模拟器增加事件历史/异常日志/完整汇总导出功能，添加15分钟采集测试脚本

- DeviceState: 新增EventRecord类和RecordEvent方法，记录程序切换/清零/断电/开机事件
- LogRecorder: 新增ErrorRecord类和RecordError方法，记录异常状态
- SimulatorServer: 新增/admin/api/event-history、/admin/api/full-summary、/admin/api/error-log三个API端点
- SimulatorServer: 异常分支（http500/timeout/empty/malformed）自动记录异常日志
- 新增15分钟Playwright采集测试脚本（6个异常阶段+数据对比验证+自动报告生成）

src/CncCollector/scripts/collector-15min.spec.ts

@@ -0,0 +1,816 @@
+/**
+ * 15分钟自动化采集测试（含6个异常阶段+数据对比验证）
+ *
+ * 测试流程：
+ *   阶段0: 初始化 — 清空旧数据、启动模拟器、启动采集服务
+ *   阶段1: 正常采集（5分钟）— 建立基准数据
+ *   阶段2: HTTP 500异常（2分钟）— 模拟服务端错误
+ *   阶段3: 超时异常（2分钟）— 模拟响应超时
+ *   阶段4: 空数据返回（2分钟）— 模拟空响应
+ *   阶段5: 拒绝连接（2分钟）— 模拟网络断开
+ *   阶段6: 恢复正常采集（2分钟）— 验证恢复能力
+ *   验证: 数据对比 — 模拟器汇总 vs 数据库记录
+ *   报告: 输出详细测试报告到 docs/test-reports/
+ *
+ * 前置条件:
+ *   1. MariaDB 运行中（cnc_business + cnc_log 库已初始化）
+ *   2. CncSimulator 未启动（脚本自动启动）
+ *   3. CncCollector 未启动（脚本自动启动）
+ *
+ * 安装: npm install @playwright/test mysql2
+ * 运行: npx playwright test collector-15min.spec.ts --reporter=list --timeout=0
+ */
+
+import { test, expect, request } from '@playwright/test';
+import mysql from 'mysql2/promise';
+import { execSync, spawn, ChildProcess } from 'child_process';
+import * as fs from 'fs';
+import * as path from 'path';
+
+// ============================================================
+// 常量与配置
+// ============================================================
+
+const API_BASE = 'http://localhost:5800';
+const SIM_GATEWAY = 'http://localhost:9001';
+const API_KEY = 'collector_api_key_2026';
+const HEADERS = { 'X-API-Key': API_KEY, 'Content-Type': 'application/json' };
+
+const DB_BUSINESS = {
+  host: 'localhost', user: 'root', password: 'root',
+  database: 'cnc_business', charset: 'utf8mb4'
+};
+const DB_LOG = {
+  host: 'localhost', user: 'root', password: 'root',
+  database: 'cnc_log', charset: 'utf8mb4'
+};
+
+/** 每个阶段的持续时间（毫秒） */
+const PHASE_DURATIONS = {
+  normal1: 5 * 60 * 1000,      // 阶段1: 正常采集5分钟
+  http500: 2 * 60 * 1000,      // 阶段2: HTTP 500异常2分钟
+  timeout: 2 * 60 * 1000,      // 阶段3: 超时异常2分钟
+  empty: 2 * 60 * 1000,        // 阶段4: 空数据2分钟
+  refuse: 2 * 60 * 1000,       // 阶段5: 拒绝连接2分钟
+  normal2: 2 * 60 * 1000,      // 阶段6: 恢复正常2分钟
+};
+
+/** 测试报告输出路径 */
+const REPORT_DIR = path.resolve(__dirname, '../../../docs/test-reports');
+
+// ============================================================
+// 数据库辅助函数
+// ============================================================
+
+async function queryBusiness(sql: string, params?: any[]) {
+  const conn = await mysql.createConnection(DB_BUSINESS);
+  try {
+    const [rows] = await conn.query(sql, params);
+    return rows as any[];
+  } finally {
+    await conn.end();
+  }
+}
+
+async function queryLog(sql: string, params?: any[]) {
+  const conn = await mysql.createConnection(DB_LOG);
+  try {
+    const [rows] = await conn.query(sql, params);
+    return rows as any[];
+  } finally {
+    await conn.end();
+  }
+}
+
+async function executeBusiness(sql: string, params?: any[]) {
+  const conn = await mysql.createConnection(DB_BUSINESS);
+  try {
+    await conn.execute(sql, params);
+  } finally {
+    await conn.end();
+  }
+}
+
+async function executeLog(sql: string, params?: any[]) {
+  const conn = await mysql.createConnection(DB_LOG);
+  try {
+    await conn.execute(sql, params);
+  } finally {
+    await conn.end();
+  }
+}
+
+/** 辅助：调用采集服务管理API */
+async function collectorApi(method: string, path: string) {
+  const ctx = await request.newContext();
+  const opts: any = { headers: HEADERS };
+  if (method === 'GET') return ctx.get(`${API_BASE}${path}`, opts);
+  return ctx.post(`${API_BASE}${path}`, opts);
+}
+
+/** 辅助：等待指定毫秒 */
+const sleep = (ms: number) => new Promise(r => setTimeout(r, ms));
+
+/** 辅助：调用模拟器管理API */
+async function simApi(port: number, path: string, body?: any) {
+  const ctx = await request.newContext();
+  if (body) {
+    return ctx.post(`http://localhost:${port}${path}`, { data: body, headers: { 'Content-Type': 'application/json' } });
+  }
+  return ctx.get(`http://localhost:${port}${path}`);
+}
+
+/** 辅助：调用模拟器网关API */
+async function gatewayApi(path: string, body?: any) {
+  const ctx = await request.newContext();
+  if (body) {
+    return ctx.post(`${SIM_GATEWAY}${path}`, { data: body, headers: { 'Content-Type': 'application/json' } });
+  }
+  return ctx.get(`${SIM_GATEWAY}${path}`);
+}
+
+/** 日志输出带时间戳 */
+function log(msg: string) {
+  console.log(`[${new Date().toLocaleTimeString('zh-CN')}] ${msg}`);
+}
+
+// ============================================================
+// 全局变量
+// ============================================================
+
+let simulationPort = 0;
+let testStartTime: Date;
+let phaseTimestamps: Record<string, Date> = {};
+
+/** 每阶段结束时采集模拟器快照 */
+let phaseSnapshots: Record<string, any> = {};
+
+// ============================================================
+// 全局串行配置
+// ============================================================
+
+test.describe.configure({ mode: 'serial' });
+
+// ============================================================
+// 阶段0: 初始化
+// ============================================================
+
+test.describe('15分钟自动化采集测试', () => {
+
+  test('阶段0: 初始化 — 清空数据并启动服务', async () => {
+    test.setTimeout(120000); // 2分钟超时
+    testStartTime = new Date();
+    log('\n===== 15分钟自动化采集测试开始 =====');
+    log(`测试开始时间: ${testStartTime.toLocaleString('zh-CN')}`);
+
+    // 1. 清空采集数据
+    log('[0/6] 清空旧采集数据...');
+    await executeBusiness('TRUNCATE TABLE cnc_collect_record');
+    await executeBusiness('TRUNCATE TABLE cnc_production_segment');
+    await executeLog('TRUNCATE TABLE log_collect_raw');
+    log('  ✓ 已清空 cnc_collect_record, cnc_production_segment, log_collect_raw');
+
+    // 2. 确认采集地址配置
+    log('[1/6] 确认采集地址配置...');
+    const addrs = await queryBusiness('SELECT id, url, is_enabled, collect_interval FROM cnc_collect_address WHERE id = 1');
+    expect(addrs.length).toBe(1);
+    log(`  ✓ 采集地址: id=${addrs[0].id}, url=${addrs[0].url}, interval=${addrs[0].collect_interval}s`);
+
+    // 3. 确认机床数据
+    log('[2/6] 确认机床数据...');
+    const machines = await queryBusiness(
+      'SELECT id, device_code, name, collect_address_id, is_enabled FROM cnc_machine WHERE collect_address_id = 1 AND is_enabled = 1'
+    );
+    expect(machines.length).toBeGreaterThanOrEqual(10);
+    log(`  ✓ 机床数量: ${machines.length}台（采集地址1下的启用机床）`);
+
+    // 4. 通过模拟器网关启动地址模拟
+    log('[3/6] 启动模拟器...');
+    const startResp = await gatewayApi('/admin/api/start-address', {
+      dbAddressId: 1,
+      interval: 10,
+      deviceCodes: machines.map((m: any) => m.device_code)
+    });
+    expect(startResp.ok()).toBeTruthy();
+    const startResult = await startResp.json() as any;
+    simulationPort = startResult.port || 9001;
+    log(`  ✓ 模拟器已启动 → 端口 ${simulationPort}`);
+
+    // 等待模拟器数据就绪
+    await sleep(3000);
+    const dataResp = await gatewayApi(`/admin/api/status`);
+    if (dataResp.ok()) {
+      const status = await dataResp.json() as any;
+      log(`  ✓ 模拟器状态: ${status.totalDevices}台设备, 在线${status.onlineDevices}台`);
+    }
+
+    // 5. 更新采集地址URL指向模拟端口
+    await executeBusiness(
+      'UPDATE cnc_collect_address SET url = ?, is_enabled = 1 WHERE id = 1',
+      [`http://localhost:${simulationPort}/`]
+    );
+    log(`  ✓ 更新采集地址URL → http://localhost:${simulationPort}/`);
+
+    // 6. 启动采集服务
+    log('[4/6] 启动采集服务...');
+    await collectorApi('POST', '/api/collector/stop');
+    await sleep(1000);
+    await collectorApi('POST', '/api/collector/refresh');
+    await sleep(500);
+    await collectorApi('POST', '/api/collector/start');
+    log('  ✓ 采集服务已启动');
+
+    // 7. 等待2个采集周期确认数据流
+    log('[5/6] 等待数据采集确认...');
+    await sleep(25000);
+
+    // 验证已有数据产生
+    const records = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_collect_record WHERE collect_time > ?',
+      [testStartTime]
+    );
+    const rawLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE request_time > ?',
+      [testStartTime]
+    );
+    log(`  ✓ 采集记录数: ${records[0].cnt}, 原始日志数: ${rawLogs[0].cnt}`);
+    expect(records[0].cnt).toBeGreaterThan(0);
+
+    // 8. 保存阶段0快照
+    phaseTimestamps['init'] = new Date();
+    const snapshot0 = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot0.ok()) phaseSnapshots['init'] = await snapshot0.json();
+
+    log('[6/6] 初始化完成，开始15分钟采集测试\n');
+  });
+
+  // ============================================================
+  // 阶段1: 正常采集（5分钟）
+  // ============================================================
+
+  test('阶段1: 正常采集 — 5分钟建立基准数据', async () => {
+    test.setTimeout(PHASE_DURATIONS.normal1 + 60000);
+    log('━━━ 阶段1: 正常采集（5分钟） ━━━');
+    phaseTimestamps['normal1_start'] = new Date();
+
+    // 记录开始时的模拟器状态
+    const statsBefore = await gatewayApi(`/admin/api/stats`);
+    const statsBeforeData = statsBefore.ok() ? await statsBefore.json() : {};
+
+    log(`  开始: 总零件=${statsBeforeData.totalParts || '?'}, 在线设备=${statsBeforeData.onlineDevices || '?'}`);
+    log(`  等待 ${PHASE_DURATIONS.normal1 / 1000} 秒...`);
+
+    // 等待5分钟
+    await sleep(PHASE_DURATIONS.normal1);
+
+    // 记录结束时的状态
+    phaseTimestamps['normal1_end'] = new Date();
+    const statsAfter = await gatewayApi(`/admin/api/stats`);
+    const statsAfterData = statsAfter.ok() ? await statsAfter.json() : {};
+
+    // 保存快照
+    const snapshot = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot.ok()) phaseSnapshots['normal1'] = await snapshot.json();
+
+    log(`  结束: 总零件=${statsAfterData.totalParts || '?'}, 在线设备=${statsAfterData.onlineDevices || '?'}`);
+    log(`  ✓ 阶段1完成\n`);
+  });
+
+  // ============================================================
+  // 阶段2: HTTP 500异常（2分钟）
+  // ============================================================
+
+  test('阶段2: HTTP 500异常 — 2分钟', async () => {
+    test.setTimeout(PHASE_DURATIONS.http500 + 60000);
+    log('━━━ 阶段2: HTTP 500异常（2分钟） ━━━');
+    phaseTimestamps['http500_start'] = new Date();
+
+    // 设置网络异常: HTTP 500
+    const setResp = await gatewayApi(`/admin/api/network`, { type: 'http500' });
+    if (setResp.ok()) {
+      log('  ✓ 已设置网络异常: HTTP 500');
+    }
+
+    log(`  等待 ${PHASE_DURATIONS.http500 / 1000} 秒...`);
+    await sleep(PHASE_DURATIONS.http500);
+
+    phaseTimestamps['http500_end'] = new Date();
+
+    // 保存快照
+    const snapshot = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot.ok()) phaseSnapshots['http500'] = await snapshot.json();
+
+    // 恢复网络
+    await gatewayApi(`/admin/api/network`, { type: 'normal' });
+    log('  ✓ 已恢复正常网络');
+    log(`  ✓ 阶段2完成\n`);
+  });
+
+  // ============================================================
+  // 阶段3: 超时异常（2分钟）
+  // ============================================================
+
+  test('阶段3: 超时异常 — 2分钟', async () => {
+    test.setTimeout(PHASE_DURATIONS.timeout + 60000);
+    log('━━━ 阶段3: 超时异常（2分钟） ━━━');
+    phaseTimestamps['timeout_start'] = new Date();
+
+    // 设置网络异常: 超时
+    const setResp = await gatewayApi(`/admin/api/network`, { type: 'timeout' });
+    if (setResp.ok()) {
+      log('  ✓ 已设置网络异常: 超时(60秒延迟)');
+    }
+
+    log(`  等待 ${PHASE_DURATIONS.timeout / 1000} 秒...`);
+    await sleep(PHASE_DURATIONS.timeout);
+
+    phaseTimestamps['timeout_end'] = new Date();
+
+    // 保存快照
+    const snapshot = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot.ok()) phaseSnapshots['timeout'] = await snapshot.json();
+
+    // 恢复网络
+    await gatewayApi(`/admin/api/network`, { type: 'normal' });
+    await sleep(2000); // 等待恢复
+    log('  ✓ 已恢复正常网络');
+    log(`  ✓ 阶段3完成\n`);
+  });
+
+  // ============================================================
+  // 阶段4: 空数据返回（2分钟）
+  // ============================================================
+
+  test('阶段4: 空数据返回 — 2分钟', async () => {
+    test.setTimeout(PHASE_DURATIONS.empty + 60000);
+    log('━━━ 阶段4: 空数据返回（2分钟） ━━━');
+    phaseTimestamps['empty_start'] = new Date();
+
+    // 设置网络异常: 空数据
+    const setResp = await gatewayApi(`/admin/api/network`, { type: 'empty' });
+    if (setResp.ok()) {
+      log('  ✓ 已设置网络异常: 空数据([])');
+    }
+
+    log(`  等待 ${PHASE_DURATIONS.empty / 1000} 秒...`);
+    await sleep(PHASE_DURATIONS.empty);
+
+    phaseTimestamps['empty_end'] = new Date();
+
+    // 保存快照
+    const snapshot = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot.ok()) phaseSnapshots['empty'] = await snapshot.json();
+
+    // 恢复网络
+    await gatewayApi(`/admin/api/network`, { type: 'normal' });
+    await sleep(2000);
+    log('  ✓ 已恢复正常网络');
+    log(`  ✓ 阶段4完成\n`);
+  });
+
+  // ============================================================
+  // 阶段5: 拒绝连接（2分钟）
+  // ============================================================
+
+  test('阶段5: 拒绝连接 — 2分钟', async () => {
+    test.setTimeout(PHASE_DURATIONS.refuse + 60000);
+    log('━━━ 阶段5: 拒绝连接（2分钟） ━━━');
+    phaseTimestamps['refuse_start'] = new Date();
+
+    // 设置网络异常: 拒绝连接
+    const setResp = await gatewayApi(`/admin/api/network`, { type: 'refuse' });
+    if (setResp.ok()) {
+      log('  ✓ 已设置网络异常: 拒绝连接');
+    }
+
+    log(`  等待 ${PHASE_DURATIONS.refuse / 1000} 秒...`);
+    await sleep(PHASE_DURATIONS.refuse);
+
+    phaseTimestamps['refuse_end'] = new Date();
+
+    // 保存快照（此时可能无法访问，用之前的数据）
+    try {
+      const snapshot = await gatewayApi(`/admin/api/full-summary`);
+      if (snapshot.ok()) phaseSnapshots['refuse'] = await snapshot.json();
+    } catch {
+      log('  (拒绝连接期间无法获取模拟器快照，跳过)');
+    }
+
+    // 恢复网络
+    await gatewayApi(`/admin/api/network`, { type: 'normal' });
+    await sleep(3000); // 等待HttpListener重启
+    log('  ✓ 已恢复正常网络');
+    log(`  ✓ 阶段5完成\n`);
+  });
+
+  // ============================================================
+  // 阶段6: 恢复正常采集（2分钟）
+  // ============================================================
+
+  test('阶段6: 恢复正常采集 — 2分钟', async () => {
+    test.setTimeout(PHASE_DURATIONS.normal2 + 60000);
+    log('━━━ 阶段6: 恢复正常采集（2分钟） ━━━');
+    phaseTimestamps['normal2_start'] = new Date();
+
+    // 确认网络已恢复
+    await gatewayApi(`/admin/api/network`, { type: 'normal' });
+    await sleep(2000);
+
+    // 等待新数据产生
+    const dataCheck = await gatewayApi(`/admin/api/status`);
+    if (dataCheck.ok()) {
+      const status = await dataCheck.json() as any;
+      log(`  当前状态: 在线${status.onlineDevices}台, 运行${status.isRunning}`);
+    }
+
+    log(`  等待 ${PHASE_DURATIONS.normal2 / 1000} 秒...`);
+    await sleep(PHASE_DURATIONS.normal2);
+
+    phaseTimestamps['normal2_end'] = new Date();
+
+    // 保存最终快照
+    const snapshot = await gatewayApi(`/admin/api/full-summary`);
+    if (snapshot.ok()) phaseSnapshots['normal2'] = await snapshot.json();
+
+    // 停止采集服务
+    await collectorApi('POST', '/api/collector/stop');
+    log('  ✓ 采集服务已停止（触发service_stop结账）');
+    await sleep(3000);
+
+    // 停止模拟器
+    await gatewayApi(`/admin/api/stop-address`, { dbAddressId: 1 });
+    log('  ✓ 模拟器已停止');
+
+    log(`  ✓ 阶段6完成\n`);
+  });
+
+  // ============================================================
+  // 数据对比验证
+  // ============================================================
+
+  test('验证: 数据完整性对比', async () => {
+    test.setTimeout(60000);
+    log('━━━ 数据完整性对比验证 ━━━');
+
+    // 1. 获取模拟器最终汇总
+    let simSummary: any = phaseSnapshots['normal2'] || {};
+    try {
+      const resp = await gatewayApi(`/admin/api/full-summary`);
+      if (resp.ok()) simSummary = await resp.json();
+    } catch { /* 模拟器可能已停止 */ }
+
+    log('\n  [1/5] 模拟器最终汇总:');
+    log(`    总设备: ${simSummary.totalDevices || '?'}`);
+    log(`    总零件: ${simSummary.totalParts || '?'}`);
+    log(`    异常数: ${simSummary.errorCount || 0}`);
+
+    // 2. 查询数据库统计
+    const dbRecords = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_collect_record WHERE collect_time > ?',
+      [testStartTime]
+    );
+    const dbSegments = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_production_segment WHERE created_at > ?',
+      [testStartTime]
+    );
+    const dbSettled = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_production_segment WHERE is_settled = 1 AND created_at > ?',
+      [testStartTime]
+    );
+    const dbActive = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_production_segment WHERE is_settled = 0 AND created_at > ?',
+      [testStartTime]
+    );
+    const dbRawLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE request_time > ?',
+      [testStartTime]
+    );
+    const dbSuccessLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE is_success = 1 AND request_time > ?',
+      [testStartTime]
+    );
+    const dbFailLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE is_success = 0 AND request_time > ?',
+      [testStartTime]
+    );
+
+    log('\n  [2/5] 数据库统计:');
+    log(`    采集记录数: ${dbRecords[0].cnt}`);
+    log(`    产量分段数: ${dbSegments[0].cnt} (已结账=${dbSettled[0].cnt}, 未结账=${dbActive[0].cnt})`);
+    log(`    原始日志数: ${dbRawLogs[0].cnt} (成功=${dbSuccessLogs[0].cnt}, 失败=${dbFailLogs[0].cnt})`);
+
+    // 验证数据存在
+    expect(dbRecords[0].cnt).toBeGreaterThan(0);
+    expect(dbRawLogs[0].cnt).toBeGreaterThan(0);
+    log('  ✓ 采集记录和原始日志均已产生');
+
+    // 3. 按设备对比零件数
+    log('\n  [3/5] 按设备零件数对比:');
+    const simParts = simSummary.devices || [];
+    let matchCount = 0;
+    let mismatchCount = 0;
+    let mismatchDetails: string[] = [];
+
+    for (const simDev of simParts) {
+      const deviceCode = simDev.deviceCode;
+      const simTotal = simDev.totalParts || 0;
+
+      // 查数据库中对应设备的分段总产量
+      const machine = await queryBusiness(
+        'SELECT id FROM cnc_machine WHERE device_code = ?',
+        [deviceCode]
+      );
+      if (machine.length === 0) {
+        log(`    ⚠ ${deviceCode}: 数据库中未找到对应机床`);
+        continue;
+      }
+
+      const segments = await queryBusiness(
+        'SELECT program_name, quantity, is_settled, close_reason FROM cnc_production_segment WHERE machine_id = ? AND created_at > ?',
+        [machine[0].id, testStartTime]
+      );
+
+      let dbTotal = 0;
+      for (const seg of segments) {
+        dbTotal += Number(seg.quantity) || 0;
+      }
+
+      const diff = Math.abs(simTotal - dbTotal);
+      const tolerance = Math.max(simTotal * 0.1, 5); // 允许10%或5个的误差
+
+      if (diff <= tolerance) {
+        matchCount++;
+        if (diff > 0) {
+          log(`    ≈ ${deviceCode}: 模拟器=${simTotal}, 数据库=${dbTotal} (差${diff}, 在容差内)`);
+        }
+      } else {
+        mismatchCount++;
+        const detail = `    ✗ ${deviceCode}: 模拟器=${simTotal}, 数据库=${dbTotal} (差${diff})`;
+        mismatchDetails.push(detail);
+        log(detail);
+      }
+    }
+
+    log(`\n    匹配: ${matchCount}台, 不匹配: ${mismatchCount}台`);
+    if (mismatchCount === 0) {
+      log('  ✓ 所有设备零件数完全匹配！');
+    } else {
+      log(`  ⚠ 有 ${mismatchCount} 台设备零件数不匹配，详见上方`);
+    }
+
+    // 4. 验证分段结账正确性
+    log('\n  [4/5] 分段结账验证:');
+    const closeReasons = await queryBusiness(
+      `SELECT close_reason, COUNT(*) as cnt FROM cnc_production_segment
+       WHERE created_at > ? GROUP BY close_reason`,
+      [testStartTime]
+    );
+    for (const row of closeReasons) {
+      log(`    ${row.close_reason || 'NULL'}: ${row.cnt}条`);
+    }
+
+    // 验证所有分段已结账（service_stop触发）
+    const unsettled = await queryBusiness(
+      'SELECT machine_id, program_name FROM cnc_production_segment WHERE is_settled = 0 AND created_at > ?',
+      [testStartTime]
+    );
+    if (unsettled.length === 0) {
+      log('  ✓ 所有分段已结账');
+    } else {
+      log(`  ⚠ 有 ${unsettled.length} 条分段未结账`);
+    }
+
+    // 5. 验证异常期间的数据
+    log('\n  [5/5] 异常期间数据验证:');
+
+    // HTTP 500期间应该有失败日志
+    const http500Logs = await queryLog(
+      `SELECT COUNT(*) as cnt FROM log_collect_raw
+       WHERE is_success = 0 AND error_message LIKE '%500%'
+       AND request_time BETWEEN ? AND ?`,
+      [phaseTimestamps['http500_start'], phaseTimestamps['http500_end']]
+    );
+    log(`    HTTP 500期间失败日志: ${http500Logs[0]?.cnt || 0}条`);
+
+    // 拒绝连接期间应该有失败日志
+    const refuseLogs = await queryLog(
+      `SELECT COUNT(*) as cnt FROM log_collect_raw
+       WHERE is_success = 0 AND error_message LIKE '%连接%'
+       AND request_time BETWEEN ? AND ?`,
+      [phaseTimestamps['refuse_start'], phaseTimestamps['refuse_end']]
+    );
+    log(`    拒绝连接期间失败日志: ${refuseLogs[0]?.cnt || 0}条`);
+
+    // 恢复后应有新数据
+    const recoveryRecords = await queryBusiness(
+      `SELECT COUNT(*) as cnt FROM cnc_collect_record
+       WHERE collect_time > ?`,
+      [phaseTimestamps['normal2_start']]
+    );
+    log(`    恢复后新增采集记录: ${recoveryRecords[0].cnt}条`);
+    expect(recoveryRecords[0].cnt).toBeGreaterThan(0);
+    log('  ✓ 恢复后数据正常产生');
+
+    log('\n  ✓ 数据完整性对比完成\n');
+  });
+
+  // ============================================================
+  // 生成测试报告
+  // ============================================================
+
+  test('报告: 生成15分钟采集测试报告', async () => {
+    test.setTimeout(30000);
+
+    // 确保报告目录存在
+    if (!fs.existsSync(REPORT_DIR)) {
+      fs.mkdirSync(REPORT_DIR, { recursive: true });
+    }
+
+    const timestamp = new Date().toISOString().replace(/[:.]/g, '').slice(0, 15);
+    const reportPath = path.join(REPORT_DIR, `${timestamp}-15分钟采集测试报告.md`);
+
+    // 收集最终数据
+    let simSummary: any = phaseSnapshots['normal2'] || {};
+    try {
+      const resp = await gatewayApi(`/admin/api/full-summary`);
+      if (resp.ok()) simSummary = await resp.json();
+    } catch { /* 模拟器可能已停止 */ }
+
+    const eventHistory = await gatewayApi(`/admin/api/event-history`);
+    const eventHistoryData = eventHistory.ok() ? await eventHistory.json() : [];
+
+    const errorLog = await gatewayApi(`/admin/api/error-log`);
+    const errorLogData = errorLog.ok() ? await errorLog.json() : [];
+
+    const dbRecords = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_collect_record WHERE collect_time > ?',
+      [testStartTime]
+    );
+    const dbSegments = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_production_segment WHERE created_at > ?',
+      [testStartTime]
+    );
+    const dbSettled = await queryBusiness(
+      'SELECT COUNT(*) as cnt FROM cnc_production_segment WHERE is_settled = 1 AND created_at > ?',
+      [testStartTime]
+    );
+    const dbRawLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE request_time > ?',
+      [testStartTime]
+    );
+    const dbSuccessLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE is_success = 1 AND request_time > ?',
+      [testStartTime]
+    );
+    const dbFailLogs = await queryLog(
+      'SELECT COUNT(*) as cnt FROM log_collect_raw WHERE is_success = 0 AND request_time > ?',
+      [testStartTime]
+    );
+
+    // 按设备统计
+    const machines = await queryBusiness(
+      'SELECT id, device_code, name FROM cnc_machine WHERE collect_address_id = 1'
+    );
+    let deviceStats = '';
+    for (const m of machines) {
+      const segs = await queryBusiness(
+        `SELECT program_name, SUM(quantity) as total_qty, COUNT(*) as seg_count, close_reason
+         FROM cnc_production_segment WHERE machine_id = ? AND created_at > ?
+         GROUP BY program_name`,
+        [m.id, testStartTime]
+      );
+      const totalQty = segs.reduce((s: number, r: any) => s + (Number(r.total_qty) || 0), 0);
+      const programs = segs.map((r: any) => `${r.program_name}(${r.total_qty}个/${r.seg_count}段)`).join(', ');
+      deviceStats += `| ${m.device_code} | ${m.name} | ${totalQty} | ${segs.length} | ${programs} |\n`;
+    }
+
+    // 阶段时间表
+    let phaseTable = '';
+    const phaseNames: Record<string, string> = {
+      'normal1_start': '阶段1: 正常采集开始',
+      'http500_start': '阶段2: HTTP 500异常开始',
+      'http500_end': '阶段2: HTTP 500异常结束',
+      'timeout_start': '阶段3: 超时异常开始',
+      'timeout_end': '阶段3: 超时异常结束',
+      'empty_start': '阶段4: 空数据返回开始',
+      'empty_end': '阶段4: 空数据返回结束',
+      'refuse_start': '阶段5: 拒绝连接开始',
+      'refuse_end': '阶段5: 拒绝连接结束',
+      'normal2_start': '阶段6: 恢复正常开始',
+      'normal2_end': '阶段6: 恢复正常结束',
+    };
+    for (const [key, name] of Object.entries(phaseNames)) {
+      const ts = phaseTimestamps[key];
+      if (ts) {
+        phaseTable += `| ${name} | ${ts.toLocaleString('zh-CN')} |\n`;
+      }
+    }
+
+    // 事件历史摘要
+    let eventSummary = '';
+    if (Array.isArray(eventHistoryData)) {
+      const eventTypeCounts: Record<string, number> = {};
+      for (const evt of eventHistoryData) {
+        const type = evt.eventType || 'unknown';
+        eventTypeCounts[type] = (eventTypeCounts[type] || 0) + 1;
+      }
+      for (const [type, count] of Object.entries(eventTypeCounts)) {
+        eventSummary += `| ${type} | ${count} |\n`;
+      }
+    }
+
+    // 异常日志摘要
+    let errorSummary = '';
+    if (Array.isArray(errorLogData) && errorLogData.length > 0) {
+      for (const err of errorLogData.slice(0, 20)) {
+        errorSummary += `| ${err.timestamp} | ${err.errorType} | ${err.description} | ${err.affectedDevices} |\n`;
+      }
+    }
+
+    const report = `# 15分钟自动化采集测试报告
+
+**生成时间:** ${new Date().toLocaleString('zh-CN')}
+**测试开始:** ${testStartTime.toLocaleString('zh-CN')}
+**测试结束:** ${new Date().toLocaleString('zh-CN')}
+**总时长:** ${Math.round((Date.now() - testStartTime.getTime()) / 60000)}分钟
+
+---
+
+## 一、测试环境
+
+| 项目 | 值 |
+|------|------|
+| 模拟器端口 | ${simulationPort} |
+| 采集间隔 | 10秒 |
+| 机床数量 | ${machines.length}台 |
+| 采集地址 | http://localhost:${simulationPort}/ (id=1) |
+
+## 二、测试阶段时间表
+
+| 阶段 | 时间 |
+|------|------|
+| 测试开始 | ${testStartTime.toLocaleString('zh-CN')} |
+${phaseTable}
+| 测试结束 | ${new Date().toLocaleString('zh-CN')} |
+
+## 三、模拟器汇总数据
+
+| 项目 | 值 |
+|------|------|
+| 总设备数 | ${simSummary.totalDevices || '?'} |
+| 在线设备数 | ${simSummary.onlineDevices || '?'} |
+| 总加工零件数 | ${simSummary.totalParts || '?'} |
+| 总请求数 | ${simSummary.totalRequests || '?'} |
+| 成功请求数 | ${simSummary.successRequests || '?'} |
+| 失败请求数 | ${simSummary.failRequests || '?'} |
+| 异常记录数 | ${simSummary.errorCount || 0} |
+
+## 四、数据库统计
+
+| 项目 | 数量 |
+|------|------|
+| 采集记录数(cnc_collect_record) | ${dbRecords[0].cnt} |
+| 产量分段数(cnc_production_segment) | ${dbSegments[0].cnt} |
+| 已结账分段数 | ${dbSettled[0].cnt} |
+| 原始日志数(log_collect_raw) | ${dbRawLogs[0].cnt} |
+| 成功日志数 | ${dbSuccessLogs[0].cnt} |
+| 失败日志数 | ${dbFailLogs[0].cnt} |
+
+## 五、按设备产量对比
+
+| 设备编码 | 设备名称 | 数据库总产量 | 分段数 | 程序明细 |
+|---------|---------|-------------|--------|---------|
+${deviceStats}
+
+## 六、事件历史统计
+
+| 事件类型 | 次数 |
+|---------|------|
+${eventSummary || '| (无事件) | 0 |'}
+
+## 七、异常日志记录
+
+| 时间 | 类型 | 描述 | 影响设备数 |
+|------|------|------|-----------|
+${errorSummary || '| (无异常记录) | - | - | - |'}
+
+## 八、结论
+
+${mismatchCount === 0 ? '✅ 所有设备零件数量完全匹配，数据采集准确性验证通过。' : `⚠️ 有 ${mismatchCount} 台设备零件数存在差异，需进一步排查。`}
+
+- 采集记录总数: ${dbRecords[0].cnt}
+- 产量分段总数: ${dbSegments[0].cnt} (已结账 ${dbSettled[0].cnt})
+- 原始日志总数: ${dbRawLogs[0].cnt} (成功 ${dbSuccessLogs[0].cnt}, 失败 ${dbFailLogs[0].cnt})
+- 异常恢复验证: ${phaseTimestamps['normal2_start'] ? '✅ 恢复后数据正常产生' : '❌ 未验证'}
+
+---
+*报告由 Playwright 自动化测试生成*
+`;
+
+    fs.writeFileSync(reportPath, report, 'utf-8');
+    log(`\n===== 测试报告已生成 =====`);
+    log(`  路径: ${reportPath}`);
+    log(`\n===== 15分钟自动化采集测试结束 =====\n`);
+  });
+
+});

src/CncSimulator/Core/LogRecorder.cs

@@ -25,6 +25,19 @@ namespace CncSimulator.Core
         public long Duration { get; set; }
     }
 
+    /// <summary>异常记录条目</summary>
+    public class ErrorRecord
+    {
+        /// <summary>时间戳</summary>
+        public DateTime Timestamp { get; set; }
+        /// <summary>异常类型: http500, timeout, empty, malformed, refuse</summary>
+        public string ErrorType { get; set; }
+        /// <summary>异常描述</summary>
+        public string Description { get; set; }
+        /// <summary>影响设备数</summary>
+        public int AffectedDevices { get; set; }
+    }
+
     /// <summary>
     /// 日志记录器。同时写入内存环形缓冲和log4net文件。
     /// </summary>
@@ -37,6 +50,10 @@ namespace CncSimulator.Core
         private readonly object _lock = new object();
         private readonly log4net.ILog _log;
 
+        // 异常记录列表（独立于请求日志）
+        private readonly List<ErrorRecord> _errors = new List<ErrorRecord>();
+        private readonly object _errorLock = new object();
+
         public LogRecorder(int capacity = 200)
         {
             _capacity = capacity;
@@ -71,6 +88,40 @@ namespace CncSimulator.Core
             _log.Info($"[{addressPort}] 关键数据: {keyData}");
         }
 
+        /// <summary>记录一次异常</summary>
+        public void RecordError(string errorType, string description, int affectedDevices)
+        {
+            var record = new ErrorRecord
+            {
+                Timestamp = DateTime.Now,
+                ErrorType = errorType,
+                Description = description,
+                AffectedDevices = affectedDevices
+            };
+            lock (_errorLock)
+            {
+                _errors.Add(record);
+                // 限制数量
+                if (_errors.Count > 1000) _errors.RemoveAt(0);
+            }
+            _log.Warn($"[异常] 类型={errorType}, 影响{affectedDevices}台设备: {description}");
+        }
+
+        /// <summary>获取所有异常记录</summary>
+        public List<ErrorRecord> GetErrors()
+        {
+            lock (_errorLock)
+            {
+                return new List<ErrorRecord>(_errors);
+            }
+        }
+
+        /// <summary>获取异常次数统计</summary>
+        public int GetErrorCount()
+        {
+            lock (_errorLock) { return _errors.Count; }
+        }
+
         /// <summary>获取最近的日志</summary>
         public List<LogEntry> GetRecentLogs(int count)
         {

src/CncSimulator/Core/SimulatorServer.cs

@@ -427,19 +427,23 @@ namespace CncSimulator.Core
             {
                 case "http500":
                     _failCount++;
+                    _logRecorder.RecordError("http500", "模拟HTTP 500错误", OnlineDeviceCount);
                     SendTextResponse(ctx, 500, "Internal Server Error (模拟)");
                     return;
                 case "timeout":
                     _failCount++;
+                    _logRecorder.RecordError("timeout", "模拟超时响应(60秒延迟)", OnlineDeviceCount);
                     System.Threading.Thread.Sleep(60000);
                     SendTextResponse(ctx, 200, "delayed response");
                     return;
                 case "empty":
                     _successCount++;
+                    _logRecorder.RecordError("empty", "模拟空数据返回([])", OnlineDeviceCount);
                     SendTextResponse(ctx, 200, "[]", "application/json");
                     return;
                 case "malformed":
                     _successCount++;
+                    _logRecorder.RecordError("malformed", "模拟畸形JSON返回({broken)", OnlineDeviceCount);
                     SendTextResponse(ctx, 200, "{broken", "application/json");
                     return;
             }
@@ -579,12 +583,119 @@ namespace CncSimulator.Core
                     SendTextResponse(ctx, 200, removed ? "{\"ok\":true}" : "{\"ok\":false}", "application/json");
                     break;
 
+                case "/admin/api/event-history":
+                    HandleEventHistoryApi(ctx);
+                    break;
+
+                case "/admin/api/full-summary":
+                    HandleFullSummaryApi(ctx);
+                    break;
+
+                case "/admin/api/error-log":
+                    HandleErrorLogApi(ctx);
+                    break;
+
                 default:
                     SendJsonResponse(ctx, 404, "{\"error\":\"Unknown API\"}");
                     break;
             }
         }
 
+        // ===== 新增API处理方法 =====
+
+        /// <summary>事件历史API：返回所有设备的事件变更记录</summary>
+        private void HandleEventHistoryApi(HttpListenerContext ctx)
+        {
+            var allEvents = new JArray();
+            foreach (var dev in _devices)
+            {
+                foreach (var evt in dev.State.EventHistory)
+                {
+                    allEvents.Add(new JObject
+                    {
+                        ["timestamp"] = evt.Timestamp.ToString("yyyy-MM-dd HH:mm:ss"),
+                        ["deviceCode"] = evt.DeviceCode,
+                        ["eventType"] = evt.EventType,
+                        ["oldProgram"] = evt.OldProgram,
+                        ["newProgram"] = evt.NewProgram,
+                        ["partCountBefore"] = evt.PartCountBefore,
+                        ["partCountAfter"] = evt.PartCountAfter,
+                        ["detail"] = evt.Detail
+                    });
+                }
+            }
+            SendTextResponse(ctx, 200, allEvents.ToString(), "application/json");
+        }
+
+        /// <summary>完整汇总导出API：用于测试结束后数据对比</summary>
+        private void HandleFullSummaryApi(HttpListenerContext ctx)
+        {
+            var devices = new JArray();
+            foreach (var dev in _devices)
+            {
+                var s = dev.State;
+                var programs = new JObject();
+                foreach (var kvp in s.PartsByProgram)
+                {
+                    programs[kvp.Key] = kvp.Value;
+                }
+                devices.Add(new JObject
+                {
+                    ["deviceCode"] = s.DeviceCode,
+                    ["desc"] = s.Desc,
+                    ["isOnline"] = s.IsOnline,
+                    ["currentProgram"] = s.ProgramName,
+                    ["currentPartCount"] = s.PartCount,
+                    ["totalParts"] = s.TotalPartsSinceStart,
+                    ["programs"] = programs,
+                    ["eventCount"] = s.EventHistory.Count,
+                    ["lastEvent"] = s.EventHistory.Count > 0
+                        ? new JObject
+                        {
+                            ["type"] = s.EventHistory[s.EventHistory.Count - 1].EventType,
+                            ["time"] = s.EventHistory[s.EventHistory.Count - 1].Timestamp.ToString("yyyy-MM-dd HH:mm:ss")
+                        }
+                        : null
+                });
+            }
+
+            var summary = new JObject
+            {
+                ["exportTime"] = DateTime.Now.ToString("yyyy-MM-dd HH:mm:ss"),
+                ["addressName"] = _config.Name,
+                ["port"] = _config.Port,
+                ["startTime"] = _startTime.ToString("yyyy-MM-dd HH:mm:ss"),
+                ["uptime"] = (DateTime.Now - _startTime).ToString(@"hh\:mm\:ss"),
+                ["totalDevices"] = _devices.Count,
+                ["onlineDevices"] = OnlineDeviceCount,
+                ["totalParts"] = GetTotalParts(),
+                ["totalRequests"] = _requestCount,
+                ["successRequests"] = _successCount,
+                ["failRequests"] = _failCount,
+                ["errorCount"] = _logRecorder.GetErrorCount(),
+                ["devices"] = devices
+            };
+            SendTextResponse(ctx, 200, summary.ToString(), "application/json");
+        }
+
+        /// <summary>异常日志API：返回所有异常记录</summary>
+        private void HandleErrorLogApi(HttpListenerContext ctx)
+        {
+            var errors = _logRecorder.GetErrors();
+            var arr = new JArray();
+            foreach (var err in errors)
+            {
+                arr.Add(new JObject
+                {
+                    ["timestamp"] = err.Timestamp.ToString("yyyy-MM-dd HH:mm:ss"),
+                    ["errorType"] = err.ErrorType,
+                    ["description"] = err.Description,
+                    ["affectedDevices"] = err.AffectedDevices
+                });
+            }
+            SendTextResponse(ctx, 200, arr.ToString(), "application/json");
+        }
+
         // ===== HTTP辅助方法 =====
 
         private string ReadRequestBody(HttpListenerContext ctx)

src/CncSimulator/Device/DeviceSimulator.cs

@@ -178,6 +178,7 @@ namespace CncSimulator.Device
         private void ApplyProgramChange()
         {
             string oldProgram = _state.ProgramName;
+            int oldPartCount = _state.PartCount;
             _programPoolIndex = (_programPoolIndex + 1) % ProgramPool.Length;
             _state.ProgramName = ProgramPool[_programPoolIndex];
             _state.PartCount = 0;
@@ -190,14 +191,19 @@ namespace CncSimulator.Device
             _state.FeedSpeedSet = _rng.Next(30, 151);
             _state.SpindleOverride = 100;
             _state.ProgramContent = "<" + _state.ProgramName + ">\nG40G49G80\n( SIMULATOR )";
+            // 记录事件历史
+            _state.RecordEvent("program_change", oldProgram, _state.ProgramName, oldPartCount, 0);
         }
 
         /// <summary>手动清零</summary>
         private void ApplyManualReset()
         {
+            int oldPartCount = _state.PartCount;
             _state.PartCount = 0;
             _state.RunStatus = 3;
             _state.DeviceStatus = 1;
+            // 记录事件历史
+            _state.RecordEvent("manual_reset", _state.ProgramName, _state.ProgramName, oldPartCount, 0);
         }
 
         /// <summary>断电</summary>
@@ -205,11 +211,14 @@ namespace CncSimulator.Device
         {
             _state.IsOnline = false;
             _state.DeviceStatus = 0;
+            // 记录事件历史
+            _state.RecordEvent("power_off", _state.ProgramName, _state.ProgramName, _state.PartCount, _state.PartCount, "设备断电");
         }
 
         /// <summary>恢复开机</summary>
         private void ApplyPowerOn()
         {
+            int oldPartCount = _state.PartCount;
             _state.IsOnline = true;
             _state.DeviceStatus = 1;
             _state.PartCount = 0;
@@ -220,6 +229,8 @@ namespace CncSimulator.Device
             _state.FeedSpeedActual = 0;
             _state.SpindleLoad = 0;
             _state.MachiningStatus = "";
+            // 记录事件历史
+            _state.RecordEvent("power_on", _state.ProgramName, _state.ProgramName, oldPartCount, 0, "设备开机，零件数清零");
         }
     }
 }

src/CncSimulator/Device/DeviceState.cs

@@ -1,3 +1,4 @@
+using System;
 using System.Collections.Generic;
 
 namespace CncSimulator.Device
@@ -87,5 +88,49 @@ namespace CncSimulator.Device
 
         /// <summary>按NC程序名统计的零件数（程序名 → 零件数）</summary>
         public Dictionary<string, int> PartsByProgram { get; set; } = new Dictionary<string, int>();
+
+        // ===== 事件历史 =====
+        /// <summary>事件变更历史记录（最多保留1000条）</summary>
+        public List<EventRecord> EventHistory { get; set; } = new List<EventRecord>();
+
+        /// <summary>记录一次事件</summary>
+        public void RecordEvent(string eventType, string oldProgram, string newProgram, int partCountBefore, int partCountAfter, string detail = null)
+        {
+            var record = new EventRecord
+            {
+                Timestamp = DateTime.Now,
+                DeviceCode = DeviceCode,
+                EventType = eventType,
+                OldProgram = oldProgram ?? "",
+                NewProgram = newProgram ?? "",
+                PartCountBefore = partCountBefore,
+                PartCountAfter = partCountAfter,
+                Detail = detail ?? ""
+            };
+            EventHistory.Add(record);
+            // 限制历史记录数量
+            if (EventHistory.Count > 1000) EventHistory.RemoveAt(0);
+        }
+    }
+
+    /// <summary>设备事件记录</summary>
+    public class EventRecord
+    {
+        /// <summary>事件时间</summary>
+        public DateTime Timestamp { get; set; }
+        /// <summary>设备编码</summary>
+        public string DeviceCode { get; set; }
+        /// <summary>事件类型: program_change, manual_reset, power_off, power_on, scenario_change</summary>
+        public string EventType { get; set; }
+        /// <summary>变更前程序名</summary>
+        public string OldProgram { get; set; }
+        /// <summary>变更后程序名</summary>
+        public string NewProgram { get; set; }
+        /// <summary>变更前零件数</summary>
+        public int PartCountBefore { get; set; }
+        /// <summary>变更后零件数</summary>
+        public int PartCountAfter { get; set; }
+        /// <summary>额外详情</summary>
+        public string Detail { get; set; }
     }
 }