CHANGELOG.md

@@ -6,6 +6,18 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ---
 
+## [1.5.4] - 2026-05-10
+
+### Fixed
+- **CRITICAL: Pair BW ACH ASCII reports using the `_ASCII.TXT` convention.**  Blastware's official Auto Call Home server writes per-event ASCII reports as `<stem>_<ext>_ASCII.TXT` (e.g. `N844L20G_630H_ASCII.TXT`), not `<binary>.TXT` (e.g. `N844L20G.630H.TXT`).  Versions v1.5.0–v1.5.3 only looked for the latter and silently shipped every binary alone, so the SFM database lost the per-event Peak Acceleration / Peak Displacement / ZC Freq / Time of Peak / Peak Vector Sum + time / sensor self-check fields on every forwarded event.  After this fix the watcher tries the ACH-convention filename first and falls back to the manual-export `<binary>.TXT` for compatibility with operator-saved exports + existing test fixtures.
+
+### Changed
+- New helper functions `ach_report_name()` and `legacy_report_name()` make the two filename conventions explicit and testable.
+- 6 new unit tests covering both pairing conventions, the precedence-when-both-present rule (ACH wins), and helper-function correctness.
+
+### Field-deploy note
+Re-running v1.5.4 on a folder where v1.5.0–v1.5.3 already ran will NOT re-forward historical events to pick up the rich metadata — the `sfm_forwarded.json` state file remembers them by sha256 and still considers them forwarded.  If you want to re-forward to populate the SFM database with the now-correctly-paired reports for the historical archive, delete the state file before starting v1.5.4.  Otherwise the fix only affects events appearing from v1.5.4 onward.
+
 ## [1.5.3] - 2026-05-10
 
 ### Changed

README.md

@@ -1,4 +1,4 @@
-# Series 3 Watcher v1.5.3
+# Series 3 Watcher v1.5.4
 
 Monitors Instantel **Series 3 (Minimate)** call-in activity on a Blastware server. Runs as a **system tray app** that starts automatically on login, reports heartbeats to terra-view, and self-updates from Gitea.
 
@@ -88,7 +88,7 @@ All settings live in `config.ini`. The Setup Wizard covers every field, but here
 | `UPDATE_SOURCE` | `gitea` (default) or `url` — where to check for updates |
 | `UPDATE_URL` | Base URL of the update server when `UPDATE_SOURCE = url` (e.g. terra-view URL). The watcher fetches `/api/updates/series3-watcher/version.txt` and `/api/updates/series3-watcher/series3-watcher.exe` from this base. |
 
-### SFM Event Forwarder (v1.5.3+)
+### SFM Event Forwarder (v1.5.4+)
 
 Forwards each Blastware event binary (and its paired `<binary>.TXT` ASCII report when present) to an SFM server's `/db/import/blastware_file` endpoint, where the report is parsed and the rich per-channel stats (PPV, ZC Freq, Time of Peak, Peak Acceleration / Displacement, sensor self-check) land in a searchable database. **Default-off** — existing deployments keep their old behaviour after auto-updating until the operator opts in.
 
@@ -155,7 +155,7 @@ To view connected watchers: **Settings → Developer → Watcher Manager**.
 
 ## Versioning
 
-Follows **Semantic Versioning**. Current release: **v1.5.3**.
+Follows **Semantic Versioning**. Current release: **v1.5.4**.
 See `CHANGELOG.md` for full history.
 
 ---

event_forwarder.py

@@ -96,9 +96,41 @@ def is_event_binary(path: str) -> bool:
     return True
 
 
+def ach_report_name(binary_name: str) -> str:
+    """BW ACH report-naming convention.
+
+    Blastware's official Auto Call Home server writes per-event ASCII
+    reports as ``<stem>_<ext>_ASCII.TXT`` — the ``.`` between stem and
+    ext is replaced with ``_`` and ``_ASCII.TXT`` is appended.
+
+    Examples:
+        ``M529LK44.AB0``  →  ``M529LK44_AB0_ASCII.TXT``
+        ``N844L20G.630H`` →  ``N844L20G_630H_ASCII.TXT``
+        ``H907L1R7.PG0H`` →  ``H907L1R7_PG0H_ASCII.TXT``
+
+    For a filename without a dot (defensive — shouldn't happen for real
+    BW events) we still append ``_ASCII.TXT``.
+    """
+    stem, dot, ext = binary_name.rpartition(".")
+    if not dot:
+        return binary_name + "_ASCII.TXT"
+    return stem + "_" + ext + "_ASCII.TXT"
+
+
+def legacy_report_name(binary_name: str) -> str:
+    """Manual-export convention: ``<binary>.TXT`` (e.g. when an operator
+    saves an event report to text directly from BW's UI rather than
+    letting ACH auto-export it).  Kept as a fallback so the codec-agent
+    test fixtures (``decode-re/5-8-26/event-c/M529LK44.AB0.TXT``) still
+    pair correctly."""
+    return binary_name + ".TXT"
+
+
 def report_path_for(binary_path: str) -> str:
-    """Return the conventional `<binary>.TXT` partner path."""
-    return binary_path + ".TXT"
+    """Legacy entry point — returns the manual-export path.  Prefer
+    :func:`ach_report_name` for new BW deployments.  Retained for
+    backward compatibility with any caller still on the old convention."""
+    return legacy_report_name(binary_path)
 
 
 def is_histogram_event(filename: str) -> bool:
@@ -109,9 +141,12 @@ def is_histogram_event(filename: str) -> bool:
     return False (the conservative answer — we don't want to suppress
     "no report" warnings on potentially-waveform old-firmware events).
 
-    Used purely for log clarity — histograms don't get auto-exported BW
-    ASCII reports, so "no report" on a histogram is not a problem to
-    flag.  Forwarding logic itself doesn't depend on this check.
+    Used purely for log clarity — when a forward goes through without a
+    paired TXT, the log distinguishes "histogram, no report expected"
+    (acceptable: BW may not have written one even though it normally
+    does for ACH-routed histograms) from "no report ⚠" on a waveform
+    (more suspicious: BW almost always writes the TXT for waveform events).
+    Forwarding logic itself doesn't depend on this check.
     """
     name = os.path.basename(filename)
     ext = os.path.splitext(name)[1].lstrip(".").upper()
@@ -314,12 +349,29 @@ def find_pending_events(
             skipped_already_forwarded += 1
             continue
 
-        # TXT pairing
-        txt_name = e.name + ".TXT"
-        # Case-insensitive match on the .TXT suffix
-        if txt_name not in names:
-            txt_name_lc = txt_name.lower()
-            txt_name = next((n for n in names if n.lower() == txt_name_lc), None)
+        # TXT pairing — try BW ACH convention first
+        # (<stem>_<ext>_ASCII.TXT) and fall back to the manual-export
+        # convention (<binary>.TXT).  Both checked case-insensitively
+        # against the cached directory listing.  ACH wins when both
+        # exist — that's the format BW's official ACH server writes.
+        candidates = [ach_report_name(e.name), legacy_report_name(e.name)]
+
+        # Case-insensitive name lookup against the cached set.
+        names_lc_to_actual = None
+        txt_name: Optional[str] = None
+        for cand in candidates:
+            if cand in names:
+                txt_name = cand
+                break
+            # Build lower-case index lazily — most folders have very few
+            # TXT files relative to binaries, so the linear scan only
+            # fires when neither exact-case candidate matches.
+            if names_lc_to_actual is None:
+                names_lc_to_actual = {n.lower(): n for n in names}
+            actual = names_lc_to_actual.get(cand.lower())
+            if actual:
+                txt_name = actual
+                break
 
         txt_path: Optional[str] = None
         if txt_name:

installer.iss

@@ -3,7 +3,7 @@
 
 [Setup]
 AppName=Series 3 Watcher
-AppVersion=1.5.3
+AppVersion=1.5.4
 AppPublisher=Terra-Mechanics Inc.
 DefaultDirName={pf}\Series3Watcher
 DefaultGroupName=Series 3 Watcher

series3_tray.py

@@ -1,5 +1,5 @@
 """
-Series 3 Watcher — System Tray Launcher  v1.5.3
+Series 3 Watcher — System Tray Launcher  v1.5.4
 Requires: pystray, Pillow, tkinter (stdlib)
 
 Run with:  pythonw series3_tray.py   (no console window)

series3_watcher.py

@@ -247,7 +247,7 @@ def scan_latest(
 
 
 # --- API heartbeat / SFM telemetry helpers ---
-VERSION = "1.5.3"
+VERSION = "1.5.4"
 
 
 def _read_log_tail(log_file: str, n: int = 25) -> Optional[list]:

settings_dialog.py

@@ -1,5 +1,5 @@
 """
-Series 3 Watcher — Settings Dialog  v1.5.3
+Series 3 Watcher — Settings Dialog  v1.5.4
 
 Provides a Tkinter settings dialog that doubles as a first-run wizard.
 

test_event_forwarder.py

@@ -50,6 +50,22 @@ class TestIsEventBinary(unittest.TestCase):
                      "something.h5", "noise.json"]:
             self.assertFalse(ef.is_event_binary(name), name)
 
+    def test_ach_report_name(self):
+        """BW ACH convention: <stem>.<ext> → <stem>_<ext>_ASCII.TXT"""
+        cases = [
+            ("M529LK44.AB0",    "M529LK44_AB0_ASCII.TXT"),
+            ("N844L20G.630H",   "N844L20G_630H_ASCII.TXT"),
+            ("I145L64P.GD0W",   "I145L64P_GD0W_ASCII.TXT"),
+            ("H907L1R7.PG0H",   "H907L1R7_PG0H_ASCII.TXT"),
+        ]
+        for binary, expected in cases:
+            self.assertEqual(ef.ach_report_name(binary), expected, binary)
+
+    def test_legacy_report_name(self):
+        """Manual-export convention: <binary>.TXT"""
+        self.assertEqual(ef.legacy_report_name("M529LK44.AB0"),
+                         "M529LK44.AB0.TXT")
+
     def test_is_histogram_event(self):
         # 4-char extension ending in H = histogram
         for name in ["H907L1R7.PG0H", "S353L4H0.8S0H", "P036L318.C80H"]:
@@ -139,6 +155,86 @@ class TestFindPendingEvents(unittest.TestCase):
             self.assertEqual(os.path.basename(pending[0][0]), "M529LK44.AB0")
             self.assertEqual(os.path.basename(pending[0][1]), "M529LK44.AB0.TXT")
 
+    def test_pairs_with_ach_underscore_ascii_naming(self):
+        """BW ACH writes M529LK44.AB0 + M529LK44_AB0_ASCII.TXT.  The
+        watcher must pair these even though the .TXT filename doesn't
+        carry a literal copy of the binary's name."""
+        with tempfile.TemporaryDirectory() as tmp:
+            tmp_p = Path(tmp)
+            self._make(tmp_p, "N844L20G.630H", age_seconds=120, content=b"binary")
+            self._make(tmp_p, "N844L20G_630H_ASCII.TXT", age_seconds=100, content=b"report")
+
+            state = ef.ForwardState(str(tmp_p / "fwd.json"))
+            pending = ef.find_pending_events(
+                str(tmp_p), state,
+                max_age_days=30,
+                quiescence_seconds=5,
+                missing_report_grace_seconds=60,
+            )
+            self.assertEqual(len(pending), 1)
+            self.assertEqual(os.path.basename(pending[0][0]), "N844L20G.630H")
+            self.assertEqual(os.path.basename(pending[0][1]),
+                             "N844L20G_630H_ASCII.TXT")
+
+    def test_pairs_with_ach_underscore_ascii_naming_for_waveform(self):
+        """Same as above but for new-firmware waveform events
+        (extension ends in W)."""
+        with tempfile.TemporaryDirectory() as tmp:
+            tmp_p = Path(tmp)
+            self._make(tmp_p, "I145L64P.GD0W", age_seconds=120, content=b"binary")
+            self._make(tmp_p, "I145L64P_GD0W_ASCII.TXT", age_seconds=100, content=b"report")
+
+            state = ef.ForwardState(str(tmp_p / "fwd.json"))
+            pending = ef.find_pending_events(
+                str(tmp_p), state,
+                max_age_days=30,
+                quiescence_seconds=5,
+                missing_report_grace_seconds=60,
+            )
+            self.assertEqual(len(pending), 1)
+            self.assertEqual(os.path.basename(pending[0][1]),
+                             "I145L64P_GD0W_ASCII.TXT")
+
+    def test_pairing_prefers_ach_naming_when_both_exist(self):
+        """If a folder has BOTH conventions (operator manually exported
+        AND ACH also auto-exported), ACH wins because that's the
+        canonical name in modern BW deployments."""
+        with tempfile.TemporaryDirectory() as tmp:
+            tmp_p = Path(tmp)
+            self._make(tmp_p, "M529LK44.AB0", age_seconds=120, content=b"binary")
+            # Both partner files present
+            self._make(tmp_p, "M529LK44.AB0.TXT",      age_seconds=100, content=b"manual")
+            self._make(tmp_p, "M529LK44_AB0_ASCII.TXT", age_seconds=100, content=b"ach")
+
+            state = ef.ForwardState(str(tmp_p / "fwd.json"))
+            pending = ef.find_pending_events(
+                str(tmp_p), state,
+                max_age_days=30,
+                quiescence_seconds=5,
+                missing_report_grace_seconds=60,
+            )
+            self.assertEqual(len(pending), 1)
+            self.assertEqual(os.path.basename(pending[0][1]),
+                             "M529LK44_AB0_ASCII.TXT")
+
+    def test_pairing_falls_back_to_dot_txt_when_ach_absent(self):
+        """If only the manual-export filename exists, the legacy
+        convention still works (preserves codec-agent test fixtures)."""
+        with tempfile.TemporaryDirectory() as tmp:
+            tmp_p = Path(tmp)
+            self._make(tmp_p, "M529LK44.AB0",     age_seconds=120, content=b"binary")
+            self._make(tmp_p, "M529LK44.AB0.TXT", age_seconds=100, content=b"manual")
+
+            state = ef.ForwardState(str(tmp_p / "fwd.json"))
+            pending = ef.find_pending_events(
+                str(tmp_p), state,
+                max_age_days=30,
+                quiescence_seconds=5,
+                missing_report_grace_seconds=60,
+            )
+            self.assertEqual(len(pending), 1)
+            self.assertEqual(os.path.basename(pending[0][1]), "M529LK44.AB0.TXT")
+
     def test_skips_if_already_forwarded(self):
         with tempfile.TemporaryDirectory() as tmp:
             tmp_p = Path(tmp)