Setup

Configure this press-line Pi. Changes are saved to /etc/dump-counter/config.yaml. Use Save & restart after counting or HAT changes so the service reloads config.

Physical stack (bottom → top): Pi → Smart Fan HAT → Eight HV Inputs HAT.

1 · Machine identity

Sent in every job summary to Supabase. Each Pi in the fleet needs a unique ID that matches the machines table (e.g. PLP1, PLP2).

Machine name Display name in dashboard and webhook JSON (machine_name). Machine ID Stable ID for Supabase (machine_id). Usually same as name.

2 · Polling

How often the service reads the inputs HAT. Default 50 ms is fine for production.

Poll interval (ms) Lower = more responsive; higher = less CPU. Do not change unless instructed.

3 · Smart Fan cooling

Controls the Sequent Smart Fan HAT (middle layer). Uses Pi CPU temperature in automatic mode with hysteresis so the fan does not rapid-cycle. Bench test on SSH: fan -list, fan 0 pwr 50.

Enable fan Disable only for bench testing without heat load. Control mode Recommended: automatic with 10°C hysteresis (default 55°C on / 45°C off).

Automatic temperature control

Fan turns on when CPU reaches the “turn on” temp, and off when it drops to the “turn off” temp. Keep at least 10°C gap between them to avoid chattering.

Turn fan ON at (°C) Default 55°C — good starting point for Pi 4 in a cabinet. Turn fan OFF at (°C) Default 45°C — 10°C below turn-on (hysteresis band). Speed when running (%) Fan power while auto mode is active. Default 50%.

Manual fixed speed

Fan runs at a constant speed whenever enabled. Use for bench testing only — automatic mode is safer for 24×7 production.

Fan speed (%) 0 = off, 50 = typical, 100 = full speed.

4 · Production counting

One section per PLC input that increments production counts. Channel numbers are the screw terminals on the inputs HAT (1–8).

Input 1

HAT channel (1–8) Which input terminal the PLC pulse is wired to. Event name in JSON Key in webhook counts.{name} — must be unique if you add multiple inputs (e.g. production_count, reject_count). Count when Most PLC outputs use contact closes (rising).

Terminal type 24 V DC → low-voltage + hardware counter (recommended). Hardware counter Required for fast dump pulses the Pi might miss in software. Ignore duplicates within (sec) Debounce: ignore pulses closer than this. PLP1 default: 5 s.

Maintenance burst: max events More than this many raw events in the window below → maintenance mode (not counted). Maintenance burst: window (min) Rolling window for maintenance detection during service work.

Input 2

5 · Supabase sync

Same webhook URL for every Pi in the fleet. Location is resolved from machine_id on the backend — you do not set location here.

Webhook URL Portland fleet: one shared URL for all PLP lines. Leave blank to disable outbound sync.

Webhook secret Must match Supabase DUMP_COUNTER_WEBHOOK_SECRET. Currently: not set. API token (incoming job start) Optional Bearer token for ERP POST /job/start. Currently: set.

Secrets stored in /etc/dump-counter/env — never overwritten when left blank.

Advanced channel YAML → Test webhook →