Operator Diagnostic Report

NEVER present hypotheses as confirmed findings

If diagnose_vibration was called without RPM, the tool cannot identify shaft-frequency faults (unbalance, misalignment, looseness). The report must:

1. State clearly: "Shaft speed was not provided; shaft-frequency analysis was not performed."
2. Report only the data the tool actually returned (RMS, kurtosis, crest factor, ISO severity, spectral peaks).
3. NOT add fault diagnoses that the tool did not produce (e.g. do not write "possible unbalance" if the tool never returned an unbalance diagnosis).

If bearing data was not provided, do NOT add bearing fault hypotheses.

Distinguish MCP tool output from general knowledge

When including information based on your general engineering knowledge (e.g. typical RPM ranges, ISO 1940 balancing grades, common maintenance procedures) rather than MCP tool output, you MUST clearly label it:

⚠️ Note — general engineering knowledge: This recommendation is based on standard engineering practice, not on data from the MCP analysis tools.

Never present general knowledge as if it were a finding from sensor data analysis.

Tools Used for Report Data

The report is generated from the output of these analysis tools:

• diagnose_vibration — Run the full automated diagnosis first (RPM is optional; if unknown, the report will note that shaft-frequency analysis was not performed)
• assess_vibration_severity — ISO 10816 zone classification for the severity section
• compute_fft_spectrum / find_spectral_peaks — For spectral evidence in findings
• load_signal — To reference the measurement data source

Report Structure

Always follow this template structure:

1. Header

• Report title
• Date and time of measurement
• Machine identification (name, tag, location)
• Technician / analyst name (if provided)

2. Executive Summary (2–3 sentences)

• Overall machine condition (Good / Acceptable / Alarm / Danger)
• Key finding in plain language
• Urgency level

3. Measurement Details

• Sensor used and mounting position (e.g., IIS3DWB accelerometer, magnetic mount)
• Sample rate and duration (auto-detected from DATALOG2 device config)
• Machine operating conditions (RPM if known, load state)
• Data source: DATALOG2 acquisition folder or imported file

4. Overall Vibration Severity

• ISO 10816 zone (A/B/C/D) with color indicator
• RMS velocity value and units
• Comparison to baseline (if available)
• Trend indication (improving / stable / degrading)

5. Findings Table

For each detected condition:

6. Detailed Analysis (for each finding)

• What was detected: Plain language description
• Evidence: The specific spectral features that indicate this
• What it means: Impact on machine operation and lifetime
• Recommended action: Specific maintenance steps

7. Recommendations Summary

Prioritized list of actions:

1. Immediate actions (Zone D / high confidence faults)
2. Planned maintenance (Zone C / medium confidence)
3. Monitoring adjustments (increase frequency, add measurement points)

8. Next Steps

• Recommended follow-up measurement date
• Additional tests if needed (alignment check, thermography, oil analysis)

Language Guidelines

• Use plain language — avoid jargon where possible
• When technical terms are necessary, provide a brief explanation
  • Example: "BPFO (outer race bearing fault frequency)" → "Vibration pattern indicating damage on the outer ring of the bearing"
• Use traffic-light colors for severity:
  • 🟢 Green = Good
  • 🟡 Yellow = Acceptable / Monitor
  • 🟠 Orange = Alarm / Plan maintenance
  • 🔴 Red = Danger / Act immediately
• Include specific numbers but always with context
  • Bad: "2× amplitude is 0.34 g"
  • Good: "Vibration at twice the shaft speed is elevated (0.34 g), which is typical of shaft misalignment"

Report Template

See report-template.md for the full Markdown template that should be used to format the report output.

Formatting Rules

• Output as Markdown (suitable for rendering or PDF conversion)
• Include tables for structured data
• Use horizontal rules to separate major sections
• Keep total report length reasonable (1–3 pages when printed)
• If multiple measurement points exist, show a summary table first, then detailed sections for each point with issues

PDF Generation with ReportLab

When the user asks for a PDF report, generate a Python script using reportlab. Follow these mandatory rules to avoid layout issues:

Table Layout — Preventing Text Overflow

CRITICAL: Long text in table cells must wrap. Never use a plain string in a cell if it might exceed the column width — it will overlap adjacent cells.

from reportlab.platypus import Table, TableStyle, Paragraph
from reportlab.lib.styles import getSampleStyleSheet
from reportlab.lib import colors
from reportlab.lib.units import inch

styles = getSampleStyleSheet()
cell_style = styles["BodyText"]  # word-wraps automatically

# ALWAYS wrap cell text in Paragraph() if it might be long
data = [
    ["#", "Finding", "Severity", "Action"],
    [
        "1",
        Paragraph("Impulsive axial vibration detected on Z-axis with elevated kurtosis", cell_style),
        "Monitor",
        Paragraph("Schedule bearing inspection within 30 days", cell_style),
    ],
]

# ALWAYS set explicit colWidths so text wraps within each column
col_widths = [0.3*inch, 2.5*inch, 0.8*inch, 2.5*inch]
table = Table(data, colWidths=col_widths)
table.setStyle(TableStyle([
    ("VALIGN", (0, 0), (-1, -1), "TOP"),
    ("WORDWRAP", (0, 0), (-1, -1), True),
]))

Rules summary

1. Always set colWidths — never let ReportLab auto-size columns
2. Wrap long text in Paragraph(text, style) — plain strings don't wrap
3. Use VALIGN=TOP so multi-line cells align properly
4. Use the page width (letter = 7.5 inch usable) to calculate proportional widths
5. For the findings table: col widths ≈ [0.3, 2.5, 0.8, 0.8, 2.5] inches

Section 5 — Detailed Findings Tables (CRITICAL)

The "Detailed Findings" section generates the worst layout problems because each finding has long descriptive text. Apply all of these rules:

from reportlab.lib import colors

# 1. Header cells: dark background + white bold text for contrast
header_style = ParagraphStyle("TableHeader", parent=styles["BodyText"],
                              textColor=colors.white, fontName="Helvetica-Bold",
                              fontSize=9)
body_style = ParagraphStyle("TableBody", parent=styles["BodyText"],
                            fontSize=8, leading=10)

# 2. EVERY cell must be a Paragraph — no plain strings
header_row = [
    Paragraph("#", header_style),
    Paragraph("Finding", header_style),
    Paragraph("Severity", header_style),
    Paragraph("Confidence", header_style),
    Paragraph("Action Required", header_style),
]
data_row = [
    Paragraph("1", body_style),
    Paragraph("Impulsive axial vibration detected…", body_style),
    Paragraph("Monitor", body_style),
    Paragraph("Medium", body_style),
    Paragraph("Schedule bearing inspection within 30 days", body_style),
]

# 3. Explicit column widths (must sum ≤ 7.5 inches)
col_widths = [0.3*inch, 2.3*inch, 0.7*inch, 0.7*inch, 2.5*inch]

table = Table([header_row, data_row], colWidths=col_widths)
table.setStyle(TableStyle([
    # Dark header row
    ("BACKGROUND", (0, 0), (-1, 0), colors.HexColor("#2C3E50")),
    ("TEXTCOLOR", (0, 0), (-1, 0), colors.white),
    # Alternating row shading for readability
    ("BACKGROUND", (0, 1), (-1, -1), colors.HexColor("#F8F9FA")),
    ("ROWBACKGROUNDS", (0, 1), (-1, -1), [colors.white, colors.HexColor("#F2F3F4")]),
    # Grid and alignment
    ("GRID", (0, 0), (-1, -1), 0.5, colors.grey),
    ("VALIGN", (0, 0), (-1, -1), "TOP"),
    ("WORDWRAP", (0, 0), (-1, -1), True),
    ("TOPPADDING", (0, 0), (-1, -1), 4),
    ("BOTTOMPADDING", (0, 0), (-1, -1), 4),
]))

Common mistakes to avoid in Section 5:

• ❌ Plain strings in cells → text overflows into adjacent columns
• ❌ No header background → header indistinguishable from body
• ❌ Missing colWidths → columns auto-size and overflow the page
• ❌ No grid lines → rows blend together
• ❌ Font size too large → text wraps excessively or overflows

Report Footer

Always end the PDF with this footer text:

Report generated automatically by Claude Edge Predictive Maintenance
Sensor: STEVAL-STWINBX1 | Firmware: FP-SNS-DATALOG2 | Analysis: vibration-analysis-mcp

Do NOT use the old wording "STWIN.box + Claude vibration diagnostics system".

Evidence & Assumptions Protocol

When presenting results, always separate:

1. Measured evidence (tool outputs, frequencies, amplitudes, ISO zone, statistics)
2. Inference (diagnostic interpretation with confidence)
3. Assumptions / prior knowledge (catalog values, typical fault heuristics, missing machine metadata)

If assumptions are used because required inputs are missing, declare this explicitly and ask for the missing data when practical.