mbproxy: initial commit through Phase 9 (TxId multiplexing)
Adds the mbproxy service end-to-end. Phases 00-08 implement the production-ready single-listener / 1:1-backend transparent Modbus TCP proxy with bidirectional BCD rewriting for the ~54-PLC DL205/DL260 fleet. Phase 9 replaces the connection layer with a single backend socket per PLC plus MBAP TxId rewriting, lifting the H2-ECOM100's 4-concurrent-client cap as an operational ceiling. Phase 9 additions of note: - PlcMultiplexer + UpstreamPipe + TxIdAllocator + CorrelationMap - InFlightRequest with IReadOnlyList<InterestedParty> (load-bearing for Phase 10 read coalescing — do not collapse to a single field) - Per-request watchdog: surfaces Modbus exception 0x0B to upstream on BackendRequestTimeoutMs, defending against lost responses, dead-PLC paths, and pymodbus 3.13.0's concurrent-multiplexed- request bug (its ServerRequestHandler.last_pdu state race) - Status DTO + HTML gain inFlight / maxInFlight / txIdWraps / disconnectCascades / queueDepth (Tier 1.6 in docs/kpi.md) Tests: 263 unit + 38 E2E. Multiplexer correctness under truly concurrent backend traffic is proved against a stub backend in PlcMultiplexerTests; MultiplexerE2ETests paces requests so pymodbus 3.13's single-PDU framer stays in known-good mode. Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
This commit is contained in:
Joseph Doherty
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// mbproxy configuration template — copy to %ProgramData%\mbproxy\appsettings.json
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// and edit before starting the service.
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//
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// The .NET configuration loader accepts // and /* */ comments in JSON files
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// (JSONC semantics) when using the default Host.CreateApplicationBuilder path.
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//
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// IMPORTANT: This file is overwritten on each install ONLY if no appsettings.json
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// already exists at the destination. An existing file is always preserved.
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{
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"Mbproxy": {
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// ── Global BCD tag list ─────────────────────────────────────────────────────────────
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// These tags apply to EVERY PLC by default.
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// Each entry: Address (Modbus PDU address, decimal), Width (16 or 32 bits).
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//
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// Width 16 — one register holds 4 BCD digits (0–9999).
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// Wire value 0x1234 decodes to decimal 1234.
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//
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// Width 32 — a CDAB-ordered register pair (Address = low word, Address+1 = high word).
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// Decoded decimal = high * 10000 + low (DirectLOGIC CDAB word order).
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//
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// Per-PLC overrides (see Plcs[].BcdTags below):
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// Add — appends extra tags beyond what Global defines, or overrides a
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// Global entry's Width when the same Address appears in both.
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// Remove — removes specific addresses from the effective set for that PLC.
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// Effective set = (Global ∪ Add) − Remove, resolved per PDU.
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"BcdTags": {
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"Global": [
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// V2000 (octal) = decimal address 1024. 16-bit BCD counter.
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{ "Address": 1024, "Width": 16 },
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// V2040 (octal) = decimal address 1056. 32-bit BCD total at 1056/1057.
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{ "Address": 1056, "Width": 32 },
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// V2100 (octal) = decimal address 1088. 16-bit BCD setpoint.
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{ "Address": 1088, "Width": 16 }
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]
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},
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// ── PLC list ────────────────────────────────────────────────────────────────────────
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// Each entry maps one upstream proxy port → one backend PLC.
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// Upstream clients connect to ListenPort; the proxy forwards to Host:Port.
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//
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// IMPORTANT: H2-ECOM100 modules accept at most 4 simultaneous TCP connections.
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// With the 1:1 upstream↔backend model, a fifth upstream client to the same proxy
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// port will cause a backend connect failure and an immediate upstream disconnect.
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"Plcs": [
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{
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"Name": "Line1-Mixer", // Human-readable name (shown on status page and in logs)
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"ListenPort": 5020, // Port the proxy listens on (upstream clients connect here)
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"Host": "10.0.1.1", // PLC IP address or hostname
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"Port": 502, // PLC Modbus TCP port (almost always 502)
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"BcdTags": {
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// Additional 32-bit tag specific to this PLC only.
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"Add": [
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{ "Address": 1200, "Width": 32 }
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],
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// Remove address 1056 from the Global list for this PLC
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// (this mixer doesn't use the 32-bit BCD total).
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"Remove": [ 1056 ]
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}
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},
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{
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"Name": "Line1-Conveyor",
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"ListenPort": 5021,
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"Host": "10.0.1.2",
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"Port": 502
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// No BcdTags override — uses the Global set as-is.
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}
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// Add one entry per PLC. Ports must be unique per host. Typical fleet: 54 PLCs.
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],
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// ── Admin port ──────────────────────────────────────────────────────────────────────
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// Read-only HTTP status page.
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// GET / → self-contained HTML (auto-refreshes every 5 s)
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// GET /status.json → same data as JSON for monitoring scrapers
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//
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// Authentication is assumed at the network layer (trusted internal segment).
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// Set to 0 to disable the admin endpoint.
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"AdminPort": 8080,
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// ── Connection timeouts ─────────────────────────────────────────────────────────────
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"Connection": {
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// Max time (ms) to wait for a TCP connect to the PLC backend.
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// Each Polly retry attempt gets its own copy of this timeout.
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"BackendConnectTimeoutMs": 3000,
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// Max time (ms) to wait for the PLC to respond to a forwarded PDU.
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// Non-idempotent FC06/FC16 writes are one-shot — the upstream client
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// is disconnected immediately on timeout (no retry).
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"BackendRequestTimeoutMs": 3000,
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// Max time (ms) to wait for in-flight PDUs to complete during graceful shutdown
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// (sc.exe stop / Windows Service stop signal). After this deadline the coordinator
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// cancels remaining work and proceeds. Keep at or below the SCM wait-hint (30 s).
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"GracefulShutdownTimeoutMs": 10000
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},
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// ── Resilience policies ─────────────────────────────────────────────────────────────
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"Resilience": {
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// Polly retry policy for backend TCP connect attempts.
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// MaxAttempts: total connect tries (including the first).
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// BackoffMs: delay between each attempt (must have MaxAttempts−1 entries).
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"BackendConnect": {
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"MaxAttempts": 3,
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"BackoffMs": [ 100, 500, 2000 ]
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},
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// Polly recovery policy for listener bind failures.
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// If a PLC's listen port can't be bound (in-use, bad IP, transient OS error),
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// the supervisor retries according to this schedule.
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// InitialBackoffMs: backoff per step (first N retries).
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// SteadyStateMs: backoff for all subsequent retries (runs indefinitely).
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"ListenerRecovery": {
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"InitialBackoffMs": [ 1000, 2000, 5000, 15000, 30000 ],
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"SteadyStateMs": 30000
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}
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}
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},
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// ── Serilog ─────────────────────────────────────────────────────────────────────────────
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// Structured log output. Default: Information level, rolling-file under ProgramData.
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// The EventLogBridge writes Error+ events to the Windows Application Event Log
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// automatically when the service runs under the SCM (not under dotnet run).
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"Serilog": {
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"Using": [ "Serilog.Sinks.Console", "Serilog.Sinks.File" ],
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"MinimumLevel": {
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"Default": "Information",
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"Override": {
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"Microsoft": "Warning",
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"System": "Warning"
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}
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},
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"WriteTo": [
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{
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"Name": "Console",
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"Args": {
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"outputTemplate": "[{Timestamp:HH:mm:ss} {Level:u3}] {Message:lj} {Properties:j}{NewLine}{Exception}"
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}
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},
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{
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"Name": "File",
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"Args": {
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// Rolling log: one file per day, kept for 30 days.
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// Survives uninstall — logs are archived to %ProgramData%\mbproxy.archived-<ts>\.
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"path": "C:\\ProgramData\\mbproxy\\logs\\mbproxy-.log",
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"rollingInterval": "Day",
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"retainedFileCountLimit": 30,
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"outputTemplate": "[{Timestamp:yyyy-MM-dd HH:mm:ss.fff zzz} {Level:u3}] {Message:lj} {Properties:j}{NewLine}{Exception}"
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}
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}
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]
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}
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}
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