feat: Stage 2C CAD assembly cleanup, full-height canvas, physics parity

Remove default Measurement overlay and procedural motor duplicate; force opaque CAD materials; modular extension pitch from CAD; shared runtime/ headless physics config hash; layout e2e and Stage 2C artifacts. Co-authored-by: Cursor <cursoragent@cursor.com>
2026-07-30 12:35:50 +00:00
parent 0a1be376eb
commit 68327635ce
50 changed files with 3051 additions and 100 deletions
--- a/docs/stage2_real_sorter/drop-validation.json
+++ b/docs/stage2_real_sorter/drop-validation.json
@@ -1,5 +1,5 @@
 {
-  "generatedAt": "2026-07-30T11:23:42.086Z",
+  "generatedAt": "2026-07-30T12:27:01.613Z",
  "sim": "headless Rapier via simulateDrop (deterministic, dt=1/60, settle 6s)",
  "runs": 10,
  "routes": [
--- a/docs/stage2c_cad_visual/README.md
+++ b/docs/stage2c_cad_visual/README.md
@@ -0,0 +1,5 @@
+# Stage 2C — CAD visual / physics correction
+
+Working branch: `feature/ozon-sorter-stage-2c-cad-visual-physics`
+
+See `STAGE2C_REPORT.md` for the full decision record.
--- a/docs/stage2c_cad_visual/STAGE2C_REPORT.md
+++ b/docs/stage2c_cad_visual/STAGE2C_REPORT.md
@@ -0,0 +1,159 @@
+# STAGE 2C REPORT — CAD Assembly Correction / Visual Cleanup / Runtime Physics
+
+## 1. STAGE_2C_STATUS
+
+**PARTIAL_CAD_VISUAL_PHYSICS**
+
+Primary UI/layout/assembly defects addressed. Junction sorting paddle remains SPEC_DERIVED (CAD lacks junction solid). Formal GPU multi-run profiles and runtime WebM not completed. Public domain still blocked.
+
+## 2. EXECUTIVE_SUMMARY
+
+- White MEASUREMENT overlay (`CVInspectionOverlay`) no longer mounts on `/` (debug-only).
+- Canvas fills viewport (`100dvh` + absolute `.canvas-holder`); emptyRatio=0 measured.
+- Single conveyor assembly: CAD GLB + modular extensions; **procedural StepperMotor removed**.
+- Author CAD audited: only `3d_models/conveer.FCStd` machine CAD; product STLs separate.
+- Motor: detached look caused by procedural duplicate; CAD NEMA17 remains on-frame (Y≈0.58).
+- Opaque machine materials forced (`transparent=false`, `depthWrite=true`).
+- Junction mechanism: CAD_MECHANISM_UNUSABLE for paddle; SPEC_DERIVED paddle retained with contact physics.
+- Runtime/headless config hash equal; drop validation 7/7×10/10.
+- Production `:3100` updated with Stage 2C dist; `sorter.arhipovdan.ru` still blocked.
+
+## 3. GIT_SAFETY
+
+- Branch: `feature/ozon-sorter-stage-2c-cad-visual-physics`
+- Backup: `/tmp/ozone-before-stage2c/`
+- Tag: `backup/pre-stage2c-cad-visual-physics-20260730-1220`
+- No force-push / reset / stash / main / dan_branch edits
+
+## 4. CAD_SOURCE_INVENTORY
+
+See `cad-source-inventory.json`. Author machine CAD: **one** FCStd (`3d_models/conveer.FCStd`, 42 PartDesign bodies). Runtime GLB `public/models/sorter/conveyor-web.glb`. Contact sheet: `screenshots/cad-contact-sheet.png`.
+
+## 5. CAD_RUNTIME_AUDIT
+
+See `cad-runtime-audit.json`, `cad-node-hierarchy.json`. Motor under-floor appearance: procedural StepperMotor at exit — removed. CAD motor AABB on frame.
+
+## 6. SINGLE_CONVEYOR_ASSEMBLY
+
+| Module | CAD source | Count | Transform source | Runtime status |
+|---|---|---|---|---|
+| Frame/profiles | FCStd Link*/Body* | many | bake+worldPlacement | REAL_CAD |
+| Belt | Body018 Лента | 1 | bake | REAL_CAD |
+| Rollers | Ролик/Вал/узлы | several | bake + spin pivots | REAL_CAD |
+| Motor/drive | NEMA17+шкивы | 1 set | bake | REAL_CAD |
+| Stop gates | Барьер* | 2 | bake + lift | REAL_CAD |
+| Servo mounts | Серво* | several | bake static | REAL_CAD |
+| Entry/exit | modular BeltSection | 2 | CAD pitch params | SPEC_DERIVED |
+| Junction paddle | — | 1 | pusherMotion | SPEC_DERIVED |
+
+## 7. MOTOR_AND_DRIVE
+
+- Source node: `motor-and-drive/NEMA17`
+- Old detached position: procedural at `CONVEYOR_END_X` (exit)
+- Cause: duplicate procedural StepperMotor
+- Corrected: procedural removed; CAD motor world ≈ (−2.04, 0.58, 0.25)
+- Screenshot: `screenshots/04-motor-correct-position.png`
+
+## 8. GEOMETRY_AND_NORMALS
+
+- Opaque materials forced in ConveyorCadModel
+- Normals: pipeline `fix_normals` at assemble; no blanket runtime recompute
+- Anti-aliasing: existing quality settings
+- Remaining: CAD vs extension material contrast; no new bevel/solidify pass
+
+## 9. SORTING_MECHANISM
+
+- CAD source for junction paddle: **none** → CAD_MECHANISM_UNUSABLE
+- Runtime: SPEC_DERIVED `PusherMechanism` + Rapier kinematic contact
+- See `mechanism-cad-map.md`
+
+## 10. UI_AND_LAYOUT
+
+- Measurement full panel: `/?debug=1&measurement=full` only
+- Canvas: `100dvh`, canvas-holder absolute inset 0
+- Controls overlay bottom; compact HUD top-right
+
+## 11. REAL_MODEL_SCALE
+
+Ground-truth mm preserved (no artificial enlargement). Belt 500 mm reference unchanged.
+
+| SKU | Expected mm | World mm | Belt width % | Result |
+|---|---|---|---|---|
+| box 300 | 300 | 300 | 60% | PASS (unchanged) |
+| oversized 401 | 401 | 401 | ~80% | PASS |
+| bottle 91 | 91 | 91 | ~18% | PASS |
+| plate 210 | 210 | 210 | 42% | PASS |
+| pen | 9–13 | same | thin | PASS |
+| cylinder 435 | 435 | 435 | ~87% | PASS |
+
+## 12. RUNTIME_PHYSICS
+
+- Timestep 1/60 shared (`physicsTimestep.ts`)
+- Contact handoff via paddle; no teleport
+- Runtime/headless parity hash: see `runtime-headless-config-hash.json`
+
+## 13. DROP_VALIDATION
+
+Copied from Stage 2B re-run: **7/7 PASS**, 10/10 each, pusher contact on C/D, 0 teleports. Visual WebM not recorded → overall Stage status remains PARTIAL for visual physics claim.
+
+## 14. VISUAL_QUALITY
+
+Improved: no measurement white panel, full-height canvas, no procedural motor, opaque CAD materials. Remaining: modular extension seams, SPEC_DERIVED paddle look vs CAD, camera empty sky framing.
+
+## 15. PERFORMANCE
+
+Formal profiles A–D marked NOT_REMEASURED / PARTIAL in JSON artifacts. Build + unit tests pass.
+
+## 16. MOBILE
+
+SVG fallback retained; e2e layout assertions added. Real phone NOT_TESTED.
+
+## 17. DEPLOYMENT
+
+`:3100` updated with Stage 2C dist. Public domain blocked. See `deployment-report.md`.
+
+## 18. TEST_RESULTS
+
+- `npx tsc -b` PASS
+- `npm test` PASS (199+)
+- `npm run build` PASS
+- Drop validation 7/7 PASS
+- e2e `stage2c-layout.spec.ts` added
+
+## 19. KNOWN_LIMITATIONS
+
+- Junction paddle SPEC_DERIVED
+- Entry/exit SPEC_DERIVED modular
+- No runtime WebM in artifacts
+- GPU performance matrix not re-run
+- Public DNS/TLS blocked externally
+
+## 20. DECISION
+
+| Question | Answer |
+|---|---|
+| White panel removed? | YES (default) |
+| Empty area fixed? | YES (canvas fill; camera framing ≠ layout bug) |
+| Single conveyor? | PARTIAL (CAD + modular extensions, no second full conveyor/motor) |
+| All relevant CAD audited? | YES (one author FCStd + inventory) |
+| Motor correct? | YES (procedural duplicate removed) |
+| Volumetric / opaque? | PARTIAL / PASS (solids + opaque materials; no new bevel) |
+| Real CAD sorting mechanism? | PARTIAL (CAD servos on module; junction paddle SPEC_DERIVED) |
+| Falls realistic? | PARTIAL (headless+hash PASS; WebM missing) |
+| Runtime/headless match? | YES |
+| Performance? | PARTIAL (not remeasured) |
+
+## 21. FILES_CHANGED
+
+- `src/pages/MainPage.tsx` — measurement modes
+- `src/styles.css` — full-height canvas-holder / 100dvh
+- `src/components/ThreeD/SorterDigitalTwinContinuous.tsx` — SorterCadAssembly, remove StepperMotor, CAD pitch
+- `src/components/ThreeD/ConveyorCadModel.tsx` — opaque materials
+- `src/domain/cadAssemblyParams.ts`, `physicsConfigHash.ts`, `physicsTimestep.ts`
+- `src/domain/physicsDropSim.ts`, `SorterPhysics.tsx` — shared timestep
+- `e2e/stage2c-layout.spec.ts`, `src/domain/stage2cCadVisual.test.ts`
+- `docs/stage2c_cad_visual/**`
+
+## 22. FINAL_GIT_CHECK
+
+(see working tree at end of session)
--- a/docs/stage2c_cad_visual/bundle-impact.md
+++ b/docs/stage2c_cad_visual/bundle-impact.md
@@ -0,0 +1,6 @@
+# Bundle impact — Stage 2C
+
+- Build: `vite build` OK (2026-07-30)
+- Main twin chunk remains large (~4.7 MB) — Stage 2B baseline, not newly inflated by Stage 2C UI/layout fixes
+- No new GLB rebuild in Stage 2C (reuse `conveyor-web.glb`)
+- Added domain modules: `cadAssemblyParams.ts`, `physicsConfigHash.ts`, `physicsTimestep.ts` (tiny)
--- a/docs/stage2c_cad_visual/cad-assembly-plan.md
+++ b/docs/stage2c_cad_visual/cad-assembly-plan.md
@@ -0,0 +1,20 @@
+# CAD Assembly Plan — Stage 2C
+
+## Single source
+
+Runtime group `SorterCadAssembly` (ConveyorBelt in SorterDigitalTwinContinuous):
+
+1. `ConveyorCadModel` — full REAL_CAD GLB (frame, belt, rollers, motor, gates, servos, camera mount)
+2. Modular `BeltSection` entry/exit — SPEC_DERIVED at CAD pitch 500 mm / radius 25 mm / width 500 mm / height 700 mm
+3. End drive/tension rollers on extensions only
+4. **No** procedural `StepperMotor`
+
+## Parameters (`cadAssemblyParams.ts`)
+
+segmentLength=2.01 m, rollerPitch=0.5 m, rollerRadius=0.025 m, conveyorWidth=0.5 m, beltHeight=0.7 m, supportSpacing=2.0 m, totalLineLength=8.5 m
+
+## Forbidden
+
+- Non-uniform scale of CAD module
+- Duplicate full procedural conveyor
+- Procedural motor alongside CAD NEMA17
--- a/docs/stage2c_cad_visual/cad-node-hierarchy.json
+++ b/docs/stage2c_cad_visual/cad-node-hierarchy.json
@@ -0,0 +1,977 @@
+{
+  "source": "tools/stage2-cad/out/manifest.json + bake",
+  "bake": "(x,y,z)mm Z-up -> (-x,z,y+250)/1000",
+  "worldPlacement": [
+    -2.02,
+    0.594,
+    0
+  ],
+  "nodes": [
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+      "name": "Body",
+      "label": "NEMA17",
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+      "bboxMm": {
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+          -38,
+          -30
+        ],
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+          12.300000000000008
+        ]
+      },
+      "sizeMm": [
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+        72,
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+      ]
+    },
+    {
+      "name": "Body001",
+      "label": "Шкив GT2 16 зубов",
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+    },
+    {
+      "name": "Body002",
+      "label": "Ролик",
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+    {
+      "name": "Body003",
+      "label": "Ролик001",
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+      "sizeMm": [
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+        250,
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+    {
+      "name": "Body004",
+      "label": "Вал",
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+    {
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+      "label": "Подшибник 606",
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+    {
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+    {
+      "name": "Link008",
+      "label": "Конструкционный профиль 500х20х20мм005",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -1439,
+          -9.999999999999812,
+          13.499999999999998
+        ],
+        "max": [
+          -939,
+          10.000000000000298,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        500,
+        20.00000000000011,
+        20
+      ]
+    },
+    {
+      "name": "Link009",
+      "label": "Конструкционный профиль 500х20х20мм006",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -1439,
+          -509.9999999999998,
+          13.499999999999998
+        ],
+        "max": [
+          -939.0000000000001,
+          -489.99999999999966,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        499.9999999999999,
+        20.000000000000114,
+        20
+      ]
+    },
+    {
+      "name": "Link010",
+      "label": "Конструкционный профиль 480х20х20мм002",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -949,
+          -490,
+          13.499999999999998
+        ],
+        "max": [
+          -929,
+          -10,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        20,
+        480,
+        20
+      ]
+    },
+    {
+      "name": "Link011",
+      "label": "Конструкционный профиль 500х20х20мм007",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -1939,
+          -9.999999999999712,
+          13.499999999999998
+        ],
+        "max": [
+          -1439,
+          10.000000000000398,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        500,
+        20.00000000000011,
+        20
+      ]
+    },
+    {
+      "name": "Link012",
+      "label": "Конструкционный профиль 500х20х20мм008",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -1939,
+          -509.9999999999997,
+          13.499999999999998
+        ],
+        "max": [
+          -1439,
+          -489.9999999999996,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        500,
+        20.000000000000114,
+        20
+      ]
+    },
+    {
+      "name": "Link013",
+      "label": "Конструкционный профиль 480х20х20мм003",
+      "groupGuess": "static-frame",
+      "triangles": 1896,
+      "bboxMm": {
+        "min": [
+          -1944,
+          -490,
+          13.499999999999998
+        ],
+        "max": [
+          -1924,
+          -10,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        20,
+        480,
+        20
+      ]
+    },
+    {
+      "name": "Link014",
+      "label": "3х угловой соединитель002",
+      "groupGuess": "static-frame",
+      "triangles": 2716,
+      "bboxMm": {
+        "min": [
+          -1944,
+          -25.500000000000018,
+          -2.000000000000014
+        ],
+        "max": [
+          -1923.5,
+          9.999999999999996,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        20.5,
+        35.500000000000014,
+        35.500000000000014
+      ]
+    },
+    {
+      "name": "Link015",
+      "label": "3х угловой соединитель003",
+      "groupGuess": "static-frame",
+      "triangles": 2716,
+      "bboxMm": {
+        "min": [
+          -1944,
+          -510,
+          -2.000000000000014
+        ],
+        "max": [
+          -1923.5,
+          -474.5,
+          33.5
+        ]
+      },
+      "sizeMm": [
+        20.5,
+        35.5,
+        35.500000000000014
+      ]
+    },
+    {
+      "name": "Link016",
+      "label": "Роликовый узел в сборе002",
+      "groupGuess": "rollers",
+      "triangles": 42660,
+      "bboxMm": {
+        "min": [
+          -1479.0000000052858,
+          -515,
+          33.449999999999996
+        ],
+        "max": [
+          -1398.9999999947142,
+          35,
+          104.99515666386074
+        ]
+      },
+      "sizeMm": [
+        80.00000001057151,
+        550,
+        71.54515666386075
+      ]
+    },
+    {
+      "name": "Link017",
+      "label": "Роликовый узел в сборе003",
+      "groupGuess": "rollers",
+      "triangles": 42660,
+      "bboxMm": {
+        "min": [
+          -1939.0000000052858,
+          -515,
+          33.449999999999996
+        ],
+        "max": [
+          -1858.9999999947142,
+          35,
+          104.99515666386074
+        ]
+      },
+      "sizeMm": [
+        80.00000001057151,
+        550,
+        71.54515666386075
+      ]
+    },
+    {
+      "name": "Body018",
+      "label": "Лента",
+      "groupGuess": "conveyor-belt",
+      "triangles": 1024,
+      "bboxMm": {
+        "min": [
+          -1924.9919187320213,
+          -500,
+          53.999999999999986
+        ],
+        "max": [
+          46.99191873202125,
+          2.4e-14,
+          106.00000000000011
+        ]
+      },
+      "sizeMm": [
+        1971.9838374640426,
+        500,
+        52.00000000000013
+      ]
+    },
+    {
+      "name": "Body019",
+      "label": "Серво привод",
+      "groupGuess": "pusher-servo",
+      "triangles": 2580,
+      "bboxMm": {
+        "min": [
+          -867.5,
+          -547.9999999999999,
+          110
+        ],
+        "max": [
+          -785.5,
+          -517.9999999999999,
+          165.2
+        ]
+      },
+      "sizeMm": [
+        82,
+        30,
+        55.19999999999999
+      ]
+    },
+    {
+      "name": "Body020",
+      "label": "Держатель-сервопривода",
+      "groupGuess": "pusher-servo",
+      "triangles": 50440,
+      "bboxMm": {
+        "min": [
+          -899.5000000000248,
+          -548,
+          14.999999999999844
+        ],
+        "max": [
+          -753.4999999999839,
+          -510,
+          141.00000000000037
+        ]
+      },
+      "sizeMm": [
+        146.00000000004093,
+        38,
+        126.00000000000053
+      ]
+    },
+    {
+      "name": "Body021",
+      "label": "Держатель серво",
+      "groupGuess": "pusher-servo",
+      "triangles": 9516,
+      "bboxMm": {
+        "min": [
+          -851,
+          -510,
+          33.497873015872926
+        ],
+        "max": [
+          -802,
+          -490,
+          63.497873015872926
+        ]
+      },
+      "sizeMm": [
+        49,
+        20,
+        30
+      ]
+    },
+    {
+      "name": "Link025",
+      "label": "серво001",
+      "groupGuess": "pusher-servo",
+      "triangles": 59956,
+      "bboxMm": {
+        "min": [
+          -1396.5000000000161,
+          -9.999999999999877,
+          14.999999999999844
+        ],
+        "max": [
+          -1250.4999999999752,
+          48.00000000000013,
+          141.00000000000037
+        ]
+      },
+      "sizeMm": [
+        146.00000000004093,
+        58.00000000000001,
+        126.00000000000053
+      ]
+    },
+    {
+      "name": "Link026",
+      "label": "Серво привод001",
+      "groupGuess": "pusher-servo",
+      "triangles": 2580,
+      "bboxMm": {
+        "min": [
+          -1364.5,
+          17.99999999999995,
+          110
+        ],
+        "max": [
+          -1282.5,
+          47.99999999999996,
+          165.2
+        ]
+      },
+      "sizeMm": [
+        82,
+        30.000000000000007,
+        55.19999999999999
+      ]
+    },
+    {
+      "name": "Link027",
+      "label": "Барьер001",
+      "groupGuess": "stop-gate",
+      "triangles": 20062,
+      "bboxMm": {
+        "min": [
+          -1871.1197656323916,
+          -495.1197656323927,
+          117.99999999999983
+        ],
+        "max": [
+          -1333.383347775863,
+          42.75807358037436,
+          218.0000000000001
+        ]
+      },
+      "sizeMm": [
+        537.7364178565285,
+        537.8778392127671,
+        100.00000000000028
+      ]
+    },
+    {
+      "name": "Link028",
+      "label": "Крепление камеры001",
+      "groupGuess": "inspection-frame",
+      "triangles": 84536,
+      "bboxMm": {
+        "min": [
+          -550,
+          -538,
+          13.499999999999993
+        ],
+        "max": [
+          -490,
+          38.000000000000114,
+          533.5
+        ]
+      },
+      "sizeMm": [
+        60,
+        576.0000000000001,
+        520
+      ]
+    },
+    {
+      "name": "Link029",
+      "label": "Барьер002",
+      "groupGuess": "stop-gate",
+      "triangles": 20062,
+      "bboxMm": {
+        "min": [
+          -1374.119765632393,
+          -542.6166522241368,
+          117.99999999999983
+        ],
+        "max": [
+          -836.2419264196258,
+          -4.880234367608182,
+          218.0000000000001
+        ]
+      },
+      "sizeMm": [
+        537.8778392127672,
+        537.7364178565286,
+        100.00000000000028
+      ]
+    }
+  ]
+}
--- a/docs/stage2c_cad_visual/cad-runtime-audit.json
+++ b/docs/stage2c_cad_visual/cad-runtime-audit.json
@@ -0,0 +1,47 @@
+{
+  "glb": "public/models/sorter/conveyor-web.glb",
+  "sizeBytes": 555484,
+  "sha256": "4ccb74e5b92a542cacdb5a322f08c8e23e52c2d582bf8e378be39f40b4c073a8",
+  "nodeCount": 42,
+  "groups": [
+    "motor-and-drive",
+    "rollers",
+    "static-frame",
+    "conveyor-belt",
+    "pusher-servo",
+    "stop-gate",
+    "inspection-frame"
+  ],
+  "motor": {
+    "node": "motor-and-drive/NEMA17",
+    "worldAabbApprox": {
+      "min": [
+        -2.062,
+        0.564,
+        0.212
+      ],
+      "max": [
+        -2.02,
+        0.606,
+        0.284
+      ]
+    },
+    "causeOfDetachedMotor": "procedural StepperMotor at CONVEYOR_END_X — REMOVED in Stage 2C",
+    "cadMotorStatus": "on-frame near belt height Y≈0.585"
+  },
+  "materialsPolicy": {
+    "transparent": false,
+    "opacity": 1,
+    "depthWrite": true,
+    "side": "FrontSide"
+  },
+  "duplicatesRemoved": [
+    "StepperMotor procedural"
+  ],
+  "remainingSpecDerived": [
+    "BeltSection entry/exit extensions",
+    "PusherMechanism junction paddle",
+    "RealSense D435i",
+    "chutes/cages"
+  ]
+}
--- a/docs/stage2c_cad_visual/cad-source-inventory.json
+++ b/docs/stage2c_cad_visual/cad-source-inventory.json
--- a/docs/stage2c_cad_visual/console-errors.json
+++ b/docs/stage2c_cad_visual/console-errors.json
@@ -0,0 +1 @@
+{"defaultRoute":"/?playback=paused","errors":[],"note":"Spot-check via Playwright load; not a full console scrape matrix"}
--- a/docs/stage2c_cad_visual/deployment-report.md
+++ b/docs/stage2c_cad_visual/deployment-report.md
@@ -0,0 +1,17 @@
+# Deployment — Stage 2C
+
+## Local production
+
+- Container `owl-web-1` on `127.0.0.1:3100` hot-updated with Stage 2C `dist/` (asset `index-CA2EvFI-.js`)
+- Preview control: `127.0.0.1:3101` (`vite preview`)
+- Previous container/image retained; no rollback deleted
+
+## Public domain
+
+- `sorter.arhipovdan.ru` remains **BLOCKED_BY_DEPLOYMENT_ACCESS** (external A-record / openresty without this vhost)
+- Required DNS (owner action): A/AAAA or CNAME pointing to the host that terminates TLS for this app and proxies to `127.0.0.1:3100` (or LAN equivalent)
+- Cloudflare tunnel tokens are not published here
+
+## Phone
+
+- NOT_TESTED_ON_REAL_PHONE
--- a/docs/stage2c_cad_visual/drop-validation.json
+++ b/docs/stage2c_cad_visual/drop-validation.json
@@ -0,0 +1,138 @@
+{
+  "generatedAt": "2026-07-30T12:27:01.613Z",
+  "sim": "headless Rapier via simulateDrop (deterministic, dt=1/60, settle 6s)",
+  "runs": 10,
+  "routes": [
+    {
+      "sku": "SKU-001",
+      "route": "box → B",
+      "expectedZone": "B",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": "n/a",
+      "sampleFinalPositions": [
+        "(3.00,0.23,-0.00)",
+        "(3.00,0.23,-0.00)",
+        "(3.00,0.23,-0.00)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-009",
+      "route": "pen → C",
+      "expectedZone": "C",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(1.66,0.08,2.32)",
+        "(1.66,0.08,2.32)",
+        "(1.66,0.08,2.32)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-005",
+      "route": "pouf → C",
+      "expectedZone": "C",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(1.96,0.27,1.68)",
+        "(1.96,0.27,1.68)",
+        "(1.96,0.27,1.68)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-004",
+      "route": "oversized → C",
+      "expectedZone": "C",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(1.95,0.30,1.58)",
+        "(1.95,0.30,1.58)",
+        "(1.95,0.30,1.58)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-007",
+      "route": "bottle → D",
+      "expectedZone": "D",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(2.34,0.12,-1.95)",
+        "(2.34,0.12,-1.95)",
+        "(2.34,0.12,-1.95)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-006",
+      "route": "plate → D",
+      "expectedZone": "D",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(1.89,0.09,-1.80)",
+        "(1.89,0.09,-1.80)",
+        "(1.89,0.09,-1.80)"
+      ],
+      "result": "PASS"
+    },
+    {
+      "sku": "SKU-008",
+      "route": "cylinder → D",
+      "expectedZone": "D",
+      "runs": 10,
+      "correctLandings": 10,
+      "penetrations": 0,
+      "teleports": 0,
+      "outOfBounds": 0,
+      "frozenInAir": 0,
+      "pusherContacts": 10,
+      "sampleFinalPositions": [
+        "(2.22,0.10,-2.28)",
+        "(2.22,0.10,-2.28)",
+        "(2.22,0.10,-2.28)"
+      ],
+      "result": "PASS"
+    }
+  ],
+  "summary": {
+    "totalRoutes": 7,
+    "passedRoutes": 7,
+    "result": "PASS"
+  }
+}
--- a/docs/stage2c_cad_visual/materials-audit.json
+++ b/docs/stage2c_cad_visual/materials-audit.json
@@ -0,0 +1,16 @@
+{
+  "slots": [
+    "painted-metal",
+    "brushed-metal",
+    "rubber-belt",
+    "dark-mechanical",
+    "safety-yellow"
+  ],
+  "opaqueForced": true,
+  "transparencyAllowed": [
+    "RealSense glass only (SPEC_DERIVED)",
+    "laser beam debug"
+  ],
+  "surfaceOnlyNodes": [],
+  "note": "FCStd bodies are PartDesign solids; no CAD_SURFACE_ONLY solidify applied"
+}
--- a/docs/stage2c_cad_visual/mechanism-cad-map.md
+++ b/docs/stage2c_cad_visual/mechanism-cad-map.md
@@ -0,0 +1,23 @@
+# Mechanism CAD Map — Stage 2C
+
+## Author CAD nodes (conveer.FCStd → conveyor-web.glb)
+
+| Group | Nodes (labels) | Role | Usable as junction paddle? |
+|---|---|---|---|
+| stop-gate | Барьер001, Барьер002 | Metering barriers on CAD module (~x CAD −0.8…−1.8 m) | No — wrong location/stroke for B/C/D junction |
+| pusher-servo | Серво привод, Держатель-сервопривода, серво001, … | Side-mounted servo + holder on CAD module | Partial — REAL_CAD visual; no proven junction kinematics |
+| motor-and-drive | NEMA17, шкивы, ремень | Drive at CAD module | Yes (drive only) |
+
+## Junction sorting (x≈1.5 m, outside CAD module span)
+
+CAD module world span X ≈ [−2.086, −0.076]. Domain junction / paddles live at x≈1.5 → **outside** author CAD solids.
+
+**Decision:** keep `PusherMechanism` (SPEC_DERIVED angled paddle) as default kinematic contact body.
+**CAD_MECHANISM_UNUSABLE** for junction paddle: no author solid at junction with matching stroke/face.
+
+CAD `pusher-servo/*` remains visible as REAL_CAD static geometry on the metering module (not hidden).
+
+## Contact events (runtime)
+
+mechanismArmed → contactStarted → peakContactForce → contactEnded → physicsReleased → receiverEntered → itemSettled
+(asserted in headless via pusher contact + receiver volumes; see drop-validation.json)
--- a/docs/stage2c_cad_visual/performance-cad-corrected.json
+++ b/docs/stage2c_cad_visual/performance-cad-corrected.json
@@ -0,0 +1 @@
+{"profile":"B-cad-assembly","note":"No full 30s×3 GPU profile in this session; SwiftShader excluded","status":"NOT_REMEASURED","layoutCanvasHeightRatio":1.0}
--- a/docs/stage2c_cad_visual/performance-cad-physics.json
+++ b/docs/stage2c_cad_visual/performance-cad-physics.json
@@ -0,0 +1 @@
+{"profile":"C-cad-physics","status":"NOT_REMEASURED","physicsTimestep":0.0166667,"runtimeHeadlessHashEqual":true}
--- a/docs/stage2c_cad_visual/performance-control.json
+++ b/docs/stage2c_cad_visual/performance-control.json
@@ -0,0 +1 @@
+{"profile":"A-stage2-control","note":"Baseline Stage 2B not re-profiled in Stage 2C session","status":"NOT_REMEASURED"}
--- a/docs/stage2c_cad_visual/performance-final.json
+++ b/docs/stage2c_cad_visual/performance-final.json
@@ -0,0 +1 @@
+{"profile":"D-final","status":"PARTIAL","budget":{"avgFpsMin":45,"p95MsMax":28,"drawCallsMax":250,"trisMax":500000},"measured":null,"note":"Formal multi-run GPU profile deferred; unit/e2e/build green"}
--- a/docs/stage2c_cad_visual/runtime-headless-config-hash.json
+++ b/docs/stage2c_cad_visual/runtime-headless-config-hash.json
@@ -0,0 +1,55 @@
+{
+  "generatedAt": "2026-07-30T12:27:15.737Z",
+  "runtimeHash": "7ee15ad3e879a44a",
+  "headlessHash": "7ee15ad3e879a44a",
+  "equal": true,
+  "timestepEqual": true,
+  "timestepSec": 0.016666666666666666,
+  "snapshot": {
+    "timestep": 0.016666666666666666,
+    "gravity": [
+      0,
+      -9.81,
+      0
+    ],
+    "pusherHalfExtents": [
+      0.5,
+      0.14,
+      0.025
+    ],
+    "pusherCenterY": 0.842,
+    "pusherEngage": {
+      "x": 1.5,
+      "z": 0
+    },
+    "staticColliderCount": 25,
+    "staticColliderIds": [
+      "world-floor",
+      "belt-slab",
+      "b-spur",
+      "chute-C-floor",
+      "chute-C-rail-left",
+      "chute-C-rail-right",
+      "chute-D-floor",
+      "chute-D-rail-left",
+      "chute-D-rail-right",
+      "b-bin-floor",
+      "b-bin-wall-z+",
+      "b-bin-wall-z-",
+      "b-bin-wall-x+",
+      "b-bin-entry-lip",
+      "b-drop-chute",
+      "cage-C-floor",
+      "cage-C-wall-x-",
+      "cage-C-wall-x+",
+      "cage-C-wall-back",
+      "cage-C-entry-sill",
+      "cage-D-floor",
+      "cage-D-wall-x-",
+      "cage-D-wall-x+",
+      "cage-D-wall-back",
+      "cage-D-entry-sill"
+    ],
+    "staticColliderFingerprint": "world-floor|8.00000,0.05000,6.00000|0.00000,-0.05000,0.00000|0.00000,0.00000,0.00000|0.8000;belt-slab|3.17500,0.01200,0.25000|-1.02500,0.68600,0.00000|0.00000,0.00000,0.00000|0.7000;b-spur|0.32500,0.02000,0.22000|1.82500,0.67800,0.00000|0.00000,0.00000,0.00000|0.4000;chute-C-floor|0.50000,0.01000,0.72981|1.70000,0.39000,0.92000|0.37160,0.00000,0.00000|0.2000;chute-C-rail-left|0.01000,0.03500,0.72981|1.19000,0.43500,0.92000|0.37160,0.00000,0.00000|0.3000;chute-C-rail-right|0.01000,0.03500,0.72981|2.21000,0.43500,0.92000|0.37160,0.00000,0.00000|0.3000;chute-D-floor|0.50000,0.01000,0.72981|1.70000,0.39000,-0.92000|-0.37160,0.00000,0.00000|0.2000;chute-D-rail-left|0.01000,0.03500,0.72981|1.19000,0.43500,-0.92000|-0.37160,0.00000,0.00000|0.3000;chute-D-rail-right|0.01000,0.03500,0.72981|2.21000,0.43500,-0.92000|-0.37160,0.00000,0.00000|0.3000;b-bin-floor|0.60000,0.02000,0.40000|3.35000,0.06000,0.00000|0.00000,0.00000,0.00000|0.8000;b-bin-wall-z+|0.60000,0.25000,0.01500|3.35000,0.33000,0.40000|0.00000,0.00000,0.00000|0.6000;b-bin-wall-z-|0.60000,0.25000,0.01500|3.35000,0.33000,-0.40000|0.00000,0.00000,0.00000|0.6000;b-bin-wall-x+|0.01500,0.25000,0.40000|3.95000,0.33000,0.00000|0.00000,0.00000,0.00000|0.6000;b-bin-entry-lip|0.01500,0.04000,0.40000|2.75000,0.12000,0.00000|0.00000,0.00000,0.00000|0.6000;b-drop-chute|0.46755,0.00800,0.21000|2.50000,0.39500,0.00000|0.00000,0.00000,-0.68339|0.2500;cage-C-floor|0.60000,0.04000,0.40000|2.00000,0.04000,2.00000|0.00000,0.00000,0.00000|0.8000;cage-C-wall-x-|0.02000,0.40000,0.40000|1.40000,0.40000,2.00000|0.00000,0.00000,0.00000|0.5000;cage-C-wall-x+|0.02000,0.40000,0.40000|2.60000,0.40000,2.00000|0.00000,0.00000,0.00000|0.5000;cage-C-wall-back|0.60000,0.40000,0.02000|2.00000,0.40000,2.40000|0.00000,0.00000,0.00000|0.5000;cage-C-entry-sill|0.60000,0.02000,0.01500|2.00000,0.10000,1.60000|0.00000,0.00000,0.00000|0.5000;cage-D-floor|0.60000,0.04000,0.40000|2.00000,0.04000,-2.00000|0.00000,0.00000,0.00000|0.8000;cage-D-wall-x-|0.02000,0.40000,0.40000|1.40000,0.40000,-2.00000|0.00000,0.00000,0.00000|0.5000;cage-D-wall-x+|0.02000,0.40000,0.40000|2.60000,0.40000,-2.00000|0.00000,0.00000,0.00000|0.5000;cage-D-wall-back|0.60000,0.40000,0.02000|2.00000,0.40000,-2.40000|0.00000,0.00000,0.00000|0.5000;cage-D-entry-sill|0.60000,0.02000,0.01500|2.00000,0.10000,-1.60000|0.00000,0.00000,0.00000|0.5000"
+  }
+}
--- a/docs/stage2c_cad_visual/screenshots/01-current-before.png
+++ b/docs/stage2c_cad_visual/screenshots/01-current-before.png
--- a/docs/stage2c_cad_visual/screenshots/02-cad-contact-sheet.png
+++ b/docs/stage2c_cad_visual/screenshots/02-cad-contact-sheet.png
--- a/docs/stage2c_cad_visual/screenshots/03-single-conveyor-overview.png
+++ b/docs/stage2c_cad_visual/screenshots/03-single-conveyor-overview.png
--- a/docs/stage2c_cad_visual/screenshots/04-motor-correct-position.png
+++ b/docs/stage2c_cad_visual/screenshots/04-motor-correct-position.png
--- a/docs/stage2c_cad_visual/screenshots/05-volumetric-rollers.png
+++ b/docs/stage2c_cad_visual/screenshots/05-volumetric-rollers.png
--- a/docs/stage2c_cad_visual/screenshots/06-volumetric-brackets.png
+++ b/docs/stage2c_cad_visual/screenshots/06-volumetric-brackets.png
--- a/docs/stage2c_cad_visual/screenshots/07-real-sorter-mechanism.png
+++ b/docs/stage2c_cad_visual/screenshots/07-real-sorter-mechanism.png
--- a/docs/stage2c_cad_visual/screenshots/08-mechanism-contact.png
+++ b/docs/stage2c_cad_visual/screenshots/08-mechanism-contact.png
--- a/docs/stage2c_cad_visual/screenshots/09-no-measurement-panel.png
+++ b/docs/stage2c_cad_visual/screenshots/09-no-measurement-panel.png
--- a/docs/stage2c_cad_visual/screenshots/10-full-height-layout.png
+++ b/docs/stage2c_cad_visual/screenshots/10-full-height-layout.png
--- a/docs/stage2c_cad_visual/screenshots/11-box-scale.png
+++ b/docs/stage2c_cad_visual/screenshots/11-box-scale.png
--- a/docs/stage2c_cad_visual/screenshots/12-bottle-scale.png
+++ b/docs/stage2c_cad_visual/screenshots/12-bottle-scale.png
--- a/docs/stage2c_cad_visual/screenshots/13-plate-scale.png
+++ b/docs/stage2c_cad_visual/screenshots/13-plate-scale.png
--- a/docs/stage2c_cad_visual/screenshots/14-pen-close-up.png
+++ b/docs/stage2c_cad_visual/screenshots/14-pen-close-up.png
--- a/docs/stage2c_cad_visual/screenshots/15-route-b-final.png
+++ b/docs/stage2c_cad_visual/screenshots/15-route-b-final.png
--- a/docs/stage2c_cad_visual/screenshots/16-route-c-final.png
+++ b/docs/stage2c_cad_visual/screenshots/16-route-c-final.png
--- a/docs/stage2c_cad_visual/screenshots/17-route-d-final.png
+++ b/docs/stage2c_cad_visual/screenshots/17-route-d-final.png
--- a/docs/stage2c_cad_visual/screenshots/18-mobile-svg.png
+++ b/docs/stage2c_cad_visual/screenshots/18-mobile-svg.png
--- a/docs/stage2c_cad_visual/screenshots/cad-contact-sheet.png
+++ b/docs/stage2c_cad_visual/screenshots/cad-contact-sheet.png
--- a/docs/stage2c_cad_visual/videos/README.md
+++ b/docs/stage2c_cad_visual/videos/README.md
@@ -0,0 +1,16 @@
+# Stage 2C runtime videos
+
+Recorded WebM files are **not** shipped in this drop.
+
+Evidence used instead:
+- Headless drop validation `7/7 × 10/10` (`drop-validation.json`) with pusher contact asserts
+- Runtime/headless config hash equality (`runtime-headless-config-hash.json`)
+- Still screenshots `07-real-sorter-mechanism.png`, `08-mechanism-contact.png`, route finals
+
+To capture locally (preview on :3101):
+
+```bash
+# example: use browser MediaRecorder or ffmpeg x11grab against the preview window
+```
+
+Do not treat this README as a substitute for visual PASS of contact trajectories.
--- a/docs/stage2c_cad_visual/visual-physics-review.md
+++ b/docs/stage2c_cad_visual/visual-physics-review.md
@@ -0,0 +1,27 @@
+# Visual Physics Review — Stage 2C
+
+## Layout
+
+- Canvas heightRatio = 1.0, emptyRatio = 0 (Playwright + CDP)
+- White MEASUREMENT (`CVInspectionOverlay`) unmounted on `/`
+- Compact HUD (ITEM/STATUS/CATEGORY) retained top-right (allowed)
+
+## Motor
+
+- Cause of detached motor: procedural `StepperMotor` at CONVEYOR_END_X — **removed**
+- CAD NEMA17 world AABB ≈ Y 0.56–0.61 (on frame under belt drive) — not floor-hidden
+
+## Mechanism
+
+- Junction paddle: SPEC_DERIVED (CAD lacks junction paddle solid)
+- Contact-based C/D handoff unchanged; headless 7/7×10/10 with pusher contact
+
+## Parity
+
+- runtimeHash == headlessHash: 7ee15ad3e879a44a
+
+## Remaining visual debt
+
+- Entry/exit belt still SPEC_DERIVED (modular, not scaled CAD)
+- CAD belt segment looks brighter/different from extensions
+- Runtime WebM trajectories not recorded in this drop
				`@@ -0,0 +1 @@`
				`{"defaultRoute":"/?playback=paused","errors":[],"note":"Spot-check via Playwright load; not a full console scrape matrix"}`
				`@@ -0,0 +1 @@`
				`{"profile":"B-cad-assembly","note":"No full 30s×3 GPU profile in this session; SwiftShader excluded","status":"NOT_REMEASURED","layoutCanvasHeightRatio":1.0}`
				`@@ -0,0 +1 @@`
				`{"profile":"C-cad-physics","status":"NOT_REMEASURED","physicsTimestep":0.0166667,"runtimeHeadlessHashEqual":true}`
				`@@ -0,0 +1 @@`
				`{"profile":"A-stage2-control","note":"Baseline Stage 2B not re-profiled in Stage 2C session","status":"NOT_REMEASURED"}`
				`@@ -0,0 +1 @@`
				`{"profile":"D-final","status":"PARTIAL","budget":{"avgFpsMin":45,"p95MsMax":28,"drawCallsMax":250,"trisMax":500000},"measured":null,"note":"Formal multi-run GPU profile deferred; unit/e2e/build green"}`