451 lines
20 KiB
Python
451 lines
20 KiB
Python
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from enum import IntEnum
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from core.state import FeedStatus
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from service.mould_service import MouldService
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from busisness.blls import ArtifactBll
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from busisness.models import ArtifactInfoModel,ArtifactInfo
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import time
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from datetime import datetime
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from hardware.RFID.rfid_service import rfid_service
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from config.settings import app_set_config
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class FeedingProcess22:
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def __init__(self, relay_controller, inverter_controller,
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transmitter_controller, vision_detector,
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camera_controller, state):
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self.relay_controller = relay_controller
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self.artifact_bll = ArtifactBll()
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self.mould_service = MouldService()
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self.inverter_controller = inverter_controller
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self.transmitter_controller = transmitter_controller
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self.vision_detector = vision_detector
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self.camera_controller = camera_controller
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self.state = state
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self.state._feed_status = FeedStatus.FCheckM
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#标志位用，是否是第一次运行
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self.is_first_flag=True
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#RFID服务
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self.rfid_service=rfid_service()
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# self.rfid_service.callback_signal.connect(self._rfid_callback)
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self.rfid_flag_succ=False
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self.rfid_data=''
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# self.rfid_service.start_receiver(self._rfid_callback)
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def _rfid_callback(self,status,data):
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try:
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if status==1:
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#成功读取到RFID标签
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#检查标识是否符号要求
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if data:
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loc_array=data.split(',')
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if len(loc_array)==4:
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if self.state.current_artifact is None or loc_array[0]!=self.state.current_artifact.MouldCode:
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self.rfid_flag_succ=True
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self.state.current_artifact={
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'MouldCode':loc_array[0],
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'BlockNumber':loc_array[1],
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'SizeSpecification':loc_array[2],
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'BetonVolume':float(loc_array[3])
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}
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print(f"RFID-生产模具车号:{loc_array[0]}")
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else:
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print("RFID-生产模具车号与当前模具车号一致")
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else:
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print("RFID标签格式错误")
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print(f"成功读取到RFID标签:{data}")
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else:
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self.rfid_flag_succ=False
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print("读取RFID标签失败")
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except Exception as e:
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print(f"RFID回调处理异常: {e}")
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#读取失败
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def start_feeding(self):
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loc_state=self.state
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loc_state._upper_weight=self.transmitter_controller.read_data(1)
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loc_state._lower_weight=self.transmitter_controller.read_data(2)
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loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
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"""开始生产管片"""
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if loc_state._feed_status == FeedStatus.FNone:
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# loc_state._feed_status = FeedStatus.FCheckM
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return
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elif loc_state._feed_status == FeedStatus.FCheckM:
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"""开始生产管片"""
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print("检查盖板对齐,")
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loc_state.lower_feeding_stage = 4
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self.rfid_flag_succ=False
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# if app_set_config.debug_feeding:
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# loc_state._feed_status = FeedStatus.FApiCheck
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if self.state.vehicle_aligned:
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loc_state._feed_status = FeedStatus.FApiCheck
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print("检查模车")
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return
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elif loc_state._feed_status == FeedStatus.FApiCheck:
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print("————————————————生产已开始————————————————————")
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# time.sleep(2)
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#模拟数据
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module_obj=ArtifactInfoModel()
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module_obj.ArtifactID="GR2B13082624F"
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module_obj.MouldCode="SHR2B2-4"
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module_obj.BetonVolume=1.9
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loc_modules=[module_obj]
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# loc_modules =self.mould_service.get_not_pour_artifacts()
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if loc_modules and loc_modules[0].ArtifactID :
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# 取第一个未浇筑的管片
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#后续放入队列处理
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loc_module = loc_modules[0]
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#API
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loc_module.Source = 1
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loc_module.BeginTime=datetime.now()
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# self.artifact_bll.insert_artifact_task(loc_module)
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loc_state.current_artifact = loc_module
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loc_state._mould_need_weight=loc_module.BetonVolume*self.state.density
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print(f"已获取到未浇筑的管片:{loc_module.MouldCode}")
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# self.artifact_bll.finish_artifact_task(loc_state.current_artifact.ArtifactID,1.92)
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loc_state._feed_status = FeedStatus.FCheckGB
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else:
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#未读取到AIP接口数据.
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print("未获取到未浇筑的管片")
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loc_artifacting_task=self.artifact_bll.get_artifacting_task()
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if loc_artifacting_task:
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loc_state.current_artifact = loc_artifacting_task
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loc_state._mould_need_weight=loc_artifacting_task.BetonVolume*self.state.density
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loc_state._feed_status = FeedStatus.FCheckGB
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else:
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loc_state.current_artifact = None
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return
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elif loc_state._feed_status == FeedStatus.FRFID:
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print("检查RFID")
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#RFID格式：模具编号,分块号,尺寸规格,方量
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while loc_state.running:
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if self.rfid_flag_succ:
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loc_state._feed_status = FeedStatus.FCheckGB
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break
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else:
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time.sleep(1)
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return
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elif loc_state._feed_status == FeedStatus.FCheckGB:
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# print("检查盖板对齐,")
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# time.sleep(5)
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loc_state._feed_status = FeedStatus.FUpperToLower
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#计算本次生产需要的总重量
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print(f"本次生产需要的总重量:{self.state._mould_need_weight}")
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return
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elif loc_state._feed_status == FeedStatus.FUpperToLower:
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print("上料斗向下料斗转移")
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#上料斗重量
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loc_state.initial_upper_weight=loc_state._upper_weight
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#下料斗重量
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loc_state.initial_lower_weight=loc_state._lower_weight
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#需要的总重量
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# loc_state._mould_need_weight=loc_state.current_artifact.BetonVolume*loc_state.density
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if loc_state._mould_need_weight > loc_state.initial_upper_weight + loc_state.initial_lower_weight:
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# 等待上料斗重量增加(多久不够报警，可能出现F块不足的情况)
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print('重量不够，需要增加')
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return
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if loc_state._mould_need_weight>loc_state.initial_lower_weight:
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if self.state._upper_door_position != 'over_lower':
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#是否需要等待上料斗下料,如果下料斗够重量,则不需要等待
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return
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else:
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# 需要等待上料斗下料
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# 最后一块进行尾数控制
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# 最后一块F块，前面多要0.25,0.3，F块直接下料（先多下0.3后续）
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# loc_FWeight=0.3*loc_state.density
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# loc_feed_weight=loc_state.need_total_weight-loc_state.initial_lower_weight-loc_FWeight
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self.transfer_material_from_upper_to_lower(loc_state,loc_state.initial_upper_weight,loc_state.initial_lower_weight)
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#完成了上料斗重量转移才进入下料斗
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#测试返回
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loc_state._feed_status = FeedStatus.FFeed1
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# loc_state._feed_status = FeedStatus.FNone
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else:
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loc_state._feed_status = FeedStatus.FFeed1
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# time.sleep(10)
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return
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elif loc_state._feed_status == FeedStatus.FFeed1:
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#下料
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# self._start_feeding_stage()
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self.feeding_stage_one(loc_state)
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print("下料1")
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return
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elif loc_state._feed_status == FeedStatus.FFeed2:
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#上料
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# self._start_feeding_stage()
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self.feeding_stage_two(loc_state)
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print("下料2")
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return
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elif loc_state._feed_status == FeedStatus.FFeed3:
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#下料
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# self._start_feeding_stage()
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self.feeding_stage_three(loc_state)
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print("下料3")
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return
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elif loc_state._feed_status == FeedStatus.FFinished:
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"""完成当前批次下料"""
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print("当前批次下料完成，关闭出砼门")
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if loc_state.overflow_detected=="浇筑满":
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# self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
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# self.relay_controller.control_upper_close()
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#更新数据库状态
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# self.artifact_bll.finish_artifact_task(loc_state.current_artifact.ArtifactID,loc_state._mould_finish_weight/loc_state.density)
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print("浇筑完成")
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# loc_state._feed_status = FeedStatus.FCheckM
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# if loc_state.mould_vibrate_time>0:
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# while True:
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# if loc_state.mould_vibrate_time-time.time()>=5*60:
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# self.inverter_controller.control('stop')
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# loc_state._mould_vibrate_status=0
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# break
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# time.sleep(1)
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print("振捣完成")
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return
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def _start_feeding_stage(self):
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"""启动指定下料阶段"""
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"""开始分步下料"""
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print("开始分步下料过程")
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self.transfer_material_from_upper_to_lower()
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def transfer_material_from_upper_to_lower(self,loc_state,initial_upper_weight,initial_lower_weight):
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"""target_upper_weight：转移后剩下的上料斗重量"""
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# 如果低于单次，全部卸掉
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_max_lower_weight=app_set_config.max_lower_volume*loc_state.density
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# if (initial_lower_weight+feed_weight>_max_lower_weight):
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feed_weight=_max_lower_weight-initial_lower_weight
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target_upper_weight=initial_upper_weight-feed_weight
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target_upper_weight = max(target_upper_weight, 0)
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# 确保下料斗出砼门关闭
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self.relay_controller.control_lower_close()
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# 打开上料斗出砼门
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# self.relay_controller.control_upper_open()
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self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
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time.sleep(3)
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loc_state._upper_door_closed=False
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# 等待物料流入下料斗，基于上料斗重量变化控制
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start_time = time.time()
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# timeout = 30 # 30秒超时
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while loc_state.running:
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# self.relay_controller.control_upper_open_sync()
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self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'close')
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current_upper_weight = self.transmitter_controller.read_data(1)
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# 如果无法读取重量，继续尝试
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if current_upper_weight is None:
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print("无法读取上料斗重量，继续尝试...")
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time.sleep(1)
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continue
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loc_state._upper_weight=current_upper_weight
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loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
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print(f"上料斗当前重量: {current_upper_weight:.2f}kg")
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# 如果达到目标重量，则关闭上料斗出砼门
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if current_upper_weight <= target_upper_weight + 50: # 允许50kg的误差范围
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print(f"达到目标重量，当前重量: {current_upper_weight:.2f}kg")
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print(f"花费时间 {time.time() - start_time:.2f}秒")
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break
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elif time.time() - start_time > 25: # 如果25秒后重量变化过小
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weight_change = initial_upper_weight - current_upper_weight
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if weight_change < 100: # 如果重量变化小于100kg
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#需要增加报警处理
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print("重量变化过小，可能存在堵塞")
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time.sleep(1)
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self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
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time.sleep(0.2)
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loc_state._upper_door_closed=True
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# 关闭上料斗出砼门
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self.relay_controller.control_upper_close()
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#测试用
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print("上料斗下料完成")
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def wait_for_vehicle_alignment(self):
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"""等待模具车对齐"""
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print("等待模具车对齐...")
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self.state.lower_feeding_stage = 4
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import time
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while self.state.lower_feeding_stage == 4 and self.state.running:
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if self.state.vehicle_aligned:
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print("模具车已对齐，开始下料")
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self.state.lower_feeding_stage = 1
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# self.feeding_stage_one()
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break
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time.sleep(app_set_config.alignment_check_interval)
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def feeding_stage_one(self,loc_state):
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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("开始第一阶段下料：下料斗低速下料")
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if self.is_first_flag:
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# self.inverter_controller.set_frequency(app_set_config.frequencies[0])
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# self.inverter_controller.control('start')
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loc_state.mould_vibrate_time=time()
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loc_state._mould_frequency=app_set_config.frequencies[0]
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loc_state._mould_vibrate_status=1
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# 确保上料斗出砼门关闭
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# self.relay_controller.control(self.relay_controller.DOOR_UPPER_CLOSE, 'close')
|
|||
|
|
# 打开下料斗出砼门
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'open')
|
|||
|
|
loc_cur_weight = loc_state._lower_weight
|
|||
|
|
if loc_cur_weight is None:
|
|||
|
|
#报警处理
|
|||
|
|
print("无法获取初始重量，取消下料")
|
|||
|
|
# self.finish_feeding_process()
|
|||
|
|
return
|
|||
|
|
loc_state.initial_lower_weight=loc_cur_weight
|
|||
|
|
self.is_first_flag=False
|
|||
|
|
|
|||
|
|
|
|||
|
|
start_time = time.time()
|
|||
|
|
|
|||
|
|
current_weight = loc_state._lower_weight
|
|||
|
|
if current_weight is None:
|
|||
|
|
#报警处理
|
|||
|
|
print("无法获取当前重量，取消下料")
|
|||
|
|
# self.finish_feeding_process()
|
|||
|
|
return
|
|||
|
|
loc_state._mould_finish_weight=loc_state.initial_lower_weight-current_weight
|
|||
|
|
target_weight = loc_state._mould_need_weight/3
|
|||
|
|
# or (time.time() - start_time) > 30
|
|||
|
|
if (current_weight is not None and loc_state._mould_finish_weight >= target_weight):
|
|||
|
|
loc_state._feed_status = FeedStatus.FFeed2
|
|||
|
|
loc_state.lower_feeding_stage = 2
|
|||
|
|
self.is_first_flag=True
|
|||
|
|
return
|
|||
|
|
else:
|
|||
|
|
time.sleep(1)
|
|||
|
|
|
|||
|
|
def feeding_stage_two(self,loc_state):
|
|||
|
|
"""第二阶段下料：下料斗向模具车下料（中速）"""
|
|||
|
|
if self.is_first_flag:
|
|||
|
|
print("开始第二阶段下料：下料斗中速下料")
|
|||
|
|
# self.inverter_controller.set_frequency(app_set_config.frequencies[1])
|
|||
|
|
# self.inverter_controller.control('start')
|
|||
|
|
# 保持下料斗出砼门打开
|
|||
|
|
# self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'open')
|
|||
|
|
# 确保上料斗出砼门关闭
|
|||
|
|
self.relay_controller.control_upper_close()
|
|||
|
|
|
|||
|
|
loc_state._mould_frequency=app_set_config.frequencies[1]
|
|||
|
|
loc_state._mould_vibrate_status=1
|
|||
|
|
# loc_cur_weight = self.transmitter_controller.read_data(2)
|
|||
|
|
# if loc_cur_weight is None:
|
|||
|
|
# #报警处理
|
|||
|
|
# print("无法获取初始重量，取消下料")
|
|||
|
|
# # self.finish_feeding_process()
|
|||
|
|
# return
|
|||
|
|
# loc_state.initial_lower_weight=loc_cur_weight
|
|||
|
|
self.is_first_flag=False
|
|||
|
|
|
|||
|
|
start_time = time.time()
|
|||
|
|
current_weight = loc_state._lower_weight
|
|||
|
|
if current_weight is None:
|
|||
|
|
#报警处理
|
|||
|
|
print("无法获取当前重量，取消下料")
|
|||
|
|
# self.finish_feeding_process()
|
|||
|
|
return
|
|||
|
|
loc_state._mould_finish_weight=loc_state.initial_lower_weight-current_weight
|
|||
|
|
target_weight = (loc_state._mould_need_weight/3)*2
|
|||
|
|
# or (time.time() - start_time) > 30
|
|||
|
|
if (current_weight is not None and loc_state._mould_finish_weight >= target_weight):
|
|||
|
|
loc_state._feed_status = FeedStatus.FFeed3
|
|||
|
|
loc_state.lower_feeding_stage = 3
|
|||
|
|
self.is_first_flag=True
|
|||
|
|
return
|
|||
|
|
else:
|
|||
|
|
time.sleep(1)
|
|||
|
|
|
|||
|
|
def feeding_stage_three(self,loc_state):
|
|||
|
|
"""第三阶段下料：下料斗向模具车下料（高速）"""
|
|||
|
|
if self.is_first_flag:
|
|||
|
|
print("开始第三阶段下料：下料斗高速下料")
|
|||
|
|
# self.inverter_controller.set_frequency(app_set_config.frequencies[2])
|
|||
|
|
# self.inverter_controller.control('start')
|
|||
|
|
loc_state._mould_frequency=app_set_config.frequencies[2]
|
|||
|
|
# 保持下料斗出砼门打开
|
|||
|
|
# self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'open')
|
|||
|
|
# 确保上料斗出砼门关闭
|
|||
|
|
self.relay_controller.control_upper_close()
|
|||
|
|
self.is_first_flag=False
|
|||
|
|
|
|||
|
|
current_weight = loc_state._lower_weight
|
|||
|
|
if current_weight is None:
|
|||
|
|
#报警处理
|
|||
|
|
print("无法获取当前重量，取消下料")
|
|||
|
|
# self.finish_feeding_process()
|
|||
|
|
return
|
|||
|
|
loc_state._mould_finish_weight=loc_state.initial_lower_weight-current_weight
|
|||
|
|
target_weight = loc_state._mould_need_weight
|
|||
|
|
|
|||
|
|
if (current_weight is not None and loc_state._mould_finish_weight >= target_weight):
|
|||
|
|
loc_state._feed_status = FeedStatus.FFinished
|
|||
|
|
loc_state.lower_feeding_stage = 5
|
|||
|
|
self.is_first_flag=True
|
|||
|
|
return
|
|||
|
|
else:
|
|||
|
|
time.sleep(1)
|
|||
|
|
|
|||
|
|
def finish_current_batch(self):
|
|||
|
|
"""完成当前批次下料"""
|
|||
|
|
print("当前批次下料完成，关闭出砼门")
|
|||
|
|
# self.inverter_controller.control('stop')
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')
|
|||
|
|
self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'close')
|
|||
|
|
|
|||
|
|
# 增加三阶段下料轮次计数
|
|||
|
|
self.state.lower_feeding_cycle += 1
|
|||
|
|
|
|||
|
|
# 检查是否完成两轮三阶段下料
|
|||
|
|
if self.state.lower_feeding_cycle >= self.state.upper_feeding_max:
|
|||
|
|
print("完成两轮三阶段下料，5吨下料任务完成")
|
|||
|
|
self.finish_feeding_process()
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
# 如果只完成一轮三阶段下料，进行第二次上料
|
|||
|
|
print("第一轮三阶段下料完成，准备第二次上料")
|
|||
|
|
# 上料斗第二次向下料斗下料
|
|||
|
|
try:
|
|||
|
|
self.transfer_material_from_upper_to_lower()
|
|||
|
|
except Exception as e:
|
|||
|
|
print(f"第二次上料失败: {e}")
|
|||
|
|
print("停止下料流程")
|
|||
|
|
self.finish_feeding_process() # 出现严重错误时结束整个流程
|
|||
|
|
return
|
|||
|
|
|
|||
|
|
# 继续等待当前模具车对齐（不需要重新等待对齐，因为是同一辆模具车）
|
|||
|
|
print("第二次上料完成，继续三阶段下料")
|
|||
|
|
self.state.lower_feeding_stage = 1 # 直接进入第一阶段下料
|
|||
|
|
self.feeding_stage_one() # 开始第二轮第一阶段下料
|
|||
|
|
|
|||
|
|
def finish_feeding_process(self):
|
|||
|
|
"""完成整个下料流程"""
|
|||
|
|
print("整个下料流程完成")
|
|||
|
|
self.state.lower_feeding_stage = 0
|
|||
|
|
self.state.lower_feeding_cycle = 0
|
|||
|
|
self.state.upper_feeding_count = 0
|
|||
|
|
# self.return_upper_door_to_default()
|
|||
|
|
|
|||
|
|
def return_upper_door_to_default(self):
|
|||
|
|
"""上料斗回到默认位置（搅拌楼下接料位置）"""
|
|||
|
|
print("上料斗回到默认位置")
|
|||
|
|
self.relay_controller.control(self.relay_controller.UPPER_TO_JBL, 'open')
|
|||
|
|
self.state._upper_door_position = 'default'
|