LucianoDev
c617854c09
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>
199 lines
12 KiB
Markdown
199 lines
12 KiB
Markdown
# HC_APTBS
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## What this is
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WPF desktop application (.NET 10 / x64) that controls a VP44 diesel injection pump test bench.
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- Reads/writes bench sensors (temperature, RPM, flow) via CAN bus (PCAN-Basic, 500 kbps)
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- Communicates with the pump ECU via K-Line/KWP2000 (FTDI USB adapter, 9600 bps)
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- Runs automated multi-phase test sequences with PID temperature control
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- Generates PDF test reports (QuestPDF)
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- Supports Ford VP44 immobilizer unlock via CAN (Types 1 & 2)
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## Build
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Windows only, .NET 10 x64. `dotnet build -r win-x64` from solution root. SDK pinned in `global.json`. No WSL/Linux — native DLLs (`PCANBasic.dll`, `ftd2xx.dll`) are x64 Windows binaries. No test project; validation is code review + manual hardware testing.
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## Stack
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- C# / .NET 10, WPF, XAML
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- CommunityToolkit.Mvvm: `[ObservableProperty]`, `[RelayCommand]`
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- Microsoft.Extensions.DependencyInjection / Hosting for bootstrap
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- QuestPDF 2025.3.2 (requires `LicenseType.Community` in constructor)
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- LiveChartsCore.SkiaSharpView.WPF 2.0.0-rc3.5 for real-time charts
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- Extended.Wpf.Toolkit 4.6.1 (AvalonDock, NumericUpDown, BusyIndicator)
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- Native DLLs in output: `PCANBasic.dll`, `ftd2xx.dll` (x64 only)
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## Architecture
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```
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Infrastructure/
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Pcan/PcanBasic.cs — Vendor P/Invoke file. NEVER modify.
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Pcan/PcanAdapter.cs — CAN read thread, OEM legitimation, frame decode, IIR filter, liveness tracking
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Kwp/FtdiInterface.cs — FTDI D2XX wrapper (manual LoadLibrary, not NativeLibrary.Load)
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Kwp/KwpCommon.cs — 5-baud slow-init, complement-ACK byte I/O
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Kwp/KW1281Connection.cs — KWP/KW1281 protocol state machine
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Kwp/Packets/ — 10 packet types (Ack, Nak, FaultCodes, Eeprom R/W, Custom, etc.)
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Logging/AppLogger.cs — Daily rotating log files (ERR/WAR/MSG/DBG)
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Services/
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ICanService.cs — CAN bus abstraction (parameter map, frame routing, liveness)
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IBenchService.cs — Test orchestration, RPM/temp control, relay control
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IKwpService.cs — K-Line ECU diagnostics (keep-alive, EEPROM, DTCs, DFI)
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IUnlockService.cs — Ford VP44 immobilizer unlock state machine
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IConfigurationService.cs — XML persistence for all config files
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ICalibrationService.cs — Sensor calibration operations
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IPdfService.cs — PDF test report generation
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Services/Impl/
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BenchService.cs — Test orchestration, temperature PID, relay control (background Task)
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BenchPidController.cs — Discrete-time PID for RPM ramp (derivative-on-measurement, anti-windup)
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KwpService.cs — All KWP operations; persistent session with keep-alive loop
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UnlockService.cs — Ford unlock: 600.5s Phase 1 + TestUnlock Phase 2 + verification
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ConfigurationService.cs — XML persistence for pumps, bench, config, clients, sensors, alarms, status
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CalibrationService.cs — Sensor calibration
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PdfService.cs — QuestPDF report generation (multi-page, charts, verdict)
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ReportChartRenderer.cs — SVG chart rendering for PDF tolerance-band visualizations
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ReportTheme.cs — Report styling constants
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Models/
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CanBusParameter.cs — CAN parameter model + BenchParameterNames/PumpParameterNames/KlineKeys constants
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BenchConfiguration.cs — Bench config + embedded AppSettings (PID, timers, safety limits)
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PumpDefinition.cs — Pump model, CAN params, tests, K-Line data
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TestDefinition.cs — Test type + phase list + tolerance evaluation
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PhaseDefinition.cs — Phase readies/sends/receives/results
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TestParameter.cs — Measurement point (name, value, tolerance)
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TestResult.cs — Accumulated result with samples and pass/fail evaluation
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MeasurementSample.cs — Single timestamped measurement
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SensorConfiguration.cs — ADC calibration (voltage → engineering units)
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Relay.cs — Relay output + RotationDirection/EncoderMode/BaudrateSelection constants
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Alarm.cs — Alarm condition (bit, description, criticality, active state)
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PumpStatusDefinition.cs — Status word bit definitions with color-coded states
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RpmVoltageRelation.cs — RPM → voltage lookup table entry
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KLineConnectionState.cs — K-Line session state enum
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Converters/
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BoolToPassFailBrushConverter.cs
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HexColorToBrushConverter.cs
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ViewModels/ — [ObservableProperty] / [RelayCommand], no UI logic
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MainViewModel.cs — Central orchestrator, event marshalling, child VMs
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PumpIdentificationViewModel.cs — Pump selection + K-Line ECU read
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DfiManageViewModel.cs — DFI calibration read/write/auto-adjust
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TestPanelViewModel.cs — Test suite management (phase enable/disable)
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TestDisplayViewModel.cs — Current test execution progress
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ResultDisplayViewModel.cs — Test result table (per-phase pass/fail)
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PumpControlViewModel.cs — Manual pump control sliders (ME, FBKW, PreIn)
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BenchControlViewModel.cs — Bench control (rotation, RPM ramp, oil pump)
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FlowmeterChartViewModel.cs — Real-time flowmeter charts
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AngleDisplayViewModel.cs — Encoder angle monitoring (PSG, INJ, Manual, Lock Angle)
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StatusDisplayViewModel.cs — Pump status word display
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Dialogs/ — KlineErrors, Progress, Report, UserCheck ViewModels
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Views/
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MainWindow.xaml — Root UI (multi-panel layout)
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Dialogs/ — KlineErrorsDialog, ProgressDialog, ReportDialog, UserCheckDialog
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UserControls/ — AngleDisplay, BenchParamConfig, DfiManage, FlowmeterChart,
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PumpControl, PumpIdentification, ResultDisplay, StatusDisplay,
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TestDisplay, TestPanel
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```
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## Configuration files
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All XML files stored in `%UserProfile%\.HC_APTBS\config\`:
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| File | Purpose |
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|------|---------|
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| `config.xml` | Global settings: temp limits, PID tuning, refresh rates, safety limits, encoder, motor, company info, K-Line port, language, users, RPM-voltage relations |
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| `pumps.xml` | Pump database: per-pump identity, CAN parameters (P1–P6 legacy), test definitions with phases |
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| `bench.xml` | Bench CAN parameters (Factor/Offset model) + relay definitions. Embedded default fallback in code |
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| `sensors.xml` | ADC sensor calibrations (channel → voltage → engineering units) |
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| `clients.xml` | Client/operator directory (name → contact) |
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| `alarms.xml` | Alarm definitions (bit position, description, criticality) |
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| `status.xml` | Pump status word bit definitions with color-coded states |
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## Constants quick reference
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Defined in `Models/CanBusParameter.cs`:
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- `BenchParameterNames` — RPM, Counter, BaudRate, BenchTemp, T-in, T-out, T4, QDelivery, QOver, Alarms, Pressure, AnalogSensor2, encoders (PSG/INJ/Manual)
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- `PumpParameterNames` — me, FBKW, mepi, RPM, Temp, Tein, MemoryRequest, TestUnlock, TestImmo, Status, Empf3
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- `KlineKeys` — pumpID, SerialNumber, ModelReference, DFI, ErrorCodes, SWV1, SWV2, PumpControl, DataRecord, result
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- `RelayNames` — Electronic, OilPump, DepositCooler, DepositHeater, Counter, Direction, TinCooler, Pulse4Signal, Flasher (in `Models/Relay.cs`)
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## Rules for all edits
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**Always:**
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- Read the file before editing it
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- Keep XML doc comments on all public types and members
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- Use `BenchParameterNames` / `PumpParameterNames` / `KlineKeys` / `RelayNames` constants — no magic strings
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- Marshal to the UI thread when consuming `IBenchService` or `IKwpService` events (they fire on background threads)
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- Use `CultureInfo.InvariantCulture` when parsing/formatting doubles in XML (avoid locale bugs)
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- Log skipped or malformed XML elements — never silently swallow parse failures
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- New bench parameters must use Factor/Offset calibration, not P1–P6 (legacy model is for pump params only)
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**Never:**
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- Modify `Infrastructure/Pcan/PcanBasic.cs` (vendor file, intentionally untouched)
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- Modify anything under `old_source/` (archived reference only)
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- Add logic to View code-behind files
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- Add `Thread.Sleep`, allocations, or logging inside the per-byte K-Line loops in `KwpCommon`/`KW1281Connection`
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## Protocol constants
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Do not change without knowing why. Use `/protocol-ref` skill for full reference including DFI encoding, IIR filter, OEM legitimation, and K-Line timing.
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## Conventions
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- ViewModels in `/ViewModels`, Views in `/Views`, Models in `/Models`
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- Async methods use `Async` suffix
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- Commit format: `feat:`, `fix:`, `refactor:` (conventional commits)
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- Git remote: self-hosted Gitea at 192.168.8.130
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## Known gaps (from old_source comparison)
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See `docs/` guidelines for full specs. Priority: CRITICAL > HIGH > MEDIUM > LOW.
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**CRITICAL:**
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- No config XML validation — malformed files silently produce partial/default state
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**HIGH — Missing safety features:**
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- No QOver zero-flow safety check (old: emergency stop if QOver==0 while RPM>300 + oil pump on)
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- No safety dialogs: 27V warning, oil pump confirmation, RPM warning
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- Alarm bit collection during tests not wired up (`PhaseDefinition.RecordErrorBit` never called)
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- No per-sample real-time UI callback during measurement (old fired per-sample events for live charts)
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- Pump parameters (ME/FBKW/PreIn) not zeroed between test phases
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**HIGH — Missing features:**
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- Ford unlock progress UI (service exists, no View — old had WUnlocker.xaml with visual ring + progress bar)
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- No localization system (old had Spanish/English resource dictionaries with runtime switching)
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- No encryption (old encrypted user passwords with AES-256 + pump data with Rijndael; new stores plaintext)
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- No KlineIDs auto-mapping (old remembered K-Line ID → pump ID associations)
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**MEDIUM — Missing UI components:**
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- WConfigPanel (full settings dialog)
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- WUsersManage (user CRUD — only auth dialog exists)
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- KlineIDSelection (COM port selection for K-Line)
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- BitDisplay / SingleBit (bit-level status toggles)
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- TimerDisplay (test timer/countdown)
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- FilteredComboBox (searchable dropdown)
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- PDF report observations/notes section missing from interface
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**LOW:**
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- 4ms PeriodicTimer may fire at ~15ms on Windows (old MultimediaTimer had ~1ms precision)
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- Sensor calibration divide-by-zero when MaxVolt==MinVolt (no guard)
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- P1–P6 transfer function can produce Infinity/NaN (no denominator check)
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- CAN parameter byteh/bytel not bounds-checked to 0–7
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## Known debt
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Do not worsen before addressing deliberately. See memory file `project_known_debt.md` for details.
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Additional debt items:
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- `KW1281Connection` allocates `List<byte>` per packet — GC pressure under long K-Line sessions
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- `PcanAdapter.DrainMessageQueue` polls with `Thread.Sleep(2)` — hardcoded, was configurable in old
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- No unit tests exist yet
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- Users stored as plaintext `user:password` in config.xml
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- Config file format has no version tracking or migration logic
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- Pump ID uniqueness not enforced on load
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- `ParseEcuText()` depends on exact spacing format (fragile)
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- AppSettings properties have no bounds validation (timer intervals, safety limits)
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- `SaveSettings()` triggers `SaveSensors()` + `SaveClients()` as side effects
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## CFG/pump data migration
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The old system had 32 CFG files defining pump-specific data NOT present in the new XML model:
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- Status bit **reaction codes** (0=none, 1=abort, 2=warning, 3=log) — controlled test flow on errors
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- **BIP-STATUS** definitions (needle-motion detection) — absent from new system entirely
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- **Diagnostic RAM addresses** (solenoid timing, temperature compensation, learning procedures)
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- **Flow regulator sensitivity parameters** (measurement time adjustment, tolerance, FM sensitivity)
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- **EEPROM/EPROM/RAM passwords** per pump family
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- **CAN-BUS-KENNUNG** protocol variant code (0/1/2/6/10) — derived implicitly in new code
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See `docs/gap-pump-data-migration.md` for migration field mapping.
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