Runout sets Spoolman to zero; surface prints waiting on a spool

- A roll that ran out is set to 0 g in Spoolman (like a weigh-in) instead
  of booking CC2 Control's delta, so a mirror whose count was off cannot
  book too much or too little.
- A tray that printed while CC2 Control still asked which spool it holds
  (untagged roll) shows the waiting millimetres on the status page and
  gets one log warning after the print.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_014GcEk5tkfFSYD6NTF66NkC

app/bridge.py

@@ -199,6 +199,7 @@ class PrinterWorker:
         self.record: dict | None = None
         self.cc2_data: dict | None = None
         self.print_info: dict | None = None  # CC2 Control /api/printer, only read while a job runs
+        self.noted_questions: dict[int, str] = {}  # slot -> question already reported
 
     @property
     def id(self) -> str:
@@ -267,6 +268,7 @@ class PrinterWorker:
             self._reconcile_cc2(cc2)
             self._process_cc2_log(cc2)
             self._consumption(cc2)
+            self._note_open_questions(cc2)
 
     def _record_id(self, n: int) -> int | None:
         for s in self.record_slots:
@@ -406,6 +408,23 @@ class PrinterWorker:
             elif loaded:
                 self._answer_again(n, m, question)
 
+    def _note_open_questions(self, cc2: dict) -> None:
+        """A tray printed while CC2 Control was still asking which spool it holds: say so once, after the print."""
+        if (cc2.get("job") or {}).get("active"):
+            return
+        for slot in cc2.get("slots") or []:
+            n = slot.get("slot")
+            mm = _num(slot.get("question_mm"))
+            if n not in (0, 1, 2, 3) or not slot.get("question") or mm < 1 or str(n) in self.st["slots"]:
+                continue
+            key = f"{n}|{slot.get('question_since')}"
+            if self.noted_questions.get(n) == key:
+                continue
+            self.noted_questions[n] = key
+            self._log("warn", f"Slot {n + 1}: {mm:.0f} mm (ca. {grams_from_mm(mm, 1.75, 1.24):.1f} g) ohne Spule gedruckt; "
+                              "CC2 Control wartet auf die Zuordnung. Rolle taggen und scannen, dann wird der Verbrauch "
+                              "nachgebucht, oder in CC2 Control „keine Spule“ wählen.")
+
     def _reinserted(self, n: int) -> None:
         """No mapping, CC2 Control asks about filament put in, and the record still names the roll
         that last left this slot: it is that roll again."""
@@ -531,6 +550,11 @@ class PrinterWorker:
                     if settled:
                         self._weighin(cid, b, name, smid, rem, newest)
                     continue
+                if any(e.get("kind") == "runout" for e in fresh):
+                    # CC2 Control sets a roll that ran out to zero; Spoolman follows absolutely, so a count
+                    # that was off (e.g. a mirror left with an old value) does not book too much or too little
+                    if not settled or self._weighin(cid, b, name, smid, rem, newest, describe(fresh)):
+                        continue
                 delta = b["remaining"] - rem
                 if delta < -MIN_BOOKING:
                     self._log("warn", f"{name}: Rest in CC2 Control um {-delta:.2f} g gestiegen; "
@@ -589,24 +613,32 @@ class PrinterWorker:
                      details, log_time)
         return True
 
-    def _weighin(self, cid: str, b: dict, name: str, smid: int, rem: float, log_time: float) -> None:
+    def _weighin(self, cid: str, b: dict, name: str, smid: int, rem: float, log_time: float,
-        """Weighed in CC2 Control: Spoolman takes the weighed value (and any use since) as it is."""
+                 runout: str | None = None) -> bool:
+        """Weighed in CC2 Control, or ran out (`runout` holds the print details): Spoolman takes CC2 Control's
+        value as it is. False when Spoolman has no start weight to set it against."""
         sm = self.bridge.spoolman.spool(smid)
         base = sm.get("initial_weight") or (sm.get("filament") or {}).get("weight")
         if not base:
+            what = "Leerlaufen per Verbrauch gebucht" if runout is not None else "Nachwiegen nicht übernommen"
             self.bridge._once_error(f"{self.id}:weigh:{cid}", f"{self.name}: {name}: Spoolman-Spule {smid} hat kein "
-                                                               "Startgewicht; Nachwiegen nicht übernommen")
+                                                               f"Startgewicht; {what}")
-            return
+            return False
         target = max(0.0, rem)
         used = round(max(0.0, float(base) - target), 3)
-        _, done = self._write(f"weigh:{cid}", f"in Spoolman den Rest von {name} auf {target:.1f} g setzen "
+        prev = _num(sm.get("remaining_weight"), float(base) - _num(sm.get("used_weight")))
-                                              "(in CC2 Control nachgewogen)",
+        why = f"(Rolle leergelaufen){runout}" if runout is not None else "(in CC2 Control nachgewogen)"
+        _, done = self._write(f"weigh:{cid}", f"in Spoolman den Rest von {name} auf {target:.1f} g setzen {why}",
                               lambda: self.bridge.spoolman.update_spool(smid, {"used_weight": used}))
         if done:
             b["remaining"] = rem
             b["log_time"] = max(b.get("log_time") or 0.0, log_time)
+            if runout is not None:
+                b["last"] = {"time": self.bridge.clock(), "grams": round(max(0.0, prev - target), 3),
+                             "details": ("Rolle leergelaufen" + runout).replace("leergelaufen – ", "leergelaufen: ")}
             self.bridge.spool_cache.pop(smid, None)
             self.bridge.state.save()
+        return True
 
     # ---------- CC2 Control's log: use of a tray left without spool after "Take out" ----------
 
@@ -691,6 +723,7 @@ class PrinterWorker:
                 "spoolman": summary(cached[1]) if cached else None,
                 "cc2_spool": cc2_spools.get(sid) if sid else None,
                 "cc2_question": cs.get("question") or "",
+                "cc2_question_mm": _num(cs.get("question_mm")) if cs.get("question") else 0.0,
                 "cc2_matches": bool(m and m.get("cc2") and sid == m["cc2"]),
                 "last_booking": (b or {}).get("last"),
             })

app/templates/status.html

@@ -120,6 +120,14 @@ function info(s) {
       out.title = 'Ohne Spoolman-Tag';
       out.hint = 'Verbrauch wird nicht gebucht. Rolle taggen und scannen, um sie zu verwalten.';
     }
+    if (s.cc2_question) {
+      const mm = s.cc2_question_mm || 0;
+      out.question = 'CC2 fragt: Spule ' + (QUESTION[s.cc2_question] || s.cc2_question);
+      out.hint = mm >= 1
+        ? `Gedruckt ohne Spule: ${fmtNum(mm)} mm (ca. ${fmtNum(mm * Math.PI * 0.765625 * 1.24 / 1000, 1)} g). CC2 Control hält den Verbrauch, bis die Spule feststeht: Rolle taggen und scannen, dann wird er nachgebucht – oder in CC2 Control „keine Spule“ wählen.`
+        : 'CC2 Control fragt, welche Spule das ist. Rolle taggen und scannen oder in CC2 Control beantworten.';
+      out.warn = mm >= 1;
+    }
   }
   return out;
 }
@@ -195,7 +203,8 @@ function slotCard(p, s) {
         <span style="min-width:0"><span class="nm" style="display:block;font-size:15px">${esc(i.title)}</span>
         <span class="small muted" style="display:block">${esc(i.sub)}</span></span>
       </button>
-      <p class="hint${i.kind === 'takeout' ? ' warn' : ''}" style="margin-top:auto">${esc(i.hint)}</p>`;
+      ${i.question ? `<div><span class="chip warn">${esc(i.question)}</span></div>` : ''}
+      <p class="hint${i.kind === 'takeout' || i.warn ? ' warn' : ''}" style="margin-top:auto">${esc(i.hint)}</p>`;
   }
   return `<article class="card slot"><div class="sh"><b>Slot ${s.slot + 1}</b>${tray}</div>${body}</article>`;
 }
@@ -205,6 +214,7 @@ function slotRow(p, s) {
   const inner = `<span style="font-weight:800;font-size:13px">${s.slot + 1}</span>`;
   let title = i.title, sub = i.sub, rest = '';
   if (i.kind === 'empty') { title = 'Leer'; sub = 'Kein Filament'; }
+  if (i.kind === 'unmanaged' && i.question) sub = i.warn ? `${fmtNum(s.cc2_question_mm)} mm ohne Spule gedruckt` : i.question;
   if (i.kind === 'managed') {
     rest = i.rest == null ? '?' : Math.round(i.rest) + ' g';
     sub = [i.sub, '#' + s.mapping.spool, i.question || i.cc2[0]].filter(Boolean).join(' · ');
@@ -282,7 +292,7 @@ function sheetHtml(p, s) {
       <h2 id="sheet-title" style="overflow-wrap:anywhere">${esc(i.title || 'Leer')}</h2>${i.sub ? `<div class="small muted">${esc(i.sub)}</div>` : ''}</div>
       <button aria-label="Schließen" onclick="closeSheet()" style="min-width:40px;padding:0;border-radius:99px">✕</button>
     </div>
-    ${i.hint ? `<p class="hint${i.kind === 'takeout' ? ' warn' : ''}">${esc(i.hint)}</p>` : ''}
+    ${i.hint ? `<p class="hint${i.kind === 'takeout' || i.warn ? ' warn' : ''}">${esc(i.hint)}</p>` : ''}
     <dl class="kv">${rows.map(([k, v]) => `<dt>${k}</dt><dd>${v}</dd>`).join('')}</dl>
     ${m ? `<div class="row" style="flex-wrap:nowrap"><button style="flex:1;min-height:48px" onclick="slotAction('${p.id}', ${s.slot}, 'reassign')">Erneut senden</button>
       <button class="danger" style="flex:1;min-height:48px" onclick="slotAction('${p.id}', ${s.slot}, 'release')">Aufheben</button></div>` : ''}`;

tests/test_bridge.py

@@ -740,8 +740,41 @@ def test_runout_and_backup_roll(env):
     cc2.job = {"active": False}
     cc2.add_log(env["clock"](), "print", "s0002", 1, -12.0, 4000.0, "vase.gcode", "complete")
     poll(env, 10)
-    assert sorted(uses(env)) == [("use", 5, 40.0), ("use", 8, 12.0)]
+    assert uses(env) == [("use", 8, 12.0)]
+    assert ("used", 5, 1000.0) in env["sm"].calls  # ran out: Spoolman's rest is 0, whatever the count said
+    assert env["sm"].db[5]["remaining_weight"] == 0
     assert any("Rolle leergelaufen" in m for m in msgs(env))
+    assert booked(env)["s0001"]["last"]["grams"] == 40.0
+
+
+def test_runout_sets_spoolman_to_zero_even_if_the_mirror_was_off(env):
+    env["sm"].add(5, remaining=300)
+    insert(env, 0, 5)
+    poll(env)
+    cc2 = env["cc2"]
+    cc2.library[0]["remaining"] = 400.0  # e.g. an old mirror reused after the roll printed elsewhere
+    booked(env)["s0001"]["remaining"] = 400.0
+    cc2.job = {"active": True}
+    cc2.consume("s0001", 380.0)
+    poll(env)
+    cc2.slots[0]["printer"] = {"status": 0}
+    cc2.slots[0]["spool"] = ""
+    t = env["clock"]()
+    cc2.add_log(t, "runout", "s0001", 0, -20.0, 0, "big.gcode", "runout")
+    cc2.library[0]["remaining"] = 0.0
+    cc2.job = {"active": False}
+    cc2.add_log(t + 5, "print", "s0001", 0, -380.0, 127000.0, "big.gcode", "runout")
+    poll(env, 15)
+    assert uses(env) == [] and env["sm"].db[5]["remaining_weight"] == 0
+
+
+def test_open_question_after_print_is_reported_once(env):
+    cc2 = env["cc2"]
+    cc2.slots[3].update({"printer": {"status": 1}, "question": "changed", "question_since": 100, "question_mm": 2605.0})
+    poll(env, 3)
+    warn = [m for m in msgs(env) if "ohne Spule gedruckt" in m]
+    assert len(warn) == 1 and "2605 mm" in warn[0] and "7.8 g" in warn[0]
+    assert env["bridge"].snapshot["printers"][0]["slots"][3]["cc2_question_mm"] == 2605.0
 
 
 def test_multicolour_print_books_each_roll(env):