private IEnumerable <JobLogDB.EventLogMaterial> CreateUnloadMaterial(MessageState state, string pal, IReadOnlyList <LogEntry> oldEvents = null)
{
var oldMat = FindMaterial(pal, oldEvents)[0];
var ret = new List <JobLogDB.EventLogMaterial>();
string partName = "";
int count = 1;
if (state.PartCompletedMessagesBySetup.Count > 0)
{
// use highest setup value
var msgs = state.PartCompletedMessagesBySetup.ElementAt(state.PartCompletedMessagesBySetup.Count - 1).Value;
count = msgs.Count;
partName = msgs[0].PartName;
}
Log.Debug("During unload, found {cnt} parts with name {part} that were unloaded/completed",
count, partName);
_log.SetDetailsForMaterialID(oldMat.MaterialID, null, partName, null);
if (_settings.SerialType == BlackMaple.MachineFramework.SerialType.AssignOneSerialPerCycle ||
_settings.SerialType == BlackMaple.MachineFramework.SerialType.AssignOneSerialPerMaterial
)
{
_log.RecordSerialForMaterialID(oldMat, _settings.ConvertMaterialIDToSerial(oldMat.MaterialID).PadLeft(_settings.SerialLength, '0'), state.LastSeenMessage.TimeUTC);
}
ret.Add(oldMat);
var oldMatDetails = _log.GetMaterialDetails(oldMat.MaterialID);
//allocate new materials, one per completed part in addition to the existing one
for (int i = 1; i < count; i++)
{
var newId = _log.AllocateMaterialID(oldMatDetails.JobUnique, oldMatDetails.PartName, 1);
var newMat = new JobLogDB.EventLogMaterial()
{
MaterialID = newId,
Process = 1,
Face = ""
};
if (_settings.SerialType == BlackMaple.MachineFramework.SerialType.AssignOneSerialPerCycle)
{
_log.RecordSerialForMaterialID(newMat, oldMatDetails.Serial, state.LastSeenMessage.TimeUTC);
}
else if (_settings.SerialType == BlackMaple.MachineFramework.SerialType.AssignOneSerialPerMaterial)
{
_log.RecordSerialForMaterialID(newMat, _settings.ConvertMaterialIDToSerial(newId).PadLeft(_settings.SerialLength, '0'), state.LastSeenMessage.TimeUTC);
}
ret.Add(newMat);
}
return(ret);
}
private static void AddUnloads(JobLogDB log, IEnumerable <LoadAction> currentActions, PalletStatus pallet, TimeSpan?elapsedLoadTime, List <BlackMaple.MachineWatchInterface.LogEntry> oldCycles, CurrentStatus status)
{
// For some reason, sometimes parts to unload don't show up in PalletSubStatus table.
// So create them here if that happens
foreach (var unload in currentActions)
{
if (unload.LoadEvent)
{
continue;
}
if (unload.LoadStation != pallet.CurrentPalletLocation.Num)
{
continue;
}
var matIDs = new Queue <long>(FindMatIDsFromOldCycles(oldCycles, unload.Unique, unload.Process));
status.Jobs.TryGetValue(unload.Unique, out InProcessJob job);
for (int i = 0; i < unload.Qty; i += 1)
{
string face = unload.Process.ToString();
long matID = -1;
if (matIDs.Count > 0)
{
matID = matIDs.Dequeue();
}
var matDetails = log.GetMaterialDetails(matID);
var inProcMat = new InProcessMaterial()
{
MaterialID = matID,
JobUnique = unload.Unique,
PartName = unload.Part,
Process = unload.Process,
Path = unload.Path,
Serial = matDetails?.Serial,
WorkorderId = matDetails?.Workorder,
SignaledInspections =
log.LookupInspectionDecisions(matID)
.Where(x => x.Inspect)
.Select(x => x.InspType)
.ToList(),
Location = new InProcessMaterialLocation()
{
Type = InProcessMaterialLocation.LocType.OnPallet,
Pallet = pallet.Pallet,
Face = unload.Process
},
Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.UnloadToCompletedMaterial,
ElapsedLoadUnloadTime = elapsedLoadTime
}
};
if (job != null)
{
if (unload.Process == job.NumProcesses)
{
inProcMat.Action.Type = InProcessMaterialAction.ActionType.UnloadToInProcess;
}
var queue = job.GetOutputQueue(process: unload.Process, path: unload.Path);
if (!string.IsNullOrEmpty(queue))
{
inProcMat.Action.UnloadIntoQueue = queue;
}
}
status.Material.Add(inProcMat);
}
}
}
private static void AddLoads(JobLogDB log, IEnumerable <LoadAction> currentLoads, string pallet, PalletLocation palLoc, TimeSpan?elapsedLoadTime, CurrentStatus curStatus)
{
var queuedMats = new Dictionary <string, List <BlackMaple.MachineFramework.JobLogDB.QueuedMaterial> >();
//process remaining loads/unloads (already processed ones have been removed from currentLoads)
foreach (var operation in currentLoads)
{
if (!operation.LoadEvent || operation.LoadStation != palLoc.Num)
{
continue;
}
for (int i = 0; i < operation.Qty; i++)
{
List <BlackMaple.MachineFramework.JobLogDB.QueuedMaterial> queuedMat = null;
if (curStatus.Jobs.ContainsKey(operation.Unique))
{
var queue = curStatus.Jobs[operation.Unique].GetInputQueue(process: operation.Process, path: operation.Path);
if (!string.IsNullOrEmpty(queue))
{
//only lookup each queue once
if (queuedMats.ContainsKey(queue))
{
queuedMat = queuedMats[queue];
}
else
{
queuedMat = log.GetMaterialInQueue(queue).ToList();
queuedMats.Add(queue, queuedMat);
}
}
}
long matId = -1;
string serial = null;
string workId = null;
var loc = new InProcessMaterialLocation()
{
Type = InProcessMaterialLocation.LocType.Free
};
if (queuedMat != null)
{
var mat = queuedMat
.Where(m => m.Unique == operation.Unique)
.Select(m => (JobLogDB.QueuedMaterial?)m)
.DefaultIfEmpty(null)
.First();
if (mat.HasValue)
{
matId = mat.Value.MaterialID;
loc = new InProcessMaterialLocation()
{
Type = InProcessMaterialLocation.LocType.InQueue,
CurrentQueue = mat.Value.Queue,
QueuePosition = mat.Value.Position,
};
queuedMat.RemoveAll(m => m.MaterialID == mat.Value.MaterialID);
var matDetails = log.GetMaterialDetails(matId);
serial = matDetails?.Serial;
workId = matDetails?.Workorder;
}
}
var inProcMat = new InProcessMaterial()
{
MaterialID = matId,
JobUnique = operation.Unique,
PartName = operation.Part,
Process = operation.Process,
Path = operation.Path,
Serial = serial,
WorkorderId = workId,
Location = loc,
Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.Loading,
LoadOntoPallet = pallet,
LoadOntoFace = operation.Process,
ProcessAfterLoad = operation.Process,
PathAfterLoad = operation.Path,
ElapsedLoadUnloadTime = elapsedLoadTime
}
};
curStatus.Material.Add(inProcMat);
}
}
}
public static CurrentStatus Build(JobDB jobDB, JobLogDB log, FMSSettings fmsSettings, IMachineGroupName machineGroupName, IQueueSyncFault queueSyncFault, MazakDbType dbType, MazakAllData mazakData, DateTime utcNow)
{
//Load process and path numbers
Dictionary <string, int> uniqueToMaxPath;
Dictionary <string, int> uniqueToMaxProcess;
CalculateMaxProcAndPath(mazakData, out uniqueToMaxPath, out uniqueToMaxProcess);
var currentLoads = new List <LoadAction>(mazakData.LoadActions);
var curStatus = new CurrentStatus();
foreach (var k in fmsSettings.Queues)
{
curStatus.QueueSizes[k.Key] = k.Value;
}
if (mazakData.Alarms != null)
{
foreach (var alarm in mazakData.Alarms)
{
if (!string.IsNullOrEmpty(alarm.AlarmMessage))
{
curStatus.Alarms.Add(alarm.AlarmMessage);
}
}
}
if (queueSyncFault.CurrentQueueMismatch)
{
curStatus.Alarms.Add("Queue contents and Mazak schedule quantity mismatch.");
}
var jobsBySchID = new Dictionary <long, InProcessJob>();
var pathBySchID = new Dictionary <long, MazakPart.IProcToPath>();
foreach (var schRow in mazakData.Schedules)
{
if (!MazakPart.IsSailPart(schRow.PartName))
{
continue;
}
MazakPartRow partRow = null;
foreach (var p in mazakData.Parts)
{
if (p.PartName == schRow.PartName)
{
partRow = p;
break;
}
}
if (partRow == null)
{
continue;
}
//Parse data from the database
var partName = partRow.PartName;
int loc = partName.IndexOf(':');
if (loc >= 0)
{
partName = partName.Substring(0, loc);
}
string jobUnique = "";
MazakPart.IProcToPath procToPath = null;
bool manual = false;
if (!string.IsNullOrEmpty(partRow.Comment))
{
MazakPart.ParseComment(partRow.Comment, out jobUnique, out procToPath, out manual);
}
if (!uniqueToMaxProcess.ContainsKey(jobUnique))
{
continue;
}
int numProc = uniqueToMaxProcess[jobUnique];
int maxProc1Path = uniqueToMaxPath[jobUnique];
InProcessJob job;
//Create or lookup the job
if (curStatus.Jobs.ContainsKey(jobUnique))
{
job = curStatus.Jobs[jobUnique];
}
else
{
var jobPaths = new int[numProc];
for (int i = 0; i < numProc; i++)
{
jobPaths[i] = maxProc1Path;
}
job = new InProcessJob(jobUnique, numProc, jobPaths);
job.PartName = partName;
job.JobCopiedToSystem = true;
curStatus.Jobs.Add(jobUnique, job);
}
jobsBySchID.Add(schRow.Id, job);
pathBySchID.Add(schRow.Id, procToPath);
//Job Basics
job.SetPlannedCyclesOnFirstProcess(procToPath.PathForProc(proc: 1), schRow.PlanQuantity);
AddCompletedToJob(schRow, job, procToPath);
job.Priority = schRow.Priority;
if (((HoldPattern.HoldMode)schRow.HoldMode) == HoldPattern.HoldMode.FullHold)
{
job.HoldEntireJob.UserHold = true;
}
else
{
job.HoldEntireJob.UserHold = false;
}
AddRoutingToJob(mazakData, partRow, job, machineGroupName, procToPath, dbType);
}
var loadedJobs = new HashSet <string>();
foreach (var j in jobsBySchID.Values)
{
if (loadedJobs.Contains(j.UniqueStr))
{
continue;
}
loadedJobs.Add(j.UniqueStr);
AddDataFromJobDB(jobDB, j);
}
//Now add pallets
foreach (var palRow in mazakData.Pallets)
{
if (palRow.PalletNumber > 0 && !curStatus.Pallets.ContainsKey(palRow.PalletNumber.ToString()))
{
var palName = palRow.PalletNumber.ToString();
var palLoc = FindPalletLocation(machineGroupName, mazakData, dbType, palRow.PalletNumber);
//Create the pallet
PalletStatus status = new PalletStatus()
{
Pallet = palName,
CurrentPalletLocation = palLoc,
FixtureOnPallet = palRow.Fixture,
NumFaces = 1,
OnHold = false
};
curStatus.Pallets.Add(status.Pallet, status);
var oldCycles = log.CurrentPalletLog(palName);
//Add the material currently on the pallet
foreach (var palSub in mazakData.PalletSubStatuses)
{
if (palSub.PalletNumber != palRow.PalletNumber)
{
continue;
}
if (palSub.FixQuantity <= 0)
{
continue;
}
if (!jobsBySchID.ContainsKey(palSub.ScheduleID))
{
continue;
}
status.NumFaces = Math.Max(status.NumFaces, palSub.PartProcessNumber);
var job = jobsBySchID[palSub.ScheduleID];
var procToPath = pathBySchID[palSub.ScheduleID];
var matIDs = new Queue <long>(FindMatIDsFromOldCycles(oldCycles, job.UniqueStr, palSub.PartProcessNumber));
for (int i = 1; i <= palSub.FixQuantity; i++)
{
int face = palSub.PartProcessNumber;
long matID = -1;
if (matIDs.Count > 0)
{
matID = matIDs.Dequeue();
}
var matDetails = log.GetMaterialDetails(matID);
var inProcMat = new InProcessMaterial()
{
MaterialID = matID,
JobUnique = job.UniqueStr,
PartName = job.PartName,
Process = palSub.PartProcessNumber,
Path = procToPath.PathForProc(palSub.PartProcessNumber),
Serial = matDetails?.Serial,
WorkorderId = matDetails?.Workorder,
SignaledInspections =
log.LookupInspectionDecisions(matID)
.Where(x => x.Inspect)
.Select(x => x.InspType)
.Distinct()
.ToList(),
LastCompletedMachiningRouteStopIndex =
oldCycles.Any(
c => c.LogType == LogType.MachineCycle &&
!c.StartOfCycle &&
c.Material.Any(m => m.MaterialID == matID && m.Process == palSub.PartProcessNumber)
)
? (int?)0
: null,
Location = new InProcessMaterialLocation()
{
Type = InProcessMaterialLocation.LocType.OnPallet,
Pallet = status.Pallet,
Face = face
},
Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.Waiting
}
};
curStatus.Material.Add(inProcMat);
//check for unloading or transfer
var loadNext = CheckLoadOfNextProcess(currentLoads, job.UniqueStr, palSub.PartProcessNumber, palLoc);
var unload = CheckUnload(currentLoads, job.UniqueStr, palSub.PartProcessNumber, palLoc);
if (loadNext != null)
{
var start = FindLoadStartFromOldCycles(oldCycles, matID);
inProcMat.Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.Loading,
LoadOntoFace = palSub.PartProcessNumber + 1,
LoadOntoPallet = status.Pallet,
ProcessAfterLoad = palSub.PartProcessNumber + 1,
PathAfterLoad = procToPath.PathForProc(palSub.PartProcessNumber + 1),
ElapsedLoadUnloadTime = start != null ? (TimeSpan?)utcNow.Subtract(start.EndTimeUTC) : null
};
}
else if (unload != null)
{
var start = FindLoadStartFromOldCycles(oldCycles, matID);
inProcMat.Action = new InProcessMaterialAction()
{
Type =
palSub.PartProcessNumber == job.NumProcesses
? InProcessMaterialAction.ActionType.UnloadToCompletedMaterial
: InProcessMaterialAction.ActionType.UnloadToInProcess,
UnloadIntoQueue = job.GetOutputQueue(
process: palSub.PartProcessNumber,
path: procToPath.PathForProc(palSub.PartProcessNumber)),
ElapsedLoadUnloadTime = start != null ? (TimeSpan?)utcNow.Subtract(start.EndTimeUTC) : null
};
}
else
{
// detect if machining
var start = FindMachineStartFromOldCycles(oldCycles, matID);
if (start != null)
{
var machStop = job.GetMachiningStop(inProcMat.Process, inProcMat.Path).FirstOrDefault();
var elapsedTime = utcNow.Subtract(start.EndTimeUTC);
inProcMat.Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.Machining,
ElapsedMachiningTime = elapsedTime,
ExpectedRemainingMachiningTime =
machStop != null?machStop.ExpectedCycleTime.Subtract(elapsedTime) : TimeSpan.Zero
};
}
}
}
}
if (palLoc.Location == PalletLocationEnum.LoadUnload)
{
var start = FindLoadStartFromOldCycles(oldCycles);
var elapsedLoad = start != null ? (TimeSpan?)utcNow.Subtract(start.EndTimeUTC) : null;
AddLoads(log, currentLoads, status.Pallet, palLoc, elapsedLoad, curStatus);
AddUnloads(log, currentLoads, status, elapsedLoad, oldCycles, curStatus);
}
}
}
//now queued
var seenMatIds = new HashSet <long>(curStatus.Material.Select(m => m.MaterialID));
foreach (var mat in log.GetMaterialInAllQueues())
{
// material could be in the process of being loaded
if (seenMatIds.Contains(mat.MaterialID))
{
continue;
}
var matLogs = log.GetLogForMaterial(mat.MaterialID);
int lastProc = 0;
foreach (var entry in log.GetLogForMaterial(mat.MaterialID))
{
foreach (var entryMat in entry.Material)
{
if (entryMat.MaterialID == mat.MaterialID)
{
lastProc = Math.Max(lastProc, entryMat.Process);
}
}
}
var matDetails = log.GetMaterialDetails(mat.MaterialID);
curStatus.Material.Add(new InProcessMaterial()
{
MaterialID = mat.MaterialID,
JobUnique = mat.Unique,
PartName = mat.PartName,
Process = lastProc,
Path = 1,
Serial = matDetails?.Serial,
WorkorderId = matDetails?.Workorder,
SignaledInspections =
log.LookupInspectionDecisions(mat.MaterialID)
.Where(x => x.Inspect)
.Select(x => x.InspType)
.Distinct()
.ToList(),
Location = new InProcessMaterialLocation()
{
Type = InProcessMaterialLocation.LocType.InQueue,
CurrentQueue = mat.Queue,
QueuePosition = mat.Position,
},
Action = new InProcessMaterialAction()
{
Type = InProcessMaterialAction.ActionType.Waiting
}
});
}
var notCopied = jobDB.LoadJobsNotCopiedToSystem(DateTime.UtcNow.AddHours(-WriteJobs.JobLookbackHours), DateTime.UtcNow);
foreach (var j in notCopied.Jobs)
{
if (curStatus.Jobs.ContainsKey(j.UniqueStr))
{
//The copy to the cell succeeded but the DB has not yet been updated.
//The thread which copies jobs will soon notice and update the database
//so we can ignore it for now.
}
else
{
curStatus.Jobs.Add(j.UniqueStr, new InProcessJob(j));
}
}
foreach (var j in curStatus.Jobs)
{
foreach (var d in jobDB.LoadDecrementsForJob(j.Value.UniqueStr))
{
j.Value.Decrements.Add(d);
}
}
return(curStatus);
}
public void ConvertsMaterialFromV17()
{
// existing v17 file has the following data in it
var now = new DateTime(2018, 7, 12, 5, 6, 7, DateTimeKind.Utc);
var mat1_1 = new LogMaterial(1, "uuu1", 1, "part1", 2, "serial1", "work1", face: "A");
var mat1_2 = new LogMaterial(1, "uuu1", 2, "part1", 2, "serial1", "work1", face: "B");
var mat2_1 = new LogMaterial(2, "uuu1", 1, "part1", 2, "serial2", "", face: "C");
var mat2_2 = new LogMaterial(2, "uuu1", 1, "part1", 2, "serial2", "", face: "D");
var mat3 = new LogMaterial(3, "uuu2", 1, "part2", 1, "", "work3", face: "E");
_log.GetLogEntries(now, now.AddDays(1)).Should().BeEquivalentTo(new[] {
new LogEntry(
cntr: -1,
mat: new [] { mat1_1, mat2_1 },
pal: "3",
ty: LogType.MachineCycle,
locName: "MC",
locNum: 1,
prog: "proggg",
start: false,
endTime: now,
result: "result",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat1_2, mat2_2 },
pal: "5",
ty: LogType.MachineCycle,
locName: "MC",
locNum: 1,
prog: "proggg2",
start: false,
endTime: now.AddMinutes(10),
result: "result2",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat1_1 },
pal: "",
ty: LogType.PartMark,
locName: "Mark",
locNum: 1,
prog: "MARK",
start: false,
endTime: now.AddMinutes(20),
result: "serial1",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat1_1 },
pal: "",
ty: LogType.OrderAssignment,
locName: "Order",
locNum: 1,
prog: "",
start: false,
endTime: now.AddMinutes(30),
result: "work1",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat2_2 },
pal: "",
ty: LogType.PartMark,
locName: "Mark",
locNum: 1,
prog: "MARK",
start: false,
endTime: now.AddMinutes(40),
result: "serial2",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat3 },
pal: "1",
ty: LogType.LoadUnloadCycle,
locName: "L/U",
locNum: 5,
prog: "LOAD",
start: false,
endTime: now.AddMinutes(50),
result: "LOAD",
endOfRoute: false
),
new LogEntry(
cntr: -1,
mat: new [] { mat3 },
pal: "",
ty: LogType.OrderAssignment,
locName: "Order",
locNum: 1,
prog: "",
start: false,
endTime: now.AddMinutes(60),
result: "work3",
endOfRoute: false
),
}, options =>
options.Excluding(x => x.Counter)
);
_log.GetMaterialDetails(1).Should().BeEquivalentTo(new MaterialDetails()
{
MaterialID = 1,
JobUnique = "uuu1",
PartName = "part1",
NumProcesses = 2,
Workorder = "work1",
Serial = "serial1",
Paths = new System.Collections.Generic.Dictionary <int, int>()
});
_log.GetMaterialDetails(2).Should().BeEquivalentTo(new MaterialDetails()
{
MaterialID = 2,
JobUnique = "uuu1",
PartName = "part1",
NumProcesses = 2,
Workorder = null,
Serial = "serial2",
Paths = new System.Collections.Generic.Dictionary <int, int>()
});
_log.GetMaterialDetails(3).Should().BeEquivalentTo(new MaterialDetails()
{
MaterialID = 3,
JobUnique = "uuu2",
PartName = "part2",
NumProcesses = 1,
Workorder = "work3",
Serial = null,
Paths = new System.Collections.Generic.Dictionary <int, int>()
});
}