updates

app/api/ingest/cycle/route.ts

@@ -172,11 +172,35 @@ export async function POST(req: Request) {
     };
   });
 
+  const result = await prisma.machineCycle.createMany({
+    data: rows,
+    skipDuplicates: true,
+  });
+
   if (rows.length === 1) {
-    const row = await prisma.machineCycle.create({ data: rows[0] });
-    return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
+    const row = await prisma.machineCycle.findFirst({
+      where: {
+        orgId: machine.orgId,
+        machineId: machine.id,
+        ts: rows[0].ts,
+        cycleCount: rows[0].cycleCount ?? null,
+      },
+      orderBy: { createdAt: "asc" },
+      select: { id: true, ts: true },
+    });
+    return NextResponse.json({
+      ok: true,
+      id: row?.id,
+      ts: row?.ts,
+      inserted: result.count,
+      duplicate: result.count === 0,
+    });
   }
 
-  const result = await prisma.machineCycle.createMany({ data: rows });
-  return NextResponse.json({ ok: true, count: result.count });
+  return NextResponse.json({
+    ok: true,
+    inserted: result.count,
+    requested: rows.length,
+    count: result.count,
+  });
 }

app/api/ingest/event/route.ts

@@ -80,6 +80,15 @@ function numberFrom(value: unknown) {
   }
   return null;
 }
+function parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
 
 function canonicalText(value: unknown) {
   return String(value ?? "")
@@ -262,6 +271,8 @@ export async function POST(req: Request) {
 
   const machine = await getMachineAuth(String(machineId), apiKey);
   if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  const bodySeq = parseSeqToBigInt(bodyRecord.seq);
+  const bodySchemaVersion = clampText(bodyRecord.schemaVersion, 16);
   const orgSettings = await prisma.orgSettings.findUnique({
     where: { orgId: machine.orgId },
     select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
@@ -410,35 +421,90 @@ export async function POST(req: Request) {
     const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
     const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
 
-    const row = await prisma.machineEvent.create({
-      data: {
-        orgId: machine.orgId,
-        machineId: machine.id,
-        ts,
-        topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
-        eventType: finalType,
-        severity: sev,
-        requiresAck: !!evRecord.requires_ack,
-        title,
-        description,
-        data: toJsonValue(dataObj),
-        workOrderId:
-          clampText(evRecord.work_order_id, 64) ??
-          clampText(evData.work_order_id, 64) ??
-          clampText(activeWorkOrder?.id, 64) ??
-          clampText(dataActiveWorkOrder?.id, 64) ??
-          null,
-        sku:
-          clampText(evRecord.sku, 64) ??
-          clampText(evData.sku, 64) ??
-          clampText(activeWorkOrder?.sku, 64) ??
-          clampText(dataActiveWorkOrder?.sku, 64) ??
-          null,
-      },
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
+    const evSeq = 
+      parseSeqToBigInt(evRecord.seq) ??
+      parseSeqToBigInt(evData.seq) ??
+      bodySeq;
+
+    const evSchemaVersion = 
+      clampText(evRecord.schemaVersion, 16) ??
+      bodySchemaVersion;
+
+    const eventData = {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      schemaVersion: evSchemaVersion,
+      seq: evSeq,
+      ts,
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+      eventType: finalType,
+      severity: sev,
+      requiresAck: !!evRecord.requires_ack,
+      title,
+      description,
+      data: toJsonValue(dataObj),
+      workOrderId:
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
     });
 
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          ts,
+          eventType: finalType,
+        },
+        orderBy: { ts: "desc" },
+      });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
+
     created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
 
+    
+
     // If the payload carries a `reason`, create the corresponding ReasonEntry.
     // If it doesn't, still create an "UNCLASSIFIED" downtime ReasonEntry for stop events so the dashboard can show coverage.
     if (evRecord.is_update || evRecord.is_auto_ack || dataObj.is_update || dataObj.is_auto_ack){

app/api/ingest/event/route.ts.bak

@@ -0,0 +1,670 @@
+import { NextResponse } from "next/server";
+import { prisma } from "@/lib/prisma";
+import { getMachineAuth } from "@/lib/machineAuthCache";
+import { z } from "zod";
+import { evaluateAlertsForEvent } from "@/lib/alerts/engine";
+import { toJsonValue } from "@/lib/prismaJson";
+import {
+  findCatalogReason,
+  loadFallbackReasonCatalog,
+  normalizeReasonCatalog,
+  toReasonCode,
+  type ReasonCatalog,
+  type ReasonCatalogKind,
+} from "@/lib/reasonCatalog";
+
+const normalizeType = (t: unknown) =>
+  String(t ?? "")
+    .trim()
+    .toLowerCase()
+    .replace(/_/g, "-");
+
+function asRecord(value: unknown): Record<string, unknown> | null {
+  if (!value || typeof value !== "object" || Array.isArray(value)) return null;
+  return value as Record<string, unknown>;
+}
+
+const CANON_TYPE: Record<string, string> = {
+  // Node-RED
+  "production-stopped": "stop",
+  "oee-drop": "oee-drop",
+  "quality-spike": "quality-spike",
+  "predictive-oee-decline": "predictive-oee-decline",
+  "performance-degradation": "performance-degradation",
+
+  // legacy / synonyms
+  "macroparo": "macrostop",
+  "macro-stop": "macrostop",
+  "microparo": "microstop",
+  "micro-paro": "microstop",
+  "down": "stop",
+  "downtime-acknowledged": "downtime-acknowledged",
+  "scrap-manual-entry": "scrap-manual-entry",
+  "mold-change": "mold-change",
+};
+
+const ALLOWED_TYPES = new Set([
+  "slow-cycle",
+  "microstop",
+  "macrostop",
+  "offline",
+  "error",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
+  "downtime-acknowledged",
+  "scrap-manual-entry",
+  "mold-change",
+]);
+
+const machineIdSchema = z.string().uuid();
+const MAX_EVENTS = 100;
+
+//when no cycle time is configed
+const DEFAULT_MACROSTOP_SEC = 300;
+
+
+function clampText(value: unknown, maxLen: number) {
+  if (value === null || value === undefined) return null;
+  const text = String(value).trim().replace(/[\u0000-\u001f\u007f]/g, "");
+  if (!text) return null;
+  return text.length > maxLen ? text.slice(0, maxLen) : text;
+}
+
+function numberFrom(value: unknown) {
+  if (typeof value === "number" && Number.isFinite(value)) return value;
+  if (typeof value === "string" && value.trim()) {
+    const parsed = Number(value);
+    if (Number.isFinite(parsed)) return parsed;
+  }
+  return null;
+}
+function parseSeqToBigInt(value: unknown): bigint | null {
+  if (value === null || value === undefined) return null;
+  if (typeof value === "number") {
+    if (!Number.isInteger(value) || value < 0) return null;
+    return BigInt(value);
+  }
+  if (typeof value === "string" && /^\d+$/.test(value)) return BigInt(value);
+  return null;
+}
+
+function canonicalText(value: unknown) {
+  return String(value ?? "")
+    .normalize("NFD")
+    .replace(/[\u0300-\u036f]/g, "")
+    .toLowerCase()
+    .replace(/[^a-z0-9]+/g, "-")
+    .replace(/^-+|-+$/g, "");
+}
+
+function parseReasonPath(rawPath: unknown) {
+  let category: string | null = null;
+  let detail: string | null = null;
+
+  if (Array.isArray(rawPath)) {
+    const first = rawPath[0];
+    const second = rawPath[1];
+    if (typeof first === "string") category = first;
+    if (typeof second === "string") detail = second;
+    if (asRecord(first)) category = clampText(first.id ?? first.label ?? first.value, 120);
+    if (asRecord(second)) detail = clampText(second.id ?? second.label ?? second.value, 120);
+  } else if (typeof rawPath === "string") {
+    const pieces = rawPath
+      .split(/>|\/|\\|\|/g)
+      .map((p) => p.trim())
+      .filter(Boolean);
+    category = pieces[0] ?? null;
+    detail = pieces[1] ?? null;
+  }
+
+  return {
+    category: clampText(category, 120),
+    detail: clampText(detail, 120),
+  };
+}
+
+function parseReasonTextPath(reasonText: unknown) {
+  const text = clampText(reasonText, 240);
+  if (!text) return { category: null as string | null, detail: null as string | null };
+  const pieces = text
+    .split(/>|\/|\\|\|/g)
+    .map((p) => p.trim())
+    .filter(Boolean);
+  return {
+    category: clampText(pieces[0] ?? null, 120),
+    detail: clampText(pieces[1] ?? null, 120),
+  };
+}
+
+function findCatalogReasonFlexible(
+  catalog: ReasonCatalog | null,
+  kind: ReasonCatalogKind,
+  categoryIdOrLabel: unknown,
+  detailIdOrLabel: unknown
+) {
+  const direct = findCatalogReason(catalog, kind, categoryIdOrLabel, detailIdOrLabel);
+  if (direct) return direct;
+  if (!catalog) return null;
+
+  const catNeedle = canonicalText(categoryIdOrLabel);
+  const detNeedle = canonicalText(detailIdOrLabel);
+  if (!catNeedle || !detNeedle) return null;
+
+  for (const category of catalog[kind] ?? []) {
+    const catMatch =
+      canonicalText(category.id) === catNeedle || canonicalText(category.label) === catNeedle;
+    if (!catMatch) continue;
+    for (const detail of category.details) {
+      const detMatch = canonicalText(detail.id) === detNeedle || canonicalText(detail.label) === detNeedle;
+      if (!detMatch) continue;
+      return {
+        categoryId: category.id,
+        categoryLabel: category.label,
+        detailId: detail.id,
+        detailLabel: detail.label,
+        reasonCode: toReasonCode(category.id, detail.id),
+        reasonLabel: `${category.label} > ${detail.label}`,
+      };
+    }
+  }
+  return null;
+}
+
+function getCatalogFromDefaults(defaultsJson: unknown) {
+  const defaults = asRecord(defaultsJson);
+  if (!defaults) return null;
+  return normalizeReasonCatalog(defaults.reasonCatalog ?? defaults.reasonCatalogData);
+}
+
+function resolveReason(
+  raw: Record<string, unknown>,
+  kind: ReasonCatalogKind,
+  catalog: ReasonCatalog | null,
+  fallbackVersion: number
+) {
+  const reasonPath = parseReasonPath(raw.reasonPath);
+  const reasonTextPath = parseReasonTextPath(raw.reasonText);
+  const categoryIdRaw = clampText(raw.categoryId ?? reasonPath.category ?? reasonTextPath.category, 64);
+  const detailIdRaw = clampText(raw.detailId ?? reasonPath.detail ?? reasonTextPath.detail, 64);
+  const fromCatalog = findCatalogReasonFlexible(catalog, kind, categoryIdRaw, detailIdRaw);
+
+  const categoryLabelRaw = clampText(raw.categoryLabel ?? reasonPath.category ?? reasonTextPath.category, 120);
+  const detailLabelRaw = clampText(raw.detailLabel ?? reasonPath.detail ?? reasonTextPath.detail, 120);
+
+  const reasonCode =
+    clampText(raw.reasonCode, 64)?.toUpperCase() ??
+    fromCatalog?.reasonCode ??
+    toReasonCode(categoryIdRaw ?? categoryLabelRaw, detailIdRaw ?? detailLabelRaw) ??
+    null;
+
+  const categoryId = fromCatalog?.categoryId ?? categoryIdRaw;
+  const detailId = fromCatalog?.detailId ?? detailIdRaw;
+  const categoryLabel = fromCatalog?.categoryLabel ?? categoryLabelRaw;
+  const detailLabel = fromCatalog?.detailLabel ?? detailLabelRaw;
+
+  const pathLabel =
+    clampText(raw.reasonText, 240) ??
+    fromCatalog?.reasonLabel ??
+    (categoryLabel && detailLabel ? `${categoryLabel} > ${detailLabel}` : null) ??
+    detailLabel ??
+    categoryLabel ??
+    reasonCode;
+
+  const catalogVersionRaw = numberFrom(raw.catalogVersion);
+  const catalogVersion = catalogVersionRaw != null ? Math.trunc(catalogVersionRaw) : fallbackVersion;
+
+  return {
+    type: kind,
+    categoryId,
+    categoryLabel,
+    detailId,
+    detailLabel,
+    reasonCode,
+    reasonLabel: pathLabel,
+    reasonText: pathLabel,
+    catalogVersion,
+  };
+}
+
+export async function POST(req: Request) {
+  const apiKey = req.headers.get("x-api-key");
+  if (!apiKey) return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+
+  let body: unknown = await req.json().catch(() => null);
+
+  // ✅ if Node-RED sent an array as the whole body, unwrap it
+  if (Array.isArray(body)) body = body[0];
+  const bodyRecord = asRecord(body) ?? {};
+  const payloadRecord = asRecord(bodyRecord.payload) ?? {};
+
+  // ✅ accept multiple common keys
+  const machineId =
+    bodyRecord.machineId ??
+    bodyRecord.machine_id ??
+    (asRecord(bodyRecord.machine)?.id ?? null);
+  let rawEvent =
+    bodyRecord.event ??
+    bodyRecord.events ??
+    bodyRecord.anomalies ??
+    payloadRecord.event ??
+    payloadRecord.events ??
+    payloadRecord.anomalies ??
+    payloadRecord ??
+    bodyRecord.data; // sometimes "data"
+
+  const rawEventRecord = asRecord(rawEvent);
+  if (rawEventRecord?.event && typeof rawEventRecord.event === "object") rawEvent = rawEventRecord.event;
+  if (Array.isArray(rawEventRecord?.events)) rawEvent = rawEventRecord.events;
+
+  if (!machineId || !rawEvent) {
+    return NextResponse.json(
+      { ok: false, error: "Invalid payload", got: { hasMachineId: !!machineId, keys: Object.keys(bodyRecord) } },
+      { status: 400 }
+    );
+  }
+
+  if (!machineIdSchema.safeParse(String(machineId)).success) {
+    return NextResponse.json({ ok: false, error: "Invalid machine id" }, { status: 400 });
+  }
+
+  const machine = await getMachineAuth(String(machineId), apiKey);
+  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  const orgSettings = await prisma.orgSettings.findUnique({
+    where: { orgId: machine.orgId },
+    select: { stoppageMultiplier: true, macroStoppageMultiplier: true, defaultsJson: true },
+  });
+  const fallbackCatalog = await loadFallbackReasonCatalog();
+  const settingsCatalog = getCatalogFromDefaults(orgSettings?.defaultsJson);
+  const reasonCatalog = settingsCatalog ?? fallbackCatalog;
+
+  const defaultMicroMultiplier = Number(orgSettings?.stoppageMultiplier ?? 1.5);
+  const defaultMacroMultiplier = Math.max(
+    defaultMicroMultiplier,
+    Number(orgSettings?.macroStoppageMultiplier ?? 5)
+  );
+
+
+  // ✅ normalize to array no matter what
+  const events = Array.isArray(rawEvent) ? rawEvent : [rawEvent];
+  if (events.length > MAX_EVENTS) {
+    return NextResponse.json({ ok: false, error: "Too many events" }, { status: 400 });
+  }
+
+  const created: { id: string; ts: Date; eventType: string }[] = [];
+  const skipped: Array<Record<string, unknown>> = [];
+
+  for (const ev of events) {
+    const evRecord = asRecord(ev);
+    if (!evRecord) {
+      skipped.push({ reason: "invalid_event_object" });
+      continue;
+    }
+    const evData = asRecord(evRecord.data) ?? {};
+    // We'll re-check reason again after parsing `data` (it may be a JSON string)
+    let evReason = asRecord(evRecord.reason) ?? asRecord(evData.reason);
+    const evDowntime = asRecord(evRecord.downtime) ?? asRecord(evData.downtime);
+    // Some producers nest the reason under `downtime.reason`
+    if (!evReason) evReason = asRecord(evDowntime?.reason);
+
+    const rawType = evRecord.eventType ?? evRecord.anomaly_type ?? evRecord.topic ?? bodyRecord.topic ?? "";
+    const typ0 = normalizeType(rawType);
+    const typ = CANON_TYPE[typ0] ?? typ0;
+
+    // Determine timestamp
+    const tsMs =
+      (typeof evRecord.timestamp === "number" && evRecord.timestamp) ||
+      (typeof evData.timestamp === "number" && evData.timestamp) ||
+      (typeof evData.event_timestamp === "number" && evData.event_timestamp) ||
+      null;
+
+    const ts = tsMs ? new Date(tsMs) : new Date();
+
+    // Severity defaulting (do not skip on severity — store for audit)
+    let sev = String(evRecord.severity ?? "").trim().toLowerCase();
+    if (!sev) sev = "warning";
+
+    // Stop classification -> microstop/macrostop
+    let finalType = typ;
+    let stopSecForReason: number | null = null;
+    if (typ === "stop") {
+      const stopSec =
+        (typeof evData.stoppage_duration_seconds === "number" && evData.stoppage_duration_seconds) ||
+        (typeof evData.stop_duration_seconds === "number" && evData.stop_duration_seconds) ||
+        null;
+      stopSecForReason = stopSec != null ? Number(stopSec) : null;
+
+      if (stopSec != null) {
+        const theoretical = Number(evData.theoretical_cycle_time ?? evData.theoreticalCycleTime ?? 0) || 0;
+
+        const microMultiplier = Number(
+          evData.micro_threshold_multiplier ?? evData.threshold_multiplier ?? defaultMicroMultiplier
+        );
+        const macroMultiplier = Math.max(
+          microMultiplier,
+          Number(evData.macro_threshold_multiplier ?? defaultMacroMultiplier)
+        );
+
+        if (theoretical > 0) {
+          const macroThresholdSec = theoretical * macroMultiplier;
+          finalType = stopSec >= macroThresholdSec ? "macrostop" : "microstop";
+        } else {
+          finalType = stopSec >= DEFAULT_MACROSTOP_SEC ? "macrostop" : "microstop";
+        }
+      } else {
+        // missing duration -> conservative
+        finalType = "microstop";
+      }
+    }
+
+    if (!ALLOWED_TYPES.has(finalType)) {
+      skipped.push({ reason: "type_not_allowed", typ: finalType, sev });
+      continue;
+    }
+
+    const title =
+      clampText(evRecord.title, 160) ||
+      (finalType === "slow-cycle" ? "Slow Cycle Detected" :
+       finalType === "macrostop" ? "Macrostop Detected" :
+       finalType === "microstop" ? "Microstop Detected" :
+       "Event");
+
+    const description = clampText(evRecord.description, 1000);
+
+    // store full blob, ensure object
+    const rawData = evRecord.data ?? evRecord;
+    const parsedData = typeof rawData === "string"
+      ? (() => {
+          try {
+            return JSON.parse(rawData);
+          } catch {
+            return { raw: rawData };
+          }
+        })()
+      : rawData;
+    const dataObj: Record<string, unknown> =
+      parsedData && typeof parsedData === "object" && !Array.isArray(parsedData)
+        ? { ...(parsedData as Record<string, unknown>) }
+        : { raw: parsedData };
+    if (evRecord.status != null && dataObj.status == null) dataObj.status = evRecord.status;
+    if (evRecord.alert_id != null && dataObj.alert_id == null) dataObj.alert_id = evRecord.alert_id;
+    if (evRecord.is_update != null && dataObj.is_update == null) dataObj.is_update = evRecord.is_update;
+    if (evRecord.is_auto_ack != null && dataObj.is_auto_ack == null) dataObj.is_auto_ack = evRecord.is_auto_ack;
+    if (evReason && dataObj.reason == null) dataObj.reason = evReason;
+    if (evDowntime && dataObj.downtime == null) dataObj.downtime = evDowntime;
+
+    // If `data` was a JSON string, the earlier evReason lookup would miss it.
+    // Re-check here using the normalized object we will persist.
+    if (!evReason) evReason = asRecord(dataObj.reason);
+    if (!evReason) evReason = asRecord(asRecord(dataObj.downtime)?.reason);
+
+    // If we have a reasonText but missing ids, derive ids from the path-like string.
+    if (evReason) {
+      const hasCat = clampText((evReason as any).categoryId, 64) ?? clampText((evReason as any).categoryLabel, 120);
+      const hasDet = clampText((evReason as any).detailId, 64) ?? clampText((evReason as any).detailLabel, 120);
+      const rt = clampText((evReason as any).reasonText, 240);
+      if ((!hasCat || !hasDet) && rt) {
+        const parsed = parseReasonTextPath(rt);
+        const next = { ...evReason } as Record<string, unknown>;
+        // Preserve any explicit ids; only fill gaps.
+        if ((next as any).categoryId == null && parsed.category) next.categoryId = canonicalText(parsed.category);
+        if ((next as any).categoryLabel == null && parsed.category) next.categoryLabel = parsed.category;
+        if ((next as any).detailId == null && parsed.detail) next.detailId = canonicalText(parsed.detail);
+        if ((next as any).detailLabel == null && parsed.detail) next.detailLabel = parsed.detail;
+        evReason = next;
+      }
+    }
+
+    const activeWorkOrder = asRecord(evRecord.activeWorkOrder);
+    const dataActiveWorkOrder = asRecord(evData.activeWorkOrder);
+
+    // ✨ Cada evento puede traer su propio seq, o usar el del payload raíz
+    const evSeq = 
+      parseSeqToBigInt(evRecord.seq) ??
+      parseSeqToBigInt(evData.seq) ??
+      bodySeq;
+
+    const evSchemaVersion = 
+      clampText(evRecord.schemaVersion, 16) ??
+      bodySchemaVersion;
+
+    const eventData = {
+      orgId: machine.orgId,
+      machineId: machine.id,
+      schemaVersion: evSchemaVersion,
+      seq: evSeq,
+      ts,
+      topic: clampText(evRecord.topic ?? finalType, 64) ?? finalType,
+      eventType: finalType,
+      severity: sev,
+      requiresAck: !!evRecord.requires_ack,
+      title,
+      description,
+      data: toJsonValue(dataObj),
+      workOrderId:
+        clampText(evRecord.work_order_id, 64) ??
+        clampText(evData.work_order_id, 64) ??
+        clampText(activeWorkOrder?.id, 64) ??
+        clampText(dataActiveWorkOrder?.id, 64) ??
+        null,
+      sku:
+        clampText(evRecord.sku, 64) ??
+        clampText(evData.sku, 64) ??
+        clampText(activeWorkOrder?.sku, 64) ??
+        clampText(dataActiveWorkOrder?.sku, 64) ??
+        null,
+    };
+
+    // ✨ Idempotente: si ya existe (mismo orgId+machineId+seq), no inserta
+    const insertResult = await prisma.machineEvent.createMany({
+      data: [eventData],
+      skipDuplicates: true,
+    });
+
+    // ✨ Buscar la fila (la recién creada o la duplicada existente)
+    let row;
+    if (evSeq != null) {
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          seq: evSeq,
+        },
+        orderBy: { ts_server: "asc" },
+      });
+    } else {
+      // Sin seq, buscar por ts (fallback compatibilidad con eventos viejos)
+      row = await prisma.machineEvent.findFirst({
+        where: { 
+          orgId: machine.orgId, 
+          machineId: machine.id, 
+          ts,
+          eventType: finalType,
+        },
+        orderBy: { ts_server: "desc" },
+      });
+    }
+
+    if (!row) {
+      skipped.push({ reason: "row_not_found_after_insert", seq: evSeq?.toString() });
+      continue;
+    }
+
+    const wasDuplicate = insertResult.count === 0;
+
+    // Si fue duplicado, no procesar reasonEntry ni alertas (ya se hicieron antes)
+    if (wasDuplicate) {
+      created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+      continue;  // ✨ saltar el resto del procesamiento
+    }
+
+    created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+
+    
+
+    // If the payload carries a `reason`, create the corresponding ReasonEntry.
+    // If it doesn't, still create an "UNCLASSIFIED" downtime ReasonEntry for stop events so the dashboard can show coverage.
+    if (evRecord.is_update || evRecord.is_auto_ack || dataObj.is_update || dataObj.is_auto_ack){
+  // skip duplicate reasonEntry for refresh/ack 
+    } else if (evReason || finalType === "microstop" || finalType === "macrostop" || finalType === "downtime-acknowledged" || finalType === "mold-change"){
+      const moldIncidentKey =
+        clampText(evData.incidentKey ?? dataObj.incidentKey, 128) ??
+        (numberFrom(evData.start_ms ?? dataObj.start_ms) != null
+          ? `mold-change:${Math.trunc(numberFrom(evData.start_ms ?? dataObj.start_ms) as number)}`
+          : null);
+      const reasonRaw: Record<string, unknown> =
+        evReason ??
+        (finalType === "mold-change"
+          ? ({
+              type: "downtime",
+              categoryId: "cambio-molde",
+              detailId: "cambio-molde",
+              categoryLabel: "Cambio molde",
+              detailLabel: "Cambio molde",
+              reasonCode: "MOLD_CHANGE",
+              reasonText: "Cambio molde",
+              incidentKey: moldIncidentKey ?? row.id,
+            } as Record<string, unknown>)
+          :
+        ({
+          type: "downtime",
+          categoryId: "unclassified",
+          detailId: "unclassified",
+          categoryLabel: "Unclassified",
+          detailLabel: "Unclassified",
+          reasonCode: "UNCLASSIFIED",
+          reasonText: "Unclassified",
+          incidentKey: row.id,
+        } as Record<string, unknown>));
+
+      const inferredKind: ReasonCatalogKind =
+        String(reasonRaw.type ?? "").toLowerCase() === "scrap" || finalType === "scrap-manual-entry"
+          ? "scrap"
+          : "downtime";
+      const resolved = resolveReason(reasonRaw, inferredKind, reasonCatalog, reasonCatalog.version);
+
+      if (resolved.reasonCode) {
+        const reasonId =
+          clampText(reasonRaw.reasonId, 128) ??
+          (inferredKind === "downtime"
+            ? `evt:${machine.id}:downtime:${clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id}`
+            : `evt:${machine.id}:scrap:${clampText(reasonRaw.scrapEntryId, 128) ?? row.id}`);
+
+        const workOrderId =
+          clampText(evRecord.work_order_id, 64) ??
+          clampText(evData.work_order_id, 64) ??
+          clampText(evRecord.workOrderId, 64) ??
+          null;
+
+        const commonWrite = {
+          reasonCode: resolved.reasonCode,
+          reasonLabel: resolved.reasonLabel ?? resolved.reasonCode,
+          reasonText: resolved.reasonText ?? null,
+          capturedAt: row.ts,
+          workOrderId,
+          schemaVersion: Math.max(1, Math.trunc(resolved.catalogVersion)),
+          meta: toJsonValue({
+            source: "ingest:event",
+            eventId: row.id,
+            eventType: row.eventType,
+            incidentKey: clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128),
+            anomalyType:
+              clampText(evRecord.anomalyType, 64) ??
+              clampText(evDowntime?.anomalyType, 64) ??
+              clampText(evRecord.anomaly_type, 64),
+            reason: {
+              type: resolved.type,
+              categoryId: resolved.categoryId,
+              categoryLabel: resolved.categoryLabel,
+              detailId: resolved.detailId,
+              detailLabel: resolved.detailLabel,
+              reasonText: resolved.reasonText,
+              catalogVersion: resolved.catalogVersion,
+            },
+          }),
+        };
+
+        if (inferredKind === "downtime") {
+          const incidentKey = clampText((reasonRaw as any).incidentKey ?? evDowntime?.incidentKey, 128) ?? row.id;
+          const durationSeconds =
+            numberFrom(evDowntime?.durationSeconds) ??
+            numberFrom(evData.duration_sec) ??
+            numberFrom(evData.stoppage_duration_seconds) ??
+            numberFrom(evData.stop_duration_seconds) ??
+            (stopSecForReason != null ? stopSecForReason : null) ??
+            null;
+          const episodeEndTsMs =
+            numberFrom(evData.end_ms) ??
+            numberFrom(evDowntime?.episodeEndTsMs) ??
+            numberFrom(evDowntime?.acknowledgedAtMs) ??
+            null;
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "downtime",
+              episodeId: incidentKey,
+              durationSeconds: durationSeconds != null ? Math.max(0, Math.trunc(durationSeconds)) : null,
+              episodeEndTs: episodeEndTsMs != null ? new Date(episodeEndTsMs) : null,
+              ...commonWrite,
+            },
+          });
+        } else {
+          const scrapEntryId =
+            clampText((reasonRaw as any).scrapEntryId, 128) ??
+            clampText(evRecord.id, 128) ??
+            clampText(evRecord.eventId, 128) ??
+            row.id;
+          const scrapQtyRaw =
+            numberFrom(evRecord.scrapDelta) ??
+            numberFrom(evData.scrapDelta) ??
+            numberFrom(evData.scrap_delta) ??
+            0;
+          const scrapQty = Math.max(0, Math.trunc(scrapQtyRaw));
+
+          await prisma.reasonEntry.upsert({
+            where: { reasonId },
+            create: {
+              orgId: machine.orgId,
+              machineId: machine.id,
+              reasonId,
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+            update: {
+              kind: "scrap",
+              scrapEntryId,
+              scrapQty,
+              scrapUnit: clampText((reasonRaw as any).scrapUnit, 16) ?? null,
+              ...commonWrite,
+            },
+          });
+        }
+      }
+    }
+
+    try {
+      if (row.eventType !== "downtime-acknowledged" && row.eventType !== "scrap-manual-entry") {
+        await evaluateAlertsForEvent(row.id);
+      }
+    } catch (err) {
+      console.error("[alerts] evaluation failed", err);
+    }
+  }
+
+  return NextResponse.json({ ok: true, createdCount: created.length, created, skippedCount: skipped.length, skipped });
+}

app/api/ingest/heartbeat/route.ts

@@ -97,26 +97,38 @@ export async function POST(req: Request) {
     // 5) Store heartbeat
     // Keep your legacy fields, but store meta fields too.
     const tsServerNow = new Date();
-    const hb = await prisma.machineHeartbeat.create({
-      data: {
-        orgId,
-        machineId: machine.id,
+    const hbRow = {
+      orgId,
+      machineId: machine.id,
+      schemaVersion,
+      seq,
+      ts: tsDeviceDate,
+      tsServer: tsServerNow,
+      status: body.status ? String(body.status) : (body.online ? "RUN" : "STOP"),
+      message: body.message ? String(body.message) : null,
+      ip: body.ip ? String(body.ip) : null,
+      fwVersion: body.fwVersion ? String(body.fwVersion) : null,
+    };
 
-        // Phase 0 meta
-        schemaVersion,
-        seq,
-        ts: tsDeviceDate,
-        tsServer: tsServerNow,
-
-        // Legacy payload compatibility
-        status: body.status ? String(body.status) : (body.online ? "RUN" : "STOP"),
-        message: body.message ? String(body.message) : null,
-        ip: body.ip ? String(body.ip) : null,
-        fwVersion: body.fwVersion ? String(body.fwVersion) : null,
-      },
+    const insertHb = await prisma.machineHeartbeat.createMany({
+      data: [hbRow],
+      skipDuplicates: true,
     });
 
-    // Optional: update machine last seen (same as KPI)
+    const hb = await prisma.machineHeartbeat.findFirst({
+      where: {
+        orgId,
+        machineId: machine.id,
+        ts: tsDeviceDate,
+      },
+      orderBy: { tsServer: "asc" },
+    });
+
+    if (!hb) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "Heartbeat row missing" }, { status: 500 });
+    }
+
+    // Optional: update machine last seen (same as KPI) — also on duplicate HB so lastSeen is fresh
     await prisma.machine.update({
       where: { id: machine.id },
       data: {
@@ -132,6 +144,7 @@ export async function POST(req: Request) {
       id: hb.id,
       tsDevice: hb.ts,
       tsServer: hb.tsServer,
+      duplicate: insertHb.count === 0,
     });
   } catch (err: unknown) {
     const msg = err instanceof Error ? err.message : "Unknown error";

app/api/ingest/kpi/route.ts

@@ -222,44 +222,42 @@ export async function POST(req: Request) {
         : typeof woRecord.cavities === "number" && woRecord.cavities > 0
           ? woRecord.cavities
           : null;
-    // Write snapshot (ts = tsDevice; tsServer auto)
-    const row = await prisma.machineKpiSnapshot.create({
-      data: {
-        orgId,
-        machineId: machine.id,
-
-        // Phase 0 meta
-        schemaVersion,
-        seq,
-        ts: tsDeviceDate, // store device-time in ts; server-time goes to ts_server
-
-        // Work order fields
-        workOrderId: activeWorkOrderId || null,
-        sku: activeSku || null,
-        target: activeTargetQty,
-        good: good != null ? Math.trunc(good) : null,
-        scrap: scrap != null ? Math.trunc(scrap) : null,
-
-        // Counters
-        cycleCount: snapshotCycleCount,
-        goodParts: snapshotGoodParts,
-        scrapParts: snapshotScrapParts,
-        cavities: safeCavities,
-
-        // Cycle times
-        cycleTime: safeCycleTime,
-        actualCycle: typeof body.actualCycleTime === "number" ? body.actualCycleTime : null,
-
-        // KPIs (0..100)
-        availability: typeof k.availability === "number" ? k.availability : null,
-        performance: typeof k.performance === "number" ? k.performance : null,
-        quality: typeof k.quality === "number" ? k.quality : null,
-        oee: typeof k.oee === "number" ? k.oee : null,
-
-        trackingEnabled: typeof body.trackingEnabled === "boolean" ? body.trackingEnabled : null,
-        productionStarted: typeof body.productionStarted === "boolean" ? body.productionStarted : null,
-      },
+    // Write snapshot (ts = tsDevice; tsServer auto). Idempotent on (org, machine, ts) to absorb retries.
+    const kpiData = {
+      orgId,
+      machineId: machine.id,
+      schemaVersion,
+      seq,
+      ts: tsDeviceDate,
+      workOrderId: activeWorkOrderId || null,
+      sku: activeSku || null,
+      target: activeTargetQty,
+      good: good != null ? Math.trunc(good) : null,
+      scrap: scrap != null ? Math.trunc(scrap) : null,
+      cycleCount: snapshotCycleCount,
+      goodParts: snapshotGoodParts,
+      scrapParts: snapshotScrapParts,
+      cavities: safeCavities,
+      cycleTime: safeCycleTime,
+      actualCycle: typeof body.actualCycleTime === "number" ? body.actualCycleTime : null,
+      availability: typeof k.availability === "number" ? k.availability : null,
+      performance: typeof k.performance === "number" ? k.performance : null,
+      quality: typeof k.quality === "number" ? k.quality : null,
+      oee: typeof k.oee === "number" ? k.oee : null,
+      trackingEnabled: typeof body.trackingEnabled === "boolean" ? body.trackingEnabled : null,
+      productionStarted: typeof body.productionStarted === "boolean" ? body.productionStarted : null,
+    };
+    const insertKpi = await prisma.machineKpiSnapshot.createMany({
+      data: [kpiData],
+      skipDuplicates: true,
     });
+    const row = await prisma.machineKpiSnapshot.findFirst({
+      where: { orgId, machineId: machine.id, ts: tsDeviceDate },
+      orderBy: { tsServer: "asc" },
+    });
+    if (!row) {
+      return NextResponse.json({ ok: false, error: "Server error", detail: "KPI snapshot row missing" }, { status: 500 });
+    }
 
     if (activeWorkOrderId) {
       await prisma.machineWorkOrder.upsert({
@@ -330,6 +328,7 @@ export async function POST(req: Request) {
       id: row.id,
       tsDevice: row.ts,
       tsServer: row.tsServer,
+      duplicate: insertKpi.count === 0,
       trace: traceEnabled ? trace : undefined,
     });
   } catch (err: unknown) {