busbar-designer/holder.py

"""Generate hex cell holder STL via OpenSCAD subprocess.

We embed Addy's hex_cell.scad (in scad/) and shell out to `openscad` with
parameter overrides via `-D var=value`. STL bytes come back from a temp file.

Cell-center coordinates are derived in *Python* using the same formulas
the .scad file uses (see static/js/importer.js for the JS mirror). That avoids
a second OpenSCAD invocation just to echo coordinates and matches the math
exactly — see `hex_holder_geometry` memory for the formulas.
"""

from __future__ import annotations

import json
import math
import os
import re
import shutil
import subprocess
import tempfile
from dataclasses import dataclass, field
from pathlib import Path
from typing import Any

# ---------------------------------------------------------------------------
# Locations / config
# ---------------------------------------------------------------------------

APP_DIR = Path(__file__).resolve().parent
SCAD_FILE = APP_DIR / "scad" / "hex_cell.scad"
OPENSCAD_BIN = os.environ.get("OPENSCAD_BIN", "openscad")
# Empty string disables; default Manifold gives ~10-50x speedup on OpenSCAD 2024+
OPENSCAD_BACKEND = os.environ.get("OPENSCAD_BACKEND", "Manifold")
RENDER_TIMEOUT = int(os.environ.get("OPENSCAD_TIMEOUT", "300"))
# Cap total cells to keep renders fast and STL sizes sane. 1000 covers
# real packs (e.g. 20×50 = 1000) while blocking accidental 120×120 = 14400.
MAX_CELLS = int(os.environ.get("HOLDER_MAX_CELLS", "1000"))


def openscad_available() -> bool:
    return shutil.which(OPENSCAD_BIN) is not None


# ---------------------------------------------------------------------------
# Parameter schema — exposed to the frontend for auto-form generation.
# Only the subset users typically touch; the .scad itself has many more knobs
# that fall back to script defaults.
# ---------------------------------------------------------------------------


@dataclass
class Param:
    name: str            # SCAD variable name
    label: str           # UI label
    kind: str            # "number" | "select" | "bool"
    default: Any
    group: str = "main"
    options: list[str] | None = None   # for kind="select"
    min: float | None = None           # for kind="number"
    max: float | None = None
    step: float | None = None
    help: str | None = None


# ----- automated scan of the bundled .scad ----------------------------------
# We extract top-level `name = literal;  // help` lines into Param entries.
# Lines whose RHS isn't a constant number / bool / string (e.g. derived
# expressions like `box_total_height = get_mock_pack_height() + ...`) are
# skipped — those would still take their default value from the .scad itself.

# Param categories — used both for grouping in the UI and for picking the
# select-typed params (those with a fixed option set). Keep keys in scad
# variable-name space; group order/labels are the rendering hint.
_SELECT_OPTIONS: dict[str, list[str]] = {
    "part":                ["holder", "cap", "box lid", "box bottom",
                            "wire clamp", "insulator",
                            "vertical box section", "busbar template"],
    "part_type":           ["normal", "mirrored", "both", "assembled"],
    "pack_style":          ["rect", "para", "tria"],
    "wire_style":          ["strip", "bus"],
    "box_style":           ["bolt", "ziptie", "both"],
    "template_outline":    ["rect", "hull"],
    "template_hole_style": ["engrave", "through", "center"],
}

# How to group each scad var into UI sections. First match wins; "advanced"
# catches the rest.
_GROUP_RULES: list[tuple[str, list[str]]] = [
    ("part",     ["part", "part_type", "pack_style", "wire_style", "box_style"]),
    ("cell",     ["cell_dia", "cell_height", "wall"]),
    ("size",     ["num_rows", "num_cols"]),
    ("holder",   ["holder_height", "slot_height", "col_slot_width",
                  "row_slot_width", "cell_top_overlap"]),
    ("cap",      ["cap_wall", "cap_clearance"]),
    ("box",      ["box_lip", "wire_clamp_add", "box_wall", "box_clearance",
                  "bms_clearance", "box_bottom_clearance",
                  "box_wire_side_clearance", "box_nonwire_side_clearance"]),
    ("insulator",["insulator_as_support", "support_z_gap", "insulator_tolerance"]),
    ("bolts",    ["bolt_dia", "bolt_head_dia", "bolt_head_thickness",
                  "ziptie_width", "ziptie_thickness", "bolt_dia_clearance",
                  "wire_clamp_bolt_dia"]),
    ("wires",    ["wire_diameter", "clamp_factor", "wire_hole_width",
                  "wire_hole_length", "wire_top_wall", "clamp_plate_height"]),
    ("stacking", ["stacking_pins", "stacking_pin_dia", "stacking_pin_alt_style",
                  "stacking_bolts", "stacking_bolt_dia", "num_pack_stacks",
                  "stacking_pins_tolerance"]),
    ("template", ["template_2d", "template_outline", "template_thickness",
                  "template_margin", "template_mark_dia", "template_hole_style",
                  "template_line_width", "template_engrave_depth",
                  "template_center_mark", "template_center_mark_dia"]),
]

# Tighter numeric input hints (min/max/step) for selected params. Anything
# not listed here gets a free-form number input.
_NUMBER_HINTS: dict[str, dict[str, float]] = {
    "cell_dia":           {"min": 10,  "max": 40,  "step": 0.1},
    "cell_height":        {"min": 30,  "max": 200, "step": 1},
    "wall":               {"min": 0.2, "max": 3,   "step": 0.1},
    "num_rows":           {"min": 1,   "max": 50,  "step": 1},
    "num_cols":           {"min": 1,   "max": 50,  "step": 1},
    "holder_height":      {"min": 4,   "max": 30,  "step": 0.5},
    "slot_height":        {"min": 0,   "max": 10,  "step": 0.5},
    "col_slot_width":     {"min": 0,   "max": 20,  "step": 0.5},
    "row_slot_width":     {"min": 0,   "max": 20,  "step": 0.5},
    "cell_top_overlap":   {"min": 0,   "max": 10,  "step": 0.5},
    "cap_wall":           {"min": 0.4, "max": 5,   "step": 0.1},
    "box_wall":           {"min": 0.4, "max": 10,  "step": 0.1},
    "num_pack_stacks":    {"min": 1,   "max": 10,  "step": 1},
}

_LITERAL_RE = re.compile(
    r"^\s*([a-z_][a-z0-9_]*)\s*=\s*"
    r"(?P<rhs>true|false|\"[^\"]*\"|[-+]?\d+(?:\.\d+)?(?:[eE][-+]?\d+)?)\s*;"
    r"(?:\s*//\s*(?P<comment>.*))?\s*$"
)


def _group_for(name: str) -> str:
    for grp, names in _GROUP_RULES:
        if name in names:
            return grp
    return "advanced"


def _pretty_label(name: str) -> str:
    return name.replace("_", " ").capitalize()


def _scan_scad(path: Path) -> list[Param]:
    out: list[Param] = []
    seen: set[str] = set()
    if not path.is_file():
        return out
    for raw in path.read_text(encoding="utf-8", errors="replace").splitlines():
        # Stop at the explicit end-of-config marker so we don't pick up
        # internal helpers (hextra, spacing, etc.).
        if "END OF CONFIGURATION" in raw or "NON-Configurable" in raw:
            break
        m = _LITERAL_RE.match(raw)
        if not m:
            continue
        name = m.group(1)
        if name in seen:
            continue
        rhs = m.group("rhs")
        help_text = (m.group("comment") or "").strip() or None

        if rhs in ("true", "false"):
            kind, default = "bool", (rhs == "true")
        elif rhs.startswith('"'):
            literal = rhs[1:-1]
            if name in _SELECT_OPTIONS:
                kind, default = "select", literal
            else:
                # Plain free-text strings aren't worth a form field.
                continue
        else:
            try:
                num = float(rhs)
                default = int(num) if num.is_integer() else num
                kind = "number"
            except ValueError:
                continue

        p = Param(
            name=name, label=_pretty_label(name), kind=kind,
            default=default, group=_group_for(name), help=help_text,
        )
        if kind == "select":
            p.options = _SELECT_OPTIONS[name]
        if kind == "number" and name in _NUMBER_HINTS:
            h = _NUMBER_HINTS[name]
            p.min, p.max, p.step = h.get("min"), h.get("max"), h.get("step")
        out.append(p)
        seen.add(name)
    return out


PARAMS: list[Param] = _scan_scad(SCAD_FILE)


def default_params() -> dict[str, Any]:
    return {p.name: p.default for p in PARAMS}


def schema_dict() -> list[dict]:
    out = []
    for p in PARAMS:
        d = {"name": p.name, "label": p.label, "kind": p.kind,
             "default": p.default, "group": p.group}
        if p.options is not None: d["options"] = p.options
        if p.min is not None:     d["min"] = p.min
        if p.max is not None:     d["max"] = p.max
        if p.step is not None:    d["step"] = p.step
        if p.help is not None:    d["help"] = p.help
        out.append(d)
    return out


# ---------------------------------------------------------------------------
# Cell-center computation (Python mirror of get_hex_center_points_*).
# Returns list of {id, x, y} in mm.
# ---------------------------------------------------------------------------


_COS30 = math.cos(math.radians(30))


def expected_cell_count(params: dict) -> int:
    """Cell count for a pack without computing coordinates."""
    rows  = int(params.get("num_rows", 6))
    cols  = int(params.get("num_cols", 12))
    style = str(params.get("pack_style", "rect"))
    if style == "tria":
        return rows * (rows + 1) // 2
    return rows * cols


def _check_cell_limit(params: dict) -> None:
    n = expected_cell_count(params)
    if n > MAX_CELLS:
        raise ValueError(
            f"Too many cells ({n} > {MAX_CELLS}). Reduce rows × cols."
        )


def compute_cells(params: dict) -> list[dict]:
    _check_cell_limit(params)
    cell_dia = float(params.get("cell_dia",  21.2))
    wall     = float(params.get("wall",      0.8))
    rows     = int(params.get("num_rows", 6))
    cols     = int(params.get("num_cols", 12))
    style    = str(params.get("pack_style", "rect"))

    hex_w  = cell_dia + 2 * wall
    hex_pt = (hex_w / 2) / _COS30
    row_y  = lambda r: r * 1.5 * hex_pt

    out: list[dict] = []
    cid = 1
    if style == "rect":
        for r in range(rows):
            for c in range(cols):
                x = (0 if r % 2 == 0 else 0.5 * hex_w) + hex_w * c
                out.append({"id": cid, "x": x, "y": row_y(r)})
                cid += 1
    elif style == "para":
        for r in range(rows):
            for c in range(cols):
                out.append({"id": cid, "x": r * 0.5 * hex_w + hex_w * c, "y": row_y(r)})
                cid += 1
    elif style == "tria":
        for r in range(rows):
            for c in range(r + 1):
                out.append({"id": cid, "x": r * 0.5 * hex_w - hex_w * c, "y": row_y(r)})
                cid += 1
    else:
        raise ValueError(f"unknown pack_style: {style!r}")
    return out


# ---------------------------------------------------------------------------
# OpenSCAD render
# ---------------------------------------------------------------------------


def _to_scad_literal(v: Any) -> str:
    """Convert a Python value to the literal text OpenSCAD expects on -D."""
    if isinstance(v, bool):
        return "true" if v else "false"
    if isinstance(v, (int, float)):
        return repr(v)
    if isinstance(v, str):
        # OpenSCAD strings are double-quoted; escape via json.
        return json.dumps(v)
    raise TypeError(f"unsupported parameter type: {type(v).__name__}")


def _filter_params(params: dict) -> dict:
    """Drop None and unknown-name params; coerce types where obvious."""
    known = {p.name: p for p in PARAMS}
    out = {}
    for k, v in (params or {}).items():
        if k not in known or v is None:
            continue
        p = known[k]
        if p.kind == "number":
            v = float(v) if p.step and p.step != int(p.step) else int(float(v))
            # keep ints for integer-step params
            if isinstance(p.default, int) and float(v).is_integer():
                v = int(v)
        elif p.kind == "bool":
            v = bool(v)
        elif p.kind == "select":
            v = str(v)
        out[k] = v
    return out


_ECHO_RE = re.compile(r'^ECHO:\s*([A-Za-z_][A-Za-z0-9_]*)\s*=\s*([-+]?[0-9]*\.?[0-9]+(?:[eE][-+]?[0-9]+)?)\s*$')


def _parse_echo_dims(stderr_bytes: bytes) -> dict:
    """Pick up `ECHO: name = N` numeric pairs from openscad stderr.

    The hex_cell.scad echoes derived measurements (pack_height_holder,
    total_length_holder, box_total_height, etc.) — useful for fit-check
    against a user enclosure without us mirroring all the SCAD math.
    """
    out: dict = {}
    for line in (stderr_bytes or b"").decode(errors="replace").splitlines():
        m = _ECHO_RE.match(line.strip())
        if m:
            try:
                out[m.group(1)] = float(m.group(2))
            except ValueError:
                pass
    return out


def render_stl(params: dict) -> tuple[bytes, dict]:
    """Render the .scad with given parameter overrides.

    Returns (stl_bytes, dimensions) where dimensions is a {name: float}
    dict harvested from openscad ECHO output (pack/box/holder sizes).
    """
    _check_cell_limit(params)
    if not openscad_available():
        raise RuntimeError(
            f"`{OPENSCAD_BIN}` not found on PATH. Install OpenSCAD "
            "(e.g. `apt install openscad` on Debian/Ubuntu)."
        )
    if not SCAD_FILE.is_file():
        raise FileNotFoundError(f"SCAD source not found at {SCAD_FILE}")

    clean = _filter_params(params)
    with tempfile.TemporaryDirectory() as tmp:
        out = Path(tmp) / "out.stl"
        cmd = [OPENSCAD_BIN, "-o", str(out)]
        if OPENSCAD_BACKEND:
            cmd += ["--backend", OPENSCAD_BACKEND]
        for k, v in clean.items():
            cmd += ["-D", f"{k}={_to_scad_literal(v)}"]
        cmd.append(str(SCAD_FILE))
        try:
            r = subprocess.run(cmd, capture_output=True, timeout=RENDER_TIMEOUT)
        except subprocess.TimeoutExpired:
            raise RuntimeError(f"openscad timed out after {RENDER_TIMEOUT}s")
        if r.returncode != 0:
            err = (r.stderr or b"").decode(errors="replace").strip()
            raise RuntimeError(f"openscad failed (exit {r.returncode}):\n{err[-800:]}")
        if not out.exists() or out.stat().st_size == 0:
            raise RuntimeError("openscad produced no STL (geometry empty?)")
        return out.read_bytes(), _parse_echo_dims(r.stderr or b"")