站点转移功能入出罐装线异常修复

pjb

2025-09-14 cb2e9ba3d787767f4d7593ed53124e1135a391d5

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

@@ -8,10 +8,11 @@
import com.core.common.Cools;
import com.core.common.DateUtils;
import com.core.common.SpringUtils;
import com.zy.asrs.entity.BasCrnOpt;
import com.zy.asrs.entity.BasCrnp;
import com.zy.asrs.service.BasCrnOptService;
import com.zy.asrs.service.BasCrnpService;
import com.zy.entity.BasCrnOpt;
import com.zy.entity.BasCrnp;
import com.zy.service.BasCrnOptService;
import com.zy.service.BasCrnpService;
import com.zy.utils.News;
import com.zy.core.CrnThread;
import com.zy.core.cache.MessageQueue;
import com.zy.core.cache.OutputQueue;
@@ -39,6 +40,10 @@
    private CrnProtocol crnProtocol;
    private boolean resetFlag = false;

    public boolean isRunning = true;

    public Long sign = System.currentTimeMillis();

    /**
     * 堆垛机是否在回原点运动中标记
     */
@@ -52,7 +57,7 @@
    @SuppressWarnings("InfiniteLoopStatement")
    public void run() {
        this.connect();
        while (true) {
        while (isRunning) {
            try {
                int step = 1;
                Task task = MessageQueue.poll(SlaveType.Crn, slave.getId());
@@ -84,6 +89,7 @@
                        command.setDestinationPosX((short)0);     // 目标库位排
                        command.setDestinationPosY((short)0);     // 目标库位列
                        command.setDestinationPosZ((short)0);     // 目标库位层
                        command.setTaskCount((short) 0);
                        write(command);
                        break;
                    default:
@@ -105,6 +111,7 @@
            crnProtocol = new CrnProtocol();
        }
        crnProtocol.setMode((short) -1);
        crnProtocol.setCrnNo(slave.getId());
//        crnProtocol.setTaskNo((short)0);
        crnProtocol.setStatus((short)-1);
        crnProtocol.setBay((short)0);
@@ -133,10 +140,10 @@
        if(connect.IsSuccess){
            result = true;
            OutputQueue.CRN.offer(MessageFormat.format( "【{0}】堆垛机plc连接成功 ===>> [id:{1}] [ip:{2}] [port:{3}] [rack:{4}] [slot:{5}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot()));
            log.info("堆垛机plc连接成功 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
            News.info("SiemensCrn"+" - 1"+" - 堆垛机plc连接成功 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
        } else {
            OutputQueue.CRN.offer(MessageFormat.format("【{0}】堆垛机plc连接失败！！！ ===>> [id:{1}] [ip:{2}] [port:{3}] [rack:{4}] [slot:{5}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot()));
            log.error("堆垛机plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
            News.error("SiemensCrn"+" - 2"+" - 堆垛机plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
            initCrn();
        }
//        siemensNet.ConnectClose();
@@ -168,13 +175,13 @@
                crnProtocol.setTemp2(siemensNet.getByteTransform().TransInt16(result.Content, 22));
                crnProtocol.setTemp3(siemensNet.getByteTransform().TransInt16(result.Content, 24));
                crnProtocol.setTemp4(siemensNet.getByteTransform().TransInt16(result.Content, 26));
                crnProtocol.setxSpeed(siemensNet.getByteTransform().TransInt16(result.Content, 28));
                crnProtocol.setySpeed(siemensNet.getByteTransform().TransInt16(result.Content, 32));
                crnProtocol.setzSpeed(siemensNet.getByteTransform().TransInt16(result.Content, 36));
                crnProtocol.setxDistance(siemensNet.getByteTransform().TransInt16(result.Content, 40));
                crnProtocol.setyDistance(siemensNet.getByteTransform().TransInt16(result.Content, 44));
                crnProtocol.setxDuration(siemensNet.getByteTransform().TransInt16(result.Content, 48));
                crnProtocol.setyDuration(siemensNet.getByteTransform().TransInt16(result.Content, 52));
                crnProtocol.setxSpeed(siemensNet.getByteTransform().TransSingle(result.Content, 28));
                crnProtocol.setySpeed(siemensNet.getByteTransform().TransSingle(result.Content, 32));
                crnProtocol.setzSpeed(siemensNet.getByteTransform().TransSingle(result.Content, 36));
                crnProtocol.setxDistance(siemensNet.getByteTransform().TransSingle(result.Content, 40));
                crnProtocol.setyDistance(siemensNet.getByteTransform().TransSingle(result.Content, 44));
                crnProtocol.setxDuration(siemensNet.getByteTransform().TransSingle(result.Content, 48));
                crnProtocol.setyDuration(siemensNet.getByteTransform().TransSingle(result.Content, 52));

                OutputQueue.CRN.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));

@@ -199,19 +206,19 @@
                    basCrnp.setCrnNo(slave.getId());
                    basCrnp.setCrnSts((int)crnProtocol.getMode());
                    if (!basCrnpService.updateById(crnProtocol.toSqlModel(basCrnp))){
                        log.error("堆垛机plc数据库更新失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
                        News.error("SiemensCrn"+" - 3"+" - 堆垛机plc数据库更新失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
                    }
                } catch (Exception ignore){}

            } else {
                initCrn();
                OutputQueue.CRN.offer(MessageFormat.format("【{0}】读取堆垛机plc状态信息失败 ===>> [id:{1}] [ip:{2}] [port:{3}] [rack:{4}] [slot:{5}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot()));
                log.error("读取堆垛机plc状态信息失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
                News.error("SiemensCrn"+" - 4"+" - 读取堆垛机plc状态信息失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
            }
        } catch (Exception e) {
            e.printStackTrace();
            OutputQueue.CRN.offer(MessageFormat.format("【{0}】读取堆垛机plc状态信息失败 ===>> [id:{1}] [ip:{2}] [port:{3}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort()));
            log.error("读取堆垛机plc状态信息失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            News.error("SiemensCrn"+" - 5"+" - 读取堆垛机plc状态信息失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            initCrn();
        }
    }
@@ -230,30 +237,142 @@
     */
    private boolean write(CrnCommand command) throws InterruptedException {
        if (null == command) {
            log.error("堆垛机写入命令为空");
            News.error("堆垛机写入命令为空");
            return false;
        }
        // 向堆垛机发任务前的堆垛机状态
        try{
            OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.0", (short) 24);
            if (resultRead.IsSuccess) {
                CrnCommand one = new CrnCommand();
                one.setTaskNo(siemensNet.getByteTransform().TransInt16(resultRead.Content, 2));
                one.setTaskMode(siemensNet.getByteTransform().TransInt16(resultRead.Content, 4));
                one.setSourcePosX(siemensNet.getByteTransform().TransInt16(resultRead.Content, 6));
                one.setSourcePosY(siemensNet.getByteTransform().TransInt16(resultRead.Content, 8));
                one.setSourcePosZ(siemensNet.getByteTransform().TransInt16(resultRead.Content, 10));
                one.setDestinationPosX(siemensNet.getByteTransform().TransInt16(resultRead.Content, 12));
                one.setDestinationPosY(siemensNet.getByteTransform().TransInt16(resultRead.Content, 14));
                one.setDestinationPosZ(siemensNet.getByteTransform().TransInt16(resultRead.Content, 16));
                if (!command.getTaskNo().equals(one.getTaskNo()) || !command.getTaskMode().equals(one.getTaskMode())
                        || !command.getSourcePosX().equals(one.getSourcePosX()) || !command.getSourcePosY().equals(one.getSourcePosY())
                        || !command.getSourcePosZ().equals(one.getSourcePosZ()) || !command.getDestinationPosX().equals(one.getDestinationPosX())
                        || !command.getDestinationPosY().equals(one.getDestinationPosY()) || !command.getDestinationPosZ().equals(one.getDestinationPosZ())
                ){
                    News.error("下发前：[id:{}] >>>>> 写入[{}],===>>回读[{}]", slave.getId(), JSON.toJSON(command),JSON.toJSON(one));
                } else {
                    News.info("下发前：[id:{}] >>>>> 写入[{}],===>>回读[{}]", slave.getId(), JSON.toJSON(command),JSON.toJSON(one));
                }
            }
        }catch (Exception e){
            News.error("堆垛机命令地址写入后回读出错");
        }
//        convertRow(command);
        command.setCrnNo(slave.getId());
        short[] array = new short[10];
        array[0] = command.getAckFinish();
        array[1] = command.getTaskNo();
        array[2] = command.getTaskMode();
        array[3] = command.getSourcePosX();
        array[4] = command.getSourcePosY();
        array[5] = command.getSourcePosZ();
        array[6] = command.getDestinationPosX();
        array[7] = command.getDestinationPosY();
        array[8] = command.getDestinationPosZ();
//        array[9] = command.getSourceStaNo();
//        array[10] = command.getDestinationStaNo();
//        short[] array = new short[10];
        short[] array = new short[12];
        array[0] = command.getAckFinish(); // 任务完成确认位
        array[1] = command.getTaskNo();  // 任务号
        array[2] = command.getTaskMode();  // 模式
        array[3] = command.getSourcePosX(); // 源位置排号
        array[4] = command.getSourcePosY(); // 源位置列号
        array[5] = command.getSourcePosZ(); // 源位置层号
        array[6] = command.getDestinationPosX();  // 目标位置排号
        array[7] = command.getDestinationPosY(); // 目标位置列号
        array[8] = command.getDestinationPosZ(); // 目标位置层号
        array[9] = command.getCommand();
        array[11] = command.getTaskCount(); // 空桶出库，告诉堆垛机取一个货还是两个货
        OperateResult result = siemensNet.Write("DB100.0", array);
        News.info("堆垛机命令下发[id:{}] >>>>> {}", slave.getId(), array);

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

        //堆垛机任务写入后，回读一次，看是否成功
        Thread.sleep(200);
        try{
            OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.0", (short) 24);
            if (resultRead.IsSuccess) {
                CrnCommand one = new CrnCommand();
                one.setTaskNo(siemensNet.getByteTransform().TransInt16(resultRead.Content, 2));
                one.setTaskMode(siemensNet.getByteTransform().TransInt16(resultRead.Content, 4));
                one.setSourcePosX(siemensNet.getByteTransform().TransInt16(resultRead.Content, 6));
                one.setSourcePosY(siemensNet.getByteTransform().TransInt16(resultRead.Content, 8));
                one.setSourcePosZ(siemensNet.getByteTransform().TransInt16(resultRead.Content, 10));
                one.setDestinationPosX(siemensNet.getByteTransform().TransInt16(resultRead.Content, 12));
                one.setDestinationPosY(siemensNet.getByteTransform().TransInt16(resultRead.Content, 14));
                one.setDestinationPosZ(siemensNet.getByteTransform().TransInt16(resultRead.Content, 16));
                one.setTraySize(siemensNet.getByteTransform().TransBool(resultRead.Content, 22));
                if (!command.getTaskNo().equals(one.getTaskNo()) || !command.getTaskMode().equals(one.getTaskMode())
                        || !command.getSourcePosX().equals(one.getSourcePosX()) || !command.getSourcePosY().equals(one.getSourcePosY())
                        || !command.getSourcePosZ().equals(one.getSourcePosZ()) || !command.getDestinationPosX().equals(one.getDestinationPosX())
                        || !command.getDestinationPosY().equals(one.getDestinationPosY()) || !command.getDestinationPosZ().equals(one.getDestinationPosZ())

                ){
                    try{
                        News.error("堆垛机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("堆垛机命令回读失败后，重新添加任务到队列 ===>> [id:{}],{}", slave.getId(), JSON.toJSON(command));
                    MessageQueue.offer(SlaveType.Crn, slave.getId(), new Task(2, command));
                    Thread.sleep(100);
                    readStatus();
                    return false;
                } else {
                    News.info("堆垛机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("堆垛机命令地址写入后回读出错");
        }


        if (command.getAckFinish() == 0) {
            short commandFinish = 1;
            Thread.sleep(100L);
            result = siemensNet.Write("DB100.18", commandFinish);
            if (result.IsSuccess) {
                Thread.sleep(300);
                //任务下发次数
                int writeCount2 = 0;

                do {
                    writeCount2++;
                    short commandFinish = (short) 1;
                    result = siemensNet.Write("DB100.18", commandFinish);
                    if(result.IsSuccess){
                        //堆垛机任务写入后，回读一次，看是否成功
                        Thread.sleep(200);
                        OperateResultExOne<byte[]> resultRead = siemensNet.Read("DB100.18", (short) 2);
                        if (resultRead.IsSuccess) {
                            commandFinish=siemensNet.getByteTransform().TransInt16(resultRead.Content, 0);
                            if (commandFinish != 1){
                                News.error("堆垛机任务确认位"+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("堆垛机任务确认位"+commandFinish+"回读成功！"+"循环执行次数:"+writeCount2+"次");
                                break;
                            }
                        }else {
                            News.error("堆垛机任务确认位"+commandFinish+"回读失败！"+"循环执行次数:"+writeCount2+"次");
                        }
                    } else {
                        News.error("堆垛机任务确认位"+commandFinish+"写入失败！"+"循环执行次数:"+writeCount2+"次");
                    }
                }while (writeCount2<5);
            }
        } else {
            BasCrnpService basCrnpService = SpringUtils.getBean(BasCrnpService.class);
            BasCrnp basCrnp = basCrnpService.selectById(slave.getId());
            basCrnp.setModiTime(new Date());
            basCrnpService.updateById(basCrnp);
//            log.info("更新{}号堆垛机执行任务完成复位时间",slave.getId());
        }

        try {
@@ -279,17 +398,20 @@
            bean.insert(basCrnOpt);
        } catch (Exception ignore) {}

        if (result != null && result.IsSuccess) {
            Thread.sleep(200);
        if (result.IsSuccess) {
            this.readStatus();
            log.info("堆垛机命令下发[id:{}] >>>>> {}", slave.getId(), JSON.toJSON(command));
            News.info("堆垛机命令下发[id:{}] >>>>> {}", slave.getId(), JSON.toJSON(command));
            OutputQueue.CRN.offer(MessageFormat.format("【{0}】[id:{1}] >>>>> 命令下发： {2}", DateUtils.convert(new Date()), slave.getId(), JSON.toJSON(command)));
            return true;
        } else {
            OutputQueue.CRN.offer(MessageFormat.format("【{0}】写入堆垛机plc数据失败 ===>> [id:{1}] [ip:{2}] [port:{3}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort()));
            log.error("写入堆垛机plc数据失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            News.error("写入堆垛机plc数据失败 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            return false;
        }
    }

    public void requestStop() {
        isRunning = false;
    }


@@ -304,7 +426,7 @@
    public static void main(String[] args) throws InterruptedException {
        CrnSlave slave = new CrnSlave();
        slave.setId(1);
        slave.setIp("192.168.6.9");
        slave.setIp("10.10.10.1");
        slave.setRack(0);
        slave.setSlot(0);
        SiemensCrnThread crnThread = new SiemensCrnThread(slave);
@@ -345,15 +467,15 @@
//        // 3.库位移转   源和目标都发 pass
//        CrnCommand command = new CrnCommand();
//        command.setCrnNo(slave.getId()); // 堆垛机编号
//        command.setTaskNo((short) 0); // 工作号
//        command.setTaskNo((short) 2); // 工作号
//        command.setAckFinish((short) 0);  // 任务完成确认位
//        command.setTaskMode(CrnTaskModeType.LOC_MOVE); // 任务模式:  库位移转
//        command.setSourcePosX((short)2);     // 源库位排
//        command.setSourcePosY((short)2);     // 源库位列
//        command.setSourcePosZ((short)3);     // 源库位层
//        command.setDestinationPosX((short)2);     // 目标库位排
//        command.setDestinationPosY((short)4);     // 目标库位列
//        command.setDestinationPosZ((short)4);     // 目标库位层
//        command.setSourcePosY((short)1);     // 源库位列
//        command.setSourcePosZ((short)1);     // 源库位层
//        command.setDestinationPosX((short)3);     // 目标库位排
//        command.setDestinationPosY((short)1);     // 目标库位列
//        command.setDestinationPosZ((short)1);     // 目标库位层
//        crnThread.write(command);

        // 4.站位移转   源和目标都发