307 lines
13 KiB
Python
307 lines
13 KiB
Python
class FeedingProcess:
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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, settings):
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self.relay_controller = relay_controller
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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.settings = settings
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def start_feeding(self):
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"""开始分步下料"""
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if self.state.lower_feeding_stage != 0:
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print("下料已在进行中")
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return
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# 检查关键设备是否可连接
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if not self._check_device_connectivity():
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print("关键设备连接失败，无法开始下料")
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return
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print("开始分步下料过程")
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# 重置计数器
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self.state.lower_feeding_cycle = 0
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self.state.upper_feeding_count = 0
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self.state.upper_feeding_max = 2
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# 第一次上料
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self.transfer_material_from_upper_to_lower()
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# 等待模具车对齐并开始第一轮下料
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self.state.lower_feeding_stage = 4
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self.wait_for_vehicle_alignment()
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def _check_device_connectivity(self):
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"""检查关键设备连接状态"""
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try:
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# 检查网络继电器连接
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test_response = self.relay_controller.send_command(self.relay_controller.read_status_command)
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if not test_response:
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print("网络继电器连接失败")
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return False
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# 检查变频器连接
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if not self.relay_controller.modbus_client.connect():
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print("无法连接到网络继电器Modbus服务")
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return False
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# 尝试读取变频器一个寄存器（测试连接）
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test_result = self.relay_controller.modbus_client.read_holding_registers(
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address=0x00,
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count=1,
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slave=self.inverter_controller.config['slave_id']
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)
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if isinstance(test_result, Exception):
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print("变频器连接测试失败")
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return False
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# 检查下料斗变送器连接
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test_weight = self.transmitter_controller.read_data(2)
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if test_weight is None:
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print("下料斗变送器连接失败")
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return False
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self.relay_controller.modbus_client.close()
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return True
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except Exception as e:
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print(f"设备连接检查失败: {e}")
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return False
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def transfer_material_from_upper_to_lower(self):
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"""上料斗向下料斗下料"""
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print(f"上料斗向下料斗下料 (第 {self.state.upper_feeding_count + 1} 次)")
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# 记录下料前的重量
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initial_upper_weight = self.transmitter_controller.read_data(1)
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# 如果无法读取重量，直接报错
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if initial_upper_weight is None:
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raise Exception("无法读取上料斗重量传感器数据，下料操作终止")
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target_upper_weight = initial_upper_weight - self.settings.single_batch_weight
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target_upper_weight = max(target_upper_weight, 0) # 确保不低于0
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print(f"上料斗初始重量: {initial_upper_weight:.2f}kg, 目标重量: {target_upper_weight:.2f}kg")
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# 确保下料斗出砼门关闭
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'close')
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# 打开上料斗出砼门
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'open')
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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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import time
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start_time = time.time()
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timeout = 30 # 30秒超时
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while time.time() - start_time < timeout:
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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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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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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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print("重量变化过小，可能存在堵塞，交由监控系统处理...")
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break
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time.sleep(1)
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# 关闭上料斗出砼门
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')
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# 验证下料结果
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final_upper_weight = self.transmitter_controller.read_data(1)
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if final_upper_weight is not None:
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actual_transferred = initial_upper_weight - final_upper_weight
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print(f"实际下料重量: {actual_transferred:.2f}kg")
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# 增加上料计数
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self.state.upper_feeding_count += 1
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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(self.settings.alignment_check_interval)
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def feeding_stage_one(self):
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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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self.inverter_controller.set_frequency(self.settings.frequencies[0])
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self.inverter_controller.control('start')
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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_LOWER_1, 'close')
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# 打开下料斗出砼门
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')
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import time
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start_time = time.time()
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initial_weight = self.transmitter_controller.read_data(2)
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if initial_weight is None:
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print("无法获取初始重量，取消下料")
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self.finish_feeding_process()
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return
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target_weight = initial_weight + self.settings.single_batch_weight
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while self.state.lower_feeding_stage == 1:
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current_weight = self.transmitter_controller.read_data(2)
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if current_weight is None:
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self.state.lower_weight_error_count += 1
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if self.state.lower_weight_error_count >= self.settings.max_error_count:
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print("下料斗传感器连续读取失败，停止下料")
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self.finish_feeding_process()
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return
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else:
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self.state.lower_weight_error_count = 0
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if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
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self.state.lower_feeding_stage = 2
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self.feeding_stage_two()
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break
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time.sleep(2)
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def feeding_stage_two(self):
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"""第二阶段下料：下料斗向模具车下料（中速）"""
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print("开始第二阶段下料：下料斗中速下料")
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self.inverter_controller.set_frequency(self.settings.frequencies[1])
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# 保持下料斗出砼门打开
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')
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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_LOWER_1, 'close')
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import time
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start_time = time.time()
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initial_weight = self.transmitter_controller.read_data(2)
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if initial_weight is None:
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print("无法获取初始重量，取消下料")
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self.finish_feeding_process()
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return
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target_weight = initial_weight + self.settings.single_batch_weight
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while self.state.lower_feeding_stage == 2:
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current_weight = self.transmitter_controller.read_data(2)
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if current_weight is None:
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self.state.lower_weight_error_count += 1
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if self.state.lower_weight_error_count >= self.settings.max_error_count:
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print("下料斗传感器连续读取失败，停止下料")
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self.finish_feeding_process()
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return
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else:
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self.state.lower_weight_error_count = 0
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if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
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self.state.lower_feeding_stage = 3
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self.feeding_stage_three()
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break
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time.sleep(2)
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def feeding_stage_three(self):
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"""第三阶段下料：下料斗向模具车下料（高速）"""
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print("开始第三阶段下料：下料斗高速下料")
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self.inverter_controller.set_frequency(self.settings.frequencies[2])
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# 保持下料斗出砼门打开
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'open')
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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_LOWER_1, 'close')
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import time
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start_time = time.time()
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initial_weight = self.transmitter_controller.read_data(2)
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if initial_weight is None:
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print("无法获取初始重量，取消下料")
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self.finish_feeding_process()
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return
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target_weight = initial_weight + self.settings.single_batch_weight
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while self.state.lower_feeding_stage == 3:
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current_weight = self.transmitter_controller.read_data(2)
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if current_weight is None:
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self.state.lower_weight_error_count += 1
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if self.state.lower_weight_error_count >= self.settings.max_error_count:
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print("下料斗传感器连续读取失败，停止下料")
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self.finish_feeding_process()
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return
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else:
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self.state.lower_weight_error_count = 0
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if (current_weight is not None and current_weight >= target_weight) or (time.time() - start_time) > 30:
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self.state.lower_feeding_stage = 4
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self.finish_current_batch()
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break
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time.sleep(2)
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def finish_current_batch(self):
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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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self.inverter_controller.control('stop')
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_1, 'close')
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_2, 'close')
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# 增加三阶段下料轮次计数
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self.state.lower_feeding_cycle += 1
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# 检查是否完成两轮三阶段下料
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if self.state.lower_feeding_cycle >= self.state.upper_feeding_max:
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print("完成两轮三阶段下料，5吨下料任务完成")
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self.finish_feeding_process()
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return
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# 如果只完成一轮三阶段下料，进行第二次上料
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print("第一轮三阶段下料完成，准备第二次上料")
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# 上料斗第二次向下料斗下料
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try:
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self.transfer_material_from_upper_to_lower()
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except Exception as e:
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print(f"第二次上料失败: {e}")
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print("停止下料流程")
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self.finish_feeding_process() # 出现严重错误时结束整个流程
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return
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# 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）
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print("第二次上料完成，继续三阶段下料")
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self.state.lower_feeding_stage = 1 # 直接进入第一阶段下料
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self.feeding_stage_one() # 开始第二轮第一阶段下料
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def finish_feeding_process(self):
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"""完成整个下料流程"""
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print("整个下料流程完成")
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self.state.lower_feeding_stage = 0
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self.state.lower_feeding_cycle = 0
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self.state.upper_feeding_count = 0
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self.return_upper_door_to_default()
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def return_upper_door_to_default(self):
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"""上料斗回到默认位置（搅拌楼下接料位置）"""
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print("上料斗回到默认位置")
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self.relay_controller.control(self.relay_controller.DOOR_UPPER, 'close')
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self.state.upper_door_position = 'default'
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