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Joseph Doherty 5f0a52864c feat(focas): real FANUC 30i/31i-B PDU-v3 support (live-validated on a 31i-B)

First real FOCAS hardware contact (Makino Pro 5 / 31i-B @ 10.201.31.5). A full
v3 data-PDU capture corrected the initial diagnosis: the v3 block envelope is
identical to v1, so only specific payload structs / request math / one client
robustness gap were wrong — not "framing rewrites".

Fixes (all re-validated live through the fixed driver):
- version gate: accept inbound PDU {1,3}, keep emitting v1 (FocasWireProtocol).
- cnc_rdtimer: 8-byte {minute,msec} payload is little-endian (ParseTimer) — the
  only decode with an in-range msec field.
- pmc_rdpmcrng: request range widened to the data-type byte width
  (end = start + width - 1) so a Word/Long isn't truncated to 0 values
  (was spurious BadOutOfRange); decode extracted to ParsePmcRange.
- cnc_rdsvmeter: per-axis LOADELM is 8 bytes (not 12) and names come from the
  0x0089 block — ParseServoMeters fixes the misaligned 655360 garbage. Also the
  "hang" was NetworkStream.ReadAsync not aborting a stalled socket: ReadExactlyAsync
  now disposes the stream on cancellation so a stalled peer can't wedge a poll loop.
- cnc_rddynamic2: contract guard rejecting axis < 1 (driver poll already 1-based).
- FocasDriverProbe: run a real wire session (initiate + cnc_statinfo) instead of
  degrading to Ok=true "TCP reachability only" when FWLIB is absent — a bare TCP
  listener no longer reports HEALTHY.

cnc_rdparam (0x000e) is unsupported on this control — EW_FUNC across 14
request-framing variants x 4 known-present params; needs a reference FWLIB trace
or is restricted. Deferred (deployed config uses macros, not parameters).

Tests: FOCAS suite 234 green (+16), full solution builds 0 errors. Raw v3
captures checked in under tests/.../Fixtures/v3/. Capture tools under scripts/focas/.

Docs: docs/plans/2026-06-25-focas-pdu-v3-{30i-b-support,implementation-plan}.md,
docs/drivers/FOCAS.md, docs/v2/focas-version-matrix.md,
docs/deployments/wonder-app-vd03-makino-z-34184.md.

2026-06-25 16:41:42 -04:00

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Deployment record — wonder-app-vd03 · Makino Pro 5 (Z-34184) FOCAS

Date configured: 2026-06-25 Host: wonder-app-vd03.zmr.zimmer.com (OtOpcUaHost Windows service, single fused admin+driver node) Status: Configured + deployed + served. Live values blocked by the FOCAS PDU-v3 driver gap — see docs/plans/2026-06-25-focas-pdu-v3-30i-b-support.md.

Equipment

Field	Value
Machine	Makino Pro 5 (FANUC 30i-B control)
IP / FOCAS endpoint	`10.201.31.5:8193` (FOCAS Ethernet, TCP) — reachable from the host (and from VPN clients)
ZTag	`Z-34184`
Manufacturer / Model	`Makino` / `Pro 5`
CNC series (driver)	`Thirty_i` (30i)

OtOpcUa host endpoints

AdminUI: http://wonder-app-vd03.zmr.zimmer.com:9000 (login disabled — Security__Auth__DisableLogin=true)
OPC UA: opc.tcp://wonder-app-vd03.zmr.zimmer.com:4840/OtOpcUa
Akka cluster: :4053 · ConfigDb: SQL OtOpcUaConfig on :1433

Deployed configuration (cluster `DEV`, Enterprise `zb` / Site `wonder-app-vd03`)

First config ever deployed on this node. All authored via the AdminUI.

Object	Value
Namespace	`dev-equipment` (Equipment), URI `urn:zb:wonder-app-vd03:equipment`
UNS path	`zb / wonder-app-vd03 / machining / makino`
FOCAS driver instance	`focas-z-34184` ("Makino Pro 5 Z-34184 (FOCAS)"), backend `wire`, FixedTree enabled
Device	`10.201.31.5:8193`, series `Thirty_i`
Equipment	`z-34184` → `EquipmentId = EQ-3686c0272279`, MachineCode `Z-34184`, ZTag `Z-34184`
Tags	`parts-count` → `MACRO:3901` (Float64/Double, Read); `parts-required` → `MACRO:3902` (Float64/Double, Read)
Deployment	`0c2db588` (rev `924b59097eba…`) — Sealed / "In sync"

OPC UA node IDs (verified served via the OtOpcUa CLI client):

Equipment: ns=2;s=EQ-3686c0272279
ns=2;s=EQ-3686c0272279/parts-count
ns=2;s=EQ-3686c0272279/parts-required

Host change required to deploy at all (Akka cluster roles)

This node was joining the Akka cluster role-less, so no deployment could ever complete ("a task was canceled"; Fleet status: "no driver-role nodes are Up"). Root cause: OTOPCUA_ROLES (set to admin,driver) drives Program.cs actor wiring but does not populate the Akka member roles — those come from config Cluster:Roles, which was unset (no Cluster__Roles env var; no Cluster section in any appsettings). No code bridges OTOPCUA_ROLES → AkkaClusterOptions.Roles.

Fix applied to the host service (HKLM\SYSTEM\CurrentControlSet\Services\OtOpcUaHost → Environment): added Cluster__Roles__0=admin and Cluster__Roles__1=driver, then restarted the service. The member now joins UP with roles ADMIN+DRIVER and deployments seal. Prior env backed up on the host at E:\ApiInstall\OtOpcUa\_envbak-20260625T145303.txt.

Product follow-up: either wire OTOPCUA_ROLES → AkkaClusterOptions.Roles, or bake Cluster:Roles into the deploy template, so a node redeploy doesn't regress to role-less.

Live verification (OtOpcUa CLI client → server)

connect + browse confirm the equipment + both tags are served at the node IDs above.

Driver fix shipped (2026-06-25): the wire client now accepts PDU v3 (see the linked plan). Validated directly against 10.201.31.5 — MACRO:3901/3902 read Good from the live 30i-B. However, the OtOpcUaHost on this box is still running the pre-v3 driver binary, so the live OPC UA tags will keep returning Bad_WaitingForInitialData until the rebuilt ZB.MOM.WW.OtOpcUa.Driver.FOCAS.dll (or a fresh self-contained host publish) is deployed to E:\ApiInstall\OtOpcUa\ and OtOpcUaHost is restarted. Once redeployed, parts-count/parts-required should go Good (FixedTree + PMC/Parameter still pending the follow-on v3 command work).

3.8 KiB Raw Blame History