Feeding_control_system/feeding/process.py

from pickle import FALSE
from cv2.gapi import ov
from config.settings import app_set_config
from hardware.relay import RelayController
from hardware.transmitter import TransmitterController
import time
import threading
from datetime import datetime
import logging
import queue
from hardware.upper_plc import OmronFinsPollingService
from vision.muju_cls.muju_utils import run_stable_classification_loop
from vision.camera_picture import save_camera_picture

class FeedingProcess:
    # 类变量，用于存储实例引用，实现单例检测
    _instance = None
    _lock = threading.Lock()
    
    def __new__(cls):
        """检测实例是否存在，实现单例模式"""
        with cls._lock:
            if cls._instance is None:
                cls._instance = super().__new__(cls)
        return cls._instance
    
    def __init__(self, relay_controller, inverter_controller,
                 transmitter_controller, state):
        """初始化视觉回调处理器"""
        # 避免重复初始化
        if hasattr(self, '_initialized') and self._initialized:
            return
        
        self.relay_controller = relay_controller
        self.inverter_controller = inverter_controller
        self.transmitter_controller = transmitter_controller
        
        # 线程安全的参数传递
        self._new_data_available = threading.Event()
        self._is_processing = threading.Lock()

        #diff参数
        self._is_processing_diff = threading.Lock()
        self._new_data_diff = threading.Event()
        self._current_diff=0
        self._current_diff_area=[]
        self._is_diff_save=False


        self._stop_event = threading.Event()
        
        # 添加下料斗门控制锁，防止两个线程同时控制
        self._door_control_lock = threading.Lock()
        # 记录当前控制门的线程名称，用于调试
        self._current_controlling_thread = None
        #是否启动后的第一个模具
        self._is_first_module=True
        self.init_val()
        # self._setup_logging_2()
        #F块完成重量的70%，控制夹脚，F块多于这个比例就没有记录了（注意）
        self._max_f_angle_ratio=0.7
        #完成多少，调整角度比例 ，多于0.8就没记录了（注意）
        self._max_angle_radio=0.8

        #重量大于95%，停留时间2秒，其他的1秒
        self._weight_ratio_955=0.955
        #完成多少，忽略未浇筑满
        self._max_ignore_radio=0.5

        self._mould_accept_aligned=None
        self._mould_before_aligned=False
        #模具开始浇筑时间   
        self._time_mould_begin=''
        #模具结束浇筑时间
        self._time_mould_end=''

        
    def run_feed_f(self):
        """第一阶段下料：下料斗向模具车下料（低速）"""
        print("--------------------开始下料（F块）--------------------")
        self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
        # loc_relay=self.relay_controller
        loc_mitter=self.transmitter_controller
        max_weight_none=5
        cur_weight_none=0
        initial_lower_weight=loc_mitter.read_data(2)
        if initial_lower_weight is None:
            print("-----f上料斗重量异常-----")
            return
        first_finish_weight=0
        self._finish_weight=first_finish_weight
        self._inital_finish_lweight=initial_lower_weight
        need_total_weight=0.54*2416
        if initial_lower_weight>100:
            if not self._is_finish:
                self.is_start_visual=True
                initial_lower_weight=loc_mitter.read_data(2)
                if initial_lower_weight is None:
                    print("-----f上料斗重量异常2-----")
                    return
                self._is_feed_stage=5
                while not self._is_finish:
                    current_weight = loc_mitter.read_data(2)
                    if current_weight is None:
                        cur_weight_none+=1
                        if cur_weight_none>max_weight_none:
                            #如果重量连续5次为None，认为下料斗未就位，跳出循环
                            print('------------f下到模具车,下料斗重量异常----------------')
                            print('------------f下到模具车,下料斗重量异常----------------')
                            self.close_lower_door_visual()
                            return
                            #视觉处理关闭，异常的话重量没有生效
                        continue
                    cur_weight_none=0
                    first_finish_weight=initial_lower_weight-current_weight
                    self._is_finish_ratio=(first_finish_weight)/need_total_weight
                    print(f'------------已下料比例: {self._is_finish_ratio}-------------')
                    if self._is_finish_ratio>self._max_f_angle_ratio:
                        #关5秒
                        #大于0.7后不再检测了，直接交给视觉控制夹脚
                        # print(f'------------已下料比例: {self._is_finish_ratio}-------------')
                        break
                        
                    # print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
                    time.sleep(1)
        # initial_lower_weight=_current_lower_weight
        print(f'------------已下料（F）: {first_finish_weight}kg-------------')
        print(f'------------已下料（F）: {first_finish_weight}kg-------------')
 
        print(f'------------已完成-------------')

    def run_feed(self):
        """第一阶段下料：下料斗向模具车下料（低速）"""
        print("--------------------开始下料（普通块）--------------------")
        self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
        loc_relay=self.relay_controller
        loc_mitter=self.transmitter_controller
        max_weight_none=5
        cur_weight_none=0

        initial_lower_weight=loc_mitter.read_data(2)
        # initial_upper_weight=loc_mitter.read_data(1)
        if initial_lower_weight is None:
            print("---------------下料斗重量异常----------------")
            return
        first_finish_weight=0
        need_total_weight=1.91*2416
        # start_time=None
        self.is_start_visual=True
        if initial_lower_weight>100:
            #下料斗的料全部下完
            self._is_feed_stage=1
            while not self._is_finish:          
                current_weight = loc_mitter.read_data(2)
                if current_weight is None:
                    cur_weight_none+=1
                    if cur_weight_none>max_weight_none:
                        print("-----------下料斗重量异常(第一次下到模具车)--------------")
                        self.close_lower_door_visual()
                        return
                    continue
                cur_weight_none=0
                if current_weight<250 and current_weight>0:
                    self.close_lower_door_visual()
                    break
                time.sleep(1)
        _current_lower_weight=loc_mitter.read_data(2)
        if _current_lower_weight is None:
            print("-------下料斗重量异常---------")
            return
        first_finish_weight=initial_lower_weight-_current_lower_weight
        # initial_lower_weight=_current_lower_weight
        print(f'------------已下料（第一次）: {first_finish_weight}kg-------------')
        print(f'------------已下料（第一次）: {first_finish_weight}kg-------------')
        self._is_feed_stage=0

        while self.plc_data!=5:
            print('------------上料斗未就位----------------')
            print('------------上料斗未就位----------------')
            time.sleep(1)

        if self.plc_data==5:
            print(f'------------上料斗向下料斗转移(留3000KG）-------------')
            #打开上料斗出砼门，开5就，开三分之一下
          
            loc_relay.control_upper_open_sync(6)
            self._is_feed_stage=2
            loc_time_count=1
            upper_open_time=time.time()
           
            while not self._is_finish:
                current_upper_weight = loc_mitter.read_data(1)
                if current_upper_weight is None:
                    cur_weight_none+=1
                    if cur_weight_none>max_weight_none:
                        #如果重量连续5次为None，认为上料斗未就位，跳出循环
                        print('------------第一次上到下,上料斗重量异常----------------')
                        print('------------第一次上到下,上料斗重量异常----------------')
                        loc_relay.control_upper_close_sync(5+loc_time_count)
                        return
                    continue
                cur_weight_none=0
                _two_lower_weight=loc_mitter.read_data(2)
                if _two_lower_weight is None:
                     _two_lower_weight=0
                if (current_upper_weight<3000 and current_upper_weight>0) or _two_lower_weight>3200:
                    #关5秒,loc_time_count多关一秒
                    loc_relay.control_upper_close_sync(5+loc_time_count)
                    break
                else:
                    if time.time()-upper_open_time>5:
                        if loc_time_count<6:
                            upper_open_time=time.time()
                            loc_relay.control_upper_open_sync(0.8)
                            loc_time_count=loc_time_count+0.8
                    else:
                        time.sleep(0.5)
            else:
                 loc_relay.control_upper_close_sync(6+loc_time_count)
        
        self.is_start_visual=True
        initial_lower_weight=loc_mitter.read_data(2)
        if initial_lower_weight is None:
            print("-------下料斗重量异常(第二次下料到模具车)---------")
            return
        self._is_feed_stage=3
        while not self._is_finish:
            current_weight = loc_mitter.read_data(2)
            if current_weight is None:
                cur_weight_none+=1
                if cur_weight_none>max_weight_none:
                    print("-------下料斗重量异常(第二次下料到模具车)---------")
                    self.close_lower_door_visual()
                    return
                continue
            cur_weight_none=0
            # second_finish_weight=initial_lower_weight-current_weight
            if current_weight<250:
                self.close_lower_door_visual()
                break
            # print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
            time.sleep(1)
        _current_lower_weight=loc_mitter.read_data(2)
        if _current_lower_weight is None:
            print("-------下料斗重量异常(第二次下到模)---------")
            return
        first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
        print(f'------------已下料（第二次）: {first_finish_weight}kg-------------')
        print(f'------------已下料（第二次）: {first_finish_weight}kg-------------')
        
        self._is_feed_stage=0
        if self.plc_data==5:
            #第二次上料斗向下料斗转移
            loc_relay.control_upper_open_sync(12)
            loc_time_count=1
            upper_open_time=time.time()
            upper_open_time_2=None
            #第二次到下料斗还需要的量
            #loc_left_need_weight=need_total_weight-first_finish_weight
            # initial_upper_weight=loc_mitter.read_data(1)
            # start_time=None
            self._is_feed_stage=4
            while not self._is_finish:
               # print(f'------------上料斗向下料斗转移22222-------------')
                current_upper_weight = loc_mitter.read_data(1)
                if current_upper_weight is None:
                    cur_weight_none+=1
                    if cur_weight_none>max_weight_none:
                        #如果重量连续5次为None，认为上料斗未就位，跳出循环
                        print('------------第二次上到下,上料斗重量异常----------------')
                        print('------------第二次上到下,上料斗重量异常----------------')
                        loc_relay.control_upper_close_sync(15)
                        break
                    continue
                cur_weight_none=0
                if (current_upper_weight<600 and current_upper_weight>0) or upper_open_time_2 is not None: 
                    if upper_open_time_2 is None:
                        upper_open_time_2=time.time()
                    if current_upper_weight<400 or time.time()-upper_open_time_2>5:
                        loc_relay.control_arch_upper_open_async(5) 
                        # loc_relay.control_arch_upper_open() 
                        loc_relay.control_upper_open_sync(5)
                            # start_time=None
                        #5秒后关闭
                        loc_relay.control_upper_close_after()#control_upper_close_sync(8+loc_time_count)
                        break
                    time.sleep(1)
                else:
                    if time.time()-upper_open_time>2:
                        # if loc_time_count<6:
                        upper_open_time=time.time()
                        loc_relay.control_upper_open_sync(1.2)
                        loc_time_count=loc_time_count+1
                    else:
                        time.sleep(0.5)
            else:
                 loc_relay.control_upper_close_sync(15)
            # time.sleep(0.4)
        
        #第三次下料斗转移到模具车
        if not self._is_finish:
            self.is_start_visual=True
            initial_lower_weight=loc_mitter.read_data(2)
            self._finish_weight=first_finish_weight
            self._inital_finish_lweight=initial_lower_weight
            if initial_lower_weight is None:
                print("-------下料斗重量异常(第三次下到模具车)---------")
                return
            self._is_feed_stage=5
            while not self._is_finish:
                current_weight = loc_mitter.read_data(2)
                if current_weight is None:
                    cur_weight_none+=1
                    if cur_weight_none>max_weight_none:
                        #重量异常退出
                        print('------------第三次下到模具车,下料斗重量异常----------------')
                        self.close_lower_door_visual()
                        return           
                    continue
                cur_weight_none=0
                second_finish_weight=initial_lower_weight-current_weight
                self._is_finish_ratio=(second_finish_weight+first_finish_weight)/need_total_weight
                print(f'------------已下料比例: {self._is_finish_ratio}-------------')
                if self._is_finish_ratio>=1:
                    #关5秒
                    # print(f'------------已下料比例: {self._is_finish_ratio}-------------')
                    break
                    
                # print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
                time.sleep(1)
            
        # _current_lower_weight=loc_mitter.read_data(2)
        # first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
        # print(f'------------已下料: {first_finish_weight}kg-------------')
        # print(f'------------已下料: {first_finish_weight}kg-------------')


        print(f'------------已完成-------------')

 
   
    @classmethod
    def instance_exists(cls):
        """检测实例是否存在"""
        return cls._instance is not None
    
 

# 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)