456 lines
19 KiB
Python
456 lines
19 KiB
Python
import sys
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import os
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sys.path.append(os.path.dirname(os.path.dirname(os.path.abspath(__file__))))
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import threading
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import time
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import queue
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from core.system_state import SystemState,FeedStatus
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from hardware.relay import RelayController
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from hardware.inverter import InverterController
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from hardware.transmitter import TransmitterController
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from config.ini_manager import ini_manager
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from hardware.upper_plc import OmronFinsPollingService
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from vision.visual_callback_dq import VisualCallback
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from opc.opcua_client_feed import OpcuaClientFeed
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from busisness.blls import ArtifactBll,PDRecordBll
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from busisness.models import ArtifactInfoModel,PDRecordModel
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class FeedingControlSystem:
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def __init__(self):
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print('FeedingControlSystem初始化')
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self.state = SystemState()
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# 初始化硬件控制器
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self.relay_controller = RelayController(
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host=ini_manager.relay_host,
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port=ini_manager.relay_port
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)
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self.inverter_controller = InverterController()
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self.transmitter_controller = TransmitterController(self.relay_controller)
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self.plc_service = OmronFinsPollingService(ini_manager.upper_plc_ip, ini_manager.upper_plc_port)
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# 初始化下料控制器
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self.feeding_controller = VisualCallback(
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relay_controller=self.relay_controller,
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transmitter_controller=self.transmitter_controller,
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state=self.state
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)
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self.plc_service.register_data_callback(self.feeding_controller.on_plc_update)
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#小屏修改过屏幕
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self.vf_auto_mode=True
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# 初始化 OPC UA 客户端
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self.opcua_client_feed = OpcuaClientFeed()
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# 线程管理
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self.feed_thread = None
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self.vf_thread = None
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self.arch_thread = None
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self.api_thread = None
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self.pd_jbl_thread = None
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# 初始化 OPC 队列监听线程,用于处理队列中的数据
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self.opc_queue_thread = None
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def initialize(self)->bool:
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"""初始化系统"""
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print("初始化控制系统...")
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# self.check_device_connectivity()
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#启用上料斗PLC
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self.plc_service.start_polling(interval=2.0)
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#启用下料线程
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self.start_feed_thread()
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#启用变频器线程
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self.start_vf_thread()
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#启用破拱线程
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self.start_arch_thread()
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#启用推送模型数据线程
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self.feeding_controller.start_visual_thread()
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#启用API(对接PD API数据)，线程
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self.start_api_thread()
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#启用派单线程
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self.start_pd_thread()
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# 启动OPC队列处理线程，维护连接的断开重连等
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self.opcua_client_feed.start()
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self.start_opc_queue_thread()
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print("控制系统初始化完成")
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return True
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def start_feed_thread(self):
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"下料线程控制，主要控制下料斗(视觉控制)以及上料斗"
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self.feed_thread = threading.Thread(
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target=self.feeding_controller._run_feed,
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daemon=True
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)
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self.feed_thread.start()
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def start_opc_queue_thread(self):
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"""启动OPC队列处理线程（从控制系统中获取数据，通过OPC外发）"""
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print('启动OPC队列处理线程')
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self.opc_queue_thread = threading.Thread(
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target=self._process_opc_queue,
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daemon=True,
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name='opc_queue_processor'
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)
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self.opc_queue_thread.start()
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def start_api_thread(self):
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"""启动PD线程"""
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# print('启动API处理线程，从API获取未浇筑数据')
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self.api_thread = threading.Thread(
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target=self._process_api_db,
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daemon=True,
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name='api_thread'
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)
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self.api_thread.start()
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def start_vf_thread(self):
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"""启动变频器控制线程(控制变频器开始启动，以及频率变换)"""
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# print('启动API处理线程，从API获取未浇筑数据')
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self.vf_thread = threading.Thread(
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target=self._process_vf,
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daemon=True,
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name='vf_thread'
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)
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self.vf_thread.start()
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def _process_vf(self):
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_begin_time=None
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_wait_times=300
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_start_wait_seconds=None
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while self.state.running:
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try:
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# if self.feeding_controller._is_finish_ratio>=0.6:
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# self.inverter_controller.set_frequency(230)
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# else:
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# self.inverter_controller.set_frequency(220)
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if self.state.vf_status in [1,2]:
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if _begin_time is None :
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print("----浇筑即将启动-----")
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if _start_wait_seconds is None:
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#记录盖板对齐时间
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_start_wait_seconds=time.time()
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if self.feeding_controller._is_finish_ratio>=0.02:
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_elasped_time=time.time()-_start_wait_seconds
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if _elasped_time<10:
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time.sleep(10-_elasped_time)
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self.inverter_controller.control('start',230)
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print("----振捣已经启动-----")
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_begin_time=time.time()
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self.state._mould_frequency=230
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self.state._mould_vibrate_status=True
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if self.state.vf_status==2:
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print("----振捣270s-----")
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_wait_time=270
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else:
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print("----振捣300秒-----")
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_wait_time=300
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else:
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print("----下料重量小于46KG,暂时不振捣-----")
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# else:
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elif self.state.vf_status==3 and _begin_time is not None:
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if time.time()-_begin_time>=_wait_time:
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if self.vf_auto_mode:
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self.inverter_controller.control('stop')
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self.state._mould_vibrate_status=False
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_begin_time=None
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_start_wait_seconds=None
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except Exception as e:
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print(f"处理变频器数据时发生错误: {e}")
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time.sleep(2)
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def _process_api_db(self):
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from service.mould_service import app_web_service
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"""处理API队列中的数据"""
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# 初始化三个列表用于跟踪ArtifactActionID
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processed_artifact_actions = [] # 已处理的ArtifactActionID列表
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processed_artifact_ids = [] # 已处理的ArtifactActionID列表
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processed_pd_records = [] # 已插入PDRecord表的ArtifactActionID列表
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processed_pd_ids=[]
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_model_task=None
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artifact_bll=ArtifactBll()
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pdrecord_bll=PDRecordBll()
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print('启动API处理线程，从API获取未浇筑数据')
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while self.state.running:
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try:
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not_poured = app_web_service.get_not_pour_artifacts()
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if not_poured:
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for item in reversed(not_poured):
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if item.MouldCode is None or item.MouldCode == '':
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continue
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_is_artifactid=True
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# 检查MouldCode是否已处理
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if item.MouldCode in processed_artifact_actions:
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#print(f"待浇筑:MouldCode {item.MouldCode} 已处理，跳过")
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#处理过了。判断是否更新
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if item.ArtifactID is None or item.ArtifactID == '':
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_is_artifactid=False
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if item.ArtifactID in processed_artifact_ids:
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# print(f"待浇筑:ArtifactID {item.ArtifactID} 已处理，跳过")
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_is_artifactid=False
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if _is_artifactid:
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_model_data = ArtifactInfoModel(**item.__dict__)
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_ret=artifact_bll.save_artifact_task(_model_data)
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if _ret > 0:
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# 标记为已处理
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processed_artifact_actions.append(item.MouldCode)
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if len(processed_artifact_actions) > 4:
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processed_artifact_actions.pop(0)
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if item.ArtifactID:
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processed_artifact_ids.append(item.ArtifactID)
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if len(processed_artifact_ids) > 4:
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processed_artifact_ids.pop(0)
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# 限制最多保存3条记录，删除最旧的
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#print(f"待浇筑:已处理MouldCode {item.MouldCode} ArtifactID {item.ArtifactID}")
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if item.MouldCode in processed_pd_records:
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#print(f"派单:MouldCode {item.MouldCode} 已处理，跳过")
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if item.ArtifactID is None or item.ArtifactID == '':
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continue
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if item.ArtifactID in processed_pd_ids:
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#print(f"待浇筑:ArtifactID {item.ArtifactID} 已处理，跳过")
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continue
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_pd_record_data=None
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if item.ArtifactID:
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if item.BetonTaskID is not None and item.BetonTaskID != '':
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#获取taskid
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if _model_task is None or item.BetonTaskID != _model_task.TaskID:
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_model_task = app_web_service.get_task_info(item.BetonTaskID)
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if _model_task is None:
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print(f"异常:BetonTaskID {item.BetonTaskID} 不存在，跳过")
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continue
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_pd_record_data = PDRecordModel(
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ArtifactID=item.ArtifactID,
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ArtifactActionID=item.ArtifactActionID,
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TaskID=_model_task.TaskID,
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ProjectName=_model_task.ProjectName,
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ProduceMixID=_model_task.ProduceMixID,
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BetonGrade=_model_task.BetonGrade,
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BetonVolume=item.BetonVolume,
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MouldCode=item.MouldCode,
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SkeletonID=item.SkeletonID,
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RingTypeCode=item.RingTypeCode,
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SizeSpecification=item.SizeSpecification,
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BuriedDepth=item.BuriedDepth,
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BlockNumber=item.BlockNumber,
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PlannedVolume=_model_task.PlannedVolume
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)
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else:
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_pd_record_data = PDRecordModel(
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MouldCode=item.MouldCode
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)
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if _pd_record_data is None:
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continue
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_ret=pdrecord_bll.save_PD_record(_pd_record_data)
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if _ret > 0:
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# 标记为已处理
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processed_pd_records.append(item.MouldCode)
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# 限制最多保存3条记录，删除最旧的
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if len(processed_pd_records) > 4:
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processed_pd_records.pop(0)
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if item.ArtifactID:
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processed_pd_ids.append(item.ArtifactID)
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if len(processed_pd_ids) > 4:
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processed_pd_ids.pop(0)
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#print(f"派单:已处理MouldCode {item.MouldCode} ArtifactID {item.ArtifactID}")
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except Exception as e:
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print(f"处理MouldCode {item.MouldCode} 时发生错误: {e}")
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time.sleep(5)
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def _process_opc_queue(self):
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"""处理OPC队列中的数据"""
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while self.state.running:
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try:
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# 从队列中获取数据，设置超时以允许线程退出
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item = self.state.opc_queue.get(timeout=1)
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if item:
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public_name, value = item
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# 这里可以添加实际的OPC处理逻辑
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print(f"Processing OPC update: {public_name} = {value}")
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self.opcua_client_feed.write_value_by_name(public_name, value)
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# 标记任务完成
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self.state.opc_queue.task_done()
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except queue.Empty:
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# 队列为空，继续循环
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continue
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except Exception as e:
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print(f"OPC队列处理错误: {e}")
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def angle_visual_callback(self, current_angle, overflow_detected, mould_aligned):
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"""角度视觉回调"""
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self.feeding_controller.angle_visual_callback(current_angle, overflow_detected, mould_aligned)
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def diff_visual_callback(self, current_diff,current_area):
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"""差异视觉回调"""
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self.feeding_controller.diff_visual_callback(current_diff,current_area)
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def shutdown(self):
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"""关闭系统"""
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self.feeding_controller.shutdown()
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self.stop()
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def start_arch_thread(self):
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"""启动系统监控和要料"""
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print('振动和要料监控线程启动')
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#启动振动线程
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self.arch_thread = threading.Thread(
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target=self.feeding_controller._arch_loop,
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daemon=True,
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name='arch'
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)
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self.arch_thread.start()
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def check_device_connectivity(self) -> bool:
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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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# 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 start_pd_thread(self):
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"""启动PD线程"""
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print('启动派单处理线程，从API获取未浇筑数据')
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self.pd_jbl_thread = threading.Thread(
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target=self._process_pd_jbl,
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daemon=True,
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name='pd_jbl_thread'
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)
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self.pd_jbl_thread.start()
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def _process_pd_jbl(self):
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# pass
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#根据当前浇筑块进行最近一块的派单
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_isFinish=False
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_start_time=None
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while self.state.running:
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#增加生产阶段检测，
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if self.state._feed_status==FeedStatus.FCheckGB:
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if not _isFinish:
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if _start_time is None:
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_start_time=time.time()
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_isSuccess=self.feeding_controller.send_pd_data()
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if _isSuccess:
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_isFinish=True
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if time.time()-_start_time>60:
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print('派单超时，人工介入')
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_isFinish=True
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elif self.state._feed_status==FeedStatus.FFinished:
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_start_time=None
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_isFinish=False
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time.sleep(5)
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def start_led(self):
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"""启动LED流程"""
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self.led_thread = threading.Thread(
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target=self._start_led,
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name="LED",
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daemon=True
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)
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self.led_thread.start()
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def _start_led(self):
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"""启动LED流程"""
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from service.mould_service import app_web_service
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while self.state.running:
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led_info = app_web_service.get_pouring_led()
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if led_info:
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if self.state.current_artifact.MouldCode==led_info.MouldCode:
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led_info.RingTypeCode=self.state.current_artifact.RingTypeCode
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led_info.UpperWeight=self.state._upper_weight
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led_info.LowerWeight=self.state._lower_weight
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led_info.VibrationFrequency=self.state._mould_frequency
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#发送到LED屏
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time.sleep(app_set_config.led_interval)
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@property
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def _is_finish(self):
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"""检查系统是否运行"""
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return self.feeding_controller._is_finish
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@property
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def _is_finish_ratio(self):
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"""检查系统是否运行"""
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return self.feeding_controller._is_finish_ratio
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@property
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def vibrate_status(self):
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"""检查系统是否运行"""
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return self.state._mould_vibrate_status
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def set_vf_mode(self,is_auto=False):
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"""设置变频器为自动模式"""
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self.vf_auto_mode=is_auto
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def stop(self):
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"""停止系统"""
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print("停止控制系统...")
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self.state.running = False
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# 等待线程结束
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if self.opc_queue_thread:
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self.opc_queue_thread.join()
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if self.vf_thread:
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self.vf_thread.join()
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if self.api_thread:
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self.api_thread.join()
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if self.pd_jbl_thread:
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self.pd_jbl_thread.join()
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if self.feed_thread:
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self.feed_thread.join()
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if self.arch_thread:
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self.arch_thread.join()
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if self.plc_service:
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self.plc_service.stop_polling()
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self.feeding_controller.shutdown()
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# 释放摄像头资源
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# self.camera_controller.release()
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print("控制系统已停止")
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if __name__ == "__main__":
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system = FeedingControlSystem()
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system.initialize()
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time.sleep(2)
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system.state._upper_weight=1000
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while True:
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time.sleep(1)
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