Issues with data flow & consistency

app/(app)/machines/[machineId]/MachineDetailClient.tsx

@@ -110,7 +110,7 @@ export default function MachineDetailClient() {
 
     async function load() {
       try {
-        const res = await fetch(`/api/machines/${machineId}`, {
+        const res = await fetch(`/api/machines/${machineId}?windowSec=10800`, {
           cache: "no-store",
           credentials: "include",
         });
@@ -242,6 +242,77 @@ export default function MachineDetailClient() {
     );
   }
 
+
+  function MachineActivityTimeline({
+    segments,
+    windowSec,
+  }: {
+    segments: TimelineSeg[];
+    windowSec: number;
+  }) {
+    return (
+      <div className="rounded-2xl border border-white/10 bg-white/5 p-5">
+        <div className="flex items-start justify-between gap-4">
+          <div>
+            <div className="text-sm font-semibold text-white">Machine Activity Timeline</div>
+            <div className="mt-1 text-xs text-zinc-400">Análisis en tiempo real de ciclos de producción</div>
+          </div>
+          <div className="text-xs text-zinc-400">{windowSec}s</div>
+        </div>
+
+        <div className="mt-4 flex flex-wrap items-center gap-4 text-xs text-zinc-300">
+          {(["normal","slow","microstop","macrostop"] as const).map((k) => (
+            <div key={k} className="flex items-center gap-2">
+              <span className="h-2.5 w-2.5 rounded-full" style={{ backgroundColor: BUCKET[k].dot }} />
+              <span>{BUCKET[k].label}</span>
+            </div>
+          ))}
+        </div>
+
+        <div className="mt-4 rounded-2xl border border-white/10 bg-black/25 p-4">
+          {/* time marks */}
+          <div className="mb-2 flex justify-between text-[11px] text-zinc-500">
+            <span>0s</span>
+            <span>3h</span>
+          </div>
+
+          {/* strip */}
+          <div className="flex h-14 w-full overflow-hidden rounded-2xl">
+            {segments.length === 0 ? (
+              <div className="flex h-full w-full items-center justify-center text-xs text-zinc-400">
+                No timeline data yet.
+              </div>
+            ) : (
+              segments.map((seg, idx) => {
+                const wPct = Math.max(0.25, (seg.durationSec / windowSec) * 100); // min width for visibility
+                const meta = BUCKET[seg.state];
+
+                const glow =
+                  seg.state === "microstop" || seg.state === "macrostop"
+                    ? `0 0 22px ${meta.glow}`
+                    : `0 0 12px ${meta.glow}`;
+
+                return (
+                  <div
+                    key={`${seg.start}-${seg.end}-${idx}`}
+                    title={`${meta.label}: ${seg.durationSec.toFixed(1)}s`}
+                    className="h-full"
+                    style={{
+                      width: `${wPct}%`,
+                      background: meta.dot,
+                      boxShadow: glow,
+                      opacity: 0.95,
+                    }}
+                  />
+                );
+              })
+            )}
+          </div>
+        </div>
+      </div>
+    );
+  }
+
   function Modal({
   open,
   onClose,
@@ -409,6 +480,91 @@ export default function MachineDetailClient() {
     return { rows, total };
   }, [cycleDerived.mapped]);
 
+  type TimelineState = "normal" | "slow" | "microstop" | "macrostop";
+type TimelineSeg = {
+  start: number;      // ms
+  end: number;        // ms
+  durationSec: number;
+  state: TimelineState;
+};
+
+function classifyGap(dtSec: number, idealSec: number): TimelineState {
+  const SLOW_X = 1.5;
+  const STOP_X = 3.0;
+  const MACRO_X = 10.0;
+
+  if (dtSec <= idealSec * SLOW_X) return "normal";
+  if (dtSec <= idealSec * STOP_X) return "slow";
+  if (dtSec <= idealSec * MACRO_X) return "microstop";
+  return "macrostop";
+}
+
+function mergeAdjacent(segs: TimelineSeg[]): TimelineSeg[] {
+  if (!segs.length) return [];
+  const out: TimelineSeg[] = [segs[0]];
+  for (let i = 1; i < segs.length; i++) {
+    const prev = out[out.length - 1];
+    const cur = segs[i];
+    // merge if same state and touching
+    if (cur.state === prev.state && cur.start <= prev.end + 1) {
+      prev.end = Math.max(prev.end, cur.end);
+      prev.durationSec = (prev.end - prev.start) / 1000;
+    } else {
+      out.push(cur);
+    }
+  }
+  return out;
+}
+
+const timeline = useMemo(() => {
+  const rows = cycles ?? [];
+  if (rows.length < 2) {
+    return { windowSec: 10800, segments: [] as TimelineSeg[], start: null as number | null, end: null as number | null };
+  }
+
+  // window: last 180s (like your screenshot)
+  const windowSec = 10800;
+  const end = rows[rows.length - 1].t;
+  const start = end - windowSec * 1000;
+
+  // keep cycles that overlap window (need one cycle before start to build first interval)
+  const idxFirst = Math.max(
+    0,
+    rows.findIndex(r => r.t >= start) - 1
+  );
+  const sliced = rows.slice(idxFirst);
+
+  const segs: TimelineSeg[] = [];
+
+  for (let i = 1; i < sliced.length; i++) {
+    const prev = sliced[i - 1];
+    const cur = sliced[i];
+
+    const s = Math.max(prev.t, start);
+    const e = Math.min(cur.t, end);
+    if (e <= s) continue;
+
+    const dtSec = (cur.t - prev.t) / 1000;
+
+    const ideal = (cur.ideal ?? prev.ideal ?? cycleTarget ?? 0) as number;
+    if (!ideal || ideal <= 0) continue;
+
+    const state = classifyGap(dtSec, ideal);
+
+    segs.push({
+      start: s,
+      end: e,
+      durationSec: (e - s) / 1000,
+      state,
+    });
+  }
+
+  const segments = mergeAdjacent(segs);
+
+  return { windowSec, segments, start, end };
+}, [cycles, cycleTarget]);
+
+
 
   return (
     <div className="p-6">
@@ -471,6 +627,10 @@ export default function MachineDetailClient() {
             </div>
           </div>
 
+          <div className="mt-6">
+            <MachineActivityTimeline segments={timeline.segments} windowSec={timeline.windowSec} />
+          </div>
+
           {/* Work order + recent events */}
           <div className="mt-6 grid grid-cols-1 gap-4 xl:grid-cols-3">
             <div className="rounded-2xl border border-white/10 bg-white/5 p-5 xl:col-span-1">

app/api/ingest/cycle/route.ts

@@ -30,7 +30,7 @@ export async function POST(req: Request) {
     data: {
       orgId: machine.orgId,
       machineId: machine.id,
-      ts,
+      ts,   
       cycleCount: typeof c.cycle_count === "number" ? c.cycle_count : null,
       actualCycleTime: Number(c.actual_cycle_time),
       theoreticalCycleTime: c.theoretical_cycle_time != null ? Number(c.theoretical_cycle_time) : null,
@@ -41,6 +41,5 @@ export async function POST(req: Request) {
       scrapDelta: typeof c.scrap_delta === "number" ? c.scrap_delta : null,
     },
   });
-
   return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
 }

app/api/ingest/event/route.ts

@@ -1,107 +1,153 @@
 import { NextResponse } from "next/server";
 import { prisma } from "@/lib/prisma";
 
+const normalizeType = (t: any) =>
+  String(t ?? "")
+    .trim()
+    .toLowerCase()
+    .replace(/_/g, "-");
+
+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",
+};
+
+const ALLOWED_TYPES = new Set([
+  "slow-cycle",
+  "microstop",
+  "macrostop",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
+]);
+
+// thresholds for stop classification (tune later / move to machine config)
+const MICROSTOP_SEC = 60;
+const MACROSTOP_SEC = 300;
+
 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 });
+  if (!apiKey) {
+    return NextResponse.json({ ok: false, error: "Missing api key" }, { status: 401 });
+  }
 
   const body = await req.json().catch(() => null);
   if (!body?.machineId || !body?.event) {
     return NextResponse.json({ ok: false, error: "Invalid payload" }, { status: 400 });
   }
+  
 
   const machine = await prisma.machine.findFirst({
     where: { id: String(body.machineId), apiKey },
     select: { id: true, orgId: true },
   });
-  if (!machine) return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  if (!machine) {
+    return NextResponse.json({ ok: false, error: "Unauthorized" }, { status: 401 });
+  }
 
-  
+  // Normalize to array (Node-RED sends array of anomalies)
+  const rawEvent = body.event;
+  const events = Array.isArray(rawEvent) ? rawEvent : [rawEvent];
 
-  // Convert ms epoch -> Date if provided
+  const created: { id: string; ts: Date; eventType: string }[] = [];
+  const skipped: any[] = [];
 
-  
+  for (const ev of events) {
-  
+    if (!ev || typeof ev !== "object") {
-const rawEvent = body.event;
+      skipped.push({ reason: "invalid_event_object" });
-const e = Array.isArray(rawEvent) ? rawEvent[0] : rawEvent;
+      continue;
-
+    }
-if (!e || typeof e !== "object") {
-  return NextResponse.json({ ok: false, error: "Invalid event object" }, { status: 400 });
-}
-const rawType =
-  e.eventType ?? e.anomaly_type ?? e.topic ?? body.topic ?? "";
-
-const normalizeType = (t: string) =>
-  String(t)
-    .trim()
-    .toLowerCase()
-    .replace(/_/g, "-");
-
-const typ = normalizeType(rawType);
-const sev = String(e.severity ?? "").trim().toLowerCase();
-
-// accept these types
-const ALLOWED_TYPES = new Set([
-  "slow-cycle",
-  "anomaly-detected",
-  "performance-degradation",
-  "scrap-spike",
-  "down",
-  "microstop",
-]);
-
-if (!ALLOWED_TYPES.has(typ)) {
-  return NextResponse.json({ ok: true, skipped: true, reason: "type_not_allowed", typ, sev }, { status: 200 });
-}
-
-// optional: severity enforcement only for SOME types (not slow-cycle)
-const NEEDS_HIGH_SEV = new Set(["down", "scrap-spike"]);
-const ALLOWED_SEVERITIES = new Set(["warning", "critical", "error"]);
-
-if (NEEDS_HIGH_SEV.has(typ) && !ALLOWED_SEVERITIES.has(sev)) {
-  return NextResponse.json({ ok: true, skipped: true, reason: "severity_too_low", typ, sev }, { status: 200 });
-}
-
-// timestamp handling (support multiple field names)
-const tsMs =
-  (typeof (e as any)?.timestamp === "number" && (e as any).timestamp) ||
-  (typeof e?.data?.timestamp === "number" && e.data.timestamp) ||
-  (typeof e?.data?.event_timestamp === "number" && e.data.event_timestamp) ||
-  (typeof e?.data?.ts === "number" && e.data.ts) ||
-  undefined;
-
-const ts = tsMs ? new Date(tsMs) : new Date(); // default to now if missing
-
-const title =
-  String(e.title ?? "").trim() ||
-  (typ === "slow-cycle" ? "Slow Cycle Detected" : "Event");
-
-const description = e.description
-  ? String(e.description)
-  : null;
-
-const row = await prisma.machineEvent.create({
-  data: {
-    orgId: machine.orgId,
-    machineId: machine.id,
-    ts,
-
-    topic: String(e.topic ?? typ),
-    eventType: typ,                 // ✅ store normalized type
-    severity: sev || "info",        // ✅ store normalized severity
-    requiresAck: !!e.requires_ack,
-    title,
-    description,
-
-    data: e.data ?? e,
-
-  workOrderId:
-    (e as any)?.work_order_id ? String((e as any).work_order_id)
-    : e?.data?.work_order_id ? String(e.data.work_order_id)
-    : null,
-  },
-});
-
-return NextResponse.json({ ok: true, id: row.id, ts: row.ts });
 
+    const rawType = (ev as any).eventType ?? (ev as any).anomaly_type ?? (ev as any).topic ?? body.topic ?? "";
+    const typ0 = normalizeType(rawType);
+    const typ = CANON_TYPE[typ0] ?? typ0;
+
+    // Determine timestamp
+    const tsMs =
+      (typeof (ev as any)?.timestamp === "number" && (ev as any).timestamp) ||
+      (typeof (ev as any)?.data?.timestamp === "number" && (ev as any).data.timestamp) ||
+      (typeof (ev as any)?.data?.event_timestamp === "number" && (ev as any).data.event_timestamp) ||
+      null;
+
+    const ts = tsMs ? new Date(tsMs) : new Date();
+
+    // Severity defaulting (do not skip on severity — store for audit)
+    let sev = String((ev as any).severity ?? "").trim().toLowerCase();
+    if (!sev) sev = "warning";
+
+    // Stop classification -> microstop/macrostop
+    let finalType = typ;
+    if (typ === "stop") {
+      const stopSec =
+        (typeof (ev as any)?.data?.stoppage_duration_seconds === "number" && (ev as any).data.stoppage_duration_seconds) ||
+        (typeof (ev as any)?.data?.stop_duration_seconds === "number" && (ev as any).data.stop_duration_seconds) ||
+        null;
+
+      if (stopSec != null) {
+        finalType = stopSec >= 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 =
+      String((ev as any).title ?? "").trim() ||
+      (finalType === "slow-cycle" ? "Slow Cycle Detected" :
+       finalType === "macrostop" ? "Macrostop Detected" :
+       finalType === "microstop" ? "Microstop Detected" :
+       "Event");
+
+    const description = (ev as any).description ? String((ev as any).description) : null;
+
+    // store full blob, ensure object
+    const rawData = (ev as any).data ?? ev;
+    const dataObj = typeof rawData === "string" ? (() => {
+      try { return JSON.parse(rawData); } catch { return { raw: rawData }; }
+    })() : rawData;
+
+    const row = await prisma.machineEvent.create({
+      data: {
+        orgId: machine.orgId,
+        machineId: machine.id,
+        ts,
+        topic: String((ev as any).topic ?? finalType),
+        eventType: finalType,
+        severity: sev,
+        requiresAck: !!(ev as any).requires_ack,
+        title,
+        description,
+        data: dataObj,
+        workOrderId:
+          (ev as any)?.work_order_id ? String((ev as any).work_order_id)
+          : (ev as any)?.data?.work_order_id ? String((ev as any).data.work_order_id)
+          : null,
+        sku:
+          (ev as any)?.sku ? String((ev as any).sku)
+          : (ev as any)?.data?.sku ? String((ev as any).data.sku)
+          : null,
+      },
+    });
+
+    created.push({ id: row.id, ts: row.ts, eventType: row.eventType });
+  }
+
+  return NextResponse.json({ ok: true, createdCount: created.length, created, skippedCount: skipped.length, skipped });
 }

app/api/machines/[machineId]/route.ts

@@ -4,9 +4,26 @@ import { prisma } from "@/lib/prisma";
 import { requireSession } from "@/lib/auth/requireSession";
 
 function normalizeEvent(row: any) {
-  // data can be object OR [object]
+  // -----------------------------
+  // 1) Parse row.data safely
+  // data may be:
+  //   - object
+  //   - array of objects
+  //   - JSON string of either
+  // -----------------------------
   const raw = row.data;
-  const blob = Array.isArray(raw) ? raw[0] : raw;
+
+  let parsed: any = raw;
+  if (typeof raw === "string") {
+    try {
+      parsed = JSON.parse(raw);
+    } catch {
+      parsed = raw; // keep as string if not JSON
+    }
+  }
+
+  // data can be object OR [object]
+  const blob = Array.isArray(parsed) ? parsed[0] : parsed;
 
   // some payloads nest details under blob.data
   const inner = blob?.data ?? blob ?? {};
@@ -17,21 +34,71 @@ function normalizeEvent(row: any) {
       .toLowerCase()
       .replace(/_/g, "-");
 
-  // Prefer the DB columns if they are meaningful
+  // -----------------------------
-  const fromDbType = row.eventType && row.eventType !== "unknown" ? row.eventType : null;
+  // 2) Alias mapping (canonical types)
-  const fromBlobType = blob?.anomaly_type ?? blob?.eventType ?? blob?.topic ?? inner?.anomaly_type ?? inner?.eventType ?? null;
+  // -----------------------------
+  const ALIAS: Record<string, string> = {
+    // Spanish / synonyms
+    macroparo: "macrostop",
+    "macro-stop": "macrostop",
+    macro_stop: "macrostop",
 
-  // infer slow-cycle if the signature exists
+    microparo: "microstop",
+    "micro-paro": "microstop",
+    micro_stop: "microstop",
+
+    // Node-RED types
+    "production-stopped": "stop", // we'll classify to micro/macro below
+
+    // legacy / generic
+    down: "stop",
+  };
+
+  // -----------------------------
+  // 3) Determine event type from DB or blob
+  // -----------------------------
+  const fromDbType =
+    row.eventType && row.eventType !== "unknown" ? row.eventType : null;
+
+  const fromBlobType =
+    blob?.anomaly_type ??
+    blob?.eventType ??
+    blob?.topic ??
+    inner?.anomaly_type ??
+    inner?.eventType ??
+    null;
+
+  // infer slow-cycle if signature exists
   const inferredType =
     fromDbType ??
     fromBlobType ??
-    ((inner?.actual_cycle_time && inner?.theoretical_cycle_time) || (blob?.actual_cycle_time && blob?.theoretical_cycle_time)
+    ((inner?.actual_cycle_time && inner?.theoretical_cycle_time) ||
+    (blob?.actual_cycle_time && blob?.theoretical_cycle_time)
       ? "slow-cycle"
       : "unknown");
 
+  const eventTypeRaw = normalizeType(inferredType);
+  let eventType = ALIAS[eventTypeRaw] ?? eventTypeRaw;
 
-  const eventType = normalizeType(inferredType);
+  // -----------------------------
+  // 4) Optional: classify "stop" into micro/macro based on duration if present
+  // (keeps old rows usable even if they stored production-stopped)
+  // -----------------------------
+  if (eventType === "stop") {
+    const stopSec =
+      (typeof inner?.stoppage_duration_seconds === "number" && inner.stoppage_duration_seconds) ||
+      (typeof blob?.stoppage_duration_seconds === "number" && blob.stoppage_duration_seconds) ||
+      (typeof inner?.stop_duration_seconds === "number" && inner.stop_duration_seconds) ||
+      null;
 
+    // tune these thresholds to match your MES spec
+    const MACROSTOP_SEC = 300; // 5 min
+    eventType = stopSec != null && stopSec >= MACROSTOP_SEC ? "macrostop" : "microstop";
+  }
+
+  // -----------------------------
+  // 5) Severity, title, description, timestamp
+  // -----------------------------
   const severity =
     String(
       (row.severity && row.severity !== "info" ? row.severity : null) ??
@@ -55,10 +122,10 @@ function normalizeEvent(row: any) {
     blob?.description ??
     inner?.description ??
     (eventType === "slow-cycle" &&
-    inner?.actual_cycle_time &&
+    (inner?.actual_cycle_time ?? blob?.actual_cycle_time) &&
-    inner?.theoretical_cycle_time &&
+    (inner?.theoretical_cycle_time ?? blob?.theoretical_cycle_time) &&
-    inner?.delta_percent != null
+    (inner?.delta_percent ?? blob?.delta_percent) != null
-      ? `Cycle took ${Number(inner.actual_cycle_time).toFixed(1)}s (+${inner.delta_percent}% vs ${Number(inner.theoretical_cycle_time).toFixed(1)}s objetivo)`
+      ? `Cycle took ${Number(inner?.actual_cycle_time ?? blob?.actual_cycle_time).toFixed(1)}s (+${Number(inner?.delta_percent ?? blob?.delta_percent)}% vs ${Number(inner?.theoretical_cycle_time ?? blob?.theoretical_cycle_time).toFixed(1)}s objetivo)`
       : null);
 
   const ts =
@@ -161,24 +228,54 @@ export async function GET(
 
 const ALLOWED_TYPES = new Set([
   "slow-cycle",
-  "anomaly-detected",
-  "performance-degradation",
-  "scrap-spike",
-  "down",
   "microstop",
+  "macrostop",
+  "oee-drop",
+  "quality-spike",
+  "performance-degradation",
+  "predictive-oee-decline",
 ]);
 
 const events = normalized
   .filter((e) => ALLOWED_TYPES.has(e.eventType))
   // keep slow-cycle even if severity is info, otherwise require warning/critical/error
-  .filter((e) => e.eventType === "slow-cycle" || ["warning", "critical", "error"].includes(e.severity))
+  .filter((e) =>
+    ["slow-cycle", "microstop", "macrostop"].includes(e.eventType) ||
+    ["warning", "critical", "error"].includes(e.severity)
+  )
   .slice(0, 30);
 
 
+// ---- cycles window ----
+const url = new URL(_req.url);
+const windowSec = Number(url.searchParams.get("windowSec") ?? "10800"); // default 3h
+
+const latestKpi = machine.kpiSnapshots[0] ?? null;
+
+// If KPI cycleTime missing, fallback to DB cycles (we fetch 1 first)
+const latestCycleForIdeal = await prisma.machineCycle.findFirst({
+  where: { orgId: session.orgId, machineId },
+  orderBy: { ts: "desc" },
+  select: { theoreticalCycleTime: true },
+});
+
+const effectiveCycleTime =
+  latestKpi?.cycleTime ??
+  latestCycleForIdeal?.theoreticalCycleTime ??
+  null;
+
+// Estimate how many cycles we need to cover the window.
+// Add buffer so the chart doesn’t look “tight”.
+const estCycleSec = Math.max(1, Number(effectiveCycleTime ?? 14));
+const needed = Math.ceil(windowSec / estCycleSec) + 50;
+
+// Safety cap to avoid crazy payloads
+const takeCycles = Math.min(5000, Math.max(200, needed));
+
 const rawCycles = await prisma.machineCycle.findMany({
   where: { orgId: session.orgId, machineId },
   orderBy: { ts: "desc" },
-  take: 200,
+  take: takeCycles,
   select: {
     ts: true,
     cycleCount: true,
@@ -194,23 +291,14 @@ const cycles = rawCycles
   .slice()
   .reverse()
   .map((c) => ({
-    ts: c.ts,                       // keep Date for “time ago” UI
+    ts: c.ts,
-    t: c.ts.getTime(),              // numeric x-axis for charts
+    t: c.ts.getTime(),
     cycleCount: c.cycleCount ?? null,
-    actual: c.actualCycleTime,      // rename to what chart expects
+    actual: c.actualCycleTime,
     ideal: c.theoreticalCycleTime ?? null,
     workOrderId: c.workOrderId ?? null,
     sku: c.sku ?? null,
-  }
+  }));
-));
-
-const latestKpi = machine.kpiSnapshots[0] ?? null;
-
-// rawCycles is ordered DESC, so [0] is the most recent cycle row
-const latestCycleIdeal = rawCycles[0]?.theoreticalCycleTime ?? null;
-
-// REAL effective value (not mock): prefer KPI if present, else fallback to cycles table
-const effectiveCycleTime = latestKpi?.cycleTime ?? latestCycleIdeal ?? null;