Merge branch 'main' of https://gitea.centraal.wbd-rd.nl/woutverheijen/rotatingMachine

README.md

@@ -1 +1,23 @@
-# rotating machine
+# rotating machine
+---Explanation KPIs---
+Mean Time Between Failures: MTBF is a key indicator of asset reliability. It represents the average amount of time between two consecutive failures during normal operation. The higher the value, the better.
+- Formula: MTBF = runtime / failures
+
+Mean Time to Repair: MTTR focuses on the speed of failure recovery. It indicates how long it takes on average to repair a failure and restore the system to operational condition. The lower the value, the better.
+- Formula: MTTR = downtime / failures
+
+Asset Availability: Asset availability indicates how often machines are available for use. Higher availability means that the equipment experiences fewer breakdowns and remains operational for a greater amount of time.
+- Formula: availability = MTBF / (MTBF + MTTR) * 100% 
+
+Asset Health Index: A score ranging from 0 (optimal condition) to 5 (worst case) that reflects the overall health status of an asset.
+
+
+---KPI message---
+The message consists of the following components:
+- asset tagnumber: 
+- asset availability
+- mean time between failures
+- mean time to repair
+- asset health index
+- asset health color: Gives a color based on the asset health index (0 = Darkgreen, 1 = Green, 2 = Yellow, 3 = Orange, 4 = Red, 5 = Darkred.)
+- total failures: the total number of failures that have occured for a particular asset

src/nodeClass.js

@@ -115,7 +115,7 @@ class nodeClass {
           const mode = m.currentMode;
           const state = m.state.getCurrentState();
           const flow = Math.round(m.measurements.type("flow").variant("predicted").position('downstream').getCurrentValue());
-          const power = Math.round(m.measurements.type("power").variant("predicted").position('upstream').getCurrentValue());
+          const power = Math.round(m.measurements.type("power").variant("predicted").position('atEquipment').getCurrentValue());
           let symbolState;
           switch(state){
             case "off":

src/specificClass.js

@@ -71,6 +71,37 @@ class Machine {
     this.child = {}; // object to hold child information so we know on what to subscribe
     this.childRegistrationUtils = new childRegistrationUtils(this); // Child registration utility
 
+        // --- KPI tracking ---
+    this.kpi = {
+      failures: 0,
+      totalRuntimeHours: 0,
+      totalDowntimeHours: 0,
+      lastFailureTime: null,
+      lastRepairTime: null,
+      MTBF: 0,
+      MTTR: 0,
+      availability: 0
+    };
+
+    this.assetHealth = {
+      index: 0  // 0 = optimal, 5 = failure
+    };
+
+    this.state.emitter.on('stateChange', (payload) => {
+
+      const stateStr = typeof payload === 'string'
+        ? payload
+        : (payload?.state ?? payload?.newState ?? payload);
+
+      if (typeof stateStr !== 'string') {
+        this.logger.warn(`stateChange event without parsable state: ${JSON.stringify(payload)}`);
+        return;
+      }
+
+      this._handleStateChangeForKPI(stateStr);
+    });
+
+
   }
 
   /*-------------------               Register child events               -------------------*/
@@ -528,6 +559,136 @@ _callMeasurementHandler(measurementType, value, position, context) {
 
     }
   }
+ 
+/////////////////////////////
+        /**
+     * Compute a single drift score in [0..1] using predicted vs measured series.
+     * Uses min/max of the *predicted* window as normalization range.
+     * If no usable data -> returns 0 (neutral).
+     */
+    _computeDriftScore() {
+      try {
+        const metrics = [
+          { key: "pressure", pos: "downstream" },
+          { key: "flow",     pos: "downstream" },
+          { key: "power",    pos: "atEquipment" }
+        ];
+
+        const values = [];
+
+        for (const m of metrics) {
+          const pred = this.measurements.type(m.key).variant("predicted").position(m.pos).getAllValues()?.values;
+          const meas = this.measurements.type(m.key).variant("measured").position(m.pos).getAllValues()?.values;
+
+          if (!Array.isArray(pred) || !Array.isArray(meas) || pred.length < 2 || meas.length < 2) continue;
+
+          const expectedMin = Math.min(...pred);
+          const expectedMax = Math.max(...pred);
+          if (!Number.isFinite(expectedMin) || !Number.isFinite(expectedMax) || expectedMax === expectedMin) continue;
+
+          const drift = this.errorMetrics.assessDrift(pred, meas, expectedMin, expectedMax);
+          if (Number.isFinite(drift)) {
+            // assessDrift is already normalized; keep it in [0..1]
+            values.push(Math.max(0, Math.min(1, Math.abs(drift))));
+          }
+        }
+
+        if (values.length === 0) return 0; // neutral if no data
+        const avg = values.reduce((s, v) => s + v, 0) / values.length;
+        return Math.max(0, Math.min(1, avg));
+      } catch (e) {
+        this.logger?.warn?.(`Drift score error: ${e.message}`);
+        return 0;
+      }
+    }
+
+    _calculateAssetHealthIndex() {
+      try {
+        // 1) Hard fail -> worst health
+        // if (this.state?.getCurrentState && this.state.getCurrentState() === "failed") 
+        if (["off"].includes(this.state?.getCurrentState?.())){
+          this.assetHealth.index = 5;
+          return 5;
+        }
+
+        // 2) Inputs (clamped to 0..1)
+        const availability   = typeof this.kpi?.availability === 'number' ? this.kpi.availability : 1;
+        const unavailability = 1 - Math.max(0, Math.min(1, availability));
+
+        const effPenalty     = Math.max(0, Math.min(1, typeof this.relDistFromPeak === 'number' ? this.relDistFromPeak : 0));
+
+        const driftScore     = this._computeDriftScore(); // 0..1
+
+        // 3) Blend (weights sum to 1.0)
+        // Tweak these if you like: e.g. make drift more/less important.
+        const wAvail = 0.4;   // unavailability weight
+        const wDrift = 0.4;   // drift weight
+        const wEff   = 0.2;   // efficiency distance weight
+
+        const score01 = (wAvail * unavailability) + (wDrift * driftScore) + (wEff * effPenalty);
+
+        // 4) Scale to 0..5 integer, clamp
+        const index = Math.max(0, Math.min(5, Math.round(score01 * 5)));
+
+        this.assetHealth.index = index;
+        return index;
+      } catch (err) {
+        this.logger?.error?.(`AHI calc error: ${err.message}`);
+        this.assetHealth.index = 0;
+        return 0;
+      }
+    }
+
+_handleStateChangeForKPI(newState) {
+  const now = Date.now();
+  const runtime = this.state.getRunTimeHours();
+  const lastState = this.state.getPreviousState?.() || "unknown";
+
+  // --- Treat OFF as failure and start of downtime ---
+  if (newState === "off") {
+    this.kpi.failures++; // always count a new failure when OFF
+    this.kpi.lastFailureTime = now; // mark the start of downtime
+    this.logger.warn(`Machine OFF (counted as failure). Total failures: ${this.kpi.failures}`);
+  }
+
+  // --- When we leave OFF and become OPERATIONAL, book downtime ---
+  if (newState === "operational") {
+    // Only calculate downtime if we had an OFF period before
+    if (this.kpi.lastFailureTime != null) {
+      const downtimeHours = (now - this.kpi.lastFailureTime) / 3600000;
+      this.kpi.totalDowntimeHours += downtimeHours;
+      this.kpi.lastRepairTime = now; // moment of "repaired"
+      this.kpi.lastFailureTime = null; // close downtime window
+      this.logger.info(`OFF → OPERATIONAL. Added ${downtimeHours.toFixed(2)}h downtime.`);
+    }
+  }
+
+  // --- Compute KPI Metrics ---
+  const failures = this.kpi.failures;
+  const downtime = this.kpi.totalDowntimeHours;
+
+  // If no failures yet: MTBF = total runtime; MTTR = 0
+  this.kpi.MTBF = failures > 0 ? runtime / failures : runtime;
+  this.kpi.MTTR = failures > 0 ? downtime / failures : 0;
+
+  // --- Compute Availability ---
+  const mtbf = this.kpi.MTBF ?? 0;
+  const mttr = this.kpi.MTTR ?? 0;
+
+  if (mtbf <= 0 && mttr <= 0) {
+    this.kpi.availability = 1; // Default: 100% if no data
+  } else {
+    const availability = mtbf / (mtbf + mttr);
+    this.kpi.availability = Math.min(1, Math.max(0, availability)); // clamp 0–1
+  }
+
+  this.logger.debug(
+    `KPI updated — MTBF: ${this.kpi.MTBF.toFixed(2)}h, MTTR: ${this.kpi.MTTR.toFixed(2)}h, ` +
+    `Availability: ${(this.kpi.availability * 100).toFixed(2)}%`
+  );
+}
+
+//////////////////////////////////////////////
 
   calcDistanceFromPeak(currentEfficiency,peakEfficiency){
     return Math.abs(currentEfficiency - peakEfficiency);
@@ -702,6 +863,13 @@ _callMeasurementHandler(measurementType, value, position, context) {
     output["cog"] = this.cog; // flow / power efficiency
     output["NCog"] = this.NCog; // normalized cog
     output["NCogPercent"] = Math.round(this.NCog * 100 * 100) / 100 ;
+    output["kpi_MTBF"] = this.kpi.MTBF;
+    output["kpi_MTTR"] = this.kpi.MTTR;
+    output["kpi_assetAvailability"] = Math.round(this.kpi.availability * 100 * 100) / 100;
+    output["kpi_totalFailuresCount"] = this.kpi.failures;
+    output["asset_tag_number"] = 'L001';
+
+    // output["asset_tag_number"] = this.assetTagNumber;
 
     if(this.flowDrift != null){
       const flowDrift = this.flowDrift;
@@ -716,6 +884,21 @@ _callMeasurementHandler(measurementType, value, position, context) {
     output["effRelDistFromPeak"] = this.relDistFromPeak;
     //this.logger.debug(`Output: ${JSON.stringify(output)}`);
 
+
+    /////////////////////////////////
+    // this._calculateAssetHealthIndex();
+    // output["assetHealthIndex"] = this.assetHealth.index;
+
+    this._calculateAssetHealthIndex();
+    output["assetHealthIndex"] = this.assetHealth.index;
+
+    // 0 = darkgreen, 1 = green, 2 = yellow, 3 = orange, 4 = red, 5 = darkred
+    // const healthColors = ["darkgreen", "green", "yellow", "orange", "red", "darkred"];
+    const healthColors = ["#006400", "#008000", "#FFFF00", "#FFA500", "#FF0000", "#8B0000"];
+    output["assetHealthColor"] = healthColors[this.assetHealth.index] || "unknown";
+    //////////////////////////
+
+
     return output;
   }
 
@@ -725,9 +908,9 @@ _callMeasurementHandler(measurementType, value, position, context) {
 module.exports = Machine;
 
 /*-------------------               Testing               -------------------*/
-/*
 
-curve = require('C:/Users/zn375/.node-red/public/fallbackData.json');
+/*
+//curve = require('C:/Users/zn375/.node-red/public/fallbackData.json');
 
 //import a child
 const Child = require('../../measurement/src/specificClass');
@@ -743,7 +926,6 @@ const PT1 = new Child(config={
   },
   functionality:{
     softwareType:"measurement",
-    positionVsParent:"upstream",
   },
   asset:{
     supplier:"Vega",
@@ -765,7 +947,6 @@ const PT2 = new Child(config={
   },
   functionality:{
     softwareType:"measurement",
-    positionVsParent:"upstream",
   },
   asset:{
     supplier:"Vega",
@@ -781,18 +962,17 @@ console.log(`Creating machine...`);
 
 const machineConfig = {
   general: {
-      name: "Hydrostal",
+      name: "Hidrostal",
       logging: {
           enabled: true,
           logLevel: "debug",
       }
   },
   asset: {
-      supplier: "Hydrostal",
+      supplier: "Hidrostal",
       type: "pump",
       category: "centrifugal",
-      model: "H05K-S03R+HGM1X-X280KO", // Ensure this field is present.
-      machineCurve: curve["machineCurves"]["Hydrostal"]["H05K-S03R+HGM1X-X280KO"],
+      model: "hidrostal-H05K-S03R", // Ensure this field is present.
   }
 }
 
@@ -821,18 +1001,17 @@ const machine = new Machine(machineConfig, stateConfig);
 machine.logger.info(`Registering child...`);
 machine.childRegistrationUtils.registerChild(PT1, "upstream");
 machine.childRegistrationUtils.registerChild(PT2, "downstream");
-
-//feed curve to the machine class
-//machine.updateCurve(curve["machineCurves"]["Hydrostal"]["H05K-S03R+HGM1X-X280KO"]);
-
+/*
 PT1.logger.info(`Enable sim...`);
 PT1.toggleSimulation();
 PT2.logger.info(`Enable sim...`);
 PT2.toggleSimulation();
-machine.getOutput();
+*/
+
+
 //manual test
 //machine.handleInput("parent", "execSequence", "startup");
-
+/*
 machine.measurements.type("pressure").variant("measured").position('upstream').value(-200);
 machine.measurements.type("pressure").variant("measured").position('downstream').value(1000);
 
@@ -842,8 +1021,8 @@ const tickLoop = setInterval(changeInput,1000);
 
 function changeInput(){
   PT1.logger.info(`tick...`);
-  PT1.tick();
-  PT2.tick();
+  //PT1.tick();
+  //PT2.tick();
 }
 
 async function testingSequences(){