feat: Remove mock sensor data and update initialization for real hardware usage

app/api/sensors/route.ts

@@ -22,18 +22,9 @@ const SENSOR_CONFIG: SensorConfig[] = [
   { id: "hip-1", x: 35, y: 50, zone: "hips", label: "Left Hip", pin: 9, baseNoise: 400, warningThreshold: 2200, alarmThreshold: 2800, warningDelayMs: 90000 },
   { id: "hip-2", x: 50, y: 50, zone: "hips", label: "Lower Back", pin: 10, baseNoise: 450, warningThreshold: 2200, alarmThreshold: 2800, warningDelayMs: 90000 },
   { id: "hip-3", x: 65, y: 50, zone: "hips", label: "Right Hip", pin: 11, baseNoise: 380, warningThreshold: 2200, alarmThreshold: 2800, warningDelayMs: 90000 },
-
   // Thigh area
   { id: "thigh-1", x: 40, y: 65, zone: "legs", label: "Left Thigh", pin: 12, baseNoise: 320, warningThreshold: 2000, alarmThreshold: 2500, warningDelayMs: 120000 },
   { id: "thigh-2", x: 60, y: 65, zone: "legs", label: "Right Thigh", pin: 13, baseNoise: 300, warningThreshold: 2000, alarmThreshold: 2500, warningDelayMs: 120000 },
-
-  // Calf area (mock data)
-  { id: "calf-1", x: 40, y: 75, zone: "legs", label: "Left Calf", baseNoise: 200, warningThreshold: 1800, alarmThreshold: 2200, warningDelayMs: 150000 },
-  { id: "calf-2", x: 60, y: 75, zone: "legs", label: "Right Calf", baseNoise: 220, warningThreshold: 1800, alarmThreshold: 2200, warningDelayMs: 150000 },
-
-  // Feet (mock data)
-  { id: "feet-1", x: 45, y: 85, zone: "feet", label: "Left Foot", baseNoise: 150, warningThreshold: 1500, alarmThreshold: 1800, warningDelayMs: 180000 },
-  { id: "feet-2", x: 55, y: 85, zone: "feet", label: "Right Foot", baseNoise: 160, warningThreshold: 1500, alarmThreshold: 1800, warningDelayMs: 180000 },
 ];
 
 // Create pin mapping from sensor config
@@ -68,18 +59,18 @@ let isHardwareConnected = false;
 // Initialize all sensor data
 function initializeSensorData() {
   SENSOR_CONFIG.forEach(sensor => {
-    if (!sensorData[sensor.id]) {
+    if (!sensorData[sensor.id] && sensor.pin) { // Only initialize sensors with pins (real hardware)
       sensorData[sensor.id] = {
         id: sensor.id,
         x: sensor.x,
         y: sensor.y,
         label: sensor.label,
         zone: sensor.zone,
-        value: 1000 + Math.random() * 500, // Start with baseline analog value (1000-1500)
+        value: 0, // Start with zero until real data arrives
         pin: sensor.pin,
         timestamp: new Date().toISOString(),
-        source: sensor.pin ? 'hardware' : 'mock',
+        source: 'hardware',
-        data: generateTimeSeriesData(),
+        data: [], // Start with empty data array
         status: 'normal',
         warningThreshold: sensor.warningThreshold,
         alarmThreshold: sensor.alarmThreshold,
@@ -89,21 +80,7 @@ function initializeSensorData() {
   });
 }
 
-// Generate time series data for a sensor
-function generateTimeSeriesData(hours = 1) {
-  const data = [];
-  const now = new Date();
 
-  for (let i = hours * 60; i >= 0; i -= 5) {
-    const time = new Date(now.getTime() - i * 60 * 1000);
-    data.push({
-      time: time.toLocaleTimeString("en-US", { hour12: false }),
-      timestamp: time.getTime(),
-      value: Math.floor(Math.random() * 4096 + Math.sin(i / 60) * 500 + 2000), // 0-4095 range
-    });
-  }
-  return data;
-}
 
 // Initialize hardware connection
 async function initializeHardware() {
@@ -133,39 +110,19 @@ async function initializeHardware() {
       isHardwareConnected = false;
     });
 
-    await bedHardwareInstance.connect();
+    await bedHardwareInstance.connect();  } catch (error) {
-  } catch (error) {
+    console.warn('Failed to connect to hardware, system will wait for real hardware data:', error);
-    console.warn('Failed to connect to hardware, using mock data:', error);
     isHardwareConnected = false;
   }
 }
 
-// Convert digital pin state to analog value with noise
-function digitalToAnalogValue(pinState: number, baseNoise: number): number {
-  // Base value from digital state
-  const baseValue = pinState === 1 ? 3000 : 1000; // High when pin is HIGH, low when LOW
-  
-  // Add realistic noise and variation
-  const timeNoise = Math.sin(Date.now() / 10000) * 200; // Slow oscillation
-  const randomNoise = (Math.random() - 0.5) * baseNoise;
-  const sensorDrift = (Math.random() - 0.5) * 50; // Small drift
-  
-  const value = baseValue + timeNoise + randomNoise + sensorDrift;
-  
-  // Clamp between 0 and 4095
-  return Math.max(0, Math.min(4095, Math.floor(value)));
-}
-
 // Update sensor data from pin change
-async function updateSensorFromPin(pin: number, state: number) {
+async function updateSensorFromPin(pin: number, value: number) {
   const mapping = PIN_SENSOR_MAP[pin];
   if (!mapping) return;
-
-  const value = digitalToAnalogValue(state, mapping.baseNoise);
   const timestamp = Date.now();
   const time = new Date(timestamp).toLocaleTimeString("en-US", { hour12: false });
-  
+    // Save to persistent storage
-  // Save to persistent storage
   const dataPoint: SensorDataPoint = {
     sensorId: mapping.id,
     value,
@@ -173,7 +130,7 @@ async function updateSensorFromPin(pin: number, state: number) {
     time,
     source: 'hardware',
     pin,
-    digitalState: state
+    digitalState: value
   };
   await sensorDataStorage.addDataPoint(dataPoint);
   
@@ -198,11 +155,10 @@ async function updateSensorFromPin(pin: number, state: number) {
     } else {
       warningStartTime = undefined; // Clear warning timer
     }
-    
+      sensorData[mapping.id] = {
-    sensorData[mapping.id] = {
       ...currentData,
       value,
-      digitalState: state,
+      digitalState: value,
       timestamp: new Date().toISOString(),
       source: 'hardware',
       data: [
@@ -219,68 +175,18 @@ async function updateSensorFromPin(pin: number, state: number) {
   }
 }
 
-// Update mock sensor data with variation
-function updateMockSensorData() {
-  SENSOR_CONFIG.forEach(sensor => {
-    if (!sensor.pin && sensorData[sensor.id]) {
-      // This is a mock sensor, update with variation
-      const currentSensor = sensorData[sensor.id];
-      const variation = (Math.random() - 0.5) * 200; // Larger variation for analog values
-      const newValue = Math.max(0, Math.min(4095, currentSensor.value + variation));
-      const timestamp = Date.now();
 
-      // Determine status based on thresholds
-      let status = 'normal';
-      let warningStartTime = currentSensor.warningStartTime;
-      
-      if (newValue >= sensor.alarmThreshold) {
-        status = 'alarm';
-        warningStartTime = undefined; // Clear warning timer for immediate alarm
-      } else if (newValue >= sensor.warningThreshold) {
-        status = 'warning';
-        if (!warningStartTime) {
-          warningStartTime = timestamp; // Start warning timer
-        } else if (timestamp - warningStartTime >= sensor.warningDelayMs) {
-          status = 'alarm'; // Escalate to alarm after delay
-        }
-      } else {
-        warningStartTime = undefined; // Clear warning timer
-      }
-      
-      sensorData[sensor.id] = {
-        ...currentSensor,
-        value: newValue,
-        timestamp: new Date().toISOString(),
-        data: [
-          ...currentSensor.data.slice(-287), // Keep last ~24 hours
-          {
-            time: new Date().toLocaleTimeString("en-US", { hour12: false }),
-            timestamp: Date.now(),
-            value: newValue,
-          }
-        ],
-        status,
-        warningStartTime
-      };
-    }
-  });
-}
 
 export async function GET() {
   try {
     // Initialize sensor data if not already done
     if (Object.keys(sensorData).length === 0) {
       initializeSensorData();
-    }
+    }    // Initialize hardware if not already done
-
-    // Initialize hardware if not already done
     if (!isHardwareConnected) {
       await initializeHardware();
     }
 
-    // Update mock sensor data
-    updateMockSensorData();
-
     // If hardware is connected, get current pin states
     if (isHardwareConnected) {
       const pinStates = bedHardwareInstance.getAllPinStates();
@@ -318,7 +224,7 @@ export async function POST(request: NextRequest) {
       return NextResponse.json({
         success: true,
         connected: isHardwareConnected,
-        message: isHardwareConnected ? 'Hardware connected' : 'Using mock data'
+        message: isHardwareConnected ? 'Hardware connected' : 'Hardware connection failed'
       });
     }