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fujinliang
2025-11-21 14:55:52 +08:00
parent e3ecd0550f
commit 26ed8df502
36 changed files with 908 additions and 433 deletions
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172
core/system.py
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@ -2,7 +2,6 @@
import threading
import time
import cv2
from config.settings import Settings
from core.state import SystemState
from hardware.relay import RelayController
from hardware.inverter import InverterController
@ -11,31 +10,32 @@ from hardware.RFID.rfid_service import rfid_service
from vision.camera import DualCameraController
from vision.detector import VisionDetector
from feeding.controller import FeedingController
from service.mould_service import app_web_service
from config.settings import app_set_config
class FeedingControlSystem:
def __init__(self, settings: Settings):
self.settings = settings
def __init__(self):
self.state = SystemState()
# 初始化硬件控制器
self.relay_controller = RelayController(
host=settings.relay_host,
port=settings.relay_port
host=app_set_config.relay_host,
port=app_set_config.relay_port
)
self.inverter_controller = InverterController(self.relay_controller)
self.transmitter_controller = TransmitterController(self.relay_controller)
# 初始化视觉系统
self.camera_controller = DualCameraController(settings.camera_configs)
self.camera_controller = DualCameraController(app_set_config.camera_configs)
self.vision_detector = VisionDetector(settings)
self.vision_detector = VisionDetector()
# 初始化RFID控制器
self.rfid_controller = rfid_service(
host=settings.rfid_host,
port=settings.rfid_port
host=app_set_config.rfid_host,
port=app_set_config.rfid_port
)
# 初始化下料控制器
self.feeding_controller = FeedingController(
@ -45,8 +45,7 @@ class FeedingControlSystem:
self.vision_detector,
self.camera_controller,
self.rfid_controller,
self.state,
settings
self.state
)
@ -56,6 +55,7 @@ class FeedingControlSystem:
self.visual_control_thread = None
self.alignment_check_thread = None
self.lower_feeding_thread = None
self.led_thread = None
def initialize(self):
"""初始化系统"""
@ -63,12 +63,12 @@ class FeedingControlSystem:
# 设置摄像头配置
# self.camera_controller.set_config(
# camera_type=self.settings.camera_type,
# ip=self.settings.camera_ip,
# port=self.settings.camera_port,
# username=self.settings.camera_username,
# password=self.settings.camera_password,
# channel=self.settings.camera_channel
# camera_type=app_set_config.camera_type,
# ip=app_set_config.camera_ip,
# port=app_set_config.camera_port,
# username=app_set_config.camera_username,
# password=app_set_config.camera_password,
# channel=app_set_config.camera_channel
# )
# # 初始化摄像头
@ -78,30 +78,33 @@ class FeedingControlSystem:
# 加载视觉模型
# if not self.vision_detector.load_models():
# raise Exception("视觉模型加载失败")
if not self.settings.debug_feeding:
if not self.check_device_connectivity():
raise Exception("设备连接失败")
self.camera_controller.start_cameras()
self.check_device_connectivity()
# self.camera_controller.start_cameras()
# if not app_set_config.debug_feeding:
# 启动系统监控(要料，破拱)线程
self.start_monitoring()
self.start_monitoring()
# 启动视觉控制(角度、溢出）线程
# self.start_visual_control()
# 启动视觉控制(角度、溢出）线程
self.start_visual_control()
# 启动对齐检查线程
self.start_alignment_check()
# 启动对齐检查线程
# self.start_alignment_check()
# 启动下料线程
self.start_lower_feeding()
#LED屏
# self.start_led()
print("控制系统初始化完成")
def start_monitoring(self):
"""启动系统监控"""
self.state.running = True
print('振动和要料监控线程启动')
self.monitor_thread = threading.Thread(
target=self._monitor_loop,
daemon=True
daemon=True,
name='monitor'
)
self.monitor_thread.start()
@ -109,7 +112,7 @@ class FeedingControlSystem:
"""监控循环"""
while self.state.running:
try:
self.feeding_controller.check_upper_material_request()
# self.feeding_controller.check_upper_material_request()
self.feeding_controller.check_arch_blocking()
time.sleep(1)
except Exception as e:
@ -117,9 +120,11 @@ class FeedingControlSystem:
def start_visual_control(self):
"""启动视觉控制"""
print('视觉控制线程启动')
self.visual_control_thread = threading.Thread(
target=self._visual_control_loop,
daemon=True
daemon=True,
name='visual_control'
)
self.visual_control_thread.start()
@ -132,37 +137,79 @@ class FeedingControlSystem:
if current_frame is not None:
# 执行视觉控制逻辑
self.feeding_controller.visual_control(current_frame)
time.sleep(self.settings.visual_check_interval)
time.sleep(app_set_config.visual_check_interval)
except Exception as e:
print(f"视觉控制循环错误: {e}")
time.sleep(self.settings.visual_check_interval)
time.sleep(app_set_config.visual_check_interval)
def start_alignment_check(self):
"""启动对齐检查"""
print('对齐检查线程启动')
self.alignment_check_thread = threading.Thread(
target=self._alignment_check_loop,
daemon=True
daemon=True,
name='align_check'
)
self.alignment_check_thread.start()
def _alignment_check_loop(self):
"""对齐检查循环"""
loc_align_status=False
loc_before_status=None
while self.state.running:
try:
if self.state._lower_feeding_stage == 4: # 等待对齐阶段
if self.state.lower_feeding_stage == 4: # 等待对齐阶段
current_frame = self.camera_controller.get_single_latest_frame()
if current_frame is not None:
self.state.vehicle_aligned = self.vision_detector.detect_vehicle_alignment(current_frame)
self.state.vehicle_aligned = self.alignment_check_status()
if self.state.vehicle_aligned:
# loc_count+=1
print("检测到模具车对齐")
else:
print("模具车未对齐")
else:
print('未检测到图像')
time.sleep(self.settings.alignment_check_interval)
# time.sleep(app_set_config.alignment_check_interval)
# loc_align_status=self.alignment_check_status()
# if loc_align_status and not loc_before_status:
# print("模具车由未对齐到对齐")
# self.state.vehicle_aligned=True
# elif not loc_align_status and loc_before_status:
# print("模具车由对齐到未对齐")
# self.state.vehicle_aligned=False
# if loc_before_status!=loc_align_status:
# loc_before_status=loc_align_status
except Exception as e:
print(f"对齐检查循环错误: {e}")
time.sleep(self.settings.alignment_check_interval)
finally:
time.sleep(app_set_config.alignment_check_interval)
def alignment_check_status(self)->bool:
"""对齐检查循环"""
loc_aligned=False
loc_count=0
for i in range(4):
try:
current_frame = self.camera_controller.get_single_latest_frame()
if current_frame is not None:
loc_aligned = self.vision_detector.detect_vehicle_alignment(current_frame)
if loc_aligned:
loc_count+=1
print("检测到模具车对齐")
else:
loc_count=0
print("模具车未对齐")
time.sleep(app_set_config.alignment_check_interval)
except Exception as e:
print(f"对齐检查循环错误: {e}")
time.sleep(app_set_config.alignment_check_interval)
if loc_count>=3:
loc_aligned=True
else:
loc_aligned=False
return loc_aligned
def start_lower_feeding(self):
"""启动下料流程"""
@ -177,7 +224,34 @@ class FeedingControlSystem:
"""启动下料流程"""
while self.state.running:
self.feeding_controller.start_feeding()
time.sleep(self.settings.lower_feeding_interval)
time.sleep(app_set_config.lower_feeding_interval)
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"""
while self.state.running:
led_info = app_web_service.get_pouring_led()
if led_info and self.state.current_artifact:
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)
def check_device_connectivity(self) -> bool:
"""检查关键设备连接状态"""
@ -194,15 +268,15 @@ class FeedingControlSystem:
return False
# 尝试读取变频器一个寄存器（测试连接）
test_result = self.relay_controller.modbus_client.read_holding_registers(
address=0x00,
count=1,
slave=self.inverter_controller.config['slave_id']
)
# test_result = self.relay_controller.modbus_client.read_holding_registers(
# address=0x00,
# count=1,
# slave=self.inverter_controller.config['slave_id']
# )
if isinstance(test_result, Exception):
print("变频器连接测试失败")
return False
# if isinstance(test_result, Exception):
# print("变频器连接测试失败")
# return False
# 检查下料斗变送器连接
test_weight = self.transmitter_controller.read_data(2)