bj_power/bj_power_mes/internal/logic/workpiece.go

package logic

import (
	"context"
	"errors"
	"strconv"
	"strings"
	"time"

	"bj_power_mes/ent"
	"bj_power_mes/ent/associationtrace"
	"bj_power_mes/ent/processstep"
	"bj_power_mes/ent/station"
	"bj_power_mes/ent/stepcriterion"
	"bj_power_mes/ent/stepdata"
	"bj_power_mes/ent/torquerecord"
	"bj_power_mes/ent/workorder"
	"bj_power_mes/ent/workpiece"
	"bj_power_mes/ent/workpieceprocess"
)

func itoa(n int) string { return strconv.Itoa(n) }
func processName(code int) string {
	names := map[int]string{1: "装配一", 2: "装配二", 3: "装配三", 4: "装配四", 5: "装配五", 6: "装配六", 7: "装配七", 8: "装配八", 9: "装配九", 10: "装配十", 11: "装配十一", 12: "装配十二"}
	if n, ok := names[code]; ok {
		return n
	}
	return "工位" + itoa(code)
}

// evalLogic 依据考核逻辑判定
func evalLogic(c *ent.StepCriterion, v float64) bool {
	switch c.Logic {
	case "GE":
		return v >= c.Target
	case "LE":
		return v <= c.Target
	case "GT":
		return v > c.Target
	case "LT":
		return v < c.Target
	case "RANGE":
		l, r := true, true
		if c.Min != nil {
			l = v >= *c.Min
		}
		if c.Max != nil {
			r = v <= *c.Max
		}
		return l && r
	case "EQUAL":
		return v == c.Target
	default:
		return true
	}
}

type StepDataReq struct {
	StepId int     `json:"stepId"`
	Name   string  `json:"name"`
	Value  float64 `json:"value"`
	Text   string  `json:"text"`
	// Checked：该步骤是否已完成「检测确认」。needCheck=true 的步骤必须为 true，服务端强校验，防止绕过前端。
	Checked bool `json:"checked"`
}

type OnlineReq struct {
	Sn          string `json:"sn"`
	OrderNo     string `json:"orderNo"`
	WorkOrderId int    `json:"workOrderId"`
	ProcessSeq  string `json:"processSeq"`
}

// OnlineWorkpiece 工件进线登记
func (s *Service) OnlineWorkpiece(ctx context.Context, req OnlineReq, operator string) error {
	if req.Sn == "" {
		return errors.New("sn 不能为空")
	}
	seq := req.ProcessSeq
	if seq == "" {
		seq = FullProcessSeq
	}
	if req.WorkOrderId == 0 {
		if wo, err := s.ctx.EntClient.WorkOrder.Query().Where(workorder.WorkOrderNo(req.OrderNo)).First(ctx); err == nil {
			req.WorkOrderId = wo.ID
			if req.ProcessSeq == "" && wo.ProcessSeq != "" {
				seq = wo.ProcessSeq
			}
		}
	}
	seq = NormalizeProcessSeq(seq)
	err := s.ctx.EntClient.Workpiece.Create().
		SetSn(req.Sn).SetOrderNo(req.OrderNo).SetWorkOrderId(req.WorkOrderId).
		SetProcessSeq(seq).SetStatus("ONLINE").SetOnlineAt(time.Now()).Exec(ctx)
	if err != nil {
		return err
	}
	s.ctx.EventLog.Write(ctx, "workpiece.online", req.OrderNo, operator, "workpiece", req.Sn, "工件进线登记", nil)
	s.notifyDashboard()
	return nil
}

type ReportProcessReq struct {
	Sn          string        `json:"sn"`
	ProcessCode int           `json:"processCode"`
	StationNo   int           `json:"stationNo"`
	Steps       []StepDataReq `json:"steps"`
	Binds       []BindItemReq `json:"binds"` // 装机绑定（本工序装配物料：结构件批次/电气件SN），随报工原子提交
	// 作业时长采集（方案 M / P0-3）：工位终端在「上料到本工位」时采 startedAt、点「报工」时采 endedAt，
	// 两端时间戳同源于终端时钟（ISO8601），离线重传也不失真；缺失则回退服务端当前时刻（时长=0）。
	StartedAt string `json:"startedAt"`
	EndedAt   string `json:"endedAt"`
}

// parseClientTime 解析工位终端上报的 ISO8601 时间戳（兼容带/不带毫秒、Z/时区偏移）。
func parseClientTime(s string) (time.Time, error) {
	s = strings.TrimSpace(s)
	if s == "" {
		return time.Time{}, errors.New("empty time")
	}
	layouts := []string{time.RFC3339Nano, time.RFC3339, "2006-01-02T15:04:05", "2006-01-02 15:04:05"}
	for _, l := range layouts {
		if t, err := time.Parse(l, s); err == nil {
			return t, nil
		}
	}
	return time.Time{}, errors.New("unrecognized time format: " + s)
}

// ReportProcess 工位报工：先应用装机绑定并做强校验（齐套才放行），再写报工实绩 + 步骤考核。
// 绑料是"落到工艺流程"的强约束：产品 BOM 中标记为本工序(processCode)的物料必须绑齐，
// 电气件按单台用量逐颗SN、结构件至少一个批次号；缺料直接拒绝报工并返回缺料清单。
func (s *Service) ReportProcess(ctx context.Context, req ReportProcessReq, operator string) error {
	if req.Sn == "" || req.ProcessCode == 0 {
		return errors.New("sn 与 processCode 必填")
	}
	wp, err := s.ctx.EntClient.Workpiece.Query().Where(workpiece.Sn(req.Sn)).First(ctx)
	if err != nil {
		return errors.New("工件未进线登记")
	}
	// 报工是"装机绑定→校验齐套→写实绩→写步骤考核→回写结果/工件状态"的多步写，必须整体事务化（方案 U3）：
	// 任一步失败全部回滚，杜绝"实绩已建但工件状态没推进/结果没落"的半成品脏数据；
	// 校验（齐套/needCheck）也走同一 tx client，才能读到本事务内刚写入的绑定。
	tx, err := s.ctx.EntClient.Tx(ctx)
	if err != nil {
		return err
	}
	committed := false
	defer func() {
		if !committed {
			_ = tx.Rollback()
		}
	}()
	client := tx.Client()
	// 阶段1：装机绑定（随报工提交）→ 落库后强校验齐套
	stationNo := ""
	if req.StationNo > 0 {
		stationNo = itoa(req.StationNo)
	}
	if _, err := s.applyBinds(ctx, client, req.Sn, wp.OrderNo, req.ProcessCode, stationNo, operator, req.Binds); err != nil {
		return err
	}
	if miss, err := s.validateStationBinds(ctx, client, req.Sn, req.ProcessCode); err != nil {
		return err
	} else if miss != "" {
		return errors.New(miss)
	}
	// 阶段2：检测确认（needCheck）强校验——服务端为准，前端勾选只是辅助提示。
	// 本工位绑定工艺流程中标记“需要检测确认”的步骤，报工数据里必须逐条带 checked=true，否则拒绝报工。
	if err := s.validateNeedCheck(ctx, client, req); err != nil {
		return err
	}
	now := time.Now()
	// 作业时长（方案 M / P0-3）：startedAt=进工位(上料)时刻、endedAt=报工时刻，均由工位终端采集；
	// 缺失或非法则回退到服务端当前时刻（durationSec=0），时钟回拨导致负数则时长归零。
	startedAt, endedAt := now, now
	if t, e := parseClientTime(req.StartedAt); e == nil {
		startedAt = t
	}
	if t, e := parseClientTime(req.EndedAt); e == nil {
		endedAt = t
	}
	durationSec := int(endedAt.Sub(startedAt).Seconds())
	if durationSec < 0 {
		durationSec = 0
		endedAt = startedAt
	}
	proc, err := client.WorkpieceProcess.Create().
		SetSn(req.Sn).SetProcessCode(req.ProcessCode).
		SetStationNo(itoa(req.StationNo)).SetOrderNo(wp.OrderNo).
		SetProcessName(processName(req.ProcessCode)).
		SetStatus("DONE").SetOperator(operator).SetResult("OK").
		SetStartedAt(startedAt).SetEndedAt(endedAt).SetDurationSec(durationSec).Save(ctx)
	if err != nil {
		return err
	}

	allOK := true
	for _, st := range req.Steps {
		ok, e := s.writeStepData(ctx, client, req.Sn, proc.ID, st, operator)
		if e != nil {
			return e
		}
		if !ok {
			allOK = false
		}
	}
	if bad, e := client.StepData.Query().
		Where(stepdata.ProcessId(proc.ID), stepdata.IsOK(false)).Exist(ctx); e != nil {
		return e
	} else if bad {
		allOK = false
	}
	result := "OK"
	if !allOK {
		result = "NG"
	}
	if _, err := client.WorkpieceProcess.UpdateOneID(proc.ID).SetResult(result).Save(ctx); err != nil {
		return err
	}
	if _, err := client.Workpiece.UpdateOneID(wp.ID).
		SetCurrentProcess(req.ProcessCode).SetStatus("PROCESSING").Save(ctx); err != nil {
		return err
	}
	if err := tx.Commit(); err != nil {
		return err
	}
	committed = true

	s.ctx.EventLog.Write(ctx, "workpiece.process.report", wp.OrderNo, operator, "workpiece", req.Sn,
		"工位报工", map[string]any{"processCode": req.ProcessCode, "result": result})
	s.notifyDashboard()
	return nil
}

// validateNeedCheck 检测确认（needCheck）服务端强校验。
// 规则：本工位绑定的工艺流程中，凡标记 needCheck=true 的工艺步骤，
// 报工请求里必须存在对应 stepId 且 checked=true 的步骤数据；缺失则拒绝报工。
// 工位未绑定流程、或流程内没有 needCheck 步骤时不拦截（与现场配置保持一致）。
func (s *Service) validateNeedCheck(ctx context.Context, client *ent.Client, req ReportProcessReq) error {
	if req.StationNo <= 0 {
		return nil
	}
	st, err := client.Station.Query().Where(station.StationNo(req.StationNo)).First(ctx)
	if err != nil || st.FlowId <= 0 {
		return nil
	}
	steps, err := client.ProcessStep.Query().
		Where(processstep.FlowId(st.FlowId), processstep.NeedCheck(true)).All(ctx)
	if err != nil || len(steps) == 0 {
		return nil
	}
	checked := map[int]bool{}
	for _, sd := range req.Steps {
		if sd.Checked {
			checked[sd.StepId] = true
		}
	}
	missing := make([]string, 0, len(steps))
	for _, ps := range steps {
		if !checked[ps.ID] {
			name := ps.Name
			if name == "" {
				name = "步骤" + itoa(ps.ID)
			}
			missing = append(missing, name)
		}
	}
	if len(missing) > 0 {
		return errors.New("以下步骤需先完成检测确认后方可报工：" + strings.Join(missing, "、"))
	}
	return nil
}

// writeStepData 写一条步骤考核数据，按标准自动判定是否合格
func (s *Service) writeStepData(ctx context.Context, client *ent.Client, sn string, processId int, st StepDataReq, operator string) (bool, error) {
	ok := true
	crits, err := client.StepCriterion.Query().Where(stepcriterion.StepId(st.StepId)).All(ctx)
	if err != nil {
		return false, err
	}
	for _, c := range crits {
		if !evalLogic(c, st.Value) {
			ok = false
		}
	}
	var cname, clogic string
	cid := 0
	if len(crits) > 0 {
		cname = crits[0].Name
		clogic = crits[0].Logic
		cid = crits[0].ID
	}
	_, err = client.StepData.Create().
		SetSn(sn).SetProcessId(processId).SetStepId(st.StepId).
		SetStepName(st.Name).SetCriterionId(cid).SetCriterionName(cname).
		SetCriterionLogic(clogic).SetValue(st.Value).SetValueText(st.Text).
		SetIsOK(ok).SetOperator(operator).Save(ctx)
	return ok, err
}

// DoneReq 完工 + 成品关联追溯
type DoneReq struct {
	Sn          string   `json:"sn"`
	BatchItems  []string `json:"batchItems"`  // 结构件批次号
	SerialItems []string `json:"serialItems"` // 电气件SN
}

// DoneWorkpiece 完工：先兜底校验全部工序装配物料齐套（工艺流程强校验），再登记成品并生成关联追溯
func (s *Service) DoneWorkpiece(ctx context.Context, req DoneReq, operator string) error {
	wp, err := s.ctx.EntClient.Workpiece.Query().Where(workpiece.Sn(req.Sn)).First(ctx)
	if err != nil {
		return errors.New("工件不存在")
	}
	// 兜底强校验：工艺路线中每个工序的装配物料都须绑齐（BOM 未配置工序时自动放行）
	if miss, err := s.validateAllProcessBinds(ctx, s.ctx.EntClient, req.Sn); err != nil {
		return err
	} else if miss != "" {
		return errors.New("完工前必须绑齐全部装配物料：" + miss)
	}
	now := time.Now()
	_, _ = s.ctx.EntClient.Workpiece.UpdateOneID(wp.ID).
		SetStatus("DONE").SetDoneAt(now).Save(ctx)

	existID, _ := s.ctx.EntClient.AssociationTrace.Query().
		Where(associationtrace.FinishedSn(req.Sn)).FirstID(ctx)
	if existID > 0 {
		_, _ = s.ctx.EntClient.AssociationTrace.UpdateOneID(existID).
			SetBatchItems(req.BatchItems).SetSerialItems(req.SerialItems).SetOperator(operator).Save(ctx)
	} else {
		_, err = s.ctx.EntClient.AssociationTrace.Create().
			SetFinishedSn(req.Sn).SetOrderNo(wp.OrderNo).SetProcessCode(wp.ProcessSeq).
			SetBatchItems(req.BatchItems).SetSerialItems(req.SerialItems).
			SetOperator(operator).Save(ctx)
		if err != nil {
			return err
		}
	}
	s.bumpWorkOrderProgress(ctx, wp.OrderNo, req.Sn)
	s.bumpDailyPlanCompleted(ctx, wp.OrderNo, now)
	s.ctx.EventLog.Write(ctx, "workpiece.done", wp.OrderNo, operator, "workpiece", req.Sn, "完工+关联追溯", map[string]any{"batchItems": req.BatchItems, "serialItems": req.SerialItems})
	// 成品完工自动回流 WMS（统一库存主表 category=3）：
	// 成品 SN = 工件 SN（进线登记即系统发号，全程唯一，保证对号可追溯）。
	// WMS 不可达/校验失败时降级：记 eventlog 不阻塞完工，与备料 WMS 校验降级策略同模式。
	s.retainFinishedToWms(ctx, wp, operator)
	s.notifyDashboard()
	return nil
}

// retainFinishedToWms 完工品回流 WMS 库存。失败仅记日志（wms.finished.retain_failed），
// 不回滚完工状态——仓管可在 WMS 侧人工补录，避免 WMS 抖动卡死产线。
func (s *Service) retainFinishedToWms(ctx context.Context, wp *ent.Workpiece, operator string) {
	wo, err := s.ctx.EntClient.WorkOrder.Get(ctx, wp.WorkOrderId)
	if err != nil || wo == nil {
		s.ctx.EventLog.Write(ctx, "wms.finished.retain_failed", wp.OrderNo, operator, "workpiece", wp.Sn,
			"成品回流WMS失败：工单不存在", map[string]any{"error": "work order not found"})
		return
	}
	if wmsErr := s.ctx.Wms.FinishedInbound(ctx, wo.ProductCode, wo.ProductName, wp.Sn, wp.OrderNo, operator); wmsErr != nil {
		s.ctx.EventLog.Write(ctx, "wms.finished.retain_failed", wp.OrderNo, operator, "workpiece", wp.Sn,
			"成品回流WMS失败（库存未入，请人工补录）", map[string]any{"error": wmsErr.Error(), "productCode": wo.ProductCode})
		return
	}
	s.ctx.EventLog.Write(ctx, "wms.finished.retain", wp.OrderNo, operator, "workpiece", wp.Sn,
		"成品完工已回流WMS库存", map[string]any{"productCode": wo.ProductCode})
}

// Trace 追溯查询（SN 维度）：工序时间线/操作人/步骤数据/物料批次SN/拧紧数据
func (s *Service) Trace(ctx context.Context, sn string) (map[string]any, error) {
	wp, err := s.ctx.EntClient.Workpiece.Query().Where(workpiece.Sn(sn)).First(ctx)
	if err != nil {
		return nil, errors.New("该SN无追溯数据")
	}
	procList, _ := s.ctx.EntClient.WorkpieceProcess.Query().
		Where(workpieceprocess.Sn(sn)).Order(ent.Asc(workpieceprocess.FieldProcessCode)).All(ctx)
	steps, _ := s.ctx.EntClient.StepData.Query().
		Where(stepdata.Sn(sn)).Order(ent.Desc(stepdata.FieldID)).All(ctx)
	assoc, _ := s.ctx.EntClient.AssociationTrace.Query().
		Where(associationtrace.FinishedSn(sn)).First(ctx)
	torque, _ := s.ctx.EntClient.TorqueRecord.Query().
		Where(torquerecord.Sn(sn)).Order(ent.Desc(torquerecord.FieldTime)).Limit(200).All(ctx)
	bindVO, _ := s.BuildBindTrace(ctx, sn)

	return map[string]any{
		"workpiece":        wp,
		"processTimeline":  procList,
		"stepData":         steps,
		"associationTrace": assoc,
		"torqueRecords":    torque,
		"bindTrace":        bindVO,
	}, nil
}

func (s *Service) ListWorkpieces(ctx context.Context, sn, orderNo string) ([]*ent.Workpiece, error) {
	q := s.ctx.EntClient.Workpiece.Query()
	if sn != "" {
		q = q.Where(workpiece.SnContains(sn))
	}
	if orderNo != "" {
		q = q.Where(workpiece.OrderNo(orderNo))
	}
	return q.Order(ent.Desc(workpiece.FieldID)).Limit(500).All(ctx)
}

// InProcessItem 在制品（已进线未完工）视图项。跨天工件继续停留，日排产不重复排。
type InProcessItem struct {
	Sn                string `json:"sn"`
	OrderNo           string `json:"orderNo"`
	ProductCode       string `json:"productCode"`
	ProductName       string `json:"productName"`
	CurrentStation    int    `json:"currentStation"`    // 0=上线位, 13=下线位, 其余为物理工位
	CurrentStationName string `json:"currentStationName"` // 工位显示名（上线位/下线位/装配X）
	Status            string `json:"status"`
	OnlineAt          string `json:"onlineAt"`
	DwellSec          int64  `json:"dwellSec"` // 停留时长（秒），自进线起算
	DoneSteps         int    `json:"doneSteps"`
	TotalSteps        int    `json:"totalSteps"`
}

// WorkpiecesInProcess 列出停在各工位、尚未完工的在制品（ONLINE/PROCESSING/REPAIR）。
// stationNo<=0 返回全部；stationNo>0 仅返回当前停在该工位（0=上线位, 13=下线位）的工件。
// 已进线未完工的工件跨天继续，日排产仅排「未开工数量」，不会重复排产。
func (s *Service) WorkpiecesInProcess(ctx context.Context, stationNo int) ([]InProcessItem, error) {
	list, err := s.ctx.EntClient.Workpiece.Query().
		Where(workpiece.Or(
			workpiece.Status("ONLINE"),
			workpiece.Status("PROCESSING"),
			workpiece.Status("REPAIR"),
		)).
		Order(ent.Desc(workpiece.FieldOnlineAt)).All(ctx)
	if err != nil {
		return nil, err
	}
	out := make([]InProcessItem, 0, len(list))
	for _, wp := range list {
		seq := ParseProcessSeq(wp.ProcessSeq)
		if len(seq) == 0 {
			seq = ParseProcessSeq(FullProcessSeq)
		}
		maxStation := 0
		for _, c := range seq {
			if c > maxStation {
				maxStation = c
			}
		}
		// 推算当前物理工位：ONLINE 在 上线位(0)；PROCESSING 且已到末端 → 下线位(13)
		cur := 0
		if wp.Status == "PROCESSING" || wp.Status == "REPAIR" {
			cp := wp.CurrentProcess
			if cp <= 0 {
				cp = maxStation
			}
			if cp >= maxStation && wp.Status == "PROCESSING" {
				cur = 13
			} else {
				cur = cp
			}
		}
		if stationNo > 0 && cur != stationNo {
			continue
		}
		dwell := int64(0)
		var onlineAt string
		if wp.OnlineAt != nil {
			dwell = int64(time.Since(*wp.OnlineAt).Seconds())
			onlineAt = wp.OnlineAt.Format("2006-01-02 15:04:05")
		}
		done := 0
		if procs, e := s.ctx.EntClient.WorkpieceProcess.Query().
			Where(workpieceprocess.Sn(wp.Sn), workpieceprocess.Status("DONE")).Count(ctx); e == nil {
			done = procs
		}
		code, name := "", ""
		if wp.WorkOrderId > 0 {
			if wo, e := s.ctx.EntClient.WorkOrder.Get(ctx, wp.WorkOrderId); e == nil {
				code, name = wo.ProductCode, wo.ProductName
			}
		}
		if code == "" && wp.OrderNo != "" {
			if wo, e := s.ctx.EntClient.WorkOrder.Query().Where(workorder.WorkOrderNo(wp.OrderNo)).First(ctx); e == nil {
				code, name = wo.ProductCode, wo.ProductName
			}
		}
		stName := stationDisplayName("", cur)
		if cur == 0 {
			stName = "上线位(虚拟)"
		} else if cur == 13 {
			stName = "下线位(虚拟)"
		}
		out = append(out, InProcessItem{
			Sn:                wp.Sn,
			OrderNo:           wp.OrderNo,
			ProductCode:       code,
			ProductName:       name,
			CurrentStation:    cur,
			CurrentStationName: stName,
			Status:            wp.Status,
			OnlineAt:          onlineAt,
			DwellSec:          dwell,
			DoneSteps:         done,
			TotalSteps:        len(seq),
		})
	}
	return out, nil
}