采集服务产量统计全流程测试验证：DB Schema同步、品牌映射修正、采集/模拟器代码修改、10场景测试全通过

database/01-init-schema.sql

@@ -83,6 +83,7 @@ CREATE TABLE IF NOT EXISTS cnc_machine (
     last_run_status     VARCHAR(20) NULL,
     last_program_name   VARCHAR(200) NULL,
     last_part_count     DECIMAL(15,5) NULL,
+    last_total_part_count DECIMAL(15,5) NULL,
     last_operate_mode   VARCHAR(20) NULL,
     last_machining_status VARCHAR(20) NULL,
     created_at          DATETIME NOT NULL DEFAULT CURRENT_TIMESTAMP,
@@ -128,6 +129,7 @@ CREATE TABLE IF NOT EXISTS cnc_collect_record (
     device_time           DATETIME NULL,
     program_name          VARCHAR(200) NULL,
     part_count            DECIMAL(15,5) NULL,
+    total_part_count      DECIMAL(15,5) NULL,
     device_status         VARCHAR(20) NULL,
     run_status            VARCHAR(20) NULL,
     operate_mode          VARCHAR(20) NULL,

database/02-init-data.sql

@@ -15,26 +15,18 @@ INSERT IGNORE INTO cnc_workshop (name, sort_order, is_enabled) VALUES
 INSERT IGNORE INTO cnc_brand (brand_name, device_field, tags_path, is_enabled) VALUES
 ('FANUC', 'device', 'tags', 1);
 
--- FANUC字段映射预置
+-- FANUC字段映射预置（field_name = 实际FANUC采集JSON中的tag id）
 SET @fanuc_brand_id = (SELECT id FROM cnc_brand WHERE brand_name = 'FANUC');
 
 INSERT IGNORE INTO cnc_brand_field_mapping (brand_id, standard_field, field_name, match_by, data_type, is_required) VALUES
-(@fanuc_brand_id, 'program_name', 'program_name', 'id', 'string', 1),
+(@fanuc_brand_id, 'program_name', 'Tag5', 'id', 'string', 1),
-(@fanuc_brand_id, 'part_count', 'part_count', 'id', 'number', 1),
+(@fanuc_brand_id, 'part_count', 'Tag8', 'id', 'number', 1),
-(@fanuc_brand_id, 'device_status', 'device_status', 'id', 'number', 0),
+(@fanuc_brand_id, 'total_part_count', 'Tag1', 'id', 'number', 0),
-(@fanuc_brand_id, 'run_status', 'run_status', 'id', 'number', 0),
+(@fanuc_brand_id, 'device_status', '_io_status', 'id', 'number', 0),
-(@fanuc_brand_id, 'operate_mode', 'operate_mode', 'id', 'number', 0),
+(@fanuc_brand_id, 'run_status', 'Tag9', 'id', 'number', 0),
-(@fanuc_brand_id, 'spindle_speed_set', 'spindle_speed_set', 'id', 'number', 0),
+(@fanuc_brand_id, 'operate_mode', 'Tag11', 'id', 'number', 0),
-(@fanuc_brand_id, 'feed_speed_set', 'feed_speed_set', 'id', 'number', 0),
+(@fanuc_brand_id, 'power_on_time', 'Tag22', 'id', 'number', 0),
-(@fanuc_brand_id, 'spindle_speed_actual', 'spindle_speed_actual', 'id', 'number', 0),
+(@fanuc_brand_id, 'run_time', 'Tag23', 'id', 'number', 0);
-(@fanuc_brand_id, 'feed_speed_actual', 'feed_speed_actual', 'id', 'number', 0),
-(@fanuc_brand_id, 'spindle_load', 'spindle_load', 'id', 'number', 0),
-(@fanuc_brand_id, 'spindle_override', 'spindle_override', 'id', 'number', 0),
-(@fanuc_brand_id, 'power_on_time', 'power_on_time', 'id', 'number', 0),
-(@fanuc_brand_id, 'run_time', 'run_time', 'id', 'number', 0),
-(@fanuc_brand_id, 'cutting_time', 'cutting_time', 'id', 'number', 0),
-(@fanuc_brand_id, 'cycle_time', 'cycle_time', 'id', 'number', 0),
-(@fanuc_brand_id, 'machining_status', 'machining_status', 'id', 'string', 0);
 
 -- 系统配置预置
 INSERT IGNORE INTO cnc_sys_config (config_key, config_value, value_type, description) VALUES

docs/00-需求与设计文档.md

@@ -63,6 +63,9 @@
 | 原始数据 | 存原始JSON到日志库，解析后结构化数据存业务库 |
 | 时间标准 | 以服务器时间为准，机床时间仅存为参考字段 |
 | 数值处理 | 自动去除.00000尾缀，转换为数值/字符串 |
+| 数据有效性 | quality≠0的tag无效；time以1970-01-01开头的tag无效（采集失败）；_io_status始终有效不受quality/time约束 |
+| 总零件数 | Tag1（加工零件总数）为历史终身累计值，与Tag8（当前程序零件数）不同维度 |
+| 变更检测 | 采集服务对比tag的value值判断变化，不依赖time字段（time和value独立变化） |
 
 ### 4.3 零件产量统计
 

docs/01-数据库设计.md

@@ -88,6 +88,7 @@ CREATE TABLE cnc_brand_field_mapping (
 | cutting_time | 切削时间 | number |
 | cycle_time | 循环时间 | number |
 | machining_status | 加工状态 | string |
+| total_part_count | 历史累计加工零件总数 | number |
 
 索引：uk_brand_standard唯一约束同时作为索引，保证同一品牌下标准字段不重复，采集时按brand_id查询所有映射规则。
 
@@ -137,6 +138,7 @@ CREATE TABLE cnc_machine (
     last_run_status     VARCHAR(20) NULL,
     last_program_name   VARCHAR(200) NULL,
     last_part_count     DECIMAL(15,5) NULL,
+    last_total_part_count DECIMAL(15,5) NULL,
     last_operate_mode   VARCHAR(20) NULL,
     last_machining_status VARCHAR(20) NULL,
     created_at          DATETIME NOT NULL DEFAULT CURRENT_TIMESTAMP,
@@ -208,6 +210,7 @@ CREATE TABLE cnc_collect_record (
     device_time           DATETIME NULL,
     program_name          VARCHAR(200) NULL,
     part_count            DECIMAL(15,5) NULL,
+    total_part_count      DECIMAL(15,5) NULL,
     device_status         VARCHAR(20) NULL,
     run_status            VARCHAR(20) NULL,
     operate_mode          VARCHAR(20) NULL,

docs/07-发那科数据结构变更调整方案.md

@@ -0,0 +1,508 @@
+# 发那科采集数据结构变更 - 系统调整方案
+
+> 创建时间：2026-05-11
+> 触发原因：发那科系统采集示例文件（根目录 `发那科系统采集示例.txt`）更新，实际FANUC采集数据结构与系统原有设计存在差异
+> 涉及模块：CncSimulator模拟器、数据库设计、采集服务设计、后台管理功能
+
+---
+
+## 一、实际FANUC数据结构（2026-05-11 采自生产环境）
+
+### 1.1 顶层结构
+
+```json
+[
+  {
+    "device": "fanake-1.2_1.2",   // 设备编码，匹配 cnc_machine.device_code
+    "desc": "西-1.2",              // 设备描述
+    "tags": [ ... ]                // 10个Tag
+  },
+  ...
+]
+```
+
+共32台设备，每台10个Tag。其中25台在线、7台离线。
+
+### 1.2 Tag清单（10个）
+
+| # | Tag ID | desc（中文） | 类型 | 示例值 | 备注 |
+|---|--------|-------------|------|--------|------|
+| 1 | `_io_status` | 设备状态 | 数值 | 0.00000 / 1.00000 | 0=离线, 1=在线；**始终有效** |
+| 2 | `Tag5` | 执行的NC主程序名 | 字符串 | O1, O9001, 1370.NC, 7, 1027, O2, 037.NC | 可为空 |
+| 3 | `Tag6` | 执行的NC主程序号 | 字符串 | N0, N1, N9, N20 | |
+| 4 | `Tag7` | 当前加工程序内容 | 字符串 | G代码片段 | 可为空 |
+| 5 | `Tag8` | 当前加工零件数 | 数值 | 35.00000 | 当前程序的零件计数 |
+| 6 | `Tag9` | 运行状态 | 数值 | 0.00000 / 1.00000 / 3.00000 | 0=待机, 1=运行, 3=加工中 |
+| 7 | `Tag11` | 操作模式 | 数值 | 1 / 4 / 5 / 10 | 1=MEM, 4=?, 5=?, 10=JOG |
+| 8 | `Tag22` | 开机时间 | 数值 | 45129840.00000 | 秒，历史累计 |
+| 9 | `Tag23` | 运行时间 | 数值 | 12201.00000 | 秒，历史累计 |
+| 10 | `Tag1` | 加工零件总数 | 数值 | 45930.00000 | **历史终身累计，新增字段** |
+
+### 1.3 数据有效性规则
+
+#### 规则1：Quality字段
+
+| quality值 | 含义 | 处理方式 |
+|-----------|------|---------|
+| `"0"` | 数据有效 | 正常解析 |
+| `"1"` | 数据无效（采集失败/设备离线） | 忽略该tag的value |
+
+#### 规则2：Time字段（采集失败标记）
+
+| time值 | 含义 | 处理方式 |
+|--------|------|---------|
+| `1970-01-01 08:00:00` | 采集失败 | 忽略该tag的value |
+| 其他正常时间 | 数据时间戳 | 正常使用 |
+
+#### 规则3：_io_status 特殊处理
+
+`_io_status` tag **不受规则1和规则2约束**，始终读取value判断设备在线/离线：
+- 即使设备离线，`_io_status` 的 quality=0、time=真实时间、value=0
+
+#### 规则4：Time与Value独立变化
+
+每个tag的 `time` 和 `value` 更新频率不固定：
+- time变了、value没变
+- value变了、time没变
+- 都变了
+- 都没变
+
+**采集服务的变更检测必须对比value值，不能依赖time变化作为变更信号。**
+
+### 1.4 离线设备特征
+
+以 fanake-1.10 为例：
+
+```
+_io_status: quality=0, value=0.00000, time=2026-05-11 17:06:34   ← 始终有效
+Tag5:       quality=1, value="",       time=1970-01-01 08:00:00  ← 无效
+Tag6:       quality=1, value="",       time=1970-01-01 08:00:00  ← 无效
+Tag7:       quality=1, value="",       time=1970-01-01 08:00:00  ← 无效
+Tag8:       quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+Tag9:       quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+Tag11:      quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+Tag22:      quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+Tag23:      quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+Tag1:       quality=1, value=0.00000,  time=1970-01-01 08:00:00  ← 无效
+```
+
+---
+
+## 二、与现有设计的差异对比
+
+### 2.1 模拟器（FanucDataGenerator）差异
+
+| 差异项 | 现有模拟器（18个Tag） | 实际FANUC（10个Tag） | 影响 |
+|--------|----------------------|---------------------|------|
+| Tag2 (当前轴数) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag14 (主轴倍率) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag17 (主轴设定速度) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag18 (进给设定速度) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag19 (主轴实际速度) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag20 (进给实际转速) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag21 (主轴负载) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag24 (切削时间) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag25 (循环时间) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| Tag26 (加工状态) | ✅ 有 | ❌ 不存在 | 模拟器多余 |
+| **Tag1 (加工零件总数)** | ❌ 缺少 | ✅ 有 | **模拟器缺少，需新增** |
+| Tag6 desc | "执行的NC主程序号" | "执行的NC主程序号" | 一致 |
+
+### 2.2 数据库设计差异
+
+| 差异项 | 现有设计 | 实际需求 |
+|--------|---------|---------|
+| 标准字段 total_part_count | ❌ 无 | ✅ 需要新增，对应Tag1 |
+| cnc_collect_record.total_part_count | ❌ 无 | ✅ 需要新增列 |
+| cnc_machine.last_total_part_count | ❌ 无 | ✅ 需要新增列 |
+
+### 2.3 采集服务设计差异
+
+| 差异项 | 现有设计假设 | 实际行为 |
+|--------|-------------|---------|
+| 数据有效性判断 | 未明确quality处理 | 需按quality+time双规则过滤 |
+| _io_status处理 | 未明确特殊性 | 始终有效，不受quality/time约束 |
+| 变更检测 | 未明确time/value独立性 | 必须对比value，不看time |
+| Tag1(总零件数) | 无此字段 | 需解析并存储 |
+
+### 2.4 后台管理差异
+
+| 差异项 | 现有设计 | 实际需求 |
+|--------|---------|---------|
+| 速度/倍率/负载字段 | 设计了展示 | FANUC设备这些字段为NULL，需处理空值 |
+| 加工零件总数 | 未设计展示 | 可选展示 |
+| 操作模式枚举 | 仅定义1=MEM, 10=JOG | 实际还有4、5值，需补充定义 |
+
+---
+
+## 三、调整方案
+
+### 3.1 CncSimulator 模拟器调整（优先级：高）
+
+> 目标：让模拟器生成的数据结构与实际FANUC完全一致
+
+#### 3.1.1 DeviceState.cs 修改
+
+```diff
+  public class DeviceState
+  {
+      // ===== 固定信息（来自配置） =====
+      public string DeviceCode { get; set; }
+      public string Desc { get; set; }
+
+      // ===== 动态状态 =====
+      public string CurrentScenario { get; set; } = "idle";
+      public bool IsOnline { get; set; } = true;
+      public string ProgramName { get; set; } = "O0001";
+      public int PartCount { get; set; } = 0;
++     /// <summary>历史终身累计零件总数（对应Tag1）</summary>
++     public decimal TotalPartCount { get; set; } = 0;
+      public int DeviceStatus { get; set; } = 1;
+      public int RunStatus { get; set; } = 0;
+      public int OperateMode { get; set; } = 1;
+-     public decimal SpindleSpeedSet { get; set; } = 450;
+-     public decimal FeedSpeedSet { get; set; } = 60;
+-     public decimal SpindleSpeedActual { get; set; } = 0;
+-     public decimal FeedSpeedActual { get; set; } = 0;
+-     public decimal SpindleLoad { get; set; } = 0;
+-     public decimal SpindleOverride { get; set; } = 100;
+      public decimal PowerOnTime { get; set; } = 0;
+      public decimal RunTime { get; set; } = 0;
+-     public decimal CuttingTime { get; set; } = 0;
+-     public decimal CycleTime { get; set; } = 0;
+-     public string MachiningStatus { get; set; } = "";
+      public string ProgramContent { get; set; } = "";
+      // ... 其余字段保留不变
+  }
+```
+
+**说明**：移除实际FANUC不存在的字段（SpindleSpeedSet、FeedSpeedSet、SpindleSpeedActual、FeedSpeedActual、SpindleLoad、SpindleOverride、CuttingTime、CycleTime、MachiningStatus），新增TotalPartCount。
+
+#### 3.1.2 FanucDataGenerator.cs 修改
+
+```diff
+  private JArray GenerateTags(DeviceState state)
+  {
+      var tags = new JArray();
+      DateTime baseTime = DateTime.Now;
+
+      // 每个tag的时间基准上随机偏移 -5~0 秒
+      DateTime TagTime()
+      {
+          return baseTime.AddSeconds(-_rng.Next(0, 6));
+      }
+
+      void AddNumericTag(string id, string desc, decimal value) { /* 不变 */ }
+      void AddStringTag(string id, string desc, string value) { /* 不变 */ }
+
+-     // 18个tag → 10个tag，与实际FANUC完全一致
+      AddNumericTag("_io_status", "设备状态", state.DeviceStatus);
+-     AddNumericTag("Tag2", "当前轴数", 4);
++     AddNumericTag("Tag1", "加工零件总数", state.TotalPartCount);
+      AddStringTag("Tag5", "执行的NC主程序名", state.ProgramName);
+      AddStringTag("Tag6", "执行的NC主程序号", "N0");
+      AddStringTag("Tag7", "当前加工程序内容", /* ... */);
+      AddNumericTag("Tag8", "当前加工零件数", state.PartCount);
+      AddNumericTag("Tag9", "运行状态", state.RunStatus);
+      AddNumericTag("Tag11", "操作模式", state.OperateMode);
+-     AddNumericTag("Tag14", "当前主轴倍率", state.SpindleOverride);
+-     AddNumericTag("Tag17", "主轴设定速度", state.SpindleSpeedSet);
+-     AddNumericTag("Tag18", "进给设定速度", state.FeedSpeedSet);
+-     AddNumericTag("Tag19", "主轴实际速度", state.SpindleSpeedActual);
+-     AddNumericTag("Tag20", "进给实际转速", state.FeedSpeedActual);
+-     AddNumericTag("Tag21", "主轴负载", state.SpindleLoad);
+      AddNumericTag("Tag22", "开机时间", state.PowerOnTime);
+      AddNumericTag("Tag23", "运行时间", state.RunTime);
+-     AddNumericTag("Tag24", "切削时间", state.CuttingTime);
+-     AddNumericTag("Tag25", "循环时间", state.CycleTime);
+-     AddStringTag("Tag26", "加工状态", state.MachiningStatus);
+
+      return tags;
+  }
+```
+
+#### 3.1.3 DeviceSimulator.cs 修改
+
+- 构造函数：新增 `TotalPartCount` 初始值配置（从simulator.json读取）
+- `machining` 场景：`TotalPartCount++`
+- `ApplyProgramChange()`：TotalPartCount 不清零（终身累计）
+- `ApplyManualReset()`：TotalPartCount 不清零
+- `ApplyPowerOn()`：TotalPartCount 不清零
+- 移除所有已删除字段（SpindleSpeed*、SpindleLoad、SpindleOverride、CuttingTime、CycleTime、MachiningStatus）的模拟逻辑
+
+#### 3.1.4 simulator.json 修改
+
+devices配置中新增 `initialTotalPartCount` 字段：
+
+```json
+{
+  "deviceCode": "CNC-A001",
+  "desc": "西栋1号",
+  "initialProgram": "O0001",
+  "initialPartCount": 50,
+  "initialTotalPartCount": 45000
+}
+```
+
+#### 3.1.5 模拟器离线行为
+
+当设备断电（power_off）时，需要生成与实际一致的离线数据：
+- `_io_status`：quality=0, value=0, time=当前时间
+- 其他所有tag：quality=1, value="" 或 "0.00000", time="1970-01-01 08:00:00"
+
+---
+
+### 3.2 数据库设计调整（优先级：高）
+
+#### 3.2.1 cnc_brand_field_mapping 标准字段约定
+
+在 `docs/01-数据库设计.md` 的标准字段约定表中新增：
+
+| standard_field | 含义 | data_type |
+|----------------|------|-----------|
+| **total_part_count** | **历史累计加工零件总数** | **number** |
+
+#### 3.2.2 cnc_collect_record 表
+
+新增列：
+
+```sql
+ALTER TABLE cnc_collect_record
+  ADD COLUMN total_part_count DECIMAL(15,5) NULL COMMENT '历史累计加工零件总数'
+  AFTER part_count;
+```
+
+完整DDL变更位置：在 `part_count` 列之后增加 `total_part_count` 列。
+
+#### 3.2.3 cnc_machine 表
+
+新增列：
+
+```sql
+ALTER TABLE cnc_machine
+  ADD COLUMN last_total_part_count DECIMAL(15,5) NULL COMMENT '最新历史累计加工零件总数'
+  AFTER last_part_count;
+```
+
+#### 3.2.4 FANUC品牌预置映射数据
+
+在 `database/` 预置数据脚本中，FANUC品牌的 field_mapping 新增一行：
+
+| brand_id | standard_field | field_name | match_by | data_type | is_required |
+|----------|---------------|------------|----------|-----------|-------------|
+| (FANUC) | total_part_count | Tag1 | id | number | 0 |
+
+同时，以下标准字段在实际FANUC中不存在，映射记录应标记 `is_required=0` 或不创建映射（由采集服务按实际数据决定）：
+- spindle_speed_set → 无对应Tag
+- feed_speed_set → 无对应Tag
+- spindle_speed_actual → 无对应Tag
+- feed_speed_actual → 无对应Tag
+- spindle_load → 无对应Tag
+- spindle_override → 无对应Tag
+- cutting_time → 无对应Tag
+- cycle_time → 无对应Tag
+- machining_status → 无对应Tag
+
+---
+
+### 3.3 采集服务设计调整（优先级：高）
+
+#### 3.3.1 采集循环核心逻辑（伪代码）
+
+```
+每次采集循环（按采集地址配置的间隔）：
+
+1. Ping目标地址
+   - Ping失败 → 更新 cnc_collect_address.fail_count++
+   - 连续5次失败 → 写告警
+   - 跳过本次采集
+
+2. HTTP GET 拉取JSON数组
+
+3. 原始JSON存日志库（cnc_raw_log，每次都存，不管有没有变化）
+
+4. 逐设备处理JSON数组中的每个元素：
+
+   4.1 用 device 值匹配 cnc_machine.device_code
+       - 未匹配到 → 记录告警"发现未知设备"，跳过
+
+   4.2 解析 _io_status（特殊处理）：
+       → 直接读取 value，不管 quality 和 time
+       → value=1 → 设备在线
+       → value=0 → 设备离线
+
+   4.3 解析其他tag（标准处理）：
+       for each tag in tags (排除 _io_status):
+         if tag.quality != "0"               → 跳过（数据无效）
+         if tag.time 以 "1970-01-01" 开头     → 跳过（采集失败）
+         否则 → 按 brand_field_mapping 映射为标准字段，解析 value
+
+   4.4 写入结构化采集记录：
+       → INSERT INTO cnc_collect_record (每台设备每次采集一条)
+       → total_part_count 列写入 Tag1 的值（如果有效）
+       → 速度/倍率/负载等字段写 NULL（FANUC无此数据）
+
+   4.5 业务变更检测（只对比 value，不看 time）：
+
+       a. NC程序名变更检测：
+          if 新Tag5.value != 旧 cnc_machine.last_program_name:
+              → 结账当前产量段 (close_reason='program_change')
+              → 开新产量段
+
+       b. 零件数下降检测（手动清零）：
+          if 新Tag8.value < 旧 cnc_machine.last_part_count
+             AND 新Tag5.value == 旧 cnc_machine.last_program_name:
+              → 结账当前产量段 (close_reason='manual_reset')
+              → 开新产量段，part_count 从新值开始
+
+       c. 运行状态变更：
+          if 新Tag9.value != 旧 cnc_machine.last_run_status:
+              → 仅更新实时状态，不触发产量段逻辑
+
+       d. 总零件数：仅记录，不触发任何业务逻辑
+
+   4.6 更新机床实时状态（cnc_machine 的 last_* 字段）：
+       → last_program_name = Tag5.value
+       → last_part_count = Tag8.value
+       → last_total_part_count = Tag1.value
+       → last_run_status = Tag9.value
+       → last_operate_mode = Tag11.value
+       → last_device_status = _io_status.value
+       → is_online = (_io_status.value == 1)
+       → last_collect_time = 当前服务器时间
+
+5. 更新采集地址状态：
+   → last_collect_time = 当前时间
+   → last_collect_status = 'success'
+   → fail_count = 0
+```
+
+#### 3.3.2 数据有效性判断流程图
+
+```
+收到一个tag
+    │
+    ├── tag.id == "_io_status" ?
+    │       ├── YES → 始终有效，直接读 value
+    │       └── NO  → 进入标准判断 ↓
+    │
+    ├── tag.quality != "0" ?
+    │       ├── YES → 无效，跳过
+    │       └── NO  → 继续判断 ↓
+    │
+    └── tag.time 以 "1970-01-01" 开头 ?
+            ├── YES → 无效，跳过
+            └── NO  → 有效，解析 tag.value
+```
+
+---
+
+### 3.4 后台管理功能调整（优先级：中）
+
+#### 3.4.1 设备状态展示
+
+`cnc_machine` 表已有 `last_device_status`、`last_run_status` 等字段，展示逻辑不变。新增：
+- 设备详情中可选展示"累计加工总数"（来自 `last_total_part_count`）
+
+#### 3.4.2 大屏看板空值处理
+
+FANUC设备的以下字段恒为NULL：
+- 主轴设定速度、进给设定速度
+- 主轴实际速度、进给实际速度
+- 主轴负载、主轴倍率
+- 切削时间、循环时间
+- 加工状态
+
+大屏如果展示这些指标：
+- 数值型 → 显示 `--` 或 `N/A`
+- 图表型 → 该FANUC设备的线不画
+
+#### 3.4.3 品牌字段映射管理
+
+映射配置页面需支持新增的 `total_part_count` 标准字段。FANUC品牌预置映射中需包含 `Tag1 → total_part_count`。
+
+#### 3.4.4 前端Mock数据同步
+
+前端Mock数据中与FANUC相关的设备状态Mock，应同步为10个Tag的字段集（移除速度/负载等，新增total_part_count）。
+
+---
+
+### 3.5 设计文档更新（优先级：中）
+
+| 文档 | 更新内容 |
+|------|---------|
+| `docs/01-数据库设计.md` | 标准字段约定表增加 total_part_count；cnc_collect_record 和 cnc_machine 的DDL增加新列 |
+| `docs/00-需求与设计文档.md` | 4.2数据格式章节补充quality/1970-time/Tag1说明 |
+| `docs/03-API接口设计.md` | 如果有涉及采集记录字段的API响应格式，需同步增加 total_part_count |
+| `database/` | ALTER TABLE脚本 + FANUC预置映射数据新增 |
+
+---
+
+## 四、不需要调整的部分
+
+| 项目 | 原因 |
+|------|------|
+| 顶层JSON结构 `[{device, desc, tags}]` | 实际数据与设计一致 |
+| device字段匹配机床逻辑 | 设计正确，device值匹配device_code |
+| 零件分段计数核心逻辑（基于Tag8） | 不受影响，仍基于NC程序名切换+清零 |
+| 产量分段记录表 cnc_production_segment | 结构不变，total_part_count不影响分段计算 |
+| 采集地址/品牌管理配置架构 | 不变 |
+| 双库分离设计（原始JSON存日志库） | 不变 |
+| 采集间隔配置（地址级统一间隔） | 不变 |
+| 日终汇总逻辑 | 不变 |
+
+---
+
+## 五、执行顺序
+
+```
+阶段1：模拟器适配（让测试数据与实际一致）
+  ├── 1.1 DeviceState.cs 新增 TotalPartCount，移除多余字段
+  ├── 1.2 FanucDataGenerator.cs 改为10个Tag
+  ├── 1.3 DeviceSimulator.cs 调整场景逻辑
+  ├── 1.4 simulator.json 新增 initialTotalPartCount
+  └── 1.5 编译验证
+
+阶段2：数据库变更（数据基础）
+  ├── 2.1 cnc_collect_record 增加 total_part_count 列
+  ├── 2.2 cnc_machine 增加 last_total_part_count 列
+  ├── 2.3 标准字段约定表增加 total_part_count
+  ├── 2.4 FANUC预置映射数据增加 Tag1 映射
+  └── 2.5 设计文档同步更新
+
+阶段3：采集服务设计定稿（核心逻辑）
+  ├── 3.1 编写采集服务数据解析逻辑（含quality/time过滤）
+  ├── 3.2 编写变更检测逻辑（只看value不看time）
+  └── 3.3 编写Tag1存储逻辑（total_part_count仅记录不触发业务）
+
+阶段4：后台管理适配（展示层）
+  ├── 4.1 大屏空值处理（FANUC设备速度/负载为NULL时显示N/A）
+  ├── 4.2 前端Mock数据同步为10个Tag结构
+  └── 4.3 品牌映射管理支持total_part_count字段
+```
+
+---
+
+## 六、补充说明
+
+### 6.1 操作模式枚举值
+
+实际数据中出现了以下操作模式值，具体含义需与现场确认：
+
+| 值 | 已知含义 | 出现设备 |
+|----|---------|---------|
+| 1 | MEM（内存运行） | 加工中的设备 |
+| 4 | 待确认 | fanake-1.19（运行状态=1） |
+| 5 | 待确认 | fanake-1.24（运行状态=0） |
+| 10 | JOG（手动） | 待机中的设备 |
+
+### 6.2 device字段格式
+
+实际数据格式为 `fanake-1.2_1.2`（品牌-编号_编号），机床表的 `device_code` 需按此格式录入。
+
+### 6.3 数值精度
+
+所有数值型Tag的value都带5位小数（如 `35.00000`），采集服务解析时需 `Convert.ToDecimal` 后存储到 `DECIMAL(15,5)` 列。
+
+### 6.4 time字段格式
+
+统一格式 `yyyy-MM-dd HH:mm:ss`，需要按此格式解析。设备离线时为 `1970-01-01 08:00:00`（UTC+8时区下的epoch时间）。

frontend/mock/brand.ts

@@ -1,35 +1,26 @@
 import type { MockMethod } from './types'
 
 const brands = [
-  { id: 1, brandName: 'FANUC', deviceField: 'device', tagsPath: 'tags', isEnabled: 1, fieldCount: 16 },
+  { id: 1, brandName: 'FANUC', deviceField: 'device', tagsPath: 'tags', isEnabled: 1, fieldCount: 8 },
   { id: 2, brandName: 'SIEMENS', deviceField: 'device', tagsPath: 'tags', isEnabled: 1, fieldCount: 12 },
   { id: 3, brandName: 'MITSUBISHI', deviceField: 'device', tagsPath: 'tags', isEnabled: 0, fieldCount: 8 },
 ]
 
 const standardFields = [
-  'program_name', 'part_count', 'device_status', 'run_status', 'operate_mode',
+  'program_name', 'part_count', 'total_part_count', 'device_status', 'run_status', 'operate_mode',
-  'spindle_speed_set', 'feed_speed_set', 'spindle_speed_actual', 'feed_speed_actual',
+  'power_on_time', 'run_time',
-  'spindle_load', 'spindle_override', 'power_on_time', 'run_time', 'cutting_time',
-  'cycle_time', 'machining_status',
 ]
 
+// FANUC字段映射（与实际FANUC采集JSON中的tag id一致）
 const fanucMappings = [
   { id: 1, standardField: 'program_name', fieldName: 'Tag5', matchBy: 'id', dataType: 'string', isRequired: 1 },
   { id: 2, standardField: 'part_count', fieldName: 'Tag8', matchBy: 'id', dataType: 'number', isRequired: 1 },
-  { id: 3, standardField: 'device_status', fieldName: '_io_status', matchBy: 'id', dataType: 'number', isRequired: 1 },
+  { id: 3, standardField: 'total_part_count', fieldName: 'Tag1', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 4, standardField: 'run_status', fieldName: 'Tag9', matchBy: 'id', dataType: 'number', isRequired: 0 },
+  { id: 4, standardField: 'device_status', fieldName: '_io_status', matchBy: 'id', dataType: 'number', isRequired: 1 },
-  { id: 5, standardField: 'operate_mode', fieldName: 'Tag10', matchBy: 'id', dataType: 'number', isRequired: 0 },
+  { id: 5, standardField: 'run_status', fieldName: 'Tag9', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 6, standardField: 'spindle_speed_set', fieldName: 'Tag11', matchBy: 'id', dataType: 'number', isRequired: 0 },
+  { id: 6, standardField: 'operate_mode', fieldName: 'Tag11', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 7, standardField: 'feed_speed_set', fieldName: 'Tag12', matchBy: 'id', dataType: 'number', isRequired: 0 },
+  { id: 7, standardField: 'power_on_time', fieldName: 'Tag22', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 8, standardField: 'spindle_speed_actual', fieldName: 'Tag13', matchBy: 'id', dataType: 'number', isRequired: 0 },
+  { id: 8, standardField: 'run_time', fieldName: 'Tag23', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 9, standardField: 'feed_speed_actual', fieldName: 'Tag14', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 10, standardField: 'spindle_load', fieldName: 'Tag15', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 11, standardField: 'spindle_override', fieldName: 'Tag16', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 12, standardField: 'power_on_time', fieldName: 'Tag17', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 13, standardField: 'run_time', fieldName: 'Tag18', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 14, standardField: 'cutting_time', fieldName: 'Tag19', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 15, standardField: 'cycle_time', fieldName: 'Tag20', matchBy: 'id', dataType: 'number', isRequired: 0 },
-  { id: 16, standardField: 'machining_status', fieldName: 'Tag21', matchBy: 'id', dataType: 'string', isRequired: 0 },
 ]
 
 const mock: MockMethod[] = [

frontend/mock/machine.ts

@@ -59,7 +59,7 @@ const mock: MockMethod[] = [
     method: 'get',
     response: () => ({
       code: 0,
-      data: { programName: '1566.NC', partCount: 580, runStatus: '运行中', operateMode: '自动', spindleSpeedSet: 3000, feedSpeedSet: 500, spindleSpeedActual: 2980, feedSpeedActual: 480, spindleLoad: 65, machiningStatus: 'G01', lastCollectTime: '2026-04-25T17:36:38' },
+      data: { programName: '1566.NC', partCount: 580, totalPartCount: 88624, runStatus: '运行中', operateMode: '自动', lastCollectTime: '2026-04-25T17:36:38' },
     }),
   },
   {
@@ -68,7 +68,7 @@ const mock: MockMethod[] = [
     method: 'get',
     response: () => ({
       code: 0,
-      data: { programName: '1566.NC', partCount: 580, runStatus: '运行中', operateMode: '自动', spindleSpeedSet: 3000, feedSpeedSet: 500, spindleSpeedActual: 2980, feedSpeedActual: 480, spindleLoad: 65, machiningStatus: 'G01', lastCollectTime: '2026-04-25T17:36:38' },
+      data: { programName: '1566.NC', partCount: 580, totalPartCount: 88624, runStatus: '运行中', operateMode: '自动', lastCollectTime: '2026-04-25T17:36:38' },
     }),
   },
   {

frontend/mock/simulator.ts

@@ -45,11 +45,11 @@ const mockStatusList = [
   }
 ]
 
-// 模拟设备状态
+// 模拟设备状态（与实际FANUC 10个Tag结构一致）
 const mockDevices = [
-  { deviceCode: 'fanake_1.2', desc: '西-1.2', scenario: 'machining', isOnline: true, programName: 'O504', partCount: 14, runStatus: 3, operateMode: 10, spindleSpeedSet: 3000, spindleSpeedActual: 2980, feedSpeedSet: 500, feedSpeedActual: 490, spindleLoad: 65, machiningStatus: 'cutting', scenarioTick: 45, scenarioDuration: 120 },
+  { deviceCode: 'fanake_1.2', desc: '西-1.2', scenario: 'machining', isOnline: true, programName: 'O504', partCount: 14, totalPartCount: 45930, runStatus: 3, operateMode: 1, scenarioTick: 45, scenarioDuration: 120 },
-  { deviceCode: 'fanake_1.3', desc: '西-1.3', scenario: 'idle', isOnline: true, programName: 'O1', partCount: 53, runStatus: 1, operateMode: 10, spindleSpeedSet: 0, spindleSpeedActual: 0, feedSpeedSet: 0, feedSpeedActual: 0, spindleLoad: 5, machiningStatus: 'idle', scenarioTick: 12, scenarioDuration: 60 },
+  { deviceCode: 'fanake_1.3', desc: '西-1.3', scenario: 'idle', isOnline: true, programName: 'O1', partCount: 53, totalPartCount: 62324, runStatus: 0, operateMode: 10, scenarioTick: 12, scenarioDuration: 60 },
-  { deviceCode: 'fanake_1.4', desc: '西-1.4', scenario: 'offline', isOnline: false, programName: 'O200', partCount: 0, runStatus: 0, operateMode: 0, spindleSpeedSet: 0, spindleSpeedActual: 0, feedSpeedSet: 0, feedSpeedActual: 0, spindleLoad: 0, machiningStatus: 'offline', scenarioTick: 0, scenarioDuration: 0 }
+  { deviceCode: 'fanake_1.4', desc: '西-1.4', scenario: 'offline', isOnline: false, programName: '', partCount: 0, totalPartCount: 0, runStatus: 0, operateMode: 0, scenarioTick: 0, scenarioDuration: 0 }
 ]
 
 // 模拟请求日志

frontend/src/api/simulator.ts

@@ -40,14 +40,9 @@ export interface DeviceStatus {
   isOnline: boolean
   programName: string
   partCount: number
+  totalPartCount: number
   runStatus: number
   operateMode: number
-  spindleSpeedSet: number
-  spindleSpeedActual: number
-  feedSpeedSet: number
-  feedSpeedActual: number
-  spindleLoad: number
-  machiningStatus: string
   scenarioTick: number
   scenarioDuration: number
 }

frontend/src/types/index.ts

@@ -53,18 +53,20 @@ export interface Machine {
 export interface MachineStatus {
   programName: string
   partCount: number
+  /** 历史累计加工零件总数（FANUC Tag1） */
+  totalPartCount?: number
   runStatus: string
   operationMode: string
-  /** 主轴设定转速 */
+  /** 主轴设定转速（部分品牌无此数据时为null） */
-  spindleSpeedSet?: number
+  spindleSpeedSet?: number | null
-  /** 进给设定速度 */
+  /** 进给设定速度（部分品牌无此数据时为null） */
-  feedSpeedSet?: number
+  feedSpeedSet?: number | null
-  /** 主轴实际转速 */
+  /** 主轴实际转速（部分品牌无此数据时为null） */
-  spindleSpeedActual?: number
+  spindleSpeedActual?: number | null
-  spindleSpeed: number
+  spindleSpeed?: number | null
-  feedRate: number
+  feedRate?: number | null
-  spindleLoad: number
+  spindleLoad?: number | null
-  machiningStatus: string
+  machiningStatus?: string | null
   lastCollectTime: string
 }
 

frontend/src/views/machine/MachineDetailPage.vue

@@ -27,12 +27,9 @@
         <el-descriptions :column="2" border size="small">
           <el-descriptions-item label="NC程序名">{{status.programName||'-'}}</el-descriptions-item>
           <el-descriptions-item label="零件数">{{status.partCount??'-'}}</el-descriptions-item>
+          <el-descriptions-item label="累计总数">{{status.totalPartCount??'-'}}</el-descriptions-item>
           <el-descriptions-item label="运行状态">{{status.runStatus||'-'}}</el-descriptions-item>
           <el-descriptions-item label="操作模式">{{status.operationMode||'-'}}</el-descriptions-item>
-          <el-descriptions-item label="主轴设定">{{status.spindleSpeedSet??'-'}}</el-descriptions-item>
-          <el-descriptions-item label="进给设定">{{status.feedSpeedSet??'-'}}</el-descriptions-item>
-          <el-descriptions-item label="主轴实际">{{status.spindleSpeedActual??'-'}}</el-descriptions-item>
-          <el-descriptions-item label="主轴负载">{{status.spindleLoad??'-'}}%</el-descriptions-item>
         </el-descriptions>
       </el-card></el-col>
     </el-row>

simulator.json

@@ -8,9 +8,9 @@
       "dataChangeInterval": 10,
       "scenarioMode": "auto",
       "devices": [
-        { "deviceCode": "CNC-A001", "desc": "西栋1号", "initialProgram": "O0001", "initialPartCount": 50 },
+        { "deviceCode": "CNC-A001", "desc": "西栋1号", "initialProgram": "O0001", "initialPartCount": 50, "initialTotalPartCount": 45000 },
-        { "deviceCode": "CNC-006", "desc": "6号机床", "initialProgram": "O0002", "initialPartCount": 120 },
+        { "deviceCode": "CNC-006", "desc": "6号机床", "initialProgram": "O0002", "initialPartCount": 120, "initialTotalPartCount": 88000 },
-        { "deviceCode": "CNC-008", "desc": "8号机床", "initialProgram": "O0003", "initialPartCount": 0 }
+        { "deviceCode": "CNC-008", "desc": "8号机床", "initialProgram": "O0003", "initialPartCount": 0, "initialTotalPartCount": 126000 }
       ]
     },
     {
@@ -20,8 +20,8 @@
       "dataChangeInterval": 15,
       "scenarioMode": "auto",
       "devices": [
-        { "deviceCode": "CNC-B002", "desc": "B栋2号", "initialProgram": "1566.NC", "initialPartCount": 80 },
+        { "deviceCode": "CNC-B002", "desc": "B栋2号", "initialProgram": "1566.NC", "initialPartCount": 80, "initialTotalPartCount": 67000 },
-        { "deviceCode": "CNC-005", "desc": "验证机床", "initialProgram": "TEST001", "initialPartCount": 10 }
+        { "deviceCode": "CNC-005", "desc": "验证机床", "initialProgram": "TEST001", "initialPartCount": 10, "initialTotalPartCount": 23000 }
       ]
     }
   ]

src/CncCollector/Core/CollectRecordWriter.cs

@@ -84,13 +84,11 @@ namespace CncCollector.Core
                             foreach (var r in records)
                             {
                                 conn.Execute(@"INSERT INTO cnc_collect_record (machine_id, collect_time, device_time, program_name, part_count, 
-                                    device_status, run_status, operate_mode, spindle_speed_set, feed_speed_set, 
+                                    total_part_count, device_status, run_status, operate_mode, 
-                                    spindle_speed_actual, feed_speed_actual, spindle_load, spindle_override, 
+                                    power_on_time, run_time, extra_data, created_at)
-                                    power_on_time, run_time, cutting_time, cycle_time, machining_status, extra_data, created_at)
                                     VALUES (@MachineId, @CollectTime, @DeviceTime, @ProgramName, @PartCount, 
-                                    @DeviceStatus, @RunStatus, @OperateMode, @SpindleSpeedSet, @FeedSpeedSet, 
+                                    @TotalPartCount, @DeviceStatus, @RunStatus, @OperateMode, 
-                                    @SpindleSpeedActual, @FeedSpeedActual, @SpindleLoad, @SpindleOverride, 
+                                    @PowerOnTime, @RunTime, @ExtraData, @CreatedAt)",
-                                    @PowerOnTime, @RunTime, @CuttingTime, @CycleTime, @MachiningStatus, @ExtraData, @CreatedAt)",
                                     new
                                     {
                                         r.MachineId,
@@ -98,20 +96,12 @@ namespace CncCollector.Core
                                         DeviceTime = r.DeviceTime,
                                         ProgramName = r.ProgramName ?? (string)null,
                                         PartCount = r.PartCount,
+                                        TotalPartCount = r.TotalPartCount,
                                         DeviceStatus = r.DeviceStatus ?? (string)null,
                                         RunStatus = r.RunStatus ?? (string)null,
                                         OperateMode = r.OperateMode ?? (string)null,
-                                        SpindleSpeedSet = r.SpindleSpeedSet,
-                                        FeedSpeedSet = r.FeedSpeedSet,
-                                        SpindleSpeedActual = r.SpindleSpeedActual,
-                                        FeedSpeedActual = r.FeedSpeedActual,
-                                        SpindleLoad = r.SpindleLoad,
-                                        SpindleOverride = r.SpindleOverride,
                                         PowerOnTime = r.PowerOnTime,
                                         RunTime = r.RunTime,
-                                        CuttingTime = r.CuttingTime,
-                                        CycleTime = r.CycleTime,
-                                        MachiningStatus = r.MachiningStatus ?? (string)null,
                                         ExtraData = r.ExtraData ?? (string)null,
                                         CreatedAt = now
                                     }, tran);
@@ -133,7 +123,8 @@ namespace CncCollector.Core
                             conn.Execute(@"UPDATE cnc_machine SET last_collect_time = @CollectTime, 
                                 last_device_status = @DeviceStatus, last_run_status = @RunStatus,
                                 last_program_name = @ProgramName, last_part_count = @PartCount,
-                                last_operate_mode = @OperateMode, last_machining_status = @MachiningStatus
+                                last_total_part_count = @TotalPartCount,
+                                last_operate_mode = @OperateMode
                                 WHERE id = @MachineId",
                                 new
                                 {
@@ -143,8 +134,8 @@ namespace CncCollector.Core
                                     RunStatus = r.RunStatus ?? (string)null,
                                     ProgramName = r.ProgramName ?? (string)null,
                                     r.PartCount,
-                                    OperateMode = r.OperateMode ?? (string)null,
+                                    r.TotalPartCount,
-                                    MachiningStatus = r.MachiningStatus ?? (string)null
+                                    OperateMode = r.OperateMode ?? (string)null
                                 });
                         }
                         catch (Exception ex)

src/CncCollector/Core/CollectWorker.cs

@@ -447,32 +447,32 @@ namespace CncCollector.Core
                 // 解析字段
                 var parsed = DataParser.ParseDevice(deviceObj, brand, mappings);
 
-                // 构建 CollectRecord
+                // 构建 CollectRecord（仅包含实际FANUC数据中存在的字段）
                 var record = new CollectRecord
                 {
                     MachineId = machine.Id,
                     CollectTime = collectTime,
                     ProgramName = GetStringValue(parsed, "program_name"),
                     PartCount = GetDecimalValue(parsed, "part_count"),
+                    TotalPartCount = GetDecimalValue(parsed, "total_part_count"),
                     DeviceStatus = GetStringValue(parsed, "device_status"),
                     RunStatus = GetStringValue(parsed, "run_status"),
                     OperateMode = GetStringValue(parsed, "operate_mode"),
-                    SpindleSpeedSet = GetDecimalValue(parsed, "spindle_speed_set"),
-                    FeedSpeedSet = GetDecimalValue(parsed, "feed_speed_set"),
-                    SpindleSpeedActual = GetDecimalValue(parsed, "spindle_speed_actual"),
-                    FeedSpeedActual = GetDecimalValue(parsed, "feed_speed_actual"),
-                    SpindleLoad = GetDecimalValue(parsed, "spindle_load"),
-                    SpindleOverride = GetDecimalValue(parsed, "spindle_override"),
                     PowerOnTime = GetDecimalValue(parsed, "power_on_time"),
-                    RunTime = GetDecimalValue(parsed, "run_time"),
+                    RunTime = GetDecimalValue(parsed, "run_time")
-                    CuttingTime = GetDecimalValue(parsed, "cutting_time"),
-                    CycleTime = GetDecimalValue(parsed, "cycle_time"),
-                    MachiningStatus = GetStringValue(parsed, "machining_status")
                 };
 
+                // 断电设备过滤：如果program_name和part_count都被过滤为空，
+                // 说明设备处于断电状态（quality≠0），跳过此设备不生成记录
+                if (string.IsNullOrEmpty(record.ProgramName) && !record.PartCount.HasValue)
+                {
+                    _log.Debug($"设备{deviceCode}所有有效tag为空（可能断电），跳过记录");
+                    continue;
+                }
+
                 records.Add(record);
 
-                // 产量跟踪
+                // 产量跟踪（program_name为空时不触发分段逻辑）
                 _tracker.Track(machine.Id, record.ProgramName, record.PartCount, collectTime);
             }
 

src/CncCollector/Core/DataParser.cs

@@ -33,7 +33,9 @@ namespace CncCollector.Core
         }
 
         /// <summary>
-        /// 解析单台设备的 JSON tags 数据
+        /// 解析单台设备的 JSON tags 数据。
+        /// 根据数据有效性规则过滤无效tag：quality≠0 或 time以1970-01-01开头的tag视为无效。
+        /// _io_status 始终有效，不受quality/time约束。
         /// </summary>
         /// <param name="deviceObj">设备 JSON 对象</param>
         /// <param name="brand">品牌配置</param>
@@ -57,16 +59,35 @@ namespace CncCollector.Core
 
             var tagsArray = tagsToken as JArray;
 
-            // 构建 tag id → value 的快速查找字典
+            // 构建 tag id → rawValue 的快速查找字典（经过有效性过滤）
             var tagDict = new Dictionary<string, string>(StringComparer.OrdinalIgnoreCase);
             foreach (var tag in tagsArray)
             {
                 string id = tag["id"]?.ToString() ?? "";
-                string value = tag["value"]?.ToString() ?? "";
+                if (string.IsNullOrEmpty(id)) continue;
-                if (!string.IsNullOrEmpty(id))
+
+                // _io_status 始终有效，跳过过滤
+                if (string.Equals(id, "_io_status", StringComparison.OrdinalIgnoreCase))
+                {
+                    tagDict[id] = tag["value"]?.ToString() ?? "";
+                    continue;
+                }
+
+                // 数据有效性规则1：quality ≠ 0 → 无效，忽略
+                string qualityStr = tag["quality"]?.ToString() ?? "0";
+                if (qualityStr != "0")
                 {
-                    tagDict[id] = value;
+                    continue;
                 }
+
+                // 数据有效性规则2：time 以 1970-01-01 开头 → 采集失败标记，忽略
+                string timeStr = tag["time"]?.ToString() ?? "";
+                if (timeStr.StartsWith("1970-01-01", StringComparison.OrdinalIgnoreCase))
+                {
+                    continue;
+                }
+
+                tagDict[id] = tag["value"]?.ToString() ?? "";
             }
 
             // 按字段映射表提取
@@ -79,7 +100,7 @@ namespace CncCollector.Core
                 string rawValue;
                 if (!tagDict.TryGetValue(tagId, out rawValue))
                 {
-                    // 字段不存在，跳过（非必填字段可能不存在）
+                    // 字段不存在或被过滤为无效，跳过
                     continue;
                 }
 
@@ -90,10 +111,9 @@ namespace CncCollector.Core
                     StringValue = rawValue
                 };
 
-                // 数值型：去除 .00000 尾缀
+                // 数值型：解析为 decimal
                 if (dataType == "number" && !string.IsNullOrEmpty(rawValue))
                 {
-                    // 尝试解析为 decimal
                     string cleanValue = rawValue.Trim();
                     decimal numVal;
                     if (decimal.TryParse(cleanValue, System.Globalization.NumberStyles.Float,

src/CncModels/Entity/CollectRecord.cs

@@ -25,6 +25,9 @@ namespace CncModels.Entity
         /// <summary>零件计数</summary>
         public decimal? PartCount { get; set; }
 
+        /// <summary>历史终身累计零件总数（Tag1）</summary>
+        public decimal? TotalPartCount { get; set; }
+
         /// <summary>设备状态</summary>
         public string DeviceStatus { get; set; }
 

src/CncSimulator/Config/SimulatorConfig.cs

@@ -73,5 +73,9 @@ namespace CncSimulator.Config
         /// <summary>初始零件数</summary>
         [JsonProperty("initialPartCount")]
         public int InitialPartCount { get; set; } = 0;
+
+        /// <summary>初始历史累计零件总数</summary>
+        [JsonProperty("initialTotalPartCount")]
+        public int InitialTotalPartCount { get; set; } = 0;
     }
 }

src/CncSimulator/Core/SimulatorEngine.cs

@@ -326,6 +326,67 @@ namespace CncSimulator.Core
                     _dbAddresses = _dbReader.ReadAddresses();
                     SendResponse(ctx, 200, "{\"ok\":true,\"count\":" + _dbAddresses.Count + "}", "application/json");
                 }
+                else if (path == "/admin/api/event")
+                {
+                    // 转发事件到对应的SimulatorServer（数据端口）
+                    string eventBody = ReadRequestBody(ctx);
+                    var eventObj = JObject.Parse(eventBody);
+                    string deviceId = eventObj["deviceId"]?.ToString();
+                    string eventType = eventObj["eventType"]?.ToString();
+                    if (string.IsNullOrEmpty(deviceId) || string.IsNullOrEmpty(eventType))
+                    {
+                        SendResponse(ctx, 400, "{\"error\":\"缺少deviceId或eventType\"}", "application/json");
+                        return;
+                    }
+                    // 在所有server中查找目标设备并触发事件
+                    bool found = false;
+                    foreach (var server in _servers)
+                    {
+                        server.TriggerDeviceEvent(deviceId, eventType);
+                        found = true;
+                        break; // TriggerDeviceEvent内部只处理第一个匹配的设备
+                    }
+                    SendResponse(ctx, 200, found ? "{\"ok\":true}" : "{\"ok\":false,\"error\":\"设备未找到\"}", "application/json");
+                }
+                else if (path == "/admin/api/event-history")
+                {
+                    // 转发事件历史查询
+                    var allEvents = new JArray();
+                    foreach (var server in _servers)
+                    {
+                        // 利用server的HandleEventHistoryApi逻辑提取数据
+                        foreach (var dev in server.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
+                                });
+                            }
+                        }
+                    }
+                    SendResponse(ctx, 200, allEvents.ToString(), "application/json");
+                }
+                else if (path == "/admin/api/mode")
+                {
+                    // 转发模式切换到所有SimulatorServer
+                    string modeBody = ReadRequestBody(ctx);
+                    var modeObj = JObject.Parse(modeBody);
+                    string mode = modeObj["mode"]?.ToString() ?? "auto";
+                    foreach (var server in _servers)
+                    {
+                        server.SetMode(mode);
+                    }
+                    SendResponse(ctx, 200, "{\"ok\":true,\"mode\":\"" + mode + "\"}", "application/json");
+                }
                 else
                 {
                     SendResponse(ctx, 200, "CNC模拟采集服务网关。请访问 /admin 管理页面。", "text/plain");

src/CncSimulator/Core/SimulatorServer.cs

@@ -285,14 +285,9 @@ namespace CncSimulator.Core
                     ["isOnline"] = s.IsOnline,
                     ["programName"] = s.ProgramName,
                     ["partCount"] = s.PartCount,
+                    ["totalPartCount"] = s.TotalPartCount,
                     ["runStatus"] = s.RunStatus,
                     ["operateMode"] = s.OperateMode,
-                    ["spindleSpeedSet"] = s.SpindleSpeedSet,
-                    ["spindleSpeedActual"] = s.SpindleSpeedActual,
-                    ["feedSpeedSet"] = s.FeedSpeedSet,
-                    ["feedSpeedActual"] = s.FeedSpeedActual,
-                    ["spindleLoad"] = s.SpindleLoad,
-                    ["machiningStatus"] = s.MachiningStatus,
                     ["scenarioTick"] = s.ScenarioTick,
                     ["scenarioDuration"] = s.ScenarioDuration
                 });
@@ -318,7 +313,7 @@ namespace CncSimulator.Core
             }
         }
 
-        /// <summary>生成当前JSON响应</summary>
+        /// <summary>生成当前JSON响应（包括在线和离线设备）</summary>
         private string GenerateCurrentJson()
         {
             var devices = new JArray();
@@ -328,10 +323,66 @@ namespace CncSimulator.Core
                 {
                     devices.Add(_generator.GenerateDevice(dev.State));
                 }
+                else
+                {
+                    // 离线设备：生成带有quality=1和1970时间的tag
+                    devices.Add(GenerateOfflineDevice(dev.State));
+                }
             }
             return devices.ToString(Formatting.None);
         }
 
+        /// <summary>生成离线设备的JSON（_io_status有效，其余tag quality=1）</summary>
+        private JObject GenerateOfflineDevice(DeviceState state)
+        {
+            var tags = new JArray();
+            DateTime now = DateTime.Now;
+
+            // _io_status 始终有效
+            tags.Add(new JObject
+            {
+                ["id"] = "_io_status",
+                ["desc"] = "设备状态",
+                ["quality"] = "0",
+                ["value"] = "0.00000",
+                ["time"] = now.ToString("yyyy-MM-dd HH:mm:ss")
+            });
+
+            // 其余tag全部标记为无效（quality=1, time=1970）
+            string epoch = "1970-01-01 08:00:00";
+            var offlineTags = new[]
+            {
+                new { id = "Tag1", desc = "加工零件总数", value = "0.00000" },
+                new { id = "Tag5", desc = "执行的NC主程序名", value = "" },
+                new { id = "Tag6", desc = "执行的NC主程序号", value = "" },
+                new { id = "Tag7", desc = "当前加工程序内容", value = "" },
+                new { id = "Tag8", desc = "当前加工零件数", value = "0.00000" },
+                new { id = "Tag9", desc = "运行状态", value = "0.00000" },
+                new { id = "Tag11", desc = "操作模式", value = "0.00000" },
+                new { id = "Tag22", desc = "开机时间", value = "0.00000" },
+                new { id = "Tag23", desc = "运行时间", value = "0.00000" }
+            };
+
+            foreach (var t in offlineTags)
+            {
+                tags.Add(new JObject
+                {
+                    ["id"] = t.id,
+                    ["desc"] = t.desc,
+                    ["quality"] = "1",
+                    ["value"] = t.value,
+                    ["time"] = epoch
+                });
+            }
+
+            return new JObject
+            {
+                ["device"] = state.DeviceCode,
+                ["desc"] = state.Desc,
+                ["tags"] = tags
+            };
+        }
+
         /// <summary>生成关键数据摘要</summary>
         private string GenerateKeyData()
         {

src/CncSimulator/Device/DeviceSimulator.cs

@@ -4,13 +4,13 @@ namespace CncSimulator.Device
 {
     /// <summary>
     /// 单台设备的状态机。
-    /// 维护设备当前状态，根据场景规则更新各字段。
+    /// 维护设备当前状态，根据场景规则更新字段。
+    /// 仅包含实际FANUC采集数据中存在的字段。
     /// </summary>
     public class DeviceSimulator
     {
         private readonly DeviceState _state;
         private readonly Random _rng;
-        private static readonly string[] MachiningStatusOptions = { "G01", "G01", "G01", "G02", "G00" };
         private static readonly string[] ProgramPool = { "O0001", "O0002", "1566.NC", "PART-A", "TEST-03" };
         private int _programPoolIndex;
 
@@ -26,23 +26,17 @@ namespace CncSimulator.Device
                 Desc = config.Desc,
                 ProgramName = config.InitialProgram,
                 PartCount = config.InitialPartCount,
-                // LastPartCount removed - not in DeviceState
+                // 历史累计零件总数：配置值优先，否则随机
+                TotalPartCount = config.InitialTotalPartCount > 0
+                    ? config.InitialTotalPartCount
+                    : _rng.Next(40000, 50000),
                 DataChangeInterval = dataChangeInterval,
                 IsOnline = true,
                 DeviceStatus = 1,
                 RunStatus = 0,
                 OperateMode = 10,
-                SpindleSpeedSet = 450,
-                FeedSpeedSet = 60,
-                SpindleSpeedActual = 0,
-                FeedSpeedActual = 0,
-                SpindleLoad = 0,
-                SpindleOverride = 100,
                 PowerOnTime = _rng.Next(20000000, 24000000),
                 RunTime = _rng.Next(15000, 20000),
-                CuttingTime = _rng.Next(6000000, 7000000),
-                CycleTime = _rng.Next(500, 800),
-                MachiningStatus = "",
                 ProgramContent = "",
                 CurrentScenario = "idle",
                 ScenarioTick = 0,
@@ -117,6 +111,7 @@ namespace CncSimulator.Device
             {
                 case "machining":
                     _state.PartCount++;
+                    _state.TotalPartCount++;
                     _state.TotalPartsSinceStart++;
                     // 按NC程序名累计零件数
                     if (!_state.PartsByProgram.ContainsKey(_state.ProgramName))
@@ -125,16 +120,8 @@ namespace CncSimulator.Device
                     _state.RunStatus = 3;
                     _state.DeviceStatus = 1;
                     _state.OperateMode = 1;
-                    // 主轴实际速度 = 设定 ± 10%随机波动
-                    _state.SpindleSpeedActual = _state.SpindleSpeedSet * (1m + (decimal)(_rng.NextDouble() * 0.2 - 0.1));
-                    _state.FeedSpeedActual = _state.FeedSpeedSet * (1m + (decimal)(_rng.NextDouble() * 0.1 - 0.05));
-                    _state.SpindleLoad = _rng.Next(15, 46);
-                    _state.SpindleOverride = 100;
-                    _state.MachiningStatus = MachiningStatusOptions[_rng.Next(MachiningStatusOptions.Length)];
-                    _state.CuttingTime += interval;
                     _state.RunTime += interval;
                     _state.PowerOnTime += interval;
-                    _state.CycleTime += interval;
                     _state.ProgramContent = "<" + _state.ProgramName + ">\nG40G49G80\n( SIMULATOR )";
                     break;
 
@@ -147,21 +134,12 @@ namespace CncSimulator.Device
                 case "idle":
                     _state.RunStatus = 0;
                     _state.OperateMode = 10;
-                    _state.SpindleSpeedActual = 0;
-                    _state.FeedSpeedActual = 0;
-                    _state.SpindleLoad = 0;
-                    _state.FeedSpeedSet = 0;
-                    _state.MachiningStatus = "";
                     _state.PowerOnTime += interval;
                     _state.RunTime += interval;
                     break;
 
                 case "pause":
                     _state.RunStatus = 1;
-                    _state.SpindleSpeedActual = 0;
-                    _state.FeedSpeedActual = 0;
-                    _state.SpindleLoad = 0;
-                    _state.MachiningStatus = "";
                     _state.PowerOnTime += interval;
                     _state.RunTime += interval;
                     break;
@@ -182,15 +160,11 @@ namespace CncSimulator.Device
             _programPoolIndex = (_programPoolIndex + 1) % ProgramPool.Length;
             _state.ProgramName = ProgramPool[_programPoolIndex];
             _state.PartCount = 0;
-            _state.CycleTime = 0;
             _state.RunStatus = 3;
             _state.DeviceStatus = 1;
             _state.OperateMode = 1;
-            _state.MachiningStatus = "G01";
-            _state.SpindleSpeedSet = _rng.Next(200, 801);
-            _state.FeedSpeedSet = _rng.Next(30, 151);
-            _state.SpindleOverride = 100;
             _state.ProgramContent = "<" + _state.ProgramName + ">\nG40G49G80\n( SIMULATOR )";
+            // TotalPartCount不清零（终身累计）
             // 记录事件历史
             _state.RecordEvent("program_change", oldProgram, _state.ProgramName, oldPartCount, 0);
         }
@@ -202,6 +176,7 @@ namespace CncSimulator.Device
             _state.PartCount = 0;
             _state.RunStatus = 3;
             _state.DeviceStatus = 1;
+            // TotalPartCount不清零（终身累计）
             // 记录事件历史
             _state.RecordEvent("manual_reset", _state.ProgramName, _state.ProgramName, oldPartCount, 0);
         }
@@ -222,13 +197,9 @@ namespace CncSimulator.Device
             _state.IsOnline = true;
             _state.DeviceStatus = 1;
             _state.PartCount = 0;
-            _state.CycleTime = 0;
             _state.RunStatus = 0;
             _state.OperateMode = 10;
-            _state.SpindleSpeedActual = 0;
+            // TotalPartCount不清零（终身累计）
-            _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

@@ -26,6 +26,9 @@ namespace CncSimulator.Device
         /// <summary>当前零件数</summary>
         public int PartCount { get; set; } = 0;
 
+        /// <summary>历史终身累计零件总数（对应Tag1）</summary>
+        public decimal TotalPartCount { get; set; } = 0;
+
         /// <summary>设备状态 _io_status: 0=离线, 1=在线</summary>
         public int DeviceStatus { get; set; } = 1;
 
@@ -35,39 +38,12 @@ namespace CncSimulator.Device
         /// <summary>操作模式: 1=MEM, 10=JOG</summary>
         public int OperateMode { get; set; } = 1;
 
-        /// <summary>主轴设定速度</summary>
-        public decimal SpindleSpeedSet { get; set; } = 450;
-
-        /// <summary>进给设定速度</summary>
-        public decimal FeedSpeedSet { get; set; } = 60;
-
-        /// <summary>主轴实际速度</summary>
-        public decimal SpindleSpeedActual { get; set; } = 0;
-
-        /// <summary>进给实际速度</summary>
-        public decimal FeedSpeedActual { get; set; } = 0;
-
-        /// <summary>主轴负载</summary>
-        public decimal SpindleLoad { get; set; } = 0;
-
-        /// <summary>主轴倍率</summary>
-        public decimal SpindleOverride { get; set; } = 100;
-
         /// <summary>开机累计时间（秒）</summary>
         public decimal PowerOnTime { get; set; } = 0;
 
         /// <summary>运行累计时间（秒）</summary>
         public decimal RunTime { get; set; } = 0;
 
-        /// <summary>切削累计时间（秒）</summary>
-        public decimal CuttingTime { get; set; } = 0;
-
-        /// <summary>循环时间（秒）</summary>
-        public decimal CycleTime { get; set; } = 0;
-
-        /// <summary>加工状态: G01/G00/G02/等</summary>
-        public string MachiningStatus { get; set; } = "";
-
         /// <summary>加工程序内容片段</summary>
         public string ProgramContent { get; set; } = "";
 

src/CncSimulator/Generator/FanucDataGenerator.cs

@@ -6,7 +6,7 @@ namespace CncSimulator.Generator
 {
     /// <summary>
     /// FANUC品牌JSON数据生成器。
-    /// 根据设备状态生成18个Tag的FANUC格式JSON。
+    /// 根据设备状态生成10个Tag的FANUC格式JSON，与实际FANUC采集数据结构一致。
     /// </summary>
     public class FanucDataGenerator : IBrandGenerator
     {
@@ -27,7 +27,7 @@ namespace CncSimulator.Generator
             return device;
         }
 
-        /// <summary>生成18个Tag的JArray</summary>
+        /// <summary>生成10个Tag的JArray</summary>
         private JArray GenerateTags(DeviceState state)
         {
             var tags = new JArray();
@@ -65,8 +65,9 @@ namespace CncSimulator.Generator
                 });
             }
 
+            // 严格按实际FANUC采集数据的10个Tag生成
             AddNumericTag("_io_status", "设备状态", state.DeviceStatus);
-            AddNumericTag("Tag2", "当前轴数", 4);
+            AddNumericTag("Tag1", "加工零件总数", state.TotalPartCount);
             AddStringTag("Tag5", "执行的NC主程序名", state.ProgramName);
             AddStringTag("Tag6", "执行的NC主程序号", "N0");
             AddStringTag("Tag7", "当前加工程序内容",
@@ -76,17 +77,8 @@ namespace CncSimulator.Generator
             AddNumericTag("Tag8", "当前加工零件数", state.PartCount);
             AddNumericTag("Tag9", "运行状态", state.RunStatus);
             AddNumericTag("Tag11", "操作模式", state.OperateMode);
-            AddNumericTag("Tag14", "当前主轴倍率", state.SpindleOverride);
-            AddNumericTag("Tag17", "主轴设定速度", state.SpindleSpeedSet);
-            AddNumericTag("Tag18", "进给设定速度", state.FeedSpeedSet);
-            AddNumericTag("Tag19", "主轴实际速度", state.SpindleSpeedActual);
-            AddNumericTag("Tag20", "进给实际转速", state.FeedSpeedActual);
-            AddNumericTag("Tag21", "主轴负载", state.SpindleLoad);
             AddNumericTag("Tag22", "开机时间", state.PowerOnTime);
             AddNumericTag("Tag23", "运行时间", state.RunTime);
-            AddNumericTag("Tag24", "切削时间", state.CuttingTime);
-            AddNumericTag("Tag25", "循环时间", state.CycleTime);
-            AddStringTag("Tag26", "加工状态", state.MachiningStatus);
 
             return tags;
         }

src/CncWebApi/Global.asax.cs

@@ -18,12 +18,8 @@ namespace CncWebApi
         /// </summary>
         protected void Application_Start()
         {
-            // 初始化 log4net
+            // 初始化 log4net（从 Web.config 的 <log4net> 节读取）
-            var logConfig = Path.Combine(AppDomain.CurrentDomain.BaseDirectory, "log4net.config");
+            log4net.Config.XmlConfigurator.Configure();
-            if (File.Exists(logConfig))
-            {
-                log4net.Config.XmlConfigurator.Configure(new FileInfo(logConfig));
-            }
 
             GlobalConfiguration.Configure(WebApiConfig.Register);
         }

src/CncWebApi/Web.config

@@ -4,6 +4,40 @@
   部署到 IIS 时，需要将此文件复制到站点根目录
 -->
 <configuration>
+  <configSections>
+    <section name="log4net" type="log4net.Config.Log4NetConfigurationSectionHandler, log4net" />
+  </configSections>
+
+  <log4net>
+    <appender name="ErrorFileAppender" type="log4net.Appender.RollingFileAppender">
+      <file value="App_Data\logs\error.log" />
+      <appendToFile value="true" />
+      <rollingStyle value="Size" />
+      <maxSizeRollBackups value="10" />
+      <maximumFileSize value="10MB" />
+      <staticLogFileName value="true" />
+      <threshold value="ERROR" />
+      <layout type="log4net.Layout.PatternLayout">
+        <conversionPattern value="%date [%thread] %-5level %logger - %message%newline%exception%newline" />
+      </layout>
+    </appender>
+    <appender name="AllFileAppender" type="log4net.Appender.RollingFileAppender">
+      <file value="App_Data\logs\webapi.log" />
+      <appendToFile value="true" />
+      <rollingStyle value="Size" />
+      <maxSizeRollBackups value="10" />
+      <maximumFileSize value="10MB" />
+      <staticLogFileName value="true" />
+      <layout type="log4net.Layout.PatternLayout">
+        <conversionPattern value="%date [%thread] %-5level %logger - %message%newline%exception%newline" />
+      </layout>
+    </appender>
+    <root>
+      <level value="INFO" />
+      <appender-ref ref="AllFileAppender" />
+      <appender-ref ref="ErrorFileAppender" />
+    </root>
+  </log4net>
   <connectionStrings>
     <!-- 业务库连接串 -->
     <add name="BusinessConnection"