merging

Reviewed-on: RnD/rotatingMachine#2

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

@@ -114,8 +114,8 @@ class nodeClass {
     try {
           const mode = m.currentMode;
           const state = m.state.getCurrentState();
-          const flow = Math.round(m.measurements.type("flow").variant("predicted").position('downstream').getCurrentValue());
+          const flow = Math.round(m.measurements.type("flow").variant("predicted").position('downstream').getCurrentValue('m3/h'));
-          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('kW'));
           let symbolState;
           switch(state){
             case "off":
@@ -145,6 +145,9 @@ class nodeClass {
             case "decelerating":
               symbolState = "⏪";
               break;
+            case "maintenance":
+              symbolState = "🔧";
+              break;
           }
           const position = m.state.getCurrentPosition();
           const roundedPosition = Math.round(position * 100) / 100;

src/specificClass.js

@@ -48,7 +48,17 @@ class Machine {
     this.errorMetrics = new nrmse(errorMetricsConfig, this.logger);
 
     // Initialize measurements
-    this.measurements = new MeasurementContainer();
+    this.measurements = new MeasurementContainer({
+      autoConvert: true,
+      windowSize: 50,
+      defaultUnits: {
+        pressure: 'mbar',
+        flow: this.config.general.unit,
+        power: 'kW',
+        temperature: 'C'
+      }
+    });
+
     this.interpolation = new interpolation();
 
     this.flowDrift = null;
@@ -68,9 +78,93 @@ class Machine {
       this.updatePosition();
     });
 
+    //When state changes look if we need to do other updates
+    this.state.emitter.on("stateChange", (newState) => {
+      this.logger.debug(`State change detected: ${newState}`);
+      this._updateState();
+    });
+
     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);
+    });
+
+
+        // --- 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);
+    });
+
+
+  }
+
+  _updateState(){
+    const isOperational = this._isOperationalState();
+    if(!isOperational){
+      //overrule the last prediction this should be 0 now
+      this.measurements.type("flow").variant("predicted").position("downstream").value(0);
+    }
+  }
+
+  _updateState(){
+    const isOperational = this._isOperationalState();
+    if(!isOperational){
+      //overrule the last prediction this should be 0 now
+      this.measurements.type("flow").variant("predicted").position("downstream").value(0);
+    }
   }
 
   /*-------------------               Register child events               -------------------*/
@@ -116,10 +210,6 @@ _callMeasurementHandler(measurementType, value, position, context) {
       this.updateMeasuredFlow(value, position, context);
       break;
       
-    case 'temperature':
-      this.updateMeasuredTemperature(value, position, context);
-      break;
-      
     default:
       this.logger.warn(`No handler for measurement type: ${measurementType}`);
       // Generic handler - just update position
@@ -165,43 +255,68 @@ _callMeasurementHandler(measurementType, value, position, context) {
   // -------- Mode and Input Management -------- //
   isValidSourceForMode(source, mode) {
     const allowedSourcesSet = this.config.mode.allowedSources[mode] || [];
-    return allowedSourcesSet.has(source);
+    const allowed = allowedSourcesSet.has(source);
+    allowed? 
+    this.logger.debug(`source is allowed proceeding with ${source} for mode ${mode}`) : 
+    this.logger.warn(`${source} is not allowed in mode ${mode}`);
+
+    return allowed;
   }
 
   isValidActionForMode(action, mode) {
     const allowedActionsSet = this.config.mode.allowedActions[mode] || [];
-    return allowedActionsSet.has(action);
+    const allowed = allowedActionsSet.has(action);
+    allowed ? 
+    this.logger.debug(`Action is allowed proceeding with ${action} for mode ${mode}`) : 
+    this.logger.warn(`${action} is not allowed in mode ${mode}`);
+
+    return allowed;
   }
 
   async handleInput(source, action, parameter) {
 
-    if (!this.isValidSourceForMode(source, this.currentMode)) {
+    this.logger.debug("hello"); 
-      let warningTxt = `Source '${source}' is not valid for mode '${this.currentMode}'.`;
+    //sanitize input
-      this.logger.warn(warningTxt);
+    if( typeof action !== 'string'){this.logger.error(`Action must be string`); return;}
-      return {status : false , feedback: warningTxt};
+    //convert to lower case to avoid to many mistakes in commands
-    }
+    action = action.toLowerCase();
+
+    // check for validity of the request
+    if(!this.isValidActionForMode(action,this.currentMode)){return ;}
+    if (!this.isValidSourceForMode(source, this.currentMode)) {return ;}
+
+    this.logger.debug("hello2"); 
     
     this.logger.info(`Handling input from source '${source}' with action '${action}' in mode '${this.currentMode}'.`);
     
     try {
       switch (action) {
-        case "execSequence":
+
+        case "execsequence":
           return await this.executeSequence(parameter);
 
-        case "execMovement":
+        case "execmovement":
           return await this.setpoint(parameter);
 
-        case "flowMovement":
+        case "entermaintenance":
+           
+          return await this.executeSequence(parameter);
+
+        
+        case "exitmaintenance":
+          return await this.executeSequence(parameter);
+
+        case "flowmovement":
           // Calculate the control value for a desired flow
           const pos = this.calcCtrl(parameter);
           // Move to the desired setpoint
           return await this.setpoint(pos);
 
-        case "emergencyStop":
+        case "emergencystop":
           this.logger.warn(`Emergency stop activated by '${source}'.`);
           return await this.executeSequence("emergencyStop");
 
-        case "statusCheck":
+        case "statuscheck":
           this.logger.info(`Status Check: Mode = '${this.currentMode}', Source = '${source}'.`);
           break;
 
@@ -501,13 +616,14 @@ _callMeasurementHandler(measurementType, value, position, context) {
     
     // Update predicted flow if you have prediction capability
     if (this.predictFlow) {
-      this.measurements.type("flow").variant("predicted").position("atEquipment").value(this.predictFlow.outputY || 0);
+      this.measurements.type("flow").variant("predicted").position("downstream").value(this.predictFlow.outputY || 0);
     }
   }
 
   // Helper method for operational state check
   _isOperationalState() {
     const state = this.state.getCurrentState();
+    this.logger.debug(`Checking operational state ${this.state.getCurrentState()} ? ${["operational", "accelerating", "decelerating"].includes(state)}`);
     return ["operational", "accelerating", "decelerating"].includes(state);
   }
 
@@ -532,6 +648,136 @@ _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);
@@ -561,7 +807,6 @@ _callMeasurementHandler(measurementType, value, position, context) {
     };
   }
 
-
    // Calculate the center of gravity for current pressure
   calcCog() {
 
@@ -677,23 +922,12 @@ _callMeasurementHandler(measurementType, value, position, context) {
 
     // Improved output object generation
     const output = {};
-    //build the output object
-    this.measurements.getTypes().forEach(type => {
-      this.measurements.getVariants(type).forEach(variant => {
 
-        const downstreamVal = this.measurements.type(type).variant(variant).position("downstream").getCurrentValue();
+    Object.entries(this.measurements.measurements).forEach(([type, variants]) => {
-        const upstreamVal = this.measurements.type(type).variant(variant).position("upstream").getCurrentValue();
+      Object.entries(variants).forEach(([variant, positions]) => {
-
+        Object.entries(positions).forEach(([position, measurement]) => {
-        if (downstreamVal != null) {
+          output[`${type}.${variant}.${position}`] = measurement.getCurrentValue();
-          output[`downstream_${variant}_${type}`] = downstreamVal;
+        });
-        }
-        if (upstreamVal != null) {
-          output[`upstream_${variant}_${type}`] = upstreamVal;
-        }
-        if (downstreamVal != null && upstreamVal != null) {
-          const diffVal = this.measurements.type(type).variant(variant).difference().value;
-          output[`differential_${variant}_${type}`] = diffVal;
-        }
       });
     });
 
@@ -706,6 +940,14 @@ _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;
+    output["maintenanceTime"] = this.state.getMaintenanceTimeHours();
 
     if(this.flowDrift != null){
       const flowDrift = this.flowDrift;
@@ -720,6 +962,21 @@ _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;
   }
 
@@ -729,9 +986,9 @@ _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');
@@ -747,7 +1004,6 @@ const PT1 = new Child(config={
   },
   functionality:{
     softwareType:"measurement",
-    positionVsParent:"upstream",
   },
   asset:{
     supplier:"Vega",
@@ -769,7 +1025,6 @@ const PT2 = new Child(config={
   },
   functionality:{
     softwareType:"measurement",
-    positionVsParent:"upstream",
   },
   asset:{
     supplier:"Vega",
@@ -785,18 +1040,17 @@ 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.
+      model: "hidrostal-H05K-S03R", // Ensure this field is present.
-      machineCurve: curve["machineCurves"]["Hydrostal"]["H05K-S03R+HGM1X-X280KO"],
   }
 }
 
@@ -825,18 +1079,17 @@ 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);
 
@@ -846,8 +1099,8 @@ const tickLoop = setInterval(changeInput,1000);
 
 function changeInput(){
   PT1.logger.info(`tick...`);
-  PT1.tick();
+  //PT1.tick();
-  PT2.tick();
+  //PT2.tick();
 }
 
 async function testingSequences(){