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.mapper.EntityWrapper;
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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.enums.RedisKeyType;
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import com.zy.core.enums.StationCommandType;
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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.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.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 ZyStationV3RealConnect implements ZyStationConnectApi {
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private static final long COMMAND_IDX_SLOW_THRESHOLD_MS = 500L;
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private static final long COMMAND_SEND_SLOW_THRESHOLD_MS = 1000L;
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private List<ZyStationStatusEntity> statusList;
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private List<StationObjModel> barcodeOriginList;
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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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private final static int taskAddressLength = 48;
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private final static int taskAddressLimit = 50;
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private final static int taskStatusOffset = 46;
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private final static int commandAreaTotalLength = taskAddressLength * taskAddressLimit;
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public ZyStationV3RealConnect(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.S1500, 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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.selectOne(new EntityWrapper<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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}
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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() * 8));
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if (result.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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statusEntity.setTaskNo(siemensNet.getByteTransform().TransInt32(result.Content, i * 8)); // 工作号
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statusEntity.setTargetStaNo((int) siemensNet.getByteTransform().TransInt16(result.Content, i * 8 + 4)); // 目标站
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boolean[] status = siemensNet.getByteTransform().TransBool(result.Content, i * 8 + 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 * 8 + 7, 1);
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statusEntity.setRunBlock(status2[1]);//重新规划路线
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statusEntity.setEnableIn(status2[3]);//启动入库
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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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}
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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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byte length = 10;//result2.Content[1];
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String barcode = siemensNet.getByteTransform().TransString(result2.Content, i * 16 + 2, length, "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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// 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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if(sb.length() > 0) {
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barcodeEntity.setError(1);
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}else {
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barcodeEntity.setError(0);
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}
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barcodeEntity.setErrorMsg(sb.toString());
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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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int maxTryCount = 999;
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int tryCount = 0;
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if (command.getCommandType().equals(StationCommandType.MOVE)) {
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int enableCommandIdx = -1;
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long sendStartMs = System.currentTimeMillis();
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EnableCommandIdxResult idxResult = null;
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while (true) {
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idxResult = getEnableCommandIdx(command.getTaskNo());
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enableCommandIdx = idxResult.enableCommandIdx;
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if(enableCommandIdx == -1) {
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if (idxResult != null && idxResult.duplicateTaskNo) {
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commandResponse.setMessage("命令区已存在相同任务号，等待已有命令执行完成");
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log.warn("[WCS Trace][输送线命令] 命令区已存在相同任务号，取消本次重复下发。deviceNo={}, taskNo={}, occupiedSlotCount={}, scanCostMs={}",
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deviceNo, command.getTaskNo(), idxResult.occupiedSlotCount, idxResult.scanCostMs);
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return commandResponse;
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}
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try {
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Thread.sleep(300);
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}catch (Exception e) {}
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}else {
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break;
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}
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tryCount++;
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if (tryCount == 1 || tryCount % 10 == 0) {
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log.warn("[WCS Trace][输送线命令] 暂未找到可用下发区域。deviceNo={}, taskNo={}, tryCount={}, occupiedSlotCount={}, scanCostMs={}",
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deviceNo, command.getTaskNo(), tryCount,
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idxResult == null ? -1 : idxResult.occupiedSlotCount,
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idxResult == null ? -1 : idxResult.scanCostMs);
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}
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if (tryCount > maxTryCount) {
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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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log.error("[WCS Trace][输送线命令] 命令下发超时。deviceNo={}, taskNo={}, totalWaitMs={}, tryCount={}",
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deviceNo, command.getTaskNo(), System.currentTimeMillis() - sendStartMs, tryCount);
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return commandResponse;
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}
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}
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if (idxResult != null && idxResult.scanCostMs > COMMAND_IDX_SLOW_THRESHOLD_MS) {
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log.warn("[WCS Trace][输送线命令] 获取可用下发区域较慢。deviceNo={}, taskNo={}, enableIdx={}, occupiedSlotCount={}, scanCostMs={}, tryCount={}",
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deviceNo, command.getTaskNo(), enableCommandIdx, idxResult.occupiedSlotCount, idxResult.scanCostMs, tryCount);
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}
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List<Integer> pathList = command.getNavigatePath();
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short[] data = new short[21];
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data[0] = command.getTargetStaNo().shortValue();
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int dataIdx = 1;
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for (Integer path : pathList) {
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data[dataIdx++] = path.shortValue();
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}
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OperateResult writeTask = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength), command.getTaskNo());
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try {
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Thread.sleep(50);
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}catch (Exception e) {}
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OperateResult writeData = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength + 4), data);
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try {
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Thread.sleep(200);
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}catch (Exception e) {}
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OperateResult writeConfirm = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength + 46), (short) 1);
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if(writeTask.IsSuccess && writeData.IsSuccess && writeConfirm.IsSuccess) {
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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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long totalCostMs = System.currentTimeMillis() - sendStartMs;
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if (totalCostMs > COMMAND_SEND_SLOW_THRESHOLD_MS) {
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log.warn("[WCS Trace][输送线命令] 命令写入总耗时较长。deviceNo={}, taskNo={}, enableIdx={}, tryCount={}, occupiedSlotCount={}, totalCostMs={}",
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deviceNo, command.getTaskNo(), enableCommandIdx, tryCount,
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idxResult == null ? -1 : idxResult.occupiedSlotCount, totalCostMs);
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}
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commandResponse.setResult(true);
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}else {
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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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}
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} else if (command.getCommandType().equals(StationCommandType.WRITE_INFO)) {
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int enableCommandIdx = -1;
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long sendStartMs = System.currentTimeMillis();
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EnableCommandIdxResult idxResult = null;
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while (true) {
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idxResult = getEnableCommandIdx(command.getTaskNo());
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enableCommandIdx = idxResult.enableCommandIdx;
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if(enableCommandIdx == -1) {
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if (idxResult != null && idxResult.duplicateTaskNo) {
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commandResponse.setMessage("命令区已存在相同任务号，等待已有命令执行完成");
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log.warn("[WCS Trace][输送线命令] WRITE_INFO 命令区已存在相同任务号，取消本次重复下发。deviceNo={}, taskNo={}, occupiedSlotCount={}, scanCostMs={}",
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deviceNo, command.getTaskNo(), idxResult.occupiedSlotCount, idxResult.scanCostMs);
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return commandResponse;
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}
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try {
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Thread.sleep(300);
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}catch (Exception e) {}
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}else {
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break;
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}
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tryCount++;
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if (tryCount == 1 || tryCount % 10 == 0) {
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log.warn("[WCS Trace][输送线命令] WRITE_INFO 暂未找到可用下发区域。deviceNo={}, taskNo={}, tryCount={}, occupiedSlotCount={}, scanCostMs={}",
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deviceNo, command.getTaskNo(), tryCount,
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idxResult == null ? -1 : idxResult.occupiedSlotCount,
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idxResult == null ? -1 : idxResult.scanCostMs);
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}
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if (tryCount > maxTryCount) {
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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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log.error("[WCS Trace][输送线命令] WRITE_INFO 命令下发超时。deviceNo={}, taskNo={}, totalWaitMs={}, tryCount={}",
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deviceNo, command.getTaskNo(), System.currentTimeMillis() - sendStartMs, tryCount);
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return commandResponse;
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}
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}
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if (idxResult != null && idxResult.scanCostMs > COMMAND_IDX_SLOW_THRESHOLD_MS) {
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log.warn("[WCS Trace][输送线命令] WRITE_INFO 获取可用下发区域较慢。deviceNo={}, taskNo={}, enableIdx={}, occupiedSlotCount={}, scanCostMs={}, tryCount={}",
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deviceNo, command.getTaskNo(), enableCommandIdx, idxResult.occupiedSlotCount, idxResult.scanCostMs, tryCount);
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}
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short[] data = new short[21];
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data[0] = command.getTargetStaNo().shortValue();
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data[1] = command.getTargetStaNo().shortValue();
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OperateResult writeTask = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength), command.getTaskNo());
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try {
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Thread.sleep(50);
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}catch (Exception e) {}
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OperateResult writeData = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength + 4), data);
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try {
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Thread.sleep(200);
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}catch (Exception e) {}
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OperateResult writeConfirm = siemensNet.Write("DB23." + (enableCommandIdx * taskAddressLength + 46), (short) 1);
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if(writeTask.IsSuccess && writeData.IsSuccess && writeConfirm.IsSuccess) {
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log.error("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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long totalCostMs = System.currentTimeMillis() - sendStartMs;
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if (totalCostMs > COMMAND_SEND_SLOW_THRESHOLD_MS) {
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log.warn("[WCS Trace][输送线命令] WRITE_INFO 命令写入总耗时较长。deviceNo={}, taskNo={}, enableIdx={}, tryCount={}, occupiedSlotCount={}, totalCostMs={}",
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deviceNo, command.getTaskNo(), enableCommandIdx, tryCount,
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idxResult == null ? -1 : idxResult.occupiedSlotCount, totalCostMs);
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}
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commandResponse.setResult(true);
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}else {
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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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}
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}
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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 EnableCommandIdxResult getEnableCommandIdx(int taskNo) {
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long startMs = System.currentTimeMillis();
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OperateResultExOne<byte[]> result = siemensNet.Read("DB23.0", (short) commandAreaTotalLength);
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EnableCommandIdxResult idxResult = new EnableCommandIdxResult();
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idxResult.scanCostMs = System.currentTimeMillis() - startMs;
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if (!result.IsSuccess || result.Content == null || result.Content.length < commandAreaTotalLength) {
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idxResult.enableCommandIdx = -1;
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idxResult.readSuccess = false;
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log.warn("[WCS Trace][输送线命令] 批量读取命令区失败。deviceNo={}, taskNo={}, contentLength={}, scanCostMs={}",
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deviceConfig == null ? null : deviceConfig.getDeviceNo(), taskNo,
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result.Content == null ? -1 : result.Content.length, idxResult.scanCostMs);
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return idxResult;
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}
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idxResult.readSuccess = true;
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int useIdx = -1;
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for (int i = 0; i < taskAddressLimit; i++) {
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int taskOffset = i * taskAddressLength;
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int commandAreaTaskNo = siemensNet.getByteTransform().TransInt32(result.Content, taskOffset);
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int taskStatus = siemensNet.getByteTransform().TransInt16(result.Content, taskOffset + taskStatusOffset);
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if (taskStatus == 1) {
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idxResult.occupiedSlotCount++;
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}
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if (commandAreaTaskNo == taskNo) {
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idxResult.enableCommandIdx = -1;
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idxResult.duplicateTaskNo = true;
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return idxResult;
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}
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if (useIdx == -1 && taskStatus != 1) {
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useIdx = i;
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}
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}
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idxResult.enableCommandIdx = useIdx;
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return idxResult;
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}
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private static class EnableCommandIdxResult {
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private int enableCommandIdx = -1;
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private int occupiedSlotCount = 0;
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private boolean duplicateTaskNo = false;
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private boolean readSuccess = false;
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private long scanCostMs = 0L;
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}
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}
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