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@@ -0,0 +1,285 @@
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+from utils.statepoint import *
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+from utils.mqttdata import *
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+from utils.s7data import *
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+from models.data_sender import *
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+import logging
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+
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+_Debug = 0
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+
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+class Counter:
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+ @property
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+ def data_mqtt(self):
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+ if self._data_mqtt.cli == None:
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+ raise ValueError('The MQTT connection to MES has not been initialized.')
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+ return self._data_mqtt
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+
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+ @property
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+ def data_s7(self):
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+ if self._data_s7 == None:
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+ raise ValueError('The S7 connection to the casting machine PLC has not been initialized.')
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+ return self._data_s7
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+
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+ @property
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+ def sender(self):
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+ if self._sender == None:
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+ raise ValueError('The sender has not been set.')
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+ return self._sender
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+
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+ # 数据点定义
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+ def create_data_point(self, ccmNo):
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+ self.ladle_weight_1 = self.data_s7.make_point('大包重量1')
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+ self.ladle_weight_2 = self.data_s7.make_point('大包重量2')
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+
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+ self.begin_pour = self.data_mqtt.make_point(f'{ccmNo}#开浇信号')
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+ self.end_pour = self.data_mqtt.make_point(f'{ccmNo}#停浇信号')
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+
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+ if _Debug:
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+ self.begin_pour_ring = self.data_s7.make_point('浇铸信号[2]')
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+
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+ self.begin_cutting = []
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+ for i in range(8):
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+ self.begin_cutting.append(self.data_s7.make_point(f'L{i+1}切割信号[0]'))
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+
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+ self.end_cutting = []
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+ for i in range(8):
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+ self.end_cutting.append(self.data_s7.make_point(f'L{i+1}切割信号[1]'))
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+
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+ self.length_cutting = []
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+ for i in range(8):
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+ self.length_cutting.append(self.data_s7.make_point(f'L{i+1}定尺'))
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+
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+ self.drawing_speed = []
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+ for i in range(8):
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+ self.drawing_speed.append(self.data_s7.make_point(f'L{i+1}拉速'))
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+
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+
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+ def init_data_point(self):
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+ # 统一初始化数据点
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+ self.begin_pour.allow_update(False)
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+ self.begin_pour.set_state(False)
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+ self.end_pour.allow_update(False)
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+ self.end_pour.set_state(False)
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+ for i in range(8):
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+ self.begin_cutting[i].allow_update(False)
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+ self.begin_cutting[i].set_state(False)
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+ self.begin_cutting[i].data = 0
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+ self.end_cutting[i].allow_update(False)
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+ self.end_cutting[i].set_state(False)
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+ self.end_cutting[i].data = 0
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+
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+ # 数据点逻辑设置
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+ self.begin_pour.set_excite_action(self.begin_pour_action)
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+ self.end_pour.set_excite_action(self.end_pour_action)
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+
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+ for i in range(8):
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+ self.begin_cutting[i].set_excite_action(lambda i=i: self.begin_cutting_action(i))
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+ self.begin_cutting[i].set_keep_time(3000)
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+ self.end_cutting[i].set_excite_action(lambda i=i: self.end_cutting_action(i))
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+ self.end_cutting[i].set_reset_action(lambda i=i: self.end_cutting[i].allow_update(False))
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+
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+ # 统一开启数据点
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+ self.begin_pour.allow_update()
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+ self.end_pour.allow_update()
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+ for i in range(8):
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+ self.begin_cutting[i].allow_update()
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+
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+
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+ def __init__(self, data_mqtt: Mqttdata, data_s7: S7data, ccmNo, logger: logging.Logger, sender: Sender):
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+ # 模块入口、出口、日志定义
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+ self._data_mqtt = data_mqtt
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+ self._data_s7 = data_s7
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+ self._sender = sender
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+ self.logger = logger
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+
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+ self.logger.info(f"[Counter]分炉分坯模块:{ccmNo}号机模块启动")
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+
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+ # 配置必须的数据点
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+ self.create_data_point(ccmNo)
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+ self.init_data_point()
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+
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+ #分炉分坯功能
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+ self.last_cutting_timestamp = 0
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+
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+ self.strand = [0, 0, 0, 0, 0, 0, 0, 0]
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+ self.cutting_state_heat = [{}, {}, {}, {}, {}, {}, {}, {}]
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+ self.cutting_state_heat_index = [0, 0, 0, 0, 0, 0, 0, 0]
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+ self.total = 0
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+ self.limit_count = 0
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+ self.limit_target = 24
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+ self.limit_flag = False
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+ self.lock = threading.Lock()
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+ self.old_heat = {}
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+ self.new_heat = {}
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+ self.last_cutting_strand = 0
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+
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+
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+ def begin_pour_action(self):
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+ # 标志是否为铸机开机的第一次开浇
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+ flag = (time.time() - self.last_cutting_timestamp) > 1800
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+
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+ # 大包重量选择算法
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+ ladle_weight = max(self.ladle_weight_1.data, self.ladle_weight_2.data)
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+
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+ # 写入日志
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+ if flag:
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+ self.logger.info(f'[Counter]首次开浇:{self.begin_pour.data['heatNo']}')
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+ elif self.new_heat == {}:
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+ self.logger.info(f'[Counter]炉次开浇:{self.begin_pour.data['heatNo']},当前出坯炉次:{"未知" if self.old_heat == {} else self.old_heat["heatNo"]}')
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+ else:
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+ self.logger.warning(f'[Counter]炉次开浇:{self.begin_pour.data['heatNo']},炉次{self.new_heat['heatNo']}被覆盖')
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+
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+ # 维护换炉操作
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+ if flag:
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+ self.old_heat = self.begin_pour.data
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+ self.new_heat = {}
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+ else:
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+ self.new_heat = self.begin_pour.data
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+ self.start_limit()
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+
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+ # 使用sender向外发送信号
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+ self.sender.begin_pour(self.begin_pour.data, ladle_weight)
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+
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+
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+ def end_pour_action(self):
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+ # 写入日志
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+ self.logger.info(f'[Counter]炉次停浇:{self.end_pour.data["heatNo"]}')
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+
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+ # 使用sender向外发送信号
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+ if self.old_heat:
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+ self.sender.end_pour(self.end_pour.data)
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+
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+
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+ def cutting_data_comple(self, i):
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+ count = 3
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+
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+ # 补充计入模块
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+ while count:
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+ time.sleep(0.5)
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+ sizing = self.length_cutting[i].data
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+ speed = self.drawing_speed[i].data
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+ if 0 < sizing < 30000 and 0 < speed < 10:
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+ self.strand_add(i+1, sizing, speed)
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+ return None
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+ count -= 1
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+
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+ time.sleep(0.5)
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+ sizing = self.length_cutting[i].data
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+ speed = self.drawing_speed[i].data
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+ if not (0 < sizing < 30000 and 0 < speed < 10):
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+ self.logger.warning("[Counter]请注意，定尺/拉速数据持续异常,已按照异常数据发送")
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+
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+ self.strand_add(i+1, sizing, speed)
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+ self.end_cutting[i].allow_update()
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+
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+ def begin_cutting_action(self, i):
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+ # 写入日志
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+ self.logger.info(f'[Counter]{i+1}流:开始切割')
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+
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+ # 计入模块
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+ sizing = self.length_cutting[i].data
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+ speed = self.drawing_speed[i].data
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+ if 0 < sizing < 30000 and 0 < speed < 10:
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+ self.strand_add(i+1, sizing, speed)
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+ self.end_cutting[i].allow_update()
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+ else:
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+ threading.Thread(target=self.cutting_data_comple, args=(i,)).start()
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+
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+
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+
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+ def end_cutting_action(self, i):
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+ # 写入日志
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+ self.logger.info(f'[Counter]{i+1}流:完成切割')
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+
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+ # 复位流状态
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+ cutting_state_heat = self.cutting_state_heat[i]
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+ cutting_state_heat_index = self.cutting_state_heat_index[i]
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+ self.cutting_state_heat[i] = {}
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+ self.cutting_state_heat_index[i] = 0
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+
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+ if cutting_state_heat:
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+ # 使用sender向外发送信号
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+ self.sender.end_cut(cutting_state_heat, cutting_state_heat_index)
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+ # 检查自己是否是本炉最后一根钢坯
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+ if self.last_cutting_strand == i+1:
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+ self.last_cutting_strand = 0
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+ self.sender.heat_last(cutting_state_heat)
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+
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+
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+ def strand_add(self, sno, sizing, speed):
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+ with self.lock:
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+ # 维护辅助时间戳
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+ self.last_cutting_timestamp = time.time()
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+
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+ #维护内部正确性的主要算法
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+ if self.limit_flag:
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+ self.limit_count += 1
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+ if self.limit_count == self.limit_target:
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+ # 此处已经在切割本炉最后一根
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+ if self.old_heat:
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+ self.last_cutting_strand = sno
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+ if self.limit_count > self.limit_target:
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+ # 此处已经在切割新炉第一根
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+ self.change_heat()
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+ self.total = 0
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+ self.strand = [0, 0, 0, 0, 0, 0, 0, 0]
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+ self.limit_count = 0
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+ self.limit_flag = False
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+ self.strand[sno-1] += 1
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+ self.total += 1
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+
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+ heatData = self.old_heat
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+ heatIndex = self.total
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+ strandIndex = self.strand[sno-1]
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+
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+ if heatData:
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+ # 记录当前流状态，帮助停切信号判断钢坯信息
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+ self.cutting_state_heat[sno-1] = heatData
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+ self.cutting_state_heat_index[sno-1] = heatIndex
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+ # 生成坯号，使用sender向外发送信号
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+ ccmNo = heatData['ccmNo']
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+ billetNo = heatData['heatNo'] + ccmNo + str(sno) + '{:0>2}'.format(strandIndex)
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+ self.logger.info(f"[Counter]{sno}流:{heatData['heatNo']}炉第{heatIndex}根计入系统,坯号:{billetNo}")
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+ self.sender.begin_cut(heatData, billetNo, heatIndex, sizing, speed)
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+ # 使用sender发送炉次首次开切信号
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+ if heatIndex == 1:
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+ self.sender.heat_first(heatData)
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+ else:
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+ self.logger.info(f"[Counter]{sno}流:未知炉第{heatIndex}根,本炉无法计入系统,下一炉开始正常")
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+
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+
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+ def start_limit(self):
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+ # 根据实际情况设置本炉总支数
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+ with self.lock:
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+ if self.old_heat:
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+ if self.total % 4 == 1:
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+ self.limit_target = 23
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+ elif self.total % 4 == 2:
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+ if self.total >= 28:
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+ self.limit_target = 22
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+ else:
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+ self.limit_target = 26
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+ elif self.total % 4 == 3:
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+ self.limit_target = 25
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+ else:
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+ self.limit_target = 24
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+ else:
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+ self.limit_target = 24
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+
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+ self.limit_flag = True
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+
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+
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+ def change_heat(self):
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+ # 异常情况
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+ if not self.new_heat:
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+ self.logger.error('[Counter]换炉:失败,无新炉次信息')
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+ return None
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+
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+ # 写入日志
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+ if self.old_heat:
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+ self.logger.info(f'[Counter]换炉:{self.old_heat["heatNo"]}->{self.new_heat["heatNo"]}')
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+ else:
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+ self.logger.info(f'[Counter]换炉:未知炉次->{self.new_heat["heatNo"]}')
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+
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+ #真正换炉过程
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+ self.old_heat = self.new_heat
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+ self.new_heat = {}
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oldwine