floor-planner/tests/flooring.test.ts
2026-09-11 22:14:24 +01:00

557 lines
24 KiB
TypeScript

import f8Fixture from './fixtures/angled-room-f8.json';
import { describe, expect, it } from 'vitest';
import ClipperLib from 'clipper-lib';
import { planFlooring } from '../src/lib/flooring';
import { buildGeometry, insetPolygon, signedArea } from '../src/lib/geometry';
import { fireplace, rectangle } from '../src/lib/defaults';
import { flooringCuts } from '../src/lib/cut-list';
import { cutLength } from '../src/lib/format';
import type { FlooringPlan, FlooringSettings, Point, Project, Room } from '../src/lib/types';
const settings: FlooringSettings = {
length: 1200,
width: 200,
gap: 10,
pattern: 'brick',
optimisation: 'cuts',
minOffset: 300,
maxOffset: 600,
minLength: 200,
minWidth: 60,
kerf: 3,
};
function room(width = 4020, height = 2220, id = '1'): Room {
const result = rectangle(id, `Room ${id}`, width, height);
result.walls.forEach((wall) => {
wall.doors = [];
});
return result;
}
function errors(plan: FlooringPlan) {
return plan.issues.filter((issue) => issue.severity === 'error');
}
function overlap(a: Point[], b: Point[]): number {
const clipper = new ClipperLib.Clipper();
const path = (points: Point[]) =>
points.map((p) => ({ X: Math.round(p.x * 1000), Y: Math.round(p.y * 1000) }));
clipper.AddPath(path(a), ClipperLib.PolyType.ptSubject, true);
clipper.AddPath(path(b), ClipperLib.PolyType.ptClip, true);
const result: ClipperLib.Paths = [];
clipper.Execute(ClipperLib.ClipType.ctIntersection, result);
return result.reduce((sum, polygon) => sum + Math.abs(ClipperLib.Clipper.Area(polygon)) / 1e6, 0);
}
function expectCoverage(plan: FlooringPlan, r: Room, gap: number) {
const inset = insetPolygon(buildGeometry(r, 1).vertices, gap);
const expectedArea = inset.reduce((sum, p) => sum + Math.abs(signedArea(p)), 0);
const pieces = plan.pieces.filter((p) => p.roomId === r.id);
// Clipping rounds intersections to 0.001 mm; permit less than 1 mm² area drift.
expect(
Math.abs(pieces.reduce((sum, p) => sum + Math.abs(signedArea(p.polygon)), 0) - expectedArea),
).toBeLessThan(1);
for (let i = 0; i < pieces.length; i++) {
expect(
Math.abs(
inset.reduce((sum, p) => sum + overlap(pieces[i].polygon, p), 0) -
Math.abs(signedArea(pieces[i].polygon)),
),
).toBeLessThan(1);
for (let j = i + 1; j < pieces.length; j++)
expect(overlap(pieces[i].polygon, pieces[j].polygon)).toBeLessThan(0.01);
}
}
function expectStockFits(plan: FlooringPlan, s: FlooringSettings) {
const ids = plan.pieces.map((piece) => piece.id);
expect(new Set(ids).size).toBe(ids.length);
expect(plan.stocks.flatMap((stock) => stock.pieceIds).sort()).toEqual([...ids].sort());
for (const stock of plan.stocks) {
const pieces = stock.pieceIds.map((id) => plan.pieces.find((piece) => piece.id === id)!);
const used = pieces.reduce((sum, piece) => sum + piece.length, 0);
expect(used + Math.max(0, pieces.length - 1) * s.kerf).toBeLessThanOrEqual(s.length + 0.02);
expect(stock.remaining).toBeGreaterThanOrEqual(0);
expect(used + stock.remaining).toBeLessThanOrEqual(s.length + 0.02);
// Crosscuts cannot create factory joints: each purchased board supplies one of each end.
for (const end of ['factoryLeft', 'factoryRight'] as const) {
expect(
pieces.filter((piece) => piece[end]).length,
`${stock.id} allocates its ${end} more than once`,
).toBeLessThanOrEqual(1);
}
for (const piece of pieces.filter((piece) => piece.factoryLeft && piece.factoryRight)) {
expect(piece.length).toBeCloseTo(s.length, 3);
expect(piece.reused).toBe(false);
expect(pieces).toHaveLength(1);
}
}
}
function expectOffsets(plan: FlooringPlan, s: FlooringSettings) {
for (let i = 1; i < plan.rows.length; i++) {
const a = plan.rows[i - 1],
b = plan.rows[i];
if (a.roomId !== b.roomId) continue;
const difference = Math.abs(a.offset - b.offset);
const distance = Math.min(difference, s.length - difference);
expect(distance).toBeGreaterThanOrEqual(s.minOffset - 0.01);
expect(distance).toBeLessThanOrEqual(s.maxOffset + 0.01);
}
}
describe('laminate planning', () => {
it('covers a rectangle exactly, without overlap, and stays inside its expansion gap', () => {
const r = room();
const plan = planFlooring([r], settings, 1);
expect(errors(plan)).toEqual([]);
expect(plan.coveredArea).toBe(4000 * 2200);
expectCoverage(plan, r, settings.gap);
expect(
plan.pieces.every((p) => p.length >= settings.minLength && p.width >= settings.minWidth),
).toBe(true);
expectOffsets(plan, settings);
expectStockFits(plan, settings);
});
it('splits a narrow remainder between first and last rows', () => {
const plan = planFlooring([room(4020, 2040)], settings, 1);
expect(errors(plan)).toEqual([]);
expect(plan.rows).toHaveLength(11);
expect(plan.rows[0].width).toBe(110);
expect(plan.rows.at(-1)?.width).toBe(110);
expect(plan.rows.slice(1, -1).every((row) => row.width === 200)).toBe(true);
expect(
plan.pieces.filter((piece) => piece.row === 1).every((piece) => piece.ripEdge === 'top'),
).toBe(true);
expect(
plan.pieces.filter((piece) => piece.row === 11).every((piece) => piece.ripEdge === 'bottom'),
).toBe(true);
});
it('rejects impossible edge widths instead of ripping factory joints off middle rows', () => {
const plan = planFlooring([room(4020, 450)], { ...settings, minWidth: 120 }, 1);
expect(plan.boardCount).toBe(0);
expect(errors(plan)[0].message).toContain('minimum row width');
});
it('reuses offcuts without double counting stock or ignoring saw kerf', () => {
const r = room(4020, 2020);
const plan = planFlooring([r], settings, 1);
expect(errors(plan)).toEqual([]);
expect(plan.reusedCount).toBeGreaterThan(0);
expectStockFits(plan, settings);
// A 600 mm starter and 600 mm finisher cannot share a 1200 mm board with a 3 mm kerf.
for (const stock of plan.stocks) {
const lengths = stock.pieceIds.map((id) => plan.pieces.find((p) => p.id === id)!.length);
expect(lengths.filter((length) => Math.abs(length - 600) < 0.01).length).toBeLessThan(2);
}
expect(plan.boardCount).toBeGreaterThanOrEqual(
Math.ceil(plan.coveredArea / (settings.length * settings.width)),
);
expect(plan.wasteArea).toBeCloseTo(
plan.boardCount * settings.length * settings.width - plan.coveredArea,
2,
);
});
describe.each([
['brick', 'cuts'],
['random', 'cuts'],
['random', 'random'],
] as const)('%s pattern, %s optimisation: factory short ends', (pattern, optimisation) => {
const s = { ...settings, pattern, optimisation };
it.each([0, 90] as const)(
'never packs three row ends onto one board, with boards running at %i degrees',
(direction) => {
const r = direction === 0 ? room(3920, 1620) : room(1620, 3920);
r.direction = direction;
const plan = planFlooring([r], s, 1);
expect(errors(plan)).toEqual([]);
expect(plan.rows).toHaveLength(8);
expect(plan.reusedCount).toBeGreaterThan(0);
for (const row of plan.rows) {
const position = (polygon: Point[]) =>
Math.min(...polygon.map((point) => (direction === 0 ? point.x : point.y)));
const pieces = row.pieceIds
.map((id) => plan.pieces.find((piece) => piece.id === id)!)
.sort((a, b) => position(a.polygon) - position(b.polygon));
expect(pieces.length).toBeGreaterThan(2);
// Derive the required joints from installed positions, independently of allocation flags.
pieces.forEach((piece, index) => {
expect(piece.factoryLeft, `${piece.id}: left joint`).toBe(index > 0);
expect(piece.factoryRight, `${piece.id}: right joint`).toBe(index < pieces.length - 1);
});
}
const shortestEnds = plan.pieces
.filter((piece) => piece.factoryLeft !== piece.factoryRight)
.map((piece) => piece.length)
.sort((a, b) => a - b)
.slice(0, 3);
expect(shortestEnds).toHaveLength(3);
// Three ends fit by length, including kerf, but cannot share only two factory joints.
expect(shortestEnds.reduce((sum, length) => sum + length, 0) + 2 * s.kerf).toBeLessThan(
s.length,
);
for (const stock of plan.stocks) expect(stock.pieceIds.length).toBeLessThanOrEqual(2);
expectStockFits(plan, s);
expectCoverage(plan, r, s.gap);
},
);
it('allows three pieces when the middle cut spans wall to wall and the outer cuts keep opposite ends', () => {
const first = room(1620, 220, 'first');
const middle = room(220, 414, 'middle');
middle.direction = 90;
const last = room(1620, 220, 'last');
const rooms = [first, middle, last];
const plan = planFlooring(rooms, s, 1);
expect(errors(plan)).toEqual([]);
const triples = plan.stocks.filter((stock) => stock.pieceIds.length === 3);
expect(triples).toHaveLength(1);
const pieces = triples[0].pieceIds.map((id) => plan.pieces.find((piece) => piece.id === id)!);
expect(
pieces.map((piece) => ({
room: piece.roomId,
length: piece.length,
left: piece.factoryLeft,
right: piece.factoryRight,
})),
).toEqual([
{ room: 'first', length: 400, left: true, right: false },
{ room: 'middle', length: 394, left: false, right: false },
{ room: 'last', length: 400, left: false, right: true },
]);
expect(plan.pieces.filter((piece) => piece.roomId === middle.id)).toEqual([pieces[1]]);
expect(pieces.map((piece) => piece.reused)).toEqual([false, true, true]);
expect(plan.boardCount).toBe(3);
expect(plan.cuts).toBe(2);
expect(triples[0].remaining).toBe(0);
expectStockFits(plan, s);
for (const r of rooms) expectCoverage(plan, r, s.gap);
});
});
it('produces exact concave fireplace templates and keeps the gap at its external corners', () => {
const r = fireplace('fire', 'Fireplace room');
const plan = planFlooring([r], { ...settings, width: 190 }, 1);
expect(errors(plan)).toEqual([]);
expectCoverage(plan, r, settings.gap);
expect(plan.pieces.some((piece) => piece.shaped)).toBe(true);
for (const piece of plan.pieces) {
expect(
piece.template.every(
(p) =>
p.x >= -0.01 && p.y >= -0.01 && p.x <= piece.length + 0.01 && p.y <= piece.width + 0.01,
),
).toBe(true);
}
expectStockFits(plan, { ...settings, width: 190 });
});
it('clips an angled wall exactly and provides shaped cut coordinates', () => {
const points = [
{ x: 0, y: 0 },
{ x: 4000, y: 0 },
{ x: 4200, y: 2200 },
{ x: 0, y: 2200 },
];
const headings = points.map(
(p, i) =>
(Math.atan2(
points[(i + 1) % points.length].y - p.y,
points[(i + 1) % points.length].x - p.x,
) *
180) /
Math.PI,
);
const r: Room = {
id: 'angled',
name: 'Angled room',
direction: 0,
walls: points.map((p, i) => ({
id: `w${i}`,
length: Math.hypot(
points[(i + 1) % points.length].x - p.x,
points[(i + 1) % points.length].y - p.y,
),
turn: ((headings[(i + 1) % points.length] - headings[i] + 540) % 360) - 180,
doors: [],
})),
};
const plan = planFlooring([r], settings, 1);
expect(errors(plan)).toEqual([]);
expectCoverage(plan, r, settings.gap);
expect(plan.pieces.filter((piece) => piece.shaped).length).toBeGreaterThan(2);
expectStockFits(plan, settings);
});
it('gives identical random plans for identical input and respects both stagger limits', () => {
const s = { ...settings, pattern: 'random' as const, minOffset: 250, maxOffset: 450 };
const a = planFlooring([room()], s, 1);
expect(errors(a)).toEqual([]);
expect(a).toEqual(planFlooring([room()], s, 1));
expect(new Set(a.rows.map((row) => row.offset)).size).toBeGreaterThan(2);
expectOffsets(a, s);
expectStockFits(a, s);
expectCoverage(a, room(), s.gap);
});
it.each([
['rectangle', room(4800, 3600, 'room-1'), 76, 42],
['fireplace', fireplace('room-2', 'Fireplace room'), 74, 48],
] as const)(
'breaks random staircases and near-brick repeats in a common %s',
(_, r, boardBudget, cutBudget) => {
const s = {
...settings,
width: 190,
pattern: 'random' as const,
optimisation: 'random' as const,
};
const plan = planFlooring([r], s, 1);
expect(errors(plan)).toEqual([]);
expect(plan).toEqual(planFlooring([r], s, 1));
const phases = plan.rows.map((row) => row.offset);
const signedDistance = (a: number, b: number) => {
let difference = b - a;
if (difference >= s.length / 2) difference -= s.length;
if (difference < -s.length / 2) difference += s.length;
return difference;
};
const steps = phases.slice(1).map((phase, i) => signedDistance(phases[i], phase));
// This case actually crosses the board boundary, so checking raw differences would miss steps.
expect(
phases.some((phase, i) => i > 0 && Math.abs(phase - phases[i - 1]) > s.length / 2),
).toBe(true);
for (let i = 1; i < steps.length; i++) {
// Similar signed steps across three rows produce a visible staircase, even with small kerf drift.
expect(Math.abs(steps[i] - steps[i - 1])).toBeGreaterThan(36);
// Returning to almost the same joint line two rows later produces an H/brick repeat.
expect(Math.abs(signedDistance(phases[i - 1], phases[i + 1]))).toBeGreaterThan(36);
}
for (let i = 2; i < steps.length; i++) {
expect(
steps.slice(i - 2, i + 1).every((step) => step > 0) ||
steps.slice(i - 2, i + 1).every((step) => step < 0),
).toBe(false);
}
// Breaking the old regular pattern must not increase the stock requirement for these rooms.
expect(plan.boardCount).toBeLessThanOrEqual(boardBudget);
expect(plan.cuts).toBeLessThanOrEqual(cutBudget);
expect(plan.reusedCount).toBeGreaterThan(0);
expect(
plan.pieces.every((piece) => piece.length >= s.minLength && piece.width >= s.minWidth),
).toBe(true);
expectOffsets(plan, s);
expectStockFits(plan, s);
expectCoverage(plan, r, s.gap);
},
);
it('keeps a constrained random layout valid when only alternating starts can fit', () => {
const r = room(2420, 1620);
const s = { ...settings, pattern: 'random' as const, minLength: 600 };
const plan = planFlooring([r], s, 1);
expect(errors(plan)).toEqual([]);
expect(plan.rows).toHaveLength(8);
expect(new Set(plan.rows.map((row) => row.offset))).toEqual(new Set([0, 600]));
expect(plan.rows[0].offset).toBe(plan.rows[2].offset);
expectOffsets(plan, s);
expectStockFits(plan, s);
expectCoverage(plan, r, s.gap);
});
it.each([400, 600])(
'respects an exact %i mm random offset even when repetition is unavoidable',
(offset) => {
const s = { ...settings, pattern: 'random' as const, minOffset: offset, maxOffset: offset };
const plan = planFlooring([room()], s, 1);
expect(errors(plan)).toEqual([]);
expect(plan).toEqual(planFlooring([room()], s, 1));
expectOffsets(plan, s);
expectStockFits(plan, s);
},
);
it('rejects impossible brick stagger constraints', () => {
const plan = planFlooring([room()], { ...settings, maxOffset: 400 }, 1);
expect(plan.boardCount).toBe(0);
expect(errors(plan)[0].message).toContain('half-board');
});
it('plans each room independently and can reuse compatible end offcuts across directions', () => {
const a = room(620, 220, '1');
// Its ends complement the first room's remnants after the 3 mm saw kerf.
const b = room(220, 617, '2');
b.direction = 90;
const combined = planFlooring([a, b], settings, 1);
const separately =
planFlooring([a], settings, 1).boardCount + planFlooring([b], settings, 1).boardCount;
expect(errors(combined)).toEqual([]);
expect(combined.boardCount).toBeLessThanOrEqual(separately);
expect(
combined.stocks.some(
(stock) =>
new Set(stock.pieceIds.map((id) => combined.pieces.find((p) => p.id === id)!.roomId))
.size > 1,
),
).toBe(true);
expectCoverage(combined, a, settings.gap);
expectCoverage(combined, b, settings.gap);
expectStockFits(combined, settings);
expectOffsets(combined, settings);
});
it('reports an unclosed room and never counts a partial floor', () => {
const r = room();
r.walls[0].length += 100;
const plan = planFlooring([r], settings, 1);
expect(plan.boardCount).toBe(0);
expect(plan.pieces).toEqual([]);
expect(errors(plan)[0].message).toContain('closed outline');
});
it('rejects zero and nonfinite settings without unbounded loops', () => {
expect(errors(planFlooring([room()], { ...settings, width: 0 }, 1))).toHaveLength(1);
const nonfinite = planFlooring([room()], { ...settings, length: NaN }, 1);
expect(errors(nonfinite)).toHaveLength(1);
expect(nonfinite.wasteArea).toBe(0);
expect(errors(planFlooring([room()], { ...settings, length: 1e308 }, 1))).toHaveLength(1);
expect(
errors(planFlooring([room()], { ...settings, width: 0.001, minWidth: 0.001 }, 1)),
).toHaveLength(1);
});
it('numbers cuts and ready offcuts continuously while preserving all row and stock references', () => {
const s = { ...settings, pattern: 'random' as const, minOffset: 250, maxOffset: 450 };
const plan = planFlooring([room()], s, 1);
const cuts = flooringCuts(plan);
expect(plan.pieces.length).toBeGreaterThan(cuts.length);
expect(cuts.some((piece) => piece.reused && !piece.cut)).toBe(true);
expect(cuts.map((piece) => piece.id)).toEqual(cuts.map((_, index) => `F${index + 1}`));
expect(
plan.pieces
.filter((piece) => !piece.cut && !piece.reused)
.every((piece) => piece.id.startsWith('FU')),
).toBe(true);
const ids = plan.pieces.map((piece) => piece.id);
expect(plan.rows.flatMap((row) => row.pieceIds).sort()).toEqual([...ids].sort());
expectStockFits(plan, s);
});
it('scopes room failures and shape warnings without scoping global material errors', () => {
const valid = room(4020, 2220, 'valid');
const open = room(4020, 2220, 'open');
open.walls[0].length += 100;
const shaped = fireplace('shaped', 'Fireplace room');
const plan = planFlooring([valid, open, shaped], { ...settings, width: 190 }, 1);
expect(plan.pieces.some((piece) => piece.roomId === valid.id)).toBe(true);
expect(plan.pieces.some((piece) => piece.roomId === open.id)).toBe(false);
expect(errors(plan).map((issue) => issue.roomId)).toEqual(['open']);
expect(
plan.issues.filter((issue) => issue.severity === 'warning').map((issue) => issue.roomId),
).toEqual(['shaped']);
expect(errors(planFlooring([valid], { ...settings, width: 0 }, 1))[0].roomId).toBeUndefined();
});
});
describe('angled room cut allocation', () => {
const project = f8Fixture.project as Project;
const plan = planFlooring(project.rooms, project.flooring, project.tolerance);
it('aligns a row seam with the inward corner that previously left F8 a thin toe', () => {
expect(errors(plan)).toEqual([]);
expect(project.rooms[0].walls).toHaveLength(13);
expect(project.rooms[0].walls.flatMap((wall) => wall.doors)).toHaveLength(2);
const corner = { x: 7607.513, y: 2160.34 };
const adjoining = plan.pieces.filter((piece) =>
piece.polygon.some((point) => Math.hypot(point.x - corner.x, point.y - corner.y) < 0.01),
);
expect(adjoining.length).toBeGreaterThanOrEqual(2);
expect(new Set(adjoining.map((piece) => piece.row)).size).toBe(2);
for (const piece of adjoining) {
// Boards run north/south: an x-boundary is the uncut factory long-edge seam.
const xs = piece.polygon.map((point) => point.x);
expect(
Math.min(Math.abs(Math.min(...xs) - corner.x), Math.abs(Math.max(...xs) - corner.x)),
).toBeLessThan(0.01);
const turns = piece.polygon.map((point, index, polygon) => {
const previous = polygon[(index + polygon.length - 1) % polygon.length];
const next = polygon[(index + 1) % polygon.length];
return (
(point.x - previous.x) * (next.y - point.y) - (point.y - previous.y) * (next.x - point.x)
);
});
expect(turns.every((turn) => turn >= -0.01) || turns.every((turn) => turn <= 0.01)).toBe(
true,
);
}
expectCoverage(plan, project.rooms[0], project.flooring.gap);
expectOffsets(plan, project.flooring);
expectStockFits(plan, project.flooring);
expect(plan).toEqual(planFlooring(project.rooms, project.flooring, project.tolerance));
});
it('fits all displayed half-millimetre blanks and their kerfs on each purchased board', () => {
expect(errors(plan)).toEqual([]);
expect(plan.pieces.some((piece) => cutLength(piece.length) > piece.length + 0.01)).toBe(true);
for (const stock of plan.stocks) {
const pieces = stock.pieceIds.map((id) => plan.pieces.find((piece) => piece.id === id)!);
const rounded = pieces.reduce((sum, piece) => sum + cutLength(piece.length), 0);
expect(
rounded + (pieces.length - 1) * project.flooring.kerf,
`${stock.id}: ${pieces.map((piece) => `${piece.id}=${cutLength(piece.length)}`).join(', ')}`,
).toBeLessThanOrEqual(project.flooring.length + 0.001);
}
});
it('preserves whole factory boards whose purchased length is not a half millimetre', () => {
const s = {
...settings,
length: 1200.2,
minOffset: 0,
maxOffset: 1200.2,
pattern: 'random' as const,
};
const r = room(1220.2, 220);
const fitted = planFlooring([r], s, 1);
expect(errors(fitted)).toEqual([]);
expect(fitted.boardCount).toBe(1);
expect(fitted.cuts).toBe(0);
expect(fitted.pieces[0].length).toBe(1200.2);
expect(fitted.pieces[0].blankLength).toBe(1200.2);
expect(fitted.stocks[0].remaining).toBe(0);
expectCoverage(fitted, r, s.gap);
});
it('uses an exact-fit fractional offcut without pretending it needs a new cut', () => {
const s = { ...settings, length: 1200.2, pattern: 'random' as const };
const fitted = planFlooring([room(620, 220, 'first'), room(617.2, 220, 'second')], s, 1);
expect(errors(fitted)).toEqual([]);
expect(fitted.boardCount).toBe(1);
expect(fitted.cuts).toBe(1);
expect(fitted.pieces.map((piece) => piece.length)).toEqual([600, 597.2]);
expect(fitted.pieces.map((piece) => piece.blankLength)).toEqual([600, 597.2]);
expect(fitted.pieces[1].reused).toBe(true);
expect(fitted.pieces[1].cut).toBe(false);
expect(fitted.stocks[0].remaining).toBe(0);
expectStockFits(fitted, s);
});
it('keeps a finishing cut visible when its rounded blank consumes a complete board', () => {
const s = { ...settings, pattern: 'random' as const };
const fitted = planFlooring([room(1219.6, 220)], s, 1);
expect(errors(fitted)).toEqual([]);
expect(fitted.boardCount).toBe(1);
expect(fitted.pieces[0].length).toBe(1199.6);
expect(fitted.pieces[0].cut).toBe(true);
expect(fitted.cuts).toBe(1);
expect(fitted.stocks[0].remaining).toBe(0);
});
it('caps a rounded rip blank at the available fractional factory width', () => {
const s = { ...settings, width: 200.2, pattern: 'random' as const };
const fitted = planFlooring([room(1220, 220.1)], s, 1);
expect(errors(fitted)).toEqual([]);
expect(fitted.boardCount).toBe(1);
expect(fitted.pieces[0].width).toBe(200.1);
expect(fitted.pieces[0].blankWidth).toBe(200.2);
expect(fitted.pieces[0].cut).toBe(true);
});
});