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refactor(ocp): lots of work for rfid and dyco contorl

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This commit is contained in:
Blake Matthes
2025-03-27 21:12:22 -05:00
parent 27d6b6e884
commit ba3d721940
19 changed files with 360 additions and 162 deletions
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41
server/services/ocp/controller/labeling/bookIn.ts
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@@ -10,7 +10,9 @@ export const bookInLabel = async (data: any) => {
// update sscc so we can book in
const SSCC = data.SSCC.slice(2);
// api url
const url = await prodEndpointCreation("public/v1.0/Warehousing/BookIn");
const url = await prodEndpointCreation(
"/public/v1.1/Manufacturing/ProductionControlling/BookIn"
);
// create bookin
const newBookin = {
@@ -26,12 +28,12 @@ export const bookInLabel = async (data: any) => {
},
});
if (res.data.Result !== 0) {
if (res.status != 200) {
createLog(
"error",
"labeling",
"ocp",
`${data.printer.name}, Error:${res.data.Message}`
`${data.printer[0].name}, Error:${res.data}`
);
//printerUpdate(data.printer, 7, "Error while booking in.");
@@ -44,7 +46,7 @@ export const bookInLabel = async (data: any) => {
// update the label.
try {
await db
const booked = await db
.update(prodlabels)
.set({
status: "Booked in",
@@ -52,7 +54,22 @@ export const bookInLabel = async (data: any) => {
})
.where(
eq(prodlabels.runningNr, parseInt(data.SSCC.slice(10, -1)))
);
)
.returning({ runningNr: prodlabels.runningNr });
createLog(
"info",
"labeling",
"ocp",
`${booked[0].runningNr} , was just booked in.`
);
return {
success: true,
message: `${parseInt(
data.SSCC.slice(10, -1)
)}, was just booked in`,
};
} catch (error) {
createLog(
"error",
@@ -61,24 +78,12 @@ export const bookInLabel = async (data: any) => {
`Error creating new runningNumber in the DB.`
);
}
// label was booked in
createLog(
"info",
"labeling",
"ocp",
`${parseInt(data.SSCC.slice(10, -1))}, was just booked in`
);
return {
success: true,
message: `${parseInt(data.SSCC.slice(10, -1))}, was just booked in`,
};
} catch (error) {
createLog(
"error",
"labeling",
"ocp",
`${data.printer.name}, "Error: ${error}`
`${data.printer[0].name}, "Error: ${error}`
);
return {
success: false,

30
server/services/ocp/controller/labeling/createLabel.ts
View File

@@ -43,7 +43,7 @@ export const createLabel = async (data: any, userPrinted: any) => {
const plantToken = settingsData.filter((n) => n.name === "plantToken");
const newLabel = {
scannerId: 99,
lotNr: data.LOT,
lotNr: data.lot,
machineId: data.machineID,
printerId: data.printerID,
//layoutId: cartonCustomers.includes(data.CustomerId.toString()) ? data.cartonLabel : data.palletLabel,
@@ -87,14 +87,24 @@ export const createLabel = async (data: any, userPrinted: any) => {
let newlabel = res.data;
try {
await db.insert(prodlabels).values({
printerID: parseInt(printer[0]?.humanReadableId!, 10),
runningNr: parseInt(newlabel.SSCC.slice(10, -1)),
printerName: printer[0].name.toLowerCase(),
line: data.MachineLocation,
status: "printed",
add_user: userPrinted || "LST_System",
});
const insertLabel = await db
.insert(prodlabels)
.values({
printerID: parseInt(printer[0]?.humanReadableId!, 10),
runningNr: parseInt(newlabel.SSCC.slice(10, -1)),
printerName: printer[0].name.toLowerCase(),
line: data.MachineLocation,
status: "printed",
add_user: userPrinted || "LST_System",
})
.returning({ runningNr: prodlabels.runningNr });
createLog(
"info",
"labeling",
"ocp",
`${insertLabel[0]?.runningNr} was just inserted into the db.`
);
} catch (error) {
createLog(
"error",
@@ -119,7 +129,7 @@ export const createLabel = async (data: any, userPrinted: any) => {
};
// check if we can remove labels or not
deleteLabels();
//deleteLabels();
return { sucess: true, message: "Label created", data: returnData }; // returning label data to be able to book in if active
} catch (error) {
createLog(

5
server/services/ocp/controller/labeling/getLabels.ts
View File

@@ -1,4 +1,4 @@
import { desc, lte, sql } from "drizzle-orm";
import { desc, gte, lte, sql } from "drizzle-orm";
import { db } from "../../../../../database/dbclient.js";
import { prodlabels } from "../../../../../database/schema/prodLabels.js";
import { tryCatch } from "../../../../globalUtils/tryCatch.js";
@@ -8,7 +8,7 @@ export const getLabels = async (hours: string) => {
.select()
.from(prodlabels)
.where(
lte(
gte(
prodlabels.upd_date,
sql.raw(`NOW() - INTERVAL '${hours} hours'`)
)
@@ -27,6 +27,7 @@ export const getLabels = async (hours: string) => {
return {
success: true,
message: "Current labels order by upd_Date.",
count: labelInfo.length,
data: labelInfo,
};
};

21
server/services/ocp/controller/labeling/labelProcess.ts
View File

@@ -50,9 +50,10 @@ export const labelingProcess = async ({
// if we got a line passed over we need to get the machine id from this.
if (line) {
const macId = await getMac(line);
// filter out the lot for the line
filteredLot = lots.data.filter((l: any) => l.machineId === macId);
filteredLot = lots.data.filter(
(l: any) => l.MachineID === macId[0].HumanReadableId
);
if (filteredLot.length === 0) {
createLog(
@@ -160,7 +161,10 @@ export const labelingProcess = async ({
`Main material is not prepaired for lot ${filteredLot[0].lot}`
);
return;
return {
success: false,
message: `Main material is not prepaired for lot ${filteredLot[0].lot}`,
};
}
// comment only but will check for color
@@ -198,16 +202,19 @@ export const labelingProcess = async ({
"ocp",
`Prolink does not match for ${filteredLot[0].MachineDescription}`
);
return;
return {
success: false,
message: `Prolink does not match for ${filteredLot[0].MachineDescription}`,
};
}
createLog("info", "labeling", "ocp", `Is prolink good? ${prolink}`);
// create the label
const label = await createLabel(filteredLot[0], userPrinted);
if (!label.success) {
return { sucess: false, message: label.message, data: label.data };
}
// if (!label.success) {
// return { sucess: false, message: label.message, data: label.data };
// }
// send over to be booked in if we can do it.
const bookin = settingData.filter((s) => s.name === "bookin");

52
server/services/ocp/controller/labeling/manualLabelLog.ts Normal file
View File

@@ -0,0 +1,52 @@
import { db } from "../../../../../database/dbclient.js";
import { manualPrinting } from "../../../../../database/schema/ocpManualPrint.js";
import { tryCatch } from "../../../../globalUtils/tryCatch.js";
import { manualTag } from "../../../rfid/controller/tags/manualTag.js";
import { labelingProcess } from "./labelProcess.js";
export const manualPrint = async (manualPrint: any) => {
/**
* add the reason we did a manual print.
*/
const manualPrintData = {
line: manualPrint.line,
printReason: manualPrint.printReason,
initials: manualPrint.initials,
additionalComments: manualPrint?.additionalComments,
add_user: "lst",
};
const { data, error } = await tryCatch(
db.insert(manualPrinting).values(manualPrintData).returning({
line: manualPrinting.line,
printReason: manualPrinting.printReason,
initials: manualPrinting.initials,
additionalComments: manualPrinting?.additionalComments,
add_user: manualPrinting.add_user,
})
);
if (error) {
return {
success: false,
message: "There was an error posting the manualPrintData",
data: error,
};
}
let label = await labelingProcess({ line: manualPrint.line });
if (manualPrint.rfidTag) {
manualTag(
manualPrint.rfidTag,
"wrapper1",
parseInt(label.data.SSCC.slice(10, -1))
);
}
return {
success: true,
message: "Log Entered label will be coming soon.",
data,
};
};

2
server/services/ocp/controller/lots/prolinkCheck.ts
View File

@@ -43,8 +43,6 @@ export const prolinkCheck = async (lot: any) => {
// run the query
try {
const prolink = await query(prolinkQuery, "Prolink Checks");
//console.log(lot);
// filter out the lot
const filterdLot = prolink.filter(
(p: any) => p.AlplaLabelOnline === lot

44
server/services/ocp/controller/manualLabelLog.ts
View File

@@ -1,44 +0,0 @@
import { db } from "../../../../database/dbclient.js";
import { manualPrinting } from "../../../../database/schema/ocpManualPrint.js";
import { tryCatch } from "../../../globalUtils/tryCatch.js";
export const manualPrint = async (manualPrint: any) => {
/**
* add the reason we did a manual print.
*/
const manualPrintData = {
line: manualPrint.line,
printReason: manualPrint.printReason,
initials: manualPrint.initials,
additionalComments: manualPrint?.additionalComments,
add_user: "lst",
};
const { data, error } = await tryCatch(
db
.insert(manualPrinting)
.values(manualPrintData)
.returning({
line: manualPrinting.line,
printReason: manualPrinting.printReason,
initials: manualPrinting.initials,
additionalComments: manualPrinting?.additionalComments,
add_user: manualPrinting.add_user,
})
);
if (error) {
return {
success: false,
message: "There was an error posting the manualPrintData",
data: error,
};
}
return {
success: true,
message: "There was an error posting the manualPrintData",
data,
};
};

45
server/services/ocp/controller/specialProcesses/dyco/plcConnection.ts
View File

@@ -2,13 +2,14 @@ import { Controller, Tag } from "st-ethernet-ip";
import { createLog } from "../../../../logger/logger.js";
import { labelerTagRead } from "./plcTags/labelerTag.js";
import { palletSendTag } from "./plcTags/palletSendTag.js";
import { strapperFaults } from "./plcTags/strapperFault.js";
let PLC = new Controller();
let isDycoRunning = false;
// PLC address
let plcAddress = "10.44.5.4";
let isReading = false;
// Initialize the interval variable outside the function
let plcCycle: any;
let plcInterval = 500;
@@ -31,17 +32,42 @@ export const dycoConnect = async () => {
await PLC.connect(plcAddress, 0).then(async () => {
createLog("info", "dyco", "ocp", `We are connected to the dyco.`);
isDycoRunning = true;
let buffer = "";
plcCycle = setInterval(async () => {
await PLC.readTag(labelerTag);
await PLC.readTag(palletSend);
if (isReading) {
createLog(
"warn",
"dyco",
"ocp",
"Skipping cycle: previous read still in progress."
);
return;
}
isReading = true; // Set flag
try {
await PLC.readTag(labelerTag);
await PLC.readTag(palletSend);
await PLC.readTag(strapperError);
// send the labeler tag data over
labelerTagRead(labelerTag);
// strapper check
strapperFaults(strapperError);
// send the end of line check over.
palletSendTag(palletSend);
}, 500);
// send the labeler tag data over
labelerTagRead(labelerTag);
// send the end of line check over.
palletSendTag(palletSend);
} catch (error: any) {
createLog(
"error",
"dyco",
"ocp",
`Error reading PLC tag: ${error.message}`
);
} finally {
isReading = false; // Reset flag
}
}, plcInterval);
});
} catch (error) {
createLog(
@@ -50,6 +76,7 @@ export const dycoConnect = async () => {
"ocp",
`There was an error in the dyco: ${error}`
);
await PLC.disconnect();
isDycoRunning = false;
}
};

50
server/services/ocp/controller/specialProcesses/dyco/plcTags/labelerTag.ts
View File

@@ -4,7 +4,10 @@ import { tryCatch } from "../../../../../../globalUtils/tryCatch.js";
import { createLog } from "../../../../../logger/logger.js";
import { readTags } from "../../../../../rfid/controller/readTags.js";
import { labelingProcess } from "../../../labeling/labelProcess.js";
import { stapperFaulted, strapperFaults } from "./strapperFault.js";
export let cameraPalletCheck = 20;
export let currentPalletCheck = 0;
let lastProcessedTimestamp = 0;
export const labelerTagRead = async (tagData: any) => {
@@ -41,11 +44,48 @@ export const labelerTagRead = async (tagData: any) => {
// Only process if this is a new timestamp within the last 5 seconds
if (tagTime !== lastProcessedTimestamp && Date.now() - tagTime <= 5000) {
lastProcessedTimestamp = tagTime;
//console.log(numericString, tagData.state.timestamp);
/**
* add logic in to see if this is the first time we run this so we return an error to validate we are in sync.
*/
createLog(
"info",
"dyco",
"ocp",
`Current pallet at the wrapper is: ${numericString}`
);
if (dycoPrint[0].value === "1") {
createLog("info", "dyco", "ocp", "Dyco will be printing the label");
// send over to print.
labelingProcess({ line: numericString });
// if (!dycoControlCheck) {
// createLog(
// "error",
// "dyco",
// "ocp",
// `Dyco was switch to be the printer guys. please validate the line is in sync, Current line is ${numericString}`
// );
// dycoControlCheck = true;
// return;
// }
// check the stapper error logic.
if (stapperFaulted) {
createLog("error", "dyco", "ocp", `Strapper is faulted.`);
return;
}
// check if we need to manual check due to 20 pallets.
if (currentPalletCheck <= cameraPalletCheck) {
currentPalletCheck = currentPalletCheck + 1;
labelingProcess({ line: numericString });
} else {
currentPalletCheck = 0;
createLog(
"error",
"dyco",
"ocp",
`You have reached 20 pallets since the last check please validate the labeler is still in sync.`
);
}
}
if (dycoPrint[0].value === "0") {
@@ -56,7 +96,9 @@ export const labelerTagRead = async (tagData: any) => {
"Rfid system is contorlling the printing"
);
// trigger the reader so we can get the label from the tag readers.
await readTags("wrapper1");
setTimeout(async () => {
await readTags("wrapper1");
}, 2 * 1000);
}
}
};

72
server/services/ocp/controller/specialProcesses/dyco/plcTags/strapperFault.ts Normal file
View File

@@ -0,0 +1,72 @@
import { db } from "../../../../../../../database/dbclient.js";
import { settings } from "../../../../../../../database/schema/settings.js";
import { tryCatch } from "../../../../../../globalUtils/tryCatch.js";
import { createLog } from "../../../../../logger/logger.js";
// strapper related issues
export let strapperActive = true;
export let stapperFaulted = false;
export let strapperFaultCount = 3; // move to db so we can control it outside the app
export const strapperFaults = async (tagData: any) => {
const { data, error } = await tryCatch(db.select().from(settings));
if (error) {
return { success: false, message: "Failed to get settings." };
}
if (strapperActive) {
// monitor strapper
//console.log(`Strapper fault is ${strapperError.value}`);
if (tagData.value && strapperFaultCount > 0) {
// strapper faulted we want to start the trigger to force the check
if (!stapperFaulted) {
createLog(
"error",
"dyco",
"ocp",
`Strapper errored triggering manual checks will be required for the next ${strapperFaultCount}`
);
}
stapperFaulted = true;
// change move fault count to db....
strapperFaultCount = 3;
}
}
const strapperCheckSetting = data.filter((n) => n.name === "strapperCheck");
if (strapperCheckSetting[0]?.value === "1") {
if (stapperFaulted && strapperFaultCount > 0) {
createLog(
"warn",
"dyco",
"ocp",
`There was a strapper error, remaining pallets to check ${strapperFaultCount}.`
);
strapperFaultCount = strapperFaultCount - 1;
return {
success: false,
message: `There was a strapper error, remaining pallets to check ${strapperFaultCount}.`,
};
} else {
createLog(
"debug",
"dyco",
"ocp",
`Strapper check is active but not faulted, remaining pallets to check ${strapperFaultCount}.`
);
// reset everything
stapperFaulted = false;
strapperFaultCount = 3; // move to db as well
return {
success: true,
message: `Strapper check is active but not faulted, remaining pallets to check ${strapperFaultCount}.`,
};
}
}
};