404 lines
17 KiB
Python
404 lines
17 KiB
Python
#!/usr/bin/env python
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# -*- coding: utf-8 -*-
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import socket
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import binascii
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import time
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import threading
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import logging
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from PySide6.QtCore import Signal, QObject
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import numpy as np
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import Constant
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class RelayController:
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need_origin_signal = Signal(str)
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take_no_photo_sigal = Signal()
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update_detect_image = Signal(np.ndarray)
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log_signal = Signal(int, str)
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def __init__(self, host='192.168.0.18', port=50000):
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# ===================== 全局线程延时参数 =====================
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self.sensor1_loop_delay = 0.2 # SENSOR1 线程轮询间隔（秒）
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self.sensor1_error_delay = 1.0 # SENSOR1 出错时延时（秒）
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self.sensor1_post_action_delay = 0.2 # SENSOR1 每次循环后延时（秒）
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self.sensor2_loop_delay = 0.1 # SENSOR2 线程轮询间隔（秒）
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# self.sensor2_loop_delay = 0.5 # SENSOR2 线程轮询间隔（秒）
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self.sensor2_error_delay = 0.5 # SENSOR2 出错时延时（秒）
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self.sensor2_post_action_delay = 0.2 # SENSOR2 每次循环后延时（秒）
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# ===================== 全局动作延时参数 =====================
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self.delay_conveyor = 0.5 # 传送带开/关动作延时（一半时间，我在控制程序和线程都加了一样的延时）
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self.delay_pusher = 0.05 # 推板开/关动作延时
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self.delay_clamp = 0.5 # 夹爪动作延时
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self.delay_after_pusher = 3.0 # 推板推出后到重启传动带时间
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# ===================== 传感器稳定检测参数 =====================
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self.sensor_stable_duration = 1.0 # 传感器状态稳定检测时间（秒）
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self.sensor_max_attempts = 3 # 连续检测次数达到此值判定有效
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self.sensor1_debounce_time = 1.0 # 传感器1防抖时间（秒）
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# ===================== 网络与设备映射 =====================
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self.host = host
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self.port = port
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self.CONVEYOR1 = 'conveyor1'
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self.PUSHER = 'pusher'
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self.CONVEYOR2 = 'conveyor2'
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self.CONVEYOR2_REVERSE = 'conveyor2_reverse'
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self.CLAMP = 'clamp'
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self.PUSHER1 = 'pusher1'
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self.SENSOR1 = 'sensor1'
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self.SENSOR2 = 'sensor2'
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self.valve_commands = {
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self.CONVEYOR1: {'open': '00000000000601050000FF00', 'close': '000000000006010500000000'},
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self.PUSHER: {'open': '00000000000601050001FF00', 'close': '000000000006010500010000'},
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#滚筒，2000 0012正转，2000 0022 2001变频器频率调整 2000正反转。
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self.CONVEYOR2: {'open': '000100000006020620000012', 'close': '000100000006020620000001'},
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#DO4
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self.CLAMP: {'open': '00000000000601050003FF00', 'close': '000000000006010500030000'},
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#DO5
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self.PUSHER1: {'open': '00000000000601050004FF00', 'close': '000000000006010500040000'},
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self.CONVEYOR2_REVERSE: {'open': '000100000006020620000022', 'close': '000100000006020620000001'}
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}
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#devices:读取继点器的状态
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#sensors 传感器的状态 D12
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self.read_status_command = {
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'devices': '000000000006010100000008',
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'sensors': '000000000006010200000008'
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}
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self.device_bit_map = {
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self.CONVEYOR1: 0,
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self.PUSHER: 1,
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self.CONVEYOR2: 2,
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self.CLAMP: 3,
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self.PUSHER1: 4,
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self.CONVEYOR2_REVERSE: 5
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}
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self.sensor_bit_map = {
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self.SENSOR1: 0,
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self.SENSOR2: 1,
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}
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self.device_name_map = {
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self.CONVEYOR1: "传送带1",
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self.PUSHER: "推板开",
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self.CONVEYOR2: "传送带2",
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self.CLAMP: "机械臂夹爪",
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self.PUSHER1: "推板关",
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self.CONVEYOR2_REVERSE: "传送带2反转"
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}
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self.sensor_name_map = {
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self.SENSOR1: '位置传感器1',
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self.SENSOR2: '位置传感器2',
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}
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# ===================== 状态控制变量 =====================
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self._running = False
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self._sensor1_thread = None
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self._sensor2_thread = None
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self.required_codes = {'0101', '0103'} # 有效状态码（传感器1）
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self.required_codes_1 = {'0102', '0103'} # 有效状态码（传感器2）
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self.sensor1_triggered = False
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self.sensor1_last_time = 0
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self.sensor2_ready = True
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self.motor_stopped_by_sensor2 = False
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# ===================== 基础通信方法 =====================
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def send_command(self, command_hex, retry_count=2, source='unknown'):
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if Constant.DebugPosition:
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return True
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byte_data = binascii.unhexlify(command_hex)
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for attempt in range(retry_count):
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try:
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with socket.socket(socket.AF_INET, socket.SOCK_STREAM) as sock:
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sock.settimeout(10)
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sock.connect((self.host, self.port))
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sock.send(byte_data)
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response = sock.recv(1024)
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hex_response = binascii.hexlify(response).decode('utf-8')
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#if source == 'sensor':
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#print(f"[传感器响应] {hex_response}")
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#elif source == 'device':
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#print(f"[设备控制响应] {hex_response}")
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#else:
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#print(f"[通信响应] {hex_response}")
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return response
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except Exception as e:
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print(f"网络继电器通信错误 ({source}): {e}, 尝试重连... ({attempt + 1}/{retry_count})")
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time.sleep(5)
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self.trigger_alarm()
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return None
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def trigger_alarm(self):
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print("警告：网络继电器连续多次通信失败，请检查设备连接！")
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# ===================== 状态读取方法 =====================
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def get_all_device_status(self, command_type='devices'):
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if Constant.DebugPosition:
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return {self.SENSOR2:True}
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command = self.read_status_command.get(command_type)
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if not command:
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print(f"未知的网络继电器读取类型: {command_type}")
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return {}
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source = 'sensor' if command_type == 'sensors' else 'device'
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response = self.send_command(command, source=source)
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status_dict = {}
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if response and len(response) >= 10:
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status_byte = response[9]
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status_bin = f"{status_byte:08b}"[::-1]
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bit_map = self.device_bit_map if command_type == 'devices' else self.sensor_bit_map
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name_map = self.device_name_map if command_type == 'devices' else self.sensor_name_map
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for key, bit_index in bit_map.items():
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status_dict[key] = status_bin[bit_index] == '1'
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else:
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print(f"网络继电器[{command_type}] 读取状态失败或响应无效")
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return status_dict
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def get_all_sensor_responses(self, command_type='sensors'):
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"""
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获取所有传感器的原始 Modbus 响应字符串
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示例：{'sensor1': '00000000000401020101', 'sensor2': '00000000000401020100'}
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"""
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command = self.read_status_command.get(command_type)
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if not command:
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print(f"未知的读取类型: {command_type}")
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return {}
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source = 'sensor' if command_type == 'sensors' else 'device'
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response = self.send_command(command, source=source)
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responses = {}
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if response and len(response) >= 10:
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hex_response = binascii.hexlify(response).decode('utf-8')
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print(f"[原始响应][{command_type}] {hex_response}")
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# 假设传感器数据从第 9 字节开始，长度为 2 字节
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for name, bit_index in self.sensor_bit_map.items():
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offset = 9 + (bit_index // 8)
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bit_pos = bit_index % 8
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byte = response[offset]
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status = (byte >> bit_pos) & 1
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responses[name] = hex_response
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else:
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print(f"[{command_type}] 无法获取响应数据")
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return responses
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def parse_status_code(self, response):
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"""
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从 Modbus 响应字符串中提取状态码（后两位）
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示例：00000000000401020101 -> '01'
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"""
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if isinstance(response, str) and len(response) >= 18:
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return response[16:20]
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return None
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def is_valid_sensor_status(self, sensor_name):
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stable_count = 0
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for _ in range(int(self.sensor_stable_duration / self.sensor1_loop_delay)):
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responses = self.get_all_sensor_responses('sensors')
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response = responses.get(sensor_name)
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if not response:
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stable_count = 0
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else:
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status_code = self.parse_status_code(response)
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if status_code in self.required_codes:
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stable_count += 1
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if stable_count >= self.sensor_max_attempts:
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return True
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else:
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stable_count = 0
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time.sleep(self.sensor1_loop_delay)
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return False
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def is_valid_sensor_status_1(self, sensor_name):
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stable_count = 0
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for _ in range(int(self.sensor_stable_duration / self.sensor2_loop_delay)):
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responses = self.get_all_sensor_responses('sensors')
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response = responses.get(sensor_name)
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if not response:
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print(f"[警告] 无法获取 {sensor_name} 的响应，尝试重试...")
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stable_count = 0
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else:
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status_code = self.parse_status_code(response)
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if status_code in self.required_codes_1:
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stable_count += 1
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if stable_count >= self.sensor_max_attempts:
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return True
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else:
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stable_count = 0
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time.sleep(self.sensor2_loop_delay)
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return False
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# ===================== 动作控制方法 =====================
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def open(self, conveyor1=False, pusher=False, conveyor2=False, clamp=False, pusher1=False, conveyor2_reverse=False):
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if Constant.DebugPosition:
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return
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status = self.get_all_device_status()
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if conveyor1 and not status.get(self.CONVEYOR1, False):
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self.send_command(self.valve_commands[self.CONVEYOR1]['open'])
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time.sleep(self.delay_conveyor)
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if pusher and not status.get(self.PUSHER, False):
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self.send_command(self.valve_commands[self.PUSHER]['open'])
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time.sleep(self.delay_pusher)
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if conveyor2 and not status.get(self.CONVEYOR2, False):
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self.send_command(self.valve_commands[self.CONVEYOR2]['open'])
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time.sleep(self.delay_conveyor)
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if clamp and not status.get(self.CLAMP, False):
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self.send_command(self.valve_commands[self.CLAMP]['open'])
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time.sleep(self.delay_clamp)
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if pusher1 and not status.get(self.PUSHER1, False):
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self.send_command(self.valve_commands[self.PUSHER1]['open'])
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time.sleep(self.delay_pusher)
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if conveyor2_reverse:
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self.send_command(self.valve_commands[self.CONVEYOR2_REVERSE]['open'])
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time.sleep(self.delay_conveyor)
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def close(self, conveyor1=False, pusher=False, conveyor2=False, clamp=False, pusher1=False, conveyor2_reverse=False):
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if conveyor1:
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self.send_command(self.valve_commands[self.CONVEYOR1]['close'])
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time.sleep(self.delay_conveyor)
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if pusher:
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self.send_command(self.valve_commands[self.PUSHER]['close'])
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time.sleep(self.delay_pusher)
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if conveyor2:
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self.send_command(self.valve_commands[self.CONVEYOR2]['close'])
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time.sleep(self.delay_conveyor)
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if clamp:
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self.send_command(self.valve_commands[self.CLAMP]['close'])
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time.sleep(self.delay_clamp)
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if pusher1:
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self.send_command(self.valve_commands[self.PUSHER1]['close'])
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time.sleep(self.delay_pusher)
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if conveyor2_reverse:
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self.send_command(self.valve_commands[self.CONVEYOR2_REVERSE]['close'])
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time.sleep(self.delay_conveyor)
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# ===================== 传感器处理线程 =====================
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def handle_sensor1(self):
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while self._running:
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try:
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if self.is_valid_sensor_status(self.SENSOR1):
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current_time = time.time()
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if not self.sensor1_triggered and (
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current_time - self.sensor1_last_time) > self.sensor1_debounce_time:
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self.sensor1_triggered = True
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self.sensor1_last_time = current_time
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# 1.停止包装机皮带电机：关闭 conveyor1
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self.close(conveyor1=True)
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time.sleep(self.delay_conveyor)
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# 2.推板开启：推出去动作
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self.open(pusher=True)
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time.sleep(self.delay_pusher)
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self.close(pusher=True)
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# 推板推出后重新启动电机时间传送带1延时
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time.sleep(self.delay_after_pusher)
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# 3.重新开启包装机皮带电机: 开启conveyor1
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self.open(conveyor1=True)
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time.sleep(self.delay_conveyor)
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# 4.推板关闭：推板收回来动作
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self.open(pusher1=True)
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time.sleep(self.delay_pusher)
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self.close(pusher1=True)
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time.sleep(1)
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# 5. 状态检查（可选）
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status = self.get_all_device_status()
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if status.get('conveyor1') and not status.get('pusher'):
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print("流程完成1：皮带运行中，推板已收回")
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else:
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print("状态异常，请检查设备")
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# 流程结束，重置触发标志
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self.sensor1_triggered = False
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time.sleep(self.sensor1_loop_delay)
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except Exception as e:
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print(f"SENSOR1 处理错误: {e}")
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self.sensor1_triggered = False
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time.sleep(self.sensor1_error_delay)
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def handle_sensor2(self):
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while self._running:
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try:
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if self.is_valid_sensor_status_1(self.SENSOR2):
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if not self.sensor2_ready:
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self.close(conveyor2=True)
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self.motor_stopped_by_sensor2 = True
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self.sensor2_ready = True
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else:
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if self.sensor2_ready: #and self.motor_stopped_by_sensor2:
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self.open(conveyor2=True)
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self.motor_stopped_by_sensor2 = False
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self.sensor2_ready = False
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time.sleep(self.sensor2_loop_delay)
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except Exception as e:
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print(f"SENSOR2 处理错误: {e}")
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time.sleep(self.sensor2_error_delay)
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# ===================== 线程控制方法 =====================
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def start(self):
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if self._running:
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print("线程已经在运行")
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return
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print("启动传感器线程")
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self._running = True
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self._sensor1_thread = threading.Thread(target=self.handle_sensor1, daemon=True)
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self._sensor2_thread = threading.Thread(target=self.handle_sensor2, daemon=True)
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self._sensor1_thread.start()
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self._sensor2_thread.start()
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def stop(self):
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if not self._running:
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print("线程未在运行")
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return
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print("停止传感器线程")
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self._running = False
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if self._sensor1_thread:
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self._sensor1_thread.join()
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if self._sensor2_thread:
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self._sensor2_thread.join()
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print("传感器线程已终止。")
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def stop_sensor(self,sensor1_thread,sensor2_thread):
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if not self._running:
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print("线程未在运行")
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return
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print("停止传感器线程")
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self._running = False
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if sensor1_thread and sensor1_thread.is_alive():
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sensor1_thread.join()
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if sensor2_thread and sensor2_thread.is_alive():
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sensor2_thread.join()
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print("传感器线程已终止。")
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def start_sensor1_only(self):
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if self._running:
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print("传感器线程已经在运行")
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return
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print("启动传感器1监听线程...")
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self._running = True
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self._sensor1_thread = threading.Thread(target=self.handle_sensor1, daemon=True)
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self._sensor1_thread.start()
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if __name__ == '__main__':
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controller = RelayController()
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controller.start()
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try:
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while True:
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time.sleep(1)
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except KeyboardInterrupt:
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controller.stop()
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