import React from 'react';
import {
  discBrakeState,
} from '../../../animations/mechanics';
import type { MachineAnimationModule } from '../../../animations/types';
import {
  MachinePart,
  Shaft,
} from './primitives';
import {
  EngineeringBaseplate,
  PartLabels,
  getPartVisualProps,
} from './proceduralSceneHelpers';
import type {
  ProceduralMachineDefinition,
  ProceduralMachineModule,
  ProceduralMachineSceneProps,
} from './types';

const definition: ProceduralMachineDefinition = {
  id: 'disc-brake-caliper',
  slug: 'disc-brake-caliper',
  title: 'Disc Brake Caliper',
  subtitle: 'Hydraulic clamping and friction heat generation',
  category: 'Structural / Other',
  difficulty: 'Beginner',
  summary: 'A floating disc brake caliper showing piston extension, pad clamp, rotor deceleration, and heat band.',
  description:
    'Disc brakes convert kinetic energy into heat through friction. Hydraulic pressure moves the piston and pads against the rotor, generating braking torque proportional to clamp force and friction coefficient.',
  keywords: ['brake', 'caliper', 'rotor', 'hydraulic', 'friction', 'heat'],
  complexity: 5,
  dateAdded: '2025-02-04',
  typicalRpm: 'Wheel speed dependent',
  facts: [
    {
      label: 'Energy conversion',
      value: 'Kinetic energy → heat',
      detail: 'Brake components must absorb and reject heat without fade or cracking.',
    },
    {
      label: 'Actuation',
      value: 'Hydraulic piston',
      detail: 'Fluid pressure multiplies pedal force into clamp force at the pads.',
    },
    {
      label: 'Friction pair',
      value: 'Pad against iron/steel rotor',
      detail: 'Pad compound affects bite, noise, dust, wear, and temperature range.',
    },
    {
      label: 'Thermal design',
      value: 'Ventilation and mass',
      detail: 'Rotor vanes, diameter, and thickness set thermal capacity and cooling.',
    },
  ],
  parts: [
    {
      id: 'rotor',
      name: 'Brake rotor',
      description: 'Rotating disc clamped by pads to create braking torque.',
      material: 'Cast iron / carbon ceramic',
      labelPosition: [-0.9, 0.8, 0.86],
    },
    {
      id: 'hub',
      name: 'Wheel hub',
      description: 'Central mounting boss tying the rotor to the wheel bearing and axle.',
      material: 'Steel / aluminium',
      labelPosition: [-0.98, -0.75, 0.72],
    },
    {
      id: 'caliper-body',
      name: 'Caliper body',
      description: 'Bridge structure carrying hydraulic piston and pad reaction loads.',
      material: 'Cast aluminium / iron',
      labelPosition: [1.35, 0.85, 0.78],
    },
    {
      id: 'inner-pad',
      name: 'Inner brake pad',
      description: 'Friction material pressed against the inboard rotor face.',
      labelPosition: [0.52, -0.98, 0.84],
    },
    {
      id: 'outer-pad',
      name: 'Outer brake pad',
      description: 'Friction material pressed against the outboard rotor face.',
      labelPosition: [1.45, -0.55, 0.84],
    },
    {
      id: 'piston',
      name: 'Hydraulic piston',
      description: 'Piston extending under brake fluid pressure to move the inner pad.',
      labelPosition: [1.68, 0.18, 0.84],
    },
    {
      id: 'brake-line',
      name: 'Brake line',
      description: 'Hydraulic feed supplying pressurized fluid to the caliper.',
      labelPosition: [2.1, 1.28, 0.78],
    },
    {
      id: 'heat-band',
      name: 'Heat band',
      description: 'Warm glow showing friction heating on the swept area of the rotor.',
      labelPosition: [-0.15, 1.28, 0.82],
      defaultOpacity: 0.42,
    },
  ],
  cameraPresets: [
    { id: 'iso', label: 'Isometric', position: [3.7, 2.5, 4.0], target: [0, 0, 0], fov: 42 },
    { id: 'front', label: 'Rotor face', position: [0, 0.4, 5.3], target: [0, 0, 0], fov: 38 },
    { id: 'caliper', label: 'Caliper clamp', position: [4.0, 1.4, 2.8], target: [0.45, 0, 0], fov: 42 },
  ],
  tour: {
    id: 'tour-disc-brake-caliper',
    machineId: 'disc-brake-caliper',
    title: 'Hydraulic braking in one clamp cycle',
    description: 'Watch pressure build, pads close, friction heat rise, and pressure release.',
    steps: [
      {
        id: 'rotor',
        title: 'Rotor spins with the wheel',
        body: 'The rotor is fixed to the hub and carries wheel kinetic energy.',
        durationSeconds: 4,
        partIds: ['rotor', 'hub'],
        camera: { position: [-2.6, 1.5, 4.0], target: [0, 0, 0], duration: 1.1 },
        rpm: 220,
      },
      {
        id: 'pressure',
        title: 'Hydraulic pressure extends the piston',
        body: 'Brake fluid pressure moves the piston and forces the inner pad toward the rotor.',
        durationSeconds: 4.5,
        partIds: ['brake-line', 'piston', 'inner-pad'],
        phaseRange: [0.18, 0.42],
        camera: { position: [3.4, 1.6, 3.3], target: [0.55, 0, 0], duration: 1.1 },
        rpm: 180,
      },
      {
        id: 'clamp',
        title: 'Pads clamp both faces',
        body: 'The caliper bridge reacts the force so both pads squeeze the disc and create braking torque.',
        durationSeconds: 5,
        partIds: ['caliper-body', 'inner-pad', 'outer-pad', 'rotor'],
        phaseRange: [0.43, 0.7],
        camera: { position: [4.1, 1.2, 2.6], target: [0.35, 0, 0], duration: 1.1 },
      },
      {
        id: 'heat',
        title: 'Friction becomes heat',
        body: 'The swept rotor band heats rapidly under clamp load, so ventilation and material matter.',
        durationSeconds: 4,
        partIds: ['heat-band', 'rotor'],
        phaseRange: [0.54, 0.86],
        camera: { position: [0.8, 1.7, 4.7], target: [0, 0, 0], duration: 1.1 },
      },
    ],
  },
  relatedMachineIds: ['ball-bearing', 'differential-gear', 'four-stroke-petrol-engine'],
};

function partProps(
  partId: string,
  props: ProceduralMachineSceneProps,
  explodeDirection: [number, number, number] = [0, 0, 0],
) {
  return {
    partId,
    registerPart: props.registerPart,
    explodeDirection,
    explodedDistance: props.explodedDistance ?? 0,
    onSelectPart: props.onSelectPart,
    onHoverPart: props.onHoverPart,
    ...getPartVisualProps(partId, props),
  };
}

export const discBrakeCaliperAnimation: MachineAnimationModule = {
  id: 'disc-brake-hydraulic-clamp',
  machineId: 'disc-brake-caliper',
  label: 'Hydraulic clamp and heat cycle',
  version: '1.0.0',
  defaultRpm: 220,
  minRpm: 5,
  maxRpm: 1500,
  cycleRevolutions: 1,
  cycleSteps: 16,
  loop: true,
  supportsReverse: true,
  reducedMotionStrategy: 'slow',
  update(context) {
    const state = discBrakeState(context.shaftAngle, context.cycleProgress);

    const rotor = context.getPart('rotor');
    if (rotor) rotor.rotation.z = -state.rotorAngle;

    const hub = context.getPart('hub');
    if (hub) hub.rotation.z = -state.rotorAngle;

    const innerPad = context.getPart('inner-pad');
    if (innerPad) innerPad.position.z = -0.24 + state.padTravel;

    const outerPad = context.getPart('outer-pad');
    if (outerPad) outerPad.position.z = 0.24 - state.padTravel;

    const piston = context.getPart('piston');
    if (piston) {
      piston.position.z = -0.48 + state.padTravel * 0.95;
      piston.scale.z = 1 + state.brakePressure * 0.18;
    }

    const brakeLine = context.getPart('brake-line');
    if (brakeLine) brakeLine.scale.setScalar(1 + state.brakePressure * 0.04);

    const heatBand = context.getPart('heat-band');
    if (heatBand) {
      heatBand.scale.setScalar(1 + state.heat * 0.03);
      heatBand.rotation.z = -state.rotorAngle * 0.88;
    }
    context.setPartOpacity('heat-band', 0.12 + state.heat * 0.78);

    context.setPhaseLabel(
      state.brakePressure > 0.15
        ? `Brake pressure ${Math.round(state.brakePressure * 100)}% — pads clamping rotor`
        : 'Released — rotor spinning freely between pads',
    );

    context.clearHighlights();
    if (state.brakePressure > 0.15) context.highlightParts(['piston', 'inner-pad', 'outer-pad', 'heat-band'], 0.9);
    else context.highlightParts(['rotor', 'hub'], 0.65);
  },
};

export function DiscBrakeCaliperScene(props: ProceduralMachineSceneProps): JSX.Element {
  return (
    <group>
      <EngineeringBaseplate width={4.8} depth={3.2} />

      <MachinePart {...partProps('rotor', props, [-0.24, 0.08, 0])}>
        <mesh castShadow receiveShadow>
          <cylinderGeometry args={[1.05, 1.05, 0.16, 96]} />
          <meshStandardMaterial color="#6c7480" metalness={0.82} roughness={0.28} />
        </mesh>
        <mesh position={[0, 0, 0.085]}>
          <torusGeometry args={[0.72, 0.03, 10, 96]} />
          <meshStandardMaterial color="#9da6b3" metalness={0.82} roughness={0.26} />
        </mesh>
        {Array.from({ length: 18 }, (_, index) => {
          const angle = (index / 18) * Math.PI * 2;
          return (
            <mesh key={index} position={[Math.cos(angle) * 0.83, Math.sin(angle) * 0.83, 0.095]}>
              <cylinderGeometry args={[0.035, 0.035, 0.03, 12]} />
              <meshStandardMaterial color="#202733" metalness={0.5} roughness={0.45} />
            </mesh>
          );
        })}
      </MachinePart>

      <MachinePart {...partProps('hub', props, [-0.25, -0.18, 0.04])}>
        <mesh>
          <cylinderGeometry args={[0.28, 0.28, 0.28, 48]} />
          <meshStandardMaterial color="#a8b2c0" metalness={0.84} roughness={0.22} />
        </mesh>
        <Shaft length={0.86} radius={0.08} axis="z" color="#b9c2cf" />
      </MachinePart>

      <MachinePart {...partProps('caliper-body', props, [0.42, 0.1, 0.12])} position={[0.72, 0.08, 0]}>
        <mesh position={[0.32, 0, 0]}>
          <boxGeometry args={[0.68, 1.42, 0.62]} />
          <meshStandardMaterial color="#253247" metalness={0.5} roughness={0.42} />
        </mesh>
        <mesh position={[-0.22, 0.67, 0]}>
          <boxGeometry args={[1.1, 0.22, 0.62]} />
          <meshStandardMaterial color="#253247" metalness={0.5} roughness={0.42} />
        </mesh>
        <mesh position={[-0.22, -0.67, 0]}>
          <boxGeometry args={[1.1, 0.22, 0.62]} />
          <meshStandardMaterial color="#253247" metalness={0.5} roughness={0.42} />
        </mesh>
      </MachinePart>

      <MachinePart {...partProps('inner-pad', props, [0.18, -0.12, -0.28])} position={[0.5, 0, -0.24]}>
        <mesh>
          <boxGeometry args={[0.34, 1.12, 0.08]} />
          <meshStandardMaterial color="#353c45" metalness={0.28} roughness={0.72} />
        </mesh>
      </MachinePart>

      <MachinePart {...partProps('outer-pad', props, [0.25, -0.12, 0.28])} position={[0.5, 0, 0.24]}>
        <mesh>
          <boxGeometry args={[0.34, 1.12, 0.08]} />
          <meshStandardMaterial color="#353c45" metalness={0.28} roughness={0.72} />
        </mesh>
      </MachinePart>

      <MachinePart {...partProps('piston', props, [0.36, 0.02, -0.32])} position={[0.92, 0, -0.48]}>
        <mesh rotation={[Math.PI / 2, 0, 0]}>
          <cylinderGeometry args={[0.26, 0.26, 0.18, 40]} />
          <meshStandardMaterial color="#aab4c2" metalness={0.86} roughness={0.2} />
        </mesh>
      </MachinePart>

      <MachinePart {...partProps('brake-line', props, [0.5, 0.34, 0.18])} position={[1.28, 1.0, -0.2]} rotation={[0, 0, -0.4]}>
        <mesh rotation={[0, 0, Math.PI / 2]}>
          <cylinderGeometry args={[0.035, 0.035, 1.2, 16]} />
          <meshStandardMaterial color="#4c8dff" metalness={0.35} roughness={0.35} />
        </mesh>
      </MachinePart>

      <MachinePart {...partProps('heat-band', props, [0, 0.16, 0.1])} opacity={props.partState?.['heat-band']?.opacity ?? 0.4}>
        <mesh position={[0, 0, 0.1]}>
          <torusGeometry args={[0.76, 0.045, 10, 96]} />
          <meshBasicMaterial color="#ff7a3c" transparent opacity={0.55} />
        </mesh>
      </MachinePart>

      <PartLabels parts={definition.parts} visible={props.labelsVisible} />
    </group>
  );
}

export const discBrakeCaliper: ProceduralMachineModule = {
  definition,
  animationModule: discBrakeCaliperAnimation,
  Scene: DiscBrakeCaliperScene,
};