acc59ec912
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>
93 lines
3.9 KiB
TypeScript
93 lines
3.9 KiB
TypeScript
/**
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* Stage 2B §16 — mandatory drop validation: 7 routes × 10 runs (headless Rapier).
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*
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* Uses the SAME simulateDrop as the unit tests — same colliders, profiles,
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* handoff and pusher as the runtime. Writes docs/stage2_real_sorter/drop-validation.json.
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*
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* Note: the sim is deterministic (fixed dt, no RNG), so the 10 runs per route
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* are identical repetitions validating stability, not a Monte Carlo sample.
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* Runtime variability is covered by the browser e2e (variable frame rate).
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*/
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import { writeFileSync, mkdirSync } from 'node:fs';
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import { dirname, join } from 'node:path';
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import { fileURLToPath } from 'node:url';
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import { initRapier, simulateDrop } from '../src/domain/physicsDropSim';
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const here = dirname(fileURLToPath(import.meta.url));
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const OUT = join(here, '../docs/stage2_real_sorter/drop-validation.json');
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const RUNS = 10;
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const ROUTES: { sku: string; zone: 'B' | 'C' | 'D'; label: string }[] = [
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{ sku: 'SKU-001', zone: 'B', label: 'box → B' },
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{ sku: 'SKU-009', zone: 'C', label: 'pen → C' },
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{ sku: 'SKU-005', zone: 'C', label: 'pouf → C' },
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{ sku: 'SKU-004', zone: 'C', label: 'oversized → C' },
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{ sku: 'SKU-007', zone: 'D', label: 'bottle → D' },
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{ sku: 'SKU-006', zone: 'D', label: 'plate → D' },
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{ sku: 'SKU-008', zone: 'D', label: 'cylinder → D' },
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];
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// Work-area bounds (m) — anything outside is out-of-bounds.
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const BOUNDS = { x: [-2.6, 4.2], y: [-0.05, 2.5], z: [-2.6, 2.6] };
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const SPEED_TELEPORT_CAP = 8; // m/s — above this is a solver blowup/teleport
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const PENETRATION_DEPTH = 0.006; // m below the belt surface = critical penetration
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await initRapier();
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const report = {
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generatedAt: new Date().toISOString(),
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sim: 'headless Rapier via simulateDrop (deterministic, dt=1/60, settle 6s)',
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runs: RUNS,
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routes: [] as unknown[],
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summary: { totalRoutes: 0, passedRoutes: 0, result: 'PASS' as 'PASS' | 'FAIL' },
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};
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for (const route of ROUTES) {
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let correct = 0;
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let penetrations = 0;
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let teleports = 0;
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let outOfBounds = 0;
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let frozenInAir = 0;
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let pusherContacts = 0;
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const finals: string[] = [];
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for (let run = 0; run < RUNS; run += 1) {
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const r = simulateDrop(route.sku, route.zone);
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if (r.insideExpectedReceiver) correct += 1;
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if (r.minClearanceM < -PENETRATION_DEPTH) penetrations += 1;
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if (r.maxSpeedMps > SPEED_TELEPORT_CAP) teleports += 1;
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const [x, y, z] = r.finalPosition;
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if (x < BOUNDS.x[0] || x > BOUNDS.x[1] || y < BOUNDS.y[0] || y > BOUNDS.y[1] || z < BOUNDS.z[0] || z > BOUNDS.z[1]) {
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outOfBounds += 1;
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}
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// Frozen in air: settled above floor level but NOT inside the receiver.
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if (!r.insideExpectedReceiver && y > 0.4) frozenInAir += 1;
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if (r.pusherContactMade) pusherContacts += 1;
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if (run < 3) finals.push(`(${x.toFixed(2)},${y.toFixed(2)},${z.toFixed(2)})`);
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}
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const pass = correct === RUNS && penetrations === 0 && teleports === 0 && outOfBounds === 0 && frozenInAir === 0
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&& (route.zone === 'B' || pusherContacts === RUNS);
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report.routes.push({
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sku: route.sku,
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route: route.label,
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expectedZone: route.zone,
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runs: RUNS,
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correctLandings: correct,
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penetrations,
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teleports,
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outOfBounds,
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frozenInAir,
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pusherContacts: route.zone === 'B' ? 'n/a' : pusherContacts,
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sampleFinalPositions: finals,
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result: pass ? 'PASS' : 'FAIL',
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});
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report.summary.totalRoutes += 1;
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if (pass) report.summary.passedRoutes += 1;
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console.log(`${pass ? 'PASS' : 'FAIL'} ${route.label} (${route.sku}): ${correct}/${RUNS} landings, pen=${penetrations}, tp=${teleports}, oob=${outOfBounds}, air=${frozenInAir}, pusher=${route.zone === 'B' ? 'n/a' : pusherContacts}`);
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}
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if (report.summary.passedRoutes !== report.summary.totalRoutes) report.summary.result = 'FAIL';
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mkdirSync(dirname(OUT), { recursive: true });
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writeFileSync(OUT, JSON.stringify(report, null, 2));
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console.log(`\n${report.summary.passedRoutes}/${report.summary.totalRoutes} routes PASS -> ${OUT}`);
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process.exit(report.summary.result === 'PASS' ? 0 : 1);
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