1

zhang

1 天以前 6b8b5a067ccfb86e3434f66e2471255d87f2ecd7

 zy-asc-conveyor/src/main/java/com/zy/acs/conveyor/core/thread/SiemensDevpThread.java

@@ -3,11 +3,13 @@
import HslCommunication.Core.Types.OperateResultExOne;
import HslCommunication.Profinet.Siemens.SiemensS7Net;
import com.zy.acs.common.utils.News;
import com.zy.acs.conveyor.core.constant.DeviceField;
import com.zy.acs.conveyor.core.constant.PlcAlarmDefinition;
import com.zy.acs.conveyor.core.constant.StationStatusField;
import com.zy.acs.common.utils.RedisSupport;
import com.zy.acs.conveyor.core.constant.*;
import com.zy.acs.conveyor.core.model.SafeSignal;
import com.zy.acs.conveyor.core.model.StaProtocol;
import com.zy.acs.conveyor.core.properties.DevpSlave;
import com.zy.acs.conveyor.core.service.DevpS7Service;
import com.zy.acs.conveyor.core.service.StationService;
import com.zy.acs.conveyor.entity.Devp;
import com.zy.acs.conveyor.service.DevpService;
import com.zy.acs.conveyor.utils.SpringContextUtil;
@@ -15,6 +17,8 @@
import lombok.Data;
import lombok.extern.slf4j.Slf4j;

import java.math.BigDecimal;
import java.math.RoundingMode;
import java.util.ArrayList;
import java.util.List;
import java.util.Map;
@@ -33,7 +37,8 @@

    private Map<Integer, StaProtocol> station;

    private volatile boolean connected = false;
    private final RedisSupport redis = RedisSupport.defaultRedisSupport;


    private static final int WRITE_RETRY_MAX = 5;

@@ -75,8 +80,20 @@
     * 读取状态 ====> 整块plc
     */
    private void read() throws InterruptedException {
        if (!connected || siemensS7Net == null) {
        if (siemensS7Net == null) {
            DevpS7Service devpS7Service = SpringContextUtil.getBean(DevpS7Service.class);
            if (devpS7Service != null) {
                siemensS7Net = devpS7Service.get(slave.getId());
            }
            log.warn("PLC未连接，跳过读取 [id:{}]", slave.getId());
            return;
        }
        if (station == null) {
            StationService stationService = SpringContextUtil.getBean(StationService.class);
            if (stationService != null) {
                station = stationService.getStationMap(slave.getId());
            }
            log.warn("站点未连接，跳过读取 [id:{}]", slave.getId());
            return;
        }

@@ -90,24 +107,30 @@

        if (!result.IsSuccess) {
            log.error("读取站点状态失败 [id:{}] [error:{}]", slave.getId(), result.Message);
            connected = false;
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNoSize; i++) {
            StaProtocol staProtocol = station.get(staNos.get(staNoSize));
            StaProtocol staProtocol = station.get(staNos.get(i));
            parseStationStatus(content, i, staProtocol);
        }

        // 读取条码
        readBarcodes();

        // 称重
        readWeight();

        // 读取外形检测错误
        readDimensionErrors();

        // 读取PLC故障
        readPlcAlarms(staNos, staNoSize);

        // 读取安全交互信号
        readSaleSingle(slave.getPutSta(), slave.getTakeSta());


        // 定期更新数据库（降低频率）
        updateDatabaseIfNeeded();
@@ -118,13 +141,17 @@
     */
    private void parseStationStatus(byte[] content, int index, StaProtocol staProtocol) {
        int offset = index * StationStatusField.ALL.getByteLength();
        staProtocol.setWorkNo(siemensS7Net.getByteTransform().TransInt32(content, offset));
        staProtocol.setWorkNo(siemensS7Net.getByteTransform().TransInt32(content, offset + StationStatusField.TASK_NUMBER.getOffset()));
        staProtocol.setStaNo((int) siemensS7Net.getByteTransform().TransInt16(
                content, offset + StationStatusField.FINAL_TARGET.getOffset()));

        boolean[] status = siemensS7Net.getByteTransform().TransBool(
        boolean[] status0 = siemensS7Net.getByteTransform().TransBool(
                content, offset + StationStatusField.STATUS_WORD.getOffset(),
                StationStatusField.STATUS_WORD.getByteLength());

        boolean[] status = siemensS7Net.getByteTransform().TransBool(
                content, offset + StationStatusField.STATUS_WORD.getOffset(),
                1);

        staProtocol.setAutoing(status[0]);
        staProtocol.setLoading(status[1]);
@@ -134,22 +161,36 @@
        staProtocol.setFullPlt(status[5]);
        staProtocol.setHigh(status[6]);
        staProtocol.setLow(status[7]);
        boolean[] status2 = siemensS7Net.getByteTransform().TransBool(
                content, offset + StationStatusField.STATUS_WORD.getOffset() + 1,
                1);
        staProtocol.setMid(status2[0]);
        staProtocol.setStartup(status2[1]);
        staProtocol.setSegApply(status2[2]);
        staProtocol.setApplyErr(status2[3]);

        if (!status2[1] && !status[1]) {
            staProtocol.setStartUpFlag(true);
        }

        for (int i = 0; i < 8; i++) {
            if (status0[i + 8] != status2[i]) {
                log.info("状态码不一致 [id:{}] [i:{}] [status0:{}] [status2:{}]", slave.getId(), i, status0[i], status2[i]);
            }
        }
    }

    /**
     * 读取条码信息
     */
    private void readBarcodes() {
        List<Integer> barcodeArr = slave.getBarcodeArr();
        if (barcodeArr == null || barcodeArr.isEmpty()) {
        if (slave.getBarcode() == null || !slave.getBarcode()) {
            return;
        }

        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                DeviceField.BARCODE.buildAddress(),
                (short) (barcodeArr.size() * DeviceField.BARCODE.getByteLength()));
                (short) (DeviceField.BARCODE.getByteLength() * DeviceField.BARCODE.getArrLength()));

        if (!result.IsSuccess) {
            log.warn("读取条码失败 [id:{}]", slave.getId());
@@ -157,15 +198,56 @@
        }

        byte[] content = result.Content;
        for (int i = 0; i < barcodeArr.size(); i++) {
        for (int i = 0; i < DeviceField.BARCODE.getArrLength(); i++) {
            int[] seg = DeviceField.BARCODE.getSeg();
            int staNo = siemensS7Net.getByteTransform().TransInt16(
                    content, seg[0] + i * DeviceField.BARCODE.getByteLength());
            String barcode = siemensS7Net.getByteTransform().TransString(
                    content, i * DeviceField.BARCODE.getByteLength(),
                    DeviceField.BARCODE.getByteLength(), "UTF-8");
                    content, seg[1] + i * DeviceField.BARCODE.getByteLength(),
                    DeviceField.BARCODE.getByteLength()-seg[1] , "UTF-8").trim();

            if (!Cools.isEmpty(barcode)) {
                StaProtocol staProtocol = station.get(barcodeArr.get(i));
            if (!Cools.isEmpty(barcode) && !barcode.contains("Default") && !barcode.contains("Error") && staNo != 0) {
                StaProtocol staProtocol = station.get(staNo);
                if (staProtocol == null) {
                    log.warn("扫码站点不存在 [id:{}] [staNo:{}]", slave.getId(), staNo);
                    continue;
                }
                staProtocol.setBarcode(barcode);
                log.info("料箱码：{}", barcode);
                //News.info("料箱码：{}", barcode);
            }
        }
    }

    /**
     * 读取重量信息
     */
    private void readWeight() {
        if (slave.getWeight() == null || !slave.getWeight()) {
            return;
        }

        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                DeviceField.WEIGHT.buildAddress(),
                (short) (DeviceField.WEIGHT.getArrLength() * DeviceField.WEIGHT.getByteLength()));

        if (!result.IsSuccess) {
            log.warn("读取重量失败 [id:{}]", slave.getId());
            return;
        }
        byte[] content = result.Content;
        for (int i = 0; i < DeviceField.WEIGHT.getArrLength(); i++) {
            int[] seg = DeviceField.WEIGHT.getSeg();
            int staNo = siemensS7Net.getByteTransform().TransInt16(
                    content, seg[0] + i * DeviceField.WEIGHT.getByteLength());
            Double weight = (double) siemensS7Net.getByteTransform().TransSingle(
                    content, seg[1] + i * DeviceField.WEIGHT.getByteLength());
            if (!Cools.isEmpty(weight) && staNo != 0) {
                StaProtocol staProtocol = station.get(staNo);
                if (staProtocol == null) {
                    log.warn(" [id:{}] [staNo:{}]", slave.getId(), staNo);
                    continue;
                }
                staProtocol.setWeight(BigDecimal.valueOf(weight).setScale(4, RoundingMode.HALF_UP).doubleValue());
            }
        }
    }
@@ -174,14 +256,13 @@
     * 读取外形检测错误
     */
    private void readDimensionErrors() {
        List<Integer> staNosError = slave.getStaNosError();
        if (staNosError == null || staNosError.isEmpty()) {
        if (slave.getStaNosError() == null || !slave.getStaNosError()) {
            return;
        }

        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                DeviceField.DIMENSION_WORD.buildAddress(),
                (short) (staNosError.size() * DeviceField.DIMENSION_WORD.getByteLength()));
                (short) (DeviceField.DIMENSION_WORD.getArrLength() * DeviceField.DIMENSION_WORD.getByteLength()));

        if (!result.IsSuccess) {
            log.warn("读取外形检测错误失败 [id:{}]", slave.getId());
@@ -189,21 +270,35 @@
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNosError.size(); i++) {
            Integer siteId = staNosError.get(i);
            StaProtocol staProtocol = station.get(siteId);
        for (int i = 0; i < DeviceField.DIMENSION_WORD.getArrLength(); i++) {
            int[] seg = DeviceField.DIMENSION_WORD.getSeg();
            int staNo = siemensS7Net.getByteTransform().TransInt16(
                    content, seg[0]);
            if (staNo != 0) {
                StaProtocol staProtocol = station.get(staNo);
                if (staProtocol == null) {
                    log.warn("异常站点不存在 [id:{}] [staNo:{}]", slave.getId(), staNo);
                    continue;
                }
                boolean[] status = siemensS7Net.getByteTransform().TransBool(
                        content, seg[1] + i * DeviceField.DIMENSION_WORD.getByteLength(),
                        1);
//未使用，预留
//                boolean[] status1 = siemensS7Net.getByteTransform().TransBool(
//                        content, seg[1]+i * DeviceField.DIMENSION_WORD.getByteLength()+1,
//                        1);

            boolean[] status = siemensS7Net.getByteTransform().TransBool(
                    content, i * DeviceField.DIMENSION_WORD.getByteLength(),
                    DeviceField.DIMENSION_WORD.getByteLength());
                staProtocol.setLeftErr(status[0]);
                staProtocol.setRightErr(status[1]);
                staProtocol.setFrontErr(status[2]);
                staProtocol.setBackErr(status[3]);
                staProtocol.setHighErr(status[4]);
                staProtocol.setLoadErr(status[5]);
                staProtocol.setWeightErr(status[6]);
                staProtocol.setBarcodeErr(status[7]);
            }

            staProtocol.setFrontErr(status[0]);
            staProtocol.setBackErr(status[1]);
            staProtocol.setHighErr(status[2]);
            staProtocol.setLeftErr(status[3]);
            staProtocol.setRightErr(status[4]);
            staProtocol.setWeightErr(status[5]);
            staProtocol.setBarcodeErr(status[6]);

        }
    }

@@ -225,6 +320,7 @@
            Integer siteId = staNos.get(i);
            StaProtocol staProtocol = station.get(siteId);
            if (staProtocol == null) {
                log.warn("站点不存在 [id:{}] [staNo:{}]", slave.getId(), siteId);
                continue;
            }

@@ -243,6 +339,64 @@
    }

    /**
     * 读取安全交互信号
     */
    private void readSaleSingle(List<DevpSlave.Sta> putSta, List<DevpSlave.Sta> takeSta) {
        int staNoSize = putSta.size();
        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                SafeSignalField.SAFE_SIGNAL_FROM_CONVEYOR.buildAddress(),
                (short) (staNoSize * SafeSignalField.SAFE_SIGNAL_FROM_CONVEYOR.getByteLength()));


        if (!result.IsSuccess) {
            log.warn("读取PLC安全交互信息异常 [id:{}]", slave.getId());
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNoSize; i++) {
            Integer put = putSta.get(i).getStaNo();
            Integer take = takeSta.get(i).getStaNo();
            StaProtocol staProtocolPut = station.get(put);
            StaProtocol staProtocolTake = station.get(take);
            if (staProtocolPut == null || staProtocolTake == null) {
                log.warn("站点不存在 [id:{}] [staNo:{},{}]", slave.getId(), put, take);
                continue;
            }

            boolean[] status = siemensS7Net.getByteTransform().TransBool(
                    content, i * SafeSignalField.SAFE_SIGNAL_FROM_CONVEYOR.getByteLength(), 1);

            boolean[] status2 = siemensS7Net.getByteTransform().TransBool(
                    content, i * SafeSignalField.SAFE_SIGNAL_FROM_CONVEYOR.getByteLength() + 2, 1);

            staProtocolPut.setHeartbeat(status[0]);
            staProtocolPut.setAllowTake(status[1]);
            staProtocolPut.setAllowPut(status[2]);
            staProtocolPut.setInComplete(status[3]);
            staProtocolPut.setOutComplete(status[4]);

            staProtocolTake.setHeartbeat(status2[0]);
            staProtocolTake.setAllowTake(status2[1]);
            staProtocolTake.setAllowPut(status2[2]);
            staProtocolTake.setInComplete(status2[3]);
            staProtocolTake.setOutComplete(status2[4]);
            //
            if (status[3]) {
                staProtocolPut.setSafeSignal(new SafeSignal(i, false, true));
                redis.push(RedisConveyorConstant.CONVEYOR_SAFE_FLAG, staProtocolPut);
                News.info("安全交互信号复位 [id:{}] [staNo:{}]", slave.getId(), staProtocolPut.getSiteId());
            }
            if (status2[4]) {
                staProtocolTake.setSafeSignal(new SafeSignal(i, false, false));
                redis.push(RedisConveyorConstant.CONVEYOR_SAFE_FLAG, staProtocolTake);
                News.info("安全交互信号复位 [id:{}] [staNo:{}]", slave.getId(), staProtocolPut.getSiteId());
            }

        }
    }

    /**
     * 按需更新数据库（降低更新频率）
     */
    private void updateDatabaseIfNeeded() {