CUB-33: Integrate Moonraker filament usage polling with UsageLog persistence

backend/API/Jobs/FilamentUsageSyncJob.cs

@@ -1,5 +1,6 @@
 using Extrudex.Domain.Interfaces;
 using Extrudex.Infrastructure.Configuration;
+using Microsoft.Extensions.DependencyInjection;
 using Microsoft.Extensions.Hosting;
 using Microsoft.Extensions.Logging;
 using Microsoft.Extensions.Options;
@@ -15,25 +16,30 @@ namespace Extrudex.API.Jobs;
 /// Configuration is bound from the "FilamentUsageSync" section in
 /// appsettings.json. Set Enabled=false to disable without removing
 /// the service registration.
+/// 
+/// Uses an IServiceScopeFactory to resolve scoped dependencies
+/// (IFilamentUsageSyncService, IUsageLogService) on each sync cycle,
+/// avoiding captive-dependency issues from injecting scoped services
+/// into the singleton BackgroundService lifetime.
 /// </summary>
 public class FilamentUsageSyncJob : BackgroundService
 {
-    private readonly IFilamentUsageSyncService _syncService;
+    private readonly IServiceScopeFactory _scopeFactory;
     private readonly FilamentUsageSyncOptions _options;
     private readonly ILogger<FilamentUsageSyncJob> _logger;
 
     /// <summary>
     /// Creates a new FilamentUsageSyncJob.
     /// </summary>
-    /// <param name="syncService">The service that performs the actual sync logic.</param>
+    /// <param name="scopeFactory">Factory for creating DI scopes to resolve scoped services.</param>
     /// <param name="options">Configuration options for polling interval and timeouts.</param>
     /// <param name="logger">Logger for diagnostic output.</param>
     public FilamentUsageSyncJob(
-        IFilamentUsageSyncService syncService,
+        IServiceScopeFactory scopeFactory,
         IOptions<FilamentUsageSyncOptions> options,
         ILogger<FilamentUsageSyncJob> logger)
     {
-        _syncService = syncService;
+        _scopeFactory = scopeFactory;
         _options = options.Value;
         _logger = logger;
     }
@@ -58,7 +64,9 @@ public class FilamentUsageSyncJob : BackgroundService
         {
             try
                        {
-                var syncedCount = await _syncService.SyncAllAsync(stoppingToken);
+                using var scope = _scopeFactory.CreateScope();
+                var syncService = scope.ServiceProvider.GetRequiredService<IFilamentUsageSyncService>();
+                var syncedCount = await syncService.SyncAllAsync(stoppingToken);
 
                 _logger.LogInformation(
                     "Filament usage sync completed — {SyncedCount} printer(s) synced. Next sync in {Interval}",

backend/API/Jobs/MoonrakerPrinterSyncJob.cs

@@ -1,5 +1,6 @@
 using Extrudex.Domain.Interfaces;
 using Extrudex.Infrastructure.Configuration;
+using Microsoft.Extensions.DependencyInjection;
 using Microsoft.Extensions.Hosting;
 using Microsoft.Extensions.Logging;
 using Microsoft.Extensions.Options;
@@ -19,22 +20,22 @@ namespace Extrudex.API.Jobs;
 /// </summary>
 public class MoonrakerPrinterSyncJob : BackgroundService
 {
-    private readonly IMoonrakerPrinterSyncService _syncService;
+    private readonly IServiceScopeFactory _scopeFactory;
     private readonly MoonrakerPrinterSyncOptions _options;
     private readonly ILogger<MoonrakerPrinterSyncJob> _logger;
 
     /// <summary>
     /// Creates a new MoonrakerPrinterSyncJob.
     /// </summary>
-    /// <param name="syncService">The service that performs the actual sync logic.</param>
+    /// <param name="scopeFactory">Factory for creating DI scopes to resolve scoped services.</param>
     /// <param name="options">Configuration options for polling interval and timeouts.</param>
     /// <param name="logger">Logger for diagnostic output.</param>
     public MoonrakerPrinterSyncJob(
-        IMoonrakerPrinterSyncService syncService,
+        IServiceScopeFactory scopeFactory,
         IOptions<MoonrakerPrinterSyncOptions> options,
         ILogger<MoonrakerPrinterSyncJob> logger)
     {
-        _syncService = syncService;
+        _scopeFactory = scopeFactory;
         _options = options.Value;
         _logger = logger;
     }
@@ -59,7 +60,9 @@ public class MoonrakerPrinterSyncJob : BackgroundService
         {
             try
             {
-                var syncedCount = await _syncService.SyncAllAsync(stoppingToken);
+                using var scope = _scopeFactory.CreateScope();
+                var syncService = scope.ServiceProvider.GetRequiredService<IMoonrakerPrinterSyncService>();
+                var syncedCount = await syncService.SyncAllAsync(stoppingToken);
 
                 _logger.LogInformation(
                     "Moonraker printer sync completed — {SyncedCount} printer(s) synced. Next sync in {Interval}",

backend/Infrastructure/Services/FilamentUsageSyncService.cs

@@ -1,21 +1,24 @@
+using Extrudex.Domain.DTOs.Moonraker;
+using Extrudex.Domain.Entities;
 using Extrudex.Domain.Enums;
 using Extrudex.Domain.Interfaces;
 using Extrudex.Infrastructure.Data;
 using Microsoft.EntityFrameworkCore;
 using Microsoft.Extensions.Logging;
 
-namespace Extrudex.Infrastructure.Configuration;
+namespace Extrudex.Infrastructure.Services;
 
 /// <summary>
 /// Service that syncs filament usage data from Moonraker printers into the
 /// Extrudex database. Queries all active Moonraker printers, fetches their
-/// current filament usage metrics, and updates spool remaining weights and
-/// print job records.
+/// current filament usage metrics, persists usage entries to the UsageLog table,
+/// creates FilamentUsage records for completed jobs, and updates spool remaining weights.
 /// </summary>
 public class FilamentUsageSyncService : IFilamentUsageSyncService
 {
     private readonly ExtrudexDbContext _dbContext;
     private readonly IMoonrakerClient _moonrakerClient;
+    private readonly IUsageLogService _usageLogService;
     private readonly ILogger<FilamentUsageSyncService> _logger;
 
     /// <summary>
@@ -23,14 +26,17 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
     /// </summary>
     /// <param name="dbContext">The EF Core database context for persisting updates.</param>
     /// <param name="moonrakerClient">The Moonraker HTTP client for fetching printer data.</param>
+    /// <param name="usageLogService">The usage log service for persisting usage entries.</param>
     /// <param name="logger">Logger for diagnostic output.</param>
     public FilamentUsageSyncService(
         ExtrudexDbContext dbContext,
         IMoonrakerClient moonrakerClient,
+        IUsageLogService usageLogService,
         ILogger<FilamentUsageSyncService> logger)
     {
         _dbContext = dbContext;
         _moonrakerClient = moonrakerClient;
+        _usageLogService = usageLogService;
         _logger = logger;
     }
 
@@ -43,7 +49,9 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
             .Where(p => p.IsActive && p.ConnectionType == ConnectionType.Moonraker)
             .Include(p => p.AmsUnits)
                 .ThenInclude(u => u.Slots)
-                    .ThenInclude(s => s.Spool)
+                    .ThenInclude(s => s.Spool!)
+                        .ThenInclude(s => s.MaterialBase)
+            .Include(p => p.PrintJobs)
             .ToListAsync(cancellationToken);
 
         if (printers.Count == 0)
@@ -60,33 +68,18 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
         {
             try
             {
-                var usageData = await _moonrakerClient.GetFilamentUsageAsync(
-                    printer.HostnameOrIp,
-                    printer.Port,
-                    printer.ApiKey,
-                    cancellationToken);
-
-                if (usageData.Count == 0)
-                {
-                    _logger.LogWarning(
-                        "No usage data returned from printer {PrinterName} ({Host}:{Port})",
-                        printer.Name, printer.HostnameOrIp, printer.Port);
-                    continue;
-                }
-
-                // Update spool remaining weights from AMS data
-                UpdateSpoolWeights(printer, usageData);
-
-                // Mark printer as seen and idle (reachable = idle, not printing)
-                printer.LastSeenAt = DateTime.UtcNow;
-                printer.Status = PrinterStatus.Idle;
-
+                await SyncPrinterAsync(printer, cancellationToken);
                 syncedCount++;
-                _logger.LogInformation(
-                    "Successfully synced filament usage from printer {PrinterName}",
-                    printer.Name);
             }
-            catch (Exception ex)
+            catch (HttpRequestException ex)
+            {
+                _logger.LogError(ex,
+                    "Connection error syncing filament usage from printer {PrinterName} ({Host}:{Port}) — printer may be offline",
+                    printer.Name, printer.HostnameOrIp, printer.Port);
+
+                printer.Status = PrinterStatus.Offline;
+            }
+            catch (Exception ex) when (ex is not OperationCanceledException)
             {
                 _logger.LogError(ex,
                     "Error syncing filament usage from printer {PrinterName} ({Host}:{Port})",
@@ -103,12 +96,168 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
         return syncedCount;
     }
 
+    /// <summary>
+    /// Syncs a single Moonraker printer: fetches print stats and history,
+    /// persists usage data to UsageLog and FilamentUsage tables, and
+    /// updates spool remaining weights.
+    /// </summary>
+    private async Task SyncPrinterAsync(Printer printer, CancellationToken cancellationToken)
+    {
+        // Step 1: Fetch current print stats for real-time filament usage
+        var printStats = await _moonrakerClient.GetPrintStatsAsync(
+            printer.HostnameOrIp, printer.Port, printer.ApiKey, cancellationToken);
+
+        // Step 2: Fetch usage dictionary for backward-compatible metrics
+        var usageData = await _moonrakerClient.GetFilamentUsageAsync(
+            printer.HostnameOrIp, printer.Port, printer.ApiKey, cancellationToken);
+
+        // Step 3: Update printer status based on print stats
+        if (printStats != null)
+        {
+            printer.Status = printStats.State.ToLowerInvariant() switch
+            {
+                "printing" => PrinterStatus.Printing,
+                "paused" => PrinterStatus.Paused,
+                "complete" => PrinterStatus.Idle,
+                "standby" => PrinterStatus.Idle,
+                "cancelled" => PrinterStatus.Idle,
+                "error" => PrinterStatus.Error,
+                _ => printer.Status
+            };
+        }
+
+        printer.LastSeenAt = DateTime.UtcNow;
+
+        // Step 4: Update spool remaining weights from AMS data
+        UpdateSpoolWeights(printer, usageData);
+
+        // Step 5: If there's filament usage from print stats, persist it
+        if (printStats != null && printStats.FilamentUsedMm > 0)
+        {
+            await PersistFilamentUsageAsync(printer, printStats, cancellationToken);
+        }
+        else if (usageData.TryGetValue("mm_extruded", out var mmExtruded) && mmExtruded > 0)
+        {
+            // Fall back to dictionary metrics if print stats aren't available
+            _logger.LogInformation(
+                "Printer {PrinterName} reports {MmExtruded}mm filament extruded in latest job (from usage dictionary)",
+                printer.Name, mmExtruded);
+        }
+
+        _logger.LogInformation(
+            "Successfully synced filament usage from printer {PrinterName}",
+            printer.Name);
+    }
+
+    /// <summary>
+    /// Persists filament usage data from print stats to the database.
+    /// Creates a FilamentUsage record and a UsageLog entry, and deducts
+    /// consumed grams from the spool's remaining weight.
+    /// </summary>
+    private async Task PersistFilamentUsageAsync(
+        Printer printer,
+        MoonrakerPrintStats printStats,
+        CancellationToken cancellationToken)
+    {
+        // Find the default spool for this printer
+        var defaultSpool = FindDefaultSpool(printer);
+
+        if (defaultSpool == null)
+        {
+            _logger.LogWarning(
+                "No default spool found for printer {PrinterName} — cannot persist filament usage of {MmExtruded}mm",
+                printer.Name, printStats.FilamentUsedMm);
+            return;
+        }
+
+        // Calculate derived grams
+        var gramsDerived = CalculateGrams(
+            printStats.FilamentUsedMm,
+            defaultSpool.FilamentDiameterMm,
+            defaultSpool.MaterialBase.DensityGperCm3);
+
+        if (gramsDerived <= 0)
+        {
+            _logger.LogDebug(
+                "No grams derived for printer {PrinterName} — skipping usage persistence",
+                printer.Name);
+            return;
+        }
+
+        // Deduct from spool remaining weight (floor at 0)
+        var previousWeight = defaultSpool.WeightRemainingGrams;
+        defaultSpool.WeightRemainingGrams = Math.Max(0, defaultSpool.WeightRemainingGrams - gramsDerived);
+
+        _logger.LogInformation(
+            "Deducted {Grams:F1}g from spool {SpoolSerial} (was {Previous:F1}g, now {Current:F1}g) for printer {PrinterName}",
+            gramsDerived, defaultSpool.SpoolSerial, previousWeight, defaultSpool.WeightRemainingGrams, printer.Name);
+
+        // Check if we already have a recent FilamentUsage for this printer
+        // to avoid double-counting on repeated poll cycles for the same job
+        var recentUsageThreshold = DateTime.UtcNow.AddMinutes(-10);
+        var existingRecentUsage = await _dbContext.FilamentUsages
+            .Where(fu => fu.PrinterId == printer.Id && fu.RecordedAt >= recentUsageThreshold)
+            .AnyAsync(cancellationToken);
+
+        if (existingRecentUsage)
+        {
+            _logger.LogDebug(
+                "Recent FilamentUsage record exists for printer {PrinterName} — skipping to avoid double-counting",
+                printer.Name);
+            return;
+        }
+
+        // Create a FilamentUsage entity for the consumption
+        var filamentUsage = new FilamentUsage
+        {
+            SpoolId = defaultSpool.Id,
+            PrinterId = printer.Id,
+            GramsUsed = gramsDerived,
+            MmExtruded = printStats.FilamentUsedMm,
+            RecordedAt = DateTime.UtcNow,
+            Notes = $"Auto-recorded from Moonraker print stats (state: {printStats.State})"
+        };
+
+        // If there's a matching print job, link it
+        var matchingJob = FindMatchingPrintJob(printer, printStats);
+        if (matchingJob != null)
+        {
+            filamentUsage.PrintJobId = matchingJob.Id;
+            filamentUsage.PrintJob = matchingJob;
+        }
+
+        _dbContext.FilamentUsages.Add(filamentUsage);
+
+        // Also persist to UsageLog via the usage logging service
+        try
+        {
+            await _usageLogService.RecordUsageAsync(
+                spoolId: defaultSpool.Id,
+                gramsUsed: gramsDerived,
+                dataSource: DataSource.Moonraker,
+                printerId: printer.Id,
+                printJobId: matchingJob?.Id,
+                mmExtruded: printStats.FilamentUsedMm,
+                notes: $"Auto-recorded from Moonraker print stats (state: {printStats.State})");
+
+            _logger.LogInformation(
+                "Persisted usage log: {Grams:F1}g / {Mm:F1}mm for spool {SpoolSerial} on printer {PrinterName}",
+                gramsDerived, printStats.FilamentUsedMm, defaultSpool.SpoolSerial, printer.Name);
+        }
+        catch (Exception ex)
+        {
+            _logger.LogError(ex,
+                "Failed to persist usage log for printer {PrinterName} — FilamentUsage entity was still created",
+                printer.Name);
+        }
+    }
+
     /// <summary>
     /// Updates spool remaining weights based on usage data received from Moonraker.
     /// For printers with AMS units, updates the remaining weight on each slot's spool.
     /// </summary>
     private void UpdateSpoolWeights(
-        Domain.Entities.Printer printer,
+        Printer printer,
         Dictionary<string, decimal> usageData)
     {
         // Update AMS slot remaining weights if available
@@ -122,7 +271,7 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
                     slot.Spool.WeightRemainingGrams = slot.RemainingWeightG.Value;
 
                     _logger.LogDebug(
-                        "Updated spool {SpoolSerial} remaining weight to {Weight}g",
+                        "Updated spool {SpoolSerial} remaining weight to {Weight}g from AMS data",
                         slot.Spool.SpoolSerial, slot.RemainingWeightG.Value);
                 }
             }
@@ -136,4 +285,56 @@ public class FilamentUsageSyncService : IFilamentUsageSyncService
                 printer.Name, mmExtruded);
         }
     }
+
+    /// <summary>
+    /// Finds the default spool for a printer. Returns the first active, non-archived spool
+    /// loaded in an AMS slot, or null if no spool is available.
+    /// </summary>
+    private static Spool? FindDefaultSpool(Printer printer)
+    {
+        foreach (var amsUnit in printer.AmsUnits)
+        {
+            foreach (var slot in amsUnit.Slots)
+            {
+                if (slot.Spool != null && slot.Spool.IsActive && !slot.Spool.IsArchived)
+                {
+                    return slot.Spool;
+                }
+            }
+        }
+
+        return null;
+    }
+
+    /// <summary>
+    /// Finds a PrintJob on this printer that matches the current print stats.
+    /// Matches by filename and non-completed status to avoid double-linking.
+    /// </summary>
+    private PrintJob? FindMatchingPrintJob(Printer printer, MoonrakerPrintStats printStats)
+    {
+        if (string.IsNullOrEmpty(printStats.Filename))
+            return null;
+
+        return printer.PrintJobs
+            .FirstOrDefault(pj => pj.PrintName == printStats.Filename
+                && pj.Status != JobStatus.Completed
+                && pj.Status != JobStatus.Cancelled);
+    }
+
+    /// <summary>
+    /// Calculates derived grams from millimeters extruded using the standard formula:
+    /// grams = mm_extruded × cross_section_area × material_density
+    /// where cross_section_area = π × (diameter / 2)²
+    /// </summary>
+    private static decimal CalculateGrams(decimal mmExtruded, decimal diameterMm, decimal densityGperCm3)
+    {
+        if (mmExtruded <= 0) return 0m;
+
+        var radiusCm = (double)diameterMm / 2.0 / 10.0; // mm to cm
+        var crossSectionAreaCm2 = Math.PI * radiusCm * radiusCm;
+        var mmToCm = (double)mmExtruded / 10.0;
+
+        var grams = mmToCm * crossSectionAreaCm2 * (double)densityGperCm3;
+        return (decimal)grams;
+    }
 }

backend/Infrastructure/Services/MoonrakerPrinterSyncService.cs

@@ -46,7 +46,7 @@ public class MoonrakerPrinterSyncService : IMoonrakerPrinterSyncService
             .Where(p => p.IsActive && p.ConnectionType == ConnectionType.Moonraker)
             .Include(p => p.AmsUnits)
                 .ThenInclude(u => u.Slots)
-                    .ThenInclude(s => s.Spool)
+                    .ThenInclude(s => s.Spool!)
                         .ThenInclude(s => s.MaterialBase)
             .Include(p => p.PrintJobs)
             .ToListAsync(cancellationToken);