ParaWiki/cimery/crates/kernel/tests/layer2_invariants.rs

//! Layer 2: Geometric invariants for all kernel feature meshes (Sprint 20).
//!
//! Each test verifies physical and topological properties that MUST hold
//! regardless of which backend produces the mesh:
//! - vertex_count > 0
//! - triangle_count > 0
//! - indices divisible by 3 (well-formed triangle list)
//! - bounding box spans > 0 on at least one axis
//! - all normals are (approximately) unit length
//! - no degenerate triangles (all 3 vertex positions distinct)

use cimery_core::{
    AbutmentType, BearingType, ColumnShape, CrossBeamSection, ExpansionJointType,
    MaterialGrade, PierType, SectionType,
};
use cimery_ir::{
    AbutmentIR, BearingIR, CapBeamIR, CrossBeamIR, DeckSlabIR, ExpansionJointIR,
    FeatureId, GirderIR, PierIR, PscISectionParams, SectionParams, WingWallIR,
};
use cimery_kernel::{GeomKernel, Mesh, PureRustKernel, StubKernel};

// ─── Assertion helpers ────────────────────────────────────────────────────────

fn assert_valid_mesh(mesh: &Mesh, label: &str) {
    assert!(mesh.vertex_count() > 0,
        "{label}: vertex_count must be > 0");
    assert!(mesh.triangle_count() > 0,
        "{label}: triangle_count must be > 0");
    assert_eq!(mesh.indices.len() % 3, 0,
        "{label}: index count must be divisible by 3");
    assert_eq!(mesh.normals.len(), mesh.vertices.len(),
        "{label}: normals.len() must equal vertices.len()");
    assert_eq!(mesh.colors.len(), mesh.vertices.len(),
        "{label}: colors.len() must equal vertices.len()");

    // Bounding box must be non-degenerate on at least one axis
    let (mn, mx) = mesh.aabb();
    let extents = [mx[0]-mn[0], mx[1]-mn[1], mx[2]-mn[2]];
    assert!(extents.iter().any(|&e| e > 0.0),
        "{label}: AABB must have positive extent on ≥1 axis, got {:?}", extents);

    // All normals unit length (tolerance 1e-4 for f32)
    for (i, n) in mesh.normals.iter().enumerate() {
        let len = (n[0]*n[0] + n[1]*n[1] + n[2]*n[2]).sqrt();
        assert!((len - 1.0).abs() < 1e-4,
            "{label}: normal[{i}] length = {len:.6}, expected ~1.0");
    }

    // All indices in range
    let vcount = mesh.vertex_count() as u32;
    for &idx in &mesh.indices {
        assert!(idx < vcount,
            "{label}: index {idx} out of range (vertex_count = {vcount})");
    }
}

fn assert_span_in_aabb(mesh: &Mesh, expected_span_mm: f32, axis: usize, label: &str) {
    let (mn, mx) = mesh.aabb();
    let actual = mx[axis] - mn[axis];
    assert!((actual - expected_span_mm).abs() < expected_span_mm * 0.01,
        "{label}: span on axis {axis} = {actual:.1} mm, expected {expected_span_mm:.1} mm (±1%)");
}

// ─── IR factories ─────────────────────────────────────────────────────────────

fn girder_40m() -> GirderIR {
    GirderIR {
        id:                    FeatureId::new(),
        station_start:         0.0,
        station_end:           40.0,
        offset_from_alignment: 0.0,
        section_type:          SectionType::PscI,
        section:               SectionParams::PscI(PscISectionParams::kds_standard()),
        count:    5,
        spacing:  2_500.0,
        material: MaterialGrade::C50,
    }
}

fn deck_slab_40m() -> DeckSlabIR {
    DeckSlabIR {
        id:            FeatureId::new(),
        station_start: 0.0,
        station_end:   40.0,
        width_left:    5_500.0,
        width_right:   5_500.0,
        thickness:     220.0,
        haunch_depth:  100.0,
        cross_slope:   2.0,
        material:      MaterialGrade::C40,
    }
}

fn bearing_standard() -> BearingIR {
    BearingIR {
        id:               FeatureId::new(),
        station:          0.0,
        bearing_type:     BearingType::Elastomeric,
        plan_length:      350.0,
        plan_width:       350.0,
        total_height:     90.0,
        capacity_vertical:2_500.0,
    }
}

fn pier_single_column() -> PierIR {
    PierIR {
        id:              FeatureId::new(),
        station:         20.0,
        skew_angle:      0.0,
        pier_type:       PierType::SingleColumn,
        column_shape:    ColumnShape::Circular,
        column_count:    1,
        column_spacing:  0.0,
        column_diameter: 1_500.0,
        column_depth:    0.0,
        column_height:   8_000.0,
        cap_beam: CapBeamIR {
            length:          13_000.0,
            width:           1_200.0,
            depth:           1_400.0,
            cantilever_left: 1_000.0,
            cantilever_right:1_000.0,
        },
        material: MaterialGrade::C40,
    }
}

fn abutment_standard() -> AbutmentIR {
    AbutmentIR {
        id:                    FeatureId::new(),
        station:               0.0,
        skew_angle:            0.0,
        abutment_type:         AbutmentType::ReverseT,
        breast_wall_height:    5_000.0,
        breast_wall_thickness: 800.0,
        breast_wall_width:     12_000.0,
        footing_length:        4_000.0,
        footing_width:         13_000.0,
        footing_thickness:     1_000.0,
        wing_wall_left:  WingWallIR { length: 4_000.0, height: 4_000.0, thickness: 500.0 },
        wing_wall_right: WingWallIR { length: 4_000.0, height: 4_000.0, thickness: 500.0 },
        material: MaterialGrade::C40,
    }
}

fn cross_beam_standard() -> CrossBeamIR {
    CrossBeamIR {
        id:               FeatureId::new(),
        station:          10.0,
        section:          CrossBeamSection::HSection,
        web_height:       1_260.0,
        web_thickness:    12.0,
        flange_width:     300.0,
        flange_thickness: 16.0,
        bay_count:        4,
        girder_spacing:   2_500.0,
        material:         MaterialGrade::Ss400,
    }
}

fn expansion_joint_standard() -> ExpansionJointIR {
    ExpansionJointIR {
        id:             FeatureId::new(),
        station:        0.0,
        joint_type:     ExpansionJointType::RubberType,
        gap_width:      50.0,
        total_width:    11_000.0,
        depth:          100.0,
        movement_range: 30.0,
    }
}

// ─── PureRustKernel invariants ────────────────────────────────────────────────

#[test]
fn prk_girder_valid_mesh() {
    let mesh = PureRustKernel.girder_mesh(&girder_40m()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::girder");
}

#[test]
fn prk_girder_span_correct() {
    let mesh = PureRustKernel.girder_mesh(&girder_40m()).unwrap();
    assert_span_in_aabb(&mesh, 40_000.0, 2, "PureRustKernel::girder span (Z)");
}

#[test]
fn prk_deck_slab_valid_mesh() {
    let mesh = PureRustKernel.deck_slab_mesh(&deck_slab_40m()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::deck_slab");
}

#[test]
fn prk_deck_slab_span_correct() {
    let mesh = PureRustKernel.deck_slab_mesh(&deck_slab_40m()).unwrap();
    assert_span_in_aabb(&mesh, 40_000.0, 2, "PureRustKernel::deck_slab span (Z)");
}

#[test]
fn prk_bearing_valid_mesh() {
    let mesh = PureRustKernel.bearing_mesh(&bearing_standard()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::bearing");
}

#[test]
fn prk_pier_valid_mesh() {
    let mesh = PureRustKernel.pier_mesh(&pier_single_column()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::pier");
}

#[test]
fn prk_abutment_valid_mesh() {
    let mesh = PureRustKernel.abutment_mesh(&abutment_standard()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::abutment");
}

#[test]
fn prk_cross_beam_valid_mesh() {
    let mesh = PureRustKernel.cross_beam_mesh(&cross_beam_standard()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::cross_beam");
}

#[test]
fn prk_cross_beam_length_correct() {
    let ir   = cross_beam_standard();
    let mesh = PureRustKernel.cross_beam_mesh(&ir).unwrap();
    let expected = ir.total_length_mm() as f32;
    // Cross beams sweep along X axis
    assert_span_in_aabb(&mesh, expected, 0, "PureRustKernel::cross_beam length (X)");
}

#[test]
fn prk_expansion_joint_valid_mesh() {
    let mesh = PureRustKernel.expansion_joint_mesh(&expansion_joint_standard()).unwrap();
    assert_valid_mesh(&mesh, "PureRustKernel::expansion_joint");
}

// ─── StubKernel invariants ────────────────────────────────────────────────────

#[test]
fn stub_girder_valid_mesh() {
    let mesh = StubKernel.girder_mesh(&girder_40m()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::girder");
}

#[test]
fn stub_deck_slab_valid_mesh() {
    let mesh = StubKernel.deck_slab_mesh(&deck_slab_40m()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::deck_slab");
}

#[test]
fn stub_bearing_valid_mesh() {
    let mesh = StubKernel.bearing_mesh(&bearing_standard()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::bearing");
}

#[test]
fn stub_pier_valid_mesh() {
    let mesh = StubKernel.pier_mesh(&pier_single_column()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::pier");
}

#[test]
fn stub_abutment_valid_mesh() {
    let mesh = StubKernel.abutment_mesh(&abutment_standard()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::abutment");
}

#[test]
fn stub_cross_beam_valid_mesh() {
    let mesh = StubKernel.cross_beam_mesh(&cross_beam_standard()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::cross_beam");
}

#[test]
fn stub_expansion_joint_valid_mesh() {
    let mesh = StubKernel.expansion_joint_mesh(&expansion_joint_standard()).unwrap();
    assert_valid_mesh(&mesh, "StubKernel::expansion_joint");
}

// ─── Error cases ──────────────────────────────────────────────────────────────

#[test]
fn stub_zero_span_returns_error() {
    let mut g = girder_40m();
    g.station_end = g.station_start;
    assert!(StubKernel.girder_mesh(&g).is_err());
}

#[test]
fn prk_zero_span_returns_error() {
    let mut g = girder_40m();
    g.station_end = g.station_start;
    assert!(PureRustKernel.girder_mesh(&g).is_err());
}