Add central material calibration support
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from datetime import UTC, datetime, timedelta
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from pathlib import Path
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from unittest.mock import MagicMock, Mock
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import psycopg
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import pytest
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import yaml
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from production_analytics.calculations.config import (
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CalculationConfigError,
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load_material_calculation,
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)
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from production_analytics.calculations.material_application import rotational_application_g_m2
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from production_analytics.calculations.material_consumption import MaterialSample
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from production_analytics.enlyze.gateway import EnlyzeApiGateway, EnlyzeProductionRun
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from production_analytics.service.material_polling import MaterialPollingService
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from production_analytics.service.postgres_material import PostgresSettings
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from production_analytics.service.postgres_material_application import (
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PostgresMaterialApplicationWriter,
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)
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NOW = datetime(2026, 9, 7, tzinfo=UTC)
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def test_realistic_application_and_generic_factor():
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assert rotational_application_g_m2([3.739, 3.956], 3.12, 8, 0.3) == pytest.approx(3001.05)
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assert rotational_application_g_m2([2, 3], 1.5, 10, 0.5) == 750
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@pytest.mark.parametrize('speed', [-10, 0, 1e-300, 0.299999999, 0.3])
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def test_inactive_and_near_zero(speed):
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assert rotational_application_g_m2([3.739, 3.956], 3.12, speed, 0.3) is None
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@pytest.mark.parametrize('speeds,factor,speed,threshold', [
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([], 3.12, 8, 0.3), ([float('nan')], 3.12, 8, 0.3),
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([1], 0, 8, 0.3), ([1], float('inf'), 8, 0.3),
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([1], 3.12, float('nan'), 0.3), ([1], 3.12, 8, 0),
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([1], 3.12, 8, float('inf')), ([1e308], 3.12, 8, 0.3),
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])
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def test_invalid_inputs(speeds, factor, speed, threshold):
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with pytest.raises(ValueError):
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rotational_application_g_m2(speeds, factor, speed, threshold)
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@pytest.mark.parametrize('width', [1, 4.85, 5, 100])
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def test_gateway_width_cancels_and_only_act_signals_requested(width):
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config = load_material_calculation('config/bento1-material-consumption.yaml')
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refs = [*config.rotational_speed_signal_refs, config.gate_signal_ref]
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client = Mock()
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client.post_json.return_value.body = {'data': {
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'columns': ['time', *refs],
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'records': [[NOW.isoformat(), 3.739, 3.956, 8],
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[(NOW + timedelta(seconds=10)).isoformat(), 3.739, 3.956, 0]],
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}}
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samples = EnlyzeApiGateway(client).get_material_samples(
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machine_id=config.machine_ref, rate_variable_id='unused',
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gate_variable_id=config.gate_signal_ref, start=NOW, end=NOW + timedelta(seconds=10),
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rotational_speed_variable_ids=config.rotational_speed_signal_refs,
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nominal_width_m=width, specific_discharge_kg_per_rev_m=3.12,
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process_application_gate_threshold=0.3,
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)
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assert samples[0].application_g_m2 == pytest.approx(3001.05)
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assert samples[1].application_g_m2 is None
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assert samples[0].material_rate_kg_per_hour == pytest.approx(7.695 * width * 3.12 * 60)
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assert client.post_json.call_args.args[1]['variables'] == [{'uuid': ref} for ref in refs]
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@pytest.mark.parametrize('changes', [
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{'process_application_calculation_id': ''}, {'process_application_calculation_id': None},
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{'process_application_calculation_id': 3}, {'process_application_calculation_id': 'x\x00'},
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{'process_application_calculation_id': 'bento1-fresh-bentonite-consumption'},
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{'gate_signal_ref': None}, {'gate_threshold': 0}, {'gate_threshold': -0.3},
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])
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def test_process_config_validation(tmp_path, changes):
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document = yaml.safe_load(Path('config/bento1-material-consumption.yaml').read_text())
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document['calculations'][0].update(changes)
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path = tmp_path / 'config.yaml'
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path.write_text(yaml.safe_dump(document))
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with pytest.raises(CalculationConfigError):
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load_material_calculation(path)
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def test_persistence_before_checkpoint_retries_and_disjoint_runs():
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old = EnlyzeProductionRun('old', 'machine', None, 'order', NOW, NOW + timedelta(seconds=10))
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current = EnlyzeProductionRun(
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'new', 'machine', None, 'order', NOW + timedelta(seconds=15), None,
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)
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gateway = Mock()
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gateway.get_open_production_run.return_value = current
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gateway.get_production_runs.return_value = [old, current]
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def samples(**kwargs):
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start = kwargs['start']
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assert kwargs['process_application_gate_threshold'] == 0.3
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return [MaterialSample(start, 7202.52, 8, 3001.05),
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MaterialSample(start + timedelta(seconds=10), 7202.52, 8, 3001.05)]
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gateway.get_material_samples.side_effect = samples
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store = Mock(load=Mock(return_value=None))
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writer = Mock()
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writer.write.side_effect = [None, psycopg.OperationalError(), None, None]
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service = MaterialPollingService(
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gateway=gateway, state_store=store, machine_id='machine', rate_variable_id='unused',
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gate_variable_id='speed', gate_threshold=0.3, max_sample_gap_seconds=20,
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rotational_speed_variable_ids=('right', 'left'), specific_discharge_kg_per_rev_m=3.12,
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nominal_width_provider=lambda order: 5, process_application_calculation_id='application',
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application_writer=writer,
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)
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with pytest.raises(psycopg.OperationalError):
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service.poll_once(now=NOW + timedelta(seconds=25))
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store.save.assert_not_called()
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result = service.poll_once(now=NOW + timedelta(seconds=25))
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assert result.state.cumulative_consumption_kg == pytest.approx(40.014)
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assert result.state.integrated_running_seconds == 20
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assert [c.kwargs['run_id'] for c in writer.write.call_args_list] == ['old', 'new', 'old', 'new']
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store.save.assert_called_once()
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def test_sql_persistence_idempotent_and_inactive_omitted(monkeypatch):
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import sqlite3
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database = sqlite3.connect(':memory:')
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database.executescript(Path('db/schema.sql').read_text())
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connection = MagicMock()
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cursor = connection.__enter__.return_value.cursor.return_value.__enter__.return_value
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cursor.executemany.side_effect = lambda sql, rows: database.executemany(
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sql.replace('%s', '?'),
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[(row[0].isoformat(), *row[1:]) for row in rows],
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)
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connect = Mock(return_value=connection)
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monkeypatch.setattr(psycopg, 'connect', connect)
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writer = PostgresMaterialApplicationWriter(PostgresSettings('host', 5432, 'db', 'u', 'p'))
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kwargs = dict(calculation_id='application', machine_id='machine', production_order='order',
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run_id='run', samples=[MaterialSample(NOW, 7202.52, 8, 3001.05),
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MaterialSample(NOW + timedelta(seconds=10), 7202.52, 0)])
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writer.write(**kwargs)
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writer.write(**kwargs)
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assert database.execute('SELECT * FROM material_application_snapshots').fetchall() == [
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(NOW.isoformat(), 'application', 'machine', 'order', 'run', 3001.05),
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]
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writer.write(**(kwargs | {'samples': [MaterialSample(NOW, 1, 0)]}))
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assert connect.call_count == 2
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database.close()
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@pytest.mark.parametrize('collision', ['output', 'consumption'])
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def test_output_ids_unique_across_config_entries(tmp_path, collision):
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document = yaml.safe_load(Path('config/bento1-material-consumption.yaml').read_text())
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first = document['calculations'][0]
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second = dict(first, id='second-consumption')
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if collision == 'consumption':
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second['process_application_calculation_id'] = first['id']
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document['calculations'].append(second)
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path = tmp_path / 'config.yaml'
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path.write_text(yaml.safe_dump(document))
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with pytest.raises(CalculationConfigError, match='unique'):
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load_material_calculation(path, first['id'])
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