Initial commit with Dockerfile and demo code

server/sim/faults.js

@@ -0,0 +1,105 @@
+/**
+ * Injectable fault profiles.
+ *
+ * Each profile turns "time since injection" into a set of physics modifiers that
+ * stations.js and line.js consume. Faults are progressive where a real fault
+ * would be progressive - the bearing does not fail the instant you press the
+ * button, it degrades, which is the whole point of showing trend extrapolation.
+ */
+
+export const FAULT_PROFILES = [
+  {
+    id: 'bearing-degradation',
+    station: 'CNC-02',
+    label: 'CNC-02 bearing degradation',
+    short: 'Bearing wear',
+    severity: 'major',
+    headline: true,
+    description:
+      'Spindle bearing begins to spall. Vibration rises exponentially, spindle load creeps up, and out-of-tolerance parts start reaching inspection.',
+  },
+  {
+    id: 'oven-burner',
+    station: 'OVN-03',
+    label: 'OVN-03 zone 2 burner fault',
+    short: 'Burner fault',
+    severity: 'major',
+    description:
+      'Zone 2 loses roughly 40% of its heating capacity. The controller saturates trying to hold setpoint, the cure runs cold, and quality falls downstream.',
+  },
+  {
+    id: 'packer-jam',
+    station: 'PKG-05',
+    label: 'PKG-05 film jam',
+    short: 'Film jam',
+    severity: 'critical',
+    description:
+      'Film binds then tears, stopping the packer. Work in progress backs up through the line and upstream stations block.',
+  },
+  {
+    id: 'sensor-dropout',
+    station: 'INS-04',
+    label: 'INS-04 sensor dropout',
+    short: 'Sensor dropout',
+    severity: 'minor',
+    description:
+      'The inspection station stops reporting. Values go stale rather than to zero, which is what a real dropout looks like and what a twin has to handle honestly.',
+  },
+];
+
+export function faultProfile(id) {
+  return FAULT_PROFILES.find((f) => f.id === id);
+}
+
+/** Time constant for the bearing ramp, in simulated seconds. */
+const BEARING_TAU = 420;
+const BEARING_GAIN = 0.35;
+const BEARING_CAP = 3.2;
+
+/**
+ * Collapse the set of active faults into physics modifiers.
+ *
+ * active: Map of faultId -> { injectedAt } in simulated seconds.
+ */
+export function computeModifiers(active, simTime) {
+  const mods = {
+    bearingVibration: 0,
+    ovenZone2Capacity: 1,
+    packerJamPhase: null,
+    faultedStations: new Set(),
+    offlineStations: new Set(),
+  };
+
+  for (const [id, info] of active) {
+    const t = Math.max(0, simTime - info.injectedAt);
+
+    switch (id) {
+      case 'bearing-degradation':
+        // Exponential ramp: slow to start, unmistakable once it moves. Crosses
+        // the 3.5 mm/s warn band around 13 simulated minutes.
+        mods.bearingVibration = Math.min(
+          BEARING_CAP,
+          BEARING_GAIN * (Math.exp(t / BEARING_TAU) - 1),
+        );
+        break;
+
+      case 'oven-burner': {
+        // Capacity degrades over the first minute rather than cliff-edging.
+        const frac = Math.min(1, t / 60);
+        mods.ovenZone2Capacity = 1 - 0.38 * frac;
+        break;
+      }
+
+      case 'packer-jam':
+        mods.faultedStations.add('PKG-05');
+        mods.packerJamPhase = t < 8 ? 'bind' : 'tear';
+        break;
+
+      case 'sensor-dropout':
+        mods.offlineStations.add('INS-04');
+        break;
+    }
+  }
+
+  return mods;
+}