1494 lines
70 KiB
Python
1494 lines
70 KiB
Python
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from pickle import FALSE
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from re import S
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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 core.relay_feed import RelayFeedController
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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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import logging
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import queue
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from hardware.upper_plc import OmronFinsPollingService
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from vision.muju_cls.muju_utils import run_stable_classification_loop
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from vision.camera_picture import save_camera_picture
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from busisness.blls import ArtifactBll,PDRecordBll
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from busisness.models import ArtifactInfoModel,PDRecordModel
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from service.mould_service import app_web_service
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from core.system_state import SystemState,FeedStatus,Upper_Door_Position,PD_StatusEnum
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from core.core_utils import CoreUtils
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from dataclasses import asdict
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import json
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import math
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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,*args, **kwargs):
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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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relay_controller:RelayController,
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transmitter_controller:TransmitterController,
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state:SystemState=None):
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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.relay_controller = relay_controller
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self.transmitter_controller = transmitter_controller
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self.relay_feed=RelayFeedController(relay_controller,state)
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self.pd_record_bll=PDRecordBll()
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self.state=state
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# 线程安全的参数传递
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self._new_data_available = threading.Event()
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self._is_processing = threading.Lock()
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#diff参数
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self._is_processing_diff = threading.Lock()
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self._new_data_diff = threading.Event()
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self._current_diff=0
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self._current_diff_area=[]
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self._is_diff_save=False
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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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#是否启动后的第一个模具
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self._is_first_module=True
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#上一次派单方量
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self.prev_pd_volume=0.0
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self.init_val()
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# self._setup_logging_2()
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#F块完成重量的70%，控制夹脚，F块多于这个比例就没有记录了（注意）
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self._max_f_angle_ratio=0.7
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#完成多少，调整角度比例 ，多于0.8就没记录了（注意）
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self._max_angle_radio=0.8
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#重量大于95%，停留时间2秒，其他的1秒
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self._weight_ratio_955=0.955
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#完成多少，忽略未浇筑满
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self._max_ignore_radio=0.8
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self._mould_accept_aligned=None
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self._mould_before_aligned=False
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#模具开始浇筑时间
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self._time_mould_begin=''
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#模具结束浇筑时间
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self._time_mould_end=''
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#记录当前模具信息model
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self._cur_mould_model=None
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self.plc_valid_data=[5,37]
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self.plc_valid_data_jbl=[66,98]
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# self.db_queue=queue.Queue()
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# 获取视觉数据线程（angle_visual_callback推送的数据），并进行处理，注意处理视觉进行夹角控制
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self.callback_thread = None
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self.diff_thread = None
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def init_val(self):
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#初始化值
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"""初始化视觉回调处理器"""
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self.angle_mode = "normal"
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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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# 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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#未浇筑满时间，用于确定是否进入未浇筑满
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self._before_finish_time=None
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#进入未浇筑满状态标志位
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self._is_before_finish=False
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#是否浇筑满标志位
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self._is_finish=False
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#用于保存diff标志位
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# self._is_diff_save=False
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#用于判断当前判断是否对齐(diff)
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self._is_diff_unaligned=False
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self._diff_f_val=0
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self._diff_f_area=[]
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#浇筑完成比例（重量）
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self._is_finish_ratio=0
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#下料阶段，汇总时用枚举
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self._is_feed_stage=0
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#振动相关参数
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self._last_arch_one_weight=0
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self._last_arch_two_weight=0
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self._last_arch_three_weight=0
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self._last_arch_four_weight=0
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self._last_arch_five_weight=0
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self._last_arch_time=0
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#是否为F块
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self._is_small_f=None
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#采集数据用，下料重量=之前下的重量+最后一阶段(下-->模具车)重量差
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#记录最后一次下料斗到模具车前的重量
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self._finish_weight=0
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#记录最后一次下料斗到车初始重量
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self._inital_finish_lweight=0
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#记录视觉停止下料时的重量（计算后面加了多少）
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self._last_lower_weight=0
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#每片开始下料斗的重量
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self._init_lower_weight=0
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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._is_running=True
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self._is_stop_one_seconds=False
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self._initialized = True
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self.plc_data=None
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self._mould_need_weight=0
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#点动等级
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self._point_speed_grade=0
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self._point_weight=0
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def start_visual_thread(self)->bool:
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"""浇筑状态回调线程"""
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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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#diff线程值传递后处理
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self.diff_thread = threading.Thread(
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target=self._diff_temp,
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daemon=True
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)
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self.diff_thread.start()
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return True
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def angle_visual_callback(self, current_angle, overflow_detected, mould_aligned):
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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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if mould_aligned is not None:
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#print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到对齐:{mould_aligned}")
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self._mould_accept_aligned=mould_aligned
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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 diff_visual_callback(self, current_diff,current_area):
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"""
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视觉模型diff回调
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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_diff.acquire(blocking=False):
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print("222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 current_diff is not None:
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# print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到diff:{current_diff}")
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self._current_diff = current_diff
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self._diff_f_val=current_diff
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if current_area is not None:
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# print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 收到area:{current_area}")
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self._current_diff_area = current_area
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self._diff_f_area = current_area
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# 通知线程有新数据可用
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self._new_data_diff.set()
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finally:
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# 释放处理锁
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self._is_processing_diff.release()
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def _diff_temp(self):
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"""
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接受视觉回调数据
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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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_temp_diff_count=0
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_temp_area_count=0
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_temp_diff_str2=''
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_temp_area_str2=''
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while not self._stop_event.is_set():
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# print('-----等待diff 数据------')
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# 等待新数据可用
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self._new_data_diff.wait()
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# 重置事件
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self._new_data_diff.clear()
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#_is_diff_save是否完成此片
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if self._is_diff_save:
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# print('-----进入diff 数据------')
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#完成了此片，然后是对齐状态
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if not self._is_diff_unaligned:
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# 处理数据
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# print('-----进入对齐数据------')
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if self._current_diff is not None and self._current_diff_area is not None:
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_timestamp = datetime.now().strftime("%Y-%m-%d %H:%M:%S")
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if _temp_diff_count<=10 and self._current_diff!=0:
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_temp_diff_str=f"diff , {_timestamp} , {self._current_diff}\n"
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_temp_diff_count+=1
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with open('weight.txt', 'a') as f:
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f.write(_temp_diff_str+'\n')
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# print('-----保存成功(diff 数据)------')
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if _temp_area_count<=10 and self._current_diff_area!=[]:
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_temp_area_str=f"area , {_timestamp} , {str(self._current_diff_area)}\n"
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_temp_area_count+=1
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with open('weight.txt', 'a') as f:
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f.write(_temp_area_str+'\n')
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# print('-----保存成功(area 数据)------')
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if _temp_diff_count>=10 and _temp_area_count>=10:
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self._is_diff_save=False
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time.sleep(1)
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continue
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# else:
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#变成了未对齐，拉起盖板后，重新计数
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# if _temp_diff_count>=10 and _temp_area_count>=10:
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# _temp_diff_count=0
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# _temp_area_count=0
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# self._is_diff_save=False
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# _temp_diff_str=''
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# _temp_area_str=''
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self._current_diff=0
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self._current_diff_area=[]
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_temp_diff_count=0
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_temp_area_count=0
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_temp_diff_str=''
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_temp_area_str=''
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time.sleep(1)
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def _arch_loop(self):
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"""破拱线程"""
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while self._is_running:
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if self._is_finish:
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time.sleep(2)
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continue
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try:
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current_time = time.time()
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# 检查下料斗破拱（只有在下料过程中才检查）
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if self._is_feed_stage==1: # 下料斗--》模具车
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_arch_weight = self.transmitter_controller.read_data(2)
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if _arch_weight is not None and _arch_weight>0:
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# 检查重量变化是否过慢
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_weight_changed=abs(_arch_weight - self._last_arch_one_weight)
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#_last_arch_one_weight默认为0，一开始就进入振动
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print(f'---------------第一阶段，重量变化:{_weight_changed}------------------')
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if (_weight_changed< 200) and \
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(current_time - self._last_arch_time) >= 2:
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self._last_arch_time = current_time
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print('---------------------第一阶段振动3秒（小于200KG）-----------------')
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if self._current_angle>25:
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self.relay_feed.control_arch_lower_open_sync(3)
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self._last_arch_one_weight = _arch_weight
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continue
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self._last_arch_one_weight = _arch_weight
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elif self._is_feed_stage==2: #上料斗到下料斗，料多，谨慎振动
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_arch_weight = self.transmitter_controller.read_data(1)
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if _arch_weight is not None and _arch_weight>0:
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# 检查重量变化是否过慢
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_weight_changed=abs(_arch_weight - self._last_arch_two_weight)
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print(f'---------------第二阶段，重量变化:{_weight_changed}------------------')
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if (_weight_changed < 100) and \
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(current_time - self._last_arch_time) >= 2:
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self._last_arch_time = current_time
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#print('---------------------第二阶段振动3秒-----------------')
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# self.relay_feed.control_arch_upper_open_sync(3)
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self._last_arch_two_weight = _arch_weight
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continue
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self._last_arch_two_weight = _arch_weight
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elif self._is_feed_stage==3: #第二次下料斗-》模具车
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_arch_weight = self.transmitter_controller.read_data(2)
|
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if _arch_weight is not None and _arch_weight>0:
|
||
#刚开始不需要振动，料太多
|
||
if self._last_arch_three_weight>0:
|
||
_weight_changed=abs(_arch_weight - self._last_arch_three_weight)
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# 检查重量变化是否过慢
|
||
print(f'---------------第三阶段，重量变化:{_weight_changed}------------------')
|
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if (_weight_changed < 100) and \
|
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(current_time - self._last_arch_time) >= 2:
|
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self._last_arch_time = current_time
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print('---------------------第三阶段振动3秒(小于100KG）-----------------')
|
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if self._current_angle>25:
|
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self.relay_feed.control_arch_lower_open_sync(3)
|
||
self._last_arch_three_weight = _arch_weight
|
||
continue
|
||
self._last_arch_three_weight = _arch_weight
|
||
|
||
elif self._is_feed_stage==4: #上料斗--》下料斗
|
||
_arch_weight = self.transmitter_controller.read_data(1)
|
||
if _arch_weight is not None and _arch_weight>0:
|
||
# 检查重量变化是否过慢
|
||
_weight_changed=abs(_arch_weight - self._last_arch_four_weight)
|
||
print(f'---------------第二阶段，重量变化:{_weight_changed}------------------')
|
||
if (_weight_changed < 200) and \
|
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(current_time - self._last_arch_time) > 2:
|
||
self._last_arch_time = current_time
|
||
print('---------------------第四阶段振动5秒-----------------')
|
||
#重量不准，暂时不振动
|
||
# self.relay_feed.control_arch_upper_open_sync(5)
|
||
self._last_arch_four_weight = _arch_weight
|
||
continue
|
||
self._last_arch_four_weight = _arch_weight
|
||
elif self._is_feed_stage==5: #下料斗->模具车
|
||
_arch_weight = self.transmitter_controller.read_data(2)
|
||
if _arch_weight is not None and _arch_weight>0:
|
||
if self._last_arch_five_weight>0:
|
||
_weight_changed=abs(_arch_weight - self._last_arch_five_weight)
|
||
print(f'---------------第五阶段，重量变化:{_weight_changed}------------------')
|
||
_min_arch_weight=20
|
||
if self._is_finish_ratio<self._max_angle_radio:
|
||
_min_arch_weight=50
|
||
if (_weight_changed < _min_arch_weight) and \
|
||
(current_time - self._last_arch_time) >= 2:
|
||
self._last_arch_time = current_time
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||
print(f'---------------------第五阶段振动3秒(小于{_min_arch_weight}kg)）-----------------')
|
||
if self._current_angle>25:
|
||
self.relay_feed.control_arch_lower_open_sync(3)
|
||
self._last_arch_five_weight = _arch_weight
|
||
continue
|
||
self._last_arch_five_weight = _arch_weight
|
||
|
||
# 更新最后读取时间
|
||
self._last_arch_time = current_time
|
||
time.sleep(2)
|
||
except Exception as e:
|
||
print(f"监控线程错误: {e}")
|
||
|
||
def _aligned_get_times(self,flag):
|
||
"""
|
||
获取对齐,1为对齐，0为未对齐
|
||
"""
|
||
_current_times=time.time()
|
||
_temp_aligned_count=0
|
||
if flag==1:
|
||
while time.time()-_current_times<=2:
|
||
# print(f'-------------{self._mould_accept_aligned}-----------------')
|
||
if self._mould_accept_aligned=='盖板对齐':
|
||
_temp_aligned_count=_temp_aligned_count+1
|
||
else:
|
||
_temp_aligned_count=0
|
||
if _temp_aligned_count>0:
|
||
print(f'-------------{datetime.now().strftime("%H:%M:%S")} 盖板对齐,次数：{_temp_aligned_count}-----------------')
|
||
time.sleep(0.2)
|
||
self._mould_accept_aligned=''
|
||
if _temp_aligned_count>=8:
|
||
return True
|
||
else:
|
||
return False
|
||
elif flag==2:
|
||
while time.time()-_current_times<=5:
|
||
|
||
if self._mould_accept_aligned=='盖板未对齐':
|
||
_temp_aligned_count=_temp_aligned_count+1
|
||
else:
|
||
_temp_aligned_count=0
|
||
if _temp_aligned_count>0:
|
||
print(f'-------------{datetime.now().strftime("%H:%M:%S")} 盖板未对齐,次数：{_temp_aligned_count}-----------------')
|
||
time.sleep(0.2)
|
||
|
||
self._mould_accept_aligned=''
|
||
if _temp_aligned_count>=20:
|
||
self._is_diff_unaligned=True
|
||
return True
|
||
else:
|
||
self._is_diff_unaligned=False
|
||
return False
|
||
|
||
def _no_aligned_diff(self):
|
||
"""
|
||
diff 未对齐检测
|
||
"""
|
||
_current_times=time.time()
|
||
_temp_aligned_count=0
|
||
while time.time()-_current_times<=1:
|
||
# print(f'-------------{self._mould_accept_aligned}-----------------')
|
||
if self._mould_accept_aligned=='盖板未对齐':
|
||
_temp_aligned_count=_temp_aligned_count+1
|
||
else:
|
||
_temp_aligned_count=0
|
||
# print(f'-------------{datetime.now().strftime("%H:%M:%S")} 盖板对齐,次数：{_temp_aligned_count}-----------------')
|
||
time.sleep(0.2)
|
||
if _temp_aligned_count>=3:
|
||
return True
|
||
else:
|
||
return False
|
||
|
||
|
||
def _run_thread_loop(self):
|
||
"""
|
||
接受视觉回调数据
|
||
线程主循环，持续运行
|
||
等待新数据，然后调用处理方法
|
||
"""
|
||
while not self._stop_event.is_set():
|
||
# 等待新数据可用
|
||
self._new_data_available.wait()
|
||
|
||
# 重置事件
|
||
self._new_data_available.clear()
|
||
|
||
# 获取当前参数（使用临时变量避免被其他线程修改）
|
||
current_angle = self._current_angle
|
||
overflow_detected = self._overflow_detected
|
||
self._is_feed_start=True
|
||
|
||
if self.is_start_visual:
|
||
# 处理数据
|
||
self._process_angle_callback(current_angle, overflow_detected)
|
||
time.sleep(0.1)
|
||
|
||
def _run_feed(self):
|
||
_is_api_request=True
|
||
while self.state.running:
|
||
# print("------------已启动----------------")
|
||
if self._is_feed_start:
|
||
|
||
# if self.plc_data==5:
|
||
#_is_finish_ratio完成 比例，根据重量过滤一下
|
||
|
||
if self._is_first_module and self._overflow_detected=='未堆料':
|
||
#第一次打开 ，未堆料，检测对齐
|
||
if _is_api_request:
|
||
self.get_current_mould()
|
||
_is_api_request=False
|
||
_is_aligned=self._aligned_get_times(1)
|
||
if _is_aligned:
|
||
_is_api_request=True
|
||
if self.state.pd_status==PD_StatusEnum.PD_Ready:
|
||
self.state.pd_status=PD_StatusEnum.PD_TimeOut
|
||
print('------------启动程序后，进入第一块-------------')
|
||
self._is_first_module=False
|
||
self._mould_before_aligned=True
|
||
if self._cur_mould_model:
|
||
self.state.current_mould=self._cur_mould_model
|
||
self.state.current_block_number=CoreUtils.get_number_by_mould_code(self._cur_mould_model.MouldCode)
|
||
self.state._db_mould_status={
|
||
'mould_code':self._cur_mould_model.MouldCode,
|
||
'status':2,
|
||
'weight':0,
|
||
}
|
||
else:
|
||
self.state.current_mould=None
|
||
self.state.current_block_number=''
|
||
|
||
|
||
_current_weight=self.transmitter_controller.read_data(2)
|
||
if _current_weight:
|
||
self._init_lower_weight=_current_weight
|
||
else:
|
||
print('------------获取上料斗重量失败-------------')
|
||
return
|
||
|
||
self.state._feed_status=FeedStatus.FCheckGB
|
||
# if not self.state.current_block_number=='F':
|
||
# self.state.pd_status=PD_StatusEnum.PD_Ready
|
||
# self.is_start_visual=True
|
||
self.run_feed_all()
|
||
elif self._is_finish and self._is_finish_ratio>=0.7:
|
||
#后续流程--》检查到未对齐，--》后又对齐+未堆料
|
||
#print('------------------进入连续块检测------------------')
|
||
if self._mould_before_aligned:
|
||
#未对齐，检测对齐
|
||
_is_not_aligned=self._aligned_get_times(2)
|
||
if _is_not_aligned:
|
||
#标志位
|
||
self._mould_before_aligned=False
|
||
print('------------连续盖板未对齐完成，进入派单标志-------------')
|
||
self.state.pd_status=PD_StatusEnum.PD_Ready
|
||
#print('------------连续盖板未对齐-------------')
|
||
else:
|
||
if _is_api_request:
|
||
self.get_current_mould()
|
||
_is_api_request=False
|
||
_is_aligned=self._aligned_get_times(1)
|
||
if _is_aligned and self._overflow_detected=='未堆料':
|
||
print('------------进入连续生产-------------')
|
||
self._mould_before_aligned=True
|
||
_is_api_request=True
|
||
if self.state.pd_status==PD_StatusEnum.PD_Ready:
|
||
self.state.pd_status=PD_StatusEnum.PD_TimeOut
|
||
if self._cur_mould_model:
|
||
self.state.current_mould=self._cur_mould_model
|
||
self.state.current_block_number=CoreUtils.get_number_by_mould_code(self._cur_mould_model.MouldCode)
|
||
self.state._db_mould_status={
|
||
'mould_code':self._cur_mould_model.MouldCode,
|
||
'status':2,
|
||
'weight':0,
|
||
}
|
||
else:
|
||
self.state.current_mould=None
|
||
self.state.current_block_number=''
|
||
|
||
_current_weight=self.transmitter_controller.read_data(2)
|
||
if not _current_weight:
|
||
print('------------获取上料斗重量失败-------------')
|
||
return
|
||
|
||
|
||
# print('-----------进入连续块111111-----------')
|
||
# self.is_start_visual=True
|
||
if self._last_lower_weight>0:
|
||
with open('weight.txt', 'a') as f:
|
||
f.write(f"补料:{self._last_lower_weight-_current_weight}\n\n"+"="*32)
|
||
|
||
self.init_val()
|
||
self._init_lower_weight=_current_weight
|
||
self.state._feed_status=FeedStatus.FCheckGB
|
||
# if not self.state.current_block_number=='F':
|
||
#这里需要判断状态是否发送完成，如果没发送完成，应该报警（时间太长），
|
||
# self.state.pd_status=PD_StatusEnum.PD_Ready
|
||
self.run_feed_all()
|
||
|
||
# else:
|
||
# print("-----------上料斗未就位----------------")
|
||
# print("---------3--上料斗未就位----------------")
|
||
|
||
time.sleep(0.2)
|
||
|
||
def safe_control_lower_close(self,duration=3):
|
||
"""线程安全的下料斗关闭方法"""
|
||
thread_name = threading.current_thread().name
|
||
# print(f"[{thread_name}] 尝试关闭下料斗...")
|
||
# 设置标志位，指示正在执行安全关闭操作
|
||
self._is_safe_closing = True
|
||
try:
|
||
with self._door_control_lock:
|
||
self._current_controlling_thread = thread_name
|
||
print(f"关闭下料斗{duration}秒")
|
||
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')
|
||
self._current_controlling_thread = None
|
||
#print(f"[{thread_name}] 释放下料斗控制权")
|
||
finally:
|
||
# 无论成功失败，都要重置标志位
|
||
self._is_safe_closing = False
|
||
|
||
def close_lower_door_visual(self):
|
||
"""关闭下料斗门"""
|
||
self.is_start_visual=False
|
||
#休眠让视觉先结束
|
||
time.sleep(0.5)
|
||
self.safe_control_lower_close()
|
||
|
||
def _visual_close(self):
|
||
self.is_start_visual=False
|
||
self._is_finish=True
|
||
self.state.vf_status=3
|
||
self.state._feed_status=FeedStatus.FFinished
|
||
self._is_feed_stage=0
|
||
print(f'--------进入关闭(浇筑满)-----------')
|
||
self.safe_control_lower_close(3)
|
||
print(f'--------浇筑完成-----------')
|
||
|
||
if self._cur_mould_model:
|
||
self.state._db_mould_status={
|
||
'mould_code':self._cur_mould_model.MouldCode,
|
||
'status':3,
|
||
'weight':self.state._mould_finish_weight,
|
||
}
|
||
|
||
# try:
|
||
# self.db_queue.put_nowait({
|
||
# "f":self._is_small_f,
|
||
# "Status": 3
|
||
# })
|
||
# except queue.Full:
|
||
# print("数据库队列已满，无法添加数据")
|
||
#记录重量
|
||
_current_weight=self.transmitter_controller.read_data(2)
|
||
if _current_weight is not None:
|
||
self._last_lower_weight=_current_weight
|
||
self._finish_weight= self._finish_weight+(self._inital_finish_lweight-_current_weight)
|
||
with open('weight.txt', 'a') as f:
|
||
timestamp = datetime.now().strftime("%Y-%m-%d %H:%M:%S")
|
||
if self._is_small_f:
|
||
if self._cur_mould_model:
|
||
f.write(f"{self._time_mould_begin},{timestamp},{self._cur_mould_model.MouldCode},F,{self._finish_weight}\n")
|
||
else:
|
||
f.write(f"{self._time_mould_begin},{timestamp},F,{self._finish_weight}\n")
|
||
else:
|
||
if self._cur_mould_model:
|
||
f.write(f"{self._time_mould_begin},{timestamp},{self._cur_mould_model.MouldCode},B,{self._finish_weight}\n")
|
||
else:
|
||
f.write(f"{self._time_mould_begin},{timestamp},B,{self._finish_weight}\n")
|
||
#开启保存diff
|
||
self._is_diff_save=True
|
||
|
||
#保存图片
|
||
save_camera_picture()
|
||
|
||
def run_feed_all(self):
|
||
"""
|
||
全流程下料：包括判断模具类型
|
||
"""
|
||
_is_f= run_stable_classification_loop()
|
||
print(f'------------已判断出模具类型: {_is_f}-------------')
|
||
if _is_f is not None:
|
||
if _is_f=='模具车1':
|
||
self._is_small_f=True
|
||
print('-------------F块模具--------------')
|
||
# print('-------------F块模具--------------')
|
||
# print('-------------F块模具--------------')
|
||
# self.send_pd_data()
|
||
self.run_feed_f()
|
||
elif _is_f=='模具车2':
|
||
self._is_small_f=False
|
||
print('-------------B-L模具---------------')
|
||
# self.send_pd_data()
|
||
self.run_feed()
|
||
|
||
if self._is_small_f is None:
|
||
print('-----------未判断出模具类型--------------')
|
||
return
|
||
|
||
def run_feed_f(self):
|
||
"""第一阶段下料：下料斗向模具车下料（低速）"""
|
||
print("--------------------开始下料（F块）--------------------")
|
||
self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
|
||
loc_mitter=self.transmitter_controller
|
||
max_weight_none=5
|
||
cur_weight_none=0
|
||
initial_lower_weight=self._init_lower_weight
|
||
first_finish_weight=0
|
||
self._finish_weight=first_finish_weight
|
||
self._inital_finish_lweight=initial_lower_weight
|
||
self._mould_need_weight=0.54*2416
|
||
need_total_weight=self._mould_need_weight
|
||
if initial_lower_weight>100:
|
||
if not self._is_finish:
|
||
self.state._feed_status=FeedStatus.FFeed5
|
||
self.state.vf_status=2
|
||
self.is_start_visual=True
|
||
self._is_feed_stage=5
|
||
while not self._is_finish:
|
||
current_weight = loc_mitter.read_data(2)
|
||
if current_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
#如果重量连续5次为None，认为下料斗未就位，跳出循环
|
||
print('------------f下到模具车,下料斗重量异常----------------')
|
||
print('------------f下到模具车,下料斗重量异常----------------')
|
||
self.close_lower_door_visual()
|
||
return
|
||
#视觉处理关闭，异常的话重量没有生效
|
||
continue
|
||
cur_weight_none=0
|
||
first_finish_weight=initial_lower_weight-current_weight
|
||
self._is_finish_ratio=(first_finish_weight)/need_total_weight
|
||
self.state._mould_finish_weight=first_finish_weight
|
||
self.state._mould_finish_ratio=self._is_finish_ratio
|
||
print(f'------------已下料比例: {self._is_finish_ratio}-------------')
|
||
# if self._is_finish_ratio>=1:
|
||
#关5秒
|
||
#大于0.7后不再检测了，直接交给视觉控制夹脚
|
||
# print(f'------------已下料比例: {self._is_finish_ratio}-------------')
|
||
# break
|
||
|
||
# print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
|
||
time.sleep(0.5)
|
||
# initial_lower_weight=_current_lower_weight
|
||
print(f'------------已下料（F）: {first_finish_weight}kg-------------')
|
||
print(f'------------已下料（F）: {first_finish_weight}kg-------------')
|
||
|
||
# print(f'------------已完成-------------')
|
||
|
||
def run_feed(self):
|
||
"""第一阶段下料：下料斗向模具车下料（低速）"""
|
||
print("--------------------开始下料（普通块）--------------------")
|
||
self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
|
||
loc_relay=self.relay_feed
|
||
loc_mitter=self.transmitter_controller
|
||
max_weight_none=5
|
||
cur_weight_none=0
|
||
|
||
initial_lower_weight=self._init_lower_weight
|
||
# initial_upper_weight=loc_mitter.read_data(1)
|
||
first_finish_weight=0
|
||
self._mould_need_weight=1.91*2416
|
||
need_total_weight=self._mould_need_weight
|
||
if self._is_finish:
|
||
return
|
||
# start_time=None
|
||
self.state._feed_status=FeedStatus.FFeed1
|
||
self.state.vf_status=1
|
||
if initial_lower_weight>100:
|
||
self.is_start_visual=True
|
||
#下料斗的料全部下完
|
||
self._is_feed_stage=1
|
||
while not self._is_finish:
|
||
current_weight = loc_mitter.read_data(2)
|
||
if current_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
print("-----------下料斗重量异常(第一次下到模具车)--------------")
|
||
self.close_lower_door_visual()
|
||
return
|
||
continue
|
||
cur_weight_none=0
|
||
self.state._mould_finish_weight=initial_lower_weight-current_weight
|
||
self._is_finish_ratio= self.state._mould_finish_weight/need_total_weight
|
||
self.state._mould_finish_ratio=self._is_finish_ratio
|
||
|
||
print(f'------------已下料比例: {self._is_finish_ratio}-------------')
|
||
if current_weight<250 and current_weight>0:
|
||
# if current_weight>100:
|
||
#100,上面粘贴的，振动一下
|
||
# loc_relay.control_arch_lower_open_async(5)
|
||
self.close_lower_door_visual()
|
||
break
|
||
time.sleep(1)
|
||
|
||
self.is_start_visual=False
|
||
_current_lower_weight=loc_mitter.read_data(2)
|
||
if _current_lower_weight is None:
|
||
print("-------下料斗重量异常---------")
|
||
return
|
||
first_finish_weight=initial_lower_weight-_current_lower_weight
|
||
# initial_lower_weight=_current_lower_weight
|
||
print(f'------------已下料（第一次）: {first_finish_weight}kg-------------')
|
||
print(f'------------已下料（第一次）: {first_finish_weight}kg-------------')
|
||
self._is_feed_stage=0
|
||
|
||
while self.plc_data not in self.plc_valid_data:
|
||
#print('------------上料斗未就位----------------')
|
||
# print('------------上料斗未就位----------------')
|
||
time.sleep(1)
|
||
if self._is_finish:
|
||
return
|
||
if self.plc_data in self.plc_valid_data:
|
||
print(f'------------上料斗就位（上料斗往下料斗阶段）-------------')
|
||
#打开上料斗出砼门，开5就，开三分之一下
|
||
|
||
loc_relay.control_upper_open_sync(6)
|
||
self._is_feed_stage=2
|
||
loc_time_count=1
|
||
upper_open_time=time.time()
|
||
self.state._upper_door_closed=1
|
||
while not self._is_finish:
|
||
current_upper_weight = loc_mitter.read_data(1)
|
||
if current_upper_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
#如果重量连续5次为None，认为上料斗未就位，跳出循环
|
||
print('------------第一次上到下,上料斗重量异常----------------')
|
||
print('------------第一次上到下,上料斗重量异常----------------')
|
||
self.state._upper_door_closed=0
|
||
loc_relay.control_upper_close_sync(5+loc_time_count)
|
||
return
|
||
continue
|
||
cur_weight_none=0
|
||
_two_lower_weight=loc_mitter.read_data(2)
|
||
if _two_lower_weight is None:
|
||
_two_lower_weight=0
|
||
if (current_upper_weight<3200 and current_upper_weight>0) or _two_lower_weight>3200:
|
||
#关5秒,loc_time_count多关一秒
|
||
self.state._upper_door_closed=0
|
||
loc_relay.control_upper_close_sync(5+loc_time_count)
|
||
break
|
||
else:
|
||
if time.time()-upper_open_time>=4:
|
||
if loc_time_count<6:
|
||
upper_open_time=time.time()
|
||
loc_relay.control_upper_open_sync(0.8)
|
||
loc_time_count=loc_time_count+0.8
|
||
else:
|
||
time.sleep(0.5)
|
||
else:
|
||
loc_relay.control_upper_close_sync(6+loc_time_count)
|
||
self.state._upper_door_closed=0
|
||
if self._is_finish:
|
||
return
|
||
self.is_start_visual=True
|
||
initial_lower_weight=loc_mitter.read_data(2)
|
||
if initial_lower_weight is None:
|
||
print("-------下料斗重量异常(第二次下料到模具车)---------")
|
||
return
|
||
self._is_feed_stage=3
|
||
while not self._is_finish:
|
||
current_weight = loc_mitter.read_data(2)
|
||
if current_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
print("-------下料斗重量异常(第二次下料到模具车)---------")
|
||
self.close_lower_door_visual()
|
||
return
|
||
continue
|
||
cur_weight_none=0
|
||
self.state._mould_finish_weight=first_finish_weight+initial_lower_weight-current_weight
|
||
self._is_finish_ratio=self.state._mould_finish_weight/need_total_weight
|
||
self.state._mould_finish_ratio=self._is_finish_ratio
|
||
if current_weight<250:
|
||
# if current_weight>100:
|
||
#100,上面粘贴的，振动一下
|
||
# loc_relay.control_arch_lower_open_async(5)
|
||
self.close_lower_door_visual()
|
||
break
|
||
# print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
|
||
time.sleep(0.5)
|
||
self.is_start_visual=False
|
||
_current_lower_weight=loc_mitter.read_data(2)
|
||
if _current_lower_weight is None:
|
||
print("-------下料斗重量异常(第二次下到模)---------")
|
||
return
|
||
first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
|
||
|
||
print(f'------------已下料（第二次）: {first_finish_weight}kg-------------')
|
||
print(f'------------已下料（第二次）: {first_finish_weight}kg-------------')
|
||
if self._is_finish:
|
||
return
|
||
self._is_feed_stage=0
|
||
if self.plc_data in self.plc_valid_data:
|
||
self.state._upper_door_closed=2
|
||
#第二次上料斗向下料斗转移
|
||
loc_relay.control_upper_open_sync(12)
|
||
loc_time_count=1
|
||
upper_open_time=time.time()
|
||
upper_open_time_2=None
|
||
#第二次到下料斗还需要的量
|
||
#loc_left_need_weight=need_total_weight-first_finish_weight
|
||
#initial_upper_weight=loc_mitter.read_data(1)
|
||
#start_time=None
|
||
self._is_feed_stage=4
|
||
|
||
while not self._is_finish:
|
||
# print(f'------------上料斗向下料斗转移22222-------------')
|
||
current_upper_weight = loc_mitter.read_data(1)
|
||
if current_upper_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
#如果重量连续5次为None，认为上料斗未就位，跳出循环
|
||
print('------------第二次上到下,上料斗重量异常----------------')
|
||
print('------------第二次上到下,上料斗重量异常----------------')
|
||
self.state._upper_door_closed=0
|
||
loc_relay.control_upper_close_sync(15)
|
||
return
|
||
continue
|
||
cur_weight_none=0
|
||
if (current_upper_weight<600 and current_upper_weight>0) or upper_open_time_2 is not None:
|
||
if upper_open_time_2 is None:
|
||
upper_open_time_2=time.time()
|
||
if current_upper_weight<400 or time.time()-upper_open_time_2>5:
|
||
loc_relay.control_arch_upper_open_async(5)
|
||
# loc_relay.control_arch_upper_open()
|
||
loc_relay.control_upper_open_sync(5)
|
||
self.state._upper_door_closed=2
|
||
# start_time=None
|
||
#5秒后关闭
|
||
loc_relay.control_upper_close_after()#control_upper_close_sync(8+loc_time_count)
|
||
break
|
||
time.sleep(0.5)
|
||
else:
|
||
if time.time()-upper_open_time>=1:
|
||
# if loc_time_count<6:
|
||
upper_open_time=time.time()
|
||
loc_relay.control_upper_open_sync(1.2)
|
||
loc_time_count=loc_time_count+1
|
||
else:
|
||
time.sleep(0.5)
|
||
else:
|
||
loc_relay.control_upper_close_sync(15)
|
||
|
||
self.state._upper_door_closed=0
|
||
# time.sleep(0.4)
|
||
|
||
#第三次下料斗转移到模具车
|
||
if not self._is_finish:
|
||
self.is_start_visual=True
|
||
initial_lower_weight=loc_mitter.read_data(2)
|
||
self._finish_weight=first_finish_weight
|
||
self._inital_finish_lweight=initial_lower_weight
|
||
if initial_lower_weight is None:
|
||
print("-------下料斗重量异常(第三次下到模具车)---------")
|
||
return
|
||
self._is_feed_stage=5
|
||
while not self._is_finish:
|
||
current_weight = loc_mitter.read_data(2)
|
||
if current_weight is None:
|
||
cur_weight_none+=1
|
||
if cur_weight_none>max_weight_none:
|
||
#重量异常退出
|
||
print('------------第三次下到模具车,下料斗重量异常----------------')
|
||
self.close_lower_door_visual()
|
||
return
|
||
continue
|
||
cur_weight_none=0
|
||
second_finish_weight=initial_lower_weight-current_weight
|
||
self.state._mould_finish_weight=second_finish_weight+first_finish_weight
|
||
self._is_finish_ratio=self.state._mould_finish_weight/need_total_weight
|
||
self.state._mould_finish_ratio=self._is_finish_ratio
|
||
print(f'------------已下料比例: {self._is_finish_ratio}-------------')
|
||
# if self._is_finish_ratio>=1:
|
||
#关5秒
|
||
# print(f'------------已下料比例: {self._is_finish_ratio}-------------')
|
||
# break
|
||
|
||
# print(f'------------已下料: {first_finish_weight+second_finish_weight}kg-------------')
|
||
time.sleep(0.5)
|
||
|
||
# _current_lower_weight=loc_mitter.read_data(2)
|
||
# first_finish_weight=first_finish_weight+initial_lower_weight-_current_lower_weight
|
||
# print(f'------------已下料: {first_finish_weight}kg-------------')
|
||
# print(f'------------已下料: {first_finish_weight}kg-------------')
|
||
|
||
|
||
# print(f'------------已完成-------------')
|
||
|
||
def _process_angle_callback(self, current_angle, overflow_detected):
|
||
"""
|
||
实时精细控制 - 基于PID思想，无固定间隔
|
||
"""
|
||
try:
|
||
# 记录控制时间戳（用于微分计算，而非限制）
|
||
current_time = time.time()
|
||
# 确保所有PID相关属性都被正确初始化
|
||
if not hasattr(self, '_last_control_time'):
|
||
self._last_control_time = current_time
|
||
if not hasattr(self, '_last_error'):
|
||
self._last_error = 0
|
||
if not hasattr(self, '_error_integral'):
|
||
self._error_integral = 0
|
||
|
||
# print(f"{self.angle_mode}")
|
||
self.overflow = overflow_detected in ["大堆料", "小堆料"]
|
||
|
||
if current_angle is None:
|
||
return
|
||
|
||
print(f"{datetime.now().strftime('%H:%M:%S.%f')[:-3]} 角度11: {current_angle:.2f}°,{overflow_detected},diff_f_val:{self._diff_f_val},diff_f_area:{self._diff_f_area}")
|
||
|
||
if self._is_small_f:
|
||
if self._is_finish_ratio>=1.02:
|
||
print('重量达到最大比例，浇筑满关闭')
|
||
self._visual_close()
|
||
return
|
||
elif self._is_finish_ratio>=0.9:
|
||
if (self._diff_f_val>=427 and self._diff_f_val<=450):
|
||
print('------------diff到达浇筑满-------------')
|
||
self._visual_close()
|
||
return
|
||
elif (len(self._diff_f_area)>0 and self._diff_f_area[-1]>=33400 and self._diff_f_area[-1]<=34500):
|
||
print('------------area到达浇筑满-------------')
|
||
self._visual_close()
|
||
return
|
||
else:
|
||
if self._is_finish_ratio>=1.01:
|
||
print('重量达到最大比例，浇筑满关闭')
|
||
self._visual_close()
|
||
return
|
||
elif self._is_finish_ratio>=0.93:
|
||
if (self._diff_f_val>=460 and self._diff_f_val<=510):
|
||
print('------------diff到达浇筑满-------------')
|
||
self._visual_close()
|
||
return
|
||
if (len(self._diff_f_area)>0 and self._diff_f_area[-1]>=38200 and self._diff_f_area[-1]<=41000):
|
||
print('------------area到达浇筑满-------------')
|
||
self._visual_close()
|
||
return
|
||
|
||
|
||
if overflow_detected == "未浇筑满" or self._is_before_finish:
|
||
if self._before_finish_time is None:
|
||
self._before_finish_time=current_time
|
||
self.safe_control_lower_close(1)
|
||
print('-----------------关闭（未浇筑满）--------------------')
|
||
# time.sleep(3)
|
||
else:
|
||
if not self._is_stop_one_seconds:
|
||
#根据角度来计算还需要多久完全关闭
|
||
if current_angle>=20:
|
||
self.safe_control_lower_close(2)
|
||
elif current_angle>=10 and current_angle<20:
|
||
self.safe_control_lower_close(1)
|
||
elif current_angle>=6 and current_angle<10:
|
||
self.safe_control_lower_close(0.5)
|
||
self._is_stop_one_seconds=True
|
||
elif current_angle>7:
|
||
#点动状态下，如果关闭后角度大于7度，关紧
|
||
self.safe_control_lower_close(0.2)
|
||
_open_time=0.3
|
||
_sleep_time=0.3
|
||
_close_time=0.5
|
||
if overflow_detected=='浇筑满':
|
||
if self._is_small_f:
|
||
self._visual_close()
|
||
return
|
||
else:
|
||
if self._diff_f_val>=410 and self._diff_f_val<450:
|
||
#排除这个范围的关闭
|
||
print(f'浇筑满状态，diff_f_val:{self._diff_f_val},不关闭')
|
||
_open_time=0.5
|
||
_sleep_time=0.3
|
||
_close_time=0.7
|
||
else:
|
||
self._visual_close()
|
||
return
|
||
|
||
# print(f'--------已关闭已关闭-----------')
|
||
elif overflow_detected=="大堆料":
|
||
print(f'--------未浇筑满，大堆料-----------')
|
||
elif overflow_detected=="小堆料":
|
||
print(f'--------未浇筑满，小堆料-----------')
|
||
_open_time=0.5
|
||
_sleep_time=0.3
|
||
_close_time=0.7
|
||
else:
|
||
if self._is_small_f:
|
||
_open_time=0.6
|
||
_sleep_time=0.3
|
||
_close_time=0.8
|
||
else:
|
||
if self._is_finish_ratio<0.9:
|
||
_open_time=1
|
||
_sleep_time=0.3
|
||
_close_time=1.2
|
||
#之前慢的参数
|
||
# _open_time=0.8
|
||
# _sleep_time=0.3
|
||
# _close_time=1
|
||
elif self._is_finish_ratio<0.95 and self._is_finish_ratio>=0.9:
|
||
if self._point_weight>=10:
|
||
_open_time=0.7
|
||
_sleep_time=0.3
|
||
_close_time=0.9
|
||
else:
|
||
#之前慢的参数
|
||
# _open_time=0.8
|
||
# _sleep_time=0.3
|
||
# _close_time=1
|
||
_open_time=0.9
|
||
_sleep_time=0.3
|
||
_close_time=1.1
|
||
else:
|
||
_open_time=0.6
|
||
_sleep_time=0.3
|
||
_close_time=0.8
|
||
|
||
if self._point_speed_grade==1:
|
||
if _open_time>0.6:
|
||
_open_time=0.6
|
||
_sleep_time=0.3
|
||
_close_time=0.8
|
||
elif self._point_speed_grade==2:
|
||
if _open_time>0.5:
|
||
_open_time=0.5
|
||
_sleep_time=0.3
|
||
_close_time=0.7
|
||
elif self._point_speed_grade==3:
|
||
if _open_time>0.4:
|
||
_open_time=0.4
|
||
_sleep_time=0.3
|
||
_close_time=0.6
|
||
elif self._point_speed_grade==4:
|
||
if _open_time>0.3:
|
||
_open_time=0.3
|
||
_sleep_time=0.3
|
||
_close_time=0.5
|
||
_last_finish_ratio=self._is_finish_ratio
|
||
print(f'--------比例开始：{_last_finish_ratio}-----------')
|
||
self._pulse_control('open',_open_time)
|
||
time.sleep(_sleep_time)
|
||
self._pulse_control('close',_close_time)
|
||
print(f'--------比例结束：{self._is_finish_ratio}-----------')
|
||
|
||
self._point_weight=(self._is_finish_ratio-_last_finish_ratio)*self._mould_need_weight
|
||
print(f'--------流速：{self._point_weight}-----------')
|
||
if self._is_small_f:
|
||
time.sleep(2.5)
|
||
else:
|
||
# if self._is_finish_ratio>= 0.93:
|
||
# time.sleep(2)
|
||
# print('--------重量已到95.5%，需要2秒休息-----------')
|
||
# else:
|
||
time.sleep(1)
|
||
#下得过快，需要2秒休息
|
||
if self._point_weight>=65:
|
||
time.sleep(5)
|
||
self._point_speed_grade=4
|
||
elif self._point_weight>=50 and self._point_weight<65:
|
||
time.sleep(4)
|
||
self._point_speed_grade=3
|
||
elif self._point_weight>=35 and self._point_weight<50:
|
||
time.sleep(3)
|
||
self._point_speed_grade=2
|
||
elif self._point_weight>=25 and self._point_weight<35:
|
||
time.sleep(2)
|
||
self._point_speed_grade=1
|
||
elif self._point_weight>=15 and self._point_weight<25:
|
||
time.sleep(1)
|
||
self._point_speed_grade=0
|
||
else:
|
||
self._point_speed_grade=0
|
||
self._is_before_finish=True
|
||
if self._is_finish_ratio<=self._max_ignore_radio:
|
||
#如果重量未达到最大忽略角度，需要跳出
|
||
self._is_before_finish=False
|
||
return
|
||
elif overflow_detected == "浇筑满":
|
||
self._visual_close()
|
||
return
|
||
else:
|
||
self._before_finish_time=None
|
||
#2160KG
|
||
if self._is_finish_ratio>=0.85 and not self._is_small_f:
|
||
if overflow_detected == "大堆料":
|
||
TARGET_ANGLE = 5.0 # 大堆料时控制在15度左右
|
||
elif overflow_detected == "小堆料":
|
||
TARGET_ANGLE = 15.0 # 小堆料时控制在35度左右
|
||
else:
|
||
TARGET_ANGLE = 35.0 # 12.25由25--》35
|
||
elif (self._is_finish_ratio>0.7 and self._is_small_f):
|
||
if overflow_detected == "大堆料":
|
||
TARGET_ANGLE = 5.0 # 大堆料时控制在15度左右
|
||
elif overflow_detected == "小堆料":
|
||
TARGET_ANGLE = 15.0 # 小堆料时控制在35度左右
|
||
else:
|
||
TARGET_ANGLE = 35.0 # 12.25由25--》35
|
||
else:
|
||
if self._is_feed_stage==1 or self._is_feed_stage==3:
|
||
#根据溢料状态动态调整目标角度
|
||
if overflow_detected == "大堆料":
|
||
if not self.state._mould_vibrate_status:
|
||
TARGET_ANGLE = 15.0 # 临时控制变频器堆料时很小
|
||
else:
|
||
TARGET_ANGLE = 35.0 # 大堆料时控制在15度左右
|
||
elif overflow_detected == "小堆料":
|
||
TARGET_ANGLE = 55.0 # 小堆料时控制在35度左右
|
||
else:
|
||
TARGET_ANGLE = 55.0 # 未溢料时开到最大56度
|
||
else:
|
||
if self._is_small_f:
|
||
#根据溢料状态动态调整目标角度
|
||
if overflow_detected == "大堆料":
|
||
TARGET_ANGLE = 15.0 # 大堆料时控制在15度左右
|
||
elif overflow_detected == "小堆料":
|
||
TARGET_ANGLE = 25.0 # 小堆料时控制在35度左右
|
||
else:
|
||
TARGET_ANGLE = 45.0 # 未溢料时开到最大56度
|
||
else:
|
||
#根据溢料状态动态调整目标角度
|
||
if overflow_detected == "大堆料":
|
||
TARGET_ANGLE = 15.0 # 大堆料时控制在15度左右
|
||
elif overflow_detected == "小堆料":
|
||
TARGET_ANGLE = 55.0 # 小堆料时控制在35度左右
|
||
else:
|
||
TARGET_ANGLE = 55.0 # 未溢料时开到最大56度
|
||
|
||
# 确保目标角度在硬件范围内（5-56度）
|
||
TARGET_ANGLE = max(5.0, min(56.0, TARGET_ANGLE))
|
||
|
||
# PID控制参数
|
||
KP = 0.2 # 比例系数
|
||
KI = 0 # 积分系数
|
||
KD = 0 # 微分系数
|
||
# KP = 0.15 # 比例系数
|
||
# KI = 0.008 # 积分系数
|
||
# KD = 0.08 # 微分系数
|
||
# if TARGET_ANGLE <= 25.0:
|
||
# KP, KI, KD = 0.18, 0.008, 0.08 # 小角度，强控制
|
||
# elif TARGET_ANGLE <= 40.0:
|
||
# KP, KI, KD = 0.15, 0.01, 0.06 # 中角度
|
||
# else:
|
||
# KP, KI, KD = 0.12, 0.012, 0.04 # 大角度，温和控制
|
||
# 计算误差
|
||
error = current_angle - TARGET_ANGLE
|
||
dt = current_time - self._last_control_time
|
||
|
||
# 积分项（抗饱和）
|
||
self._error_integral += error * dt
|
||
self._error_integral = max(min(self._error_integral, 50), -50) # 积分限幅
|
||
|
||
# 微分项
|
||
error_derivative = (error - self._last_error) / dt if dt > 0 else 0
|
||
|
||
# PID输出
|
||
pid_output = (KP * error + KI * self._error_integral + KD * error_derivative)
|
||
#print(f"📊 PID计算: 误差={error:.2f}°, 积分={self._error_integral:.2f}, "
|
||
# 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("处理视觉回调时发生异常: ")
|
||
print("处理视觉回调时发生异常: ")
|
||
print("处理视觉回调时发生异常: ")
|
||
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
|
||
if self.plc_data in self.plc_valid_data:
|
||
if self.state._upper_door_position!=Upper_Door_Position.ZDS:
|
||
self.state._upper_door_position=Upper_Door_Position.ZDS
|
||
self.relay_controller.control(self.relay_controller.UPPER_TO_ZD, 'close')
|
||
elif self.plc_data in self.plc_valid_data_jbl:
|
||
if self.state._upper_door_position!=Upper_Door_Position.JBL:
|
||
self.state._upper_door_position=Upper_Door_Position.JBL
|
||
self.relay_controller.control(self.relay_controller.UPPER_TO_JBL, 'close')
|
||
else:
|
||
if self.state._upper_door_position!=Upper_Door_Position.Returning:
|
||
self.state._upper_door_position=Upper_Door_Position.Returning
|
||
|
||
# @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()
|
||
|
||
self._is_running=False
|
||
self._is_finish=True
|
||
self.is_start_visual=False
|
||
# #关闭下料斗
|
||
# self.safe_control_lower_close()
|
||
|
||
# 等待线程结束
|
||
if self.callback_thread and self.callback_thread.is_alive():
|
||
self.callback_thread.join(timeout=1.0)
|
||
if self.diff_thread and self.diff_thread.is_alive():
|
||
self.diff_thread.join(timeout=1.0)
|
||
|
||
|
||
def get_current_mould(self):
|
||
"""获取当前要浇筑的管片"""
|
||
# if self.state.pd_status==PD_StatusEnum.PD_Ready:
|
||
# self.state.pd_status=PD_StatusEnum.PD_TimeOut
|
||
_not_poured=app_web_service.get_not_pour_artifacts()
|
||
if _not_poured is not None and len(_not_poured)>=1:
|
||
_cur_poured_model=_not_poured[-1]
|
||
if _cur_poured_model.MouldCode:
|
||
self._cur_mould_model=_cur_poured_model
|
||
# self.state.current_mould=_cur_poured_model
|
||
# self.state.current_block_number=CoreUtils.get_number_by_mould_code(_cur_poured_model.MouldCode)
|
||
print(f'当前要浇筑的管片 {json.dumps(asdict(_cur_poured_model), ensure_ascii=False)}')
|
||
else:
|
||
self._cur_mould_model=None
|
||
# self.state.current_mould=None
|
||
# self.state.current_block_number=''
|
||
print('当前没有未浇筑的管片')
|
||
|
||
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) |