package com.zy.core.thread;
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import HslCommunication.Core.Types.OperateResult;
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import HslCommunication.Core.Types.OperateResultExOne;
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import HslCommunication.Profinet.Siemens.SiemensPLCS;
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import HslCommunication.Profinet.Siemens.SiemensS7Net;
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import com.alibaba.fastjson.JSON;
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import com.zy.acs.framework.common.Cools;
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import com.zy.acs.framework.common.DateUtils;
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import com.zy.asrs.entity.Devp;
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import com.zy.asrs.service.DevpService;
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import com.zy.asrs.utils.SpringContextUtil;
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import com.zy.common.utils.News;
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import com.zy.core.DevpThread;
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import com.zy.core.cache.MessageQueue;
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import com.zy.core.cache.OutputQueue;
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import com.zy.core.cache.SlaveConnection;
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import com.zy.core.constant.*;
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import com.zy.core.enums.SlaveType;
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import com.zy.core.enums.TaskType;
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import com.zy.core.model.DevpSlave;
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import com.zy.core.model.Task;
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import com.zy.core.model.protocol.StaProtocol;
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import lombok.Data;
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import lombok.extern.slf4j.Slf4j;
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import java.text.MessageFormat;
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import java.util.ArrayList;
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import java.util.Date;
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import java.util.List;
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import java.util.Map;
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import java.util.concurrent.ConcurrentHashMap;
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/**
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* 输送线线程
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* Created by vincent on 2020/8/4
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*/
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@Data
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@Slf4j
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public class SiemensDevpThread implements Runnable, DevpThread {
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private DevpSlave slave;
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private SiemensS7Net siemensS7Net;
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private Map<Integer, StaProtocol> station = new ConcurrentHashMap<>();
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private volatile boolean connected = false;
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private static final int WRITE_RETRY_MAX = 5;
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private static final int WRITE_RETRY_INTERVAL_MS = 200;
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private static final int READ_INTERVAL_MS = 100;
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private static final int DB_UPDATE_INTERVAL_MS = 1000; // 数据库更新间隔
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private long lastDbUpdateTime = 0;
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public SiemensDevpThread(DevpSlave slave) {
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this.slave = slave;
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}
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@Override
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@SuppressWarnings("InfiniteLoopStatement")
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public void run() {
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connect();
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while (!Thread.currentThread().isInterrupted()) {
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try {
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TaskType step = TaskType.READ;
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Task task = MessageQueue.poll(SlaveType.Devp, slave.getId());
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if (task != null) {
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step = task.getStep();
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}
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switch (step) {
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// 读数据
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case READ:
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read();
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break;
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// 写数据 ID+目标站
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case WRITE:
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write((StaProtocol) task.getData());
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break;
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default:
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break;
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}
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Thread.sleep(READ_INTERVAL_MS);
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} catch (InterruptedException e) {
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Thread.currentThread().interrupt();
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log.warn("SiemensDevp线程被中断 [id:{}]", slave.getId());
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break;
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} catch (Exception e) {
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log.error("SiemensDevp线程运行异常 [id:{}]", slave.getId(), e);
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// 发生异常时尝试重连
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reconnect();
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}
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}
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// 线程退出时关闭连接
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close();
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log.info("SiemensDevp线程已退出 [id:{}]", slave.getId());
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}
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/**
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* 初始化或重置站点状态
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*/
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private void initSite() {
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List<Integer> staNos = slave.getStaNos();
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for (Integer siteId : staNos) {
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StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
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resetStaProtocol(staProtocol);
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}
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}
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/**
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* 获取或创建站点协议对象
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*/
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private StaProtocol getOrCreateStaProtocol(Integer siteId) {
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return station.computeIfAbsent(siteId, id -> {
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StaProtocol protocol = new StaProtocol();
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protocol.setSiteId(id);
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return protocol;
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});
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}
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/**
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* 重置站点协议状态
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*/
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private void resetStaProtocol(StaProtocol staProtocol) {
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staProtocol.setWorkNo(0);
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staProtocol.setAutoing(false);
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staProtocol.setLoading(false);
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staProtocol.setInEnable(false);
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staProtocol.setOutEnable(false);
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staProtocol.setEmptyMk(false);
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staProtocol.setStaNo(0);
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if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
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staProtocol.setPakMk(true);
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}
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}
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@Override
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public boolean connect() {
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// 如果已连接，先关闭旧连接
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if (siemensS7Net != null) {
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try {
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siemensS7Net.ConnectClose();
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} catch (Exception e) {
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log.warn("关闭旧PLC连接异常 [id:{}]", slave.getId(), e);
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}
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}
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siemensS7Net = new SiemensS7Net(SiemensPLCS.S1200, slave.getIp());
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siemensS7Net.setRack(slave.getRack().byteValue());
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siemensS7Net.setSlot(slave.getSlot().byteValue());
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OperateResult connect = siemensS7Net.ConnectServer();
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if (connect.IsSuccess) {
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connected = true;
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News.info("SiemensDevp - 1 - 输送线plc连接成功 ===>> [id:{}] [ip:{}] [port:{}]",
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slave.getId(), slave.getIp(), slave.getPort());
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log.info("输送线plc连接成功 [id:{}] [ip:{}] [rack:{}] [slot:{}]",
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slave.getId(), slave.getIp(), slave.getRack(), slave.getSlot());
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} else {
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connected = false;
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OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线plc连接失败！！！ ===>> [id:{1}] [ip:{2}] [port:{3}] [rack:{4}] [slot:{5}]",
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DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot()));
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News.error("SiemensDevp - 2 - 输送线plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}]",
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slave.getId(), slave.getIp(), slave.getPort());
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log.error("输送线plc连接失败 [id:{}] [ip:{}] [error:{}]",
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slave.getId(), slave.getIp(), connect.Message);
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}
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initSite();
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return connected;
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}
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/**
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* 重连机制
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*/
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private void reconnect() {
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log.warn("尝试重新连接PLC [id:{}]", slave.getId());
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try {
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Thread.sleep(1000); // 重连前等待1秒
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} catch (InterruptedException e) {
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Thread.currentThread().interrupt();
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return;
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}
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connect();
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}
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/**
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* 读取状态 ====> 整块plc
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*/
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private void read() throws InterruptedException {
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if (!connected || siemensS7Net == null) {
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log.warn("PLC未连接，跳过读取 [id:{}]", slave.getId());
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return;
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}
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List<Integer> staNos = slave.getStaNos();
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int staNoSize = staNos.size();
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// 读取站点状态
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OperateResultExOne<byte[]> result = siemensS7Net.Read(
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StationStatusField.ALL.buildAddress(),
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(short) (staNoSize * StationStatusField.ALL.getByteLength()));
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if (!result.IsSuccess) {
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log.error("读取站点状态失败 [id:{}] [error:{}]", slave.getId(), result.Message);
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OutputQueue.DEVP.offer(MessageFormat.format("【{0}】读取输送线plc状态信息失败 ===>> [id:{1}] [ip:{2}]",
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DateUtils.convert(new Date()), slave.getId(), slave.getIp()));
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connected = false;
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return;
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}
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byte[] content = result.Content;
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for (int i = 0; i < staNoSize; i++) {
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Integer siteId = staNos.get(i);
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StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
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parseStationStatus(content, i, staProtocol);
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}
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// 读取条码
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readBarcodes();
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// 读取外形检测错误
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readDimensionErrors();
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// 读取PLC故障
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readPlcAlarms(staNos, staNoSize);
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// 定期更新数据库（降低频率）
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updateDatabaseIfNeeded();
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}
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/**
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* 解析单个站点状态
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*/
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private void parseStationStatus(byte[] content, int index, StaProtocol staProtocol) {
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int offset = index * StationStatusField.ALL.getByteLength();
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staProtocol.setWorkNo(siemensS7Net.getByteTransform().TransInt32(content, offset));
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staProtocol.setStaNo((int) siemensS7Net.getByteTransform().TransInt16(
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content, offset + StationStatusField.FINAL_TARGET.getOffset()));
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boolean[] status = siemensS7Net.getByteTransform().TransBool(
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content, offset + StationStatusField.STATUS_WORD.getOffset(),
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StationStatusField.STATUS_WORD.getByteLength());
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staProtocol.setAutoing(status[0]);
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staProtocol.setLoading(status[1]);
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staProtocol.setInEnable(status[2]);
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staProtocol.setOutEnable(status[3]);
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staProtocol.setEmptyMk(status[4]);
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staProtocol.setFullPlt(status[5]);
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staProtocol.setHigh(status[6]);
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staProtocol.setLow(status[7]);
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if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
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staProtocol.setPakMk(true);
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}
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}
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/**
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* 读取条码信息
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*/
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private void readBarcodes() {
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List<Integer> barcodeArr = slave.getBarcodeArr();
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if (barcodeArr == null || barcodeArr.isEmpty()) {
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return;
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}
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OperateResultExOne<byte[]> result = siemensS7Net.Read(
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DeviceField.BARCODE.buildAddress(),
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(short) (barcodeArr.size() * DeviceField.BARCODE.getByteLength()));
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if (!result.IsSuccess) {
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log.warn("读取条码失败 [id:{}]", slave.getId());
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return;
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}
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byte[] content = result.Content;
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for (int i = 0; i < barcodeArr.size(); i++) {
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String barcode = siemensS7Net.getByteTransform().TransString(
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content, i * DeviceField.BARCODE.getByteLength(),
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DeviceField.BARCODE.getByteLength(), "UTF-8");
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BarcodeThread barcodeThread = (BarcodeThread) SlaveConnection.get(
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SlaveType.Barcode, barcodeArr.get(i));
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if (Cools.isEmpty(barcode)) {
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if (barcodeThread != null) {
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barcodeThread.clearBarcode();
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}
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} else {
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if (barcodeThread != null && !barcode.equals(barcodeThread.getBarcode())) {
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barcodeThread.setBarcode(barcode);
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log.info("料箱码：{}", barcode);
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}
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}
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}
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}
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/**
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* 读取外形检测错误
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*/
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private void readDimensionErrors() {
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List<Integer> staNosError = slave.getStaNosError();
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if (staNosError == null || staNosError.isEmpty()) {
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return;
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}
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OperateResultExOne<byte[]> result = siemensS7Net.Read(
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DeviceField.DIMENSION_WORD.buildAddress(),
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(short) (staNosError.size() * DeviceField.DIMENSION_WORD.getByteLength()));
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if (!result.IsSuccess) {
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log.warn("读取外形检测错误失败 [id:{}]", slave.getId());
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return;
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}
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byte[] content = result.Content;
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for (int i = 0; i < staNosError.size(); i++) {
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Integer siteId = staNosError.get(i);
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StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
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boolean[] status = siemensS7Net.getByteTransform().TransBool(
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content, i * DeviceField.DIMENSION_WORD.getByteLength(),
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DeviceField.DIMENSION_WORD.getByteLength());
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staProtocol.setFrontErr(status[0]);
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staProtocol.setBackErr(status[1]);
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staProtocol.setHighErr(status[2]);
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staProtocol.setLeftErr(status[3]);
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staProtocol.setRightErr(status[4]);
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staProtocol.setWeightErr(status[5]);
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staProtocol.setBarcodeErr(status[6]);
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}
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}
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/**
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* 读取PLC故障信息
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*/
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private void readPlcAlarms(List<Integer> staNos, int staNoSize) {
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OperateResultExOne<byte[]> result = siemensS7Net.Read(
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PlcAlarmDefinition.ALL.buildAddress(),
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(short) (staNoSize * PlcAlarmDefinition.ALL.getByteLength()));
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if (!result.IsSuccess) {
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log.warn("读取PLC故障信息失败 [id:{}]", slave.getId());
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return;
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}
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byte[] content = result.Content;
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for (int i = 0; i < staNoSize; i++) {
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Integer siteId = staNos.get(i);
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StaProtocol staProtocol = station.get(siteId);
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if (staProtocol == null) {
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continue;
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}
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boolean[] status = siemensS7Net.getByteTransform().TransBool(
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content, i * PlcAlarmDefinition.ALL.getByteLength(), 1);
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staProtocol.setBreakerErr(status[0]);
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staProtocol.setInfraredErr(status[1]);
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staProtocol.setOutTimeErr(status[2]);
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staProtocol.setSeizeSeatErr(status[3]);
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staProtocol.setWrkYgoodsN(status[4]);
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staProtocol.setInverterErr(status[5]);
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staProtocol.setContactErr(status[6]);
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staProtocol.setUpcontactErr(status[7]);
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}
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}
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/**
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* 按需更新数据库（降低更新频率）
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*/
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private void updateDatabaseIfNeeded() {
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long currentTime = System.currentTimeMillis();
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if (currentTime - lastDbUpdateTime < DB_UPDATE_INTERVAL_MS) {
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return;
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}
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try {
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List<Integer> staNos = slave.getStaNos();
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List<Devp> devps = new ArrayList<>(staNos.size());
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for (Integer siteId : staNos) {
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StaProtocol staProtocol = station.get(siteId);
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if (staProtocol != null) {
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devps.add(staProtocol.toSqlModel());
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}
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}
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if (devps.isEmpty()) {
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return;
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}
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DevpService devpService = SpringContextUtil.getBean(DevpService.class);
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if (devpService != null) {
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devpService.updateBatchByDevpNo(devps);
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lastDbUpdateTime = currentTime;
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log.debug("批量更新数据库成功 [id:{}] [count:{}]", slave.getId(), devps.size());
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} else {
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log.error("DevpService未找到，无法更新数据库 [id:{}]", slave.getId());
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}
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} catch (Exception e) {
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log.error("更新数据库数据失败 [id:{}]", slave.getId(), e);
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OutputQueue.DEVP.offer(MessageFormat.format("【{0}】更新数据库数据失败 ===>> [id:{1}]",
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DateUtils.convert(new Date()), slave.getId()));
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News.error("SiemensDevp - 3 - 更新数据库数据失败 ===>> [id:{}]", slave.getId());
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// 更新失败时重置站点状态
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initSite();
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}
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}
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/**
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* 写入 ID+目标站 =====> 单站点写入
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*/
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private void write(StaProtocol staProtocol) throws InterruptedException {
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if (staProtocol == null) {
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log.warn("写入数据为空，跳过 [id:{}]", slave.getId());
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return;
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}
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if (!connected || siemensS7Net == null) {
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log.error("PLC未连接，无法写入 [id:{}]", slave.getId());
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return;
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}
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List<Integer> staNos = slave.getStaNos();
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int index = staNos.indexOf(staProtocol.getSiteId());
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if (index < 0) {
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log.error("站点编号不存在于配置中 [id:{}] [siteId:{}]", slave.getId(), staProtocol.getSiteId());
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return;
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}
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int baseOffset = index * TaskField.ALL.getByteLength();
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String workNoAddr = TaskField.TASK_NUMBER.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION
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+ (baseOffset + TaskField.TASK_NUMBER.getOffset());
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String destStaAddr = TaskField.DEST_STATION.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION
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+ (baseOffset + TaskField.DEST_STATION.getOffset());
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// 任务下发重试机制
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int writeCount = 0;
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boolean success = false;
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while (writeCount < WRITE_RETRY_MAX) {
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OperateResult writeResult = siemensS7Net.Write(workNoAddr, staProtocol.getWorkNo().shortValue());
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Thread.sleep(WRITE_RETRY_INTERVAL_MS);
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OperateResult writeResult1 = siemensS7Net.Write(destStaAddr, staProtocol.getStaNo().shortValue());
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if (writeResult.IsSuccess && writeResult1.IsSuccess) {
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log.info("写入输送线命令成功 [id:{}] [siteId:{}] [workNo:{}] [destSta:{}] [retry:{}]",
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slave.getId(), staProtocol.getSiteId(), staProtocol.getWorkNo(),
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staProtocol.getStaNo(), writeCount);
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success = true;
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break;
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}
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writeCount++;
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log.error("写入输送线命令失败 [id:{}] [siteId:{}] [retry:{}] [workErr:{}] [destErr:{}]",
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slave.getId(), staProtocol.getSiteId(), writeCount,
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writeResult.Message, writeResult1.Message);
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if (writeCount < WRITE_RETRY_MAX) {
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Thread.sleep(WRITE_RETRY_INTERVAL_MS);
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}
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}
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if (!success) {
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StaProtocol currentSta = station.get(staProtocol.getSiteId());
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if (currentSta != null && currentSta.getWorkNo() == 0 && currentSta.getStaNo() == 0) {
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currentSta.setPakMk(true);
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}
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String errorMsg = MessageFormat.format("【{0}】写入输送线站点数据失败。输送线plc编号={1}，站点数据={2}",
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slave.getId(), JSON.toJSON(staProtocol));
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OutputQueue.DEVP.offer(errorMsg);
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News.error("SiemensDevp - 4 - 写入输送线站点数据失败。输送线plc编号={}，站点数据={}",
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slave.getId(), JSON.toJSON(staProtocol));
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log.error(errorMsg);
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}
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}
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/**
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* 设置入库标记
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*/
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@Override
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public void setPakMk(Integer siteId, boolean pakMk) {
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StaProtocol staProtocol = station.get(siteId);
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if (null != staProtocol) {
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staProtocol.setPakMk(pakMk);
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}
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}
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@Override
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public void close() {
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if (siemensS7Net != null) {
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try {
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siemensS7Net.ConnectClose();
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log.info("PLC连接已关闭 [id:{}]", slave.getId());
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} catch (Exception e) {
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log.error("关闭PLC连接异常 [id:{}]", slave.getId(), e);
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} finally {
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connected = false;
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}
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}
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}
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}
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