1

zhang

6 天以前 62107c34d3bb40649c6af1385a5f61d81104cf47

1

 zy-acs-cv/src/main/java/com/zy/core/Slave.java

@@ -16,6 +16,5 @@

    private Integer port;

    private List<Integer> staNos;

}

 zy-acs-cv/src/main/java/com/zy/core/cache/MessageQueue.java

@@ -35,27 +35,18 @@
     */
    public static void init(SlaveType type, Slave slave) {
        switch (type) {
            case Crn:
                CRN_EXCHANGE.put(slave.getId(), new LinkedBlockingQueue<>(1));
                break;
            case Rgv:
                RGV_EXCHANGE.put(slave.getId(), new LinkedBlockingQueue<>(1));
                break;

            case Devp:
                DEVP_EXCHANGE.put(slave.getId(), new ConcurrentLinkedQueue<>());
                break;
            case Barcode:
                BARCODE_EXCHANGE.put(slave.getId(), new ConcurrentLinkedQueue<>());
                break;
            case Led:
                LED_EXCHANGE.put(slave.getId(), new LinkedBlockingQueue<>(1));
                break;

            case Scale:
                SCALE_EXCHANGE.put(slave.getId(), new ConcurrentLinkedQueue<>());
                break;
            case Car:
                CAR_EXCHANGE.put(slave.getId(), new ConcurrentLinkedQueue<>());
                break;

            default:
                break;
        }
@@ -67,20 +58,15 @@
     */
    public static boolean offer(SlaveType type, Integer id, Task task) {
        switch (type) {
            case Crn:
                return CRN_EXCHANGE.get(id).offer(task);
            case Rgv:
                return RGV_EXCHANGE.get(id).offer(task);

            case Devp:
                return DEVP_EXCHANGE.get(id).offer(task);
            case Barcode:
                return BARCODE_EXCHANGE.get(id).offer(task);
            case Led:
                return LED_EXCHANGE.get(id).offer(task);

            case Scale:
                return SCALE_EXCHANGE.get(id).offer(task);
            case Car:
                return CAR_EXCHANGE.get(id).offer(task);

            default:
                return false;
        }
@@ -92,20 +78,15 @@
     */
    public static Task poll(SlaveType type, Integer id) {
        switch (type) {
            case Crn:
                return CRN_EXCHANGE.get(id).poll();
            case Rgv:
                return RGV_EXCHANGE.get(id).poll();

            case Devp:
                return DEVP_EXCHANGE.get(id).poll();
            case Barcode:
                return BARCODE_EXCHANGE.get(id).poll();
            case Led:
                return LED_EXCHANGE.get(id).poll();

            case Scale:
                return SCALE_EXCHANGE.get(id).poll();
            case Car:
                return CAR_EXCHANGE.get(id).poll();

            default:
                return null;
        }
@@ -116,20 +97,12 @@
     */
    public static Task peek(SlaveType type, Integer id) {
        switch (type) {
            case Crn:
                return CRN_EXCHANGE.get(id).peek();
            case Rgv:
                return RGV_EXCHANGE.get(id).peek();
            case Devp:
                return DEVP_EXCHANGE.get(id).peek();
            case Barcode:
                return BARCODE_EXCHANGE.get(id).peek();
            case Led:
                return LED_EXCHANGE.get(id).peek();
            case Scale:
                return SCALE_EXCHANGE.get(id).peek();
            case Car:
                return CAR_EXCHANGE.get(id).peek();
            default:
                return null;
        }
@@ -137,27 +110,16 @@

    public static void clear(SlaveType type, Integer id) {
        switch (type) {
            case Crn:
                CRN_EXCHANGE.get(id).clear();
                break;
            case Rgv:
                RGV_EXCHANGE.get(id).clear();
                break;
            case Devp:
                DEVP_EXCHANGE.get(id).clear();
                break;
            case Barcode:
                BARCODE_EXCHANGE.get(id).clear();
                break;
            case Led:
                LED_EXCHANGE.get(id).clear();
                break;
            case Scale:
                SCALE_EXCHANGE.get(id).clear();
                break;
            case Car:
                CAR_EXCHANGE.get(id).clear();
                break;

            default:
                break;
        }

 zy-acs-cv/src/main/java/com/zy/core/constant/StationStatusField.java

@@ -5,7 +5,7 @@
 * 站点状态字段枚举（对应 §2.1）
 */
public enum StationStatusField {
    ALL("DB100", 0, 12),
    ALL("DB100", 0, 10),
    TASK_NUMBER("DB100", 0, 4),          // 任务号，偏移0，4字节
    FINAL_TARGET("DB100", 4, 2),          // 最终目标站，偏移4，2字节
    STATUS_WORD("DB100", 6, 2),           // 状态字，偏移6，2字节

 zy-acs-cv/src/main/java/com/zy/core/enums/SlaveType.java

@@ -2,13 +2,10 @@

public enum SlaveType {

    Crn,

    Devp,
    Barcode,
    Led,
    Scale,
    Car,
    Rgv;
    Scale;

    public static SlaveType findInstance(String s) {
        for (SlaveType type : SlaveType.values()) {

 zy-acs-cv/src/main/java/com/zy/core/properties/SlaveProperties.java

@@ -21,11 +21,6 @@
@ConfigurationProperties(prefix = "cv-slave")
public class SlaveProperties {

    private boolean doubleDeep;

    private List<Integer> doubleLocs = new ArrayList<>();

    private int groupCount;

    private List<DevpSlave> devp = new ArrayList<>();


 zy-acs-cv/src/main/java/com/zy/core/service/DevpS7Service.java

New file
@@ -0,0 +1,77 @@
package com.zy.core.service;

import HslCommunication.Core.Types.OperateResult;
import HslCommunication.Profinet.Siemens.SiemensPLCS;
import HslCommunication.Profinet.Siemens.SiemensS7Net;
import com.zy.acs.framework.common.DateUtils;
import com.zy.common.utils.News;
import com.zy.core.cache.OutputQueue;
import com.zy.core.model.DevpSlave;
import com.zy.core.properties.SlaveProperties;
import lombok.extern.slf4j.Slf4j;
import org.springframework.beans.factory.annotation.Autowired;
import org.springframework.stereotype.Service;

import javax.annotation.PostConstruct;
import java.text.MessageFormat;
import java.util.Date;
import java.util.List;
import java.util.Map;
import java.util.concurrent.ConcurrentHashMap;


@Slf4j
@Service
public class DevpS7Service {

    @Autowired
    private SlaveProperties slaveProperties;

    private final Map<Integer, SiemensS7Net> CHARGE_CACHE = new ConcurrentHashMap<>();


    @PostConstruct
    public void init() {
        List<DevpSlave> devpSlaves = slaveProperties.getDevp();
        for (DevpSlave devp : devpSlaves) {
            add(devp.getId(), connect(devp));
        }
    }


    public void add(Integer id, SiemensS7Net siemensS7Net) {
        CHARGE_CACHE.put(id, siemensS7Net);
    }

    public void remove(Integer id) {
        CHARGE_CACHE.remove(id);
    }

    public SiemensS7Net get(Integer id) {
        SiemensS7Net siemensS7Net = CHARGE_CACHE.get(id);
        if (siemensS7Net != null) {
            return siemensS7Net;
        }
        slaveProperties.getDevp().stream().filter(devp -> devp.getId().equals(id)).findFirst().ifPresent(devp -> {
            add(id, connect(devp));
        });
        return CHARGE_CACHE.get(id);
    }


    private SiemensS7Net connect(DevpSlave devp) {
        SiemensS7Net siemensS7Net = new SiemensS7Net(SiemensPLCS.S1200, devp.getIp());
        siemensS7Net.setRack(devp.getRack().byteValue());
        siemensS7Net.setSlot(devp.getSlot().byteValue());
        OperateResult connect = siemensS7Net.ConnectServer();
        if (connect.IsSuccess) {
            News.info("SiemensDevp" + " - 1" + " - 输送线plc连接成功 ===>> [id:{}] [ip:{}] [port:{}]", devp.getId(), devp.getIp(), devp.getPort());
        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线plc连接失败！！！ ===>> [id:{1}] [ip:{2}] [port:{3}]  [rack:{4}] [slot:{5}]", DateUtils.convert(new Date()), devp.getId(), devp.getIp(), devp.getPort(), devp.getRack(), devp.getSlot()));
            News.error("SiemensDevp" + " - 2" + " - 输送线plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}]", devp.getId(), devp.getIp(), devp.getPort());
        }
        siemensS7Net.ConnectClose();
        return siemensS7Net;
    }

}

 zy-acs-cv/src/main/java/com/zy/core/service/Snap7Service.java

New file
@@ -0,0 +1,21 @@
package com.zy.core.service;

import HslCommunication.Core.Types.OperateResultExOne;
import HslCommunication.Profinet.Siemens.SiemensS7Net;
import com.zy.core.constant.StationStatusField;
import com.zy.core.model.protocol.StaProtocol;
import org.springframework.stereotype.Service;


public class Snap7Service {

    public void read(StaProtocol staProtocol , SiemensS7Net siemensS7Net){

    }


    public void write(SiemensS7Net siemensS7Net, int staNo, int workNo, boolean autoing, boolean loading, boolean inEnable, boolean outEnable, boolean emptyMk, boolean fullPlt, boolean high, boolean low){


    }
}

 zy-acs-cv/src/main/java/com/zy/core/thread/SiemensDevpThread.java

@@ -45,6 +45,15 @@

    private Map<Integer, StaProtocol> station = new ConcurrentHashMap<>();

    private volatile boolean connected = false;

    private static final int WRITE_RETRY_MAX = 5;
    private static final int WRITE_RETRY_INTERVAL_MS = 200;
    private static final int READ_INTERVAL_MS = 100;
    private static final int DB_UPDATE_INTERVAL_MS = 1000; // 数据库更新间隔

    private long lastDbUpdateTime = 0;


    public SiemensDevpThread(DevpSlave slave) {
        this.slave = slave;
@@ -55,7 +64,7 @@
    @SuppressWarnings("InfiniteLoopStatement")
    public void run() {
        connect();
        while (true) {
        while (!Thread.currentThread().isInterrupted()) {
            try {
                TaskType step = TaskType.READ;
                Task task = MessageQueue.poll(SlaveType.Devp, slave.getId());
@@ -74,181 +83,333 @@
                    default:
                        break;
                }
                Thread.sleep(100);
                Thread.sleep(READ_INTERVAL_MS);
            } catch (InterruptedException e) {
                Thread.currentThread().interrupt();
                log.warn("SiemensDevp线程被中断 [id:{}]", slave.getId());
                break;
            } catch (Exception e) {
                e.printStackTrace();
                log.error("SiemensDevp线程运行异常 [id:{}]", slave.getId(), e);
                // 发生异常时尝试重连
                reconnect();
            }
        }
        // 线程退出时关闭连接
        close();
        log.info("SiemensDevp线程已退出 [id:{}]", slave.getId());
    }

    /**
     * 初始化或重置站点状态
     */
    private void initSite() {
        List<Integer> staNos = slave.getStaNos();
        for (Integer siteId : staNos) {
            StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
            resetStaProtocol(staProtocol);
        }
    }

    /**
     * 初始化站点状态
     * 获取或创建站点协议对象
     */
    private void initSite() {
        List<Integer> staNos = slave.getStaNos();
        // 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(0);     // 目标站
    private StaProtocol getOrCreateStaProtocol(Integer siteId) {
        return station.computeIfAbsent(siteId, id -> {
            StaProtocol protocol = new StaProtocol();
            protocol.setSiteId(id);
            return protocol;
        });
    }

            if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
                staProtocol.setPakMk(true);
            }
    /**
     * 重置站点协议状态
     */
    private void resetStaProtocol(StaProtocol staProtocol) {
        staProtocol.setWorkNo(0);
        staProtocol.setAutoing(false);
        staProtocol.setLoading(false);
        staProtocol.setInEnable(false);
        staProtocol.setOutEnable(false);
        staProtocol.setEmptyMk(false);
        staProtocol.setStaNo(0);

        if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
            staProtocol.setPakMk(true);
        }
    }

    @Override
    public boolean connect() {
        boolean result = false;
        // 如果已连接，先关闭旧连接
        if (siemensS7Net != null) {
            try {
                siemensS7Net.ConnectClose();
            } catch (Exception e) {
                log.warn("关闭旧PLC连接异常 [id:{}]", slave.getId(), e);
            }
        }

        siemensS7Net = new SiemensS7Net(SiemensPLCS.S1200, slave.getIp());
        siemensS7Net.setRack(slave.getRack().byteValue());
        siemensS7Net.setSlot(slave.getSlot().byteValue());
        
        OperateResult connect = siemensS7Net.ConnectServer();
        if (connect.IsSuccess) {
            result = true;
            //OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线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()));
            News.info("SiemensDevp" + " - 1" + " - 输送线plc连接成功 ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            connected = true;
            News.info("SiemensDevp - 1 - 输送线plc连接成功 ===>> [id:{}] [ip:{}] [port:{}]", 
                    slave.getId(), slave.getIp(), slave.getPort());
            log.info("输送线plc连接成功 [id:{}] [ip:{}] [rack:{}] [slot:{}]", 
                    slave.getId(), slave.getIp(), slave.getRack(), slave.getSlot());
        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线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()));
            News.error("SiemensDevp" + " - 2" + " - 输送线plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}]", slave.getId(), slave.getIp(), slave.getPort());
            connected = false;
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】输送线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()));
            News.error("SiemensDevp - 2 - 输送线plc连接失败！！！ ===>> [id:{}] [ip:{}] [port:{}]", 
                    slave.getId(), slave.getIp(), slave.getPort());
            log.error("输送线plc连接失败 [id:{}] [ip:{}] [error:{}]", 
                    slave.getId(), slave.getIp(), connect.Message);
        }
        siemensS7Net.ConnectClose();
        
        initSite();
        return result;
        return connected;
    }

    /**
     * 重连机制
     */
    private void reconnect() {
        log.warn("尝试重新连接PLC [id:{}]", slave.getId());
        try {
            Thread.sleep(1000); // 重连前等待1秒
        } catch (InterruptedException e) {
            Thread.currentThread().interrupt();
            return;
        }
        connect();
    }

    /**
     * 读取状态 ====> 整块plc
     */
    private void read() throws InterruptedException {
        if (!connected || siemensS7Net == null) {
            log.warn("PLC未连接，跳过读取 [id:{}]", slave.getId());
            return;
        }

        List<Integer> staNos = slave.getStaNos();
        int staNoSize = staNos.size();
        OperateResultExOne<byte[]> result = siemensS7Net.Read(StationStatusField.ALL.buildAddress(), (short) (staNoSize * StationStatusField.ALL.getByteLength()));
        if (result.IsSuccess) {
            for (int i = 0; i < staNoSize; i++) {
                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.setWorkNo((int) siemensS7Net.getByteTransform().TransUInt32(result.Content, i * StationStatusField.ALL.getByteLength()));
                staProtocol.setStaNo((int) siemensS7Net.getByteTransform().TransInt16(result.Content, i * StationStatusField.ALL.getByteLength() + 4));
                boolean[] status = siemensS7Net.getByteTransform().TransBool(result.Content, i * StationStatusField.ALL.getByteLength() + 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

                if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
                    staProtocol.setPakMk(true);
                }
            }
        
        // 读取站点状态
        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                StationStatusField.ALL.buildAddress(), 
                (short) (staNoSize * StationStatusField.ALL.getByteLength()));
        
        if (!result.IsSuccess) {
            log.error("读取站点状态失败 [id:{}] [error:{}]", slave.getId(), result.Message);
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】读取输送线plc状态信息失败 ===>> [id:{1}] [ip:{2}]", 
                    DateUtils.convert(new Date()), slave.getId(), slave.getIp()));
            connected = false;
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNoSize; i++) {
            Integer siteId = staNos.get(i);
            StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
            parseStationStatus(content, i, staProtocol);
        }

        //条码扫描器
        // 读取条码
        readBarcodes();

        // 读取外形检测错误
        readDimensionErrors();

        // 读取PLC故障
        readPlcAlarms(staNos, staNoSize);

        // 定期更新数据库（降低频率）
        updateDatabaseIfNeeded();
    }

    /**
     * 解析单个站点状态
     */
    private void parseStationStatus(byte[] content, int index, StaProtocol staProtocol) {
        int offset = index * StationStatusField.ALL.getByteLength();
        staProtocol.setWorkNo(siemensS7Net.getByteTransform().TransInt32(content, offset));
        staProtocol.setStaNo((int) siemensS7Net.getByteTransform().TransInt16(
                content, offset + StationStatusField.FINAL_TARGET.getOffset()));
        
        boolean[] status = siemensS7Net.getByteTransform().TransBool(
                content, offset + StationStatusField.STATUS_WORD.getOffset(), 
                StationStatusField.STATUS_WORD.getByteLength());
        
        staProtocol.setAutoing(status[0]);
        staProtocol.setLoading(status[1]);
        staProtocol.setInEnable(status[2]);
        staProtocol.setOutEnable(status[3]);
        staProtocol.setEmptyMk(status[4]);
        staProtocol.setFullPlt(status[5]);
        staProtocol.setHigh(status[6]);
        staProtocol.setLow(status[7]);

        if (!staProtocol.isPakMk() && !staProtocol.isLoading()) {
            staProtocol.setPakMk(true);
        }
    }

    /**
     * 读取条码信息
     */
    private void readBarcodes() {
        List<Integer> barcodeArr = slave.getBarcodeArr();
        OperateResultExOne<byte[]> result5 = siemensS7Net.Read(DeviceField.BARCODE.buildAddress(), (short) (barcodeArr.size() * DeviceField.BARCODE.getByteLength()));
        if (result5.IsSuccess) {
            for (int i = 0; i < barcodeArr.size(); i++) {
                String barcode = siemensS7Net.getByteTransform().TransString(result5.Content, i * DeviceField.BARCODE.getByteLength(), DeviceField.BARCODE.getByteLength(), "UTF-8");
                BarcodeThread barcodeThread = (BarcodeThread) SlaveConnection.get(SlaveType.Barcode, barcodeArr.get(i));
                if (Cools.isEmpty(barcode)) {
        if (barcodeArr == null || barcodeArr.isEmpty()) {
            return;
        }

        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                DeviceField.BARCODE.buildAddress(), 
                (short) (barcodeArr.size() * DeviceField.BARCODE.getByteLength()));
        
        if (!result.IsSuccess) {
            log.warn("读取条码失败 [id:{}]", slave.getId());
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < barcodeArr.size(); i++) {
            String barcode = siemensS7Net.getByteTransform().TransString(
                    content, i * DeviceField.BARCODE.getByteLength(), 
                    DeviceField.BARCODE.getByteLength(), "UTF-8");
            
            BarcodeThread barcodeThread = (BarcodeThread) SlaveConnection.get(
                    SlaveType.Barcode, barcodeArr.get(i));
            
            if (Cools.isEmpty(barcode)) {
                if (barcodeThread != null) {
                    barcodeThread.clearBarcode();
                } else {
                    if (!Cools.isEmpty(barcodeThread) && !barcodeThread.getBarcode().equals(barcode)) {
                        barcodeThread.setBarcode(barcode);
                        log.info("料箱码：{}", barcode);
                    }
                }
            } else {
                if (barcodeThread != null && !barcode.equals(barcodeThread.getBarcode())) {
                    barcodeThread.setBarcode(barcode);
                    log.info("料箱码：{}", barcode);
                }
            }
        }
    }

    /**
     * 读取外形检测错误
     */
    private void readDimensionErrors() {
        List<Integer> staNosError = slave.getStaNosError();
        OperateResultExOne<byte[]> resultError = siemensS7Net.Read(DeviceField.DIMENSION_WORD.buildAddress(), (short) (staNoSize * DeviceField.DIMENSION_WORD.getByteLength()));
        if (resultError.IsSuccess) {
            for (int i = 0; i < staNosError.size(); i++) {
                Integer siteId = staNosError.get(i); // 站点编号
                StaProtocol staProtocol = station.get(siteId);
                if (null == staProtocol) {
                    staProtocol = new StaProtocol();
                    staProtocol.setSiteId(siteId);
                    station.put(siteId, staProtocol);
                }
                boolean[] status = siemensS7Net.getByteTransform().TransBool(resultError.Content, i * DeviceField.DIMENSION_WORD.getByteLength(), DeviceField.DIMENSION_WORD.getByteLength());
                staProtocol.setFrontErr(status[0]);// 前超限
                staProtocol.setBackErr(status[1]);// 后超限
                staProtocol.setHighErr(status[2]);// 高超限
                staProtocol.setLeftErr(status[3]);// 左超限
                staProtocol.setRightErr(status[4]);// 右超限
                staProtocol.setWeightErr(status[5]); // 超重
                staProtocol.setBarcodeErr(status[6]);// 扫码失败
            }
        if (staNosError == null || staNosError.isEmpty()) {
            return;
        }

        //plc故障
        OperateResultExOne<byte[]> resultErr2 = siemensS7Net.Read(PlcAlarmDefinition.ALL.buildAddress(), (short) (staNoSize * PlcAlarmDefinition.ALL.getByteLength()));
        if (resultErr2.IsSuccess) {
            for (int i = 0; i < staNoSize; i++) {
                Integer siteId = staNos.get(i); // 站点编号
                boolean[] status = siemensS7Net.getByteTransform().TransBool(resultErr2.Content, i * PlcAlarmDefinition.ALL.getByteLength(), PlcAlarmDefinition.ALL.getByteLength());
        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                DeviceField.DIMENSION_WORD.buildAddress(), 
                (short) (staNosError.size() * DeviceField.DIMENSION_WORD.getByteLength()));
        
        if (!result.IsSuccess) {
            log.warn("读取外形检测错误失败 [id:{}]", slave.getId());
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNosError.size(); i++) {
            Integer siteId = staNosError.get(i);
            StaProtocol staProtocol = getOrCreateStaProtocol(siteId);
            
            boolean[] status = siemensS7Net.getByteTransform().TransBool(
                    content, i * DeviceField.DIMENSION_WORD.getByteLength(), 
                    DeviceField.DIMENSION_WORD.getByteLength());
            
            staProtocol.setFrontErr(status[0]);
            staProtocol.setBackErr(status[1]);
            staProtocol.setHighErr(status[2]);
            staProtocol.setLeftErr(status[3]);
            staProtocol.setRightErr(status[4]);
            staProtocol.setWeightErr(status[5]);
            staProtocol.setBarcodeErr(status[6]);
        }
    }

    /**
     * 读取PLC故障信息
     */
    private void readPlcAlarms(List<Integer> staNos, int staNoSize) {
        OperateResultExOne<byte[]> result = siemensS7Net.Read(
                PlcAlarmDefinition.ALL.buildAddress(), 
                (short) (staNoSize * PlcAlarmDefinition.ALL.getByteLength()));
        
        if (!result.IsSuccess) {
            log.warn("读取PLC故障信息失败 [id:{}]", slave.getId());
            return;
        }

        byte[] content = result.Content;
        for (int i = 0; i < staNoSize; i++) {
            Integer siteId = staNos.get(i);
            StaProtocol staProtocol = station.get(siteId);
            if (staProtocol == null) {
                continue;
            }

            boolean[] status = siemensS7Net.getByteTransform().TransBool(
                    content, i * PlcAlarmDefinition.ALL.getByteLength(), 1);
            
            staProtocol.setBreakerErr(status[0]);
            staProtocol.setInfraredErr(status[1]);
            staProtocol.setOutTimeErr(status[2]);
            staProtocol.setSeizeSeatErr(status[3]);
            staProtocol.setWrkYgoodsN(status[4]);
            staProtocol.setInverterErr(status[5]);
            staProtocol.setContactErr(status[6]);
            staProtocol.setUpcontactErr(status[7]);
        }
    }

    /**
     * 按需更新数据库（降低更新频率）
     */
    private void updateDatabaseIfNeeded() {
        long currentTime = System.currentTimeMillis();
        if (currentTime - lastDbUpdateTime < DB_UPDATE_INTERVAL_MS) {
            return;
        }

        try {
            List<Integer> staNos = slave.getStaNos();
            List<Devp> devps = new ArrayList<>(staNos.size());
            for (Integer siteId : staNos) {
                StaProtocol staProtocol = station.get(siteId);
                if (staProtocol != null) {
                    staProtocol.setBreakerErr(status[0]);
                    staProtocol.setInfraredErr(status[1]);
                    staProtocol.setOutTimeErr(status[2]);
                    staProtocol.setSeizeSeatErr(status[3]);
                    staProtocol.setWrkYgoodsN(status[4]);
                    staProtocol.setInverterErr(status[5]);
                    staProtocol.setContactErr(status[6]);
                    staProtocol.setUpcontactErr(status[7]);
                }
            }
        }

        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
            try {
                List<Devp> devps = new ArrayList<>();
                for (Integer siteId : staNos) {
                    StaProtocol staProtocol = station.get(siteId);
                    devps.add(staProtocol.toSqlModel());
                }
                DevpService devpService = SpringContextUtil.getBean(DevpService.class);
                if (null != devpService) {
                    devpService.updateBatchByDevpNo(devps);
                } else {
                    throw new Exception("更新数据库数据失败");
                }
            } catch (Exception e) {
                initSite();
                e.printStackTrace();
                OutputQueue.DEVP.offer(MessageFormat.format("【{0}】更新数据库数据失败 ===>> [id:{1}] [ip:{2}] [port:{3}] [rack:{4}] [slot:{5}]", DateUtils.convert(new Date()), slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot()));
                News.error("SiemensDevp" + " - 3" + " - 更新数据库数据失败 ===>> [id:{}] [ip:{}] [port:{}] [rack:{}] [slot:{}]", slave.getId(), slave.getIp(), slave.getPort(), slave.getRack(), slave.getSlot());
            }

        } else {
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】读取输送线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()));
            if (devps.isEmpty()) {
                return;
            }

            DevpService devpService = SpringContextUtil.getBean(DevpService.class);
            if (devpService != null) {
                devpService.updateBatchByDevpNo(devps);
                lastDbUpdateTime = currentTime;
                log.debug("批量更新数据库成功 [id:{}] [count:{}]", slave.getId(), devps.size());
            } else {
                log.error("DevpService未找到，无法更新数据库 [id:{}]", slave.getId());
            }
        } catch (Exception e) {
            log.error("更新数据库数据失败 [id:{}]", slave.getId(), e);
            OutputQueue.DEVP.offer(MessageFormat.format("【{0}】更新数据库数据失败 ===>> [id:{1}]", 
                    DateUtils.convert(new Date()), slave.getId()));
            News.error("SiemensDevp - 3 - 更新数据库数据失败 ===>> [id:{}]", slave.getId());
            // 更新失败时重置站点状态
            initSite();
        }
    }

@@ -256,36 +417,69 @@
     * 写入 ID+目标站 =====> 单站点写入
     */
    private void write(StaProtocol staProtocol) throws InterruptedException {
        if (null == staProtocol) {
        if (staProtocol == null) {
            log.warn("写入数据为空，跳过 [id:{}]", slave.getId());
            return;
        }

        if (!connected || siemensS7Net == null) {
            log.error("PLC未连接，无法写入 [id:{}]", slave.getId());
            return;
        }

        List<Integer> staNos = slave.getStaNos();
        int index = staNos.indexOf(staProtocol.getSiteId());
        if (index < 0) {
            log.error("站点编号不存在于配置中 [id:{}] [siteId:{}]", slave.getId(), staProtocol.getSiteId());
            return;
        }

        OperateResult write = null;
        OperateResult write1 = null;
        //任务下发次数
        int baseOffset = index * TaskField.ALL.getByteLength();
        String workNoAddr = TaskField.TASK_NUMBER.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION 
                + (baseOffset + TaskField.TASK_NUMBER.getOffset());
        String destStaAddr = TaskField.DEST_STATION.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION 
                + (baseOffset + TaskField.DEST_STATION.getOffset());

        // 任务下发重试机制
        int writeCount = 0;
        do {
            write = siemensS7Net.Write(TaskField.TASK_NUMBER.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION + (index * TaskField.ALL.getByteLength() + TaskField.TASK_NUMBER.getOffset()), staProtocol.getWorkNo().shortValue());    // 工作号
            Thread.sleep(200);
            write1 = siemensS7Net.Write(TaskField.DEST_STATION.getAddressPattern() + PlcConstant.ADDRESS_CONCATENATION + (index * TaskField.ALL.getByteLength() + TaskField.DEST_STATION.getOffset()), staProtocol.getStaNo().shortValue());    // 目标站
            if (write.IsSuccess && write1.IsSuccess) {
                log.info("写入输送线命令成功。输送线plc编号={}，站点数据={},写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
        boolean success = false;
        
        while (writeCount < WRITE_RETRY_MAX) {
            OperateResult writeResult = siemensS7Net.Write(workNoAddr, staProtocol.getWorkNo().shortValue());
            Thread.sleep(WRITE_RETRY_INTERVAL_MS);
            
            OperateResult writeResult1 = siemensS7Net.Write(destStaAddr, staProtocol.getStaNo().shortValue());
            
            if (writeResult.IsSuccess && writeResult1.IsSuccess) {
                log.info("写入输送线命令成功 [id:{}] [siteId:{}] [workNo:{}] [destSta:{}] [retry:{}]", 
                        slave.getId(), staProtocol.getSiteId(), staProtocol.getWorkNo(), 
                        staProtocol.getStaNo(), writeCount);
                success = true;
                break;
            } else {
                writeCount++;
                log.error("写入输送线命令失败。输送线plc编号={}，站点数据={},写入次数={}", slave.getId(), JSON.toJSON(staProtocol), writeCount);
            }
        } while (writeCount < 5);
            
            writeCount++;
            log.error("写入输送线命令失败 [id:{}] [siteId:{}] [retry:{}] [workErr:{}] [destErr:{}]", 
                    slave.getId(), staProtocol.getSiteId(), writeCount, 
                    writeResult.Message, writeResult1.Message);
            
            if (writeCount < WRITE_RETRY_MAX) {
                Thread.sleep(WRITE_RETRY_INTERVAL_MS);
            }
        }

        if (!write.IsSuccess) {
            staProtocol = station.get(staProtocol.getSiteId());
            if (staProtocol.getWorkNo() == 0 && staProtocol.getStaNo() == 0) {
                staProtocol.setPakMk(true);
        if (!success) {
            StaProtocol currentSta = station.get(staProtocol.getSiteId());
            if (currentSta != null && currentSta.getWorkNo() == 0 && currentSta.getStaNo() == 0) {
                currentSta.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));
            
            String errorMsg = 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));
            OutputQueue.DEVP.offer(errorMsg);
            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(errorMsg);
        }
    }

@@ -303,7 +497,16 @@

    @Override
    public void close() {
        siemensS7Net.ConnectClose();
        if (siemensS7Net != null) {
            try {
                siemensS7Net.ConnectClose();
                log.info("PLC连接已关闭 [id:{}]", slave.getId());
            } catch (Exception e) {
                log.error("关闭PLC连接异常 [id:{}]", slave.getId(), e);
            } finally {
                connected = false;
            }
        }
    }