359 lines
16 KiB
Python
359 lines
16 KiB
Python
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from pickle import FALSE
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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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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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class FeedingProcess:
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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, relay_controller, inverter_controller,
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transmitter_controller, state):
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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.inverter_controller = inverter_controller
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self.transmitter_controller = transmitter_controller
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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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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=0.5
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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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def run_feed_f(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（F块）--------------------")
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self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
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# loc_relay=self.relay_controller
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loc_mitter=self.transmitter_controller
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max_weight_none=5
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cur_weight_none=0
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initial_lower_weight=loc_mitter.read_data(2)
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if initial_lower_weight is None:
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print("-----f上料斗重量异常-----")
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return
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first_finish_weight=0
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self._finish_weight=first_finish_weight
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self._inital_finish_lweight=initial_lower_weight
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need_total_weight=0.54*2416
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if initial_lower_weight>100:
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if not self._is_finish:
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self.is_start_visual=True
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initial_lower_weight=loc_mitter.read_data(2)
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if initial_lower_weight is None:
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print("-----f上料斗重量异常2-----")
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return
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self._is_feed_stage=5
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while not self._is_finish:
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current_weight = loc_mitter.read_data(2)
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if current_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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#如果重量连续5次为None，认为下料斗未就位，跳出循环
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print('------------f下到模具车,下料斗重量异常----------------')
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print('------------f下到模具车,下料斗重量异常----------------')
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self.close_lower_door_visual()
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return
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#视觉处理关闭，异常的话重量没有生效
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continue
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cur_weight_none=0
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first_finish_weight=initial_lower_weight-current_weight
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self._is_finish_ratio=(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 self._is_finish_ratio>self._max_f_angle_ratio:
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#关5秒
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#大于0.7后不再检测了，直接交给视觉控制夹脚
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# print(f'------------已下料比例: {self._is_finish_ratio}-------------')
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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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# initial_lower_weight=_current_lower_weight
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print(f'------------已下料（F）: {first_finish_weight}kg-------------')
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print(f'------------已下料（F）: {first_finish_weight}kg-------------')
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print(f'------------已完成-------------')
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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（普通块）--------------------")
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self._time_mould_begin=datetime.now().strftime("%Y-%m-%d %H:%M:%S")
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loc_relay=self.relay_controller
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loc_mitter=self.transmitter_controller
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max_weight_none=5
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cur_weight_none=0
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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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if initial_lower_weight is None:
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print("---------------下料斗重量异常----------------")
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return
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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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self._is_feed_stage=1
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while not self._is_finish:
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current_weight = loc_mitter.read_data(2)
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if current_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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print("-----------下料斗重量异常(第一次下到模具车)--------------")
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self.close_lower_door_visual()
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return
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continue
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cur_weight_none=0
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if current_weight<250 and current_weight>0:
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self.close_lower_door_visual()
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break
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time.sleep(1)
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_current_lower_weight=loc_mitter.read_data(2)
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if _current_lower_weight is None:
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print("-------下料斗重量异常---------")
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return
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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（第一次）: {first_finish_weight}kg-------------')
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print(f'------------已下料（第一次）: {first_finish_weight}kg-------------')
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self._is_feed_stage=0
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while self.plc_data!=5:
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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(1)
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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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self._is_feed_stage=2
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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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current_upper_weight = loc_mitter.read_data(1)
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if current_upper_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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#如果重量连续5次为None，认为上料斗未就位，跳出循环
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print('------------第一次上到下,上料斗重量异常----------------')
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print('------------第一次上到下,上料斗重量异常----------------')
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loc_relay.control_upper_close_sync(5+loc_time_count)
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return
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continue
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cur_weight_none=0
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_two_lower_weight=loc_mitter.read_data(2)
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if _two_lower_weight is None:
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_two_lower_weight=0
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if (current_upper_weight<3000 and current_upper_weight>0) or _two_lower_weight>3200:
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#关5秒,loc_time_count多关一秒
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loc_relay.control_upper_close_sync(5+loc_time_count)
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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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if loc_time_count<6:
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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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else:
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loc_relay.control_upper_close_sync(6+loc_time_count)
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self.is_start_visual=True
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initial_lower_weight=loc_mitter.read_data(2)
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if initial_lower_weight is None:
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print("-------下料斗重量异常(第二次下料到模具车)---------")
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return
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self._is_feed_stage=3
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while not self._is_finish:
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current_weight = loc_mitter.read_data(2)
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if current_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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print("-------下料斗重量异常(第二次下料到模具车)---------")
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self.close_lower_door_visual()
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return
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continue
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cur_weight_none=0
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# second_finish_weight=initial_lower_weight-current_weight
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if current_weight<250:
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self.close_lower_door_visual()
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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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if _current_lower_weight is None:
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print("-------下料斗重量异常(第二次下到模)---------")
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return
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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（第二次）: {first_finish_weight}kg-------------')
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print(f'------------已下料（第二次）: {first_finish_weight}kg-------------')
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self._is_feed_stage=0
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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(12)
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loc_time_count=1
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upper_open_time=time.time()
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upper_open_time_2=None
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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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self._is_feed_stage=4
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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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current_upper_weight = loc_mitter.read_data(1)
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if current_upper_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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#如果重量连续5次为None，认为上料斗未就位，跳出循环
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print('------------第二次上到下,上料斗重量异常----------------')
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print('------------第二次上到下,上料斗重量异常----------------')
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loc_relay.control_upper_close_sync(15)
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break
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continue
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cur_weight_none=0
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if (current_upper_weight<600 and current_upper_weight>0) or upper_open_time_2 is not None:
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if upper_open_time_2 is None:
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upper_open_time_2=time.time()
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if current_upper_weight<400 or time.time()-upper_open_time_2>5:
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loc_relay.control_arch_upper_open_async(5)
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# loc_relay.control_arch_upper_open()
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loc_relay.control_upper_open_sync(5)
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# start_time=None
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#5秒后关闭
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loc_relay.control_upper_close_after()#control_upper_close_sync(8+loc_time_count)
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break
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time.sleep(1)
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else:
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if time.time()-upper_open_time>2:
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# if loc_time_count<6:
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upper_open_time=time.time()
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loc_relay.control_upper_open_sync(1.2)
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loc_time_count=loc_time_count+1
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else:
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time.sleep(0.5)
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else:
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loc_relay.control_upper_close_sync(15)
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# time.sleep(0.4)
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#第三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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initial_lower_weight=loc_mitter.read_data(2)
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self._finish_weight=first_finish_weight
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self._inital_finish_lweight=initial_lower_weight
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if initial_lower_weight is None:
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print("-------下料斗重量异常(第三次下到模具车)---------")
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return
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self._is_feed_stage=5
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while not self._is_finish:
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current_weight = loc_mitter.read_data(2)
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if current_weight is None:
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cur_weight_none+=1
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if cur_weight_none>max_weight_none:
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#重量异常退出
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print('------------第三次下到模具车,下料斗重量异常----------------')
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self.close_lower_door_visual()
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return
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continue
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cur_weight_none=0
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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 self._is_finish_ratio>=1:
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#关5秒
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# print(f'------------已下料比例: {self._is_finish_ratio}-------------')
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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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print(f'------------已完成-------------')
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@classmethod
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def instance_exists(cls):
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"""检测实例是否存在"""
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return cls._instance is not None
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# 创建默认实例
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# visual_callback_instance = VisualCallback()
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# 兼容层，保持原来的函数调用方式可用
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# def angle_visual_callback(current_angle, overflow_detected):
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# """
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# 兼容旧版本的函数调用方式
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# 将调用转发到默认实例的angle_visual_callback方法
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# """
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# visual_callback_instance.angle_visual_callback(current_angle, overflow_detected) |