变频器集成以及增加点动控制(0209)

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2026-02-09 11:36:37 +08:00
parent 88dfc53b9d
commit d6ad01274a
45 changed files with 7161 additions and 1578 deletions

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feeding/process copy.py Normal file
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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,ArtifactInfo
import time
from datetime import datetime
from hardware.RFID.rfid_service import rfid_service
from config.settings import app_set_config
class FeedingProcess:
def __init__(self, relay_controller, inverter_controller,
transmitter_controller, vision_detector,
camera_controller, state):
self.relay_controller = relay_controller
self.artifact_bll = ArtifactBll()
self.mould_service = MouldService()
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
#标志位用,是否是第一次运行
self.is_first_flag=True
def start_feeding(self):
loc_state=self.state
loc_state._upper_weight=self.transmitter_controller.read_data(1)
loc_state._lower_weight=self.transmitter_controller.read_data(2)
# loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
"""开始生产管片"""
if loc_state._feed_status == FeedStatus.FNone:
return
elif loc_state._feed_status == FeedStatus.FCheckM:
print("---------------初始化数据------------------")
loc_state._mould_need_weight= 1200
loc_state._feed_status = FeedStatus.FFeed
return
elif loc_state._feed_status == FeedStatus.FFeed:
print("----------------下料------------------")
loc_state.mould_vibrate_time=time.time()
loc_state._mould_frequency=app_set_config.frequencies[0]
loc_state._mould_vibrate_status=1
#上料斗重量
loc_state.initial_upper_weight=loc_state._upper_weight
#下料斗重量
loc_state.initial_lower_weight=loc_state._lower_weight
self.feeding_stage(loc_state)
# if loc_state._mould_need_weight>loc_state.initial_lower_weight:
# self.transfer_material_from_upper_to_lower(loc_state,loc_state.initial_upper_weight,loc_state.initial_lower_weight)
# loc_state._feed_status = FeedStatus.FFeed1
# else:
# loc_state._feed_status = FeedStatus.FFeed1
return
elif loc_state._feed_status == FeedStatus.FFinished:
"""完成当前批次下料"""
print("振捣完成")
print("关闭所有网络继电器")
self.relay_controller.close_all()
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,loc_state,initial_upper_weight,initial_lower_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=app_set_config.max_lower_volume*loc_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,同步关5秒
self.relay_controller.control_lower_close()
# 打开上料斗出砼门
# self.relay_controller.control_upper_open()
#一直打开3秒
self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
time.sleep(3)
loc_state._upper_door_closed=False
# 等待物料流入下料斗,基于上料斗重量变化控制
start_time = time.time()
# timeout = 30 # 30秒超时
while loc_state.running:
# self.relay_controller.control_upper_open_sync()
self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'close')
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
loc_state._upper_weight=current_upper_weight
loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
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}")
break
# time.sleep(1)
# self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
# time.sleep(0.2)
loc_state._upper_door_closed=True
# 关闭上料斗出砼门d
self.relay_controller.control_upper_close()
#测试用
print("上料斗下料完成")
def feeding_stage(self,loc_state):
"""第一阶段下料:下料斗向模具车下料(低速)"""
print("开始下料")
# self.relay_controller.control
first_finish_weight=0
while True:
current_weight = loc_state._lower_weight
loc_state._mould_finish_weight=loc_state.initial_lower_weight-current_weight
first_finish_weight=loc_state._mould_finish_weight
if current_weight<100:
#关5秒
self.relay_controller.control_lower_close()
break
time.sleep(1)
#打开上料斗出砼门
self.relay_controller.control_upper_open_sync(5)
while True:
if loc_state._upper_weight<3000:
#关5秒
self.relay_controller.control_upper_close()
break
loc_state.initial_lower_weight=loc_state.lower_weight
while True:
current_weight = loc_state._lower_weight
loc_state._mould_finish_weight=first_finish_weight+loc_state.initial_lower_weight-current_weight
if current_weight<100:
#关5秒
self.relay_controller.control_lower_close()
break
time.sleep(1)
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'

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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,ArtifactInfo
import time
from datetime import datetime
from hardware.RFID.rfid_service import rfid_service
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, vision_detector,
camera_controller, state):
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.artifact_bll = ArtifactBll()
self.mould_service = MouldService()
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
#标志位用,是否是第一次运行
self.is_first_flag=True
def start_feeding(self):
loc_state=self.state
loc_state._upper_weight=self.transmitter_controller.read_data(1)
loc_state._lower_weight=self.transmitter_controller.read_data(2)
# loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
"""开始生产管片"""
if loc_state._feed_status == FeedStatus.FNone:
return
elif loc_state._feed_status == FeedStatus.FCheckM:
print("---------------初始化数据------------------")
loc_state._mould_need_weight= 1200
loc_state._feed_status = FeedStatus.FFeed
return
elif loc_state._feed_status == FeedStatus.FFeed:
print("----------------下料------------------")
loc_state.mould_vibrate_time=time.time()
loc_state._mould_frequency=app_set_config.frequencies[0]
loc_state._mould_vibrate_status=1
#上料斗重量
loc_state.initial_upper_weight=loc_state._upper_weight
#下料斗重量
loc_state.initial_lower_weight=loc_state._lower_weight
self.feeding_stage(loc_state)
# if loc_state._mould_need_weight>loc_state.initial_lower_weight:
# self.transfer_material_from_upper_to_lower(loc_state,loc_state.initial_upper_weight,loc_state.initial_lower_weight)
# loc_state._feed_status = FeedStatus.FFeed1
# else:
# loc_state._feed_status = FeedStatus.FFeed1
return
elif loc_state._feed_status == FeedStatus.FFinished:
"""完成当前批次下料"""
print("振捣完成")
print("关闭所有网络继电器")
self.relay_controller.close_all()
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,loc_state,initial_upper_weight,initial_lower_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=app_set_config.max_lower_volume*loc_state.density
# if (initial_lower_weight+feed_weight>_max_lower_weight):
feed_weight=_max_lower_weight-initial_lower_weight
# 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()
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,同步关5秒
self.relay_controller.control_lower_close()
# 打开上料斗出砼门
# self.relay_controller.control_upper_open()
#一直打开3秒
self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
time.sleep(3)
loc_state._upper_door_closed=False
# 等待物料流入下料斗,基于上料斗重量变化控制
start_time = time.time()
# timeout = 30 # 30秒超时
# 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
while loc_state.running:
# self.relay_controller.control_upper_open_sync()
self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'close')
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
loc_state._upper_weight=current_upper_weight
loc_state._upper_volume=round(loc_state._upper_weight/self.state.density,1)
print(f"上料斗当前重量: {current_upper_weight:.2f}kg")
#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
# 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}")
break
# time.sleep(1)
# self.relay_controller.control(self.relay_controller.DOOR_UPPER_OPEN, 'open')
# time.sleep(0.2)
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=''
loc_state._upper_door_closed=True
# 关闭上料斗出砼门d
self.relay_controller.control_upper_close()
#测试用
print("上料斗下料完成")
def feeding_stage(self,loc_state):
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")
# self.relay_controller.control
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
while True:
current_weight = loc_state._lower_weight
loc_state._mould_finish_weight=loc_state.initial_lower_weight-current_weight
first_finish_weight=loc_state._mould_finish_weight
if current_weight<100:
#关5秒
self.relay_controller.control_lower_close()
break
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)
#打开上料斗出砼门
self.relay_controller.control_upper_open_sync(5)
while True:
if loc_state._upper_weight<3000:
#关5秒
self.relay_controller.control_upper_close()
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
loc_state.initial_lower_weight=loc_state.lower_weight
while True:
current_weight = loc_state._lower_weight
loc_state._mould_finish_weight=first_finish_weight+loc_state.initial_lower_weight-current_weight
if current_weight<100:
#关5秒
self.relay_controller.control_lower_close()
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
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'
# 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)