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projects/Plastico/CHANGES_REFERENCE.md
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396
projects/Plastico/CHANGES_REFERENCE.md
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# Quick Reference: Multi-Phase Implementation Changes
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## Modified Function Nodes in flows.json
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### 1. Machine Cycles (ID: 0d023d87a13bf56f) - Phase 2
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**Added:**
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- 5-second throttling for DB persistence
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- Global variable `lastWorkOrderDbWrite` to track last write time
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- Enhanced 4th output to include `progress_percent`
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**Key Code Addition:**
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```javascript
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const lastDbWrite = global.get("lastWorkOrderDbWrite") || 0;
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const timeSinceLastWrite = now - lastDbWrite;
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let persistCycleCount = null;
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if (timeSinceLastWrite >= 5000) {
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persistCycleCount = {
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topic: "UPDATE work_orders SET cycle_count = ?, good_parts = ?, progress_percent = ?, updated_at = NOW() WHERE work_order_id = ?",
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payload: [cycles, produced, progress, activeOrder.id]
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};
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global.set("lastWorkOrderDbWrite", now);
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}
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```
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### 2. Work Order buttons (ID: 9bbd4fade968036d) - Phases 3 & 4
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**Modified Actions:**
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- `start-work-order`: Now queries DB for existing progress
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- `complete-work-order`: Persists final counts before marking DONE
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**New Actions:**
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- `resume-work-order`: Loads work order with existing database values
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- `restart-work-order`: Resets work order to zero in database and global state
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**Key Changes:**
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**start-work-order:**
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```javascript
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case "start-work-order": {
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msg._mode = "check-progress";
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const order = msg.payload || {};
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flow.set("pendingWorkOrder", order);
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msg.topic = "SELECT cycle_count, good_parts, progress_percent FROM work_orders WHERE work_order_id = ?";
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msg.payload = [order.id];
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return [null, null, msg, null];
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}
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```
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**resume-work-order:**
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```javascript
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case "resume-work-order": {
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msg._mode = "resume";
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const order = msg.payload || {};
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const existingCycles = Number(order.cycle_count) || 0;
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global.set("activeWorkOrder", order);
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global.set("cycleCount", existingCycles); // Load from DB
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msg.topic = "UPDATE work_orders SET status = ... 'RUNNING' ...";
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return [null, null, msg, null];
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}
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```
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**complete-work-order (Phase 4):**
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```javascript
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case "complete-work-order": {
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const finalCycles = Number(global.get("cycleCount")) || 0;
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const finalGoodParts = Math.max(0, totalProduced - scrapTotal);
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msg.topic = "UPDATE work_orders SET status = 'DONE', cycle_count = ?, good_parts = ?, progress_percent = 100, updated_at = NOW() WHERE work_order_id = ?";
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msg.payload = [finalCycles, finalGoodParts, order.id];
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return [null, null, null, msg];
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}
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```
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### 3. Refresh Trigger (ID: 578c92e75bf0f266) - Phase 3
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**Added Modes:**
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- `check-progress`: Routes to Back to UI for progress check processing
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- `resume`: Routes to Back to UI and triggers work order list refresh
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- `restart`: Routes to Back to UI and triggers work order list refresh
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**Key Addition:**
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```javascript
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if (msg._mode === "resume" || msg._mode === "restart") {
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const originalMsg = {...msg};
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msg._mode = "select";
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msg.topic = "SELECT * FROM work_orders ORDER BY updated_at DESC;";
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return [msg, originalMsg];
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}
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if (msg._mode === "check-progress") {
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return [null, msg];
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}
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```
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### 4. Back to UI (ID: f2bab26e27e2023d) - Phases 3 & 5
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**New Modes:**
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- `check-progress`: Sends resumePrompt to UI if progress exists
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- `resume`: Sends activeWorkOrder with database values
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- `restart`: Sends activeWorkOrder with zeroed values
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**Modified Modes:**
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- `restore-query`: Enhanced documentation (Phase 5)
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**Key Additions:**
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**check-progress:**
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```javascript
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if (mode === "check-progress") {
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const rows = Array.isArray(msg.payload) ? msg.payload : [];
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if (rows.length > 0) {
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const row = rows[0];
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const cycleCount = Number(row.cycle_count) || 0;
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const goodParts = Number(row.good_parts) || 0;
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if (cycleCount > 0 || goodParts > 0) {
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msg.topic = "resumePrompt";
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msg.payload = {
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id: pendingOrder.id,
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sku: pendingOrder.sku,
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cycleCount: cycleCount,
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goodParts: goodParts,
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progressPercent: Number(row.progress_percent) || 0
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};
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return [null, msg, null, null];
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}
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}
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// Auto-start if no progress
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global.set("cycleCount", 0);
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return [null, null, null, null];
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}
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```
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---
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## Message Flow Diagram
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### Load Work Order (Phase 3)
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```
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User clicks Load
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↓
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Work Order buttons (start-work-order)
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↓ (output 3, _mode: "check-progress")
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mariaDB (SELECT cycle_count, good_parts...)
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↓
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Refresh Trigger (routes check-progress)
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↓ (output 2)
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Back to UI (check-progress)
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↓
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IF progress exists:
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→ Send resumePrompt to UI
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→ UI shows Resume/Restart dialog
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ELSE:
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→ Auto-start with zero values
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```
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### Resume Work Order (Phase 3)
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```
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User clicks Resume
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↓
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Work Order buttons (resume-work-order)
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↓ (output 3, _mode: "resume")
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mariaDB (UPDATE status = 'RUNNING'...)
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↓
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Refresh Trigger (routes resume + refreshes WO list)
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↓ (output 2)
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Back to UI (resume)
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↓
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Send activeWorkOrder to Home template
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(with existing cycle_count and good_parts)
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```
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### Machine Cycle (Phase 2)
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```
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Every machine cycle
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↓
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Machine Cycles function
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↓
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Check throttle (5 seconds elapsed?)
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↓
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IF yes:
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↓ (output 4)
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DB Guard (Cycles)
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↓
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mariaDB (UPDATE cycle_count, good_parts...)
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ELSE:
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→ Skip DB write
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```
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### Complete Work Order (Phase 4)
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```
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User clicks Done
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↓
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Work Order buttons (complete-work-order)
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↓ Calculate final counts
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↓ (output 4, _mode: "complete")
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mariaDB (UPDATE status='DONE', cycle_count=?, good_parts=?...)
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↓
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Refresh Trigger (routes complete + refreshes WO list)
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↓ (output 2)
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Back to UI (complete)
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↓
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Clear activeWorkOrder from Home template
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```
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---
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## Database Schema Requirements
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```sql
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-- Required columns in work_orders table
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CREATE TABLE work_orders (
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work_order_id VARCHAR(255) PRIMARY KEY,
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sku VARCHAR(255),
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target_qty INT,
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cycle_count INT DEFAULT 0, -- Added Phase 1
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good_parts INT DEFAULT 0, -- Added Phase 1
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scrap_parts INT DEFAULT 0,
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progress_percent INT DEFAULT 0,
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status VARCHAR(50) DEFAULT 'PENDING',
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cycle_time DECIMAL(10,2),
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updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP ON UPDATE CURRENT_TIMESTAMP,
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created_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP,
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INDEX idx_work_order_id (work_order_id),
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INDEX idx_status (status)
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);
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```
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---
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## Global Variables Reference
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| Variable | Type | Purpose | Set By | Used By |
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|----------|------|---------|--------|---------|
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| activeWorkOrder | Object | Current work order | Work Order buttons | Machine Cycles, Back to UI |
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| cycleCount | Number | Current cycle count | Machine Cycles, Work Order buttons | Machine Cycles, Complete |
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| lastWorkOrderDbWrite | Number | Timestamp of last DB write | Machine Cycles | Machine Cycles (throttling) |
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| trackingEnabled | Boolean | Production tracking active | Work Order buttons (start/stop) | Machine Cycles |
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| productionStarted | Boolean | Production has started | Machine Cycles, Work Order buttons | Machine Cycles |
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| moldActive | Number | Cavities in current mold | Mold settings | Machine Cycles, Complete |
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| scrapPromptIssuedFor | String | Work order ID for scrap prompt | Machine Cycles | Machine Cycles |
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## Flow Context Variables
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| Variable | Type | Purpose | Set By | Used By |
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|----------|------|---------|--------|---------|
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| pendingWorkOrder | Object | Work order awaiting resume/restart decision | Work Order buttons (start) | Back to UI (check-progress) |
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| lastMachineState | Number | Previous machine state (0 or 1) | Machine Cycles | Machine Cycles (edge detection) |
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---
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## Testing SQL Queries
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### Check Current Progress
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```sql
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SELECT work_order_id, cycle_count, good_parts, progress_percent, status, updated_at
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FROM work_orders
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WHERE status = 'RUNNING';
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```
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### Verify Throttling (should update every ~5 seconds)
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```sql
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SELECT work_order_id, cycle_count, good_parts, updated_at
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FROM work_orders
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WHERE work_order_id = 'YOUR_WO_ID'
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ORDER BY updated_at DESC
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LIMIT 10;
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```
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### Check Completed Work Orders
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```sql
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SELECT work_order_id, cycle_count, good_parts, status, updated_at
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FROM work_orders
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WHERE status = 'DONE'
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ORDER BY updated_at DESC;
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```
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### Manually Reset Work Order for Testing
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```sql
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UPDATE work_orders
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SET cycle_count = 0,
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good_parts = 0,
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progress_percent = 0,
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status = 'PENDING'
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WHERE work_order_id = 'YOUR_WO_ID';
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```
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---
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## Troubleshooting
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### Work Order Not Persisting
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1. Check Node-RED debug output for `[DB PERSIST]` messages
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2. Verify 5 seconds have elapsed between cycles
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3. Check DB Guard (Cycles) node is receiving messages
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4. Verify mariaDB connection is active
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### Resume Prompt Not Showing
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1. UI template not yet implemented (expected - see IMPLEMENTATION_SUMMARY.md)
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2. Check Back to UI debug for `[RESUME PROMPT]` message
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3. Verify msg.topic === "resumePrompt" in debug output
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### Cycle Count Not Restoring After Restart
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1. Check `restore-query` mode in Back to UI
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2. Verify work order status is 'RUNNING' in database
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3. Check global.cycleCount is being set from database value
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4. Look for `[RESTORE]` message in debug output
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### Complete Button Not Saving Final Counts
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1. Verify complete-work-order SQL includes cycle_count and good_parts
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2. Check database after clicking Done
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3. Look for `[COMPLETE] Persisting final counts` in debug output
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---
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## Rollback Commands
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```bash
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cd /home/mdares/projects/Plastico
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# List available backups
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ls -lh flows.json.backup*
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# Rollback to original
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cp flows.json.backup flows.json
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# Rollback to specific phase
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cp flows.json.backup_phase2_YYYYMMDD_HHMMSS flows.json
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# Verify rollback
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head -n 1 flows.json
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# Restart Node-RED to apply changes
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# (method depends on your setup - systemctl, pm2, docker, etc.)
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```
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---
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## Next Implementation: UI Dialog
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To complete Phase 3, add this to Home or Work Orders template:
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```html
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<div v-if="showResumePrompt" class="resume-dialog">
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<h3>Resume Work Order?</h3>
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<p>{{ resumeData.sku }} ({{ resumeData.id }})</p>
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<p>Current Progress: {{ resumeData.goodParts }} / {{ resumeData.target }} parts</p>
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<p>{{ resumeData.progressPercent }}% complete ({{ resumeData.cycleCount }} cycles)</p>
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<button @click="resumeWorkOrder" class="btn-resume">
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Resume from {{ resumeData.goodParts }} parts
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</button>
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<button @click="confirmRestart" class="btn-restart">
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Restart from Zero
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</button>
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</div>
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```
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```javascript
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// In template <script>
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scope.$watch('msg', function(msg) {
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if (msg.topic === "resumePrompt") {
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scope.showResumePrompt = true;
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scope.resumeData = msg.payload;
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}
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});
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scope.resumeWorkOrder = function() {
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scope.send({
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action: "resume-work-order",
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payload: scope.resumeData
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});
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scope.showResumePrompt = false;
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};
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scope.confirmRestart = function() {
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if (confirm("Are you sure? This will reset all progress to zero.")) {
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scope.send({
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action: "restart-work-order",
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payload: scope.resumeData
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});
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scope.showResumePrompt = false;
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}
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};
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```
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