输送线条码读取bug、出入库模式信号、链条控制信号

Junjie

2023-06-10 b7e0039880d9f6e71230dbf9c13538de4f8135b8

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

@@ -5,22 +5,36 @@
import HslCommunication.Core.Types.OperateResultExOne;
import HslCommunication.ModBus.ModbusTcpNet;
import com.alibaba.fastjson.JSON;
import com.core.common.Cools;
import com.core.common.DateUtils;
import com.core.common.SpringUtils;
import com.core.exception.CoolException;
import com.zy.asrs.entity.BasLift;
import com.zy.asrs.entity.BasLiftOpt;
import com.zy.asrs.entity.BasShuttle;
import com.zy.asrs.entity.BasShuttleOpt;
import com.zy.asrs.service.BasLiftOptService;
import com.zy.asrs.service.BasLiftService;
import com.zy.asrs.service.BasShuttleOptService;
import com.zy.asrs.service.BasShuttleService;
import com.zy.common.utils.CommonUtils;
import com.zy.common.utils.RedisUtil;
import com.zy.core.News;
import com.zy.core.ThreadHandler;
import com.zy.core.cache.MessageQueue;
import com.zy.core.cache.OutputQueue;
import com.zy.core.enums.SlaveType;
import com.zy.core.enums.*;
import com.zy.core.model.LiftSlave;
import com.zy.core.model.Task;
import com.zy.core.model.command.LiftCommand;
import com.zy.core.model.command.*;
import com.zy.core.model.protocol.LiftProtocol;
import lombok.Data;
import lombok.extern.slf4j.Slf4j;

import java.text.MessageFormat;
import java.util.ArrayList;
import java.util.Date;
import java.util.List;

/**
 * 提升机线程
@@ -32,9 +46,11 @@
    private ModbusTcpNet modbusTcpNet;
    private LiftSlave slave;
    private LiftProtocol liftProtocol;
    private RedisUtil redisUtil;

    public LiftThread(LiftSlave slave) {
    public LiftThread(LiftSlave slave,RedisUtil redisUtil) {
        this.slave = slave;
        this.redisUtil = redisUtil;
    }

    @Override
@@ -56,6 +72,10 @@
                    case 2:
                        write((LiftCommand) task.getData());
                        break;
                    //分配任务
                    case 3:
                        assignWork((LiftAssignCommand) task.getData());
                        break;
                    default:
                        break;
                }
@@ -70,7 +90,7 @@
    public boolean connect() {
        boolean result = false;
        //-------------------------提升机连接方法------------------------//
        modbusTcpNet = new ModbusTcpNet(slave.getIp(), slave.getPort(), (byte) 0x01);
        modbusTcpNet = new ModbusTcpNet(slave.getIp(), slave.getPort(), (byte) 0x02);
        // 当你需要指定格式的数据解析时，就需要设置下面的这个信息
        modbusTcpNet.setDataFormat(DataFormat.ABCD);
        OperateResult connect = modbusTcpNet.ConnectServer();
@@ -94,7 +114,7 @@

    private void readStatus() {
        try {
            OperateResultExOne<byte[]> result = modbusTcpNet.Read("29", (short) 17);
            OperateResultExOne<byte[]> result = modbusTcpNet.Read("29", (short) 50);
            if (result.IsSuccess) {
                if (null == liftProtocol) {
                    liftProtocol = new LiftProtocol();
@@ -105,55 +125,105 @@
                //获取数据
                byte[] content = result.Content;
                //提升机锁定
                liftProtocol.setLiftLock(modbusTcpNet.getByteTransform().TransInt16(content,0));
                liftProtocol.setLiftLock(CommonUtils.shortToBoolean(modbusTcpNet.getByteTransform().TransInt16(content, 0)));
                //位置到达反馈
                liftProtocol.setPositionArrivalFeedback(modbusTcpNet.getByteTransform().TransInt16(content,2));
                //准备就绪
                liftProtocol.setReady(modbusTcpNet.getByteTransform().TransBool(content,3));
                liftProtocol.setReady(CommonUtils.shortToBoolean(modbusTcpNet.getByteTransform().TransInt16(content,4)));
                //运行中
                liftProtocol.setRunning(modbusTcpNet.getByteTransform().TransBool(content,4));
                liftProtocol.setRunning(CommonUtils.shortToBoolean(modbusTcpNet.getByteTransform().TransInt16(content,6)));
                //联机/单机
                liftProtocol.setMode(modbusTcpNet.getByteTransform().TransBool(content,5));
                liftProtocol.setMode(CommonUtils.shortToBoolean(modbusTcpNet.getByteTransform().TransInt16(content,8)));

                //以下参数并未进行调整(需要后续针对实机进行获取和调试)
                //输送线前端光电有货
                liftProtocol.setLineFrontHasStock(modbusTcpNet.getByteTransform().TransBool(content,6));
                liftProtocol.setLineFrontHasStock(modbusTcpNet.getByteTransform().TransBool(content,10));
                //输送线正转反馈
                liftProtocol.setForwardRotationFeedback(modbusTcpNet.getByteTransform().TransBool(content,7));
                liftProtocol.setForwardRotationFeedback(modbusTcpNet.getByteTransform().TransBool(content,12));
                //输送线反转反馈
                liftProtocol.setReverseFeedback(modbusTcpNet.getByteTransform().TransBool(content,8));
                liftProtocol.setReverseFeedback(modbusTcpNet.getByteTransform().TransBool(content,14));
                //输送线电机过载
                liftProtocol.setMotorOverload(modbusTcpNet.getByteTransform().TransBool(content,9));
                liftProtocol.setMotorOverload(modbusTcpNet.getByteTransform().TransBool(content,16));
                //输送线末端光电有货
                liftProtocol.setLineEndHasStock(modbusTcpNet.getByteTransform().TransBool(content,10));
                liftProtocol.setLineEndHasStock(modbusTcpNet.getByteTransform().TransBool(content,18));
                //进输送线卡托盘报警
                liftProtocol.setInConveyLineCardTrayAlarm(modbusTcpNet.getByteTransform().TransBool(content,11));
                liftProtocol.setInConveyLineCardTrayAlarm(modbusTcpNet.getByteTransform().TransBool(content,20));
                //出输送线卡托盘报警
                liftProtocol.setOutConveyLineCardTrayAlarm(modbusTcpNet.getByteTransform().TransBool(content,12));
                liftProtocol.setOutConveyLineCardTrayAlarm(modbusTcpNet.getByteTransform().TransBool(content,22));
                //平台位置偏差报警
                liftProtocol.setPlatPositionDeviationAlarm(modbusTcpNet.getByteTransform().TransBool(content,13));
                liftProtocol.setPlatPositionDeviationAlarm(modbusTcpNet.getByteTransform().TransBool(content,24));
                //平台扭矩偏差报警
                liftProtocol.setPlatTorqueDeviationAlarm(modbusTcpNet.getByteTransform().TransBool(content,14));
                liftProtocol.setPlatTorqueDeviationAlarm(modbusTcpNet.getByteTransform().TransBool(content,26));
                //平台四向车检测
                liftProtocol.setPlatShuttleCheck(modbusTcpNet.getByteTransform().TransBool(content,15));
                liftProtocol.setPlatShuttleCheck(modbusTcpNet.getByteTransform().TransBool(content,28));
                //未就绪状态
                liftProtocol.setNotReady(modbusTcpNet.getByteTransform().TransInt16(content,16));
                liftProtocol.setNotReady(modbusTcpNet.getByteTransform().TransInt16(content,30));
                //伺服1错误
                liftProtocol.setServoError1(modbusTcpNet.getByteTransform().TransInt16(content,17));
                liftProtocol.setServoError1(modbusTcpNet.getByteTransform().TransInt16(content,32));
                //伺服2错误
                liftProtocol.setServoError2(modbusTcpNet.getByteTransform().TransInt16(content,18));
                liftProtocol.setServoError2(modbusTcpNet.getByteTransform().TransInt16(content,34));
                //伺服3错误
                liftProtocol.setServoError3(modbusTcpNet.getByteTransform().TransInt16(content,19));
                liftProtocol.setServoError3(modbusTcpNet.getByteTransform().TransInt16(content,36));
                //伺服4错误
                liftProtocol.setServoError4(modbusTcpNet.getByteTransform().TransInt16(content,20));
                liftProtocol.setServoError4(modbusTcpNet.getByteTransform().TransInt16(content,38));
                //提升机实际速度反馈
                liftProtocol.setLiftActualSpeed(modbusTcpNet.getByteTransform().TransInt16(content,21));
                liftProtocol.setLiftActualSpeed(modbusTcpNet.getByteTransform().TransInt16(content,40));

                ///读取提升机状态-end

                OutputQueue.LIFT.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));
                log.info(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));
                //小车处于运行状态，将标记置为true
                if (liftProtocol.getRunning()) {
                    liftProtocol.setPakMk(true);
                }

                // 根据实时信息更新数据库
                //.....
                //提升机处于锁定、未运行、就绪、标记true、有任务号
                if (liftProtocol.getLiftLock()
                        && !liftProtocol.getRunning()
                        && liftProtocol.getReady()
                        && liftProtocol.getPakMk()
                        && liftProtocol.getTaskNo() != 0) {
                    //还有未完成的命令
                    executeWork(liftProtocol.getTaskNo());
                }

                //将提升机状态保存至数据库
                BasLiftService liftService = SpringUtils.getBean(BasLiftService.class);
                BasLift basLift = liftService.selectById(liftProtocol.getLiftNo());
                if (basLift == null) {
                    basLift = new BasLift();
                    //提升机号
                    basLift.setLiftNo(slave.getId());
                    liftService.insert(basLift);
                }
                basLift.setStatus(liftProtocol.getProtocolStatus());
                basLift.setWrkNo(liftProtocol.getTaskNo().intValue());
                basLift.setUpdateTime(new Date());
                basLift.setPakMk(liftProtocol.getPakMk());
                basLift.setLiftLock(liftProtocol.getLiftLock());
                basLift.setPositionArrivalFeedback(liftProtocol.getPositionArrivalFeedback().intValue());
                basLift.setReady(liftProtocol.getReady());
                basLift.setRunning(liftProtocol.getRunning());
                basLift.setMode(liftProtocol.getMode());
                basLift.setLineFrontHasStock(liftProtocol.getLineFrontHasStock());
                basLift.setForwardRotationFeedback(liftProtocol.getForwardRotationFeedback());
                basLift.setReverseFeedback(liftProtocol.getReverseFeedback());
                basLift.setMotorOverload(liftProtocol.getMotorOverload());
                basLift.setLineEndHasStock(liftProtocol.getLineEndHasStock());
                basLift.setInConveyLineCardTrayAlarm(liftProtocol.getInConveyLineCardTrayAlarm());
                basLift.setOutConveyLineCardTrayAlarm(liftProtocol.getOutConveyLineCardTrayAlarm());
                basLift.setPlatPositionDeviationAlarm(liftProtocol.getPlatPositionDeviationAlarm());
                basLift.setPlatTorqueDeviationAlarm(liftProtocol.getPlatTorqueDeviationAlarm());
                basLift.setPlatShuttleCheck(liftProtocol.getPlatShuttleCheck());
                basLift.setNotReady(liftProtocol.getNotReady().intValue());
                basLift.setServoError1(liftProtocol.getServoError1().intValue());
                basLift.setServoError2(liftProtocol.getServoError2().intValue());
                basLift.setServoError3(liftProtocol.getServoError3().intValue());
                basLift.setServoError4(liftProtocol.getServoError4().intValue());
                basLift.setLiftActualSpeed(liftProtocol.getLiftActualSpeed().intValue());
                if (liftService.updateById(basLift)) {
                    OutputQueue.LIFT.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));
//                    log.info(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));
                }

            }else {
                OutputQueue.LIFT.offer(MessageFormat.format("【{0}】{1}提升机plc状态信息失败", DateUtils.convert(new Date()), slave.getId()));
@@ -171,23 +241,35 @@
            return false;
        }

        command.setLiftNo(slave.getId());
        command.setLiftNo(slave.getId().shortValue());
        // 开始任务
        short[] array = new short[30];
        //开始运行
        array[0] = command.getRun();
        //目标位置
        array[1] = command.getDistPosition();
        //运行速度
        array[2] = command.getSpeed();
        //二层高度设定
        array[3] = command.getHeight2();
        //三层高度设定
        array[4] = command.getHeight3();
        //四层高度设定
        array[5] = command.getHeight4();
        //提升机锁定
        array[29] = command.getLiftLock();
        if (command.getDistPosition() != null) {
            //目标位置
            array[1] = command.getDistPosition();
        }
        if (command.getSpeed() != null) {
            //运行速度
            array[2] = command.getSpeed();
        }
        if (command.getHeight2() != null) {
            //二层高度设定
            array[3] = command.getHeight2();
        }
        if (command.getHeight3() != null) {
            //三层高度设定
            array[4] = command.getHeight3();
        }
        if (command.getHeight4() != null) {
            //四层高度设定
            array[5] = command.getHeight4();
        }
        if (command.getLiftLockShortValue() != null) {
            //提升机锁定
            array[29] = command.getLiftLockShortValue();
        }

        OperateResult result = modbusTcpNet.Write("0", array);;
        if (result != null && result.IsSuccess) {
@@ -199,6 +281,202 @@
            News.error("写入提升机plc数据失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            return false;
        }
    }

    //分配任务
    private void assignWork(LiftAssignCommand assignCommand) {
        //手动模式指令
        if (!assignCommand.getAuto()) {
            LiftCommand command = new LiftCommand();
            //提升机当前楼层
            Short lev = liftProtocol.getLev();
            List<LiftCommand> commands = assignCommand.getCommands();
            if (commands == null) {
                commands = new ArrayList<LiftCommand>();
            }
            liftProtocol.setTaskNo(assignCommand.getTaskNo());
            switch (assignCommand.getTaskMode()) {
                case 1://上升一层
                    command = getLiftUpDownCommand(++lev);//获取提升机上升下降命令
                    break;
                case 2://下降一层
                    command = getLiftUpDownCommand(--lev);//获取提升机上升下降命令
                    break;
                case 3://有货正转
                    command = getLiftTurnCommand(1);//获取提升机转动命令
                    break;
                case 4://有货反转
                    command = getLiftTurnCommand(2);//获取提升机转动命令
                    break;
                case 5://复位
                    command = getResetCommand();//获取复位命令
                    break;
                default:
            }
            commands.add(command);
            assignCommand.setCommands(commands);
        }

        LiftRedisCommand redisCommand = new LiftRedisCommand();
        redisCommand.setLiftNo(assignCommand.getLiftNo());//提升机号
        redisCommand.setWrkNo(assignCommand.getTaskNo());//工作号
        redisCommand.setCommandStep(0);//命令执行步序
        redisCommand.setAssignCommand(assignCommand);//命令
        //任务数据保存到redis
        redisUtil.set("lift_wrk_no_" + assignCommand.getTaskNo(), JSON.toJSONString(redisCommand));
        liftProtocol.setAssignCommand(assignCommand);
        liftProtocol.setProtocolStatus(LiftProtocolStatusType.WORKING);
        //执行下发任务
        executeWork(assignCommand.getTaskNo());
    }

    //执行任务
    private boolean executeWork(Short wrkNo) {
        //读取redis数据
        if (wrkNo == null) {
            return false;
        }

        //将标记置为false(防止重发)
        liftProtocol.setPakMk(false);

        Object o = redisUtil.get("lift_wrk_no_" + wrkNo);
        if (o == null) {
            return false;
        }
        LiftRedisCommand redisCommand = JSON.parseObject(o.toString(), LiftRedisCommand.class);
        List<LiftCommand> commands = redisCommand.getAssignCommand().getCommands();
        //当前步序
        int commandStep = redisCommand.getCommandStep();
        //总步序
        int size = commands.size();
        LiftAssignCommand assignCommand = redisCommand.getAssignCommand();

        //取出命令
        LiftCommand command = commands.get(commandStep);
        //下发命令
        if (!write(command)) {
            News.error("提升机命令下发失败，提升机号={}，任务数据={}", command.getLiftNo(), JSON.toJSON(command));
            return false;
        }else {
            News.info("提升机命令下发成功，提升机号={}，任务数据={}", command.getLiftNo(), JSON.toJSON(command));

            //判断数据是否执行完成
            if (commandStep < size - 1) {
                //更新redis数据
                //步序增加
                commandStep++;
                redisCommand.setCommandStep(commandStep);
                //任务数据保存到redis
                redisUtil.set("lift_wrk_no_" + redisCommand.getWrkNo(), JSON.toJSONString(redisCommand));
            }else {
                //已执行完成
                //保存数据到数据库做流水
                BasLiftOptService liftOptService = SpringUtils.getBean(BasLiftOptService.class);
                if (liftOptService != null) {
                    BasLiftOpt opt = new BasLiftOpt(
                            redisCommand.getWrkNo().intValue(),
                            redisCommand.getLiftNo().intValue(),
                            new Date(),
                            null,
                            null,
                            null,
                            JSON.toJSONString(assignCommand)
                    );
                    liftOptService.insert(opt);
                }
                //删除redis
                redisUtil.del("lift_wrk_no_" + redisCommand.getWrkNo());

                if (assignCommand.getAuto()) {
                    //对主线程抛出等待确认状态waiting
                    liftProtocol.setProtocolStatus(LiftProtocolStatusType.WAITING);
                    News.info("提升机任务执行完成等待确认中，提升机号={}，任务数据={}", command.getLiftNo(), JSON.toJSON(command));
                }else {
                    //手动模式不抛出等待状态
                    liftProtocol.setTaskNo((short) 0);
                    liftProtocol.setShuttleNo((short) 0);
                    liftProtocol.setProtocolStatus(LiftProtocolStatusType.IDLE);
                    liftProtocol.setPakMk(true);
                    liftProtocol.setSecurityMk(false);
                    News.info("提升机手动任务执行完成，提升机号={}，任务数据={}", command.getLiftNo(), JSON.toJSON(command));
                }

                //下发一条提升机解锁命令
                LiftCommand unlockCommand = getUnlockCommand(command.getLiftNo());
                if (write(unlockCommand)) {
                    News.info("提升机状态已解锁，提升机号={}，任务数据={}", command.getLiftNo(), JSON.toJSON(command));
                }

            }
        }

        return true;
    }

    /**
     * 获取提升机解锁命令
     */
    public LiftCommand getUnlockCommand(Short liftNo) {
        LiftCommand command = new LiftCommand();
        command.setRun((short) 0);
        command.setLiftNo(liftNo);
        command.setLiftLock(false);
        return command;
    }

    /**
     * 获取复位命令
     */
    public LiftCommand getResetCommand() {
        LiftCommand command = new LiftCommand();
        command.setRun((short) 0);
        command.setLiftLock(false);
        return command;
    }

    /**
     * 获取提升机上升下降命令
     */
    public LiftCommand getLiftUpDownCommand(Short lev) {
        LiftCommand command = new LiftCommand();
        command.setRun((short) 1);//升降
        command.setDistPosition(lev);
        return command;
    }

    /**
     * 获取提升机上升下降命令
     */
    public LiftCommand getLiftUpDownCommand(Short liftNo, Short taskNo, Short lev) {
        LiftCommand command = new LiftCommand();
        command.setRun((short) 1);//升降
        command.setLiftNo(liftNo);//提升机号
        command.setTaskNo(taskNo);//任务号
        command.setDistPosition(lev);//目标楼层1层
        command.setLiftLock(true);//锁定提升机
        return command;
    }

    /**
     * 获取提升机转动命令，direction：1=》有货正转，2=》有货反转
     */
    public LiftCommand getLiftTurnCommand(Integer direction) {
        LiftCommand command = new LiftCommand();
        command.setRun(direction == 1 ? (short) 6 : (short) 3);
        return command;
    }

    /**
     * 获取提升机转动命令，direction：1=》有货正转，2=》有货反转
     */
    public LiftCommand getLiftTurnCommand(Short liftNo, Short taskNo, Integer direction) {
        LiftCommand command = new LiftCommand();
        command.setRun(direction == 1 ? (short) 6 : (short) 3);
        command.setLiftNo(liftNo);//提升机号
        command.setTaskNo(taskNo);//任务号
        command.setLiftLock(true);//锁定提升机
        return command;
    }

    /**
@@ -218,19 +496,19 @@
        slave.setId(1);
        slave.setIp("192.168.4.24");
        slave.setPort(502);
        LiftThread thread = new LiftThread(slave);
        thread.connect();
        thread.readStatus();

        LiftCommand command = new LiftCommand();
        command.setRun((short) 0);
        command.setDistPosition((short) 12);
        command.setSpeed((short) 300);
        command.setHeight2((short) 100);
        command.setHeight3((short) 200);
        command.setHeight4((short) 303);
        command.setLiftLock((short) 1);
        thread.write(command);
//        LiftThread thread = new LiftThread(slave,);
//        thread.connect();
//        thread.readStatus();
//
//        LiftCommand command = new LiftCommand();
//        command.setRun((short) 1);
//        command.setDistPosition((short) 12);
//        command.setSpeed((short) 300);
//        command.setHeight2((short) 100);
//        command.setHeight3((short) 200);
//        command.setHeight4((short) 303);
//        command.setLiftLock(true);
//        thread.write(command);

    }