package com.zy.core.network.real;
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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.alibaba.fastjson.JSONObject;
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import com.baomidou.mybatisplus.core.conditions.query.QueryWrapper;
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import com.core.common.DateUtils;
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import com.core.common.SpringUtils;
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import com.zy.asrs.entity.BasDevp;
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import com.zy.asrs.entity.DeviceConfig;
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import com.zy.asrs.service.BasDevpService;
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import com.zy.common.utils.RedisUtil;
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import com.zy.core.News;
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import com.zy.core.cache.OutputQueue;
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import com.zy.core.model.CommandResponse;
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import com.zy.core.model.StationObjModel;
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import com.zy.core.model.command.StationCommand;
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import com.zy.core.model.protocol.StationTaskBufferItem;
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import com.zy.core.network.api.ZyStationConnectApi;
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import com.zy.core.network.entity.ZyStationStatusEntity;
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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.Collections;
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import java.util.Comparator;
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import java.util.Date;
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import java.util.List;
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/**
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* 输送站真实连接（PLC）
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*/
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@Slf4j
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public class ZyStationV4RealConnect implements ZyStationConnectApi {
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private static final int TASK_AREA_LENGTH = 48;
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private static final int TASK_AREA_SLOT_SIZE = 12;
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private static final int TASK_AREA_SLOT_COUNT = 3;
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private static final String[] CONVEYOR_COMMON_ALARM_MESSAGES = {
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"急停",
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"低位断路器断开",
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"低位变频器故障",
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"输送运行超时",
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"顶升运行超时",
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"申请任务超时",
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"托盘突出报警",
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"任务运行超时",
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"FWD旋转限位报警",
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"REV旋转限位报警",
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"扫码检验异常",
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"安全门打开报警",
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"任务重复报警",
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"入站过程中前置条件异常",
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"入站前置条件等待超时",
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"出站过程中前置条件异常",
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"出站前置条件等待超时",
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"高位断路器断开",
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"高位变频器故障",
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"顶升限位信号异常",
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"入站运行中，上站同步运行请求消失",
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"出站完成后，仍然检测到托盘",
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"入站完成后，没有检测到托盘",
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"下站站号异常",
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"路径查询异常"
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};
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private List<ZyStationStatusEntity> statusList;
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private List<StationObjModel> barcodeOriginList;
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private List<StationObjModel> inStationOriginList;
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private SiemensS7Net siemensNet;
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private DeviceConfig deviceConfig;
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private RedisUtil redisUtil;
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public ZyStationV4RealConnect(DeviceConfig deviceConfig, RedisUtil redisUtil) {
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this.deviceConfig = deviceConfig;
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this.redisUtil = redisUtil;
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}
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@Override
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public boolean connect() {
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boolean connected = false;
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siemensNet = new SiemensS7Net(SiemensPLCS.S1200, deviceConfig.getIp());
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OperateResult connect = siemensNet.ConnectServer();
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if (connect.IsSuccess) {
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connected = true;
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OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送站plc连接成功 ===>> [id:{1}] [ip:{2}] [port:{3}]",
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DateUtils.convert(new Date()), deviceConfig.getDeviceNo(), deviceConfig.getIp(),
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deviceConfig.getPort()));
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News.info("输送站plc连接成功 ===>> [id:{}] [ip:{}] [port:{}]",
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deviceConfig.getDeviceNo(), deviceConfig.getIp(), deviceConfig.getPort());
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} else {
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OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送站plc连接失败！！！ ===>> [id:{1}] [ip:{2}] [port:{3}]",
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DateUtils.convert(new Date()), deviceConfig.getDeviceNo(), deviceConfig.getIp(),
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deviceConfig.getPort()));
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News.error("输送站plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}]",
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deviceConfig.getDeviceNo(), deviceConfig.getIp(), deviceConfig.getPort());
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}
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// siemensNet.ConnectClose();
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return connected;
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}
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@Override
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public boolean disconnect() {
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siemensNet.ConnectClose();
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return true;
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}
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@Override
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public List<ZyStationStatusEntity> getStatus(Integer deviceNo) {
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if (statusList == null) {
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BasDevpService basDevpService = SpringUtils.getBean(BasDevpService.class);
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if (basDevpService == null) {
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return Collections.emptyList();
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}
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BasDevp basDevp = basDevpService
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.getOne(new QueryWrapper<BasDevp>().eq("devp_no", deviceConfig.getDeviceNo()));
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if (basDevp == null) {
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return Collections.emptyList();
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}
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statusList = JSONObject.parseArray(basDevp.getStationList(), ZyStationStatusEntity.class);
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if (statusList != null) {
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statusList.sort(Comparator.comparing(ZyStationStatusEntity::getStationId));
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}
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barcodeOriginList = basDevp.getBarcodeStationList$();
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inStationOriginList = sortStationObjModelsByStationId(basDevp.getInStationList$());
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}
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if (siemensNet == null) {
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return statusList;
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}
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OperateResultExOne<byte[]> result = siemensNet.Read("DB100.0", (short) (statusList.size() * 10));
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if (result.IsSuccess) {
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byte[] taskBufferRaw = readTaskBufferRaw();
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for (int i = 0; i < statusList.size(); i++) {
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ZyStationStatusEntity statusEntity = statusList.get(i); // 站点编号
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statusEntity.setTaskNo(siemensNet.getByteTransform().TransInt32(result.Content, i * 10)); // 工作号
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statusEntity.setTargetStaNo((int) siemensNet.getByteTransform().TransInt16(result.Content, i * 10 + 4)); // 目标站
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boolean[] status = siemensNet.getByteTransform().TransBool(result.Content, i * 10 + 6, 1);
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statusEntity.setAutoing(status[0]); // 自动
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statusEntity.setLoading(status[1]); // 有物
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statusEntity.setInEnable(status[2]); // 可入
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statusEntity.setOutEnable(status[3]);// 可出
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statusEntity.setEmptyMk(status[4]); // 空托盘
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statusEntity.setFullPlt(status[5]); // 满托盘
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boolean[] status2 = siemensNet.getByteTransform().TransBool(result.Content, i * 10 + 7, 1);
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statusEntity.setEnableIn(status2[1]);//启动入库
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statusEntity.setRunBlock(status2[2]);//重新规划路线
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Integer palletHeight = null;
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if (status[7]) {
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palletHeight = 1;//低
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}
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if (status2[0]) {
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palletHeight = 2;//中
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}
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if (status[6]) {
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palletHeight = 3;//高
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}
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statusEntity.setPalletHeight(palletHeight);//高低信号
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statusEntity.setError(0);//默认无报警
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statusEntity.setErrorMsg("");
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statusEntity.setTaskWriteIdx((int) siemensNet.getByteTransform().TransInt16(result.Content, i * 10 + 8));//任务可写区
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fillTaskBufferStatus(taskBufferRaw, i, statusEntity);
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}
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}
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// 条码扫描器
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OperateResultExOne<byte[]> result2 = siemensNet.Read("DB101.16", (short) (barcodeOriginList.size() * 16));
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if (result2.IsSuccess) {
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for (int i = 0; i < barcodeOriginList.size(); i++) {
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ZyStationStatusEntity barcodeEntity = findStatusEntityByBarcodeIdx(i + 1);
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if (barcodeEntity == null) {
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continue;
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}
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String barcode = siemensNet.getByteTransform().TransString(result2.Content, i * 16 + 2, 14, "UTF-8");
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barcode = barcode.trim();
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barcodeEntity.setBarcode(barcode);
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}
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}
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// 称重
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OperateResultExOne<byte[]> result3 = siemensNet.Read("DB102.4", (short) (barcodeOriginList.size() * 4));
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if (result3.IsSuccess) {
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for (int i = 0; i < barcodeOriginList.size(); i++) {
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ZyStationStatusEntity barcodeEntity = findStatusEntityByBarcodeIdx(i + 1);
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if (barcodeEntity == null) {
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continue;
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}
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double weight = (double) siemensNet.getByteTransform().TransSingle(result3.Content, i * 4);
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barcodeEntity.setWeight(weight);
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}
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}
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// 条码站报警信息
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OperateResultExOne<byte[]> result4 = siemensNet.Read("DB103.2", (short) (barcodeOriginList.size() * 2));
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if (result4.IsSuccess) {
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for (int i = 0; i < barcodeOriginList.size(); i++) {
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ZyStationStatusEntity barcodeEntity = findStatusEntityByBarcodeIdx(i + 1);
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if (barcodeEntity == null) {
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continue;
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}
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StringBuilder sb = new StringBuilder();
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boolean[] status1 = siemensNet.getByteTransform().TransBool(result4.Content, i * 2, 1);
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boolean[] status2 = siemensNet.getByteTransform().TransBool(result4.Content, i * 2 + 1, 1);
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if(status1[0]){
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sb.append("左超宽报警;");
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}
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if(status1[1]) {
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sb.append("右超宽报警;");
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}
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if(status1[2]) {
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sb.append("前超长报警;");
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}
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if(status1[3]) {
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sb.append("后超长报警;");
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}
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if(status1[4]) {
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sb.append("超高报警;");
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}
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if(status1[5]) {
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sb.append("有货报警，空托入库时检测托盘上有无货物;");
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}
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if(status1[6]) {
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sb.append("重量异常报警;");
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}
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if(status1[7]) {
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sb.append("扫码异常;");
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}
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applyAlarmMessage(barcodeEntity, sb.toString());
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}
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}
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// 输送站点通用报警信息
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OperateResultExOne<byte[]> result5 = siemensNet.Read("DB25.0", (short) (statusList.size() * 4));
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if (result5.IsSuccess) {
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for (int i = 0; i < statusList.size(); i++) {
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ZyStationStatusEntity statusEntity = statusList.get(i); // 站点编号
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boolean[] status1 = siemensNet.getByteTransform().TransBool(result5.Content, i * 4, 1);
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boolean[] status2 = siemensNet.getByteTransform().TransBool(result5.Content, i * 4 + 1, 1);
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boolean[] status3 = siemensNet.getByteTransform().TransBool(result5.Content, i * 4 + 2, 1);
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boolean[] status4 = siemensNet.getByteTransform().TransBool(result5.Content, i * 4 + 3, 1);
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String alarmMsg = buildConveyorCommonAlarmMessage(status1, status2, status3, status4);
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applyAlarmMessage(statusEntity, mergeAlarmMessages(statusEntity.getErrorMsg(), alarmMsg));
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}
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}
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// 出入库模式
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OperateResultExOne<byte[]> result6 = siemensNet.Read("DB167.2", (short) (inStationOriginList.size() * 2));
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if (result6.IsSuccess) {
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clearInStationIoModes();
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for (int i = 0; i < inStationOriginList.size(); i++) {
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ZyStationStatusEntity inStationEntity = findStatusEntityByInStationIdx(i);
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if (inStationEntity == null) {
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continue;
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}
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Integer ioMode = normalizeIoMode((int) siemensNet.getByteTransform().TransInt16(result6.Content, i * 2));
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inStationEntity.setIoMode(ioMode);
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}
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}
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return statusList;
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}
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@Override
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public CommandResponse sendCommand(Integer deviceNo, StationCommand command) {
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CommandResponse commandResponse = new CommandResponse(false);
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if (null == command) {
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commandResponse.setMessage("命令为空");
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return commandResponse;
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}
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getStatus(deviceNo);
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int stationIdx = findIndex(command.getStationId());
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if (stationIdx == -1) {
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commandResponse.setMessage("命令下发失败，未找到站点状态");
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return commandResponse;
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}
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ZyStationStatusEntity statusEntity = statusList.get(stationIdx);
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Integer taskWriteIdx = statusEntity == null ? null : statusEntity.getTaskWriteIdx();
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if (taskWriteIdx == null || taskWriteIdx <= 0) {
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commandResponse.setMessage("命令下发失败，当前无可用任务写入区");
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return commandResponse;
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}
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int useTaskWriteIdx = getTaskWriteIdx(stationIdx, taskWriteIdx);
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if (useTaskWriteIdx == -1) {
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commandResponse.setMessage("命令下发超时，无法找到可用下发区域");
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return commandResponse;
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}
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int taskBaseOffset = stationIdx * TASK_AREA_LENGTH + (useTaskWriteIdx * TASK_AREA_SLOT_SIZE);
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OperateResult writeTaskNo = siemensNet.Write("DB13." + taskBaseOffset, command.getTaskNo());
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if (!writeTaskNo.IsSuccess) {
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log.error("写入输送线命令失败。站点编号={}，站点数据={}", command.getTaskNo(), JSON.toJSON(command));
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commandResponse.setResult(false);
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commandResponse.setMessage("命令下发失败，写入工作号失败");
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return commandResponse;
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}
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OperateResult writeTarget = siemensNet.Write("DB13." + (taskBaseOffset + 6), command.getTargetStaNo().shortValue());
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if (!writeTarget.IsSuccess) {
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log.error("写入输送线命令失败。站点编号={}，站点数据={}", command.getTaskNo(), JSON.toJSON(command));
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commandResponse.setResult(false);
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commandResponse.setMessage("命令下发失败，写入目标设备号失败");
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return commandResponse;
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}
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log.info("写入输送线命令成功。任务号={}，站点数据={}", command.getTaskNo(), JSON.toJSON(command));
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commandResponse.setResult(true);
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return commandResponse;
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}
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@Override
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public CommandResponse clearTaskBufferSlot(Integer deviceNo, Integer stationId, Integer slotIdx) {
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CommandResponse commandResponse = new CommandResponse(false);
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if (stationId == null) {
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commandResponse.setMessage("站点号为空");
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return commandResponse;
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}
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if (slotIdx == null || slotIdx <= 0 || slotIdx > TASK_AREA_SLOT_COUNT) {
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commandResponse.setMessage("缓存区槽位无效");
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return commandResponse;
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}
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getStatus(deviceNo);
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int stationIdx = findIndex(stationId);
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if (stationIdx < 0) {
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commandResponse.setMessage("未找到站点状态");
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return commandResponse;
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}
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int slotBaseOffset = stationIdx * TASK_AREA_LENGTH + slotIdx * TASK_AREA_SLOT_SIZE;
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CommandResponse clearTaskNo = sendOriginCommand("DB13." + slotBaseOffset, new short[]{0, 0});
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if (clearTaskNo == null || !Boolean.TRUE.equals(clearTaskNo.getResult())) {
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commandResponse.setMessage(clearTaskNo == null ? "清空任务号失败" : clearTaskNo.getMessage());
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return commandResponse;
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}
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CommandResponse clearTarget = sendOriginCommand("DB13." + (slotBaseOffset + 6), new short[]{0});
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if (clearTarget == null || !Boolean.TRUE.equals(clearTarget.getResult())) {
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commandResponse.setMessage(clearTarget == null ? "清空目标站失败" : clearTarget.getMessage());
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return commandResponse;
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}
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commandResponse.setResult(true);
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commandResponse.setMessage("缓存区槽位清理成功");
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return commandResponse;
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}
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@Override
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public synchronized CommandResponse sendOriginCommand(String address, short[] data) {
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CommandResponse commandResponse = new CommandResponse(false);
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if (null == data || data.length == 0) {
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commandResponse.setMessage("数据为空");
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return commandResponse;
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}
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OperateResult write = siemensNet.Write(address, data);
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if (write.IsSuccess) {
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log.info("写入原始命令成功。地址={}，数据={}", address, JSON.toJSON(data));
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commandResponse.setResult(true);
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} else {
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log.error("写入原始命令失败。地址={}，数据={}", address, JSON.toJSON(data));
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commandResponse.setResult(false);
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}
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return commandResponse;
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}
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@Override
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public byte[] readOriginCommand(String address, int length) {
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OperateResultExOne<byte[]> result = siemensNet.Read(address, (short) length);
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if (result.IsSuccess) {
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return result.Content;
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}
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return new byte[0];
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}
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private ZyStationStatusEntity findStatusEntityByBarcodeIdx(Integer barcodeIdx) {
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Integer stationId = null;
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for (StationObjModel stationObjModel : barcodeOriginList) {
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if (stationObjModel.getBarcodeIdx().equals(barcodeIdx)) {
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stationId = stationObjModel.getStationId();
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break;
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}
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}
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for (ZyStationStatusEntity zyStationStatusEntity : statusList) {
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if(zyStationStatusEntity.getStationId().equals(stationId)) {
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return zyStationStatusEntity;
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}
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}
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return null;
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}
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private ZyStationStatusEntity findStatusEntityByInStationIdx(Integer idx) {
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Integer stationId = findInStationIdByOrder(inStationOriginList, idx);
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for (ZyStationStatusEntity zyStationStatusEntity : statusList) {
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if(zyStationStatusEntity.getStationId().equals(stationId)) {
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return zyStationStatusEntity;
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}
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}
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return null;
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}
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private void clearInStationIoModes() {
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if (inStationOriginList == null || statusList == null) {
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return;
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}
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for (StationObjModel stationObjModel : inStationOriginList) {
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if (stationObjModel == null || stationObjModel.getStationId() == null) {
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continue;
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}
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for (ZyStationStatusEntity statusEntity : statusList) {
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if (stationObjModel.getStationId().equals(statusEntity.getStationId())) {
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statusEntity.setIoMode(null);
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break;
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}
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}
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}
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}
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private int getTaskWriteIdx(int stationIdx, Integer taskWriteIdx) {
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int useIdx = -1;
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if (stationIdx < 0 || taskWriteIdx == null || taskWriteIdx <= 0) {
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return useIdx;
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}
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OperateResultExOne<byte[]> resultTask = siemensNet.Read("DB13." + (stationIdx * TASK_AREA_LENGTH), (short) TASK_AREA_LENGTH);
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if (resultTask.IsSuccess) {
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int taskNo = siemensNet.getByteTransform().TransInt32(resultTask.Content, taskWriteIdx * TASK_AREA_SLOT_SIZE);
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int targetPoint = siemensNet.getByteTransform().TransInt16(resultTask.Content, taskWriteIdx * TASK_AREA_SLOT_SIZE + 6);
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if (taskNo == 0 && targetPoint == 0) {
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useIdx = taskWriteIdx;
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}
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}
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return useIdx;
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}
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private byte[] readTaskBufferRaw() {
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int totalLength = statusList == null ? 0 : statusList.size() * TASK_AREA_LENGTH;
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if (totalLength <= 0) {
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return null;
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}
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OperateResultExOne<byte[]> resultTask = siemensNet.Read("DB13.0", (short) totalLength);
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if (!resultTask.IsSuccess || resultTask.Content == null || resultTask.Content.length < totalLength) {
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return null;
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}
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return resultTask.Content;
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}
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private void fillTaskBufferStatus(byte[] taskBufferRaw, int stationIdx, ZyStationStatusEntity statusEntity) {
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if (statusEntity == null || stationIdx < 0 || taskBufferRaw == null) {
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statusEntity.setTaskBufferItems(new ArrayList<>());
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return;
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}
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List<StationTaskBufferItem> itemList = new ArrayList<>();
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int stationOffset = stationIdx * TASK_AREA_LENGTH;
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if (stationOffset + TASK_AREA_LENGTH > taskBufferRaw.length) {
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statusEntity.setTaskBufferItems(itemList);
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return;
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}
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for (int slotIdx = 1; slotIdx <= TASK_AREA_SLOT_COUNT; slotIdx++) {
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int offset = stationOffset + (slotIdx * TASK_AREA_SLOT_SIZE);
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int taskNo = siemensNet.getByteTransform().TransInt32(taskBufferRaw, offset);
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int targetPoint = siemensNet.getByteTransform().TransInt16(taskBufferRaw, offset + 6);
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StationTaskBufferItem item = new StationTaskBufferItem();
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item.setSlotIdx(slotIdx);
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item.setTaskNo(taskNo);
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item.setTargetStaNo(targetPoint);
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itemList.add(item);
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}
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statusEntity.setTaskBufferItems(itemList);
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}
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private int findIndex(Integer stationId) {
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for (int i = 0; i < statusList.size(); i++) {
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ZyStationStatusEntity statusEntity = statusList.get(i);
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if (statusEntity.getStationId().equals(stationId)) {
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return i;
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}
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}
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return -1;
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}
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static String buildConveyorCommonAlarmMessage(boolean[] status1, boolean[] status2, boolean[] status3, boolean[] status4) {
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StringBuilder sb = new StringBuilder();
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appendConveyorCommonAlarmMessages(sb, status1, 0);
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appendConveyorCommonAlarmMessages(sb, status2, 8);
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appendConveyorCommonAlarmMessages(sb, status3, 16);
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appendConveyorCommonAlarmMessages(sb, status4, 24);
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return sb.toString();
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}
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static String mergeAlarmMessages(String currentMsg, String appendMsg) {
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String current = currentMsg == null ? "" : currentMsg;
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String append = appendMsg == null ? "" : appendMsg;
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if (append.isEmpty()) {
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return current;
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}
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if (current.isEmpty()) {
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return append;
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}
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if (!current.endsWith(";")) {
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current += ";";
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}
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return current + append;
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}
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static Integer normalizeIoMode(Integer rawMode) {
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if (rawMode == null) {
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return null;
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}
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if (rawMode == 1 || rawMode == 2) {
|
return rawMode;
|
}
|
return null;
|
}
|
|
static Integer findInStationIdByOrder(List<StationObjModel> inStationOriginList, Integer orderIdx) {
|
if (inStationOriginList == null || orderIdx == null || orderIdx < 0 || orderIdx >= inStationOriginList.size()) {
|
return null;
|
}
|
StationObjModel stationObjModel = inStationOriginList.get(orderIdx);
|
return stationObjModel == null ? null : stationObjModel.getStationId();
|
}
|
|
static List<StationObjModel> sortStationObjModelsByStationId(List<StationObjModel> stationObjModels) {
|
if (stationObjModels == null) {
|
return Collections.emptyList();
|
}
|
stationObjModels.sort(Comparator.comparing(StationObjModel::getStationId, Comparator.nullsLast(Integer::compareTo)));
|
return stationObjModels;
|
}
|
|
private static void appendConveyorCommonAlarmMessages(StringBuilder sb, boolean[] status, int startIdx) {
|
if (status == null) {
|
return;
|
}
|
int limit = Math.min(status.length, 8);
|
for (int i = 0; i < limit; i++) {
|
int alarmIdx = startIdx + i;
|
if (!status[i] || alarmIdx >= CONVEYOR_COMMON_ALARM_MESSAGES.length) {
|
continue;
|
}
|
sb.append(CONVEYOR_COMMON_ALARM_MESSAGES[alarmIdx]).append(";");
|
}
|
}
|
|
private static void applyAlarmMessage(ZyStationStatusEntity statusEntity, String alarmMsg) {
|
if (statusEntity == null) {
|
return;
|
}
|
String message = alarmMsg == null ? "" : alarmMsg;
|
statusEntity.setError(message.isEmpty() ? 0 : 1);
|
statusEntity.setErrorMsg(message);
|
}
|
|
}
|
