Feeding_control_system/feeding/process.py

from enum import IntEnum
from core.state import FeedStatus
from service.mould_service import MouldService
from busisness.blls import ArtifactBll
from busisness.models import ArtifactInfoModel

class FeedingProcess:
    def __init__(self, relay_controller, inverter_controller,
                 transmitter_controller, vision_detector,
                 camera_controller, state, settings):
        self.relay_controller = relay_controller
        self.artifact_bll = ArtifactBll()
        self.inverter_controller = inverter_controller
        self.transmitter_controller = transmitter_controller
        self.vision_detector = vision_detector
        self.camera_controller = camera_controller
        self.state = state
        self.state.feed_status = FeedStatus.FNone

        self.settings = settings

    def start_feeding(self):
        loc_state=self.state
        """开始生产管片"""
        if loc_state.feed_status == FeedStatus.FNone:
            loc_state.feed_status = FeedStatus.FCheckM
            return
        elif loc_state.feed_status == FeedStatus.FCheckM:
            loc_state._lower_feeding_stage = 4
            self.wait_for_vehicle_alignment()
            loc_state.feed_status = FeedStatus.FStart
            print("生产已检查模车")
            return
        elif loc_state.feed_status == FeedStatus.FApiCheck:
            print("生产已开始")
            time.sleep(2)
            loc_modules = MouldService.get_not_pour_artifacts()
            if loc_modules:
                # 取第一个未浇筑的管片
                loc_module = loc_modules[0]
                self.state.current_artifact = loc_module
            else:
                #未读取到AIP接口数据.
                self.state.current_artifact = None
            return
        elif loc_state.feed_status == FeedStatus.FRFID:
            print("生产已检查RFID")
            #RFID格式：模具编号,分块号,尺寸规格,方量
            rfid_info =''
            loc_MouldCode='SHZB1-4'
            loc_SizeSpecification='6600*1200'
            loc_BlockNumber='B1'
            loc.BetonVolume=1.56
            if self.state.current_artifact:
                #检测是否和RFID识别的管理一致
                self.state.feed_status = FeedStatus.FCheckGB
            else:
                #以RFID为准
                loc_module= ArtifactInfoModel()
                loc_module.MouldCode=loc_MouldCode
                loc_module.SizeSpecification=loc_SizeSpecification
                loc_module.BlockNumber=loc_BlockNumber
                loc_module.BetonVolume=loc.BetonVolume
                self.state.current_artifact = loc_module

            #确认是否保存到数据库
            self.state.feed_status = FeedStatus.FCheckGB
            return
        elif loc_state.feed_status == FeedStatus.FCheckGB:
            print("检查盖板对齐,")
            time.sleep(10)
            loc_state.feed_status = FeedStatus.FUpperToLower
            #计算本次生产需要的总重量
            print(f"本次生产需要的总重量:{self.state.need_total_weight}")
            return
        elif loc_state.feed_status == FeedStatus.FUpperToLower:
            print("上料斗向下料斗转移")
            #上料斗重量
            loc_state.initial_upper_weight=self.transmitter_controller.read_data(1)
            #下料斗重量
            loc_state.initial_lower_weight=self.transmitter_controller.read_data(2)
            #需要的总重量
            loc_state.need_total_weight=loc_state.current_artifact.BetonVolume*loc_state.density
            if loc_state.need_total_weight > loc_state.initial_upper_weight + loc_state.initial_lower_weight:
                # 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)
                print('重量不够，需要增加')
                return
            
            if loc_state.need_total_weight>loc_state.initial_lower_weight:
                if self.state._upper_door_position != 'over_lower':
                    #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
                    return 
                else:
                     # 需要等待上料斗下料
                     # 最后一块进行尾数控制
                     # 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）
                    loc_FWeight=0.3*loc_state.density
                    loc_feed_weight=loc_state.need_total_weight-loc_state.initial_lower_weight-loc_FWeight
                    self.transfer_material_from_upper_to_lower(loc_state.initial_upper_weight,loc_state.initial_lower_weight,loc_feed_weight)

            self.state.feed_status = FeedStatus.FFeed1      
            # time.sleep(10)
            return
        elif self.state.feed_status == FeedStatus.FFeed1:
            #下料
            # self._start_feeding_stage()
            print("下料1")
            return
        elif self.state.feed_status == FeedStatus.FFeed2:
            #上料
            # self._start_feeding_stage()
            print("下料2")
            return
        elif self.state.feed_status == FeedStatus.FFeed3:
            #下料
            # self._start_feeding_stage()
            print("下料3")
            return
        elif self.state.feed_status == FeedStatus.FFinished:
            print("生产已完成")
            self.state.feed_status = FeedStatus.FCheckM
            return
 
    def _start_feeding_stage(self):
        """启动指定下料阶段"""
        """开始分步下料"""
        print("开始分步下料过程")
        self.transfer_material_from_upper_to_lower()

    def transfer_material_from_upper_to_lower(self,initial_upper_weight,initial_lower_weight,feed_weight):
        
        """target_upper_weight：转移后剩下的上料斗重量"""
        # 如果低于单次，全部卸掉
        _max_lower_weight=self.settings.max_lower_volume*self.state.density
        if (initial_lower_weight+feed_weight>_max_lower_weight):
            feed_weight=_max_lower_weight-initial_lower_weight
        
        target_upper_weight=initial_upper_weight-feed_weight
        target_upper_weight = max(target_upper_weight, 0)  
        # 确保下料斗出砼门关闭
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'close')
        # 打开上料斗出砼门
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'open')

        # 等待物料流入下料斗，基于上料斗重量变化控制
        import time
        start_time = time.time()
        # timeout = 30  # 30秒超时

        while self.state.running:
            current_upper_weight = self.transmitter_controller.read_data(1)
            # 如果无法读取重量，继续尝试
            if current_upper_weight is None:
                print("无法读取上料斗重量，继续尝试...")
                time.sleep(1)
                continue

            print(f"上料斗当前重量: {current_upper_weight:.2f}kg")

            # 如果达到目标重量，则关闭上料斗出砼门
            if current_upper_weight <= target_upper_weight + 50:  # 允许50kg的误差范围
                print(f"达到目标重量，当前重量: {current_upper_weight:.2f}kg")
                print(f"花费时间 {time.time() - start_time:.2f}秒")
                break
            elif time.time() - start_time > 25:  # 如果25秒后重量变化过小
                weight_change = initial_upper_weight - current_upper_weight
                if weight_change < 100:  # 如果重量变化小于100kg
                    #需要增加报警处理
                    print("重量变化过小，可能存在堵塞")
            time.sleep(1)
        # 关闭上料斗出砼门
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')
        print("上料斗下料完成")

    def wait_for_vehicle_alignment(self):
        """等待模具车对齐"""
        print("等待模具车对齐...")
        self.state._lower_feeding_stage = 4

        import time
        while self.state._lower_feeding_stage == 4 and self.state.running:
            if self.state.vehicle_aligned:
                print("模具车已对齐，开始下料")
                self.state._lower_feeding_stage = 1
                # self.feeding_stage_one()
                break
            time.sleep(self.settings.alignment_check_interval)

    def feeding_stage_one(self):
        """第一阶段下料：下料斗向模具车下料（低速）"""
        print("开始第一阶段下料：下料斗低速下料")
        self.inverter_controller.set_frequency(self.settings.frequencies[0])
        self.inverter_controller.control('start')

        # 确保上料斗出砼门关闭
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')
        # 打开下料斗出砼门
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')

        import time
        start_time = time.time()
        initial_weight = self.transmitter_controller.read_data(2)
        if initial_weight is None:
            print("无法获取初始重量，取消下料")
            self.finish_feeding_process()
            return

        target_weight = initial_weight + self.settings.single_batch_weight

        while self.state._lower_feeding_stage == 1:
            current_weight = self.transmitter_controller.read_data(2)
            if current_weight is None:
                self.state.lower_weight_error_count += 1
                if self.state.lower_weight_error_count >= self.settings.max_error_count:
                    print("下料斗传感器连续读取失败，停止下料")
                    self.finish_feeding_process()
                    return
            else:
                self.state.lower_weight_error_count = 0

            if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
                self.state._lower_feeding_stage = 2
                self.feeding_stage_two()
                break
            time.sleep(2)

    def feeding_stage_two(self):
        """第二阶段下料：下料斗向模具车下料（中速）"""
        print("开始第二阶段下料：下料斗中速下料")
        self.inverter_controller.set_frequency(self.settings.frequencies[1])

        # 保持下料斗出砼门打开
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')
        # 确保上料斗出砼门关闭
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')

        import time
        start_time = time.time()
        initial_weight = self.transmitter_controller.read_data(2)
        if initial_weight is None:
            print("无法获取初始重量，取消下料")
            self.finish_feeding_process()
            return

        target_weight = initial_weight + self.settings.single_batch_weight

        while self.state._lower_feeding_stage == 2:
            current_weight = self.transmitter_controller.read_data(2)
            if current_weight is None:
                self.state.lower_weight_error_count += 1
                if self.state.lower_weight_error_count >= self.settings.max_error_count:
                    print("下料斗传感器连续读取失败，停止下料")
                    self.finish_feeding_process()
                    return
            else:
                self.state.lower_weight_error_count = 0

            if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
                self.state._lower_feeding_stage = 3
                self.feeding_stage_three()
                break
            time.sleep(2)

    def feeding_stage_three(self):
        """第三阶段下料：下料斗向模具车下料（高速）"""
        print("开始第三阶段下料：下料斗高速下料")
        self.inverter_controller.set_frequency(self.settings.frequencies[2])

        # 保持下料斗出砼门打开
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')
        # 确保上料斗出砼门关闭
        self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')

        import time
        start_time = time.time()
        initial_weight = self.transmitter_controller.read_data(2)
        if initial_weight is None:
            print("无法获取初始重量，取消下料")
            self.finish_feeding_process()
            return

        target_weight = initial_weight + self.settings.single_batch_weight

        while self.state._lower_feeding_stage == 3:
            current_weight = self.transmitter_controller.read_data(2)
            if current_weight is None:
                self.state.lower_weight_error_count += 1
                if self.state.lower_weight_error_count >= self.settings.max_error_count:
                    print("下料斗传感器连续读取失败，停止下料")
                    self.finish_feeding_process()
                    return
            else:
                self.state.lower_weight_error_count = 0

            if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
                self.state._lower_feeding_stage = 4
                self.finish_current_batch()
                break
            time.sleep(2)

    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.DOOR_UPPER, 'close')
        self.state._upper_door_position = 'default'