#配置信号

1

3 天以前 82374fe4b32d58956810f445b7889f1a370f1ab9

 src/main/java/com/zy/core/thread/RgvThread.java

@@ -5,12 +5,13 @@
import HslCommunication.Profinet.Siemens.SiemensPLCS;
import HslCommunication.Profinet.Siemens.SiemensS7Net;
import com.alibaba.fastjson.JSON;
import com.baomidou.mybatisplus.mapper.EntityWrapper;
import com.core.common.Cools;
import com.core.common.DateUtils;
import com.core.common.SpringUtils;
import com.zy.asrs.entity.BasRgv;
import com.zy.asrs.entity.BasRgvOpt;
import com.zy.asrs.service.BasRgvOptService;
import com.zy.asrs.service.BasRgvService;
import com.core.exception.CoolException;
import com.zy.asrs.entity.*;
import com.zy.asrs.service.*;
import com.zy.common.utils.News;
import com.zy.core.RgvThread2;
import com.zy.core.ThreadHandler;
@@ -25,11 +26,14 @@
import com.zy.core.model.command.CrnCommand;
import com.zy.core.model.command.RgvCommand;
import com.zy.core.model.protocol.RgvProtocol;
import com.zy.core.model.protocol.StaProtocol;
import lombok.Data;
import lombok.extern.slf4j.Slf4j;

import java.sql.Wrapper;
import java.text.MessageFormat;
import java.util.Date;
import java.util.*;
import java.util.concurrent.ConcurrentHashMap;

/**
 * RGV线程
@@ -42,6 +46,8 @@
    private SiemensS7Net siemensNet;
    private RgvSlave slave;
    private RgvProtocol rgvProtocol;
    private Map<Integer, StaProtocol> station = new ConcurrentHashMap<>();

    /**
     * 工位1复位信号
     */
@@ -54,13 +60,17 @@
    //锁定标记
    private boolean PakMk = true;
    //入库标记
    private boolean PakIn = true;
    //出库标记
    private boolean PakOut = true;
    //根据距离跳过取货
    private boolean PakRgv = true;
    //接驳标记
    private boolean PakToCrn = true;
//    private boolean PakIn = true;
//    //出库标记
//    private boolean PakOut = true;
//    //根据距离跳过取货
//    private boolean PakRgv  = true;
//    //接驳标记
//    private boolean PakToCrn = true;
    // 任务锁定
    private boolean Paking  = true;
//    //连续任务下发
//    private boolean PakAll = true;

    public RgvThread(RgvSlave slave) {
        this.slave = slave;
@@ -97,7 +107,8 @@
                        command.setTaskStatus(RgvTaskStatusType.NONE); // 任务模式
                        command.setTargetPosition(0);     // 源站
                        command.setWrkTaskPri(0);     // 目标站
                        write(command);
                        command.setCommand(false);
                        write2(command);
                        break;
                    default:
                        break;
@@ -108,6 +119,46 @@
            }

        }
    }
    private static final Set<Integer> specialSites = new HashSet<>(
            Arrays.asList(1004,1014,1018,1028,1035,2006,2012,2018,2024,2030));
    public static final Map<Integer, Integer> StaPosition = new HashMap<Integer, Integer>() {{
        put(1004, 1001);put(1014, 1011);put(1018, 1015);put(1028, 1025);put(1035, 1032);
        put(2006, 2004);put(2012, 2010);put(2018, 2016);put(2024, 2022);put(2030, 2028);

    }};
    public static final ArrayList<Integer> staNos1 = new ArrayList<Integer>() {{
        add(1);add(2);

    }};

    public static final ArrayList<Integer> staNos2 = new ArrayList<Integer>() {{
        add(3);add(4);

    }};
    /**
     * 初始化站点状态
     */
    private void initSite() {
        ArrayList<Integer> staNos = getStaNo();

            // 站点编号
            for (Integer siteId : staNos) {
                StaProtocol staProtocol = station.get(siteId);
                if (null == staProtocol) {
                    staProtocol = new StaProtocol();
                    staProtocol.setSiteId(siteId);
                    station.put(siteId, staProtocol);
                }
                staProtocol.setWorkNo(0);    // ID
                staProtocol.setAutoing(false);      // 自动
                staProtocol.setLoading(false);      // 有物
                staProtocol.setInEnable(false);     // 可入
                staProtocol.setOutEnable(false);    // 可出
                staProtocol.setEmptyMk(false);      // 空板信号
                staProtocol.setStaNo((short) 0);     // 目标站

            }
    }

    /**
@@ -145,7 +196,16 @@
//        rgvProtocol.setxDistance((short) 0);
//        rgvProtocol.setxDuration((short) 0);
    }

    private ArrayList<Integer> getStaNo() {
        switch (slave.getId()) {
            case 1:
                return staNos1;
            case 2:
                return staNos2;
            default:
                throw new CoolException("服务器异常");
        }
    }
    @Override
    public boolean connect() {
        boolean result = false;
@@ -173,13 +233,48 @@
            buffer[byteIndex] &= ~(1 << bitIndex); // 清零
        }
    }
    private void updateFlagInDb(String field, boolean value) {
        try {
            BasRgvService basRgvService = SpringUtils.getBean(BasRgvService.class);

            EntityWrapper<BasRgv> wrapper = new EntityWrapper<>();
            wrapper.eq("rgv_no", slave.getId());

            BasRgv entity = new BasRgv();
            switch (field) {
                case "pak_mk":    entity.setPakMk(value ? "1" : "0"); break;
                case "pak_in":    entity.setPakIn(value ? "1" : "0"); break;
                case "pak_out":   entity.setPakOut(value ? "1" : "0"); break;
                case "pak_rgv":   entity.setPakRgv(value ? "1" : "0"); break;
                case "pak_to_crn":entity.setPakToCrn(value ? "1" : "0"); break;
                case "paking":entity.setPaking(value ? "1" : "0"); break;
                case "pak_all":entity.setPakAll(value ? "1" : "0"); break;
                default:
                    log.warn("未知标志位字段: {}", field);
                    return;
            }

            basRgvService.update(entity, wrapper);
//            log.info("RGV标志位更新成功 [rgv_no:{}] {}={}", slave.getId(), field, value ? "1" : "0");

        } catch (Exception e) {
            log.error("更新RGV标志位异常 [rgv_no:{}] {}={} 错误：{}", slave.getId(), field, value, e.getMessage());
        }
    }


    public void setPakMk(boolean pakMk) {
        this.PakMk = pakMk;
        updateFlagInDb("pak_mk", pakMk);
    }

    /**
     * 读取状态
     */
    private void readStatus(){
        try {
            OperateResultExOne<byte[]> result = siemensNet.Read("DB101.0", (short) 27);

            OperateResultExOne<byte[]> result = siemensNet.Read("DB101.0", (short) 42);
            if (result.IsSuccess) {
                if (null == rgvProtocol) {
                    rgvProtocol = new RgvProtocol();
@@ -192,10 +287,12 @@
                rgvProtocol.setStatus1(siemensNet.getByteTransform().TransInt16(result.Content, 12));
                rgvProtocol.setTaskNo1(siemensNet.getByteTransform().TransInt32(result.Content, 16));
                rgvProtocol.setTaskNo2(siemensNet.getByteTransform().TransInt32(result.Content, 20));
                boolean[] status1 = siemensNet.getByteTransform().TransBool(result.Content, 24, 2);
                rgvProtocol.setStaNo1(siemensNet.getByteTransform().TransInt32(result.Content, 28));
                rgvProtocol.setStaNo2(siemensNet.getByteTransform().TransInt32(result.Content, 32));
                boolean[] status1 = siemensNet.getByteTransform().TransBool(result.Content, 24, 1);
                rgvProtocol.setLoaded1(status1[0]);
                rgvProtocol.setLoaded2(status1[1]);
                boolean[] status2 = siemensNet.getByteTransform().TransBool(result.Content, 26, 1);
                boolean[] status2 = siemensNet.getByteTransform().TransBool(result.Content, 36,1);
                rgvProtocol.setErr1(status2[0]);
                rgvProtocol.setErr2(status2[1]);
                rgvProtocol.setErr3(status2[2]);
@@ -203,14 +300,79 @@
                rgvProtocol.setErr5(status2[4]);
                rgvProtocol.setErr6(status2[5]);
                rgvProtocol.setErr7(status2[6]);
                OutputQueue.RGV.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功", DateUtils.convert(new Date()), slave.getId()));
                rgvProtocol.setErr8(status2[7]);
                boolean[] status3 = siemensNet.getByteTransform().TransBool(result.Content, 37, 1);
                rgvProtocol.setErr9(status3[0]);
                rgvProtocol.setErr10(status3[1]);
                rgvProtocol.setErr11(status3[2]);
                rgvProtocol.setErr12(status3[3]);
                boolean[] statusErr = siemensNet.getByteTransform().TransBool(result.Content, 36, 6);
                rgvProtocol.setEmergencyStop(statusErr[0]);       // 急停触发
                rgvProtocol.setSlot1EmptyNoData(statusErr[1]);   // 1号位有物无资料
                rgvProtocol.setSlot2EmptyNoData(statusErr[2]);   // 2号位有物无资料
                rgvProtocol.setCommandErrorChainConflict(statusErr[3]); // 命令错误走链条冲突
                rgvProtocol.setTargetPositionIssue(statusErr[4]); // 目标位下发错误
                rgvProtocol.setTravelInverterError(statusErr[5]); // 走行变频器异常
                rgvProtocol.setPhotoelectric1Error(statusErr[6]); // 1号光电异常
                rgvProtocol.setPhotoelectric2Error(statusErr[7]); // 2号光电异常
                rgvProtocol.setTimeoutConnectionWithLine(statusErr[8]); // 与输线时接超时
                rgvProtocol.setLeftRollerTimeout(statusErr[9]);    // 左侧滚筒运行超时
                rgvProtocol.setRightRollerTimeout(statusErr[10]);   // 右侧滚筒运行超时
                rgvProtocol.setRgvRunTimeout(statusErr[11]);        // rgv运行超时
                rgvProtocol.setPosition1ChainInverterError(statusErr[12]); // 1号工位链条变频器异常
                rgvProtocol.setPosition2ChainInverterError(statusErr[13]); // 2号工位链条变频器异常
                rgvProtocol.setFrontRearLimit(statusErr[14]);      // 前后极限位
                rgvProtocol.setEmergencyButton(statusErr[15]);     // 急停按钮
                rgvProtocol.setForwardButton(statusErr[16]);       // 前进按钮
                rgvProtocol.setReverseButton(statusErr[17]);       // 后退按钮
                rgvProtocol.setLocalRemote(statusErr[18]);         // 本地/远程
                rgvProtocol.setReset(statusErr[19]);               // 复位
                rgvProtocol.setTravelBrakeSwitch(statusErr[20]);   // 走行抱闸开关钮
                rgvProtocol.setTravelSpeedLimitPhotoelectric(statusErr[21]); // 走行强制减速光电
                rgvProtocol.setLeftOverlimit1(statusErr[22]);      // 左超限 1
                rgvProtocol.setRightOverlimit1(statusErr[23]);     // 右超限 1
                rgvProtocol.setLeftAtPosition1(statusErr[24]);     // 左到位 1
                rgvProtocol.setRightAtPosition1(statusErr[25]);    // 右到位 1
                rgvProtocol.setChainForward1(statusErr[26]);       // 链条前进 1
                rgvProtocol.setChainReverse1(statusErr[27]);       // 链条后退 1
                rgvProtocol.setInverterAlarm(statusErr[28]);       // 变频器报警
                rgvProtocol.setLeftOverlimit2(statusErr[29]);      // 左超限 2
                rgvProtocol.setRightOverlimit2(statusErr[30]);     // 右超限 2
                rgvProtocol.setLeftAtPosition2(statusErr[31]);     // 左到位 2
                rgvProtocol.setRightAtPosition2(statusErr[32]);    // 右到位 2
                rgvProtocol.setCargoSpeedReduction(statusErr[33]); // 货物减速
                rgvProtocol.setConveyorInverterAlarm2(statusErr[34]); // 输送变频器报警 2
                rgvProtocol.setRightConveyor2(statusErr[35]);      // 右输送 2
                rgvProtocol.setLeftConveyor2(statusErr[36]);       // 左输送 2
                if(rgvProtocol.getStatus() == 99){
                    rgvProtocol.setErrorMk(true);//若存在异常触发写入
                }else{
                    rgvProtocol.setWriteMk(true);//无异常后才能继续写入
                    rgvProtocol.setErrorMk(false);
                }



//                BasRgvMapService basRgvMapService = SpringUtils.getBean(BasRgvMapService.class);
                OutputQueue.RGV.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功", DateUtils.convert(new Date()), slave.getId()));
                try {
                    // 根据实时信息更新数据库
                    BasRgvService basRgvService = SpringUtils.getBean(BasRgvService.class);
                    BasRgv basRgv = new BasRgv();
                    basRgv.setRgvNo(slave.getId());
                    basRgv.setRgvSts((int)rgvProtocol.getMode());
                    if(rgvProtocol.isWriteMk() && rgvProtocol.isErrorMk()){
                        try {
                            // 日志记录异常情况
                            BasRgvErrorLog basRgvErrorLogs;
                            basRgvErrorLogs = rgvProtocol.toSqlModelError();
                            BasRgvErrorLogService basRgvErrorLogService = SpringUtils.getBean(BasRgvErrorLogService.class);
                            basRgvErrorLogService.insert(basRgvErrorLogs);
                            rgvProtocol.setWriteMk(false);
                        } catch (Exception ignore) {
                            log.error(ignore.getMessage());
                        }
                    }
                    if (!basRgvService.updateById(rgvProtocol.toSqlModel(basRgv))){
                        log.error("RGV plc数据库更新失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
                    }
@@ -249,6 +411,9 @@
        }
        byte[] writeBytes = new byte[14];
        command.setRgvNo(slave.getId());
        if(specialSites.contains(command.getTargetPosition())){
            command.setTargetPosition(StaPosition.get(command.getTargetPosition()));
        }
        writeInt32(writeBytes, 0, command.getWrkTaskPri());
        writeInt32(writeBytes, 4, command.getTargetPosition());
        writeInt16(writeBytes, 8, (short)command.getTaskStatus());
@@ -307,15 +472,145 @@
            int writeCount2 = 0;
            do {
                writeCount2++;
                boolean commandFinish = true;
                Short commandFinish = 1;
                result = siemensNet.Write("DB100.34.0", commandFinish);
                if(result.IsSuccess){
                    //RGV任务写入后，回读一次，看是否成功
                    Thread.sleep(200);
                    OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.34", (short) 2);
                    if (resultRead.IsSuccess) {
                        commandFinish=siemensNet.getByteTransform().TransBool(resultRead.Content, 0);
                        if (!commandFinish){
                        commandFinish=siemensNet.getByteTransform().TransInt16(resultRead.Content, 0);
                        if (commandFinish !=1){
                            News.error("RGV任务确认位"+commandFinish+"写入数据与回读数据不一致！"+"循环执行次数:"+writeCount2+"次");
                        }else{
                            //任务命令写入成功
                            News.info("RGV任务确认位"+commandFinish+"回读成功！"+"循环执行次数:"+writeCount2+"次");
                            break;
                        }
                    }else {
                        News.error("RGV任务确认位"+commandFinish+"回读失败！"+"循环执行次数:"+writeCount2+"次");
                    }
                } else {
                    News.error("RGV任务确认位"+commandFinish+"写入失败！"+"循环执行次数:"+writeCount2+"次");
                }
            }while (writeCount2<5);
        }
        try {
            // 日志记录
            BasRgvOptService bean = SpringUtils.getBean(BasRgvOptService.class);
            BasRgvOpt basRgvOpt = new BasRgvOpt(
                    command.getTaskNo(),
                    command.getRgvNo(),
                    new Date(),
                    command.getTaskStatus().toString(),
                    command.getTargetPosition(),
                    command.getWrkTaskPri(),
                    new Date()
            );
            bean.insert(basRgvOpt);
        } catch (Exception ignore) {
            log.error(ignore.getMessage());
        }

        if (result != null && result.IsSuccess) {
            Thread.sleep(200);
            this.readStatus();
            log.info("RGV 工位命令下发[id:{}] >>>>> {}", slave.getId(), JSON.toJSON(command));
            OutputQueue.RGV.offer(MessageFormat.format("【{0}】[id:{1}] >>>>> 工位命令下发： {2}", DateUtils.convert(new Date()), slave.getId(), JSON.toJSON(command)));
            return true;
        } else {
            OutputQueue.RGV.offer(MessageFormat.format("【{0}】写入RGV plc工位数据失败 ===>> [id:{1}] [ip:{2}] [port:{3}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort()));
            log.error("写入RGV plc工位数据失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            return false;
        }
    }
    private boolean write2(RgvCommand command) throws InterruptedException {
        if (null == command) {
            log.error("RGV写入命令为空");
            return false;
        }
        OperateResultExOne<byte[]> result1 = siemensNet.Read("DB100.0", (short) 39);
        if (result1.IsSuccess){
            RgvCommand one = new RgvCommand();
            one.setWrkTaskPri(siemensNet.getByteTransform().TransInt32(result1.Content, 0));//执行工位
            one.setTargetPosition(siemensNet.getByteTransform().TransInt32(result1.Content, 4));//行走目标站
            one.setTaskStatus(siemensNet.getByteTransform().TransInt16(result1.Content, 8));//小车状态
            one.setTaskNo(siemensNet.getByteTransform().TransInt32(result1.Content, 10));//下发工作号
            News.info("RGV命令下发前读取状态[id:{}] >>>>> 写入[{}],===>>回读[{}]", slave.getId(), JSON.toJSON(command),JSON.toJSON(one));
        }
        byte[] writeBytes = new byte[36];
        command.setRgvNo(slave.getId());
        if(specialSites.contains(command.getTargetPosition())){
            command.setTargetPosition(StaPosition.get(command.getTargetPosition()));
        }
        writeInt32(writeBytes, 0, command.getWrkTaskPri());
        writeInt32(writeBytes, 4, command.getTargetPosition());
        writeInt16(writeBytes, 8, (short)command.getTaskStatus());
        writeInt32(writeBytes, 10, command.getTaskNo());
        writeBool(writeBytes, 34, 0, command.getCommand());
        OperateResult result = siemensNet.Write("DB100.0", writeBytes);

        if (!result.IsSuccess){
            News.error("写入RGVplc数据失败，重新添加任务到队列 ===> [id:{}],{}",slave.getId(),JSON.toJSON(command));
            MessageQueue.offer(SlaveType.Rgv,slave.getId(),new Task(2,command));
            Thread.sleep(100);
            readStatus();
            return false;
        }

        //RGV任务写入后，回读一次，看是否成功
        Thread.sleep(400);
        try {
            OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.0", (short) 14);
            if (resultRead.IsSuccess){
                RgvCommand one = new RgvCommand();
                one.setWrkTaskPri(siemensNet.getByteTransform().TransInt32(resultRead.Content, 0));//执行工位
                one.setTargetPosition(siemensNet.getByteTransform().TransInt32(resultRead.Content, 4));//行走目标站
                one.setTaskStatus(siemensNet.getByteTransform().TransInt16(resultRead.Content, 8));//小车状态
                one.setTaskNo(siemensNet.getByteTransform().TransInt32(resultRead.Content, 10));//下发工作号
                if (
                        !command.getTaskNo().equals(one.getTaskNo()) ||
                                !command.getTaskStatus().equals(one.getTaskStatus()) ||
                                !command.getWrkTaskPri().equals(one.getWrkTaskPri()) ||
                                !command.getTargetPosition().equals(one.getTargetPosition())
                ) {
                    try{
                        News.error("RGV命令地址写入后回读失败[id:{}] >>>>> 写入[{}],===>>回读[{}]", slave.getId(), JSON.toJSON(command),JSON.toJSON(one));
                    }catch (Exception e){
                        try{
                            News.error("日志打印失败：===>>参数one报错 [id:{}],{}", slave.getId(), JSON.toJSON(command),JSON.toJSON(resultRead));
                        }catch (Exception e1){
                            News.error("日志打印失败：===>> [id:{}],{}", slave.getId(), JSON.toJSON(command));
                        }
                    }
                    News.error("Rgv命令回读失败后，重新添加任务到队列 ===>> [id:{}],{}", slave.getId(), JSON.toJSON(command));
                    MessageQueue.offer(SlaveType.Rgv, slave.getId(), new Task(2, command));
                    Thread.sleep(100);
                    readStatus();
                    return false;
                }else {
                    News.info("RGV命令地址写入后回读成功[id:{}] >>>>> 写入[{}],===>>回读[{}]", slave.getId(), JSON.toJSON(command),JSON.toJSON(one));
                }
            }
        }catch (Exception e){
            News.error("RGV命令地址写入后回读出错");
        }

        if (result.IsSuccess) {  //任务下发确认
            Thread.sleep(300);
            //任务下发次数
            int writeCount2 = 0;
            do {
                writeCount2++;
                Short commandFinish = 1;
                result = siemensNet.Write("DB100.34.0", commandFinish);
                if(result.IsSuccess){
                    //RGV任务写入后，回读一次，看是否成功
                    Thread.sleep(200);
                    OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.34", (short) 2);
                    if (resultRead.IsSuccess) {
                        commandFinish=siemensNet.getByteTransform().TransInt16(resultRead.Content, 0);
                        if (commandFinish !=1){
                            News.error("RGV任务确认位"+commandFinish+"写入数据与回读数据不一致！"+"循环执行次数:"+writeCount2+"次");
                        }else{
                            //任务命令写入成功
@@ -380,7 +675,33 @@
        }
    }

    public Integer getRgvPosI(Integer pos) {
        if (pos == null) return 0;

        // key: 站点号  value: 基准物理位置
        Map<Integer, Integer> posMap = new HashMap<>();
        posMap.put(1004, 6534);
        posMap.put(1007, 33634);
        posMap.put(1010, 75174);
        posMap.put(1014, 102124);
        posMap.put(1018, 138224);
        posMap.put(1021, 178034);
        posMap.put(1024, 219684);
        posMap.put(1028, 246724);
        posMap.put(1031, 288194);
        posMap.put(1035, 315204);
        int tolerance = 50; // 允许误差范围

        for (Map.Entry<Integer, Integer> entry : posMap.entrySet()) {
            int site = entry.getKey();
            int basePos = entry.getValue();
            if (Math.abs(pos - basePos) <= tolerance) {
                return site;
            }
        }

        return 0; // 没匹配到站点
    }

    @Override
    public void close() {