最后可运行版本

zyh

2 天以前 e98d4b1133ed058bfe1e6af75be9975aebfc32d8

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

@@ -13,6 +13,7 @@
import com.zy.asrs.entity.DeviceDataLog;
import com.zy.asrs.service.BasDevpService;
import com.zy.asrs.service.DeviceDataLogService;
import com.zy.asrs.service.impl.RcsServiceImpl;
import com.zy.common.utils.News;
import com.zy.core.DevpThread;
import com.zy.core.cache.MessageQueue;
@@ -25,6 +26,7 @@
import com.zy.core.model.protocol.StaProtocol;
import lombok.Data;
import lombok.extern.slf4j.Slf4j;
import org.springframework.beans.factory.annotation.Autowired;

import java.text.MessageFormat;
import java.util.*;
@@ -44,6 +46,11 @@
    private short heartBeatVal = 1;

    /**
     * 条码数量
     */
    private int barcodeSize = 2;

    /**
     * 日志采集时间
     */
    private Long deviceDataLogTime = System.currentTimeMillis();
@@ -53,7 +60,7 @@
    }};

    public static final ArrayList<Integer> staNos2 = new ArrayList<Integer>() {{
//        add(2000);add(2001);add(2002);add(1001);add(1002);add(1003);add(1004);add(1005);add(1006);add(1007);

    }};


@@ -61,11 +68,11 @@

    public static final ArrayList<Integer> barcode1 = new ArrayList<Integer>() {{
        add(1);
        add(2);
//        add(2);
    }};

    public static final ArrayList<Integer> barcode2 = new ArrayList<Integer>() {{
//        add(3);
        add(2);
//        add(4);
    }};

@@ -125,6 +132,9 @@
                    // 写数据 ID+目标站
                    case 2:
                        write((StaProtocol)task.getData());
                        break;
                    case 3:
                        write1((StaProtocol)task.getData());
                        break;
                    default:
                        break;
@@ -197,7 +207,7 @@
//        updateIoMode();
        ArrayList<Integer> staNos = getStaNo();
        int staNoSize = staNos.size();
        OperateResultExOne<byte[]> result = siemensS7Net.Read("DB101.0", (short) (staNoSize * 18));
        OperateResultExOne<byte[]> result = siemensS7Net.Read("DB101.0", (short) (staNoSize*8));
        if (result.IsSuccess) {
            for (int i = 0; i < staNoSize; i++) {
                Integer siteId = staNos.get(i); // 站点编号
@@ -207,40 +217,20 @@
                    staProtocol.setSiteId(siteId);
                    station.put(siteId, staProtocol);
                }
                staProtocol.setSiteId(siteId);
                staProtocol.setWorkNo((short) siemensS7Net.getByteTransform().TransInt32(result.Content, (i * 18)));     // 工作号
                staProtocol.setStaNo((short) siemensS7Net.getByteTransform().TransInt32(result.Content, (i * 18) + 4));   // 目标站
                staProtocol.setWorkNo((short)siemensS7Net.getByteTransform().TransInt32(result.Content, i*8));     // 工作号

                short locHeight = siemensS7Net.getByteTransform().TransInt16(result.Content, (i * 18) + 8);//库位高度
                if (locHeight == 2) {//high
                    staProtocol.setHigh(true);
                    staProtocol.setLow(false);
                }else {//low
                    staProtocol.setHigh(false);
                    staProtocol.setLow(true);
                }
                staProtocol.setStaNo(siemensS7Net.getByteTransform().TransInt16(result.Content, i*8 + 4));   // 目标站

                staProtocol.setError(siemensS7Net.getByteTransform().TransInt16(result.Content, (i * 18) + 10));   // 报警

                boolean[] status = siemensS7Net.getByteTransform().TransBool(result.Content, (i * 18) + 12, 1);
                staProtocol.setAutoing(status[0]);  // 自动
                staProtocol.setLoading(status[1]);  // 有物
                staProtocol.setInEnable(status[2]); // 可入
                staProtocol.setOutEnable(status[3]);// 可出
                staProtocol.setEmptyMk(status[4]);  // 空板信号
                staProtocol.setFullPlt(status[5]);  // 满托盘

                boolean[] statusError = siemensS7Net.getByteTransform().TransBool(result.Content, (i * 18) + 13, 1);
                staProtocol.setFrontError(statusError[0]);  // 前超报警
                staProtocol.setBackError(statusError[1]);  // 后超报警
                staProtocol.setHighError(statusError[2]); // 超高报警
                staProtocol.setLeftError(statusError[3]);// 左高报警
                staProtocol.setRightError(statusError[4]);  // 右高报警
                staProtocol.setWeightError(statusError[5]);  // 超重报警
                staProtocol.setBarcodeError(statusError[6]);  // 扫码报警

                short emptyInType = siemensS7Net.getByteTransform().TransInt16(result.Content, (i * 18) + 14);//预留1-空托入库类型，1:立库方向 2:产线方向
                staProtocol.setEmptyInType(emptyInType);
                boolean[] status = siemensS7Net.getByteTransform().TransBool(result.Content, i*8 + 6, 2);
                staProtocol.setAutoing(status[0]);      // 自动
                staProtocol.setLoading(status[1]);      // 有物
                staProtocol.setInEnable(status[2]);     // 可入
                staProtocol.setOutEnable(status[3]);    // 可出
                staProtocol.setEmptyMk(status[4]);      // 空板信号
                staProtocol.setFullPlt(status[5]);      // 满托盘
                staProtocol.setHigh(status[6]);         // 高库位
                staProtocol.setLow(status[7]);          // 低库位
                staProtocol.setEmptyOutType(status[8]); //空料架

                if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
                    staProtocol.setPakMk(true);
@@ -248,40 +238,77 @@
            }
        }

        //条码扫描器
        Thread.sleep(200);
        ArrayList<Integer> barcodeList = getBarcode();
        int barcodeSize = barcodeList.size();
        OperateResultExOne<byte[]> result2 = siemensS7Net.Read("DB103.0", (short) (barcodeSize * 8));
        if (result2.IsSuccess) {
            for (int i = 0; i < barcodeSize; i++) {
                String barcode = siemensS7Net.getByteTransform().TransString(result2.Content, i * 8, 8, "UTF-8");
                Integer barcodeId = barcodeList.get(i);
                BarcodeThread barcodeThread = (BarcodeThread) SlaveConnection.get(SlaveType.Barcode, barcodeId);
                if(!Cools.isEmpty(barcodeThread) && !barcodeThread.getBarcode().equals(barcode)){
                    barcodeThread.setBarcode(barcode);
        //外形检测 - 带防抖处理
        Integer[] arr={401,402};
        OperateResultExOne<byte[]> resultErr1 = siemensS7Net.Read("DB101.702.0", (short) (arr.length*6));

        for (int i = 0; i < arr.length; i++) {
            StaProtocol staProtocol1 = station.get(arr[i]);
            if(resultErr1.IsSuccess && staProtocol1 != null){
                boolean[] status1 = siemensS7Net.getByteTransform().TransBool(resultErr1.Content, i*6, 1);

                // 【新增】保存旧的超高状态
                boolean oldHighError = staProtocol1.isHighError();

                // 更新所有状态
                staProtocol1.setFrontError(status1[0]);
                staProtocol1.setBackError(status1[1]);
                staProtocol1.setHighError(status1[2]);  // 超高状态
                staProtocol1.setLeftError(status1[3]);
                staProtocol1.setRightError(status1[4]);
                staProtocol1.setWeightError(status1[5]);
                staProtocol1.setBarcodeError(status1[6]);

                // 【新增】超高状态变化处理 - 只有变化时才调用
                if (oldHighError != status1[2]) {
                    try {
                        RcsServiceImpl rcsService = SpringUtils.getBean(RcsServiceImpl.class);
                        if (rcsService != null) {
                            rcsService.agvPause(staProtocol1);
                            log.info("超高状态变化 - 站点: {}, 状态: {} -> {}, 已调用AGV控制",
                                    arr[i], oldHighError, status1[2]);
                        }
                    } catch (Exception e) {
                        log.error("调用agvPause失败 - 站点: {}, 错误: {}", arr[i], e.getMessage());
                    }
                }
            }

        }

        if (System.currentTimeMillis() - deviceDataLogTime > 1000 * 1) {
            //采集时间超过5s，保存一次数据记录
            //保存数据记录
            DeviceDataLogService deviceDataLogService = SpringUtils.getBean(DeviceDataLogService.class);
            DeviceDataLog deviceDataLog = new DeviceDataLog();
            deviceDataLog.setOriginData(Base64.getEncoder().encodeToString(result.Content));
            deviceDataLog.setWcsData(JSON.toJSONString(station));
            deviceDataLog.setType("devp");
            deviceDataLog.setDeviceNo(slave.getId());
            deviceDataLog.setCreateTime(new Date());
            deviceDataLogService.insert(deviceDataLog);

            //更新采集时间
            deviceDataLogTime = System.currentTimeMillis();

        Thread.sleep(200);
        if(slave.getId()==1) {
            OperateResultExOne<byte[]> result2 = siemensS7Net.Read("DB101.600.0", (short) (barcodeSize * 8));
            if (result2.IsSuccess) {
                for (int i = 0; i < barcodeSize; 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)) {
                        barcodeThread.setBarcode(barcode);
                    }
                }

            }
        }
        if (result.IsSuccess) {
            if (System.currentTimeMillis() - deviceDataLogTime > 1000 * 1) {
                //采集时间超过5s，保存一次数据记录
                //保存数据记录
                DeviceDataLogService deviceDataLogService = SpringUtils.getBean(DeviceDataLogService.class);
                DeviceDataLog deviceDataLog = new DeviceDataLog();
                deviceDataLog.setOriginData(Base64.getEncoder().encodeToString(result.Content));
                deviceDataLog.setWcsData(JSON.toJSONString(station));
                deviceDataLog.setType("devp");
                deviceDataLog.setDeviceNo(slave.getId());
                deviceDataLog.setCreateTime(new Date());
                deviceDataLogService.insert(deviceDataLog);

        if (result.IsSuccess && result2.IsSuccess) {
                //更新采集时间
                deviceDataLogTime = System.currentTimeMillis();
            }
        }
        if (result.IsSuccess) {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】[id:{1}] <<<<< 实时数据更新成功",DateUtils.convert(new Date()), slave.getId()));

            // 根据实时信息更新数据库
@@ -317,57 +344,47 @@
        }
        ArrayList<Integer> staNos = getStaNo();
        int index = staNos.indexOf(staProtocol.getSiteId());
        int[] array = new int[3];
        array[0] = staProtocol.getWorkNo().intValue();
        array[1] = staProtocol.getStaNo().intValue();
        array[2] = staProtocol.getPalletSize().intValue();
        short[] array = new short[2];
        OperateResult writeResult1 = siemensS7Net.Write("DB100." + index*6,  staProtocol.getWorkNo().intValue());    // 工作号
        OperateResult writeResult2 = siemensS7Net.Write("DB100." + (index*6+4), staProtocol.getStaNo());    // 目标站

        OperateResult write = siemensS7Net.Write("DB102." + index * 16, array);
//        OperateResult write = siemensS7Net.Write("DB100.0" + index*4, staProtocol.getWorkNo());    // 工作号
//        Thread.sleep(500);
//        OperateResult write1 = siemensS7Net.Write("DB100.2" + index*4+2, staProtocol.getStaNo());    // 目标站

//        OperateResult write = null;
//        OperateResult write1 = null;
//        //任务下发次数
//        int writeCount = 0;
//        do {
//            write = siemensS7Net.Write("DB100." + index*2, staProtocol.getWorkNo());    // 工作号
//            Thread.sleep(500);
//            write1 = siemensS7Net.Write("DB101." + index*2, staProtocol.getStaNo());    // 目标站
//            if(write.IsSuccess || write1.IsSuccess){
//                Thread.sleep(200);
//                OperateResultExOne<byte[]> readResult = siemensS7Net.Read("DB100." + index*2, (short) 2);
//                OperateResultExOne<byte[]> readResult1 = siemensS7Net.Read("DB101." + index*2, (short) 2);
//                if(readResult.IsSuccess && readResult1.IsSuccess){
//                    short workNo = siemensS7Net.getByteTransform().TransInt16(readResult.Content, 0);
//                    short staNo = siemensS7Net.getByteTransform().TransInt16(readResult1.Content, 0);
//                    if(staProtocol.getWorkNo().equals(workNo) && staProtocol.getStaNo().equals(staNo)){
//                        //任务命令写入成功
//                        log.info("写入输送线命令后返回成功，并且回读成功。输送线plc编号={}，{}，写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
//                        break;
//                    } else {//返回结果是成功了，但是真实值不相同
//                        writeCount++;
//                        log.error("写入输送线命令后返回成功，但是读取任务值不一致。输送线plc编号={}，{}，写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
//                    }
//                } else {
//                    writeCount++;
//                    log.error("写入输送线命令后读取失败。输送线plc编号={}，站点数据={},写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
//                }
//            }
//            else {
//                writeCount++;
//                log.error("写入输送线命令后读取失败。输送线plc编号={}，站点数据={},写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
//            }
//        }while (writeCount<5);

        if (!write.IsSuccess) {
        if (!writeResult1.IsSuccess&&!writeResult2.IsSuccess) {
            staProtocol = station.get(staProtocol.getSiteId());
            if (staProtocol.getWorkNo() == 0 && staProtocol.getStaNo() ==0) {
                staProtocol.setPakMk(true);
            }
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】写入输送线站点数据失败。输送线plc编号={1}，站点数据={2}", slave.getId(), JSON.toJSON(staProtocol)));
            News.error("SiemensDevp"+" - 4"+" - 写入输送线站点数据失败。输送线plc编号={}，站点数据={}", slave.getId(), JSON.toJSON(staProtocol));
            log.error("写入输送线站点数据失败。输送线plc编号={}，站点数据={}", slave.getId(), JSON.toJSON(staProtocol));
        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】 输送线命令下发 [id:{1}] >>>>> {2}", DateUtils.convert(new Date()), slave.getId(), JSON.toJSON(staProtocol)));
            News.info("SiemensDevp"+" - 5"+" - 输送线命令下发 [id:{}] >>>>> 命令下发： {}",  slave.getId(), JSON.toJSON(staProtocol));
            log.info("输送线命令下发 [id:{}] >>>>> 命令下发： {}",  slave.getId(), JSON.toJSON(staProtocol));
        }
    }

    /**
     * 扫码器触发
     */
    private void write1(StaProtocol staProtocol) throws InterruptedException {
        if (null == staProtocol) {
            return;
        }

        int index = 0;
        if(staProtocol.getSiteId() == 402){
            index = 1;
        }
        OperateResult writeResult1 = siemensS7Net.Write("DB100.500." + index,  true);    // 扫码器触发
        if (!writeResult1.IsSuccess) {

            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】写入输送线站点数据失败。输送线plc编号={1}，站点数据={2}", slave.getId(), JSON.toJSON(staProtocol)));
            log.error("写入输送线站点数据失败。输送线plc编号={}，站点数据={}", slave.getId(), JSON.toJSON(staProtocol));
        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】 输送线命令下发 [id:{1}] >>>>> {2}", DateUtils.convert(new Date()), slave.getId(), JSON.toJSON(staProtocol)));
            log.info("输送线命令下发 [id:{}] >>>>> 命令下发： {}",  slave.getId(), JSON.toJSON(staProtocol));
        }
    }