445 lines
17 KiB
Python
445 lines
17 KiB
Python
"""Measurement service - pass/fail calculation, data storage."""
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import math
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from datetime import datetime
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from src.backend.utils.tempo import utcnow
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from decimal import Decimal
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from typing import TYPE_CHECKING
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from fastapi import HTTPException, status
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from sqlalchemy import func, select
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from sqlalchemy.ext.asyncio import AsyncSession
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from src.backend.models.orm.measurement import Measurement
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from src.backend.models.orm.production import ProductionEvent
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from src.backend.models.orm.recipe import Recipe, RecipeVersion
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from src.backend.models.orm.task import (
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MEASURING_TASK_TYPES, RecipeSubtask, RecipeTask,
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)
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from src.backend.models.orm.user import User
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if TYPE_CHECKING:
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from src.backend.models.orm.production import ProductionRun
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# What the Measurement.value column (DECIMAL(12,6)) can actually hold.
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_MAX_ABS_VALUE = 1_000_000
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def _validate_measured_value(value: float) -> None:
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"""Refuse a value that would corrupt the verdict or the INSERT.
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NaN makes every tolerance comparison false, so a bad reading silently
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comes out as "pass"; NaN and Infinity then both fail the DECIMAL(12,6)
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column at insert time with an IntegrityError the operator never asked
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for. Raised as a plain HTTPException with a string detail rather than as
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a pydantic Field constraint on the request model: a Field rejecting NaN
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(via allow_inf_nan or a gt/lt bound) makes pydantic echo that same NaN
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back in the validation error's "input", and FastAPI's default error
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response then crashes with a 500 trying to JSON-encode it
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(Starlette's JSONResponse calls json.dumps(..., allow_nan=False)).
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"""
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if not math.isfinite(value):
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="Measured value must be a finite number (no NaN/Infinity)",
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)
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if abs(value) >= _MAX_ABS_VALUE:
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail=f"Measured value out of range: |value| must be < {_MAX_ABS_VALUE}",
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)
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def calculate_pass_fail(
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value: float, subtask: RecipeSubtask
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) -> tuple[str, float | None]:
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"""Calculate pass/fail status and deviation based on tolerances.
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Returns (status, deviation) where status is 'pass', 'warning', or 'fail'.
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Logic:
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- If value is outside UTL/LTL -> 'fail'
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- If value is outside UWL/LWL but inside UTL/LTL -> 'warning'
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- Otherwise -> 'pass'
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The value is rounded to 6 decimals first - the precision the DECIMAL(12,6)
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column keeps - so the verdict is computed on the same number that ends up
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stored, and a value like 10.5000004 does not fail against a 10.5 limit.
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"""
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value = round(value, 6)
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deviation = None
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if subtask.nominal is not None:
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deviation = float(Decimal(str(value)) - Decimal(str(subtask.nominal)))
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# Check fail (outside tolerance limits)
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if subtask.utl is not None and value > float(subtask.utl):
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return "fail", deviation
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if subtask.ltl is not None and value < float(subtask.ltl):
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return "fail", deviation
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# Check warning (outside warning limits)
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if subtask.uwl is not None and value > float(subtask.uwl):
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return "warning", deviation
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if subtask.lwl is not None and value < float(subtask.lwl):
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return "warning", deviation
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return "pass", deviation
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async def recipe_of_version(db: AsyncSession, version_id: int) -> Recipe | None:
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"""The recipe a version belongs to - where the rules of measurement live."""
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result = await db.execute(
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select(Recipe)
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.join(RecipeVersion, RecipeVersion.recipe_id == Recipe.id)
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.where(RecipeVersion.id == version_id)
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)
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return result.scalar_one_or_none()
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def _enforce_recipe_rules(
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recipe: Recipe | None,
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lot_number: str | None,
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serial_number: str | None,
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input_method: str,
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) -> None:
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"""Refuse a measurement the recipe does not allow.
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Checked here rather than only on the screen because a rule that lives in the
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frontend is a suggestion: the keypad can be hidden and the same request still
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sent. This is the one place every measurement passes through.
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"""
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if recipe is None:
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return
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if recipe.requires_lot and not (lot_number or "").strip():
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="This recipe requires a lot number",
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)
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if recipe.requires_serial and not (serial_number or "").strip():
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="This recipe requires a serial number",
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)
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if input_method == "manual" and not recipe.allow_manual_input:
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="This recipe does not allow values typed by hand: use the caliper",
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)
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def _scope(query, version_id: int, measured_by: int, production_run_id: int | None):
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"""Narrow a measurement query to the run in progress, or to this operator's work.
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Inside a production the run is the boundary. Outside one - a recipe executed on
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its own - the boundary is the version and the person doing it, so two operators
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on the same recipe do not block each other.
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"""
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if production_run_id is not None:
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return query.where(Measurement.production_run_id == production_run_id)
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return query.where(
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Measurement.version_id == version_id,
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Measurement.measured_by == measured_by,
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Measurement.production_run_id.is_(None),
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)
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async def pending_authorisation(
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db: AsyncSession,
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version_id: int,
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measured_by: int,
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production_run_id: int | None = None,
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) -> Measurement | None:
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"""The out-of-tolerance measurement that is holding everything up, if any.
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Only the *latest* reading of each quote counts. Measuring the same quote again
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is allowed - the caliper slips, the piece is reseated - and a second reading
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within tolerance releases the block. What is not allowed is moving on to the
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next quote while the one in hand is out of tolerance and nobody has said so.
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How many attempts that permits is point 4's business, not this one's. Every
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reading stays in the record either way.
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"""
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latest_per_subtask = _scope(
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select(func.max(Measurement.id)),
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version_id, measured_by, production_run_id,
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).group_by(Measurement.subtask_id)
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result = await db.execute(
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select(Measurement)
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.where(
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Measurement.id.in_(latest_per_subtask),
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Measurement.pass_fail == "fail",
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Measurement.supervisor_id.is_(None),
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)
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.order_by(Measurement.id)
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.limit(1)
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)
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return result.scalar_one_or_none()
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async def task_progress(
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db: AsyncSession,
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version_id: int,
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measured_by: int,
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production_run_id: int | None = None,
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) -> list[dict]:
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"""How far each measurement task of a version has got.
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A task left half done is the thing the operator cannot see today: they walk
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away from it, come back to the list, and it looks exactly like one never
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started. Counting quotes against measurements is what tells them apart.
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Documental tasks are not in here. A note cannot be half read, and marking one
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incomplete for ever would be noise on the only screen that has to stay legible.
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Which tasks count is read from the declared type, not from whether quotes happen
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to have been entered yet - the same rule point 2 settled everywhere else.
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"""
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rows = (await db.execute(
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select(RecipeTask.id, RecipeSubtask.id)
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.join(RecipeSubtask, RecipeSubtask.task_id == RecipeTask.id, isouter=True)
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.where(
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RecipeTask.version_id == version_id,
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RecipeTask.task_type.in_(MEASURING_TASK_TYPES),
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)
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)).all()
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if not rows:
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return []
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by_task: dict[int, set[int]] = {}
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for task_id, subtask_id in rows:
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quotes = by_task.setdefault(task_id, set())
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if subtask_id is not None:
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quotes.add(subtask_id)
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measured = set((await db.execute(
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_scope(
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select(Measurement.subtask_id).distinct(),
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version_id, measured_by, production_run_id,
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)
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)).scalars().all())
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progress = []
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for task_id, subtask_ids in by_task.items():
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total = len(subtask_ids)
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done = len(subtask_ids & measured)
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if total == 0:
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# Declared as a measurement but with no quotes on it yet: nothing to
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# take, so nothing to report as missing either.
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state = "empty"
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elif done == total:
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state = "complete"
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elif done:
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state = "partial"
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else:
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state = "none"
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progress.append({
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"task_id": task_id,
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"quotes": total,
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"measured": done,
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"state": state,
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})
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progress.sort(key=lambda row: row["task_id"])
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return progress
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async def current_cycle_measurements(
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db: AsyncSession, run_id: int, task_id: int,
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) -> list[dict]:
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"""The quotes of a task already measured in the cycle that is under way.
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A reload, a timer redirect or an auto-logout throws away what the page held in
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memory; the operator would measure the same quotes again and the duplicates
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would reach the SPC statistics. The cycle needs no column of its own: it starts
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at the latest event of the run that opens one for this task - the run start, a
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cycle_completed, or a remeasure of this task.
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If a task_measured of this task follows that boundary the task is already
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closed in this cycle and there is nothing to restore. Where a quote was measured
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more than once, the last reading stands.
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"""
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boundary = (await db.execute(
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select(ProductionEvent.id, ProductionEvent.created_at)
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.where(
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ProductionEvent.run_id == run_id,
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(ProductionEvent.event_type.in_(("start", "cycle_completed")))
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| (
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(ProductionEvent.event_type == "remeasure")
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& (ProductionEvent.task_id == task_id)
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),
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)
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.order_by(ProductionEvent.id.desc())
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.limit(1)
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)).first()
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event_filter = [ProductionEvent.run_id == run_id]
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measurement_filter = [Measurement.production_run_id == run_id]
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if boundary is not None:
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boundary_id, boundary_at = boundary
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event_filter.append(ProductionEvent.id > boundary_id)
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measurement_filter.append(Measurement.measured_at > boundary_at)
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closed = (await db.execute(
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select(ProductionEvent.id).where(
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*event_filter,
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ProductionEvent.event_type == "task_measured",
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ProductionEvent.task_id == task_id,
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).limit(1)
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)).first()
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if closed is not None:
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return []
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rows = (await db.execute(
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select(Measurement)
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.join(RecipeSubtask, RecipeSubtask.id == Measurement.subtask_id)
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.where(*measurement_filter, RecipeSubtask.task_id == task_id)
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.order_by(Measurement.measured_at, Measurement.id)
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)).scalars().all()
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latest: dict[int, Measurement] = {}
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for m in rows:
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latest[m.subtask_id] = m
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return [
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{
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"subtask_id": m.subtask_id,
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"value": float(m.value),
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"pass_fail": m.pass_fail,
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"measured_at": m.measured_at,
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}
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for m in sorted(latest.values(), key=lambda m: (m.measured_at, m.id))
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]
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async def validate_run_for_version(
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db: AsyncSession, run_id: int, version_id: int,
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) -> "ProductionRun":
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"""The run a measurement is being filed against, checked for coherence.
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Three things have to hold before a value goes in against a production: the
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run has to exist, it has to belong to the same recipe as the version being
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measured (a run started for another product must not collect another
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product's history), and it has to be in a state that accepts measurements
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(not closed, not paused). Shared with vision_service, which files camera
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measurements against a run the same way a manual reading does.
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"""
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# Local import: production_service imports this module at module scope,
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# so importing it back here at module scope would be circular.
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from src.backend.services import production_service
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run = await production_service.get_run(db, run_id) # 404 if missing
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recipe = await recipe_of_version(db, version_id)
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if recipe is None or run.recipe_id != recipe.id:
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="Production run belongs to a different recipe than this version",
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)
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production_service._require_measurable(run) # 409 if closed or paused
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return run
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async def authorise_measurement(
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db: AsyncSession, measurement: Measurement, supervisor: User,
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) -> Measurement:
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"""Let an out-of-tolerance value stand, on the supervisor's name."""
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measurement.supervisor_id = supervisor.id
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measurement.authorised_at = utcnow()
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await db.flush()
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await db.refresh(measurement)
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return measurement
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async def save_measurement(
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db: AsyncSession,
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subtask_id: int,
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version_id: int,
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measured_by: int,
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value: float,
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lot_number: str | None = None,
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serial_number: str | None = None,
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input_method: str = "manual",
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input_duration_ms: int | None = None,
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production_run_id: int | None = None,
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vision_result_id: int | None = None,
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enforce_tolerance_gate: bool = True,
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) -> Measurement:
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"""Save a single measurement with auto-calculated pass/fail.
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``enforce_tolerance_gate=False`` skips only the pending-authorisation check
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below - everything else (verdict, recipe rules, deviation) still applies.
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This is for a caller that has already evaluated the gate itself for a whole
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batch of quotes taken at the same instant (see Ruling R10 / vision_service):
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the gate models "moving on" between measurements taken one after another,
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which does not exist inside a single camera acquisition.
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"""
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_validate_measured_value(value)
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# Get subtask for tolerance values
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result = await db.execute(
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select(RecipeSubtask).where(RecipeSubtask.id == subtask_id)
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)
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subtask = result.scalar_one_or_none()
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if subtask is None:
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raise ValueError(f"Subtask {subtask_id} not found")
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# The quote has to belong to a task of the declared version - otherwise the
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# tolerances just read off `subtask` are not the ones this version's operator
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# was shown, and pass/fail is computed against the wrong recipe.
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task_row = await db.execute(
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select(RecipeTask.version_id).where(RecipeTask.id == subtask.task_id)
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)
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subtask_version_id = task_row.scalar_one_or_none()
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if subtask_version_id != version_id:
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raise HTTPException(
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status_code=status.HTTP_422_UNPROCESSABLE_CONTENT,
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detail="Subtask does not belong to the given version",
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)
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if production_run_id is not None:
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await validate_run_for_version(db, production_run_id, version_id)
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recipe = await recipe_of_version(db, version_id)
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_enforce_recipe_rules(recipe, lot_number, serial_number, input_method)
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# No moving on while a quote is out of tolerance and unauthorised. Measuring
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# that same quote again is the way out that does not need the capoturno; the
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# next quote is not.
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if enforce_tolerance_gate:
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blocking = await pending_authorisation(
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db, version_id, measured_by, production_run_id,
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)
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if blocking is not None and blocking.subtask_id != subtask_id:
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raise HTTPException(
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status_code=status.HTTP_409_CONFLICT,
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detail=(
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"A measurement is out of tolerance and awaiting the supervisor: "
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"authorise it or measure that quote again before going on"
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),
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)
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# Rounded once, here, so the stored value is exactly the one the verdict
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# above was computed on - calculate_pass_fail rounds internally too, but
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# matching it here keeps the persisted row from disagreeing with itself.
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value = round(value, 6)
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pass_fail, deviation = calculate_pass_fail(value, subtask)
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measurement = Measurement(
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subtask_id=subtask_id,
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version_id=version_id,
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measured_by=measured_by,
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value=value,
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pass_fail=pass_fail,
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deviation=deviation,
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lot_number=lot_number,
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serial_number=serial_number,
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input_method=input_method,
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input_duration_ms=input_duration_ms,
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production_run_id=production_run_id,
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vision_result_id=vision_result_id,
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)
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db.add(measurement)
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await db.flush()
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await db.refresh(measurement)
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return measurement
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