Projects-plastic/modified_machine_cycles.js

// ===== MACHINE CYCLES FUNCTION (MODIFIED WITH DB PERSISTENCE) =====

const current = Number(msg.payload) || 0;

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];  // Added third output for DB sync
}

// Check if tracking is enabled (START button clicked)
const trackingEnabled = !!global.get("trackingEnabled");
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) {
    // *** NEW: Sync to DB on state changes (throttled) ***
    if (stateChanged) {
        const dbSyncMsg = createDbSyncMessage(false);  // throttled sync
        return [null, stateMsg, dbSyncMsg];
    }
    return [null, stateMsg, null];
}

let cycles = Number(global.get("cycleCount") || 0) + 1;
global.set("cycleCount", cycles);

// ===== PHASE 2: OPERATING TIME TRACKING =====
// Track actual operating time between cycles
const now = Date.now();
const lastCycleTime = global.get("lastCycleTime");

if (lastCycleTime) {
    const deltaMs = now - lastCycleTime;
    const deltaSec = deltaMs / 1000;
    const currentOperatingTime = global.get("operatingTime") || 0;
    global.set("operatingTime", currentOperatingTime + deltaSec);
}

global.set("lastCycleTime", now);

// Auto-prompt for scrap when target is reached
const scrapPromptIssuedFor = global.get("scrapPromptIssuedFor");
if (cycles === Number(activeOrder.target) && scrapPromptIssuedFor !== activeOrder.id) {
    // Mark that we've prompted for this work order to prevent repeated prompts
    global.set("scrapPromptIssuedFor", activeOrder.id);

    // Send scrap prompt message
    const scrapPromptMsg = {
        _mode: "scrap-prompt",
        payload: {
            workOrderId: activeOrder.id,
            cycles: cycles,
            target: activeOrder.target,
            message: `Target of ${activeOrder.target} cycles reached. Do you have scrap parts to report?`
        }
    };

    // *** NEW: Sync to DB when target is reached (forced) ***
    const dbSyncMsg = createDbSyncMessage(true);  // forced sync
    return [scrapPromptMsg, stateMsg, dbSyncMsg];
}

// *** NEW: Sync to DB on each cycle (throttled) ***
const dbSyncMsg = createDbSyncMessage(false);  // throttled sync
return [null, stateMsg, dbSyncMsg];

// ========================================
// HELPER FUNCTION: Create DB Sync Message
// ========================================
function createDbSyncMessage(forceUpdate) {
    const now = Date.now();
    const lastSync = flow.get("lastSessionSync") || 0;

    // Throttle: only sync every 5 seconds unless forced
    if (!forceUpdate && (now - lastSync) < 5000) {
        return null;
    }

    flow.set("lastSessionSync", now);

    const sessionId = global.get("currentSessionId") || "session_" + Date.now();
    global.set("currentSessionId", sessionId);

    const activeOrder = global.get("activeWorkOrder");
    const activeOrderId = activeOrder ? activeOrder.id : null;
    const activeOrderData = activeOrder ? JSON.stringify(activeOrder) : null;

    const sessionData = {
        session_id: sessionId,
        production_start_time: global.get("productionStartTime") || null,
        operating_time: global.get("operatingTime") || 0,
        last_update_time: now,
        tracking_enabled: global.get("trackingEnabled") ? 1 : 0,
        cycle_count: global.get("cycleCount") || 0,
        active_work_order_id: activeOrderId,
        active_work_order_data: activeOrderData,
        machine_online: global.get("machineOnline") ? 1 : 0,
        production_started: global.get("productionStarted") ? 1 : 0,
        last_cycle_time: global.get("lastCycleTime") || null,
        last_machine_state: flow.get("lastMachineState") || 0,
        created_at: now,
        updated_at: now,
        is_active: 1
    };

    // Escape single quotes in JSON data
    const escapedOrderData = sessionData.active_work_order_data
        ? sessionData.active_work_order_data.replace(/'/g, "''")
        : null;

    // Create upsert query
    const query = `
        INSERT INTO session_state (
            session_id, production_start_time, operating_time, last_update_time,
            tracking_enabled, cycle_count, active_work_order_id, active_work_order_data,
            machine_online, production_started, last_cycle_time, last_machine_state,
            created_at, updated_at, is_active
        ) VALUES (
            '${sessionData.session_id}',
            ${sessionData.production_start_time},
            ${sessionData.operating_time},
            ${sessionData.last_update_time},
            ${sessionData.tracking_enabled},
            ${sessionData.cycle_count},
            ${sessionData.active_work_order_id ? "'" + sessionData.active_work_order_id + "'" : "NULL"},
            ${escapedOrderData ? "'" + escapedOrderData + "'" : "NULL"},
            ${sessionData.machine_online},
            ${sessionData.production_started},
            ${sessionData.last_cycle_time},
            ${sessionData.last_machine_state},
            ${sessionData.created_at},
            ${sessionData.updated_at},
            ${sessionData.is_active}
        )
        ON DUPLICATE KEY UPDATE
            production_start_time = VALUES(production_start_time),
            operating_time = VALUES(operating_time),
            last_update_time = VALUES(last_update_time),
            tracking_enabled = VALUES(tracking_enabled),
            cycle_count = VALUES(cycle_count),
            active_work_order_id = VALUES(active_work_order_id),
            active_work_order_data = VALUES(active_work_order_data),
            machine_online = VALUES(machine_online),
            production_started = VALUES(production_started),
            last_cycle_time = VALUES(last_cycle_time),
            last_machine_state = VALUES(last_machine_state),
            updated_at = VALUES(updated_at),
            is_active = VALUES(is_active);
    `;

    return {
        _mode: "session-sync",
        topic: query,
        sessionData: sessionData
    };
}