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);

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");
// FIX: moldActive is object, extract cavities property
const cavities = Number(global.get("moldActive")) || 1;
if (!activeOrder || !activeOrder.id || cavities <= 0) {
    return [null, stateMsg, { _triggerKPI: true }, null];
}

var trackingEnabled = !!global.get("trackingEnabled");
if (!trackingEnabled) {
    return [null, stateMsg, { _triggerKPI: true }, null];
}

if (prev === 1 || current !== 1) {
    return [null, stateMsg, { _triggerKPI: true }, null];
}

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

// Clear startup mode after first real cycle
if (global.get("kpiStartupMode")) {
    global.set("kpiStartupMode", false);
    node.warn('[MACHINE CYCLE] First cycle - cleared kpiStartupMode');
}

const now = Date.now();
const lastCycleTime = global.get("lastCycleTime") || now;
const timeSinceLastCycle = now - lastCycleTime;

let operatingTime = global.get("operatingTime") || 0;
operatingTime += (timeSinceLastCycle / 1000);

global.set("operatingTime", operatingTime);
node.warn(`[MACHINE CYCLE] operatingTime updated to ${operatingTime}`);
global.set("lastCycleTime", now);

const scrapTotal = Number(activeOrder.scrap) || 0;
const totalProduced = cycles * cavities;
// FIX: Guard negative produced
const produced = Math.max(0, totalProduced - scrapTotal);
const target = Number(activeOrder.target) || 0;
const progress = target > 0 ? Math.min(100, Math.round((produced / target) * 100)) : 0;

activeOrder.good = produced;
activeOrder.progressPercent = progress;
activeOrder.lastUpdateIso = new Date().toISOString();
global.set("activeWorkOrder", activeOrder);

const promptIssued = global.get("scrapPromptIssuedFor") || null;
if (!promptIssued && target > 0 && produced >= target) {
    global.set("scrapPromptIssuedFor", activeOrder.id);
    msg._mode = "scrap-prompt";
    msg.scrapPrompt = {
        id: activeOrder.id,
        sku: activeOrder.sku || "",
        target,
        produced
    };
    return [null, msg, null, null];
}

const dbMsg = {
    _mode: "cycle",
    cycle: {
        id: activeOrder.id,
        sku: activeOrder.sku || "",
        target,
        good: produced,
        scrap: Number(activeOrder.scrap) || 0,
        cycleTime: Number(activeOrder.cycleTime || activeOrder.theoreticalCycleTime || 0),
        progressPercent: progress,
        lastUpdateIso: activeOrder.lastUpdateIso,
        machineOnline: true,
        productionStarted: productionRunning
    },
    // SQL with bound parameters for safety
    topic: "UPDATE work_orders SET good_parts = ?, progress_percent = ?, updated_at = NOW() WHERE work_order_id = ?",
    payload: [produced, progress, activeOrder.id]
};

const kpiTrigger = { _triggerKPI: true };

if (trackingEnabled && dbMsg) {
    global.set("lastMachineCycleTime", Date.now());
}

// 4th output: persist cycle_count and good_parts (throttled to 5 seconds)
const lastDbWrite = global.get("lastWorkOrderDbWrite") || 0;
const timeSinceLastWrite = now - lastDbWrite;
let persistCycleCount = null;

// Only send DB update every 5 seconds (5000ms) to reduce DB load
if (timeSinceLastWrite >= 5000) {
    persistCycleCount = {
        topic: "UPDATE work_orders SET cycle_count = ?, good_parts = ?, progress_percent = ?, updated_at = NOW() WHERE work_order_id = ?",
        payload: [cycles, produced, progress, activeOrder.id]
    };
    global.set("lastWorkOrderDbWrite", now);
    node.warn(`[DB PERSIST] Writing to work_orders: cycles=${cycles}, good_parts=${produced}, progress=${progress}%`);
}

return [dbMsg, stateMsg, kpiTrigger, persistCycleCount];