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HC_APTBS/docs/gap-pump-data-migration.md
LucianoDev c617854c09 feat: implement SavePump/SaveAlarms, fix config round-trip bugs, redesign PDF reports 
Config system fixes:
- Implement SavePump() — full XML serialization with insert/update by pump ID
- Add CanBusParameter.ToPumpXml() for legacy P1-P6 pump param format
- Fix LastRotationDirection never loaded in LoadSettings()
- Add SaveAlarms() to ConfigurationService and IConfigurationService
- Remove dead fields AppSettings.Clients and AppSettings.PumpIds

PDF report redesign:
- Professional layout with charts, verdict badges, and tolerance bands
- Add ReportChartRenderer (SVG) and ReportTheme styling constants
- Embed default_logo.png as fallback report logo

Documentation:
- Add gap analysis docs (config validation, ford unlock, missing features)
- Update CLAUDE.md architecture, known gaps, and debt tracking

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-04-15 15:21:22 +02:00

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# Gap: Pump Data Migration (Old CFG/TXT → New XML)
## Overview
The old system had 32 CFG files (Bosch PSG format), 117 test plan TXT files, and reference data files that were processed by `HerlicScripts/Program.cs` into an encrypted `data.herlic` pump database. The new system uses `pumps.xml` (plain XML). This document maps every old data field to its new equivalent and identifies what cannot be migrated.
## Source Files
- `old_source/HerlicScripts/CFGs/*.CFG` — 32 pump config files
- `old_source/HerlicScripts/TestPlansLargos/*.txt` — 117 test plan files
- `old_source/HerlicScripts/AngulosDeBloqueo.txt` — Lock angle reference (114 entries)
- `old_source/HerlicScripts/AvanceInyeccion.txt` — Injection advance CAN data
- `old_source/HerlicScripts/ListadoBombas.txt` — Master pump database (108 pumps)
- `old_source/HerlicScripts/PreDatos.txt` / `PosDatos.txt` — XML header/footer templates
- `old_source/HerlicScripts/Program.cs` — Migration tool source
## CFG Families
| Family | CFGs | Description | KENNUNG |
|--------|------|-------------|---------|
| Type 1 | T06102, T062xx (21 files) | PSG2/5-Opel | 0 |
| Type 2 | T15xxx, T31804 (7 files) | PSG5-PI with pre-injection | 2 or 10 |
| Type 3 | T18xxx (3 files) | PSG5-PI-Ford | 6 |
| Type 4 | T06301 (1 file) | PSG5-FIEONA | 1 |
## Field Mapping: CFG → pumps.xml
### Fully Migrated (present in new PumpDefinition model)
| CFG Field | New Model Property | Notes |
|-----------|--------------------|-------|
| `ID-SEND1` | `ParametersByName[me/FBKW/mepi].MessageId` | TX message ID |
| `ID-EMPF1` | `ParametersByName[Status].MessageId` | RX status ID |
| `ID-EMPF2` | `ParametersByName[RPM/Temp].MessageId` | RX diagnostics ID |
| `ID-EMPF3` | `ParametersByName[Empf3].MessageId` | RX self-test ID |
| `CAN-MESOLL` P1-P6 | `CanBusParameter.P1-P6` | Fuel quantity formula |
| `CAN-FB-KW` P1-P6 | `CanBusParameter.P1-P6` | FBKW injection angle |
| `CAN-KW-N` P1-P6 | `CanBusParameter.P1-P6` | RPM formula |
| `CAN-THYBR` P1-P6 | `CanBusParameter.P1-P6` | Temperature formula |
| `CAN-BAUDRATE` | `PumpDefinition.CanBaudrate` | 500 or 250 kBaud |
| Lock angles | `PumpDefinition.LockAngle` | From AngulosDeBloqueo.txt |
| Rotation direction | `PumpDefinition.Rotation` | left/right |
| Pre-injection flag | `PumpDefinition.HasPreInjection` | Type 2/3 pumps |
| Unlock type | `PumpDefinition.UnlockType` | 0/1/2 |
| Test plans | `PumpDefinition.Tests` | From test plan TXT files |
### Partially Migrated (structure exists but data incomplete)
| CFG Field | New Model | Gap |
|-----------|-----------|-----|
| `CAN-STATUS*` bit definitions | `PumpStatusDefinition` in status.xml | Only display info (bit, state, color, description) migrated. **Missing:** reaction codes (0=none, 1=abort, 2=warning, 3=log), special function codes, special parameters |
| `CAN-PSGTEST*` self-test bits | `PumpStatusDefinition` | Same gap as above — no reaction/function codes |
| `CAN-MESOLL-PI` / `CAN-PHIAD-PI` | `CanBusParameter` for mepi | Formula exists but only if pump HasPreInjection |
### NOT Migrated (no equivalent in new model)
| CFG Field | Purpose | Impact |
|-----------|---------|--------|
| `PAS-EPROM-LES` | EPROM read password (4 bytes + scope) | KWP passwords now handled in KwpService code, not per-pump config. Currently only 3 hardcoded password versions (V1/V2/V3-V4). If a pump needs a different password, it can't be configured. |
| `PAS-EEPROM-LES/SCHREIB` | EEPROM read/write passwords | Same as above |
| `PAS-RAM-SCHREIB` | RAM write password | Same |
| `CAN-PASSWORT-EWS` | EWS immobilizer password | Always 0xFFFF in all CFGs (unused in practice) |
| `BIP-STATUS*` | Needle-motion detection (8 definitions with HEX pattern matching) | Entirely absent. Pre-injection pumps use BIP to verify injection timing. |
| `EMPFINDLICHKEIT` | Flow regulator sensitivity (dAD, measurement time, tolerance, max sensitivity, regulator current) | Not stored per-pump. Bench-level config only. |
| `EMPFINDLICHKEIT-2` | Flow regulator part 2 (dFM-Empf, Fehl-zul, Messzeit) | Same |
| `ADR-MV-SCHALTZEIT` | Solenoid valve switching time RAM address | Diagnostic addresses not per-pump |
| `ADR-F_TK_TE_W` | Temperature compensation switch address | Same |
| `ADR-TK_AT_W` | Dynamic temp compensation switch | Same |
| `ADR-SV-SOLL` / `ADR-SV-IST` | SV actuator target/actual addresses | Same |
| `ADR-TO_MV_600_HE` | MV pre-control value address | Same |
| `ADR-MV-T-ABGLEICH*` | MV time adjustment addresses | Same |
| `ADR-S_BIP_HW_UW` | BIP status address | Same |
| `ADR-ID-EMPF2-SENDEN` | EMPF2 auto-send control address | Same |
| `ADR-REL-CAN-SRC` | CAN source relative address | Same |
| `ADR-LERN-VERF` | Learning procedure switch | Same |
| `ADR-RESET` | PSG auto-reset address | Same |
| `BASISADR` | EEPROM base address table | Same |
| `CAN-BUS-KENNUNG` | Protocol variant code (0/1/2/6/10) | Derived implicitly from CAN IDs and UnlockType |
| `PHI-LUECKE-SYNCH` | Sync pulse angle offset | Not stored |
| `ATS-SERVICE` | Ford service CAN ID | Not stored separately |
| `KW_SIM_UMSCHALTUNG` | SV control/regulation switching debounce | Not stored |
| `MSG-KONFIGURATION` | Message config byte | Not stored |
| WTSS formulas (`N-NW`, `MESOLL`, `PHIAD`, `FB-NW`, `FB-KW`, `PHI1`, `FB-MASS`, `THYBR-OFFSET`) | Secondary scaling for WTSS transfer | Not stored |
## Status Bit Reaction Codes — Impact Assessment
The old CFGs defined per-bit reaction behavior:
- **Reaction 0:** No action (display only)
- **Reaction 1:** Abort test immediately
- **Reaction 2:** Show warning, continue
- **Reaction 3:** Log only
The new `PumpStatusDefinition` stores only display info (description + color). There is no mechanism to:
- Abort a test when a specific status bit asserts
- Show a warning for specific bits during test execution
- Differentiate between critical and informational bits per pump model
**Recommendation:** Add a `Reaction` property (int, 0-3) to `StatusBitValue` in `PumpStatusDefinition.cs`. Wire it into `BenchService` test execution to check active status bits against their reaction codes per phase.
## BIP-STATUS — Impact Assessment
BIP (Brennraumindikator-Prüfung / combustion indicator test) is a per-cylinder needle-motion detection system used on pre-injection VP44 pumps. The old system defined 6-7 BIP status conditions with HEX pattern matching (e.g., "BIP detected OK", "No BIP in capture window", "BIP deviation too large").
**Impact:** Without BIP status monitoring, pre-injection pump testing lacks validation that the injection nozzle is actually opening correctly. This is a diagnostic gap for Type 2 (T15xxx) and Type 3 (T18xxx) pumps.
**Recommendation:** Add a `BipStatusDefinition` model class and integrate BIP pattern matching into the test execution flow for pre-injection pumps.
## Test Plan TXT Format
Each test plan file follows this structure:
```
[TestName] [TestType] [nPhases] [ConditioningTime] [MeasurementTime] [MeasurementsPerSec]
[PhaseName] [RPM] [me] [FBKW] [ME_PI] [T-In] [QOver] [Tolerance_me] [Tolerance_FBKW] ...
```
108 pump IDs have corresponding test plan files. These should already be in `pumps.xml` if the old `Program.cs` migration was run. Verify coverage by comparing pump IDs in `pumps.xml` against `ListadoBombas.txt`.
## Migration Tool Approach
If re-migration is needed:
1. Port the parsing logic from `old_source/HerlicScripts/Program.cs` into a standalone console app
2. Read each CFG file using the pipe-delimited parser (`GetParamCFG`)
3. Read test plans from TXT files
4. Read lock angles from `AngulosDeBloqueo.txt`
5. Generate `pumps.xml` and `status.xml` in the new schema
6. Run once, commit the generated files, do not ship the migration tool
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