stalendeuren/lib/door-models.ts

/**
 * Door Manufacturing Specifications
 * Based on "Metalworks" market analysis
 * All dimensions in millimeters (mm)
 */

// ============================================
// MANUFACTURING CONSTANTS
// ============================================

export const PROFILE_WIDTH = 40; // mm - Face width
export const PROFILE_DEPTH = 40; // mm - Tube depth
export const PROFILE_CORNER_RADIUS = 2; // mm - Rounded corners for welding

export const STILE_WIDTH = 40; // mm - Vertical profiles
export const RAIL_WIDTH = 20; // mm - Horizontal slim-line profiles

export const GLASS_THICKNESS = 7; // mm - Standard 33.1 Safety Glass
export const GLASS_OFFSET = 15; // mm - Center glass in 40mm profile

export const RAIL_HEIGHT_SLIM = 20; // mm - Slim horizontal rails
export const RAIL_HEIGHT_ROBUST = 40; // mm - Standard robust rails

export const TAATS_PIVOT_OFFSET = 60; // mm
export const STELRUIMTE = 10; // mm
export const HANGNAAD = 3; // mm
export const WALL_THICKNESS = 150; // mm

export function calculateMountingDimensions(sparingsmaatWidth: number, sparingsmaatHeight: number) {
  const frameOuterWidth = sparingsmaatWidth - STELRUIMTE;
  const frameOuterHeight = sparingsmaatHeight - STELRUIMTE / 2;
  const doorLeafWidth = frameOuterWidth - (2 * HANGNAAD);
  const doorLeafHeight = frameOuterHeight - (2 * HANGNAAD);

  return {
    sparingsmaatWidth,
    sparingsmaatHeight,
    frameOuterWidth,
    frameOuterHeight,
    doorLeafWidth,
    doorLeafHeight,
    stelruimtePerSide: STELRUIMTE / 2,
    hangnaadPerSide: HANGNAAD,
  };
}

// ============================================
// PHYSICAL PART TYPES
// ============================================

export type PartType = 'stile' | 'rail' | 'glass' | 'divider';
export type DoorModel = 'taats' | 'scharnier' | 'paneel';
export type GridLayout =
  | 'geen'
  | '2-vlak'
  | '3-vlak'
  | '4-vlak'
  | '6-vlak'
  | '8-vlak'
  | 'kruis'
  | 'ongelijk-3'
  | 'boerderij'
  | 'herenhuis';

export interface PhysicalPart {
  type: PartType;
  x: number;
  y: number;
  z: number;
  width: number;
  height: number;
  depth: number;
  label?: string;
  isGlass?: boolean;
}

export interface DoorAssembly {
  modelId: DoorModel;
  gridLayout: GridLayout;
  doorWidth: number;
  doorHeight: number;
  parts: PhysicalPart[];
}

// ============================================
// GRID PATTERN DEFINITIONS (DATA-DRIVEN)
// ============================================

/**
 * Grid pattern definition as data.
 * horizontalPositions: fractional Y positions (0 = bottom, 1 = top) for horizontal dividers
 * verticalPositions: fractional X positions (0 = left, 1 = right) for vertical dividers
 */
interface GridPatternDef {
  horizontalPositions: number[];
  verticalPositions: number[];
}

const GRID_PATTERNS: Record<GridLayout, GridPatternDef> = {
  'geen': { horizontalPositions: [], verticalPositions: [] },
  '2-vlak': { horizontalPositions: [0.5], verticalPositions: [] },
  '3-vlak': { horizontalPositions: [1 / 3, 2 / 3], verticalPositions: [] },
  '4-vlak': { horizontalPositions: [0.25, 0.5, 0.75], verticalPositions: [] },
  '6-vlak': { horizontalPositions: [1 / 3, 2 / 3], verticalPositions: [0.5] },
  '8-vlak': { horizontalPositions: [0.25, 0.5, 0.75], verticalPositions: [0.5] },
  'kruis': { horizontalPositions: [0.5], verticalPositions: [0.5] },
  'ongelijk-3': { horizontalPositions: [0.35, 0.65], verticalPositions: [] },
  'boerderij': { horizontalPositions: [0.7], verticalPositions: [0.5] },
  'herenhuis': { horizontalPositions: [0.3, 0.7], verticalPositions: [] },
};

// ============================================
// LAYOUT GENERATION
// ============================================

export function generateDoorAssembly(
  modelId: DoorModel,
  gridLayout: GridLayout,
  doorWidth: number,
  doorHeight: number
): DoorAssembly {
  const parts: PhysicalPart[] = [];
  const pattern = GRID_PATTERNS[gridLayout] || GRID_PATTERNS['geen'];

  // ============================================
  // PERIMETER FRAME
  // ============================================

  // LEFT STILE
  parts.push({
    type: 'stile',
    x: -doorWidth / 2 + PROFILE_WIDTH / 2,
    y: 0,
    z: 0,
    width: PROFILE_WIDTH,
    height: doorHeight,
    depth: PROFILE_DEPTH,
    label: 'Left Stile',
  });

  // RIGHT STILE
  parts.push({
    type: 'stile',
    x: doorWidth / 2 - PROFILE_WIDTH / 2,
    y: 0,
    z: 0,
    width: PROFILE_WIDTH,
    height: doorHeight,
    depth: PROFILE_DEPTH,
    label: 'Right Stile',
  });

  // TOP RAIL
  const topRailWidth = doorWidth - PROFILE_WIDTH * 2;
  parts.push({
    type: 'rail',
    x: 0,
    y: doorHeight / 2 - RAIL_HEIGHT_ROBUST / 2,
    z: 0,
    width: topRailWidth,
    height: RAIL_HEIGHT_ROBUST,
    depth: PROFILE_DEPTH,
    label: 'Top Rail',
  });

  // BOTTOM RAIL
  parts.push({
    type: 'rail',
    x: 0,
    y: -doorHeight / 2 + RAIL_HEIGHT_ROBUST / 2,
    z: 0,
    width: topRailWidth,
    height: RAIL_HEIGHT_ROBUST,
    depth: PROFILE_DEPTH,
    label: 'Bottom Rail',
  });

  // ============================================
  // HORIZONTAL DIVIDERS (from pattern data)
  // ============================================

  const innerHeight = doorHeight - RAIL_HEIGHT_ROBUST * 2;
  const innerBottom = -doorHeight / 2 + RAIL_HEIGHT_ROBUST;

  for (const fraction of pattern.horizontalPositions) {
    const dividerY = innerBottom + innerHeight * fraction;

    // Determine width: if there are vertical dividers, horizontal dividers span full width
    // (vertical dividers will be handled separately)
    parts.push({
      type: 'divider',
      x: 0,
      y: dividerY,
      z: 0,
      width: topRailWidth,
      height: RAIL_HEIGHT_SLIM,
      depth: PROFILE_DEPTH,
      label: `H-Divider ${Math.round(fraction * 100)}%`,
    });
  }

  // ============================================
  // VERTICAL DIVIDERS (from pattern data)
  // ============================================

  const innerWidth = doorWidth - PROFILE_WIDTH * 2;
  const innerLeft = -doorWidth / 2 + PROFILE_WIDTH;

  for (const fraction of pattern.verticalPositions) {
    const dividerX = innerLeft + innerWidth * fraction;
    const verticalDividerHeight = innerHeight;

    parts.push({
      type: 'divider',
      x: dividerX,
      y: 0,
      z: 0,
      width: PROFILE_WIDTH,
      height: verticalDividerHeight,
      depth: PROFILE_DEPTH,
      label: `V-Divider ${Math.round(fraction * 100)}%`,
    });
  }

  // ============================================
  // PANEEL TYPE CENTER VERTICAL DIVIDER
  // ============================================

  if (modelId === 'paneel' && !pattern.verticalPositions.includes(0.5)) {
    const verticalDividerHeight = doorHeight - RAIL_HEIGHT_ROBUST * 2;

    parts.push({
      type: 'divider',
      x: 0,
      y: 0,
      z: 0,
      width: PROFILE_WIDTH,
      height: verticalDividerHeight,
      depth: PROFILE_DEPTH,
      label: 'Center Vertical Divider',
    });
  }

  // ============================================
  // GLASS PANELS
  // ============================================

  const glassWidth = doorWidth - PROFILE_WIDTH * 2 - GLASS_OFFSET * 2;
  const glassHeight = doorHeight - RAIL_HEIGHT_ROBUST * 2 - GLASS_OFFSET * 2;

  parts.push({
    type: 'glass',
    x: 0,
    y: 0,
    z: 0,
    width: glassWidth,
    height: glassHeight,
    depth: GLASS_THICKNESS,
    label: 'Main Glass Panel',
    isGlass: true,
  });

  return {
    modelId,
    gridLayout,
    doorWidth,
    doorHeight,
    parts,
  };
}

export function mmToMeters(mm: number): number {
  return mm / 1000;
}

export function getDividerPositions(
  gridLayout: GridLayout,
  doorHeight: number
): number[] {
  const pattern = GRID_PATTERNS[gridLayout];
  if (!pattern) return [];

  const doorHeightMeters = mmToMeters(doorHeight);
  const innerHeight = doorHeightMeters - mmToMeters(RAIL_HEIGHT_ROBUST * 2);
  const innerBottom = -doorHeightMeters / 2 + mmToMeters(RAIL_HEIGHT_ROBUST);

  return pattern.horizontalPositions.map(
    (fraction) => innerBottom + innerHeight * fraction
  );
}

export function validateDoorDimensions(
  doorWidth: number,
  doorHeight: number
): { valid: boolean; errors: string[] } {
  const errors: string[] = [];

  if (doorWidth < PROFILE_WIDTH * 3) {
    errors.push(`Door width too small (min: ${PROFILE_WIDTH * 3}mm)`);
  }

  if (doorHeight < RAIL_HEIGHT_ROBUST * 3) {
    errors.push(`Door height too small (min: ${RAIL_HEIGHT_ROBUST * 3}mm)`);
  }

  if (doorWidth > 1200) {
    errors.push('Door width exceeds maximum (1200mm) - structural integrity');
  }

  if (doorHeight > 3000) {
    errors.push('Door height exceeds maximum (3000mm) - structural integrity');
  }

  return {
    valid: errors.length === 0,
    errors,
  };
}