Files
MIS-Contro-Tower/app/api/ingest/event/route.ts
2026-04-26 16:31:04 +00:00

673 lines
24 KiB
TypeScript

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 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 },
});
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: "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){
// 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 });
}