billetManager/models/billet_counter.py

from utils.statepoint import *
from utils.mqttdata import *
from utils.s7data import *
from models.data_sender import *
import logging

_Debug = 0

class Counter:
    @property
    def data_mqtt(self):
        if self._data_mqtt.cli == None:
            raise ValueError('The MQTT connection to MES has not been initialized.')
        return self._data_mqtt
    
    @property
    def data_s7(self):
        if self._data_s7 == None:
            raise ValueError('The S7 connection to the casting machine PLC has not been initialized.')
        return self._data_s7
    
    @property
    def sender(self):
        if self._sender == None:
            raise ValueError('The sender has not been set.')
        return self._sender
        
    # 数据点定义
    def create_data_point(self, ccmNo):
        self.ladle_weight_1 = self.data_s7.make_point('大包重量1')
        self.ladle_weight_2 = self.data_s7.make_point('大包重量2')

        self.begin_pour = self.data_mqtt.make_point(f'{ccmNo}#开浇信号')
        self.end_pour = self.data_mqtt.make_point(f'{ccmNo}#停浇信号')

        if _Debug:
            self.begin_pour_ring = self.data_s7.make_point('浇铸信号[2]')

        self.begin_cutting = []
        for i in range(8):
            self.begin_cutting.append(self.data_s7.make_point(f'L{i+1}切割信号[0]'))

        self.end_cutting = []
        for i in range(8):
            self.end_cutting.append(self.data_s7.make_point(f'L{i+1}切割信号[1]'))

        self.length_cutting = []
        for i in range(8):
            self.length_cutting.append(self.data_s7.make_point(f'L{i+1}定尺'))

        self.drawing_speed = []
        for i in range(8):
            self.drawing_speed.append(self.data_s7.make_point(f'L{i+1}拉速'))


    def init_data_point(self):
        # 统一初始化数据点
        self.begin_pour.allow_update(False)
        self.begin_pour.set_state(False)
        self.end_pour.allow_update(False)
        self.end_pour.set_state(False)
        for i in range(8):
            self.begin_cutting[i].allow_update(False)
            self.begin_cutting[i].set_state(False)
            self.begin_cutting[i].data = 0
            self.end_cutting[i].allow_update(False)
            self.end_cutting[i].set_state(False)
            self.end_cutting[i].data = 0

        # 数据点逻辑设置
        self.begin_pour.set_excite_action(self.begin_pour_action)
        self.end_pour.set_excite_action(self.end_pour_action)

        for i in range(8):
            self.begin_cutting[i].set_excite_action(lambda i=i: self.begin_cutting_action(i))
            self.begin_cutting[i].set_keep_time(3000)
            self.end_cutting[i].set_excite_action(lambda i=i: self.end_cutting_action(i))
            self.end_cutting[i].set_reset_action(lambda i=i: self.end_cutting[i].allow_update(False))

        # 统一开启数据点
        self.begin_pour.allow_update()
        self.end_pour.allow_update()
        for i in range(8):
            self.begin_cutting[i].allow_update()


    def __init__(self, data_mqtt: Mqttdata, data_s7: S7data, ccmNo, logger: logging.Logger, sender: Sender):
        # 模块入口、出口、日志定义
        self._data_mqtt = data_mqtt
        self._data_s7 = data_s7
        self._sender = sender
        self.logger = logger

        self.logger.info(f"[Counter]分炉分坯模块:{ccmNo}号机模块启动")

        # 配置必须的数据点
        self.create_data_point(ccmNo)
        self.init_data_point()

        #分炉分坯功能
        self.last_cutting_timestamp = 0

        self.strand = [0, 0, 0, 0, 0, 0, 0, 0]
        self.cutting_state_heat = [{}, {}, {}, {}, {}, {}, {}, {}]
        self.cutting_state_heat_index = [0, 0, 0, 0, 0, 0, 0, 0]
        self.total = 0
        self.limit_count = 0
        self.limit_target = 24
        self.limit_flag = False
        self.lock = threading.Lock()
        self.old_heat = {}
        self.new_heat = {}
        self.last_cutting_strand = 0


    def begin_pour_action(self):
        # 标志是否为铸机开机的第一次开浇
        flag = (time.time() - self.last_cutting_timestamp) > 1800

        # 大包重量选择算法
        ladle_weight = max(self.ladle_weight_1.data, self.ladle_weight_2.data)

        # 写入日志
        if flag:
            self.logger.info(f'[Counter]首次开浇:{self.begin_pour.data['heatNo']}')
        elif self.new_heat == {}:
            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"]}')
        else:
            self.logger.warning(f'[Counter]炉次开浇:{self.begin_pour.data['heatNo']},炉次{self.new_heat['heatNo']}被覆盖')

        # 维护换炉操作
        if flag:
            self.old_heat = self.begin_pour.data
            self.new_heat = {}
        else:
            self.new_heat = self.begin_pour.data
            self.start_limit()

        # 使用sender向外发送信号
        self.sender.begin_pour(self.begin_pour.data, ladle_weight)


    def end_pour_action(self):
        # 写入日志
        self.logger.info(f'[Counter]炉次停浇:{self.end_pour.data["heatNo"]}')

        # 使用sender向外发送信号
        if self.old_heat:
            self.sender.end_pour(self.end_pour.data)


    def cutting_data_comple(self, i):
        count = 3

        # 补充计入模块
        while count:
            time.sleep(0.5)
            sizing = self.length_cutting[i].data
            speed = self.drawing_speed[i].data
            if 0 < sizing < 30000 and 0 < speed < 10:
                self.strand_add(i+1, sizing, speed)
                return None
            count -= 1
        
        time.sleep(0.5)
        sizing = self.length_cutting[i].data
        speed = self.drawing_speed[i].data
        if not (0 < sizing < 30000 and 0 < speed < 10):
            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")

        self.strand_add(i+1, sizing, speed)
        self.end_cutting[i].allow_update()

    def begin_cutting_action(self, i):
        # 写入日志
        self.logger.info(f'[Counter]{i+1}流:开始切割')

        # 计入模块
        sizing = self.length_cutting[i].data
        speed = self.drawing_speed[i].data
        if 0 < sizing < 30000 and 0 < speed < 10:
            self.strand_add(i+1, sizing, speed)
            self.end_cutting[i].allow_update()
        else:
            threading.Thread(target=self.cutting_data_comple, args=(i,)).start()



    def end_cutting_action(self, i):
        # 写入日志
        self.logger.info(f'[Counter]{i+1}流:完成切割')

        # 复位流状态
        cutting_state_heat = self.cutting_state_heat[i]
        cutting_state_heat_index = self.cutting_state_heat_index[i]
        self.cutting_state_heat[i] = {}
        self.cutting_state_heat_index[i] = 0

        if cutting_state_heat:
            # 使用sender向外发送信号
            self.sender.end_cut(cutting_state_heat, cutting_state_heat_index)
            # 检查自己是否是本炉最后一根钢坯
            if self.last_cutting_strand == i+1:
                self.last_cutting_strand = 0
                self.sender.heat_last(cutting_state_heat)


    def strand_add(self, sno, sizing, speed):
        with self.lock:
            # 维护辅助时间戳
            self.last_cutting_timestamp = time.time()

            #维护内部正确性的主要算法
            if self.limit_flag:
                self.limit_count += 1
                if self.limit_count == self.limit_target:
                    # 此处已经在切割本炉最后一根
                    if self.old_heat:
                        self.last_cutting_strand = sno
                if self.limit_count > self.limit_target:
                    # 此处已经在切割新炉第一根
                    self.change_heat()
                    self.total = 0
                    self.strand = [0, 0, 0, 0, 0, 0, 0, 0]
                    self.limit_count = 0
                    self.limit_flag = False
            self.strand[sno-1] += 1
            self.total += 1

            heatData = self.old_heat
            heatIndex = self.total
            strandIndex = self.strand[sno-1]
        
        if heatData:
            # 记录当前流状态，帮助停切信号判断钢坯信息
            self.cutting_state_heat[sno-1] = heatData
            self.cutting_state_heat_index[sno-1] = heatIndex
            # 生成坯号，使用sender向外发送信号
            ccmNo = heatData['ccmNo']
            billetNo = heatData['heatNo'] + ccmNo + str(sno) + '{:0>2}'.format(strandIndex)
            self.logger.info(f"[Counter]{sno}流:{heatData['heatNo']}炉第{heatIndex}根计入系统,坯号:{billetNo}")
            self.sender.begin_cut(heatData, billetNo, heatIndex, sizing, speed)
            # 使用sender发送炉次首次开切信号
            if heatIndex == 1:
                self.sender.heat_first(heatData)
        else:
            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")


    def start_limit(self):
        # 根据实际情况设置本炉总支数
        with self.lock:
            if self.old_heat:
                if self.total % 4 == 1:
                    self.limit_target = 23
                elif self.total % 4 == 2:
                    if self.total >= 28:
                        self.limit_target = 22
                    else:
                        self.limit_target = 26
                elif self.total % 4 == 3:
                    self.limit_target = 25
                else:
                    self.limit_target = 24
            else:
                self.limit_target = 24
                
            self.limit_flag = True


    def change_heat(self):
        # 异常情况
        if not self.new_heat:
            self.logger.error('[Counter]换炉:失败,无新炉次信息')
            return None
        
        # 写入日志
        if self.old_heat:
            self.logger.info(f'[Counter]换炉:{self.old_heat["heatNo"]}->{self.new_heat["heatNo"]}')
        else:
            self.logger.info(f'[Counter]换炉:未知炉次->{self.new_heat["heatNo"]}')

        #真正换炉过程
        self.old_heat = self.new_heat
        self.new_heat = {}