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server: first stab at converting elapsed lul time to per-op
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@wuzzeb
wuzzeb committed Oct 1, 2024
1 parent f30abe8 commit ddcb110
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Showing 5 changed files with 418 additions and 822 deletions.
228 changes: 38 additions & 190 deletions server/lib/BlackMaple.MachineFramework/backend/BuildCellState.cs
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Original file line number Diff line number Diff line change
Expand Up @@ -348,12 +348,6 @@ public record LoadedPalletStatus
{
private LoadedPalletStatus() { }

public record LoadFinished : LoadedPalletStatus
{
public required int LoadNum { get; init; }
public required ImmutableList<InProcessMaterial> Material { get; init; }
}

public record MachineStopped() : LoadedPalletStatus;

public record MachineRunning : LoadedPalletStatus
Expand All @@ -367,7 +361,6 @@ public record Unloading : LoadedPalletStatus
{
public required int LoadNum { get; init; }
public ImmutableList<int> UnloadingFaces { get; init; } = ImmutableList<int>.Empty;
public ImmutableList<int> UnloadCompletedFaces { get; init; } = ImmutableList<int>.Empty;
public Func<LoadedFace, ImmutableList<InProcessMaterial>>? AdjustUnloadingMaterial { get; init; } =
null;
public ImmutableList<InProcessMaterial>? NewMaterialToLoad { get; init; } = null;
Expand All @@ -393,16 +386,6 @@ FMSSettings settings
{
switch (status)
{
case LoadedPalletStatus.LoadFinished loadFinished:
return CheckExpectedMaterialOnPallet(
pal: pal,
loadNum: loadFinished.LoadNum,
material: loadFinished.Material,
db: db,
nowUTC: nowUTC,
jobs: jobs
);

case LoadedPalletStatus.MachineStopped machineStopped:
return SetMachineNotRunning(pal: pal, db: db, machineControl: machineControl, nowUTC: nowUTC);

Expand Down Expand Up @@ -435,17 +418,6 @@ FMSSettings settings
adjustUnloadingMats: unloading.AdjustUnloadingMaterial
);
}
foreach (var face in unloading.UnloadCompletedFaces)
{
pal = SetUnloadComplete(
pal: pal,
faceNum: face,
lulNum: unloading.LoadNum,
fmsSettings: settings,
db: db,
nowUTC: nowUTC
);
}
if (unloading.NewMaterialToLoad != null)
{
pal = pal with
Expand All @@ -457,30 +429,14 @@ FMSSettings settings

case LoadedPalletStatus.CompletePalletCycle complete:
pal = SetMachineNotRunning(pal: pal, db: db, machineControl: machineControl, nowUTC: nowUTC);
DateTime? unloadStartTime = null;
foreach (var face in pal.Faces.Values)
{
pal = SetUnloadComplete(
pal: pal,
faceNum: face.FaceNum,
lulNum: complete.LoadNum,
fmsSettings: settings,
db: db,
nowUTC: nowUTC
);
if (face.UnloadStart != null)
{
unloadStartTime = face.UnloadStart.EndTimeUTC;
}
}
pal = CompletePalletCycle(
pal: pal,
loadNum: complete.LoadNum,
materialToLoad: complete.MaterialToLoad,
unloadStartTime: unloadStartTime,
jobs: jobs,
db: db,
nowUTC: nowUTC
nowUTC: nowUTC,
fmsSettings: settings
);
return pal;

Expand All @@ -489,82 +445,6 @@ FMSSettings settings
}
}

public static Pallet CheckExpectedMaterialOnPallet(
Pallet pal,
int loadNum,
ImmutableList<InProcessMaterial> material,
IRepository db,
IJobCacheWithDefaultStops jobs,
DateTime nowUTC
)
{
var matToLoad = CalcMaterialToLoad(palletNum: pal.PalletNum, materialToLoad: material, jobs: jobs);

foreach (var (face, _) in matToLoad)
{
var oldFace = pal.Faces.GetValueOrDefault(face.FaceNum);
if (oldFace != null)
{
if (face.MaterialIDs.Any(m => !oldFace.Material.Any(om => om.MaterialID == m)))
{
// we must have missed some events, the material was switchted
Serilog.Log.Warning(
"Mismatch between material on face {FaceNum} of pallet {Pallet} and material being loaded",
face.FaceNum,
pal.PalletNum
);
Serilog.Log.Debug(
"Mismatch between material on face {FaceNum} of pallet {@Pallet} and material being loaded: {@matOnPal}",
face.FaceNum,
pal,
material
);
pal = pal with { Faces = pal.Faces.Remove(face.FaceNum) };
}
else
{
return pal;
}
}
}

TimeSpan? elapsedTime = material
.Select(m => m.Action.ElapsedLoadUnloadTime)
.FirstOrDefault(t => t.HasValue);
if (!elapsedTime.HasValue && pal.LoadBegin != null)
{
elapsedTime = nowUTC - pal.LoadBegin.EndTimeUTC;
}

var loadEnds = db.RecordLoadEnd(
toLoad: new[]
{
new MaterialToLoadOntoPallet()
{
LoadStation = loadNum,
Elapsed = elapsedTime ?? TimeSpan.Zero,
Faces = matToLoad.Select(m => m.Item1).ToImmutableList(),
},
},
pallet: pal.PalletNum,
timeUTC: nowUTC.AddSeconds(1)
);

var newFaces = pal.Faces.ToBuilder();
foreach (var (_, createLoadedFace) in matToLoad)
{
var loadedFace = createLoadedFace(loadEnds);
newFaces.Add(loadedFace.FaceNum, loadedFace);
}

return pal with
{
Faces = newFaces.ToImmutable(),
Log = pal.Log.AddRange(loadEnds),
NewLogEvents = true,
};
}

private static Pallet SetMachineRunning(
Pallet pal,
string machineGroup,
Expand Down Expand Up @@ -829,71 +709,27 @@ oldMat with
};
}

private static Pallet SetUnloadComplete(
Pallet pal,
int faceNum,
int lulNum,
IRepository db,
FMSSettings fmsSettings,
DateTime nowUTC
)
private static MaterialToUnloadFromFace? UnloadMaterial(Pallet pal, int faceNum)
{
var face = pal.Faces.GetValueOrDefault(faceNum);
if (face == null)
return pal;

var sendToExternal = Enumerable.Empty<MaterialToSendToExternalQueue>();
IEnumerable<LogEntry>? newEvts = null;
return null;

if (face.UnloadEnd == null)
{
Dictionary<long, string>? queues = null;
var outputQueue = OutputQueueForMaterial(face, pal.Log);

if (!string.IsNullOrEmpty(outputQueue) && fmsSettings.Queues.ContainsKey(outputQueue))
{
queues = face.Material.ToDictionary(m => m.MaterialID, m => outputQueue);
}
else if (
!string.IsNullOrEmpty(outputQueue)
&& fmsSettings.ExternalQueues.TryGetValue(outputQueue, out var serverName)
)
return new MaterialToUnloadFromFace()
{
sendToExternal = face.Material.Select(mat => new MaterialToSendToExternalQueue()
{
Server = serverName,
PartName = mat.PartName,
Queue = outputQueue,
Serial = mat.Serial ?? "",
});
}

newEvts = db.RecordUnloadEnd(
mats: face.Material.Select(m => new EventLogMaterial()
{
MaterialID = m.MaterialID,
Process = m.Process,
Face = faceNum,
}),
pallet: pal.PalletNum,
lulNum: lulNum,
timeUTC: nowUTC,
elapsed: face.UnloadStart != null ? nowUTC - face.UnloadStart.EndTimeUTC : TimeSpan.Zero,
active: (face.ExpectedUnloadTimeForOnePieceOfMaterial ?? TimeSpan.Zero) * face.Material.Count,
unloadIntoQueues: queues
);
MaterialIDToQueue = face.Material.ToImmutableDictionary(m => m.MaterialID, m => outputQueue),
Process = face.Process,
FaceNum = face.FaceNum,
ActiveOperationTime =
(face.ExpectedUnloadTimeForOnePieceOfMaterial ?? TimeSpan.Zero) * face.Material.Count,
};
}

var newPal = pal with
{
Faces = pal.Faces.Remove(faceNum),
Log = newEvts != null ? pal.Log.AddRange(newEvts) : pal.Log,
NewLogEvents = pal.NewLogEvents || newEvts != null,
};

System.Threading.Tasks.Task.Run(() => SendMaterialToExternalQueue.Post(sendToExternal));

return newPal;
return null;
}

private static ImmutableList<(
Expand Down Expand Up @@ -1012,33 +848,45 @@ private static Pallet CompletePalletCycle(
Pallet pal,
int loadNum,
IEnumerable<InProcessMaterial>? materialToLoad,
DateTime? unloadStartTime,
IRepository db,
FMSSettings fmsSettings,
IJobCacheWithDefaultStops jobs,
DateTime nowUTC
)
{
DateTime? unloadStartTime = null;
var toUnload = new List<MaterialToUnloadFromFace>();
foreach (var face in pal.Faces.Values)
{
var u = UnloadMaterial(pal, face.FaceNum);
if (u != null)
{
toUnload.Add(u);
}
if (face.UnloadStart != null)
{
unloadStartTime = face.UnloadStart.EndTimeUTC;
}
}

var matsToLoad =
materialToLoad != null
? CalcMaterialToLoad(palletNum: pal.PalletNum, materialToLoad: materialToLoad, jobs: jobs)
: ImmutableList<(MaterialToLoadOntoFace, Func<IEnumerable<LogEntry>, LoadedFace>)>.Empty;

var (cycleEvt, loadEvts) = db.CompletePalletCycle(
pal: pal.PalletNum,
var newEvts = db.RecordLoadUnloadComplete(
toLoad: matsToLoad.Select((m) => m.Item1).ToImmutableList(),
toUnload: toUnload,
lulNum: loadNum,
pallet: pal.PalletNum,
totalElapsed: nowUTC - (unloadStartTime ?? pal.LoadBegin?.EndTimeUTC ?? nowUTC),
timeUTC: nowUTC,
generateSerials: false,
matFromPendingLoads: null,
additionalLoads: new[]
{
new MaterialToLoadOntoPallet()
{
LoadStation = loadNum,
Faces = matsToLoad.Select(m => m.Item1).ToImmutableList(),
Elapsed = unloadStartTime.HasValue ? nowUTC - unloadStartTime.Value : TimeSpan.Zero,
},
}
externalQueues: fmsSettings.ExternalQueues
);

var cycleEvt = newEvts.First(e => e.LogType == LogType.PalletCycle);
var loadEvts = newEvts.Where(e => e.EndTimeUTC > nowUTC).ToImmutableList();

var newFaces = ImmutableDictionary.CreateBuilder<int, LoadedFace>();
foreach (var (_, face) in matsToLoad)
{
Expand Down
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