#输送线循环覆写由plc执行

lty

2025-03-29 c588ec9236ef644fe13af957920198bdcb4e05e8

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

@@ -24,6 +24,7 @@
import com.zy.core.enums.SlaveType;
import com.zy.core.model.DevpSlave;
import com.zy.core.model.Task;
import com.zy.core.model.protocol.Cycle;
import com.zy.core.model.protocol.StaProtocol;
import lombok.Data;
import lombok.extern.slf4j.Slf4j;
@@ -48,7 +49,12 @@
    private Map<Integer, StaProtocol> station = new ConcurrentHashMap<>();
    private short heartBeatVal = 1;
    public static final ArrayList<Integer> staNos1 = new ArrayList<Integer>() {{
        add(100);add(101);add(102);add(103);add(104);add(105);add(106);add(107);
        add(100);add(101);add(102);add(103);add(104);
        add(105);add(106);add(107);add(108);add(109);
        add(110);add(111);add(112);add(113);add(114);
        add(115);add(116);add(117);add(118);add(119);
        add(120);add(121);add(122);add(123);add(124);
        add(125);add(1001);add(1002);add(1003);add(1004);
    }};
    /*public static final ArrayList<Integer> staNos2 = new ArrayList<Integer>() {{
        add(200);add(201);add(202);add(203);
@@ -73,7 +79,7 @@
    /**
     * 条码数量
     */
    private int barcodeSize = 7;
    private int barcodeSize = 1;

    /**
     * 入出库模式
@@ -127,7 +133,7 @@
                        break;
                    // 写数据 ID+目标站
                    case 4:
                        writeAgvOk((StaProtocol)task.getData());
                        writeCycle((StaProtocol)task.getData());
                        read();
                        break;
                   /* case 3:
@@ -234,41 +240,79 @@
            }
        }

        OperateResultExOne<byte[]> resultAgvAndPlc = siemensS7Net.Read("DB102.0", (short) 30);
        if (resultAgvAndPlc.IsSuccess) {
            for (int i = 0; i < staNoSize; i++) {
                int sign =(i+2)/2-1;
                if ((i+2)%2!=0){
                    Integer siteId = staNos.get(i); // 站点编号
                    StaProtocol staProtocol = station.get(siteId);
                    if (null == staProtocol) {
                        staProtocol = new StaProtocol();
                        staProtocol.setSiteId(siteId);
                        station.put(siteId, staProtocol);
                    }
                    staProtocol.setAgvStartPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6+4));     // 允许取货
                    staProtocol.setAgvStartPlace((short)0);   // 允许放货
                    continue;
                }
                Integer siteId = staNos.get(i); // 站点编号
                StaProtocol staProtocol = station.get(siteId);
                if (null == staProtocol) {
                    staProtocol = new StaProtocol();
                    staProtocol.setSiteId(siteId);
                    station.put(siteId, staProtocol);
                }
                staProtocol.setAgvStartPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6));     // 允许取货
                staProtocol.setAgvStartPlace(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6 + 2));   // 允许放货
            }
        }
//        OperateResultExOne<byte[]> resultAgvAndPlc = siemensS7Net.Read("DB102.0", (short) 30);
//        if (resultAgvAndPlc.IsSuccess) {
//            for (int i = 0; i < staNoSize; i++) {
//                int sign =(i+2)/2-1;
//                if ((i+2)%2!=0){
//                    Integer siteId = staNos.get(i); // 站点编号
//                    StaProtocol staProtocol = station.get(siteId);
//                    if (null == staProtocol) {
//                        staProtocol = new StaProtocol();
//                        staProtocol.setSiteId(siteId);
//                        station.put(siteId, staProtocol);
//                    }
//                    staProtocol.setAgvStartPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6+4));     // 允许取货
//                    staProtocol.setAgvStartPlace((short)0);   // 允许放货
//                    continue;
//                }
//                Integer siteId = staNos.get(i); // 站点编号
//                StaProtocol staProtocol = station.get(siteId);
//                if (null == staProtocol) {
//                    staProtocol = new StaProtocol();
//                    staProtocol.setSiteId(siteId);
//                    station.put(siteId, staProtocol);
//                }
//                staProtocol.setAgvStartPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6));     // 允许取货
//                staProtocol.setAgvStartPlace(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlc.Content, sign*6 + 2));   // 允许放货
//            }
//        }

//        OperateResultExOne<byte[]> resultAgvAndPlcOk = siemensS7Net.Read("DB132.0", (short) 30);
//        if (resultAgvAndPlcOk.IsSuccess) {
//            for (int i = 0; i < staNoSize; i++) {
//                int sign =(i+2)/2-1;
//                if ((i+2)%2!=0){
//                    Integer siteId = staNos.get(i); // 站点编号
//                    StaProtocol staProtocol = station.get(siteId);
//                    if (null == staProtocol) {
//                        staProtocol = new StaProtocol();
//                        staProtocol.setSiteId(siteId);
//                        station.put(siteId, staProtocol);
//                    }
//                    staProtocol.setAgvTargetPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlcOk.Content, sign*6+4));     // 允许取货
//                    staProtocol.setAgvTargetPlace((short)0);   // 允许放货
//                    continue;
//                }
//                Integer siteId = staNos.get(i); // 站点编号
//                StaProtocol staProtocol = station.get(siteId);
//                if (null == staProtocol) {
//                    staProtocol = new StaProtocol();
//                    staProtocol.setSiteId(siteId);
//                    station.put(siteId, staProtocol);
//                }
//                try{
//                    staProtocol.setAgvTargetPick(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlcOk.Content, sign*6));     // 取货完成
//                    if (staProtocol.getAgvTargetPick()!=0){
//                        System.out.println(staProtocol.getAgvTargetPick());
//                    }
//                    staProtocol.setAgvTargetPlace(siemensS7Net.getByteTransform().TransInt16(resultAgvAndPlcOk.Content, sign*6 + 2));   // 放货完成
//                    if (staProtocol.getAgvTargetPlace()!=0){
//                        System.out.println(staProtocol.getAgvTargetPlace());
//                    }
//                }catch (Exception e){
//                    log.error(""+e);
//                }
//            }
//        }


        if (slave.getId() == 1) {
            //条码
            //Thread.sleep(200);
            OperateResultExOne<byte[]> result2 = siemensS7Net.Read("DB101.840.0", (short) 32);
            OperateResultExOne<byte[]> result2 = siemensS7Net.Read("DB101.848.0", (short) 8);
            if (result2.IsSuccess) {
                for (int i = 0; i < 4; i++) {
                for (int i = 0; i < 1; i++) {
                    String barcode = siemensS7Net.getByteTransform().TransString(result2.Content, i * 8, 8, "UTF-8");
                    BarcodeThread barcodeThread = (BarcodeThread) SlaveConnection.get(SlaveType.Barcode, i + 1);
                    if (!Cools.isEmpty(barcodeThread) && !barcodeThread.getBarcode().equals(barcode)) {
@@ -277,8 +321,19 @@
                }
            }

            //外形检测
            OperateResultExOne<byte[]> resultErr1 = siemensS7Net.Read("DB101.810.0", (short) (barcodeSize*1));
            StaProtocol staProtocol1 = station.get(116);
            boolean[] status1 = siemensS7Net.getByteTransform().TransBool(resultErr1.Content, 0, 1);
            staProtocol1.setFrontErr(status1[0]);
            staProtocol1.setBackErr(status1[1]);
            staProtocol1.setHighErr(status1[2]);
            staProtocol1.setLeftErr(status1[3]);
            staProtocol1.setRightErr(status1[4]);
            staProtocol1.setWeightErr(status1[5]);
            staProtocol1.setBarcodeErr(status1[6]);

            OperateResultExOne<byte[]> resultErr = siemensS7Net.Read("DB13.2", (short) (staNoSize * 4));
            OperateResultExOne<byte[]> resultErr = siemensS7Net.Read("DB101.922.0", (short) (staNoSize * 4));
            if (resultErr.IsSuccess) {
                for (int i = 0; i < staNoSize; i++) {
                    Integer siteId = staNos.get(i); // 站点编号
@@ -363,7 +418,7 @@
        }
        ArrayList<Integer> staNos = getStaNo();
        int index = staNos.indexOf(staProtocol.getSiteId());
        if (staProtocol.getAgvTypeSign()==0){  //0取货
        if (staProtocol.getAgvTypeSign()==0 || staProtocol.getAgvTypeSign()==2 ){  //0取货
            switch (staProtocol.getSiteId()){
                case 100:
                    index=32;
@@ -415,7 +470,11 @@
        //任务下发次数
        int writeCount = 0;
        do {
            write = siemensS7Net.Write("DB102." + index, true);    // 任务完成
            short textWrite = 1;// 任务完成
            if (staProtocol.getAgvTypeSign()>1){
                textWrite = 0;// 任务复位
            }
            write = siemensS7Net.Write("DB102." + index, textWrite);
            if(write.IsSuccess){
                writeCount=6;
            }else {
@@ -435,38 +494,203 @@

    }
    private void write(StaProtocol staProtocol) throws InterruptedException {
        if (null == staProtocol) {
        if (staProtocol == null) {
            return;
        }

        ArrayList<Integer> staNos = getStaNo();

        int index = staNos.indexOf(staProtocol.getSiteId());
        short[] array = new short[2];
        array[0] = staProtocol.getWorkNo();
        array[1] = staProtocol.getStaNo();
//        OperateResult write = siemensS7Net.Write("DB100." + index*4, array);

        OperateResult writeResult;
        //任务下发次数
        int writeCount = 0;
        //任务下发成功标识
        boolean writeFlag = false;
        OperateResult writeResult1 = siemensS7Net.Write("DB100." + index*6, (int) staProtocol.getWorkNo());    // 工作号
        OperateResult writeResult2 = siemensS7Net.Write("DB100." + (index*6+4), staProtocol.getStaNo());    // 目标站
        if(writeResult1.IsSuccess&&writeResult2.IsSuccess){
            //更新任务步序
            TaskWrkService taskWrkService = SpringUtils.getBean(TaskWrkService.class);
            TaskWrk taskWrk = taskWrkService.selectByWrkNo((int) staProtocol.getWorkNo());
            if (taskWrk != null) {
                taskWrk.setCommandStep(taskWrk.getCommandStep() + 1);//更新指令步序
                taskWrkService.updateById(taskWrk);
            }else{
                log.error("输送线写入失败"+staProtocol+"++++++++++++++++++++++++++++++++++++++");
        if (index == -1) {
            log.error("站点编号 {} 不在已知列表中，无法写入任务！", staProtocol.getSiteId());
            return;
        }

        int writeCount = 0; // 任务下发尝试次数
        boolean writeFlag = false; // 任务下发成功标记
        String plcAddressWorkNo = "DB100." + index * 6;
        String plcAddressStaNo = "DB100." + (index * 6 + 4);

        while (writeCount < 5) {
            // **读取当前PLC状态，避免不必要的写入**
            OperateResultExOne<byte[]> readResult = siemensS7Net.Read(plcAddressWorkNo, (short) 6);
            if (readResult.IsSuccess) {
                int currentWorkNo = siemensS7Net.getByteTransform().TransInt32(readResult.Content, 0);
                short currentStaNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 4);

                if (currentWorkNo == staProtocol.getWorkNo().intValue() && currentStaNo == staProtocol.getStaNo()) {
                    log.info("站点 {} 当前状态已匹配，无需重复写入", staProtocol.getSiteId());
                    return;
                }
            }

            // **清零并确认**
            if (!clearPLCData(plcAddressWorkNo, plcAddressStaNo, staProtocol.getSiteId())) {
                writeCount++;
                continue; // 重新尝试清零
            }

            // **写入新任务**
            if (writeTaskToPLC(plcAddressWorkNo, plcAddressStaNo, staProtocol)) {
                writeFlag = true;
                log.info("输送线命令写入成功，PLC编号={}，站点数据={}，尝试次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
                break;
            }

            log.warn("输送线命令写入失败，PLC编号={}，站点数据={}，尝试次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
            writeCount++;
        }

        // **写入失败处理**
        handleWriteFailure(staProtocol, writeFlag);
    }

    private void writeCycle(StaProtocol staProtocol) throws InterruptedException {
        if (staProtocol == null) {
            return;
        }

        ArrayList<Integer> staNos = getStaNo();
        int index = staNos.indexOf(staProtocol.getSiteId());

        if (index == -1) {
            log.error("站点编号 {} 不在已知列表中，无法写入任务！", staProtocol.getSiteId());
            return;
        }

        int writeCount = 0; // 任务下发尝试次数
        boolean writeFlag = false; // 任务下发成功标记
        String plcAddressWorkNo = "";
        String plcAddressStaNo = "" ;
        switch (staProtocol.getSiteId()){
            case 105:
                plcAddressWorkNo = "DB73." + 0;
                plcAddressStaNo = "DB73." + 4;
                break;
            case 106:
                plcAddressWorkNo = "DB73." + 6;
                plcAddressStaNo = "DB73." + (6 + 4);
                break;
            case 108:
                plcAddressWorkNo = "DB73." + 2 * 6;
                plcAddressStaNo = "DB73." + (2 * 6 + 4);
                break;
            case 110:
                plcAddressWorkNo = "DB73." + 3 * 6;
                plcAddressStaNo = "DB73." + (3 * 6 + 4);
                break;
            case 112:
                plcAddressWorkNo = "DB73." + 4 * 6;
                plcAddressStaNo = "DB73." + (4 * 6 + 4);
                break;
        }
//        String plcAddressWorkNo = "DB100." + index * 6;
//        String plcAddressStaNo = "DB100." + (index * 6 + 4);

        while (writeCount < 5) {
            // **读取当前PLC状态，避免不必要的写入**
            OperateResultExOne<byte[]> readResult = siemensS7Net.Read(plcAddressWorkNo, (short) 6);
            if (readResult.IsSuccess) {
                int currentWorkNo = siemensS7Net.getByteTransform().TransInt32(readResult.Content, 0);
                short currentStaNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 4);

                if (currentWorkNo == staProtocol.getWorkNo().intValue() && currentStaNo == staProtocol.getStaNo()) {
                    log.info("站点 {} 当前状态已匹配，无需重复写入", staProtocol.getSiteId());
                    return;
                }
            }

            // **写入新任务**
            if (writeTaskToPLC(plcAddressWorkNo, plcAddressStaNo, staProtocol)) {
                writeFlag = true;
                log.info("输送线命令写入成功，PLC编号={}，站点数据={}，尝试次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
                break;
            }

            log.warn("输送线命令写入失败，PLC编号={}，站点数据={}，尝试次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
            writeCount++;
        }

        // **写入失败处理**
        handleWriteFailure(staProtocol, writeFlag);
    }

    /**
     * 清零 PLC 数据并验证清零是否成功
     */
    private boolean clearPLCData(String plcAddressWorkNo, String plcAddressStaNo, int siteId) throws InterruptedException {
        siemensS7Net.Write(plcAddressWorkNo, 0);
        siemensS7Net.Write(plcAddressStaNo, (short) 0);
        Thread.sleep(100); // 等待PLC识别

        OperateResultExOne<byte[]> readResult = siemensS7Net.Read(plcAddressWorkNo, (short) 6);
        if (readResult.IsSuccess) {
            int readWorkNo = siemensS7Net.getByteTransform().TransInt32(readResult.Content, 0);
            short readStaNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 4);
            if (readWorkNo == 0 && readStaNo == 0) {
                return true; // 清零成功
            }
        }


        log.warn("站点 {} 清零失败，尝试重新清零...", siteId);
        return false;
    }

    /**
     * 写入新任务到 PLC 并验证是否成功
     */
    private boolean writeTaskToPLC(String plcAddressWorkNo, String plcAddressStaNo, StaProtocol staProtocol) throws InterruptedException {
        OperateResult writeResult1 = siemensS7Net.Write(plcAddressWorkNo, staProtocol.getWorkNo().intValue());
        OperateResult writeResult2 = siemensS7Net.Write(plcAddressStaNo, staProtocol.getStaNo());

        if (writeResult1.IsSuccess && writeResult2.IsSuccess) {
            Thread.sleep(200); // 等待 PLC 识别新值
            OperateResultExOne<byte[]> readResult = siemensS7Net.Read(plcAddressWorkNo, (short) 6);
            if (readResult.IsSuccess) {
                int workNo = siemensS7Net.getByteTransform().TransInt32(readResult.Content, 0);
                short staNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 4);
                return workNo == staProtocol.getWorkNo().intValue() && staNo == staProtocol.getStaNo();
            }
        }
        return false;
    }

    private boolean writeTaskToPLC(String plcAddressWorkNo, String plcAddressStaNo, Cycle cycle) throws InterruptedException {
        OperateResult writeResult1 = siemensS7Net.Write(plcAddressWorkNo, cycle.getWorkNo().intValue());
        OperateResult writeResult2 = siemensS7Net.Write(plcAddressStaNo, cycle.getStaNo());

        if (writeResult1.IsSuccess && writeResult2.IsSuccess) {
            Thread.sleep(200); // 等待 PLC 识别新值
            OperateResultExOne<byte[]> readResult = siemensS7Net.Read(plcAddressWorkNo, (short) 6);
            if (readResult.IsSuccess) {
                int workNo = siemensS7Net.getByteTransform().TransInt32(readResult.Content, 0);
                short staNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 4);
                return workNo == cycle.getWorkNo().intValue() && staNo == cycle.getStaNo();
            }
        }
        return false;
    }

    /**
     * 处理写入失败的情况
     */
    private void handleWriteFailure(StaProtocol staProtocol, boolean writeFlag) {
        if (!writeFlag) {
            StaProtocol currentStaProtocol = station.get(staProtocol.getSiteId());
            if (currentStaProtocol.getWorkNo() == 0 && currentStaProtocol.getStaNo() == 0) {
                currentStaProtocol.setPakMk(true);
            }
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线命令尝试5次失败。PLC编号={1}，站点数据={2}",
                    slave.getId(), JSON.toJSON(currentStaProtocol)));
            log.error("输送线命令尝试5次失败，PLC编号={}，站点数据={}", slave.getId(), JSON.toJSON(currentStaProtocol));
        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线命令成功 [id:{1}] >>>>> {2}",
                    DateUtils.convert(new Date()), slave.getId(), JSON.toJSON(staProtocol)));
            log.info("输送线命令成功 [id:{}] >>>>> {}", slave.getId(), JSON.toJSON(staProtocol));
        }
    }


    private void write2(StaProtocol staProtocol) throws InterruptedException {
        if (null == staProtocol) {
            return;