feat(ocp): added zechettis stuff in

lstV2/server/services/ocp/controller/labeling/labelProcess.ts

@@ -78,6 +78,7 @@ export const labelingProcess = async ({
 
     // if we are running the zechettii
     if (zechette) {
+        if (zechette.line === "0") return;
         const macId = await getMac(zechette.line);
         // filter out the lot for the line
         filteredLot = lots.data.filter(
@@ -163,7 +164,11 @@ export const labelingProcess = async ({
     }
 
     // if there are more than 2 lots it might be an auto labeler, autolabeler will be defined by its id for now only dayton
-    if (filteredLot?.length > 2 && plantToken[0].value !== "usday1") {
+    const plantsCanHaveMultiLots = ["usday1", "usmcd1"];
+    if (
+        filteredLot?.length > 2 &&
+        !plantsCanHaveMultiLots.includes(plantToken[0].value)
+    ) {
         createLog(
             "error",
             "labeling",
@@ -205,6 +210,8 @@ export const labelingProcess = async ({
         };
     }
 
+    // as we want to allow zechetti to print no matter what if we zechettii is true skip all this and just print the label
+    if (!zechette) {
         // check the material... mm,color (auto and manual combined), pkg
         const mmStaged = await isMainMatStaged(filteredLot[0]);
 
@@ -226,7 +233,10 @@ export const labelingProcess = async ({
         );
 
         // do we want to over run
-    if (filteredLot[0].overPrinting === "no" && filteredLot[0].Remaining <= 0) {
+        if (
+            filteredLot[0].overPrinting === "no" &&
+            filteredLot[0].Remaining <= 0
+        ) {
             createLog(
                 "error",
                 "labeling",
@@ -258,6 +268,7 @@ export const labelingProcess = async ({
             };
         }
         createLog("info", "labeling", "ocp", `Is prolink good? ${prolink}`);
+    }
 
     // create the label
     const label = await createLabel(filteredLot[0], userPrinted);
@@ -273,9 +284,12 @@ export const labelingProcess = async ({
     }
 
     // send over to be booked in if we can do it.
+
+    // same here if we are passing zechettii dont try to book in
+
     const bookin = settingData.filter((s) => s.name === "bookin");
     let book: any = [];
-    if (bookin[0].value === "1") {
+    if (bookin[0].value === "1" && !zechette) {
         book = await bookInLabel(label.data);
 
         if (!book.success) {

lstV2/server/services/ocp/controller/specialProcesses/zechettis/zechetti1.ts

@@ -1,177 +0,0 @@
-import { Controller, Tag } from "st-ethernet-ip";
-import { labelingProcess } from "../../labeling/labelProcess.js";
-import { createLog } from "../../../../logger/logger.js";
-
-let plcAddress = "192.168.193.97"; // zechetti 2
-let lastProcessedTimestamp = 0;
-let PLC = new Controller() as any;
-const labelerTag = new Tag("N7[0]"); // change the car to a or b depending on what zechetti.
-//const t = new Tag("CONV_M01_SHTL_UNLD_IN_FROM_PREV_CONV_TRACK_CODE.PAL_ORIGIN_LINE_N") // this is for the new zechette to reach the pallet form
-
-let pollingInterval: any = null;
-let heartbeatInterval: any = null;
-let reconnecting = false;
-let lastTag = 0;
-// Track last successful read
-let lastHeartbeat: number = Date.now();
-
-export async function zechitti1Connect() {
-    try {
-        createLog(
-            "info",
-            "zechitti1",
-            "ocp",
-            `Connecting to PLC at ${plcAddress}...`
-        );
-        await PLC.connect(plcAddress, 0);
-        createLog("info", "zechitti1", "ocp", "Zechetti 2 connected.");
-
-        // Start polling tags
-        startPolling();
-
-        // Start heartbeat
-        // startHeartbeat();
-
-        // Handle disconnects/errors
-        PLC.on("close", () => {
-            console.warn("PLC connection closed.");
-            handleReconnect();
-        });
-
-        PLC.on("error", (err: any) => {
-            createLog("error", "zechitti1", "ocp", `PLC error: ${err.message}`);
-            handleReconnect();
-        });
-    } catch (err: any) {
-        createLog(
-            "error",
-            "zechitti1",
-            "ocp",
-            `Initial connection failed: ${err.message}`
-        );
-        handleReconnect();
-    }
-}
-
-function startPolling() {
-    if (pollingInterval) clearInterval(pollingInterval);
-
-    pollingInterval = setInterval(async () => {
-        try {
-            await PLC.readTag(labelerTag);
-            //lastHeartbeat = Date.now();
-
-            const tagTime: any = new Date(labelerTag.timestamp);
-
-            // so we make sure we are not missing a pallet remove it from the lastTag so we can get this next label correctly
-            if (
-                labelerTag.value == 0 &&
-                Date.now() - lastProcessedTimestamp >= 45000
-            ) {
-                lastTag = labelerTag.value;
-            }
-
-            // if the tag is not zero and its been longer than 30 seconds and the last tag is not equal to the current tag we can print
-            if (
-                labelerTag.value !== 0 &&
-                lastTag !== labelerTag.value &&
-                tagTime !== lastProcessedTimestamp &&
-                Date.now() - lastProcessedTimestamp >= 30000
-            ) {
-                lastProcessedTimestamp = tagTime;
-                lastTag = labelerTag.value;
-                console.log(
-                    `Time since last check: ${
-                        Date.now() - tagTime
-                    }, greater than 30000, ${
-                        Date.now() - lastProcessedTimestamp >= 30000
-                    }, the line to be printed is ${labelerTag.value}`
-                );
-                //console.log(labelerTag);
-                const zechette = {
-                    line: labelerTag.value.toString(),
-                    printer: 22, // this is the id of the zechetti 2 to print we should move this to the db
-                    printerName: "Zechetti1",
-                };
-                labelingProcess({ zechette: zechette });
-            }
-        } catch (err: any) {
-            createLog(
-                "error",
-                "zechitti1",
-                "ocp",
-                `Polling error: ${err.message}`
-            );
-            handleReconnect();
-        }
-    }, 1000);
-}
-
-// function startHeartbeat() {
-//     if (heartbeatInterval) clearInterval(heartbeatInterval);
-
-//     heartbeatInterval = setInterval(() => {
-//         const diff = Date.now() - lastHeartbeat;
-//         if (diff > 60000) {
-//             // 1 minute
-//             console.warn(`⚠️ Heartbeat timeout: no data for ${diff / 1000}s`);
-//             handleReconnect();
-//         }
-//     }, 10000); // check every 10s
-// }
-
-async function handleReconnect() {
-    if (reconnecting) return;
-    reconnecting = true;
-
-    if (pollingInterval) {
-        clearInterval(pollingInterval);
-        pollingInterval = null;
-    }
-
-    let delay = 2000; // start at 2s
-    let attempts = 0;
-    const maxAttempts = 10; // or limit by time, e.g. 2 min total
-
-    while (!PLC.connected && attempts < maxAttempts) {
-        attempts++;
-        createLog(
-            "info",
-            "zechitti1",
-            "ocp",
-            `Reconnect attempt ${attempts}/${maxAttempts} in ${
-                delay / 1000
-            }s...`
-        );
-        await new Promise((res) => setTimeout(res, delay));
-
-        try {
-            PLC = new Controller(); // fresh instance
-            await PLC.connect(plcAddress, 0);
-            createLog("info", "zechitti1", "ocp", "Reconnected to PLC!");
-            reconnecting = false;
-            startPolling();
-            return;
-        } catch (err: any) {
-            createLog(
-                "error",
-                "zechitti1",
-                "ocp",
-                `Reconnect attempt failed: ${err.message}`
-            );
-            delay = Math.min(delay * 2, 30000); // exponential backoff up to 30s
-        }
-    }
-
-    if (!PLC.connected) {
-        createLog(
-            "error",
-            "zechitti1",
-            "ocp",
-            "Max reconnect attempts reached. Stopping retries."
-        );
-        reconnecting = false;
-        // optional: exit process or alert someone here
-        // process.exit(1);
-    }
-}

lstV2/server/services/ocp/controller/specialProcesses/zechettis/zechettiConnect.ts

@@ -0,0 +1,27 @@
+import { createPlcMonitor } from "../../../utils/plcController.js";
+
+export const zechettiConnect = () => {
+    const config: any = {
+        controllers: [
+            {
+                id: "Z1",
+                ip: "192.168.193.97",
+                slot: 0,
+                rpi: 250,
+                tags: ["N7[0]"],
+            },
+            {
+                id: "Z2",
+                ip: "192.168.193.111",
+                slot: 0,
+                rpi: 100,
+                tags: ["N8[0]"],
+            },
+        ],
+    };
+
+    const monitor = createPlcMonitor(config);
+
+    // Start
+    monitor.start();
+};

lstV2/server/services/ocp/ocpService.ts

@@ -17,7 +17,6 @@ import { assignedPrinters } from "./utils/checkAssignments.js";
 import { printerCycle } from "./controller/printers/printerCycle.js";
 import stopPrinterCycle from "./routes/printers/stopCycle.js";
 import startPrinterCycle from "./routes/printers/startCycle.js";
-import { printerCycleAutoLabelers } from "./controller/printers/printerCycleAutoLabelers.js";
 import AutostartPrinterCycle from "./routes/printers/autoLabelerStart.js";
 import AutostopPrinterCycle from "./routes/printers/autoLabelerStop.js";
 import { deleteLabels } from "../../globalUtils/dbCleanUp/labelCleanUp.js";
@@ -26,7 +25,8 @@ import labelRatio from "./routes/labeling/getLabelRatio.js";
 import resetRatio from "./routes/labeling/resetLabelRatio.js";
 import materialTransferLot from "./routes/materials/lotTransfer.js";
 import pendingTransfers from "./routes/materials/currentPending.js";
-import { zechitti1Connect } from "./controller/specialProcesses/zechettis/zechetti1.js";
+import { createPlcMonitor } from "./utils/plcController.js";
+import { zechettiConnect } from "./controller/specialProcesses/zechettis/zechettiConnect.js";
 
 const app = new OpenAPIHono();
 
@@ -85,7 +85,7 @@ setTimeout(() => {
 // if zechetti plc is wanted we will connect
 setTimeout(() => {
     if (zechetti[0]?.value === "1") {
-        zechitti1Connect();
+        zechettiConnect();
     }
 }, 3 * 1000);
 

lstV2/server/services/ocp/utils/plcController.ts

@@ -0,0 +1,155 @@
+import { ControllerManager } from "st-ethernet-ip";
+import { getMac } from "./getMachineId.js";
+import { format } from "date-fns-tz";
+import { tryCatch } from "../../../globalUtils/tryCatch.js";
+
+import { getCurrentLabel } from "../../sqlServer/querys/ocp/getLabel.js";
+import { query } from "../../sqlServer/prodSqlServer.js";
+import { createLog } from "../../logger/logger.js";
+
+export const createPlcMonitor = (config: any) => {
+    let cm: any;
+    let controllers: any = {};
+    let stats: any = {};
+    let isRunning = false;
+
+    const nowISO = () => {
+        return new Date().toISOString();
+    };
+
+    const start = () => {
+        if (isRunning) return;
+
+        cm = new ControllerManager();
+
+        config.controllers.forEach((cfg: any) => {
+            const plc: any = cm.addController(
+                cfg.ip,
+                cfg.slot,
+                cfg.rpi,
+                true,
+                cfg.retrySP || 3000
+            );
+
+            plc.connect();
+            controllers[cfg.id] = plc;
+
+            // initialize stats
+            stats[cfg.id] = {
+                id: cfg.id,
+                ip: cfg.ip,
+                slot: cfg.slot,
+                scanRate: cfg.rpi,
+                connected: false,
+                lastConnectedAt: null,
+                lastDisconnectedAt: null,
+                reconnectCount: 0,
+            };
+            // Add tags
+            cfg.tags.forEach((tag: any) => plc.addTag(tag));
+
+            // Events
+            plc.on("Connected", () => {
+                const s = stats[cfg.id];
+                s.connected = true;
+                s.lastConnectedAt = nowISO();
+                if (s.lastDisconnectedAt) {
+                    s.reconnectCount++;
+                }
+                console.log(`[${cfg.id}] Connected @ ${cfg.ip}:${cfg.slot}`);
+            });
+
+            plc.on("Disconnected", () => {
+                const s = stats[cfg.id];
+                s.connected = false;
+                s.lastDisconnectedAt = nowISO();
+                console.log(`[${cfg.id}] Disconnected`);
+            });
+
+            plc.on("error", (err: any) => {
+                console.error(`[${cfg.id}] Error:`, err.message);
+            });
+
+            plc.on("TagChanged", async (tag: any, prevVal: any) => {
+                if (tag.value !== 0) {
+                    const time = nowISO();
+                    if (tag.value === 0) return;
+                    setTimeout(async () => {
+                        if (tag.value === 0) return;
+                        const macId = await getMac(tag.value);
+                        console.log(macId);
+                        const { data, error } = (await tryCatch(
+                            query(
+                                getCurrentLabel
+                                    .replace(
+                                        "[macId]",
+                                        macId[0]?.HumanReadableId
+                                    )
+                                    .replace(
+                                        "[time]",
+                                        format(time, "yyyy-MM-dd HH:mm")
+                                    ),
+                                "Current label data"
+                            )
+                        )) as any;
+
+                        createLog(
+                            "info",
+                            "zechettii",
+                            "zechettii",
+                            `${format(time, "yyyy-MM-dd HH:mm")} [${cfg.id}] ${
+                                tag.name
+                            }: ${prevVal} -> ${
+                                tag.value
+                            }, the running number is ${
+                                error ? null : data.data[0]?.LfdNr
+                            }}`
+                        );
+                    }, 1000);
+                }
+            });
+        });
+
+        isRunning = true;
+    };
+
+    const stop = () => {
+        if (!isRunning) return;
+        Object.values(controllers).forEach((plc: any) => {
+            try {
+                plc.disconnect();
+            } catch {}
+        });
+        controllers = {};
+        cm = null;
+        isRunning = false;
+        console.log("Monitor stopped");
+    };
+
+    const restart = () => {
+        console.log("Restarting the plc(s)");
+        stop();
+        new Promise((resolve) => setTimeout(resolve, 1500));
+        start();
+    };
+
+    const status = () => {
+        const result: any = {};
+
+        for (const [id, s] of Object.entries(stats)) {
+            let s: any;
+            let uptimeMs = null,
+                downtimeMs = null;
+            if (s.connected && s.lastConnectedAt) {
+                uptimeMs = Date.now() - new Date(s.lastConnectedAt).getTime();
+            } else if (!s.connected && s.lastDisconnectedAt) {
+                downtimeMs =
+                    Date.now() - new Date(s.lastDisconnectedAt).getTime();
+            }
+            result[id] = { ...s, uptimeMs, downtimeMs };
+        }
+        return result;
+    };
+
+    return { start, stop, restart, status };
+};