635 lines
27 KiB
Python
635 lines
27 KiB
Python
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from cv2.gapi import ov
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from config.settings import app_set_config
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from hardware.relay import RelayController
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from hardware.transmitter import TransmitterController
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import time
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import threading
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from datetime import datetime
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from hardware.upper_plc import OmronFinsPollingService
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class VisualCallback:
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# 类变量，用于存储实例引用，实现单例检测
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_instance = None
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_lock = threading.Lock()
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def __new__(cls):
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"""检测实例是否存在，实现单例模式"""
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with cls._lock:
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if cls._instance is None:
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cls._instance = super().__new__(cls)
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return cls._instance
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def __init__(self):
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"""初始化视觉回调处理器"""
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# 避免重复初始化
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if hasattr(self, '_initialized') and self._initialized:
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return
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self.angle_mode = "normal"
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self.relay_controller = RelayController()
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self.transmitter_controller = TransmitterController(self.relay_controller)
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self.init_weight = 100
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self.mould_finish_weight = 0
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self.mould_need_weight = 100
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self.finish_count = 0
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self.overflow = False
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self.is_start_visual=False
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# 线程安全的参数传递
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self._current_angle = None
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self._overflow_detected = None
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self._new_data_available = threading.Event()
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self._is_processing = threading.Lock()
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self._stop_event = threading.Event()
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# 添加下料斗门控制锁，防止两个线程同时控制
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self._door_control_lock = threading.Lock()
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# 记录当前控制门的线程名称，用于调试
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self._current_controlling_thread = None
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# 新增标志位：指示safe_control_lower_close是否正在执行
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self._is_safe_closing = False
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self._is_feed_start=True
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# 创建并启动单个持续运行的线程
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self.callback_thread = threading.Thread(
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target=self._run_thread_loop,
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daemon=True
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)
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self.callback_thread.start()
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self.feed_thread = threading.Thread(
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target=self._run_feed,
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daemon=True
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)
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self.feed_thread.start()
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self._before_finish_time=None
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self._is_before_finish=False
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self._is_finish=False
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# self._is_finish_ratio=0
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#是否震荡关闭平面（设想90%后关闭几秒，让液面平整）
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# self._is_zd_close=False
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# 初始化控制间隔和堆料状态跟踪属性
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self._last_overflow_state = False
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self._last_control_time = 0
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self._initialized = True
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self.plc_data=None
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# self.plc_data=5
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self.plc_service = OmronFinsPollingService("192.168.250.233")
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self.plc_service.register_data_callback(self.on_plc_update)
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# self.plc_service.register_status_callback(self.on_status_change)
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self.plc_service.start_polling(interval=2.0)
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def angle_visual_callback(self, current_angle, overflow_detected):
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"""
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视觉控制主逻辑，供外部推送数据
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使用单个持续运行的线程，通过参数设置传递数据
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如果线程正在处理数据，则丢弃此次推送
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"""
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#print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到推送数据")
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# 尝试获取处理锁，若失败则说明正在处理，丢弃数据
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if not self._is_processing.acquire(blocking=False):
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print("回调线程仍在执行，丢弃此次推送数据")
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return
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try:
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# 更新参数
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if overflow_detected is not None:
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#print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到溢料:{overflow_detected}")
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self._overflow_detected = overflow_detected
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if current_angle is not None:
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#print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到角度:{current_angle}")
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self._current_angle = current_angle
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# 通知线程有新数据可用
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self._new_data_available.set()
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finally:
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# 释放处理锁
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self._is_processing.release()
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def _run_thread_loop(self):
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"""
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线程主循环，持续运行
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等待新数据，然后调用处理方法
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"""
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while not self._stop_event.is_set():
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# 等待新数据可用
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self._new_data_available.wait()
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# 重置事件
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self._new_data_available.clear()
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# 获取当前参数（使用临时变量避免被其他线程修改）
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current_angle = self._current_angle
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overflow_detected = self._overflow_detected
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self._is_feed_start=True
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if self.is_start_visual:
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# 处理数据
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self._process_angle_callback(current_angle, overflow_detected)
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time.sleep(0.1)
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def _run_feed(self):
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while True:
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print("------------已启动----------------")
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if self._is_feed_start:
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if self.plc_data==5:
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self.run_feed()
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break
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else:
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print("-----------上料斗未就位----------------")
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print("-----------上料斗未就位----------------")
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time.sleep(0.5)
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def safe_control_lower_close(self,duration=3):
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"""线程安全的下料斗关闭方法"""
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thread_name = threading.current_thread().name
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print(f"[{thread_name}] 尝试关闭下料斗...")
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# 设置标志位，指示正在执行安全关闭操作
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self._is_safe_closing = True
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try:
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with self._door_control_lock:
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self._current_controlling_thread = thread_name
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print(f"[{thread_name}] 获得下料斗控制权，执行关闭操作")
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'open')
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time.sleep(duration)
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self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
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self._current_controlling_thread = None
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print(f"[{thread_name}] 释放下料斗控制权")
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finally:
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# 无论成功失败，都要重置标志位
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self._is_safe_closing = False
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def run_feed(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("--------------------开始下料--------------------")
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loc_relay=self.relay_controller
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loc_mitter=self.transmitter_controller
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initial_lower_weight=loc_mitter.read_data(2)
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initial_upper_weight=loc_mitter.read_data(1)
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first_finish_weight=0
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# need_total_weight=1.91*2416
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start_time=None
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self.is_start_visual=True
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if initial_lower_weight>100:
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#下料斗的料全部下完
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while not self._is_finish:
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loc_mitter.is_start_lower=True
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current_weight = loc_mitter.read_data(2)
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first_finish_weight=initial_lower_weight-current_weight
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if current_weight<500:
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# 破拱控制
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if start_time is None or time.time()-start_time>5:
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start_time=time.time()
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loc_relay.control_arch_lower_open()
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if current_weight<250:
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start_time=None
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self.is_start_visual=False
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loc_mitter.is_start_lower=False
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time.sleep(0.5)
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self.safe_control_lower_close()
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break
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print(f'------------已下料: {first_finish_weight}kg-------------')
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time.sleep(1)
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# _current_lower_weight=loc_mitter.read_data(2)
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# first_finish_weight=initial_lower_weight-_current_lower_weight
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# initial_lower_weight=_current_lower_weight
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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if self.plc_data==5:
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print(f'------------上料斗向下料斗转移(留3000KG）-------------')
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#打开上料斗出砼门，开5就，开三分之一下
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loc_relay.control_upper_open_sync(6)
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loc_time_count=1
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upper_open_time=time.time()
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while not self._is_finish:
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loc_mitter.is_start_upper=True
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current_upper_weight = loc_mitter.read_data(1)
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if current_upper_weight<3000:
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#关5秒,loc_time_count多关一秒
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loc_relay.control_upper_close_sync(4+loc_time_count)
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loc_mitter.is_start_upper=False
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break
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else:
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if time.time()-upper_open_time>5:
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upper_open_time=time.time()
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loc_relay.control_upper_open_sync(0.5)
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loc_time_count=loc_time_count+0.5
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else:
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time.sleep(0.5)
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# time.sleep(0.4)
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self.is_start_visual=True
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loc_mitter.is_start_lower=False
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loc_mitter.test_lower_weight=2000
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initial_lower_weight=loc_mitter.read_data(2)
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while not self._is_finish:
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loc_mitter.is_start_lower=True
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current_weight = loc_mitter.read_data(2)
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second_finish_weight=initial_lower_weight-current_weight
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if current_weight<500:
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#关5秒
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if start_time is None or time.time()-start_time>5:
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start_time=time.time()
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loc_relay.control_arch_lower_open()
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if current_weight<250:
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start_time=None
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self.is_start_visual=False
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loc_mitter.is_start_lower=False
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time.sleep(0.5)
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self.safe_control_lower_close()
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break
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print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
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time.sleep(1)
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# _current_lower_weight=loc_mitter.read_data(2)
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# first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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if self.plc_data==5:
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#第二次上料斗向下料斗转移
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loc_relay.control_upper_open_sync(6)
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loc_time_count=1
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upper_open_time=time.time()
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loc_mitter.is_start_upper=False
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loc_mitter.test_upper_weight=3000
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#第二次到下料斗还需要的量
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#loc_left_need_weight=need_total_weight-first_finish_weight
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initial_upper_weight=loc_mitter.read_data(1)
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start_time=None
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while not self._is_finish:
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# print(f'------------上料斗向下料斗转移22222-------------')
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loc_mitter.is_start_upper=True
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current_upper_weight = loc_mitter.read_data(1)
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if current_upper_weight<500:
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#关5秒,loc_time_count多关一秒
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if start_time is None or time.time()-start_time>4:
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start_time=time.time()
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loc_relay.control_arch_upper_open()
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if current_upper_weight<100:
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start_time=None
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loc_relay.control_upper_close_sync(4+loc_time_count)
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loc_mitter.is_start_upper=False
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break
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else:
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if time.time()-upper_open_time>3:
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upper_open_time=time.time()
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loc_relay.control_upper_open_sync(0.8)
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loc_time_count=loc_time_count+0.8
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else:
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time.sleep(0.5)
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# time.sleep(0.4)
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#第二次下料斗转移到模具车
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if not self._is_finish:
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self.is_start_visual=True
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# loc_mitter.is_start_lower=False
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# loc_mitter.test_lower_weight=2000
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# initial_lower_weight=loc_mitter.read_data(2)
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# while not self._is_finish:
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# loc_mitter.is_start_lower=True
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# current_weight = loc_mitter.read_data(2)
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# second_finish_weight=initial_lower_weight-current_weight
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# # self._is_finish_ratio=(second_finish_weight+first_finish_weight)/need_total_weight
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# # print(f'------------已下料比例: {self._is_finish_ratio}-------------')
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# if current_weight<500:
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# #关5秒
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# if start_time is None or time.time()-start_time>5:
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# start_time=time.time()
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# loc_relay.control_arch_lower_open()
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# print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
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# time.sleep(1)
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# _current_lower_weight=loc_mitter.read_data(2)
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# first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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# print(f'------------已下料: {first_finish_weight}kg-------------')
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print(f'------------已完成-------------')
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def _process_angle_callback(self, current_angle, overflow_detected):
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"""
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实时精细控制 - 基于PID思想，无固定间隔
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"""
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try:
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# 记录控制时间戳（用于微分计算，而非限制）
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current_time = time.time()
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# 确保所有PID相关属性都被正确初始化
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if not hasattr(self, '_last_control_time'):
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self._last_control_time = current_time
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if not hasattr(self, '_last_error'):
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self._last_error = 0
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if not hasattr(self, '_error_integral'):
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self._error_integral = 0
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# print(f"{self.angle_mode}")
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self.overflow = overflow_detected in ["大堆料", "小堆料"]
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if current_angle is None:
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return
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print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 角度11: {current_angle:.2f}°,{overflow_detected}")
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if overflow_detected == "未浇筑满" or self._is_before_finish:
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if self._before_finish_time is None:
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self._before_finish_time=current_time
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self.safe_control_lower_close(3)
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print('-----------------关闭--------------------')
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# time.sleep(3)
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else:
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if overflow_detected=='浇筑满':
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self.is_start_visual=False
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self._is_finish=True
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self.safe_control_lower_close(3)
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elif overflow_detected=="大堆料":
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print(f'--------未浇筑满，大堆料，不开关-----------')
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else:
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self._pulse_control('open',0.5)
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time.sleep(0.3)
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self._pulse_control('close',0.6)
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time.sleep(2)
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self._is_before_finish=True
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return
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elif overflow_detected == "浇筑满":
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self.is_start_visual=False
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self._is_finish=True
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self.safe_control_lower_close(3)
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return
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else:
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self._before_finish_time=None
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# if self._is_finish_ratio>=0.8:
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# if overflow_detected == "大堆料":
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# TARGET_ANGLE = 10.0 # 大堆料时控制在15度左右
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# elif overflow_detected == "小堆料":
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# TARGET_ANGLE = 20.0 # 小堆料时控制在35度左右
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# else:
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# TARGET_ANGLE = 25.0 # 未溢料时开到最大56度
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# if self._is_finish_ratio>=0.9 and not self._is_zd_close:
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# #关闭10秒，直接关闭，不等待
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# print('-----------------达到90% 关闭--------------------')
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# self._is_zd_close=True
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# self.safe_control_lower_close()
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# time.sleep(10)
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# return
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# else:
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#根据溢料状态动态调整目标角度
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if overflow_detected == "大堆料":
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TARGET_ANGLE = 15.0 # 大堆料时控制在15度左右
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elif overflow_detected == "小堆料":
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TARGET_ANGLE = 25.0 # 小堆料时控制在35度左右
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else:
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TARGET_ANGLE = 45.0 # 未溢料时开到最大56度
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# 确保目标角度在硬件范围内（5-56度）
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TARGET_ANGLE = max(5.0, min(56.0, TARGET_ANGLE))
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# PID控制参数
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KP = 0.15 # 比例系数
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KI = 0 # 积分系数
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KD = 0 # 微分系数
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# KP = 0.15 # 比例系数
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# KI = 0.008 # 积分系数
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# KD = 0.08 # 微分系数
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# if TARGET_ANGLE <= 25.0:
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# KP, KI, KD = 0.18, 0.008, 0.08 # 小角度，强控制
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# elif TARGET_ANGLE <= 40.0:
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# KP, KI, KD = 0.15, 0.01, 0.06 # 中角度
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# else:
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# KP, KI, KD = 0.12, 0.012, 0.04 # 大角度，温和控制
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# 计算误差
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error = current_angle - TARGET_ANGLE
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dt = current_time - self._last_control_time
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# 积分项（抗饱和）
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self._error_integral += error * dt
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self._error_integral = max(min(self._error_integral, 50), -50) # 积分限幅
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# 微分项
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error_derivative = (error - self._last_error) / dt if dt > 0 else 0
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# PID输出
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pid_output = (KP * error + KI * self._error_integral + KD * error_derivative)
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print(f"📊 PID计算: 误差={error:.2f}°, 积分={self._error_integral:.2f}, "
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f"微分={error_derivative:.2f}, 输出={pid_output:.2f}")
|
||
# 更新历史值
|
||
self._last_error = error
|
||
self._last_control_time = current_time
|
||
|
||
# 状态机 + PID控制
|
||
|
||
if self.angle_mode == "normal":
|
||
self._normal_mode_advanced(current_angle, pid_output,TARGET_ANGLE)
|
||
|
||
elif self.angle_mode == "reducing":
|
||
self._reducing_mode_advanced(current_angle, pid_output, TARGET_ANGLE)
|
||
|
||
elif self.angle_mode == "maintaining":
|
||
self._maintaining_mode_advanced(current_angle, pid_output, TARGET_ANGLE)
|
||
|
||
except Exception as e:
|
||
print(f"处理视觉回调时发生异常: {e}")
|
||
|
||
def _normal_mode_advanced(self, current_angle, pid_output,target_angle):
|
||
"""高级正常模式控制"""
|
||
if self.overflow:
|
||
self.angle_mode = "reducing"
|
||
print("检测到溢料，切换到减小模式")
|
||
return
|
||
|
||
# 🎯 修复1: 添加强制控制机制
|
||
|
||
|
||
# 基于PID输出的智能控制
|
||
control_threshold = 2 # 从2.0减小到0.5，提高灵敏度
|
||
|
||
if abs(pid_output) > control_threshold:
|
||
if pid_output > 0:
|
||
# 需要减小角度（关门）
|
||
pulse_time = min(0.3, pid_output * 0.1)
|
||
self._pulse_control("close", pulse_time)
|
||
print(f"正常模式: 角度偏高{pid_output:.1f}，关门{pulse_time:.2f}秒")
|
||
else:
|
||
# 需要增大角度（开门）
|
||
pulse_time = min(0.3, abs(pid_output) * 0.1)
|
||
self._pulse_control("open", pulse_time)
|
||
print(f"正常模式: 角度偏低{abs(pid_output):.1f}，开门{pulse_time:.2f}秒")
|
||
else:
|
||
# 在死区内，保持静止
|
||
error = current_angle - target_angle
|
||
abs_error = abs(error)
|
||
|
||
# 强制控制：如果误差超过5度，强制控制
|
||
if abs_error > 5:
|
||
if error > 0: # 当前角度 > 目标角度，需要关门
|
||
pulse_time=0.1 # 根据误差计算脉冲时间
|
||
self._pulse_control("close", pulse_time)
|
||
print(f"🚨 强制关门: 误差{abs_error:.1f}°过大，脉冲{pulse_time:.3f}s")
|
||
else: # 当前角度 < 目标角度，需要开门
|
||
pulse_time =0.1
|
||
self._pulse_control("open", pulse_time)
|
||
print(f"🚨 强制开门: 误差{abs_error:.1f}°过大，脉冲{pulse_time:.3f}s")
|
||
return
|
||
else:
|
||
self._stop_door()
|
||
print(f"正常模式: 角度在目标范围内，保持静止")
|
||
|
||
def _reducing_mode_advanced(self, current_angle, pid_output, target_angle):
|
||
"""高级减小模式控制"""
|
||
if not self.overflow:
|
||
if current_angle <= target_angle + 5.0:
|
||
self.angle_mode = "normal"
|
||
print("溢料消除且角度合适，返回正常模式")
|
||
else:
|
||
# 缓慢恢复
|
||
self._pulse_control("close", 0.1)
|
||
return
|
||
|
||
# 有溢料，积极减小角度
|
||
if current_angle > target_angle:
|
||
# 使用PID输出计算控制量
|
||
pulse_time = min(0.5, max(0.1, pid_output * 0.15))
|
||
self._pulse_control("close", pulse_time)
|
||
print(f"减小模式: 积极关门{pulse_time:.2f}秒，PID输出:{pid_output:.1f}")
|
||
else:
|
||
self.angle_mode = "maintaining"
|
||
print("角度已达标，进入维持模式")
|
||
|
||
def _maintaining_mode_advanced(self, current_angle, pid_output, target_angle):
|
||
"""高级维持模式控制"""
|
||
if not self.overflow:
|
||
self.angle_mode = "normal"
|
||
print("溢料消除，返回正常模式")
|
||
return
|
||
|
||
# 精确维持控制
|
||
dead_zone = 1.5 # 更小的死区
|
||
|
||
if abs(pid_output) > dead_zone:
|
||
pulse_time = min(0.2, abs(pid_output) * 0.05) # 更精细的控制
|
||
|
||
if pid_output > 0:
|
||
self._pulse_control("close", pulse_time)
|
||
print(f"维持模式: 微调关门{pulse_time:.2f}秒")
|
||
else:
|
||
self._pulse_control("open", pulse_time)
|
||
print(f"维持模式: 微调开门{pulse_time:.2f}秒")
|
||
else:
|
||
self._stop_door()
|
||
print("维持模式: 角度精确控制中")
|
||
|
||
def _pulse_control(self, action, duration):
|
||
"""统一的脉冲控制方法"""
|
||
# 检查是否正在执行safe_control_lower_close，如果是则跳过relay操作
|
||
if self._is_safe_closing:
|
||
thread_name = threading.current_thread().name
|
||
print(f"[{thread_name}] safe_control_lower_close正在执行，跳过脉冲控制 {action}")
|
||
return
|
||
|
||
if duration <= 0:
|
||
return
|
||
|
||
thread_name = threading.current_thread().name
|
||
print(f"[{thread_name}] 尝试脉冲控制 {action}，时长 {duration:.2f}秒...")
|
||
|
||
with self._door_control_lock:
|
||
self._current_controlling_thread = thread_name
|
||
print(f"[{thread_name}] 获得下料斗控制权，执行脉冲控制")
|
||
|
||
if action == "open":
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'open')
|
||
time.sleep(duration)
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
||
print(f"[{thread_name}] 开门脉冲: {duration:.2f}秒")
|
||
else: # close
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'open')
|
||
time.sleep(duration)
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
||
print(f"[{thread_name}] 关门脉冲: {duration:.2f}秒")
|
||
|
||
self._current_controlling_thread = None
|
||
print(f"[{thread_name}] 释放下料斗控制权")
|
||
|
||
def _stop_door(self):
|
||
"""停止门运动"""
|
||
# 检查是否正在执行safe_control_lower_close，如果是则跳过relay操作
|
||
if self._is_safe_closing:
|
||
thread_name = threading.current_thread().name
|
||
print(f"[{thread_name}] safe_control_lower_close正在执行，跳过停止门运动操作")
|
||
return
|
||
|
||
thread_name = threading.current_thread().name
|
||
print(f"[{thread_name}] 尝试停止门运动...")
|
||
|
||
with self._door_control_lock:
|
||
self._current_controlling_thread = thread_name
|
||
print(f"[{thread_name}] 获得下料斗控制权，执行停止操作")
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_OPEN, 'close')
|
||
self.relay_controller.control(self.relay_controller.DOOR_LOWER_CLOSE, 'close')
|
||
self._current_controlling_thread = None
|
||
print(f"[{thread_name}] 释放下料斗控制权")
|
||
|
||
def _open_door(self, duration=0.5):
|
||
"""打开门"""
|
||
self._pulse_control("open", 0.3)
|
||
|
||
def _close_door(self, duration=0.5):
|
||
"""关闭门"""
|
||
self._pulse_control("close", 1)
|
||
|
||
def on_plc_update(self,data: int, binary: str):
|
||
#4即将振捣室5振捣室 64即将搅拌楼 66到达搅拌楼
|
||
print(f"[数据回调] 数值: 0x{data:02X} | 十进制: {data:3d} | 二进制: {binary}")
|
||
self.plc_data=data
|
||
|
||
@classmethod
|
||
def instance_exists(cls):
|
||
"""检测实例是否存在"""
|
||
return cls._instance is not None
|
||
|
||
def shutdown(self):
|
||
"""关闭线程，清理资源"""
|
||
# 设置停止事件
|
||
self._stop_event.set()
|
||
# 唤醒线程以便它能检测到停止事件
|
||
self._new_data_available.set()
|
||
|
||
if self.plc_service:
|
||
self.plc_service.stop_polling()
|
||
# 等待线程结束
|
||
if self.callback_thread.is_alive():
|
||
self.callback_thread.join(timeout=1.0)
|
||
|
||
def __del__(self):
|
||
"""析构函数，确保线程安全关闭"""
|
||
self.shutdown()
|
||
|
||
# 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)
|