src/comparison/gap_overlap.py

"""Gap and overlap detection on boundary edges."""

from __future__ import annotations

import logging
from dataclasses import dataclass, field

import numpy as np
import open3d as o3d
from OCP.BRep import BRep_Tool
from OCP.BRepAdaptor import BRepAdaptor_Curve
from OCP.GCPnts import GCPnts_UniformAbscissa
from OCP.TopAbs import TopAbs_EDGE, TopAbs_FACE
from OCP.TopExp import TopExp_Explorer
from OCP.TopoDS import TopoDS, TopoDS_Shape

logger = logging.getLogger(__name__)

NUM_EDGE_SAMPLES = 50


@dataclass
class GapOverlapResult:
    """Gap and overlap detection results."""

    gap_distances: list[float] = field(default_factory=list)
    overlap_distances: list[float] = field(default_factory=list)
    gap_locations: list[np.ndarray] = field(default_factory=list)
    overlap_locations: list[np.ndarray] = field(default_factory=list)

    @property
    def gap_count(self) -> int:
        return len(self.gap_distances)

    @property
    def overlap_count(self) -> int:
        return len(self.overlap_distances)

    @property
    def max_gap(self) -> float:
        return max(self.gap_distances) if self.gap_distances else 0.0

    @property
    def max_overlap(self) -> float:
        return max(self.overlap_distances) if self.overlap_distances else 0.0


def _sample_boundary_edges(shape: TopoDS_Shape) -> np.ndarray:
    """Sample points along boundary edges of a shape.

    Boundary edges are edges that belong to only one face.
    """
    # Collect edge-to-face counts
    edge_face_count: dict[int, int] = {}
    edge_map: dict[int, object] = {}

    face_exp = TopExp_Explorer(shape, TopAbs_FACE)
    while face_exp.More():
        face = TopoDS.Face_s(face_exp.Current())
        edge_exp = TopExp_Explorer(face, TopAbs_EDGE)
        while edge_exp.More():
            edge = TopoDS.Edge_s(edge_exp.Current())
            h = hash(edge)
            edge_face_count[h] = edge_face_count.get(h, 0) + 1
            edge_map[h] = edge
            edge_exp.Next()
        face_exp.Next()

    # Boundary edges: shared by only one face
    boundary_edges = [edge_map[h] for h, count in edge_face_count.items() if count == 1]
    logger.info("Found %d boundary edges out of %d total", len(boundary_edges), len(edge_map))

    if not boundary_edges:
        return np.empty((0, 3), dtype=np.float64)

    points = []
    for edge in boundary_edges:
        try:
            curve = BRepAdaptor_Curve(edge)
            u_first = curve.FirstParameter()
            u_last = curve.LastParameter()

            distributor = GCPnts_UniformAbscissa(curve, NUM_EDGE_SAMPLES, u_first, u_last)
            if not distributor.IsDone():
                continue

            for i in range(1, distributor.NbPoints() + 1):
                param = distributor.Parameter(i)
                pnt = curve.Value(param)
                points.append([pnt.X(), pnt.Y(), pnt.Z()])
        except Exception:
            continue

    if not points:
        return np.empty((0, 3), dtype=np.float64)

    return np.array(points, dtype=np.float64)


def detect_gaps_and_overlaps(
    shape_a: TopoDS_Shape,
    shape_b: TopoDS_Shape,
    vertices_b: np.ndarray,
    gap_tolerance_mm: float = 0.05,
    overlap_tolerance_mm: float = 0.05,
) -> GapOverlapResult:
    """Detect gaps and overlaps by projecting boundary edge points.

    Samples boundary edges of shape_a and measures distance to
    the closest point on shape_b's mesh surface.

    Args:
        shape_a: First shape (will sample boundary edges from).
        shape_b: Second shape (reference).
        vertices_b: Tessellated vertices of shape_b.
        gap_tolerance_mm: Gap detection threshold.
        overlap_tolerance_mm: Overlap detection threshold.

    Returns:
        GapOverlapResult with detected gaps and overlaps.
    """
    boundary_points = _sample_boundary_edges(shape_a)

    if len(boundary_points) == 0:
        logger.info("No boundary edges found -- skipping gap/overlap detection")
        return GapOverlapResult()

    if len(vertices_b) == 0:
        logger.warning("Target mesh has no vertices -- skipping gap/overlap detection")
        return GapOverlapResult()

    # Build KDTree on target mesh
    target_pcd = o3d.geometry.PointCloud()
    target_pcd.points = o3d.utility.Vector3dVector(vertices_b)
    kdtree = o3d.geometry.KDTreeFlann(target_pcd)

    result = GapOverlapResult()

    for point in boundary_points:
        _, idx, dist_sq = kdtree.search_knn_vector_3d(point, 1)
        dist = np.sqrt(dist_sq[0])

        if dist > gap_tolerance_mm:
            result.gap_distances.append(float(dist))
            result.gap_locations.append(point)
        elif dist < overlap_tolerance_mm * 0.1:
            # Very close = potential overlap (surface interpenetration)
            result.overlap_distances.append(float(dist))
            result.overlap_locations.append(point)

    logger.info(
        "Gap/overlap detection: %d gaps (max=%.4f mm), %d overlaps (max=%.4f mm)",
        result.gap_count, result.max_gap,
        result.overlap_count, result.max_overlap,
    )
    return result