm}
        )

    if width_mm is None or height_mm is None:
        logger.error("Cannot assemble: width=%s, height=%s", width_mm, height_mm)
        return None

    if depth_mm is None:
        logger.warning("Depth not found — defaulting to 18mm")
        depth_mm = 18.0

    # Cross-validate
    _cross_validate(
        front_dims, side_dims, top_dims,
        width_mm, height_mm, depth_mm, tolerance_mm,
    )

    logger.info(
        "Assembled: %s×%s×%smm (W×H×D)", width_mm, height_mm, depth_mm
    )

    return PartGeometry(
        width_mm=width_mm,
        height_mm=height_mm,
        depth_mm=depth_mm,
        origin=(0.0, 0.0, 0.0),
        name=part_name,
    )


def _extract_dimension(
    dims: list[DimensionAnnotation],
    direction: DimensionDirection,
    dim_name: str,
) -> float | None:
    """Extract the largest dimension of a given direction (primary/overall dimension).

    Returns the largest value of matching direction, or None if none found.
    """
    matching = [d for d in dims if d.direction == direction]

    if not matching:
        # If no exact direction match, try all dims and pick the largest
        logger.debug(
            "No %s dimension found for %s, using all", direction.name, dim_name
        )
        matching = dims

    if not matching:
        return None

    # Return the largest dimension (overall/total, not partial)
    return max(d.value_mm for d in matching)


def _extract_smallest_remaining(
    dims: list[DimensionAnnotation],
    exclude: set[float | None],
) -> float | None:
    """Extract the smallest dimension value not in the exclude set."""
    values = sorted(d.value_mm for d in dims if d.value_mm not in exclude)
    return values[0] if values else None


def _cross_validate(
    front_dims: list[DimensionAnnotation],
    side_dims: list[DimensionAnnotation],
    top_dims: list[DimensionAnnotation],
    width: float,
    height: float,
    depth: float,
    tolerance: float,
) -> None:
    """Cross-validate dimensions from different views and log warnings/info."""
    # Check front height ≈ side height
    if front_dims and side_dims:
        front_heights = [
            d.value_mm for d in front_dims
            if d.direction == DimensionDirection.VERTICAL
        ]
        side_heights = [
            d.value_mm for d in side_dims
            if d.direction == DimensionDirection.VERTICAL
        ]
        if front_heights and side_heights:
            front_h = max(front_heights)
            side_h = max(side_heights)
            if abs(front_h - side_h) <= tolerance:
                logger.info(
                    "Cross-validation: front H (%smm) ≈ side H (%smm) ✓",
                    front_h, side_h,
                )
            else:
                logger.warning(
                    "Cross-validation: front H (%smm) ≠ side H (%smm) — using front",
                    front_h, side_h,
                )

    # Check front width ≈ top width
    if front_dims and top_dims:
        front_widths = [
            d.value_mm for d in front_dims
            if d.direction == DimensionDirection.HORIZONTAL
        ]
        top_widths = [
            d.value_mm for d in top_dims
            if d.direction == DimensionDirection.HORIZONTAL
        ]
        if front_widths and top_widths:
            front_w = max(front_widths)
            top_w = max(top_widths)
            if abs(front_w - top_w) <= tolerance:
                logger.info(
                    "Cross-validation: front W (%smm) ≈ top W (%smm) ✓",
                    front_w, top_w,
                )
            else:
                logger.warning(
                    "Cross-validation: front W (%smm) ≠ top W (%smm) — using front",
                    front_w, top_w,
                )