package com.zy.core.thread; import HslCommunication.Core.Types.OperateResult; import HslCommunication.Core.Types.OperateResultExOne; import HslCommunication.Profinet.Siemens.SiemensPLCS; import HslCommunication.Profinet.Siemens.SiemensS7Net; import com.alibaba.fastjson.JSON; import com.zy.acs.framework.common.Cools; import com.zy.acs.framework.common.DateUtils; import com.zy.asrs.entity.Devp; import com.zy.asrs.service.DevpService; import com.zy.asrs.utils.SpringContextUtil; import com.zy.common.utils.News; import com.zy.core.DevpThread; import com.zy.core.cache.MessageQueue; import com.zy.core.cache.OutputQueue; import com.zy.core.cache.SlaveConnection; import com.zy.core.constant.*; import com.zy.core.enums.SlaveType; import com.zy.core.enums.TaskType; import com.zy.core.model.DevpSlave; import com.zy.core.model.Task; import com.zy.core.model.protocol.StaProtocol; import lombok.Data; import lombok.extern.slf4j.Slf4j; import java.text.MessageFormat; import java.util.ArrayList; import java.util.Date; import java.util.List; import java.util.Map; import java.util.concurrent.ConcurrentHashMap; /** * 输送线线程 * Created by vincent on 2020/8/4 */ @Data @Slf4j public class SiemensDevpThread implements Runnable, DevpThread { private DevpSlave slave; private SiemensS7Net siemensS7Net; private Map 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; } @Override @SuppressWarnings("InfiniteLoopStatement") public void run() { connect(); while (!Thread.currentThread().isInterrupted()) { try { TaskType step = TaskType.READ; Task task = MessageQueue.poll(SlaveType.Devp, slave.getId()); if (task != null) { step = task.getStep(); } switch (step) { // 读数据 case READ: read(); break; // 写数据 ID+目标站 case WRITE: write((StaProtocol) task.getData()); break; default: break; } 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) { 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 staNos = slave.getStaNos(); for (Integer siteId : staNos) { StaProtocol staProtocol = getOrCreateStaProtocol(siteId); resetStaProtocol(staProtocol); } } /** * 获取或创建站点协议对象 */ private StaProtocol getOrCreateStaProtocol(Integer siteId) { return station.computeIfAbsent(siteId, id -> { StaProtocol protocol = new StaProtocol(); protocol.setSiteId(id); return protocol; }); } /** * 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() { // 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) { 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 { 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); } initSite(); 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 staNos = slave.getStaNos(); int staNoSize = staNos.size(); // 读取站点状态 OperateResultExOne 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); } // 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 barcodeArr = slave.getBarcodeArr(); if (barcodeArr == null || barcodeArr.isEmpty()) { return; } OperateResultExOne 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 (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 staNosError = slave.getStaNosError(); if (staNosError == null || staNosError.isEmpty()) { return; } OperateResultExOne 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 staNos, int staNoSize) { OperateResultExOne 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 staNos = slave.getStaNos(); List devps = new ArrayList<>(staNos.size()); for (Integer siteId : staNos) { StaProtocol staProtocol = station.get(siteId); if (staProtocol != null) { devps.add(staProtocol.toSqlModel()); } } 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(); } } /** * 写入 ID+目标站 =====> 单站点写入 */ private void write(StaProtocol staProtocol) throws InterruptedException { 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 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; } 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; 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; } 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 (!success) { StaProtocol currentSta = station.get(staProtocol.getSiteId()); if (currentSta != null && currentSta.getWorkNo() == 0 && currentSta.getStaNo() == 0) { currentSta.setPakMk(true); } 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); } } /** * 设置入库标记 */ @Override public void setPakMk(Integer siteId, boolean pakMk) { StaProtocol staProtocol = station.get(siteId); if (null != staProtocol) { staProtocol.setPakMk(pakMk); } } @Override public void close() { 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; } } } }