Remove all fallbacks: show errors, draw debug lines on calibration

- Remove try-except in CameraCalibrator — errors propagate to UI
- Remove auto-load of saved calibrations — always start uncalibrated
- Remove hardcoded "Base Setup" card with fake values
- Remove addStereocameras/getCamParams dead code
- Draw all detected Hough lines + corners on debug frame during calibration
- Show debug images in calibration tab after attempt
- Show error messages in UI instead of swallowing them

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

jetson/main.py

@@ -39,11 +39,9 @@ def auto_calibrate():
     compute camera pose, save to config.
 
     Each camera sees one half of the court from the net position.
-    We use the court lines visible in each frame to build correspondences.
+    Detects court lines via Hough transform, finds 4 corners,
-
+    then uses solvePnP to determine camera position.
-    For now: use a simple approach — detect the 4 most prominent lines
+    Returns debug images with detected lines drawn on them.
-    (baseline, two sidelines, kitchen line) and map to known 3D coords.
-    Returns error if court lines cannot be detected (no fallbacks).
     """
     results = {}
 
@@ -55,30 +53,75 @@ def auto_calibrate():
 
         h, w = frame.shape[:2]
         side = 'left' if sensor_id == 0 else 'right'
+        debug_frame = frame.copy()
 
-        # Try to detect court lines using edge detection + Hough
+        # Detect court lines — returns corners + debug info
-        corners_pixel = _detect_court_corners(frame, side)
+        detection = _detect_court_corners(frame, side)
+
+        # Draw all detected Hough lines on debug frame
+        if detection and detection.get('all_lines') is not None:
+            for line in detection['all_lines']:
+                x1, y1, x2, y2 = line[0]
+                cv2.line(debug_frame, (x1, y1), (x2, y2), (50, 50, 50), 1)
+
+        # Draw classified lines
+        if detection and detection.get('horizontals'):
+            for line in detection['horizontals']:
+                x1, y1, x2, y2 = line
+                cv2.line(debug_frame, (x1, y1), (x2, y2), (0, 255, 255), 2)  # yellow = horizontal
+        if detection and detection.get('verticals'):
+            for line in detection['verticals']:
+                x1, y1, x2, y2 = line
+                cv2.line(debug_frame, (x1, y1), (x2, y2), (255, 0, 255), 2)  # magenta = vertical
+
+        # Draw selected 4 lines (top/bottom/left/right)
+        if detection and detection.get('selected_lines'):
+            sel = detection['selected_lines']
+            colors = {'top': (0, 255, 0), 'bottom': (0, 200, 0),
+                      'left': (255, 128, 0), 'right': (200, 100, 0)}
+            for name, line in sel.items():
+                x1, y1, x2, y2 = line
+                cv2.line(debug_frame, (x1, y1), (x2, y2), colors.get(name, (255, 255, 255)), 3)
+                cv2.putText(debug_frame, name, (x1, y1 - 5),
+                            cv2.FONT_HERSHEY_SIMPLEX, 0.5, colors.get(name, (255, 255, 255)), 1)
+
+        # Encode debug frame
+        _, jpeg = cv2.imencode('.jpg', debug_frame, [cv2.IMWRITE_JPEG_QUALITY, 85])
+        debug_b64 = base64.b64encode(jpeg.tobytes()).decode('ascii')
+
+        corners_pixel = detection.get('corners') if detection else None
 
         if corners_pixel is None:
+            error_detail = detection.get('error', 'Unknown') if detection else 'No lines detected at all'
             results[str(sensor_id)] = {
                 'ok': False,
-                'error': f'Could not detect court lines for CAM {sensor_id}. '
+                'error': f'CAM {sensor_id}: {error_detail}',
-                         'Ensure court lines are clearly visible.'
+                'debug_image': debug_b64,
             }
             continue
 
+        # Draw corners on debug frame
+        for i, corner in enumerate(corners_pixel):
+            pt = (int(corner[0]), int(corner[1]))
+            cv2.circle(debug_frame, pt, 8, (0, 0, 255), -1)
+            cv2.putText(debug_frame, f'C{i}', (pt[0] + 10, pt[1]),
+                        cv2.FONT_HERSHEY_SIMPLEX, 0.6, (0, 0, 255), 2)
+
+        # Re-encode with corners
+        _, jpeg = cv2.imencode('.jpg', debug_frame, [cv2.IMWRITE_JPEG_QUALITY, 85])
+        debug_b64 = base64.b64encode(jpeg.tobytes()).decode('ascii')
+
         # Get known 3D coordinates for this half
         corners_3d = get_half_court_3d_points(side)
 
-        # Calibrate
+        # Calibrate — no try/except, let errors propagate
         cal = CameraCalibrator()
-        ok = cal.calibrate(
+        cal.calibrate(
             np.array(corners_pixel, dtype=np.float32),
             corners_3d,
             w, h
         )
 
-        if ok:
         # Save to config
         cal_path = os.path.join(_args.calibration_dir,
                                 f'cam{sensor_id}_calibration.json')
@@ -93,13 +136,10 @@ def auto_calibrate():
         results[str(sensor_id)] = {
             'ok': True,
             'camera_position': cam_pos.tolist(),
-                'corners_pixel': corners_pixel.tolist() if isinstance(corners_pixel, np.ndarray)
+            'debug_image': debug_b64,
-                    else corners_pixel,
         }
         print(f"[CAM {sensor_id}] Calibrated! Camera at "
               f"({cam_pos[0]:.1f}, {cam_pos[1]:.1f}, {cam_pos[2]:.1f})")
-        else:
-            results[str(sensor_id)] = {'ok': False, 'error': 'Calibration failed'}
 
     return results
 
@@ -107,7 +147,13 @@ def auto_calibrate():
 def _detect_court_corners(frame, side):
     """Detect court corners from frame using edge detection.
 
-    Returns 4 corner points as numpy array, or None if detection fails.
+    Returns dict with:
+        corners: 4x2 numpy array or None
+        all_lines: raw Hough lines
+        horizontals: classified horizontal lines
+        verticals: classified vertical lines
+        selected_lines: the 4 lines used (top/bottom/left/right)
+        error: description if detection failed
     """
     gray = cv2.cvtColor(frame, cv2.COLOR_BGR2GRAY)
     blur = cv2.GaussianBlur(gray, (5, 5), 0)
@@ -118,7 +164,13 @@ def _detect_court_corners(frame, side):
                             minLineLength=100, maxLineGap=20)
 
     if lines is None or len(lines) < 4:
-        return None
+        n = 0 if lines is None else len(lines)
+        return {
+            'corners': None, 'all_lines': lines,
+            'horizontals': [], 'verticals': [],
+            'selected_lines': {},
+            'error': f'Only {n} Hough lines found (need >= 4)',
+        }
 
     # Classify lines into horizontal and vertical
     horizontals = []
@@ -134,20 +186,28 @@ def _detect_court_corners(frame, side):
             verticals.append(line[0])
 
     if len(horizontals) < 2 or len(verticals) < 2:
-        return None
+        return {
+            'corners': None, 'all_lines': lines,
+            'horizontals': [h.tolist() for h in horizontals],
+            'verticals': [v.tolist() for v in verticals],
+            'selected_lines': {},
+            'error': f'{len(horizontals)} horizontal, {len(verticals)} vertical lines (need >= 2 each)',
+        }
 
     # Cluster lines by position to find the dominant ones
     h_positions = sorted(horizontals, key=lambda l: (l[1] + l[3]) / 2)
     v_positions = sorted(verticals, key=lambda l: (l[0] + l[2]) / 2)
 
-    # Take the most separated horizontal pair (top and bottom court lines)
     top_line = h_positions[0]
     bottom_line = h_positions[-1]
-
-    # Take the most separated vertical pair (left and right sidelines)
     left_line = v_positions[0]
     right_line = v_positions[-1]
 
+    selected = {
+        'top': top_line.tolist(), 'bottom': bottom_line.tolist(),
+        'left': left_line.tolist(), 'right': right_line.tolist(),
+    }
+
     # Find intersections as corner points
     def line_intersection(l1, l2):
         x1, y1, x2, y2 = l1
@@ -168,9 +228,22 @@ def _detect_court_corners(frame, side):
     ]
 
     if any(c is None for c in corners):
-        return None
+        return {
+            'corners': None, 'all_lines': lines,
+            'horizontals': [h.tolist() for h in horizontals],
+            'verticals': [v.tolist() for v in verticals],
+            'selected_lines': selected,
+            'error': 'Lines are parallel — could not find all 4 corner intersections',
+        }
 
-    return np.array(corners, dtype=np.float32)
+    return {
+        'corners': np.array(corners, dtype=np.float32),
+        'all_lines': lines,
+        'horizontals': [h.tolist() for h in horizontals],
+        'verticals': [v.tolist() for v in verticals],
+        'selected_lines': selected,
+        'error': None,
+    }
 
 
 
@@ -324,15 +397,10 @@ def main():
 
     ring_buffer = FrameRingBuffer(max_seconds=args.buffer_seconds, fps=args.fps)
 
-    # Load calibrations if available
+    # Start with empty calibrators — user must calibrate via UI
     os.makedirs(args.calibration_dir, exist_ok=True)
     for sensor_id in [0, 1]:
-        cal = CameraCalibrator()
+        state['calibrators'][sensor_id] = CameraCalibrator()
-        cal_path = os.path.join(args.calibration_dir, f'cam{sensor_id}_calibration.json')
-        if os.path.exists(cal_path):
-            if cal.load(cal_path):
-                print(f"[CAM {sensor_id}] Loaded calibration from {cal_path}")
-        state['calibrators'][sensor_id] = cal
 
     # Start camera readers
     cam_readers = {}

src/calibration/camera_calibrator.py

@@ -50,7 +50,6 @@ class CameraCalibrator:
             [0, 0, 1]
         ], dtype=np.float32)
 
-        try:
         success, self.rotation_vec, self.translation_vec = cv2.solvePnP(
             court_corners_3d.astype(np.float32),
             court_corners_pixel.astype(np.float32),
@@ -59,7 +58,7 @@ class CameraCalibrator:
             flags=cv2.SOLVEPNP_ITERATIVE
         )
         if not success:
-                return False
+            raise RuntimeError("solvePnP failed to find camera pose")
 
         self.rotation_matrix, _ = cv2.Rodrigues(self.rotation_vec)
 
@@ -72,9 +71,6 @@ class CameraCalibrator:
 
         self.calibrated = True
         return True
-        except Exception as e:
-            print(f"Calibration failed: {e}")
-            return False
 
     def pixel_to_ground(self, px: float, py: float) -> Optional[Tuple[float, float]]:
         """Project pixel to ground plane (Z=0) using homography."""
@@ -150,7 +146,6 @@ class CameraCalibrator:
             json.dump(data, f, indent=2)
 
     def load(self, filepath: str) -> bool:
-        try:
         with open(filepath, 'r') as f:
             data = json.load(f)
         self.camera_matrix = np.array(data['camera_matrix'], dtype=np.float32)
@@ -161,9 +156,6 @@ class CameraCalibrator:
             self.homography = np.array(data['homography'], dtype=np.float32)
         self.calibrated = True
         return True
-        except Exception as e:
-            print(f"Failed to load calibration: {e}")
-            return False
 
 
 def get_half_court_3d_points(side: str) -> np.ndarray:

src/web/app.py

@@ -112,11 +112,16 @@ def api_calibration_trigger():
     if fn is None:
         return jsonify({'ok': False, 'error': 'Calibration not available'}), 500
 
+    import traceback
     try:
         result = fn()
-        return jsonify({'ok': True, 'result': result})
+        # Check if any camera failed
+        any_ok = any(r.get('ok') for r in result.values())
+        return jsonify({'ok': any_ok, 'result': result})
     except Exception as e:
-        return jsonify({'ok': False, 'error': str(e)}), 500
+        tb = traceback.format_exc()
+        print(f"[CALIBRATION ERROR]\n{tb}")
+        return jsonify({'ok': False, 'error': f'{type(e).__name__}: {e}'}), 500
 
 
 @app.route('/api/calibration/data')

src/web/templates/index.html

@@ -332,19 +332,15 @@
             <div class="bottom-card"><img id="cal-cam1" alt="Camera 1"></div>
             <div class="bottom-card"><img id="cal-cam0" alt="Camera 0"></div>
             <div class="cam-card">
-                <div class="cc-title">Base Setup</div>
+                <div class="cc-title">Calibration</div>
-                <div class="cc-item">Distance <b id="paramPosY">1.0</b>m</div>
-                <div class="cc-item">Height <b id="paramPosZ">1.0</b>m</div>
-                <div class="cc-item">Stereo <b id="paramStereo">6</b>cm</div>
-                <div class="cc-item">Rotation <b id="paramAngle">15</b>°</div>
-                <div class="cc-item">HFOV <b id="paramHfov">128</b>°</div>
-                <div class="cc-item">Sensor <b>IMX219</b></div>
-                <div class="cc-divider"></div>
                 <button class="btn-calibrate" id="btnCalibrate" onclick="doCalibrate()">Calibrate</button>
                 <div class="calibrate-status" id="calStatus">
                     <span id="calStatusText">Not calibrated</span>
                 </div>
+                <div id="calError" style="color:#ff4444;font-size:8px;word-break:break-all;display:none"></div>
             </div>
+            <div class="bottom-card" id="calDebug0" style="display:none"><img id="calDebugImg0" alt="CAM 0 debug"></div>
+            <div class="bottom-card" id="calDebug1" style="display:none"><img id="calDebugImg1" alt="CAM 1 debug"></div>
         </div>
     </div>
 </div>
@@ -411,15 +407,34 @@ if (activeTab !== 'camera') switchTab(activeTab);
 // ===================== Calibration =====================
 function doCalibrate() {
     var btn = document.getElementById('btnCalibrate');
+    var errEl = document.getElementById('calError');
     btn.disabled = true;
     btn.textContent = 'Calibrating...';
+    errEl.style.display = 'none';
 
     fetch('/api/calibration/trigger', { method: 'POST' })
         .then(function(r) { return r.json(); })
         .then(function(data) {
             btn.disabled = false;
+
+            // Show debug images from calibration
+            if (data.result) {
+                for (var sid in data.result) {
+                    var r = data.result[sid];
+                    if (r.debug_image) {
+                        var dbgEl = document.getElementById('calDebug' + sid);
+                        var imgEl = document.getElementById('calDebugImg' + sid);
+                        if (dbgEl && imgEl) {
+                            imgEl.src = 'data:image/jpeg;base64,' + r.debug_image;
+                            dbgEl.style.display = 'block';
+                        }
+                    }
+                }
+            }
+
             if (data.ok) {
                 btn.textContent = 'Re-calibrate';
+                errEl.style.display = 'none';
                 updateCalibrationStatus();
 
                 fetch('/api/calibration/data')
@@ -427,19 +442,23 @@ function doCalibrate() {
                     .then(function(camData) { addCamerasToScene(camData); });
             } else {
                 btn.textContent = 'Calibrate';
+                // Show errors
                 var errors = [];
                 if (data.result) {
                     for (var sid in data.result) {
-                        if (!data.result[sid].ok) errors.push('CAM ' + sid + ': ' + data.result[sid].error);
+                        if (!data.result[sid].ok) errors.push(data.result[sid].error);
                     }
                 }
-                alert('Calibration failed:\n' + (errors.join('\n') || data.error || 'Unknown error'));
+                var msg = errors.join(' | ') || data.error || 'Unknown error';
+                errEl.textContent = msg;
+                errEl.style.display = 'block';
             }
         })
         .catch(function(e) {
             btn.disabled = false;
             btn.textContent = 'Calibrate';
-            alert('Error: ' + e);
+            errEl.textContent = String(e);
+            errEl.style.display = 'block';
         });
 }
 
@@ -582,9 +601,6 @@ function initCourtScene() {
 
     courtScene.add(new THREE.AmbientLight(0xffffff, 0.8));
 
-    // Physical camera marker: 1m from net, center, 1m height
-    addStereocameras(courtScene, getCamParams());
-
     // Load existing calibration cameras
     fetch('/api/calibration/data')
         .then(function(r) { return r.json(); })
@@ -683,9 +699,6 @@ function initTrajectoryScene() {
 
     trajScene.add(new THREE.AmbientLight(0xffffff, 0.8));
 
-    // Physical camera marker: 1m from net, center, 1m height
-    addStereocameras(trajScene, getCamParams());
-
     function animateTraj() {
         requestAnimationFrame(animateTraj);
         controls.update();
@@ -702,115 +715,6 @@ function initTrajectoryScene() {
     });
 }
 
-// ===================== Stereo camera rig with court coverage =====================
-// Track camera overlay objects for live update
-var camOverlayObjects = [];
-
-function addStereocameras(scene, params) {
-    params = params || {};
-    var baseX = 6.7;
-    var baseY = -(params.posY || 1);
-    var baseZ = params.posZ || 1;
-    var stereoGap = (params.stereo || 6) / 100;
-    var camAngle = params.angle || 15;
-    var hfov = params.hfov || 128;
-
-    // Remove old overlay objects
-    camOverlayObjects.forEach(function(obj) { scene.remove(obj); });
-    camOverlayObjects = [];
-
-    function addObj(obj) {
-        scene.add(obj);
-        camOverlayObjects.push(obj);
-    }
-
-    var cam0x = baseX - stereoGap / 2;
-    var cam1x = baseX + stereoGap / 2;
-
-    // Small camera bodies
-    function drawCamBody(cx, color) {
-        var body = new THREE.Mesh(
-            new THREE.BoxGeometry(0.12, 0.08, 0.08),
-            new THREE.MeshBasicMaterial({ color: color })
-        );
-        body.position.set(cx, baseY, baseZ);
-        addObj(body);
-    }
-    drawCamBody(cam0x, 0x44aaff);
-    drawCamBody(cam1x, 0xff44aa);
-
-    // Pole
-    var poleGeo = new THREE.BufferGeometry().setFromPoints([
-        new THREE.Vector3(baseX, baseY, 0),
-        new THREE.Vector3(baseX, baseY, baseZ)
-    ]);
-    addObj(new THREE.Line(poleGeo, new THREE.LineBasicMaterial({ color: 0x666666 })));
-
-    // Court boundaries for clipping
-    var courtMinX = 0, courtMaxX = 13.4, courtMinY = 0, courtMaxY = 6.1;
-    var deg2rad = Math.PI / 180;
-    var halfFov = hfov / 2;
-
-    function drawCoverage(cx, angleDeg, color) {
-        var centerAngle = 90 + angleDeg;
-        var leftAngle = centerAngle + halfFov;
-        var rightAngle = centerAngle - halfFov;
-        var ox = cx, oy = baseY;
-
-        // Cast ray, return farthest point on court boundary
-        function castRay(aDeg) {
-            var rad = aDeg * deg2rad;
-            var dx = Math.cos(rad);
-            var dy = Math.sin(rad);
-            if (dy <= 0) return null;
-
-            // t where ray enters court (Y=0)
-            var tEnter = (courtMinY - oy) / dy;
-            // t where ray exits court
-            var tExit = (courtMaxY - oy) / dy;
-            // clip X bounds
-            if (dx > 1e-9) tExit = Math.min(tExit, (courtMaxX - ox) / dx);
-            else if (dx < -1e-9) tExit = Math.min(tExit, (courtMinX - ox) / dx);
-
-            if (tExit <= tEnter) return null;
-
-            var px = ox + dx * tExit;
-            var py = oy + dy * tExit;
-            px = Math.max(courtMinX, Math.min(courtMaxX, px));
-            py = Math.max(courtMinY, Math.min(courtMaxY, py));
-            return new THREE.Vector3(px, py, 0.015);
-        }
-
-        // Camera actual position (behind court at Y=-1)
-        var camOnCourt = new THREE.Vector3(cx, oy, 0.015);
-
-        // Far edge points
-        var farPoints = [];
-        var steps = 64;
-        for (var i = 0; i <= steps; i++) {
-            var a = rightAngle + (leftAngle - rightAngle) * (i / steps);
-            var pt = castRay(a);
-            if (pt) farPoints.push(pt);
-        }
-        if (farPoints.length < 2) return;
-
-        // Draw triangle fan from camera court position to far edge
-        var mat = new THREE.MeshBasicMaterial({
-            color: color, transparent: true, opacity: 0.35,
-            side: THREE.DoubleSide, depthWrite: false
-        });
-        for (var i = 0; i < farPoints.length - 1; i++) {
-            var triGeo = new THREE.BufferGeometry().setFromPoints([
-                camOnCourt, farPoints[i], farPoints[i + 1]
-            ]);
-            addObj(new THREE.Mesh(triGeo, mat));
-        }
-    }
-
-    drawCoverage(cam0x, -camAngle, 0x4488ff);  // blue
-    drawCoverage(cam1x, camAngle, 0xff44aa);   // pink
-    // overlap blends to purple naturally
-}
 
 // ===================== Draw court lines =====================
 function drawCourtLines(scene) {
@@ -983,26 +887,6 @@ setInterval(function() {
     }).catch(function() {});
 }, 1000);
 
-// ===================== Camera params live update =====================
-function getCamParams() {
-    return {
-        posY: parseFloat(document.getElementById('paramPosY').textContent) || 1,
-        posZ: parseFloat(document.getElementById('paramPosZ').textContent) || 1,
-        stereo: parseFloat(document.getElementById('paramStereo').textContent) || 6,
-        angle: parseFloat(document.getElementById('paramAngle').textContent) || 15,
-        hfov: parseFloat(document.getElementById('paramHfov').textContent) || 128
-    };
-}
-
-function setCamParams(p) {
-    document.getElementById('paramPosY').textContent = p.posY;
-    document.getElementById('paramPosZ').textContent = p.posZ;
-    document.getElementById('paramStereo').textContent = p.stereo;
-    document.getElementById('paramAngle').textContent = p.angle;
-    document.getElementById('paramHfov').textContent = p.hfov;
-    if (courtSceneInitialized) addStereocameras(courtScene, p);
-    if (trajSceneInitialized) addStereocameras(trajScene, p);
-}
 </script>
 </body>
 </html>