481 lines
19 KiB
Python
481 lines
19 KiB
Python
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from cv2.gapi import ov
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from config.settings import app_set_config
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from hardware.relay import RelayController
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from hardware.transmitter import TransmitterController
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import time
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import threading
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from datetime import datetime
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class VisualCallback:
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# 类变量，用于存储实例引用，实现单例检测
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_instance = None
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_lock = threading.Lock()
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def __new__(cls):
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"""检测实例是否存在，实现单例模式"""
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with cls._lock:
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if cls._instance is None:
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cls._instance = super().__new__(cls)
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return cls._instance
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def __init__(self):
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"""初始化视觉回调处理器"""
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# 避免重复初始化
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if hasattr(self, '_initialized') and self._initialized:
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return
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self.angle_mode = "normal"
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self.relay_controller = RelayController()
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self.transmitter_controller = TransmitterController(self.relay_controller)
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self.init_weight = 100
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self.mould_finish_weight = 0
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self.mould_need_weight = 100
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self.finish_count = 0
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self.overflow = False
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self.is_start_visual=True
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# 线程安全的参数传递
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self._current_angle = None
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self._overflow_detected = None
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self._new_data_available = threading.Event()
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self._is_processing = threading.Lock()
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self._stop_event = threading.Event()
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# 添加下料斗门控制锁，防止两个线程同时控制
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self._door_control_lock = threading.Lock()
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# 记录当前控制门的线程名称，用于调试
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self._current_controlling_thread = None
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# 新增标志位：指示safe_control_lower_close是否正在执行
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self._is_safe_closing = False
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self._is_feed_start=False
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# 创建并启动单个持续运行的线程
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self.callback_thread = threading.Thread(
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target=self._run_thread_loop,
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daemon=True
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)
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self.callback_thread.start()
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self.feed_thread = threading.Thread(
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target=self._run_feed,
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daemon=True
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)
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# self.feed_thread.start()
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self._before_finish_time=None
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self._is_finish=False
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# 初始化控制间隔和堆料状态跟踪属性
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self._last_overflow_state = False
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self._last_control_time = 0
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self._initialized = True
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def angle_visual_callback(self, current_angle, overflow_detected):
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"""
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视觉控制主逻辑，供外部推送数据
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使用单个持续运行的线程，通过参数设置传递数据
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如果线程正在处理数据，则丢弃此次推送
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"""
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print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到推送数据")
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# 尝试获取处理锁，若失败则说明正在处理，丢弃数据
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if not self._is_processing.acquire(blocking=False):
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print("回调线程仍在执行，丢弃此次推送数据")
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return
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try:
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# 更新参数
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if overflow_detected is not None:
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print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到溢料:{overflow_detected}")
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self._overflow_detected = overflow_detected
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if current_angle is not None:
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print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到角度:{current_angle}")
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self._current_angle = current_angle
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# 通知线程有新数据可用
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self._new_data_available.set()
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finally:
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# 释放处理锁
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self._is_processing.release()
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def _run_thread_loop(self):
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"""
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线程主循环，持续运行
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等待新数据，然后调用处理方法
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"""
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while not self._stop_event.is_set():
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# 等待新数据可用
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self._new_data_available.wait()
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# 重置事件
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self._new_data_available.clear()
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# 获取当前参数（使用临时变量避免被其他线程修改）
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current_angle = self._current_angle
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overflow_detected = self._overflow_detected
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self._is_feed_start=True
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if self.is_start_visual:
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# 处理数据
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self._process_angle_callback(current_angle, overflow_detected)
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time.sleep(0.1)
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def _run_feed(self):
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while True:
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print("------------已启动----------------")
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if self._is_feed_start:
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print("------------下料启动----------------")
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print("------------下料启动----------------")
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print("------------下料启动----------------")
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self.run_feed()
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break
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time.sleep(0.5)
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def safe_control_lower_close(self,duration=3):
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"""线程安全的下料斗关闭方法"""
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thread_name = threading.current_thread().name
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print(f"[{thread_name}] 尝试关闭下料斗...")
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# 设置标志位，指示正在执行安全关闭操作
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self._is_safe_closing = True
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try:
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with self._door_control_lock:
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self._current_controlling_thread = thread_name
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print(f"[{thread_name}] 获得下料斗控制权，执行关闭操作")
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'open')
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time.sleep(duration)
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
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self._current_controlling_thread = None
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print(f"[{thread_name}] 释放下料斗控制权")
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finally:
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# 无论成功失败，都要重置标志位
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self._is_safe_closing = False
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def run_feed(self):
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"""第一阶段下料：下料斗向模具车下料（低速）"""
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print("--------------------开始下料--------------------")
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loc_relay=self.relay_controller
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loc_mitter=self.transmitter_controller
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initial_lower_weight=loc_mitter.read_data(2)
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initial_upper_weight=loc_mitter.read_data(1)
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first_finish_weight=0
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start_time=None
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self.is_start_visual=True
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while True:
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loc_mitter.is_start_lower=True
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current_weight = loc_mitter.read_data(2)
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first_finish_weight=initial_lower_weight-current_weight
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if current_weight<500:
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# 破拱控制
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if start_time is None or time.time()-start_time>5:
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start_time=time.time()
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loc_relay.control_arch_lower_open()
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if current_weight<100:
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start_time=None
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self.is_start_visual=False
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loc_mitter.is_start_lower=False
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time.sleep(0.5)
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self.safe_control_lower_close()
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break
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print(f'------------已下料: {first_finish_weight}kg-------------')
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time.sleep(1)
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#打开上料斗出砼门，开5就，开三分之一下
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loc_relay.control_upper_open_sync(6)
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loc_time_count=1
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upper_open_time=time.time()
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while True:
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print(f'------------上料斗向下料斗转移-------------')
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loc_mitter.is_start_upper=True
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current_upper_weight = loc_mitter.read_data(1)
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if current_upper_weight<4000:
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#关5秒
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loc_relay.control_upper_close_sync(4+loc_time_count)
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loc_mitter.is_start_upper=False
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break
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else:
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if time.time()-upper_open_time>3:
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upper_open_time=time.time()
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loc_relay.control_upper_open_sync(0.5)
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loc_time_count=loc_time_count+0.5
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else:
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time.sleep(0.5)
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# time.sleep(0.4)
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self.is_start_visual=True
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loc_mitter.is_start_lower=False
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loc_mitter.test_lower_weight=2000
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initial_lower_weight=loc_mitter.read_data(2)
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while True:
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loc_mitter.is_start_lower=True
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current_weight = loc_mitter.read_data(2)
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second_finish_weight=initial_lower_weight-current_weight
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if current_weight<500:
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#关5秒
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if start_time is None or time.time()-start_time>5:
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start_time=time.time()
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loc_relay.control_arch_lower_open()
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if current_weight<100:
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start_time=None
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self.is_start_visual=False
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loc_mitter.is_start_lower=False
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time.sleep(0.5)
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self.safe_control_lower_close()
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break
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print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
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time.sleep(1)
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print(f'------------已完成-------------')
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print(f'------------已完成-------------')
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print(f'------------已完成-------------')
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def _process_angle_callback(self, current_angle, overflow_detected):
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"""
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实时精细控制 - 基于PID思想，无固定间隔
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"""
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try:
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# 记录控制时间戳（用于微分计算，而非限制）
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current_time = time.time()
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# 确保所有PID相关属性都被正确初始化
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if not hasattr(self, '_last_control_time'):
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self._last_control_time = current_time
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if not hasattr(self, '_last_error'):
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self._last_error = 0
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if not hasattr(self, '_error_integral'):
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self._error_integral = 0
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print(f"{self.angle_mode}")
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self.overflow = overflow_detected in ["大堆料", "小堆料"]
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if current_angle is None:
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return
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print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 当前角度: {current_angle:.2f}°")
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if overflow_detected == "未浇筑满":
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if self._before_finish_time is None:
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self._before_finish_time=current_time
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self.safe_control_lower_close(1)
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if time.time()-self._before_finish_time>3:
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TARGET_ANGLE=25
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elif overflow_detected == "浇筑满":
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self.is_start_visual=False
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self._is_finish=True
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self.safe_control_lower_close(3)
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return
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else:
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TARGET_ANGLE=25
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# 根据溢料状态动态调整目标角度
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# if overflow_detected == "大堆料":
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# TARGET_ANGLE = 15.0 # 大堆料时控制在15度左右
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# elif overflow_detected == "小堆料":
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# TARGET_ANGLE = 25.0 # 小堆料时控制在35度左右
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# else:
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# TARGET_ANGLE = 45.0 # 未溢料时开到最大56度
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# 确保目标角度在硬件范围内（5-56度）
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TARGET_ANGLE = max(5.0, min(56.0, TARGET_ANGLE))
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# PID控制参数
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KP = 0.1 # 比例系数
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KI = 0.01 # 积分系数
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KD = 0.05 # 微分系数
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# 计算误差
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error = current_angle - TARGET_ANGLE
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dt = current_time - self._last_control_time
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# 积分项（抗饱和）
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self._error_integral += error * dt
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self._error_integral = max(min(self._error_integral, 50), -50) # 积分限幅
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# 微分项
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error_derivative = (error - self._last_error) / dt if dt > 0 else 0
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# PID输出
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pid_output = (KP * error + KI * self._error_integral + KD * error_derivative)
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# 更新历史值
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self._last_error = error
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self._last_control_time = current_time
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# 状态机 + PID控制
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if self.angle_mode == "normal":
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self._normal_mode_advanced(current_angle, pid_output)
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elif self.angle_mode == "reducing":
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self._reducing_mode_advanced(current_angle, pid_output, TARGET_ANGLE)
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elif self.angle_mode == "maintaining":
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self._maintaining_mode_advanced(current_angle, pid_output, TARGET_ANGLE)
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except Exception as e:
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print(f"处理视觉回调时发生异常: {e}")
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def _normal_mode_advanced(self, current_angle, pid_output):
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"""高级正常模式控制"""
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if self.overflow:
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self.angle_mode = "reducing"
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print("检测到溢料，切换到减小模式")
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
# 基于PID输出的智能控制
|
|||
|
|
control_threshold = 2.0 # 控制死区
|
|||
|
|
|
|||
|
|
if abs(pid_output) > control_threshold:
|
|||
|
|
if pid_output > 0:
|
|||
|
|
# 需要减小角度（关门）
|
|||
|
|
pulse_time = min(0.3, pid_output * 0.1)
|
|||
|
|
self._pulse_control("close", pulse_time)
|
|||
|
|
print(f"正常模式: 角度偏高{pid_output:.1f}，关门{pulse_time:.2f}秒")
|
|||
|
|
else:
|
|||
|
|
# 需要增大角度（开门）
|
|||
|
|
pulse_time = min(0.3, abs(pid_output) * 0.1)
|
|||
|
|
self._pulse_control("open", pulse_time)
|
|||
|
|
print(f"正常模式: 角度偏低{abs(pid_output):.1f}，开门{pulse_time:.2f}秒")
|
|||
|
|
else:
|
|||
|
|
# 在死区内，保持静止
|
|||
|
|
self._stop_door()
|
|||
|
|
print(f"正常模式: 角度在目标范围内，保持静止")
|
|||
|
|
|
|||
|
|
def _reducing_mode_advanced(self, current_angle, pid_output, target_angle):
|
|||
|
|
"""高级减小模式控制"""
|
|||
|
|
if not self.overflow:
|
|||
|
|
if current_angle <= target_angle + 5.0:
|
|||
|
|
self.angle_mode = "normal"
|
|||
|
|
print("溢料消除且角度合适，返回正常模式")
|
|||
|
|
else:
|
|||
|
|
# 缓慢恢复
|
|||
|
|
self._pulse_control("close", 0.1)
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
# 有溢料，积极减小角度
|
|||
|
|
if current_angle > target_angle:
|
|||
|
|
# 使用PID输出计算控制量
|
|||
|
|
pulse_time = min(0.5, max(0.1, pid_output * 0.15))
|
|||
|
|
self._pulse_control("close", pulse_time)
|
|||
|
|
print(f"减小模式: 积极关门{pulse_time:.2f}秒，PID输出:{pid_output:.1f}")
|
|||
|
|
else:
|
|||
|
|
self.angle_mode = "maintaining"
|
|||
|
|
print("角度已达标，进入维持模式")
|
|||
|
|
|
|||
|
|
def _maintaining_mode_advanced(self, current_angle, pid_output, target_angle):
|
|||
|
|
"""高级维持模式控制"""
|
|||
|
|
if not self.overflow:
|
|||
|
|
self.angle_mode = "normal"
|
|||
|
|
print("溢料消除，返回正常模式")
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
# 精确维持控制
|
|||
|
|
dead_zone = 1.5 # 更小的死区
|
|||
|
|
|
|||
|
|
if abs(pid_output) > dead_zone:
|
|||
|
|
pulse_time = min(0.2, abs(pid_output) * 0.05) # 更精细的控制
|
|||
|
|
|
|||
|
|
if pid_output > 0:
|
|||
|
|
self._pulse_control("close", pulse_time)
|
|||
|
|
print(f"维持模式: 微调关门{pulse_time:.2f}秒")
|
|||
|
|
else:
|
|||
|
|
self._pulse_control("open", pulse_time)
|
|||
|
|
print(f"维持模式: 微调开门{pulse_time:.2f}秒")
|
|||
|
|
else:
|
|||
|
|
self._stop_door()
|
|||
|
|
print("维持模式: 角度精确控制中")
|
|||
|
|
|
|||
|
|
def _pulse_control(self, action, duration):
|
|||
|
|
"""统一的脉冲控制方法"""
|
|||
|
|
# 检查是否正在执行safe_control_lower_close，如果是则跳过relay操作
|
|||
|
|
if self._is_safe_closing:
|
|||
|
|
thread_name = threading.current_thread().name
|
|||
|
|
print(f"[{thread_name}] safe_control_lower_close正在执行，跳过脉冲控制 {action}")
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
if duration <= 0:
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
thread_name = threading.current_thread().name
|
|||
|
|
print(f"[{thread_name}] 尝试脉冲控制 {action}，时长 {duration:.2f}秒...")
|
|||
|
|
|
|||
|
|
with self._door_control_lock:
|
|||
|
|
self._current_controlling_thread = thread_name
|
|||
|
|
print(f"[{thread_name}] 获得下料斗控制权，执行脉冲控制")
|
|||
|
|
|
|||
|
|
if action == "open":
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'open')
|
|||
|
|
time.sleep(duration)
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
|||
|
|
print(f"[{thread_name}] 开门脉冲: {duration:.2f}秒")
|
|||
|
|
else: # close
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'open')
|
|||
|
|
time.sleep(duration)
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
|||
|
|
print(f"[{thread_name}] 关门脉冲: {duration:.2f}秒")
|
|||
|
|
|
|||
|
|
self._current_controlling_thread = None
|
|||
|
|
print(f"[{thread_name}] 释放下料斗控制权")
|
|||
|
|
|
|||
|
|
def _stop_door(self):
|
|||
|
|
"""停止门运动"""
|
|||
|
|
# 检查是否正在执行safe_control_lower_close，如果是则跳过relay操作
|
|||
|
|
if self._is_safe_closing:
|
|||
|
|
thread_name = threading.current_thread().name
|
|||
|
|
print(f"[{thread_name}] safe_control_lower_close正在执行，跳过停止门运动操作")
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
thread_name = threading.current_thread().name
|
|||
|
|
print(f"[{thread_name}] 尝试停止门运动...")
|
|||
|
|
|
|||
|
|
with self._door_control_lock:
|
|||
|
|
self._current_controlling_thread = thread_name
|
|||
|
|
print(f"[{thread_name}] 获得下料斗控制权，执行停止操作")
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
|||
|
|
self._current_controlling_thread = None
|
|||
|
|
print(f"[{thread_name}] 释放下料斗控制权")
|
|||
|
|
|
|||
|
|
def _open_door(self, duration=0.5):
|
|||
|
|
"""打开门"""
|
|||
|
|
self._pulse_control("open", 0.3)
|
|||
|
|
|
|||
|
|
def _close_door(self, duration=0.5):
|
|||
|
|
"""关闭门"""
|
|||
|
|
self._pulse_control("close", 1)
|
|||
|
|
|
|||
|
|
@classmethod
|
|||
|
|
def instance_exists(cls):
|
|||
|
|
"""检测实例是否存在"""
|
|||
|
|
return cls._instance is not None
|
|||
|
|
|
|||
|
|
def shutdown(self):
|
|||
|
|
"""关闭线程，清理资源"""
|
|||
|
|
# 设置停止事件
|
|||
|
|
self._stop_event.set()
|
|||
|
|
# 唤醒线程以便它能检测到停止事件
|
|||
|
|
self._new_data_available.set()
|
|||
|
|
# 等待线程结束
|
|||
|
|
if self.callback_thread.is_alive():
|
|||
|
|
self.callback_thread.join(timeout=1.0)
|
|||
|
|
|
|||
|
|
# 创建默认实例
|
|||
|
|
visual_callback_instance = VisualCallback()
|
|||
|
|
|
|||
|
|
# 兼容层，保持原来的函数调用方式可用
|
|||
|
|
def angle_visual_callback(current_angle, overflow_detected):
|
|||
|
|
"""
|
|||
|
|
兼容旧版本的函数调用方式
|
|||
|
|
将调用转发到默认实例的angle_visual_callback方法
|
|||
|
|
"""
|
|||
|
|
visual_callback_instance.angle_visual_callback(current_angle, overflow_detected)
|