Feeding_control_system/core/system.py

import sys
import os
sys.path.append(os.path.dirname(os.path.dirname(os.path.abspath(__file__))))
import threading
import time
import queue
from core.system_state import SystemState,FeedStatus
from hardware.relay import RelayController
from hardware.inverter import InverterController
from hardware.transmitter import TransmitterController
from config.ini_manager import ini_manager
from hardware.upper_plc import OmronFinsPollingService
from vision.visual_callback_dq import VisualCallback
from opc.opcua_client_feed import OpcuaClientFeed
from busisness.blls import ArtifactBll,PDRecordBll
from busisness.models import ArtifactInfoModel,PDRecordModel    


class FeedingControlSystem:
    def __init__(self):
        print('FeedingControlSystem初始化')
        self.state = SystemState()

        # 初始化硬件控制器
        self.relay_controller = RelayController(
            host=ini_manager.relay_host,
            port=ini_manager.relay_port
        )

        self.inverter_controller = InverterController()
        self.transmitter_controller = TransmitterController(self.relay_controller)

        self.plc_service = OmronFinsPollingService(ini_manager.upper_plc_ip, ini_manager.upper_plc_port) 
      
        # 初始化下料控制器
        self.feeding_controller = VisualCallback(
            relay_controller=self.relay_controller,
            transmitter_controller=self.transmitter_controller,
            state=self.state
        )

        self.plc_service.register_data_callback(self.feeding_controller.on_plc_update)

        #小屏修改过屏幕
        self.vf_auto_mode=True
        # 初始化 OPC UA 客户端
        self.opcua_client_feed = OpcuaClientFeed()

        # 线程管理
        self.feed_thread = None
        self.vf_thread = None
        self.arch_thread = None
        self.api_thread = None
        self.pd_jbl_thread = None
        # 初始化 OPC 队列监听线程,用于处理队列中的数据
        self.opc_queue_thread = None

    def initialize(self)->bool:
        """初始化系统"""
        print("初始化控制系统...")
        # self.check_device_connectivity()
        #启用上料斗PLC
        self.plc_service.start_polling(interval=2.0)
        #启用下料线程
        self.start_feed_thread()
        #启用变频器线程
        self.start_vf_thread()
        #启用破拱线程
        self.start_arch_thread()
        #启用推送模型数据线程
        self.feeding_controller.start_visual_thread()
        #启用API(对接PD API数据)，线程
        self.start_api_thread()
        #启用派单线程
        self.start_pd_thread()
        # 启动OPC队列处理线程，维护连接的断开重连等
        self.opcua_client_feed.start()

        self.start_opc_queue_thread()
       
        print("控制系统初始化完成")
        return True

    def start_feed_thread(self):
        "下料线程控制，主要控制下料斗(视觉控制)以及上料斗"
        self.feed_thread = threading.Thread(
            target=self.feeding_controller._run_feed, 
            daemon=True
        )
        self.feed_thread.start()

    def start_opc_queue_thread(self):
        """启动OPC队列处理线程（从控制系统中获取数据，通过OPC外发）"""
        print('启动OPC队列处理线程')
        self.opc_queue_thread = threading.Thread(
            target=self._process_opc_queue,
            daemon=True,
            name='opc_queue_processor'
        )
        self.opc_queue_thread.start()
    
    def start_api_thread(self):
        """启动PD线程"""
        # print('启动API处理线程，从API获取未浇筑数据')
        self.api_thread = threading.Thread(
            target=self._process_api_db,
            daemon=True,
            name='api_thread'
        )
        self.api_thread.start()
       
    def start_vf_thread(self):
        """启动变频器控制线程(控制变频器开始启动，以及频率变换)"""
        # print('启动API处理线程，从API获取未浇筑数据')
        self.vf_thread = threading.Thread(
            target=self._process_vf,
            daemon=True,
            name='vf_thread'
        )
        self.vf_thread.start()

    def _process_vf(self):
        _begin_time=None
        _wait_times=300
        _start_wait_seconds=None
        while self.state.running:
            try:
                # if self.feeding_controller._is_finish_ratio>=0.6:
                #     self.inverter_controller.set_frequency(230)
                # else:
                #     self.inverter_controller.set_frequency(220)
                
                if self.state.vf_status in [1,2]:
                    if _begin_time is None :
                        print("----浇筑即将启动-----")
                        if _start_wait_seconds is None:
                            #记录盖板对齐时间
                            _start_wait_seconds=time.time()
                        if self.feeding_controller._is_finish_ratio>=0.02:
                            _elasped_time=time.time()-_start_wait_seconds
                            if _elasped_time<10:
                                time.sleep(10-_elasped_time)
                            self.inverter_controller.control('start',230)
                            print("----振捣已经启动-----")
                            _begin_time=time.time()
                            self.state._mould_frequency=230
                            self.state._mould_vibrate_status=True
                            if self.state.vf_status==2:
                                print("----振捣270s-----")
                                _wait_time=270
                            else:
                                print("----振捣300秒-----")
                                _wait_time=300
                        else:
                            print("----下料重量小于46KG,暂时不振捣-----")
                    # else:
                elif self.state.vf_status==3 and _begin_time is not None:
                    if time.time()-_begin_time>=_wait_time:
                       if self.vf_auto_mode:
                           self.inverter_controller.control('stop')
                       self.state._mould_vibrate_status=False
                       _begin_time=None
                       _start_wait_seconds=None
            except Exception as e:
                print(f"处理变频器数据时发生错误: {e}")                       
            time.sleep(2)

    def _process_api_db(self):
        from service.mould_service import app_web_service
        """处理API队列中的数据"""
           # 初始化三个列表用于跟踪ArtifactActionID
        processed_artifact_actions = []  # 已处理的ArtifactActionID列表
        processed_artifact_ids = []  # 已处理的ArtifactActionID列表
        processed_pd_records = []          # 已插入PDRecord表的ArtifactActionID列表
        processed_pd_ids=[]
        _model_task=None
        artifact_bll=ArtifactBll()
        pdrecord_bll=PDRecordBll()
        print('启动API处理线程，从API获取未浇筑数据')
        while self.state.running:
            try:
                not_poured = app_web_service.get_not_pour_artifacts()
                if not_poured: 
                    for item in reversed(not_poured):

                        if item.MouldCode is None or item.MouldCode == '':
                            continue
                        
                        _is_artifactid=True
                        # 检查MouldCode是否已处理
                        if item.MouldCode in processed_artifact_actions:
                            #print(f"待浇筑:MouldCode {item.MouldCode} 已处理，跳过")
                            #处理过了。判断是否更新
                            if item.ArtifactID is None or item.ArtifactID == '':
                                _is_artifactid=False
                            if item.ArtifactID in processed_artifact_ids:
                               # print(f"待浇筑:ArtifactID {item.ArtifactID} 已处理，跳过")
                                _is_artifactid=False
                        if _is_artifactid:
                            _model_data = ArtifactInfoModel(**item.__dict__)                      
                            _ret=artifact_bll.save_artifact_task(_model_data)
                            if _ret > 0:
                            # 标记为已处理
                                processed_artifact_actions.append(item.MouldCode)
                                if len(processed_artifact_actions) > 4:
                                    processed_artifact_actions.pop(0)
                                if item.ArtifactID:
                                    processed_artifact_ids.append(item.ArtifactID)
                                    if len(processed_artifact_ids) > 4:
                                        processed_artifact_ids.pop(0)
                                # 限制最多保存3条记录，删除最旧的
                            
                        #print(f"待浇筑:已处理MouldCode {item.MouldCode} ArtifactID {item.ArtifactID}")

                        if item.MouldCode in processed_pd_records:
                            #print(f"派单:MouldCode {item.MouldCode} 已处理，跳过")
                            if item.ArtifactID is None or item.ArtifactID == '':
                                continue
                            if item.ArtifactID in processed_pd_ids:
                                #print(f"待浇筑:ArtifactID {item.ArtifactID} 已处理，跳过")
                                continue

                        _pd_record_data=None
                        if item.ArtifactID:
                            if item.BetonTaskID is not None and item.BetonTaskID != '':
                                #获取taskid
                                if _model_task is None or item.BetonTaskID != _model_task.TaskID:
                                    _model_task = app_web_service.get_task_info(item.BetonTaskID)
                                    if _model_task is None:
                                        print(f"异常:BetonTaskID {item.BetonTaskID} 不存在，跳过")
                                        continue                 

                                _pd_record_data = PDRecordModel(
                                    ArtifactID=item.ArtifactID,
                                    ArtifactActionID=item.ArtifactActionID,
                                    TaskID=_model_task.TaskID,
                                    ProjectName=_model_task.ProjectName,
                                    ProduceMixID=_model_task.ProduceMixID,
                                    BetonGrade=_model_task.BetonGrade,
                                    BetonVolume=item.BetonVolume,
                                    MouldCode=item.MouldCode,
                                    SkeletonID=item.SkeletonID,
                                    RingTypeCode=item.RingTypeCode,
                                    SizeSpecification=item.SizeSpecification,
                                    BuriedDepth=item.BuriedDepth,
                                    BlockNumber=item.BlockNumber,
                                    PlannedVolume=_model_task.PlannedVolume
                                )
                        else:
                           _pd_record_data = PDRecordModel(
                            MouldCode=item.MouldCode
                             )                      
                                       
                        if _pd_record_data is None:
                            continue
                        _ret=pdrecord_bll.save_PD_record(_pd_record_data)
                        if _ret > 0:
                            # 标记为已处理
                            processed_pd_records.append(item.MouldCode)
                                # 限制最多保存3条记录，删除最旧的
                            if len(processed_pd_records) > 4:
                                processed_pd_records.pop(0)
                            if item.ArtifactID:
                                processed_pd_ids.append(item.ArtifactID)
                                if len(processed_pd_ids) > 4:
                                    processed_pd_ids.pop(0)
                                                
                        #print(f"派单:已处理MouldCode {item.MouldCode} ArtifactID {item.ArtifactID}")          
            except Exception as e:
                  print(f"处理MouldCode {item.MouldCode} 时发生错误: {e}")
        
            time.sleep(5)

    def _process_opc_queue(self):
        """处理OPC队列中的数据"""
        while self.state.running:
            try:
                # 从队列中获取数据，设置超时以允许线程退出
                item = self.state.opc_queue.get(timeout=1)
                if item:
                    public_name, value = item
                    # 这里可以添加实际的OPC处理逻辑
                    print(f"Processing OPC update: {public_name} = {value}")
                    self.opcua_client_feed.write_value_by_name(public_name, value)
                    # 标记任务完成
                    self.state.opc_queue.task_done()
            except queue.Empty:
                # 队列为空，继续循环
                continue
            except Exception as e:
                print(f"OPC队列处理错误: {e}")

    def angle_visual_callback(self, current_angle, overflow_detected, mould_aligned):
        """角度视觉回调"""
        self.feeding_controller.angle_visual_callback(current_angle, overflow_detected, mould_aligned)

    def diff_visual_callback(self, current_diff,current_area):
        """差异视觉回调"""
        self.feeding_controller.diff_visual_callback(current_diff,current_area)

    def shutdown(self):
        """关闭系统"""
        self.feeding_controller.shutdown()
        self.stop()

    def start_arch_thread(self):
        """启动系统监控和要料"""
        print('振动和要料监控线程启动')
         #启动振动线程
        self.arch_thread = threading.Thread(
            target=self.feeding_controller._arch_loop,
            daemon=True,
            name='arch'
        )   
        self.arch_thread.start()

    def check_device_connectivity(self) -> bool:
        """检查关键设备连接状态"""
        try:
            # 检查网络继电器连接
            test_response = self.relay_controller.send_command(self.relay_controller.read_status_command)
            if not test_response:
                print("网络继电器连接失败")
                return False

            # 检查变频器连接
            if not self.relay_controller.modbus_client.connect():
                print("无法连接到网络继电器Modbus服务")
                return False

            # 检查下料斗变送器连接
            test_weight = self.transmitter_controller.read_data(2)
            if test_weight is None:
                print("下料斗变送器连接失败")
                return False

            self.relay_controller.modbus_client.close()
            return True
        except Exception as e:
            print(f"设备连接检查失败: {e}")
            return False
  
    def start_pd_thread(self):
        """启动PD线程"""
        print('启动派单处理线程，从API获取未浇筑数据')
        self.pd_jbl_thread = threading.Thread(
            target=self._process_pd_jbl,
            daemon=True,
            name='pd_jbl_thread'
        )
        self.pd_jbl_thread.start()
    
    def _process_pd_jbl(self):
        # pass
        #根据当前浇筑块进行最近一块的派单
        _isFinish=False
        _start_time=None
        while self.state.running:
            #增加生产阶段检测，
            if self.state._feed_status==FeedStatus.FCheckGB:
                if not _isFinish:
                    if _start_time is None:
                        _start_time=time.time()
                    _isSuccess=self.feeding_controller.send_pd_data()          
                    if _isSuccess:
                        _isFinish=True
                    if time.time()-_start_time>60:
                        print('派单超时，人工介入')
                        _isFinish=True
            elif self.state._feed_status==FeedStatus.FFinished:
                _start_time=None
                _isFinish=False
            time.sleep(5)
        
    def start_led(self):
        """启动LED流程"""
        self.led_thread = threading.Thread(
                target=self._start_led,
                name="LED",
                daemon=True
            )
        self.led_thread.start()

    def _start_led(self):
        """启动LED流程"""
        from service.mould_service import app_web_service

        while self.state.running:
            led_info = app_web_service.get_pouring_led()
            if led_info:
               if self.state.current_artifact.MouldCode==led_info.MouldCode:
                    led_info.RingTypeCode=self.state.current_artifact.RingTypeCode
                    led_info.UpperWeight=self.state._upper_weight
                    led_info.LowerWeight=self.state._lower_weight
                    led_info.VibrationFrequency=self.state._mould_frequency

                     #发送到LED屏
                
            time.sleep(app_set_config.led_interval)


    @property
    def _is_finish(self):
        """检查系统是否运行"""
        return self.feeding_controller._is_finish

    @property
    def _is_finish_ratio(self):
        """检查系统是否运行"""
        return self.feeding_controller._is_finish_ratio

    @property
    def vibrate_status(self):
        """检查系统是否运行"""
        return self.state._mould_vibrate_status

    def set_vf_mode(self,is_auto=False):
        """设置变频器为自动模式"""
        self.vf_auto_mode=is_auto


    def stop(self):
        """停止系统"""
        print("停止控制系统...")
        self.state.running = False

        # 等待线程结束
        if self.opc_queue_thread:
            self.opc_queue_thread.join()
        if self.vf_thread:
            self.vf_thread.join()
        if self.api_thread:
            self.api_thread.join()
        if self.pd_jbl_thread:
            self.pd_jbl_thread.join()
        if self.feed_thread:
            self.feed_thread.join()
        if self.arch_thread:
            self.arch_thread.join()
        if self.plc_service:
            self.plc_service.stop_polling()
        self.feeding_controller.shutdown()
        # 释放摄像头资源
        # self.camera_controller.release()
        print("控制系统已停止")


if __name__ == "__main__":
    system = FeedingControlSystem()
    system.initialize()
    time.sleep(2)
    system.state._upper_weight=1000

    while True:
        time.sleep(1)