"""Inspect outboard 2020 brackets without changing the existing 76 mm parts.

Run as a GUI macro via rebuild_shared76_outward_check.FCMacro. All fastener,
slot, phase and motor data remain the documented first-fit assumptions.
"""
from pathlib import Path
import math, time, traceback
import FreeCAD as A
import FreeCADGui as G
import Part, Import
from pivy import coin

R = Path(__file__).resolve().parent.parent
O = R / 'models' / 'shared76_outward_check'
O.mkdir(parents=True, exist_ok=True)
V = A.Vector

def cylinder(r, h, x, y, z):
    return Part.makeCylinder(r, h, V(x,y,z))

def valid(shape):
    return not shape.isNull() and shape.isValid()

def item(doc, name, label, shape, color, transparent=0):
    obj = doc.addObject('PartDesign::Feature', name)
    obj.Label = label
    obj.Shape = shape
    obj.ViewObject.ShapeColor = color
    obj.ViewObject.LineColor = (0.1,0.1,0.1)
    obj.ViewObject.Transparency = transparent
    return obj

try:
    source = A.openDocument(str(R/'models'/'encoder_shared76_print_v1'/'Shared76_Assembly.FCStd'))
    objects = [o for o in source.Objects if hasattr(o, 'Shape') and not o.Shape.isNull()]
    original = {o.Name:o.Shape.copy() for o in objects}
    colors = {o.Name:tuple(o.ViewObject.ShapeColor) for o in objects}
    transparencies = {o.Name:o.ViewObject.Transparency for o in objects}
    labels = {o.Name:o.Label for o in objects}
    A.closeDocument(source.Name)
    names = list(original)
    corners = [n for n in names if n.startswith('Corner')]
    rails = [n for n in names if n.startswith('Rail')]
    frame_name = 'EncoderBracket'
    if len(corners)!=4 or len(rails)!=2 or frame_name not in original:
        raise RuntimeError('Expected existing components were not found: ' + str(names))

    # M4 shaft 3.9 assumed; 9.5x5.5 oval gives 4mm straight travel and
    # 0.8mm radial clearance; 2.75mm shift leaves ~0.05mm at the slot end.
    shifted = {}
    for name in corners+rails:
        shape = original[name].copy()
        x = (shape.BoundBox.XMin+shape.BoundBox.XMax)/2
        direction = -1 if x < 0 else 1
        shape.translate(V(direction*2.75,0,0))
        shifted[name] = shape
    p50 = 25/math.sqrt(2)
    heads = []
    tools = []
    centers=[]
    for side in (-1,1):
        for ysign in (-1,1):
            x, y = side*p50, ysign*p50
            centers.append((x,y))
            heads.append(cylinder(3.5,3,x,y,0))
            # Access envelope: 7.5mm diameter including screw head to lift it,
            # measured from the top of the head through the rear access side.
            tools.append(cylinder(3.75,22,x,y,3.01))

    reports = ['ASSEMBLY STUDY, all dimensions mm.',
               '50 mm screws ARE NOT in the current product; heads are only assumed envelopes Ø7 x 3 at z=0..3.',
               'Corner/rail move ±2.75 in X, encoder, motor and 76 mm fixing studs unchanged.',
               'Oval slot 9.5x5.5, M4 male diameter 3.9 assumed; outer limit clearance 0.05.',
               '50 and 76 mm hole-circle angular phase 45 degrees is assumed.',
               'Screw head zero separation may be intended contact; positive volume indicates interference.',
               '50 mm head versus same-quadrant corner:']
    for i,(x,y) in enumerate(centers):
        matching = min(corners, key=lambda n: (((original[n].BoundBox.XMin+original[n].BoundBox.XMax)/2)-x)**2+(((original[n].BoundBox.YMin+original[n].BoundBox.YMax)/2)-y)**2)
        before=original[matching]; after=shifted[matching]; head=heads[i]
        reports.append('%s (%+.2f,%+.2f) before common=%.4f after common=%.4f mm3; after separation=%.4f mm' %
                       (matching,x,y,before.common(head).Volume,after.common(head).Volume,after.distToShape(head)[0]))

    fixed = [n for n in names if n not in corners+rails]
    collisions=[]
    for c in corners+rails:
        a=shifted[c]
        for n in fixed:
            b=original[n]
            if not a.BoundBox.intersect(b.BoundBox): continue
            volume=a.common(b).Volume
            if volume>.001:collisions.append('%s / %s: %.5f mm3'%(c,n,volume))
    for i,a_name in enumerate(corners):
        for b_name in corners[i+1:]+rails:
            a,b=shifted[a_name],shifted[b_name]
            if a.BoundBox.intersect(b.BoundBox):
                volume=a.common(b).Volume
                if volume>.001:collisions.append('%s / %s: %.5f mm3'%(a_name,b_name,volume))
    reports += ['Shifted corners and rails versus existing components (>0.001mm3):']+(collisions or ['none in checked pairs'])
    for i, tool in enumerate(tools):
        found=[]
        for name in [frame_name]+corners+rails+['PCB','Chip','Holder','Magnet']:
            sh=shifted.get(name,original[name])
            if tool.BoundBox.intersect(sh.BoundBox):
                vol=tool.common(sh).Volume
                if vol>.001:found.append('%s %.3fmm3'%(name,vol))
        reports.append('50 hole %d access envelope Ø7.5 from z=3.01..25.01: %s'%(i, ', '.join(found) if found else 'no checked obstruction'))

    # Separate optional candidate, no mutation of existing printed STL:
    # Ø8 clearance holes allow the assumed Ø7 screw head to pass from behind.
    frame=original[frame_name].copy()
    for x,y in centers:
        frame=frame.cut(cylinder(4,3.24,x,y,11.28))
    frame=frame.removeSplitter()
    if not valid(frame) or len(frame.Solids)!=1:raise RuntimeError('access hole candidate not a valid single solid')
    candidate_hits=[]
    for i,tool in enumerate(tools):
        for name in [frame_name]+corners+rails+['PCB','Chip','Holder','Magnet']:
            sh=frame if name==frame_name else shifted.get(name,original[name])
            if tool.BoundBox.intersect(sh.BoundBox):
                vol=tool.common(sh).Volume
                if vol>.001:candidate_hits.append('hole%d/%s: %.3fmm3'%(i,name,vol))
    reports += ['OPTIONAL Ø8 access holes in encoder bracket, only a concept, NOT a released print file:',
                'Assumed 50 mm head Ø7; fastener head diameter, tool, screw, and wiring need physical verification.',
                'Ø7.5 access envelope candidate:'] + (candidate_hits or ['no checked obstruction'])
    (O/'geometry_check.txt').write_text('\n'.join(reports)+'\n',encoding='utf8')

    def make_doc(name, use_candidate):
        doc=A.newDocument(name)
        colors2={'Motor':(.35,.35,.37),'EncoderBracket':(.16,.43,.85),'PCB':(.04,.65,.22),
                 'Holder':(.98,.55,.10),'Magnet':(.8,.8,.8)}
        items=[]
        for n in names:
            shape=frame if n==frame_name and use_candidate else shifted.get(n,original[n])
            c=colors2.get(n, colors[n])
            items.append(item(doc,n,labels[n],shape,c,75 if n=='Motor' else transparencies[n]))
        # pink marks hypothetical 50-hole heads; omitted from STEP export by design.
        for i,head in enumerate(heads):
            items.append(item(doc,'Assumed50Head%d'%i,'50mm M4 head envelope ONLY - not installed',head,(.85,.15,.62)))
        doc.recompute()
        if any(not valid(o.Shape) for o in items):raise RuntimeError('Invalid object in '+name)
        G.activateWorkbench('PartWorkbench')
        view=G.activeDocument().activeView()
        def render(kind,path):
            if kind=='rear':view.viewTop()
            else:
                view.viewAxonometric();G.updateGui();time.sleep(.4)
                view.getCameraNode().orientation.setValue(coin.SbRotation(.880476,.115917,-.279848,-.364705))
            G.updateGui();time.sleep(.7);view.fitAll();G.updateGui();time.sleep(.7);G.updateGui()
            view.saveImage(str(O/path),1600,1200,'White')
        render('rear',name+'_rear.png')
        render('axon',name+'_axon.png')
        for ob in items:
            if ob.Name.startswith('Assumed50Head'):ob.ViewObject.Visibility=False
        render('axon',name+'_assembly.png')
        for ob in items:
            if ob.Name.startswith('Assumed50Head'):ob.ViewObject.Visibility=True
        doc.recompute();doc.saveAs(str(O/(name+'.FCStd')))
        Import.export([o for o in items if not o.Name.startswith('Assumed50Head')],str(O/(name+'.step')))
        A.closeDocument(doc.Name)
    make_doc('Outward',False)
    make_doc('ServiceHolesConcept',True)
    (O/'DONE.txt').write_text('success\n',encoding='utf8')
except Exception:
    (O/'ERROR.txt').write_text(traceback.format_exc(),encoding='utf8')
    raise