346 lines
15 KiB
Python
346 lines
15 KiB
Python
from enum import IntEnum
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from core.state import FeedStatus
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from service.mould_service import MouldService
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from busisness.blls import ArtifactBll
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from busisness.models import ArtifactInfoModel
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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.artifact_bll = ArtifactBll()
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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.state.feed_status = FeedStatus.FNone
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self.settings = settings
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def start_feeding(self):
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loc_state=self.state
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"""开始生产管片"""
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if loc_state.feed_status == FeedStatus.FNone:
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loc_state.feed_status = FeedStatus.FCheckM
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return
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elif loc_state.feed_status == FeedStatus.FCheckM:
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loc_state._lower_feeding_stage = 4
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self.wait_for_vehicle_alignment()
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loc_state.feed_status = FeedStatus.FStart
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print("生产已检查模车")
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return
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elif loc_state.feed_status == FeedStatus.FApiCheck:
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print("生产已开始")
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time.sleep(2)
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loc_modules = MouldService.get_not_pour_artifacts()
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if loc_modules:
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# 取第一个未浇筑的管片
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loc_module = loc_modules[0]
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self.state.current_artifact = loc_module
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else:
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#未读取到AIP接口数据.
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self.state.current_artifact = None
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return
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elif loc_state.feed_status == FeedStatus.FRFID:
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print("生产已检查RFID")
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#RFID格式：模具编号,分块号,尺寸规格,方量
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rfid_info =''
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loc_MouldCode='SHZB1-4'
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loc_SizeSpecification='6600*1200'
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loc_BlockNumber='B1'
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loc.BetonVolume=1.56
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if self.state.current_artifact:
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#检测是否和RFID识别的管理一致
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self.state.feed_status = FeedStatus.FCheckGB
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else:
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#以RFID为准
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loc_module= ArtifactInfoModel()
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loc_module.MouldCode=loc_MouldCode
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loc_module.SizeSpecification=loc_SizeSpecification
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loc_module.BlockNumber=loc_BlockNumber
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loc_module.BetonVolume=loc.BetonVolume
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self.state.current_artifact = loc_module
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#确认是否保存到数据库
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self.state.feed_status = FeedStatus.FCheckGB
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return
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elif loc_state.feed_status == FeedStatus.FCheckGB:
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print("检查盖板对齐,")
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time.sleep(10)
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loc_state.feed_status = FeedStatus.FUpperToLower
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#计算本次生产需要的总重量
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print(f"本次生产需要的总重量:{self.state.need_total_weight}")
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return
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elif loc_state.feed_status == FeedStatus.FUpperToLower:
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print("上料斗向下料斗转移")
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#上料斗重量
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loc_state.initial_upper_weight=self.transmitter_controller.read_data(1)
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#下料斗重量
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loc_state.initial_lower_weight=self.transmitter_controller.read_data(2)
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#需要的总重量
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loc_state.need_total_weight=loc_state.current_artifact.BetonVolume*loc_state.density
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if loc_state.need_total_weight > loc_state.initial_upper_weight + loc_state.initial_lower_weight:
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# 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)
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print('重量不够，需要增加')
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return
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if loc_state.need_total_weight>loc_state.initial_lower_weight:
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if self.state._upper_door_position != 'over_lower':
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#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
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return
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else:
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# 需要等待上料斗下料
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# 最后一块进行尾数控制
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# 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）
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loc_FWeight=0.3*loc_state.density
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loc_feed_weight=loc_state.need_total_weight-loc_state.initial_lower_weight-loc_FWeight
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self.transfer_material_from_upper_to_lower(loc_state.initial_upper_weight,loc_state.initial_lower_weight,loc_feed_weight)
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self.state.feed_status = FeedStatus.FFeed1
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# time.sleep(10)
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return
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elif self.state.feed_status == FeedStatus.FFeed1:
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#下料
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# self._start_feeding_stage()
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print("下料1")
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return
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elif self.state.feed_status == FeedStatus.FFeed2:
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#上料
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# self._start_feeding_stage()
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print("下料2")
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return
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elif self.state.feed_status == FeedStatus.FFeed3:
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#下料
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# self._start_feeding_stage()
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print("下料3")
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return
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elif self.state.feed_status == FeedStatus.FFinished:
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print("生产已完成")
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self.state.feed_status = FeedStatus.FCheckM
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return
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def _start_feeding_stage(self):
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"""启动指定下料阶段"""
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"""开始分步下料"""
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print("开始分步下料过程")
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self.transfer_material_from_upper_to_lower()
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def transfer_material_from_upper_to_lower(self,initial_upper_weight,initial_lower_weight,feed_weight):
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"""target_upper_weight：转移后剩下的上料斗重量"""
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# 如果低于单次，全部卸掉
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_max_lower_weight=self.settings.max_lower_volume*self.state.density
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if (initial_lower_weight+feed_weight>_max_lower_weight):
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feed_weight=_max_lower_weight-initial_lower_weight
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target_upper_weight=initial_upper_weight-feed_weight
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target_upper_weight = max(target_upper_weight, 0)
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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 self.state.running:
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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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print(f"花费时间 {time.time() - start_time:.2f}秒")
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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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#需要增加报警处理
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print("重量变化过小，可能存在堵塞")
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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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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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