production-analytics/tests/test_channel_material.py

from datetime import UTC, datetime, timedelta
from pathlib import Path
from unittest.mock import Mock

import pytest

from production_analytics.calculations.channel_config import load_channel_material_calculation
from production_analytics.calculations.channel_material import (
    MATERIAL_AMBIGUOUS,
    MATERIAL_UNAVAILABLE,
    DosingChannelSample,
    channel_rates,
    validate_active_percentage_sum,
)
from production_analytics.enlyze.gateway import EnlyzeApiGateway, EnlyzeProductionRun
from production_analytics.service.channel_material import (
    ChannelDefinition,
    ChannelMaterialPollingService,
)
from production_analytics.service.channel_material_state_store import JsonChannelMaterialStateStore

NOW = datetime(2026, 9, 1, tzinfo=UTC)
E1_CONFIG = (
    Path(__file__).resolve().parents[1] / "config/e1-channel-material-consumption.example.yaml"
)


def sample(*, on=True, percent=100, material=None, timestamp=NOW):
    return DosingChannelSample(timestamp, 120, on, percent, 10, material)


def test_off_channel_with_nonzero_displayed_percentage_contributes_zero():
    assert channel_rates((sample(on=False, percent=40),))[0].sample.material_rate_kg_per_hour == 0


def test_e1_config_dry_run_resolves_every_signal_through_gateway_without_sampling():
    config = load_channel_material_calculation(E1_CONFIG)
    origins = {
        reference
        for channel in config.channels
        for reference in (
            channel.total_rate_signal_ref,
            channel.status_signal_ref,
            channel.percentage_signal_ref,
            channel.screw_speed_signal_ref,
        )
    }
    client = Mock()
    client.get.return_value.body = {
        "data": [
            {
                "uuid": f"variable-{index}",
                "details": {"origin_identifier": {"code": origin}},
            }
            for index, origin in enumerate(sorted(origins))
        ]
    }

    resolved = EnlyzeApiGateway(client).resolve_dosing_channel_signal_refs(
        machine_id=config.machine_ref,
        channels=config.channels,
    )

    assert config.machine_ref == "8302e3d1-b1e5-42f1-8540-615eb6c73e08"
    assert len(config.channels) == 14
    assert len(origins) == 44
    assert len(resolved) == 14
    assert all(len(refs) == 5 and refs[-1] is None for refs in resolved.values())
    client.get.assert_called_once_with("/v2/variables", {"machine": config.machine_ref})
    client.post_json.assert_not_called()


def test_active_percentages_sum_to_100_and_deviation_is_reported_not_normalized():
    active = (sample(percent=40), sample(percent=60))
    assert validate_active_percentage_sum(active, tolerance=0.1)
    assert not validate_active_percentage_sum(
        (sample(percent=40), sample(percent=50)), tolerance=0.1
    )
    assert [x.sample.material_rate_kg_per_hour for x in channel_rates(active)] == [48, 72]


def test_null_and_duplicate_material_assignments_are_not_inferred():
    assert (
        channel_rates((sample(material=None),))[0].material_mapping_status == MATERIAL_UNAVAILABLE
    )
    rates = channel_rates((sample(material="123"), sample(material="123")))
    assert all(rate.material_mapping_status == MATERIAL_AMBIGUOUS for rate in rates)
    assert all(rate.material_number is None and rate.material_name is None for rate in rates)


def test_run_change_and_json_restart_preserve_channel_total(tmp_path):
    channels = (ChannelDefinition("Ex1", "C1", "rate", "on", "pct", "rpm"),)
    store, gateway = JsonChannelMaterialStateStore(tmp_path), Mock()
    gateway.get_production_runs.return_value = []
    gateway.get_open_production_run.return_value = EnlyzeProductionRun(
        "r1", "m", None, "order", NOW, None
    )
    key = "C1\0Ex1"
    gateway.get_dosing_channel_samples.return_value = {
        key: [sample(timestamp=NOW), sample(timestamp=NOW + timedelta(seconds=10))]
    }
    first = ChannelMaterialPollingService(
        gateway=gateway,
        state_store=store,
        machine_id="m",
        channels=channels,
        max_sample_gap_seconds=20,
    )
    assert first.poll_once(now=NOW + timedelta(seconds=10))[
        0
    ].state.cumulative_consumption_kg == pytest.approx(10 / 30)
    gateway.get_open_production_run.return_value = EnlyzeProductionRun(
        "r2", "m", None, "order", NOW + timedelta(seconds=20), None
    )
    gateway.get_dosing_channel_samples.return_value = {
        key: [
            sample(timestamp=NOW + timedelta(seconds=20)),
            sample(timestamp=NOW + timedelta(seconds=30)),
        ]
    }
    restarted = ChannelMaterialPollingService(
        gateway=gateway,
        state_store=store,
        machine_id="m",
        channels=channels,
        max_sample_gap_seconds=20,
    )
    assert restarted.poll_once(now=NOW + timedelta(seconds=30))[
        0
    ].state.cumulative_consumption_kg == pytest.approx(20 / 30)


def test_bootstrap_replays_closed_runs_without_integrating_the_inter_run_gap(tmp_path):
    channels = (ChannelDefinition("Ex1", "C1", "rate", "on", "pct", "rpm"),)
    closed = EnlyzeProductionRun("r1", "m", None, "order", NOW, NOW + timedelta(seconds=10))
    current = EnlyzeProductionRun("r2", "m", None, "order", NOW + timedelta(seconds=20), None)
    gateway = Mock()
    gateway.get_open_production_run.return_value = current
    gateway.get_production_runs.return_value = [closed, current]
    key = "C1\0Ex1"
    gateway.get_dosing_channel_samples.side_effect = [
        {key: [sample(timestamp=NOW), sample(timestamp=NOW + timedelta(seconds=10))]},
        {
            key: [
                sample(timestamp=NOW + timedelta(seconds=20)),
                sample(timestamp=NOW + timedelta(seconds=30)),
            ]
        },
    ]
    result = ChannelMaterialPollingService(
        gateway=gateway,
        state_store=JsonChannelMaterialStateStore(tmp_path),
        machine_id="m",
        channels=channels,
        max_sample_gap_seconds=20,
    ).poll_once(now=NOW + timedelta(seconds=30))
    assert result is not None
    assert result[0].state.cumulative_consumption_kg == pytest.approx(20 / 30)