feat: finish Stage 2B continuous sorter realism and local deploy

Unify CAD conveyor on / and /details, add RealSense D435i + contact paddle physics, keep items moving through scan, lock 7×10 drop validation, and ship Stage 2 artifacts with production on :3100 (permanent HTTPS still blocked). Co-authored-by: Cursor <cursoragent@cursor.com>
2026-07-30 12:00:09 +00:00
parent 40e9b18e8d
commit acc59ec912
81 changed files with 2530 additions and 878 deletions
--- a/e2e/controls.spec.ts
+++ b/e2e/controls.spec.ts
@@ -1,26 +1,31 @@
 import { test, expect } from '@playwright/test';
+import { dismissFinished, ensurePaused, ensureRunning, openPausedCase } from './helpers';

 test.describe('controls', () => {
+  test.setTimeout(90_000);
+
  test.beforeEach(async ({ page }) => {
-    await page.goto('/');
-    await expect(page.locator('canvas')).toBeVisible({ timeout: 60_000 });
-    await expect(page.getByTestId('demo-hud')).toBeVisible();
+    await openPausedCase(page, 0, '1');
  });

  test('seek next/prev and jump cases, speed, presentation', async ({ page }) => {
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');

    await page.getByTestId('demo-next').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('2/10');
+    await ensurePaused(page);
+    await expect(page.getByTestId('demo-case-label')).toHaveText('2/11');

    await page.getByTestId('demo-prev').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await ensurePaused(page);
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');

    await page.getByTestId('demo-case-8').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('9/10');
+    await ensurePaused(page);
+    await expect(page.getByTestId('demo-case-label')).toHaveText('9/11');

    await page.getByTestId('demo-case-0').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await ensurePaused(page);
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');

    for (const speed of ['0.5', '1', '1.5', '2'] as const) {
      await page.getByTestId(`demo-speed-${speed}`).click();
@@ -34,5 +39,8 @@ test.describe('controls', () => {
    await page.locator('.presentation-exit').click();
    await expect(page.getByTestId('demo-hud')).toBeVisible();
    await expect(page.getByTestId('demo-presentation')).toBeVisible();
+
+    await page.goto('/?debug=1');
+    await ensureRunning(page);
  });
 });
--- a/e2e/helpers.ts
+++ b/e2e/helpers.ts
@@ -0,0 +1,55 @@
+/** Shared e2e helpers — Stage 2B autostart means / opens already running. */
+import { expect, type Page } from '@playwright/test';
+
+/** Close the Demo Complete overlay if it is covering the controls. */
+export async function dismissFinished(page: Page) {
+  const finished = page.getByTestId('demo-finished');
+  if (await finished.isVisible().catch(() => false)) {
+    await finished.getByRole('button', { name: /Replay/i }).click({ force: true });
+    await expect(finished).toHaveCount(0, { timeout: 10_000 });
+  }
+}
+
+/** Ensure playback is running (noop if already on Pause button). */
+export async function ensureRunning(page: Page) {
+  await dismissFinished(page);
+  const pause = page.getByTestId('demo-pause');
+  if (await pause.isVisible().catch(() => false)) return;
+  const play = page.getByTestId('demo-play');
+  await expect(play.or(pause)).toBeVisible({ timeout: 15_000 });
+  if (await play.isVisible().catch(() => false)) {
+    await play.click({ force: true });
+  }
+  await expect(page.getByTestId('demo-pause')).toBeVisible({ timeout: 10_000 });
+}
+
+export async function ensurePaused(page: Page) {
+  await dismissFinished(page);
+  const play = page.getByTestId('demo-play');
+  if (await play.isVisible().catch(() => false)) return;
+  await page.getByTestId('demo-pause').click({ force: true });
+  await expect(page.getByTestId('demo-play')).toBeVisible({ timeout: 10_000 });
+}
+
+/** Assert either Play or Pause control is present (autostart-safe). */
+export async function expectPlaybackControl(page: Page) {
+  await expect(
+    page.getByTestId('demo-play').or(page.getByTestId('demo-pause')),
+  ).toBeVisible({ timeout: 15_000 });
+}
+
+/**
+ * Open debug demo, pause, then seek to a case WHILE paused (seek preserves
+ * paused status — unlike seek from idle which auto-starts).
+ */
+export async function openPausedCase(page: Page, caseIndex: number, speed: '0.5' | '1' | '1.5' | '2' = '1') {
+  await page.goto('/?debug=1');
+  await expect(page.locator('canvas')).toBeVisible({ timeout: 60_000 });
+  await expect(page.getByTestId('demo-hud')).toBeVisible();
+  await ensurePaused(page);
+  await page.getByTestId(`demo-speed-${speed}`).click();
+  await page.getByTestId(`demo-case-${caseIndex}`).click();
+  await dismissFinished(page);
+  await ensurePaused(page);
+  await expect(page.getByTestId('demo-case-label')).toHaveText(`${caseIndex + 1}/11`);
+}
--- a/e2e/mobile-fallback.spec.ts
+++ b/e2e/mobile-fallback.spec.ts
@@ -1,4 +1,5 @@
 import { test, expect } from '@playwright/test';
+import { ensureRunning } from './helpers';

 /**
 * Stage 0 — mobile fallback & WebGL context resilience.
@@ -67,9 +68,9 @@ test.describe('mobile fallback (390x844)', () => {
    // Auto-camera toggle must not claim hidden 3D works
    await expect(page.locator('.auto-camera-toggle')).toHaveCount(0);

-    // Play/pause drive the visible SVG scene (same playback state)
-    await page.getByTestId('demo-play').click();
-    await expect(page.getByTestId('demo-pause')).toBeVisible({ timeout: 10_000 });
+    // Play/pause drive the visible SVG scene (same playback state).
+    // Stage 2B autostart may already be running — ensureRunning is idempotent.
+    await ensureRunning(page);
    await expect(page.getByTestId('demo-status')).not.toHaveText('FINISHED');
    await page.getByTestId('demo-pause').click();
    await expect(page.getByTestId('demo-play')).toBeVisible({ timeout: 10_000 });
@@ -185,7 +186,7 @@ test.describe('stage2 mobile capability policy', () => {
    // Mobile Low mounts the real 3D canvas at low quality
    await expect(page.locator('canvas')).toBeVisible({ timeout: 60_000 });
    await expect(page.getByTestId('main-svg-fallback')).toHaveCount(0);
-    await page.getByTestId('demo-play').click();
+    await ensureRunning(page);
    await page.waitForTimeout(4000);
    expect(pageErrors, `pageerrors: ${pageErrors.join('; ')}`).toEqual([]);
  });
@@ -227,7 +228,7 @@ test.describe('stage0 prototype mode', () => {
    await toggle.click();
    await expect(toggle).toContainText('Auto Cam: ON');

-    await page.getByTestId('demo-play').click();
+    await ensureRunning(page);
    await page.waitForTimeout(4000);
    expect(pageErrors, `pageerrors: ${pageErrors.join('; ')}`).toEqual([]);
    expect(consoleErrors, `console errors: ${consoleErrors.join('; ')}`).toEqual([]);
--- a/e2e/production.smoke.spec.ts
+++ b/e2e/production.smoke.spec.ts
@@ -17,7 +17,7 @@ test.describe('production smoke @production', () => {
      }
    });

-    await page.goto('/');
+    await page.goto('/?debug=1');
    const html = await page.content();
    const bundle = html.match(/index-[A-Za-z0-9_-]+\.js/)?.[0] ?? '';
    expect(bundle).toMatch(/^index-/);
@@ -50,7 +50,7 @@ test.describe('production smoke @production', () => {
    expect(webgl.ok).toBe(true);

    await expect(page.getByTestId('demo-play').or(page.getByTestId('demo-pause'))).toBeVisible();
-    await expect(page.getByTestId('demo-case-9')).toBeVisible();
+    await expect(page.getByTestId('demo-case-10')).toBeVisible();

    // Play / seek
    const pauseBtn = page.getByTestId('demo-pause');
@@ -59,11 +59,11 @@ test.describe('production smoke @production', () => {
    }
    await page.waitForTimeout(600);
    await page.getByTestId('demo-case-0').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');

    // Jam
    await page.getByTestId('demo-speed-2').click();
-    await page.getByTestId('demo-case-8').click();
+    await page.getByTestId('demo-case-9').click();
    await expect
      .poll(async () => {
        const status = (await page.getByTestId('demo-status').textContent()) ?? '';
@@ -73,7 +73,7 @@ test.describe('production smoke @production', () => {
      .toMatch(/FAULT|JAM/i);

    // E-stop
-    await page.getByTestId('demo-case-9').click();
+    await page.getByTestId('demo-case-10').click();
    await expect
      .poll(async () => {
        const status = (await page.getByTestId('demo-status').textContent()) ?? '';
@@ -88,7 +88,7 @@ test.describe('production smoke @production', () => {
      await stop.click({ force: true });
    }
    await page.getByTestId('demo-case-0').click({ force: true });
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');

    await page.goto('/details');
    await expect(page.locator('#root')).toBeVisible();
@@ -96,7 +96,7 @@ test.describe('production smoke @production', () => {
    await expect(page.locator('#root')).toBeVisible();

    // Back home — version still matches
-    await page.goto('/');
+    await page.goto('/?debug=1');
    const version2 = await page.evaluate(async () => {
      const r = await fetch('/version.json', { cache: 'no-store' });
      return r.ok ? r.json() : null;
--- a/e2e/real-models.spec.ts
+++ b/e2e/real-models.spec.ts
@@ -10,6 +10,7 @@
 *   - no console errors throughout
 */
 import { test, expect, type Page } from '@playwright/test';
+import { ensureRunning } from './helpers';

 const MODEL_RE = /\/models\/.*\.stl$/;

@@ -32,7 +33,7 @@ test.describe('Stage 1 real models', () => {

    await page.goto('/', { waitUntil: 'domcontentloaded' });
    await page.waitForSelector('canvas', { timeout: 30000 });
-    await page.locator('[data-testid="demo-play"]').first().click();
+    await ensureRunning(page);

    // Playlist starts with SKU-001 (box-300.stl, preloaded); let playback settle.
    await page.waitForTimeout(9000);
@@ -49,7 +50,7 @@ test.describe('Stage 1 real models', () => {

    await page.goto('/', { waitUntil: 'domcontentloaded' });
    await page.waitForSelector('canvas', { timeout: 30000 });
-    await page.locator('[data-testid="demo-play"]').first().click();
+    await ensureRunning(page);

    // Play through several cases incl. the bottle case; scene must stay alive.
    await page.waitForTimeout(15000);
@@ -120,7 +121,7 @@ test.describe('Stage 1 real models', () => {
    const errors = watchConsole(page);
    await page.goto('/?stage1=1&verify=real-models&sku=SKU-001', { waitUntil: 'domcontentloaded' });
    await page.waitForSelector('canvas', { timeout: 30000 });
-    await page.locator('[data-testid="demo-play"]').first().click();
+    await ensureRunning(page);
    await page.waitForTimeout(8000);

    const card = page.locator('text=STAGE1 VERIFY · SKU-001');
@@ -135,7 +136,7 @@ test.describe('Stage 1 real models', () => {
    const errors = watchConsole(page);
    await page.goto('/?stage1=1&verify=real-models&sku=SKU-011', { waitUntil: 'domcontentloaded' });
    await page.waitForSelector('canvas', { timeout: 30000 });
-    await page.locator('[data-testid="demo-play"]').first().click();
+    await ensureRunning(page);

    // SKU-011 is the 7th playlist case — seek forward deterministically.
    for (let i = 0; i < 6; i++) {
--- a/e2e/safety.spec.ts
+++ b/e2e/safety.spec.ts
@@ -1,17 +1,13 @@
 import { test, expect } from '@playwright/test';
+import { ensureRunning, openPausedCase } from './helpers';

 test.describe('safety', () => {
-  test.beforeEach(async ({ page }) => {
-    await page.goto('/');
-    await expect(page.locator('canvas')).toBeVisible({ timeout: 60_000 });
-    await expect(page.getByTestId('demo-hud')).toBeVisible();
-    // Speed up to reach fault phases sooner
-    await page.getByTestId('demo-speed-2').click();
-  });
+  test.setTimeout(90_000);

  test('jam case shows FAULT in status or command', async ({ page }) => {
-    await page.getByTestId('demo-case-8').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('9/10');
+    await openPausedCase(page, 9, '1');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('10/11');
+    await ensureRunning(page);

    await expect
      .poll(
@@ -20,14 +16,15 @@ test.describe('safety', () => {
          const command = (await page.getByTestId('demo-command').textContent()) ?? '';
          return `${status} ${command}`;
        },
-        { timeout: 25_000 },
+        { timeout: 20_000, intervals: [50, 100, 100] },
      )
      .toMatch(/FAULT/i);
  });

  test('emergency case shows EMERGENCY in status or command', async ({ page }) => {
-    await page.getByTestId('demo-case-9').click();
-    await expect(page.getByTestId('demo-case-label')).toHaveText('10/10');
+    await openPausedCase(page, 10, '1');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('11/11');
+    await ensureRunning(page);

    await expect
      .poll(
@@ -36,7 +33,7 @@ test.describe('safety', () => {
          const command = (await page.getByTestId('demo-command').textContent()) ?? '';
          return `${status} ${command}`;
        },
-        { timeout: 25_000 },
+        { timeout: 20_000, intervals: [50, 100, 100] },
      )
      .toMatch(/EMERGENCY/i);
  });
--- a/e2e/smoke.spec.ts
+++ b/e2e/smoke.spec.ts
@@ -1,4 +1,5 @@
 import { test, expect } from '@playwright/test';
+import { ensureRunning, expectPlaybackControl } from './helpers';

 test.describe('smoke', () => {
  test('home opens, canvas loads, play works', async ({ page }) => {
@@ -13,10 +14,9 @@ test.describe('smoke', () => {
    await expect(canvas).toBeVisible({ timeout: 60_000 });

    await expect(page.getByTestId('demo-hud')).toBeVisible();
-    await expect(page.getByTestId('demo-play')).toBeVisible();
-
-    await page.getByTestId('demo-play').click();
-    await expect(page.getByTestId('demo-pause')).toBeVisible({ timeout: 10_000 });
+    // Stage 2B: demo autostarts — Pause is present immediately; Play after pause.
+    await expectPlaybackControl(page);
+    await ensureRunning(page);
    await expect(page.getByTestId('demo-status')).not.toHaveText('FINISHED');

    const finished = page.getByTestId('demo-finished');
--- a/e2e/visual.spec.ts
+++ b/e2e/visual.spec.ts
@@ -3,11 +3,14 @@ import { test, expect, type Page } from '@playwright/test';
 test.setTimeout(90_000);

 async function waitScene(page: Page) {
-  await page.goto('/');
+  await page.goto('/?debug=1&playback=paused');
  await expect(page.locator('canvas')).toBeVisible({ timeout: 60_000 });
  await page.evaluate(() => document.fonts.ready);
  await expect(page.getByTestId('demo-hud')).toBeVisible();
-  // Demo auto-starts as running — pin speed early
+  // seek pins case 0 and starts running — pause again for deterministic HUD snaps
+  await page.getByTestId('demo-case-0').click();
+  const pause = page.getByTestId('demo-pause');
+  if (await pause.isVisible().catch(() => false)) await pause.click();
  await page.getByTestId('demo-speed-2').click();
 }

@@ -22,7 +25,7 @@ async function dismissFinishedIfNeeded(page: Page) {
 async function jumpCase(page: Page, index: number) {
  await dismissFinishedIfNeeded(page);
  await page.getByTestId(`demo-case-${index}`).click();
-  await expect(page.getByTestId('demo-case-label')).toHaveText(`${index + 1}/10`, {
+  await expect(page.getByTestId('demo-case-label')).toHaveText(`${index + 1}/11`, {
    timeout: 10_000,
  });
 }
@@ -52,7 +55,7 @@ test.describe('visual regression', () => {
    if (await pause.isVisible().catch(() => false)) {
      await pause.click();
    }
-    await expect(page.getByTestId('demo-case-label')).toHaveText('1/10');
+    await expect(page.getByTestId('demo-case-label')).toHaveText('1/11');
    await snapHud(page, '01-home-idle-hud.png');
  });

@@ -85,7 +88,7 @@ test.describe('visual regression', () => {

  test('05 jam fault HUD', async ({ page }) => {
    await waitScene(page);
-    await jumpCase(page, 8);
+    await jumpCase(page, 9);
    await ensureRunning(page);
    await expect
      .poll(async () => {
@@ -100,7 +103,7 @@ test.describe('visual regression', () => {

  test('06 emergency stop HUD', async ({ page }) => {
    await waitScene(page);
-    await jumpCase(page, 9);
+    await jumpCase(page, 10);
    await ensureRunning(page);
    await expect
      .poll(async () => {
@@ -139,7 +142,7 @@ test.describe('visual regression', () => {

  test('09 recovery after jam stop', async ({ page }) => {
    await waitScene(page);
-    await jumpCase(page, 8);
+    await jumpCase(page, 9);
    await ensureRunning(page);
    await expect
      .poll(async () => {