MVP

phase1_machine_cycles_function.js

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+// ============================================================================
+// UPDATED "Machine cycles" Function
+// Location: flows.json, line 1150, node ID: 0d023d87a13bf56f
+// Outputs: 3 (added third output for database state backup)
+// ============================================================================
+
+const current = Number(msg.payload) || 0;
+
+// ============================================================================
+// SECTION 1: TIME TRACKING (NEW - Must run BEFORE any early returns)
+// ============================================================================
+const now = Date.now();
+const trackingEnabled = !!global.get("trackingEnabled");
+const lastUpdate = global.get("lastUpdateTime") || now;
+const deltaMs = now - lastUpdate;
+const deltaSeconds = deltaMs / 1000;
+
+// Sanity check: Protect against clock skew (negative delta or >5 min gap)
+if (deltaSeconds < 0 || deltaSeconds > 300) {
+    node.warn(`[TIME] Abnormal delta: ${deltaSeconds.toFixed(2)}s - clock skew or restart detected, resetting timer`);
+    global.set("lastUpdateTime", now);
+    // Don't accumulate time, but continue processing
+} else {
+    // Normal delta, accumulate time if tracking is enabled
+    if (trackingEnabled) {
+        // Initialize timing vars if they don't exist (handles restart scenario)
+        if (!global.get("productionStartTime")) {
+            node.warn("[TIME] Production start time missing, initializing now");
+            global.set("productionStartTime", now);
+            global.set("operatingTime", 0);
+            global.set("downtime", 0);
+        }
+
+        // Accumulate operating time when machine is running (state 1)
+        if (current === 1) {
+            const opTime = global.get("operatingTime") || 0;
+            global.set("operatingTime", opTime + deltaSeconds);
+        }
+        // Accumulate downtime when machine is stopped (state 0) while tracking
+        else if (current === 0) {
+            const downTime = global.get("downtime") || 0;
+            global.set("downtime", downTime + deltaSeconds);
+        }
+    }
+    global.set("lastUpdateTime", now);
+}
+
+// ============================================================================
+// SECTION 2: EXISTING CYCLE COUNTING LOGIC (UNCHANGED)
+// ============================================================================
+let zeroStreak = flow.get("zeroStreak") || 0;
+zeroStreak = current === 0 ? zeroStreak + 1 : 0;
+flow.set("zeroStreak", zeroStreak);
+
+const prev = flow.get("lastMachineState") ?? 0;
+flow.set("lastMachineState", current);
+
+global.set("machineOnline", true);   // force ONLINE for now
+
+let productionRunning = !!global.get("productionStarted");
+let stateChanged = false;
+
+if (current === 1 && !productionRunning) {
+    productionRunning = true;
+    stateChanged = true;
+} else if (current === 0 && zeroStreak >= 2 && productionRunning) {
+    productionRunning = false;
+    stateChanged = true;
+}
+
+global.set("productionStarted", productionRunning);
+
+const stateMsg = stateChanged
+    ? {
+        _mode: "production-state",
+        machineOnline: true,
+        productionStarted: productionRunning
+    }
+    : null;
+
+const activeOrder = global.get("activeWorkOrder");
+const cavities = Number(global.get("moldActive") || 0);
+if (!activeOrder || !activeOrder.id || cavities <= 0) {
+    // We still want to pass along any state change even if there's no active WO.
+    return [null, stateMsg, null];
+}
+
+// Check if tracking is enabled (START button clicked)
+if (!trackingEnabled) {
+    // Cycles are happening but we're not tracking them yet
+    return [null, stateMsg, null];
+}
+
+// only count rising edges (0 -> 1) for production totals
+if (prev === 1 || current !== 1) {
+    return [null, stateMsg, null];
+}
+
+let cycles = Number(global.get("cycleCount") || 0) + 1;
+global.set("cycleCount", cycles);
+
+// Calculate good parts: total produced minus accumulated scrap
+const scrapTotal = Number(activeOrder.scrap) || 0;
+const totalProduced = cycles * cavities;
+const produced = totalProduced - scrapTotal;
+const target = Number(activeOrder.target) || 0;
+const progress = target > 0 ? Math.min(100, Math.round((produced / target) * 100)) : 0;
+
+activeOrder.good = produced;
+activeOrder.progressPercent = progress;
+activeOrder.lastUpdateIso = new Date().toISOString();
+global.set("activeWorkOrder", activeOrder);
+
+const promptIssued = global.get("scrapPromptIssuedFor") || null;
+
+if (!promptIssued && target > 0 && produced >= target) {
+    node.warn(`[DEBUG] TRIGGERING PROMPT!`);
+    global.set("scrapPromptIssuedFor", activeOrder.id);
+    msg._mode = "scrap-prompt";
+    msg.scrapPrompt = {
+        id: activeOrder.id,
+        sku: activeOrder.sku || "",
+        target,
+        produced
+    };
+    return [null, msg, null]; // bypass the DB update on this cycle
+}
+
+// ============================================================================
+// SECTION 3: DATABASE UPDATE MESSAGE (EXISTING)
+// ============================================================================
+const dbMsg = {
+    _mode: "cycle",
+    cycle: {
+        id: activeOrder.id,
+        sku: activeOrder.sku || "",
+        target,
+        good: produced,
+        scrap: Number(activeOrder.scrap) || 0,
+        cycleTime: Number(activeOrder.cycleTime || activeOrder.theoreticalCycleTime || 0),
+        progressPercent: progress,
+        lastUpdateIso: activeOrder.lastUpdateIso,
+        machineOnline: true,
+        productionStarted: productionRunning
+    },
+    topic: `
+      UPDATE work_orders
+      SET
+        good_parts = ${produced},
+        progress_percent = ${progress},
+        updated_at = NOW()
+      WHERE work_order_id = '${activeOrder.id}';
+    `
+};
+
+// ============================================================================
+// SECTION 4: STATE BACKUP TO DATABASE (NEW - Every 10th cycle to reduce load)
+// ============================================================================
+let cyclesSinceBackup = flow.get("cyclesSinceBackup") || 0;
+cyclesSinceBackup++;
+flow.set("cyclesSinceBackup", cyclesSinceBackup);
+
+let stateBackupMsg = null;
+if (cyclesSinceBackup >= 10) {
+    // Reset counter
+    flow.set("cyclesSinceBackup", 0);
+
+    // Backup current state to database
+    const productionStartTime = global.get("productionStartTime") || null;
+    const operatingTime = global.get("operatingTime") || 0;
+    const downtime = global.get("downtime") || 0;
+    const lastUpdateTime = global.get("lastUpdateTime") || null;
+    const scrapPromptIssuedFor = global.get("scrapPromptIssuedFor") || null;
+
+    stateBackupMsg = {
+        _mode: "state-backup",
+        topic: `
+          UPDATE session_state
+          SET
+            work_order_id = '${activeOrder.id}',
+            cycle_count = ${cycles},
+            production_start_time = ${productionStartTime},
+            operating_time = ${operatingTime.toFixed(2)},
+            downtime = ${downtime.toFixed(2)},
+            last_update_time = ${lastUpdateTime},
+            tracking_enabled = ${trackingEnabled ? 1 : 0},
+            machine_state = ${current},
+            scrap_prompt_issued_for = ${scrapPromptIssuedFor ? `'${scrapPromptIssuedFor}'` : 'NULL'}
+          WHERE session_key = 'current_session';
+        `
+    };
+}
+
+// ============================================================================
+// OUTPUTS:
+// Output 1: Database update for work_orders table (existing)
+// Output 2: State message to UI (existing)
+// Output 3: State backup to session_state table (NEW)
+// ============================================================================
+return [dbMsg, stateMsg, stateBackupMsg];