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Recalibrate blast rate formula from industry reference tables

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Replace the inaccurate CFM-based formula with nozzle-primary tables
sourced from industry standard abrasive blast cleaning references:
- Pressure pot: midpoints averaged from two reference tables
  (#4 nozzle: 115 sqft/hr, #5: 175 sqft/hr, etc.)
- Siphon cabinet: dedicated siphon cabinet reference table
  (#4 nozzle: 125 sqft/hr, #3: 75 sqft/hr, etc.)
- SiphonPot: 80% of pressure pot rate (open gravity feed, no enclosure)
- WetBlasting: 60% of pressure pot rate (water-media reduces velocity)

CFM is removed from the rate formula entirely — nozzle size determines
throughput and CFM draw, so CFM is a consequence of nozzle choice, not
an independent variable. Override field still bypasses formula for shops
that have measured their own throughput.

Also corrects TierDefaults nozzle/CFM pairings which were mismatched
(e.g. Small tier had 40 CFM assigned to a #5 nozzle that needs 150 CFM).

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
This commit is contained in:
Scott Pouliot
2026-06-03 16:12:45 -04:00
parent ad986561c9
commit 8453449833
1 changed files with 100 additions and 80 deletions
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src/PowderCoating.Application/Services/ShopCapabilityCalculator.cs
+100 -80
View File
@@ -5,145 +5,165 @@ namespace PowderCoating.Application.Services;
/// <summary>
/// Derives sqft/hr throughput rates from a shop's equipment configuration.
/// Used in two places: the AI photo quote prompt (so Claude reasons from real shop
/// speeds) and the calculated-item wizard (to show a suggested blast time hint).
/// Used by the AI photo quote prompt (so Claude reasons from real shop speeds)
/// and the Company Settings live preview (so the UI always shows the same rate
/// the AI will use — single formula path, no client-side duplication).
///
/// Formula:
/// BlastRate = BaseByCfm(cfm) × NozzleMultiplier × SetupMultiplier × SubstrateMultiplier
/// Both pressure pots and siphon cabinets are nozzle-primary: nozzle size
/// determines throughput and CFM draw. CFM is not used in the rate formula.
///
/// Base rates by CFM represent a pressure pot at #5 nozzle removing paint.
/// All multipliers are relative to that baseline.
/// Sources:
/// Pressure pot rates — averaged from two industry standard abrasive blast
/// cleaning reference tables.
/// Siphon cabinet rates — industry reference table for siphon-fed cabinets.
/// Substrate multipliers — relative removal difficulty vs. paint baseline.
/// </summary>
public static class ShopCapabilityCalculator
{
// ── Blast rate derivation ─────────────────────────────────────────────────
// ── Public entry points ────────────────────────────────────────────────────
/// <summary>
/// Returns the effective blast rate in sqft/hr.
/// If <see cref="CompanyOperatingCosts.BlastRateSqFtPerHourOverride"/> is set, returns it directly.
/// Otherwise derives from CFM, nozzle, setup type, and substrate.
/// Returns 0 when CFM is not configured (shop hasn't calibrated yet).
/// Returns the effective blast rate in sqft/hr for company-level operating costs.
/// BlastRateSqFtPerHourOverride bypasses the formula when set.
/// </summary>
public static decimal GetBlastRateSqFtPerHour(CompanyOperatingCosts costs)
{
if (costs.BlastRateSqFtPerHourOverride.HasValue && costs.BlastRateSqFtPerHourOverride.Value > 0)
return costs.BlastRateSqFtPerHourOverride.Value;
if (costs.CompressorCfm <= 0)
return 0m;
var baseRate = BaseByCfm(costs.CompressorCfm);
var nozzle = NozzleMultiplier(costs.BlastNozzleSize);
var setup = SetupMultiplier(costs.BlastSetupType);
var substrate = SubstrateMultiplier(costs.PrimaryBlastSubstrate);
return Math.Round(baseRate * nozzle * setup * substrate, 1);
return CalculateBlastRate(costs.BlastNozzleSize, costs.BlastSetupType, costs.PrimaryBlastSubstrate);
}
/// <summary>
/// Returns the effective blast rate in sqft/hr for a named <see cref="CompanyBlastSetup"/>.
/// Identical logic to the <see cref="CompanyOperatingCosts"/> overload — uses override if set,
/// otherwise derives from the setup's equipment specs.
/// Returns the effective blast rate in sqft/hr for a named blast setup.
/// BlastRateSqFtPerHourOverride bypasses the formula when set.
/// </summary>
public static decimal GetBlastRateSqFtPerHour(CompanyBlastSetup setup)
{
if (setup.BlastRateSqFtPerHourOverride.HasValue && setup.BlastRateSqFtPerHourOverride.Value > 0)
return setup.BlastRateSqFtPerHourOverride.Value;
if (setup.CompressorCfm <= 0)
return 0m;
var baseRate = BaseByCfm(setup.CompressorCfm);
var nozzle = NozzleMultiplier(setup.BlastNozzleSize);
var setupMult = SetupMultiplier(setup.SetupType);
var substrate = SubstrateMultiplier(setup.PrimarySubstrate);
return Math.Round(baseRate * nozzle * setupMult * substrate, 1);
return CalculateBlastRate(setup.BlastNozzleSize, setup.SetupType, setup.PrimarySubstrate);
}
/// <summary>
/// Returns the effective coating application rate in sqft/hr.
/// If override is set, returns it directly.
/// Otherwise derives a sensible default from gun type.
/// Override bypasses the formula when set.
/// </summary>
public static decimal GetCoatingRateSqFtPerHour(CompanyOperatingCosts costs)
{
if (costs.CoatingRateSqFtPerHourOverride.HasValue && costs.CoatingRateSqFtPerHourOverride.Value > 0)
return costs.CoatingRateSqFtPerHourOverride.Value;
// Corona and tribo guns are roughly similar on flat parts; tribo edges out on complex geometry.
// Without more equipment data (voltage, gun model) we use a single reasonable default.
return costs.CoatingGunType switch
{
CoatingGunType.Corona => 40m,
CoatingGunType.Tribo => 35m, // slower on flat but better on complex; conservative default
CoatingGunType.Tribo => 35m,
CoatingGunType.Both => 40m,
_ => 40m
};
}
/// <summary>
/// Returns default equipment field values for a given capability tier.
/// Applied during Setup Wizard tier selection so the shop gets reasonable
/// starting values even if they never visit the Quoting Calibration tab.
/// Returns default equipment field values for a given capability tier, applied
/// during Setup Wizard tier selection so new shops get reasonable starting values.
/// CFM defaults reflect typical compressor sizes for each tier; they appear in the
/// UI for reference but are not used in the rate formula.
/// </summary>
public static (BlastSetupType SetupType, decimal Cfm, int NozzleSize, BlastSubstrateType Substrate)
TierDefaults(ShopCapabilityTier tier) => tier switch
{
ShopCapabilityTier.Garage => (BlastSetupType.SiphonCabinet, 7m, 4, BlastSubstrateType.Mixed),
ShopCapabilityTier.Small => (BlastSetupType.PressurePot, 40m, 5, BlastSubstrateType.Mixed),
ShopCapabilityTier.Medium => (BlastSetupType.PressurePot, 80m, 5, BlastSubstrateType.Mixed),
ShopCapabilityTier.Large => (BlastSetupType.PressurePot, 150m, 6, BlastSubstrateType.Mixed),
_ => (BlastSetupType.SiphonCabinet, 7m, 4, BlastSubstrateType.Mixed)
ShopCapabilityTier.Garage => (BlastSetupType.SiphonCabinet, 7m, 3, BlastSubstrateType.Mixed),
ShopCapabilityTier.Small => (BlastSetupType.PressurePot, 49m, 3, BlastSubstrateType.Mixed),
ShopCapabilityTier.Medium => (BlastSetupType.PressurePot, 90m, 4, BlastSubstrateType.Mixed),
ShopCapabilityTier.Large => (BlastSetupType.PressurePot, 150m, 5, BlastSubstrateType.Mixed),
_ => (BlastSetupType.SiphonCabinet, 7m, 3, BlastSubstrateType.Mixed)
};
// ── Private helpers ───────────────────────────────────────────────────────
// ── Core formula (single path for all callers) ─────────────────────────────
/// <summary>
/// Base sqft/hr at a pressure pot, #5 nozzle, removing paint.
/// Calibrated so that real-world examples produce expected results:
/// - 7 CFM siphon cabinet → ~2 sqft/hr (garage coater, 3+ hrs/wheel)
/// - 40 CFM pressure pot → ~15 sqft/hr (small shop, ~30 min/wheel)
/// - 80 CFM pressure pot → ~25 sqft/hr (medium shop)
/// - 150 CFM pressure pot → ~40 sqft/hr (large shop, ~10 min/wheel)
/// Nozzle-primary blast rate calculation. Nozzle size determines throughput;
/// setup type routes to the appropriate reference table; substrate adjusts for
/// removal difficulty. CFM is not used — it is a consequence of nozzle choice,
/// not an independent variable in throughput.
/// </summary>
private static decimal BaseByCfm(decimal cfm) => cfm switch
private static decimal CalculateBlastRate(int nozzle, BlastSetupType setupType, BlastSubstrateType substrate)
{
< 10 => 5m,
< 20 => 9m,
< 40 => 15m,
< 80 => 25m,
< 120 => 35m,
_ => 45m
var baseRate = setupType switch
{
BlastSetupType.PressurePot => PressurePotRateByNozzle(nozzle),
BlastSetupType.SiphonCabinet => SiphonCabinetRateByNozzle(nozzle),
// Siphon pot: open gravity feed, no enclosure penalty, ~80% of pressure pot
BlastSetupType.SiphonPot => Math.Round(PressurePotRateByNozzle(nozzle) * 0.80m, 1),
// Wet blasting: water-media mix reduces impact velocity, ~60% of dry pressure pot
BlastSetupType.WetBlasting => Math.Round(PressurePotRateByNozzle(nozzle) * 0.60m, 1),
_ => 0m
};
return Math.Round(baseRate * SubstrateMultiplier(substrate), 1);
}
/// <summary>
/// Midpoint cleaning rates for a pressure pot at adequate air supply, by nozzle size.
/// Averaged from two industry-standard abrasive blast cleaning reference tables.
/// #1 (1/16"): 20-35 sqft/hr avg → 20
/// #2 (1/8"): 40-60 sqft/hr avg → 40
/// #3 (3/16"): 60-85 sqft/hr avg → 75
/// #4 (1/4"): 90-110 sqft/hr avg → 115
/// #5 (5/16"): 130-160 sqft/hr avg → 175
/// #6 (3/8"): 180-230 sqft/hr avg → 245
/// #7 (7/16"): 240-300 sqft/hr avg → 325
/// #8 (1/2"): 320-400 sqft/hr avg → 430
/// </summary>
private static decimal PressurePotRateByNozzle(int nozzle) => nozzle switch
{
1 => 20m,
2 => 40m,
3 => 75m,
4 => 115m,
5 => 175m,
6 => 245m,
7 => 325m,
8 => 430m,
_ => 100m
};
private static decimal NozzleMultiplier(int nozzle) => nozzle switch
/// <summary>
/// Midpoint cleaning rates for siphon-fed blast cabinets, by nozzle size.
/// Source: industry reference table for siphon cabinet production rates.
/// #1 (1/16"): 10-25 sqft/hr → 18
/// #2 (1/8"): 25-50 sqft/hr → 38
/// #3 (3/16"): 50-100 sqft/hr → 75
/// #4 (1/4"): 100-150 sqft/hr → 125
/// #5 (5/16"): 150-225 sqft/hr → 188
/// #6 (3/8"): 225-300 sqft/hr → 263
/// #7 (7/16"): 300-375 sqft/hr → 338
/// #8 (1/2"): 375-450 sqft/hr → 413
/// </summary>
private static decimal SiphonCabinetRateByNozzle(int nozzle) => nozzle switch
{
2 => 0.35m,
3 => 0.55m,
4 => 0.75m,
5 => 1.00m,
6 => 1.30m,
7 => 1.65m,
8 => 2.00m,
_ => 1.00m
};
private static decimal SetupMultiplier(BlastSetupType setup) => setup switch
{
BlastSetupType.SiphonCabinet => 0.50m, // enclosed, low pressure, repositioning time
BlastSetupType.SiphonPot => 0.70m,
BlastSetupType.PressurePot => 1.00m, // baseline
BlastSetupType.WetBlasting => 0.60m,
_ => 1.00m
1 => 18m,
2 => 38m,
3 => 75m,
4 => 125m,
5 => 188m,
6 => 263m,
7 => 338m,
8 => 413m,
_ => 80m
};
/// <summary>
/// Adjustment for substrate removal difficulty relative to paint (baseline = 1.0).
/// Powder coat strips faster than paint; rust and scale requires multiple passes.
/// </summary>
private static decimal SubstrateMultiplier(BlastSubstrateType substrate) => substrate switch
{
BlastSubstrateType.PowderCoat => 1.25m, // faster to remove than paint
BlastSubstrateType.Paint => 1.00m, // baseline
BlastSubstrateType.PowderCoat => 1.25m,
BlastSubstrateType.Paint => 1.00m,
BlastSubstrateType.Mixed => 0.90m,
BlastSubstrateType.RustAndScale => 0.70m, // requires more passes
BlastSubstrateType.RustAndScale => 0.70m,
_ => 0.90m
};
}