1439 lines
67 KiB
C#
1439 lines
67 KiB
C#
// 统一引入所有必要命名空间
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using MDM.Services.Plant;
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using Microsoft.Extensions.Options;
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using NPOI.SS.Formula.Functions;
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using Quartz;
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using RIZO.Admin.WebApi.PLC.Model;
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using RIZO.Common;
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using S7.Net;
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using SqlSugar;
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using System;
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using System.Collections.Concurrent;
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using System.Collections.Generic;
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using System.Linq;
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using System.Text;
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using System.Threading;
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using System.Threading.Tasks;
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namespace RIZO.Admin.WebApi.PLC.Service
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{
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/// <summary>
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/// PLC通信服务（封装连接、读写、生产数据采集等功能）
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/// </summary>
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public class PlcService : IDisposable
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{
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#region 字段与构造函数
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// 标记是否已释放资源，避免重复释放
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private bool _disposed = false;
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// PLC配置参数（从配置文件注入）
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private readonly List<PlcConfig> _plcConfigs;
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private readonly GlobalPlcConfig _globalConfig;
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private PlcProductionDataService _plcProductionDataService = new PlcProductionDataService();
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private PlantWorkstationService _plantWorkstationService = new PlantWorkstationService();
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// 先在类中添加2个核心优化字段（支撑高频访问）
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private readonly SemaphoreSlim _concurrencySemaphore = new SemaphoreSlim(15, 50); // 限制20并发（适配50台PLC）
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private readonly ConcurrentDictionary<string, (Plc Client, DateTime LastUsedTime)> _plcConnPool = new(); // 连接池
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#region PLC地址块儿映射
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// OP070-1 专属地址映射
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private readonly Dictionary<string, (string Addr, int Len)> _op070_1StringMap = new()
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{
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//{ "报警信息", ("DB1011.DBB58", 48) }, // Array[1..48] of Byte
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{ "订单名称", ("DB1011.DBB1000", 48) }, // String[48]
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{ "产品名称", ("DB1011.DBB1054", 48) }, // String[48]
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{ "产品型号", ("DB1011.DBB2006", 28) }, // String[28]
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{ "SN_1", ("DB1011.DBB2100", 28) }, // String[28]
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{ "SN_2", ("DB1011.DBB2134", 28) } // String[28]
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};
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private readonly Dictionary<string, string> _op070_1IntMap = new()
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{
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{ "运行状态", "DB1011.DBW0" }, // Int
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{ "设备模式", "DB1011.DBW2" }, // Int
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{ "设备在线状态", "DB1011.DBW4" }, // Int
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{ "ByPass", "DB1011.DBW6" }, // Int
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{ "生产模式", "DB1011.DBW8" }, // Int
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{ "实际产量", "DB1011.DBD1104" }, // DInt
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//{ "合格数量", "DB1011.DBD1108" }, // DInt
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//{ "失败数量", "DB1011.DBD1112" }, // DInt
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{ "查询请求", "DB1011.DBW2000" }, // Int
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{ "保存请求", "DB1011.DBW2002" }, // Int
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{ "托盘号", "DB1011.DBW2004" }, // Int
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{ "相机结果", "DB1011.DBW2164" }, // Int
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{ "站位结果", "DB1011.DBW2166" }, // Int
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{ "节拍时间", "DB1011.DBD2168" } // Real
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};
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// OP075 专属地址映射
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private readonly Dictionary<string, (string Addr, int Len)> _op075StringMap = new()
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{
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//{ "报警信息", ("DB1011.DBB58", 48) }, // Array[1..48] of Byte
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{ "订单名称", ("DB1011.DBB1000", 48) }, // String[48]
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{ "产品名称", ("DB1011.DBB1054", 48) }, // String[48]
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{ "产品型号", ("DB1011.DBB2006", 28) }, // String[28]
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{ "SN_1", ("DB1011.DBB2100", 28) }, // String[28]
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{ "SN_2", ("DB1011.DBB2192", 28) }, // String[28]
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{ "芯片SN", ("DB1011.DBB2222", 28) } // String[28]
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};
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private readonly Dictionary<string, string> _op075IntMap = new()
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{
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{ "运行状态", "DB1011.DBW0" }, // Int
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{ "设备模式", "DB1011.DBW2" }, // Int
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{ "设备在线状态", "DB1011.DBW4" }, // Int
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{ "ByPass", "DB1011.DBW6" }, // Int
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{ "生产模式", "DB1011.DBW8" }, // Int
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{ "实际产量", "DB1011.DBD1104" }, // DInt
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//{ "合格数量", "DB1011.DBD1108" }, // DInt
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//{ "失败数量", "DB1011.DBD1112" }, // DInt
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{ "查询请求", "DB1011.DBW2000" }, // Int
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{ "保存请求", "DB1011.DBW2002" }, // Int
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{ "托盘号", "DB1011.DBW2004" }, // Int
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{ "站位结果", "DB1011.DBW2252" }, // Int
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{ "节拍时间", "DB1011.DBD2284" } // Real
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};
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// OP080-1 专属地址映射
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private readonly Dictionary<string, (string Addr, int Len)> _op080_1StringMap = new()
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{
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//{ "报警信息", ("DB1016.DBB58", 48) }, // Array[1..48] of Byte
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{ "订单名称", ("DB1016.DBB1000", 48) }, // String[48]
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{ "产品名称", ("DB1016.DBB1054", 48) }, // String[48]
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{ "合装位机壳_SN", ("DB1016.DBB2100", 28) }, // String[28]
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{ "合装位PCB_SN", ("DB1016.DBB2130", 28) }, // String[28]
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{ "拧紧位机壳_SN", ("DB1016.DBB2904", 28) }, // String[28]
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{ "拧紧位PCB_SN", ("DB1016.DBB3092", 28) }, // String[28]
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};
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private readonly Dictionary<string, string> _op080_1IntMap = new()
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{
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{ "运行状态", "DB1016.DBW0" }, // Int
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{ "设备模式", "DB1016.DBW2" }, // Int
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{ "设备在线状态", "DB1016.DBW4" }, // Int
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{ "ByPass", "DB1016.DBW6" }, // Int
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{ "生产模式", "DB1016.DBW8" }, // Int
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{ "实际产量", "DB1016.DBD1104" }, // DInt
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{ "合格数量", "DB1016.DBD1108" }, // DInt
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{ "失败数量", "DB1016.DBD1112" }, // DInt
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{ "合装工位查询请求", "DB1016.DBW2000" }, // Int
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{ "合装结果保存请求", "DB1016.DBW2004" }, // Int
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{ "拧紧结果保存请求", "DB1016.DBW2006" }, // Int
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{ "合装位托盘号", "DB1016.DBW2100" }, // Int
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{ "拧紧位托盘号", "DB1016.DBW3152" }, // Int
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// 2号螺钉
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{ "2号螺钉_结果", "DB1016.DBW3164" }, // Int
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{ "2号螺钉_扭矩", "DB1016.DBD3166" }, // Real
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{ "2号螺钉_深度", "DB1016.DBD3170" }, // Real
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{ "2号螺钉_角度", "DB1016.DBD3174" }, // Real
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{ "2号螺钉_拧紧时间", "DB1016.DBD3178" }, // Real
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// 3号螺钉
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{ "3号螺钉_结果", "DB1016.DBW3182" }, // Int
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{ "3号螺钉_扭矩", "DB1016.DBD3184" }, // Real
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{ "3号螺钉_深度", "DB1016.DBD3188" }, // Real
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{ "3号螺钉_角度", "DB1016.DBD3192" }, // Real
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{ "3号螺钉_拧紧时间", "DB1016.DBD3196" }, // Real
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// 4号螺钉
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{ "4号螺钉_结果", "DB1016.DBW3200" }, // Int
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{ "4号螺钉_扭矩", "DB1016.DBD3202" }, // Real
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{ "4号螺钉_深度", "DB1016.DBD3206" }, // Real
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{ "4号螺钉_角度", "DB1016.DBD3210" }, // Real
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{ "4号螺钉_拧紧时间", "DB1016.DBD3214" }, // Real
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// 1号螺钉
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{ "1号螺钉_结果", "DB1016.DBW3218" }, // Int
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{ "1号螺钉_扭矩", "DB1016.DBD3220" }, // Real
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{ "1号螺钉_深度", "DB1016.DBD3224" }, // Real
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{ "1号螺钉_角度", "DB1016.DBD3228" }, // Real
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{ "1号螺钉_拧紧时间", "DB1016.DBD3232" }, // Real
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// 5号螺钉
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{ "5号螺钉_结果", "DB1016.DBW3236" }, // Int
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{ "5号螺钉_扭矩", "DB1016.DBD3238" }, // Real
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{ "5号螺钉_深度", "DB1016.DBD3242" }, // Real
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{ "5号螺钉_角度", "DB1016.DBD3246" }, // Real
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{ "5号螺钉_拧紧时间", "DB1016.DBD3250" }, // Real
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// 6号螺钉
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{ "6号螺钉_结果", "DB1016.DBW3254" }, // Int
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{ "6号螺钉_扭矩", "DB1016.DBD3256" }, // Real
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{ "6号螺钉_深度", "DB1016.DBD3260" }, // Real
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{ "6号螺钉_角度", "DB1016.DBD3264" }, // Real
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{ "6号螺钉_拧紧时间", "DB1016.DBD3268" }, // Real
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// 7号螺钉
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{ "7号螺钉_结果", "DB1016.DBW3272" }, // Int
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{ "7号螺钉_扭矩", "DB1016.DBD3274" }, // Real
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{ "7号螺钉_深度", "DB1016.DBD3278" }, // Real
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{ "7号螺钉_角度", "DB1016.DBD3282" }, // Real
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{ "7号螺钉_拧紧时间", "DB1016.DBD3286" }, // Real
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};
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#endregion
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/// <summary>
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/// 构造函数（依赖注入获取PLC配置）
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/// </summary>
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/// <param name="plcConfigs">所有PLC的连接配置</param>
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/// <param name="globalConfig">PLC全局超时配置</param>
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public PlcService(IOptions<GlobalPlcConfig> globalConfig)
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{
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_globalConfig = globalConfig?.Value ?? throw new ArgumentNullException(nameof(globalConfig), "PLC全局配置不能为空");
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//初始化plcConfigs
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_plcConfigs = initPlcConfigs(_plcConfigs);
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}
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#endregion
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#region 核心业务方法
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/// <summary>
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/// 读取PLC生产数据（优化版：连接池+并发控制+OP070-1/OP080专属适配）
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/// </summary>
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/// <param name="ip">PLC IP地址</param>
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/// <param name="plcName">PLC名称（支持OP070-1/OP080）</param>
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/// <param name="rack">机架号</param>
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/// <param name="slot">槽位号</param>
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/// <param name="cpuType">PLC型号（默认S7-1500）</param>
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/// <returns>读取结果（状态+数据+消息）</returns>
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public async Task<(bool Success, PlcProductionData Data, string Message)> ReadProductionDataAsync(
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string ip,
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string plcName,
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short rack,
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short slot,
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CpuType cpuType = CpuType.S71500)
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{
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// 1. 强化参数校验（补充PLC名称校验+白名单控制）
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if (string.IsNullOrWhiteSpace(ip))
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return (false, null, "PLC IP地址不能为空");
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if (string.IsNullOrWhiteSpace(plcName))
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return (false, null, "PLC名称不能为空");
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if (rack < 0 || rack > 10)
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return (false, null, $"PLC机架号{rack}无效（有效值0-10）");
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if (slot < 0 || slot > 4)
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return (false, null, $"PLC槽位号{slot}无效（有效值0-4）");
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Plc plc = null;
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bool isConnReused = false;
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var poolKey = $"{ip}_{rack}_{slot}_{cpuType}";
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PlcProductionData prodData = null;
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// 2. 并发控制（核心保留，防止端口/线程耗尽）
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await _concurrencySemaphore.WaitAsync();
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try
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{
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// 3. 连接池复用+精简重试逻辑（提升可读性）
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if (_plcConnPool.TryGetValue(poolKey, out var poolItem) && poolItem.Client.IsConnected)
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{
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plc = poolItem.Client;
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_plcConnPool.TryUpdate(poolKey, (plc, DateTime.Now), poolItem);
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isConnReused = true;
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}
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else
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{
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plc = CreatePlcClient(cpuType, ip, rack, slot);
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bool isConnected = false;
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// for循环替代while，逻辑更直观
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try
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{
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await OpenPlcConnectionAsync(plc);
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isConnected = plc.IsConnected;
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}
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catch
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{
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}
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if (!isConnected)
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return (false, null, $"{plcName}连接失败（含2次重试）");
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_plcConnPool.TryAdd(poolKey, (plc, DateTime.Now));
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}
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// 4. 多工位查询请求标志适配（核心：区分不同工位的寄存器地址）
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int iQueryRequest = 0;
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int iSaveRequest = 0;
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string strSaveRequest = "";
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if (plcName == "OP070-1" || plcName == "OP070-2" || plcName == "OP070-3")
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{
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iQueryRequest = await ReadPlcIntAsync(plc, _op070_1IntMap["查询请求"]);
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iSaveRequest = await ReadPlcIntAsync(plc, _op070_1IntMap["保存请求"]);
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}
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else if (plcName == "OP075")
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{
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iQueryRequest = await ReadPlcIntAsync(plc, _op075IntMap["查询请求"]);
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iSaveRequest = await ReadPlcIntAsync(plc, _op075IntMap["保存请求"]);
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}
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else if (plcName == "OP080-1")
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{
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iQueryRequest = await ReadPlcIntAsync(plc, _op080_1IntMap["合装工位查询请求"]);
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//考虑一条数据更新两次，还是生成两条数据
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int iSaveRequest1 = await ReadPlcIntAsync(plc, _op080_1IntMap["合装结果保存请求"]);
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int iSaveRequest2 = await ReadPlcIntAsync(plc, _op080_1IntMap["拧紧结果保存请求"]);
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if (iSaveRequest1 == 1)
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{
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iSaveRequest = 1;
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strSaveRequest = "合装结果保存请求";
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}
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if (iSaveRequest2 == 1)
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{
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iSaveRequest = 1;
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if (strSaveRequest.Length > 0)
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{
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strSaveRequest += ",拧紧结果保存请求";
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}
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else
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{
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strSaveRequest = "拧紧结果保存请求";
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}
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}
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} // 无效请求直接返回（避免无谓资源消耗）
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if (iQueryRequest != 1 && iSaveRequest != 1)
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{
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return (false, null, $"");
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}
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//给PLC返回数据
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if (iQueryRequest == 1)
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{
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}
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if (iSaveRequest == 1)
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{
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// 5. 多工位专属数据读取（预留扩展，逻辑隔离）
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if (plcName == "OP070-1" || plcName == "OP070-2" || plcName == "OP070-3")
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{
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prodData = await ReadOP070_1DataAsync(plc, ip, plcName);
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}
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else if (plcName == "OP075")
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{
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prodData = await ReadOP075DataAsync(plc, ip, plcName);
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}
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else if (plcName == "OP080-1" || plcName == "OP080-2")
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{
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int iSaveRequest1 = await ReadPlcIntAsync(plc, _op080_1IntMap["合装结果保存请求"]);
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int iSaveRequest2 = await ReadPlcIntAsync(plc, _op080_1IntMap["拧紧结果保存请求"]);
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prodData = await ReadOP080_1DataAsync(plc, ip, plcName, strSaveRequest);
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}
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// 6. 统一空值兜底（避免空引用）
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if (prodData != null)
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{
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prodData.QualificationFlag ??= "0";
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prodData.ReworkFlag ??= "0";
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prodData.ProductionCycle ??= 0;
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// 7. 异步保存数据（日志补充PLC名称，便于定位）
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_ = Task.Run(() => _plcProductionDataService.AddPlcProductionData(prodData))
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.ContinueWith(t =>
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{
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if (t.IsFaulted)
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{
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Console.WriteLine($"{plcName}({ip})数据保存失败：{t.Exception?.InnerException?.Message}");
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}
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});
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}
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}
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// 8. 个性化返回消息（区分工位和连接类型）
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var successMsg = isConnReused
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? $"{plcName}生产数据读取成功（复用连接）"
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: $"{plcName}生产数据读取成功（新建连接）";
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return (true, prodData, successMsg);
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}
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catch (Exception ex)
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{
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// 精细化异常日志（包含PLC名称，快速定位故障）
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Console.WriteLine($"{plcName}({ip})生产数据读取异常：{ex.Message}\n{ex.StackTrace}");
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return (false, null, $"{plcName}生产数据读取失败：{ex.Message}");
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}
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finally
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{
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// 资源安全释放（核心：防止死锁/连接泄漏）
|
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if (!isConnReused)
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{
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ReleasePlcConnection(plc);
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}
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_concurrencySemaphore.Release();
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}
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}
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|
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#region 工位专属读取方法
|
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/// <summary>
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/// OP070-1数据读取
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/// </summary>
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private async Task<PlcProductionData> ReadOP070_1DataAsync(Plc plc, string ip,string workstationCode)
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{
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||
// 1. 批量并行读取所有字段（沿用原有结构+增强型读取方法）
|
||
var (strFields, intFields, realFields) = await Task.Run(async () => (
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// 字符串字段（增强空值和异常处理）
|
||
(
|
||
//await ReadPlcStringAsync(plc, _op070_1StringMap["报警信息"].Addr, _op070_1StringMap["报警信息"].Len),
|
||
await ReadPlcStringAsync(plc, _op070_1StringMap["产品名称"].Addr, _op070_1StringMap["产品名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op070_1StringMap["订单名称"].Addr, _op070_1StringMap["订单名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op070_1StringMap["产品型号"].Addr, _op070_1StringMap["产品型号"].Len),
|
||
await ReadPlcStringAsync(plc, _op070_1StringMap["SN_1"].Addr, _op070_1StringMap["SN_1"].Len),
|
||
await ReadPlcStringAsync(plc, _op070_1StringMap["SN_2"].Addr, _op070_1StringMap["SN_2"].Len)
|
||
),
|
||
// Int字段（使用增强版ReadPlcIntAsync）
|
||
(
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["运行状态"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["设备模式"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["设备在线状态"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["ByPass"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["生产模式"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["查询请求"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["保存请求"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["托盘号"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["相机结果"]),
|
||
await ReadPlcIntAsync(plc, _op070_1IntMap["站位结果"])
|
||
),
|
||
// DInt字段（增强版读取方法）
|
||
//(
|
||
// await ReadPlcDIntAsync(plc, _op070_1IntMap["实际产量"]),
|
||
// await ReadPlcDIntAsync(plc, _op070_1IntMap["合格数量"]),
|
||
// await ReadPlcDIntAsync(plc, _op070_1IntMap["失败数量"])
|
||
//),
|
||
// Real字段（增强版读取方法）
|
||
(
|
||
await ReadPlcRealAsync(plc, _op070_1IntMap["节拍时间"])
|
||
)
|
||
));
|
||
|
||
// 2. 解构字段（保持原有逻辑，空值兜底）
|
||
var (productName,orderName, productModel, sn1, sn2) = strFields;
|
||
var (runStatus, machineModel, onlineStatus, byPass, produceModel, queryReq, saveReq, trayNo, cameraResult, stationResult) = intFields;
|
||
//var (actualOutput, qualifiedQty, failedQty) = dintFields;
|
||
float cycleTime = realFields;
|
||
|
||
// 3. 写入保存请求（异步+增强异常日志）
|
||
try
|
||
{
|
||
WritePlcValue(plc, _op070_1IntMap["保存请求"], "0");
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"OP070-1({ip})写保存请求失败：{ex.Message}");
|
||
}
|
||
|
||
// 4. 极简条件计算（增强类型安全）
|
||
var reworkFlag = produceModel == 4 ? "1" : "0";
|
||
string produceModelDesc = produceModel switch
|
||
{
|
||
1 => "正常模式",
|
||
2 => "清线模式",
|
||
4 => "返工模式",
|
||
8 => "换型模式",
|
||
16 => "预热模式",
|
||
_ => $"未知({produceModel})"
|
||
};
|
||
string runStatusDesc = runStatus switch { 1 => "空闲", 2 => "运行中", 3 => "故障", _ => $"未知({runStatus})" };
|
||
string onlineStatusDesc = onlineStatus == 1 ? "离线" : "在线";
|
||
//string byPassDesc = byPass == 1 ? "旁路模式" : "正常模式";
|
||
string qualificationFlag = stationResult switch { 1 => "1", 2 => "0", _ => stationResult.ToString() };
|
||
string cameraResultDesc = cameraResult switch { 1 => "OK", 2 => "NG", _ => $"未知({cameraResult})" };
|
||
|
||
// 调试日志：输出关键读取结果
|
||
Console.WriteLine($"OP070-1({ip})读取结果：产品型号={productModel}，运行状态={runStatusDesc},订单名称={orderName}");
|
||
|
||
// 5. 构建数据实体（增强空值处理）
|
||
return new PlcProductionData
|
||
{
|
||
PlcIp = ip.Trim(),
|
||
OccurTime = DateTime.Now,
|
||
LineCode = "line2",
|
||
WorkstationCode = workstationCode,
|
||
ProductModel = productModel ?? string.Empty,
|
||
ProductName = productName ?? string.Empty,
|
||
ProductCode = sn2 ?? string.Empty,
|
||
SN1 = sn1 ?? string.Empty,
|
||
SN2 = sn2 ?? string.Empty,
|
||
QualificationFlag = qualificationFlag,
|
||
ReworkFlag = reworkFlag,
|
||
Automanual = machineModel,
|
||
Runstatus = runStatus,
|
||
OnlineStatus = onlineStatusDesc,
|
||
//ByPass = byPassDesc,
|
||
ProduceModel = produceModelDesc,
|
||
TrayNo = trayNo.ToString(),
|
||
CameraResult = cameraResultDesc,
|
||
//ActualOutput = actualOutput,
|
||
//QualifiedQuantity = qualifiedQty,
|
||
//FailedQuantity = failedQty,
|
||
ProductionCycle = (int?)cycleTime,
|
||
//AlarmMsg = alarmMsg ?? string.Empty,
|
||
CreatedBy = "PLC",
|
||
CreatedTime = DateTime.Now
|
||
};
|
||
}
|
||
/// <summary>
|
||
/// OP075数据读取
|
||
/// </summary>
|
||
private async Task<PlcProductionData> ReadOP075DataAsync(Plc plc, string ip, string workstationCode)
|
||
{
|
||
// 1. 批量并行读取所有字段（沿用原有结构+增强型读取方法）
|
||
var (strFields, intFields, realFields) = await Task.Run(async () => (
|
||
// 字符串字段（增强空值和异常处理）
|
||
(
|
||
//await ReadPlcStringAsync(plc, _op075StringMap["报警信息"].Addr, _op075StringMap["报警信息"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["产品名称"].Addr, _op075StringMap["产品名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["订单名称"].Addr, _op075StringMap["订单名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["产品型号"].Addr, _op075StringMap["产品型号"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["SN_1"].Addr, _op075StringMap["SN_1"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["SN_2"].Addr, _op075StringMap["SN_2"].Len),
|
||
await ReadPlcStringAsync(plc, _op075StringMap["芯片SN"].Addr, _op075StringMap["芯片SN"].Len)
|
||
),
|
||
// Int字段（使用增强版ReadPlcIntAsync）
|
||
(
|
||
await ReadPlcIntAsync(plc, _op075IntMap["运行状态"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["设备模式"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["设备在线状态"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["ByPass"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["生产模式"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["查询请求"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["保存请求"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["托盘号"]),
|
||
await ReadPlcIntAsync(plc, _op075IntMap["站位结果"])
|
||
),
|
||
// DInt字段（增强版读取方法）
|
||
//(
|
||
// await ReadPlcDIntAsync(plc, _op075IntMap["实际产量"]),
|
||
// await ReadPlcDIntAsync(plc, _op075IntMap["合格数量"]),
|
||
// await ReadPlcDIntAsync(plc, _op075IntMap["失败数量"])
|
||
//),
|
||
// Real字段（增强版读取方法）
|
||
(
|
||
await ReadPlcRealAsync(plc, _op075IntMap["节拍时间"])
|
||
)
|
||
));
|
||
|
||
// 2. 解构字段（保持原有逻辑，空值兜底）
|
||
var (productName, orderName, productModel, sn1, sn2,chipsn) = strFields;
|
||
var (runStatus, machineModel, onlineStatus, byPass, produceModel, queryReq, saveReq, trayNo, stationResult) = intFields;
|
||
//var (actualOutput, qualifiedQty, failedQty) = dintFields;
|
||
float cycleTime = realFields;
|
||
|
||
// 3. 写入保存请求（异步+增强异常日志）
|
||
try
|
||
{
|
||
WritePlcValue(plc, _op075IntMap["保存请求"], "0");
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"OP075({ip})写保存请求失败：{ex.Message}");
|
||
}
|
||
|
||
// 4. 极简条件计算（增强类型安全）
|
||
var reworkFlag = produceModel == 4 ? "1" : "0";
|
||
string produceModelDesc = produceModel switch
|
||
{
|
||
1 => "正常模式",
|
||
2 => "清线模式",
|
||
4 => "返工模式",
|
||
8 => "换型模式",
|
||
16 => "预热模式",
|
||
_ => $"未知({produceModel})"
|
||
};
|
||
string runStatusDesc = runStatus switch { 1 => "空闲", 2 => "运行中", 3 => "故障", _ => $"未知({runStatus})" };
|
||
string onlineStatusDesc = onlineStatus == 1 ? "离线" : "在线";
|
||
//string byPassDesc = byPass == 1 ? "旁路模式" : "正常模式";
|
||
string qualificationFlag = stationResult switch { 1 => "1", 2 => "0", _ => stationResult.ToString() };
|
||
|
||
// 调试日志：输出关键读取结果
|
||
Console.WriteLine($"OP075({ip})读取结果：产品型号={productModel}，运行状态={runStatusDesc},订单名称={orderName}");
|
||
|
||
// 5. 构建数据实体（增强空值处理）
|
||
return new PlcProductionData
|
||
{
|
||
PlcIp = ip.Trim(),
|
||
OccurTime = DateTime.Now,
|
||
LineCode = "line2",
|
||
WorkstationCode = workstationCode,
|
||
ProductModel = productModel ?? string.Empty,
|
||
ProductName = productName ?? string.Empty,
|
||
ProductCode = sn2 ?? string.Empty,
|
||
SN1 = sn1 ?? string.Empty,
|
||
SN2 = sn2 ?? string.Empty,
|
||
QualificationFlag = qualificationFlag,
|
||
ReworkFlag = reworkFlag,
|
||
Automanual = machineModel,
|
||
Runstatus = runStatus,
|
||
OnlineStatus = onlineStatusDesc,
|
||
//ByPass = byPassDesc,
|
||
ProduceModel = produceModelDesc,
|
||
TrayNo = trayNo.ToString(),
|
||
ChipSN = chipsn,
|
||
//ActualOutput = actualOutput,
|
||
//QualifiedQuantity = qualifiedQty,
|
||
//FailedQuantity = failedQty,
|
||
ProductionCycle = (int?)cycleTime,
|
||
//AlarmMsg = alarmMsg ?? string.Empty,
|
||
CreatedBy = "PLC",
|
||
CreatedTime = DateTime.Now
|
||
};
|
||
}
|
||
/// <summary>
|
||
/// 读取OP080-1数据
|
||
/// </summary>
|
||
/// <param name="plc"></param>
|
||
/// <param name="ip"></param>
|
||
/// <param name="workstationCode"></param>
|
||
/// <returns></returns>
|
||
private async Task<PlcProductionData> ReadOP080_1DataAsync(Plc plc, string ip, string workstationCode,string strSaveRequest)
|
||
{
|
||
// 1. 批量并行读取所有字段（沿用原有结构+增强型读取方法）
|
||
var (strFields, intFields, realFields) = await Task.Run(async () => (
|
||
// 字符串字段（增强空值和异常处理）
|
||
(
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["订单名称"].Addr, _op080_1StringMap["订单名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["产品名称"].Addr, _op080_1StringMap["产品名称"].Len),
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["合装位机壳_SN"].Addr, _op080_1StringMap["合装位机壳_SN"].Len),
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["合装位PCB_SN"].Addr, _op080_1StringMap["合装位PCB_SN"].Len),
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["拧紧位机壳_SN"].Addr, _op080_1StringMap["拧紧位机壳_SN"].Len),
|
||
await ReadPlcStringAsync(plc, _op080_1StringMap["拧紧位PCB_SN"].Addr, _op080_1StringMap["拧紧位PCB_SN"].Len)
|
||
),
|
||
// Int/DInt字段（使用增强版ReadPlcIntAsync/ReadPlcDIntAsync）
|
||
(
|
||
// 基础状态字段
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["运行状态"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["设备模式"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["设备在线状态"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["ByPass"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["生产模式"]),
|
||
// 产量统计字段（DInt类型，需用ReadPlcDIntAsync）
|
||
//await ReadPlcDIntAsync(plc, _op080_1IntMap["实际产量"]),
|
||
//await ReadPlcDIntAsync(plc, _op080_1IntMap["合格数量"]),
|
||
//await ReadPlcDIntAsync(plc, _op080_1IntMap["失败数量"]),
|
||
// 请求/托盘字段
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["合装工位查询请求"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["合装结果保存请求"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["拧紧结果保存请求"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["合装位托盘号"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["拧紧位托盘号"]),
|
||
// 螺钉结果字段（Int类型）
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["1号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["2号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["3号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["4号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["5号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["6号螺钉_结果"]),
|
||
await ReadPlcIntAsync(plc, _op080_1IntMap["7号螺钉_结果"])
|
||
),
|
||
// Real字段（螺钉扭矩/深度/角度/时间，增强版读取方法）
|
||
(
|
||
// 1号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["1号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["1号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["1号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["1号螺钉_拧紧时间"]),
|
||
// 2号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["2号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["2号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["2号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["2号螺钉_拧紧时间"]),
|
||
// 3号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["3号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["3号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["3号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["3号螺钉_拧紧时间"]),
|
||
// 4号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["4号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["4号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["4号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["4号螺钉_拧紧时间"]),
|
||
// 5号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["5号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["5号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["5号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["5号螺钉_拧紧时间"]),
|
||
// 6号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["6号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["6号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["6号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["6号螺钉_拧紧时间"]),
|
||
// 7号螺钉Real字段
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["7号螺钉_扭矩"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["7号螺钉_深度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["7号螺钉_角度"]),
|
||
await ReadPlcRealAsync(plc, _op080_1IntMap["7号螺钉_拧紧时间"])
|
||
)
|
||
));
|
||
|
||
// 2. 解构字段（保持原有逻辑，空值兜底）
|
||
var (orderName, productName, hzMachineSN, hzPcbsn, njMachineSN, njPcbsn) = strFields;
|
||
|
||
var (runStatus, machineModel, onlineStatus, byPass, produceModel,
|
||
hzQueryReq, hzSaveReq, njSaveReq,
|
||
hzTrayNo, njTrayNo, screw1Result, screw2Result, screw3Result,
|
||
screw4Result, screw5Result, screw6Result, screw7Result) = intFields;
|
||
|
||
// 解构螺钉Real字段（按顺序对应）
|
||
var (
|
||
// 1号螺钉
|
||
screw1Torque, screw1Depth, screw1Angle, screw1Time,
|
||
// 2号螺钉
|
||
screw2Torque, screw2Depth, screw2Angle, screw2Time,
|
||
// 3号螺钉
|
||
screw3Torque, screw3Depth, screw3Angle, screw3Time,
|
||
// 4号螺钉
|
||
screw4Torque, screw4Depth, screw4Angle, screw4Time,
|
||
// 5号螺钉
|
||
screw5Torque, screw5Depth, screw5Angle, screw5Time,
|
||
// 6号螺钉
|
||
screw6Torque, screw6Depth, screw6Angle, screw6Time,
|
||
// 7号螺钉
|
||
screw7Torque, screw7Depth, screw7Angle, screw7Time
|
||
) = realFields;
|
||
|
||
// 3. 写入保存请求（异步+增强异常日志）,收完数据给这个数据位置0
|
||
try
|
||
{
|
||
if (strSaveRequest.Contains("合装结果保存请求"))
|
||
{
|
||
WritePlcValue(plc, _op080_1IntMap["合装结果保存请求"], "0");
|
||
}
|
||
if (strSaveRequest.Contains("拧紧结果保存请求"))
|
||
{
|
||
WritePlcValue(plc, _op080_1IntMap["拧紧结果保存请求"], "0");
|
||
}
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"OP080-1({ip})写保存请求失败：{ex.Message}");
|
||
}
|
||
|
||
// 4. 极简条件计算（增强类型安全）
|
||
var reworkFlag = produceModel == 4 ? "1" : "0";
|
||
string produceModelDesc = produceModel switch
|
||
{
|
||
1 => "正常模式",
|
||
2 => "清线模式",
|
||
4 => "返工模式",
|
||
8 => "换型模式",
|
||
16 => "预热模式",
|
||
_ => $"未知({produceModel})"
|
||
};
|
||
string runStatusDesc = runStatus switch { 1 => "空闲", 2 => "运行中", 3 => "故障", _ => $"未知({runStatus})" };
|
||
string onlineStatusDesc = onlineStatus == 1 ? "离线" : "在线";
|
||
|
||
// 计算整体工位合格标识（所有螺钉合格则工位合格）
|
||
var allScrewQualified = new[] { screw1Result, screw2Result, screw3Result, screw4Result, screw5Result, screw6Result, screw7Result }
|
||
.All(s => s == 1);
|
||
string qualificationFlag = allScrewQualified ? "1" : "0";
|
||
|
||
// 调试日志：输出关键读取结果
|
||
Console.WriteLine($"OP080-1({ip})读取结果：产品名称={productName}，运行状态={runStatusDesc},订单名称={orderName}，螺钉整体合格={allScrewQualified}");
|
||
|
||
// 5. 构建数据实体（严格匹配PlcProductionData字段定义）
|
||
var plcData = new PlcProductionData
|
||
{
|
||
// 基础字段
|
||
PlcIp = ip.Trim(),
|
||
OccurTime = DateTime.Now,
|
||
LineCode = "line2", // 可根据实际产线调整
|
||
WorkstationCode = workstationCode,
|
||
ProductName = productName ?? string.Empty,
|
||
ProductCode = njPcbsn ?? string.Empty, // 拧紧位PCB SN作为产品编码
|
||
|
||
// 合格/返工标志
|
||
QualificationFlag = qualificationFlag,
|
||
ReworkFlag = reworkFlag,
|
||
|
||
// 设备状态相关
|
||
Automanual = machineModel, // 设备模式：0-自动，1-手动
|
||
Runstatus = runStatus, // 运行状态:1=空闲，2=运行中，3=故障
|
||
OnlineStatus = onlineStatusDesc, // 设备在线状态1=离线,0=在线
|
||
ProduceModel = produceModelDesc, // 生产模式描述
|
||
|
||
// 托盘号相关（拆分合装/拧紧位托盘号）
|
||
TrayNo = $"{hzTrayNo}!{njTrayNo}", // 合并显示
|
||
AssemblyTrayNo = hzTrayNo.ToString(), // 合装位托盘号
|
||
TightenTrayNo = njTrayNo.ToString(), // 拧紧位托盘号
|
||
|
||
// SN相关字段
|
||
SN1 = hzMachineSN ?? string.Empty, // 合装位机壳SN
|
||
SN2 = njMachineSN ?? string.Empty, // 拧紧位机壳SN
|
||
AssemblyHousingSN = hzMachineSN ?? string.Empty, // 合装位机壳SN
|
||
AssemblyPCBSN = hzPcbsn ?? string.Empty, // 合装位PCB SN
|
||
TightenHousingSN = njMachineSN ?? string.Empty, // 拧紧位机壳SN
|
||
TightenPCBSN = njPcbsn ?? string.Empty, // 拧紧位PCB SN
|
||
|
||
// 螺钉相关字段（严格匹配实体类）
|
||
Screw1Result = screw1Result.ToString(),
|
||
Screw1Torque = screw1Torque.ToString("0.00"),
|
||
Screw1Depth = screw1Depth.ToString("0.00"),
|
||
Screw1Angle = screw1Angle.ToString("0.00"),
|
||
Screw1TightenTime = screw1Time.ToString("0.00"),
|
||
|
||
Screw2Result = screw2Result.ToString(),
|
||
Screw2Torque = screw2Torque.ToString("0.00"),
|
||
Screw2Depth = screw2Depth.ToString("0.00"),
|
||
Screw2Angle = screw2Angle.ToString("0.00"),
|
||
Screw2TightenTime = screw2Time.ToString("0.00"),
|
||
|
||
Screw3Result = screw3Result.ToString(),
|
||
Screw3Torque = screw3Torque.ToString("0.00"),
|
||
Screw3Depth = screw3Depth.ToString("0.00"),
|
||
Screw3Angle = screw3Angle.ToString("0.00"),
|
||
Screw3TightenTime = screw3Time.ToString("0.00"),
|
||
|
||
Screw4Result = screw4Result.ToString(),
|
||
Screw4Torque = screw4Torque.ToString("0.00"),
|
||
Screw4Depth = screw4Depth.ToString("0.00"),
|
||
Screw4Angle = screw4Angle.ToString("0.00"),
|
||
Screw4TightenTime = screw4Time.ToString("0.00"),
|
||
|
||
Screw5Result = screw5Result.ToString(),
|
||
Screw5Torque = screw5Torque.ToString("0.00"),
|
||
Screw5Depth = screw5Depth.ToString("0.00"),
|
||
Screw5Angle = screw5Angle.ToString("0.00"),
|
||
Screw5TightenTime = screw5Time.ToString("0.00"),
|
||
|
||
Screw6Result = screw6Result.ToString(),
|
||
Screw6Torque = screw6Torque.ToString("0.00"),
|
||
Screw6Depth = screw6Depth.ToString("0.00"),
|
||
Screw6Angle = screw6Angle.ToString("0.00"),
|
||
Screw6TightenTime = screw6Time.ToString("0.00"),
|
||
|
||
Screw7Result = screw7Result.ToString(),
|
||
Screw7Torque = screw7Torque.ToString("0.00"),
|
||
Screw7Depth = screw7Depth.ToString("0.00"),
|
||
Screw7Angle = screw7Angle.ToString("0.00"),
|
||
Screw7TightenTime = screw7Time.ToString("0.00"),
|
||
|
||
// 系统字段
|
||
CreatedBy = "PLC",
|
||
CreatedTime = DateTime.Now,
|
||
// 可选字段（无值时置空）
|
||
ParamName = string.Empty,
|
||
ParamValue = string.Empty,
|
||
ProductionCycle = null,
|
||
Remark = string.Empty,
|
||
UpdatedBy = string.Empty,
|
||
UpdatedTime = null,
|
||
ProductModel = string.Empty, // 无产品型号数据时置空
|
||
WorkstationName = string.Empty, // 无工站名称数据时置空
|
||
CameraResult = string.Empty // 无相机结果数据时置空
|
||
};
|
||
return plcData;
|
||
}
|
||
|
||
#endregion
|
||
|
||
// 可选：添加连接池清理方法（防止长期运行导致连接泄露）
|
||
private void CleanupExpiredConnections()
|
||
{
|
||
var expiredTime = DateTime.Now.AddMinutes(-5); // 5分钟未使用的连接清理
|
||
// 先复制所有Key到列表，避免遍历中修改原集合
|
||
var allKeys = _plcConnPool.Keys.ToList();
|
||
|
||
foreach (var key in allKeys)
|
||
{
|
||
if (!_plcConnPool.TryGetValue(key, out var poolItem))
|
||
continue;
|
||
|
||
if (poolItem.LastUsedTime < expiredTime)
|
||
{
|
||
if (_plcConnPool.TryRemove(key, out var removedItem))
|
||
{
|
||
try
|
||
{
|
||
if (removedItem.Client != null && removedItem.Client.IsConnected)
|
||
removedItem.Client.Close();
|
||
if (removedItem.Client is IDisposable disposable)
|
||
disposable.Dispose();
|
||
// 可选：置空引用，帮助GC回收
|
||
removedItem.Client = null;
|
||
}
|
||
catch
|
||
{
|
||
// 静默释放，避免清理失败影响主流程
|
||
}
|
||
}
|
||
}
|
||
}
|
||
}
|
||
|
||
// 在类的构造函数中启动定时清理（可选）
|
||
// public PlcService(IOptions<GlobalPlcConfig> globalConfig)
|
||
// {
|
||
// _globalConfig = globalConfig?.Value ?? throw new ArgumentNullException(nameof(globalConfig));
|
||
// _plcConfigs = initPlcConfigs(_plcConfigs);
|
||
// // 每30秒清理一次过期连接
|
||
// new Timer(_ => CleanupExpiredConnections(), null, TimeSpan.Zero, TimeSpan.FromSeconds(30));
|
||
// }
|
||
|
||
/// <summary>
|
||
/// 测试单个PLC的连接、读、写功能
|
||
/// </summary>
|
||
/// <param name="config">单个PLC的配置参数</param>
|
||
/// <param name="cancellationToken">取消令牌</param>
|
||
/// <returns>测试结果</returns>
|
||
public async Task<PlcTestResult> TestSinglePlcAsync(PlcConfig config, CancellationToken cancellationToken = default)
|
||
{
|
||
// 1. 极简参数校验（提前返回，减少嵌套）
|
||
if (config == null)
|
||
throw new ArgumentNullException(nameof(config), "PLC测试配置不能为空");
|
||
if (string.IsNullOrWhiteSpace(config.Ip))
|
||
return new PlcTestResult { PlcName = config.PlcName, Ip = config.Ip, ConnectSuccess = false, ConnectMessage = "IP地址为空" };
|
||
|
||
var result = new PlcTestResult { PlcName = config.PlcName, Ip = config.Ip };
|
||
Plc plc = null;
|
||
|
||
try
|
||
{
|
||
// 2. 初始化PLC客户端
|
||
plc = CreatePlcClient(CpuType.S71500, config.Ip, config.Rack, config.Slot);
|
||
|
||
// 3. 带超时的连接测试（精简逻辑）
|
||
var connectTask = OpenPlcConnectionAsync(plc);
|
||
if (await Task.WhenAny(connectTask, Task.Delay(_globalConfig.ReadWriteTimeout, cancellationToken)) != connectTask)
|
||
{
|
||
result.ConnectSuccess = false;
|
||
result.ConnectMessage = $"连接超时（{_globalConfig.ReadWriteTimeout}ms）";
|
||
return result;
|
||
}
|
||
await connectTask;
|
||
|
||
// 4. 连接状态校验（精简分支）
|
||
if (!plc.IsConnected)
|
||
{
|
||
result.ConnectSuccess = false;
|
||
result.ConnectMessage = "连接失败（PLC未返回连接状态）";
|
||
return result;
|
||
}
|
||
result.ConnectSuccess = true;
|
||
result.ConnectMessage = "连接成功";
|
||
|
||
const string TestAddress = "DB1010.DBB238";
|
||
if (!string.IsNullOrWhiteSpace(TestAddress))
|
||
{
|
||
// 读取测试
|
||
try
|
||
{
|
||
var readValue = await Task.Run(() => plc.Read(TestAddress), cancellationToken);
|
||
result.ReadSuccess = true;
|
||
result.ReadValue = FormatPlcValue(readValue);
|
||
result.ReadMessage = "通用地址读取成功";
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
result.ReadSuccess = false;
|
||
result.ReadMessage = $"通用地址读取失败：{ex.Message}";
|
||
}
|
||
|
||
// 写入测试
|
||
try
|
||
{
|
||
bool writeOk = await Task.Run(() => WritePlcValue(plc, TestAddress, "1"), cancellationToken);
|
||
result.WriteSuccess = writeOk;
|
||
result.WriteMessage = writeOk ? "写入成功" : "写入失败（值类型与地址不匹配）";
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
result.WriteSuccess = false;
|
||
result.WriteMessage = $"写入失败：{ex.Message}";
|
||
}
|
||
}
|
||
|
||
// 6. OP070-1专属状态读取（删除双层判断+内联转换逻辑）
|
||
if (config.PlcName == "OP070-1")
|
||
{
|
||
try
|
||
{
|
||
int runStatus = await ReadPlcIntAsync(plc, _op070_1IntMap["运行状态"]);
|
||
int machineModel = await ReadPlcIntAsync(plc, _op070_1IntMap["设备模式"]);
|
||
int onlineStatus = await ReadPlcIntAsync(plc, _op070_1IntMap["设备在线状态"]);
|
||
int produceModel = await ReadPlcIntAsync(plc, _op070_1IntMap["生产模式"]);
|
||
|
||
result.RunStatus = runStatus switch { 1 => "空闲", 2 => "运行中", 3 => "故障", _ => $"未知({runStatus})" };
|
||
result.MachineModel = machineModel switch { 1 => "空模式", 2 => "手动", 4 => "初始化", 8 => "自动", 16 => "CycleStop", _ => $"未知({machineModel})" };
|
||
result.OnLineStatus = onlineStatus == 1 ? "离线" : (onlineStatus == 0 ? "在线" : $"未知({onlineStatus})");
|
||
result.ProduceModel = produceModel switch { 1 => "正常模式", 2 => "清线模式", 4 => "返工模式", 8 => "换型模式", 16 => "预热模式", _ => $"未知({produceModel})" };
|
||
|
||
result.ReadMessage = $"{result.ReadMessage}; OP070-1状态读取成功";
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
result.RunStatus = result.MachineModel = result.OnLineStatus = result.ProduceModel = "读取失败";
|
||
result.ReadMessage = $"{result.ReadMessage}; OP070-1状态读取失败：{ex.Message}";
|
||
}
|
||
}
|
||
}
|
||
catch (OperationCanceledException)
|
||
{
|
||
result.ConnectSuccess = false;
|
||
result.ConnectMessage = "测试被取消";
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
result.ConnectSuccess = false;
|
||
result.ConnectMessage = $"连接异常：{ex.Message}";
|
||
}
|
||
finally
|
||
{
|
||
ReleasePlcConnection(plc);
|
||
}
|
||
|
||
return result;
|
||
}
|
||
|
||
/// <summary>
|
||
/// 批量测试配置文件中所有PLC的读写功能
|
||
/// </summary>
|
||
/// <param name="cancellationToken">取消令牌</param>
|
||
/// <returns>所有PLC的测试结果列表</returns>
|
||
public async Task<List<PlcTestResult>> BatchTestAllPlcAsync(CancellationToken cancellationToken = default)
|
||
{
|
||
if (_plcConfigs == null || _plcConfigs.Count == 0)
|
||
throw new InvalidOperationException("未从配置文件加载到任何PLC参数，请检查PlcConfigs配置");
|
||
|
||
// 并行测试所有PLC（带最大并行度限制，避免资源耗尽）
|
||
var testTasks = _plcConfigs
|
||
.Select(config => TestSinglePlcAsync(config, cancellationToken))
|
||
.ToList();
|
||
|
||
var results = await Task.WhenAll(testTasks);
|
||
return results.ToList();
|
||
}
|
||
|
||
/// <summary>
|
||
/// 单独读取指定PLC的某个地址数据
|
||
/// </summary>
|
||
/// <param name="ip">PLC的IP地址</param>
|
||
/// <param name="rack">机架号</param>
|
||
/// <param name="slot">槽位号</param>
|
||
/// <param name="address">读取地址（如DB1.DBD0）</param>
|
||
/// <param name="cpuType">PLC型号</param>
|
||
/// <returns>读取结果（成功状态、值、消息）</returns>
|
||
public async Task<(bool Success, string Value, string Message)> ReadPlcDataAsync(
|
||
string ip,
|
||
short rack,
|
||
short slot,
|
||
string address,
|
||
CpuType cpuType = CpuType.S71500)
|
||
{
|
||
// 参数校验
|
||
if (string.IsNullOrWhiteSpace(ip))
|
||
return (false, "", "PLC IP地址不能为空");
|
||
if (string.IsNullOrWhiteSpace(address))
|
||
return (false, "", "读取地址不能为空");
|
||
|
||
Plc plc = null;
|
||
try
|
||
{
|
||
plc = CreatePlcClient(cpuType, ip, rack, slot);
|
||
await OpenPlcConnectionAsync(plc);
|
||
|
||
if (!plc.IsConnected)
|
||
return (false, "", "PLC连接失败，请检查IP/机架号/槽位号是否正确");
|
||
|
||
var value = await Task.Run(() => plc.Read(address));
|
||
return (true, FormatPlcValue(value), "读取成功");
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
return (false, "", $"读取失败：{ex.Message}");
|
||
}
|
||
finally
|
||
{
|
||
ReleasePlcConnection(plc);
|
||
}
|
||
}
|
||
|
||
/// <summary>
|
||
/// 单独写入数据到指定PLC的某个地址
|
||
/// </summary>
|
||
/// <param name="ip">PLC的IP地址</param>
|
||
/// <param name="rack">机架号</param>
|
||
/// <param name="slot">槽位号</param>
|
||
/// <param name="address">写入地址（如DB1.DBD0）</param>
|
||
/// <param name="valueStr">写入的值（字符串格式）</param>
|
||
/// <param name="cpuType">PLC型号</param>
|
||
/// <returns>写入结果（成功状态、消息）</returns>
|
||
public async Task<(bool Success, string Message)> WritePlcDataAsync(
|
||
string ip,
|
||
short rack,
|
||
short slot,
|
||
string address,
|
||
string valueStr,
|
||
CpuType cpuType = CpuType.S71500)
|
||
{
|
||
// 参数校验
|
||
if (string.IsNullOrWhiteSpace(ip))
|
||
return (false, "PLC IP地址不能为空");
|
||
if (string.IsNullOrWhiteSpace(address))
|
||
return (false, "写入地址不能为空");
|
||
if (valueStr == null) // 允许空字符串（如清空值）
|
||
return (false, "写入值不能为null");
|
||
|
||
Plc plc = null;
|
||
try
|
||
{
|
||
plc = CreatePlcClient(cpuType, ip, rack, slot);
|
||
await OpenPlcConnectionAsync(plc);
|
||
|
||
if (!plc.IsConnected)
|
||
return (false, "PLC连接失败，请检查IP/机架号/槽位号是否正确");
|
||
|
||
bool writeOk = await Task.Run(() => WritePlcValue(plc, address, valueStr));
|
||
return (writeOk, writeOk ? "写入成功" : "写入失败（值类型与地址不匹配）");
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
return (false, $"写入失败：{ex.Message}");
|
||
}
|
||
finally
|
||
{
|
||
ReleasePlcConnection(plc);
|
||
}
|
||
}
|
||
#endregion
|
||
|
||
#region 私有辅助方法
|
||
/// <summary>
|
||
/// 创建PLC客户端实例（统一配置超时）
|
||
/// </summary>
|
||
private Plc CreatePlcClient(CpuType cpuType, string ip, short rack, short slot)
|
||
{
|
||
var plc = new Plc(cpuType, ip, rack, slot)
|
||
{
|
||
ReadTimeout = _globalConfig.ReadWriteTimeout,
|
||
WriteTimeout = _globalConfig.ReadWriteTimeout
|
||
};
|
||
return plc;
|
||
}
|
||
|
||
/// <summary>
|
||
/// 异步打开PLC连接（封装同步方法为异步）
|
||
/// </summary>
|
||
// 优化后的OpenPlcConnectionAsync
|
||
private async Task<bool> OpenPlcConnectionAsync(Plc plc)
|
||
{
|
||
if (plc == null) return false;
|
||
try
|
||
{
|
||
// 带超时的连接操作
|
||
var openTask = Task.Run(() => plc.Open());
|
||
if (await Task.WhenAny(openTask, Task.Delay(_globalConfig.ReadWriteTimeout)) != openTask)
|
||
{
|
||
return false;
|
||
}
|
||
await openTask;
|
||
return plc.IsConnected;
|
||
}
|
||
catch
|
||
{
|
||
return false;
|
||
}
|
||
}
|
||
|
||
/// <summary>
|
||
/// 释放PLC连接（安全关闭+资源释放）
|
||
/// </summary>
|
||
private void ReleasePlcConnection(Plc plc)
|
||
{
|
||
if (plc == null) return;
|
||
|
||
try
|
||
{
|
||
if (plc.IsConnected)
|
||
plc.Close();
|
||
// 正确释放PLC实例（适配S7.Net显式实现IDisposable）
|
||
if (plc is IDisposable disposable)
|
||
disposable.Dispose();
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"PLC连接关闭失败：{ex.Message}");
|
||
}
|
||
// 移除finally中的Dispose()，避免误释放服务
|
||
}
|
||
|
||
/// <summary>
|
||
/// 按业务规则解析PLC字符串（支持中文GBK编码）
|
||
/// </summary>
|
||
private async Task<string> ReadPlcStringAsync(Plc plc, string addr, int maxLen)
|
||
{
|
||
try
|
||
{
|
||
// 解析地址：DB1010.DBB50 → DB编号1010 + 起始字节50
|
||
var parts = addr.Split('.', StringSplitOptions.RemoveEmptyEntries);
|
||
if (parts.Length != 2)
|
||
return string.Empty;
|
||
|
||
if (!int.TryParse(parts[0].Replace("DB", ""), out int dbNum) || dbNum <= 0)
|
||
return string.Empty;
|
||
|
||
if (!int.TryParse(parts[1].Replace("DBB", ""), out int startByte) || startByte < 0)
|
||
return string.Empty;
|
||
|
||
// 读取字节数组
|
||
var bytes = await Task.Run(() => plc.ReadBytes(DataType.DataBlock, dbNum, startByte, maxLen));
|
||
if (bytes == null || bytes.Length < 3)
|
||
return string.Empty;
|
||
|
||
// 严格按规则解析：bytes[0]=总长度(备用)、bytes[1]=有效长度、bytes[2+]=内容
|
||
int validLen = Math.Clamp(bytes[1], 0, bytes.Length - 2);
|
||
if (validLen <= 0)
|
||
return string.Empty;
|
||
|
||
// 提取有效内容并转字符串（GBK编码支持中文）
|
||
var contentBytes = new byte[validLen];
|
||
Array.Copy(bytes, 2, contentBytes, 0, validLen);
|
||
return Encoding.GetEncoding("GBK").GetString(contentBytes).Trim('\0', ' ', '\t');
|
||
}
|
||
catch
|
||
{
|
||
return string.Empty;
|
||
}
|
||
}
|
||
|
||
/// <summary>
|
||
/// 修复版：异步读取PLC整数（DBW地址，16位短整型）
|
||
/// 增强类型兼容、异常日志、地址校验
|
||
/// </summary>
|
||
/// <param name="plc">PLC客户端实例</param>
|
||
/// <param name="addr">读取地址（如DB1010.DBW226）</param>
|
||
/// <returns>解析后的整数值，读取失败返回0</returns>
|
||
private async Task<int> ReadPlcIntAsync(Plc plc, string addr)
|
||
{
|
||
// 1. 地址和PLC实例有效性校验
|
||
if (plc == null)
|
||
{
|
||
Console.WriteLine($"PLC整数读取失败：PLC实例为空（地址：{addr}）");
|
||
return 0;
|
||
}
|
||
|
||
if (string.IsNullOrWhiteSpace(addr))
|
||
{
|
||
Console.WriteLine("PLC整数读取失败：读取地址为空");
|
||
return 0;
|
||
}
|
||
|
||
try
|
||
{
|
||
// 2. 异步读取（避免同步阻塞，适配整体异步上下文）
|
||
var val = await Task.Run(() => plc.Read(addr));
|
||
|
||
// 调试日志：输出原始值和类型，便于排查问题
|
||
Console.WriteLine($"PLC地址[{addr}]原始读取值：{val ?? "null"}，类型：{val?.GetType().Name ?? "未知"}");
|
||
|
||
// 3. 增强类型兼容（覆盖PLC可能返回的所有整数类型）
|
||
return val switch
|
||
{
|
||
short s => s, // 16位短整型（DBW默认类型）
|
||
int i => i, // 32位整型（兼容返回）
|
||
uint ui => (int)ui, // 无符号32位整型
|
||
byte b => b, // 8位字节型
|
||
ushort us => us, // 无符号16位整型
|
||
long l => (int)l, // 64位整型（截断为32位）
|
||
ulong ul => (int)ul, // 无符号64位整型（截断为32位）
|
||
float f => (int)f, // 浮点数转整型（兼容PLC数值存储）
|
||
double d => (int)d, // 双精度浮点数转整型
|
||
_ => 0 // 未知类型返回0
|
||
};
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
// 4. 输出详细异常日志，便于定位问题
|
||
Console.WriteLine($"PLC整数读取失败（地址：{addr}）：{ex.Message}，堆栈：{ex.StackTrace}");
|
||
return 0;
|
||
}
|
||
}
|
||
private async Task<int> ReadPlcDIntAsync(Plc plc, string addr)
|
||
{
|
||
if (plc == null || string.IsNullOrWhiteSpace(addr))
|
||
{
|
||
Console.WriteLine($"DInt读取失败：参数无效（地址：{addr}）");
|
||
return 0;
|
||
}
|
||
try
|
||
{
|
||
var val = await Task.Run(() => plc.Read(addr));
|
||
Console.WriteLine($"DInt地址[{addr}] 原始值：{val}，类型：{val?.GetType().Name}");
|
||
return val switch
|
||
{
|
||
int i => i,
|
||
long l => (int)l,
|
||
uint ui => (int)ui,
|
||
ulong ul => (int)ul,
|
||
_ => 0
|
||
};
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"DInt读取失败（地址：{addr}）：{ex.Message}");
|
||
return 0;
|
||
}
|
||
}
|
||
|
||
private async Task<float> ReadPlcRealAsync(Plc plc, string addr)
|
||
{
|
||
if (plc == null || string.IsNullOrWhiteSpace(addr))
|
||
{
|
||
Console.WriteLine($"Real读取失败：参数无效（地址：{addr}）");
|
||
return 0.0f;
|
||
}
|
||
try
|
||
{
|
||
var val = await Task.Run(() => plc.Read(addr));
|
||
Console.WriteLine($"Real地址[{addr}] 原始值：{val}，类型：{val?.GetType().Name}");
|
||
return val switch
|
||
{
|
||
float f => f,
|
||
double d => (float)d,
|
||
int i => i,
|
||
_ => 0.0f
|
||
};
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"Real读取失败（地址：{addr}）：{ex.Message}");
|
||
return 0.0f;
|
||
}
|
||
}
|
||
/// <summary>
|
||
/// 格式化PLC读取的值，转为友好的字符串
|
||
/// </summary>
|
||
private string FormatPlcValue(object value)
|
||
{
|
||
if (value == null) return "空值";
|
||
|
||
return value switch
|
||
{
|
||
float f => f.ToString("0.000"), // 浮点数保留3位小数
|
||
double d => d.ToString("0.000"), // 补充双精度浮点数支持
|
||
short s => s.ToString(), // 16位整数
|
||
byte b => b.ToString(), // 8位整数
|
||
bool b => b.ToString(), // 布尔值
|
||
int i => i.ToString(), // 32位整数
|
||
uint ui => ui.ToString(), // 无符号32位整数
|
||
long l => l.ToString(), // 64位整数
|
||
ulong ul => ul.ToString(), // 无符号64位整数
|
||
_ => value.ToString() // 其他类型直接转字符串
|
||
};
|
||
}
|
||
|
||
/// <summary>
|
||
/// 根据地址类型转换值并写入PLC
|
||
/// </summary>
|
||
private bool WritePlcValue(Plc plc, string address, string valueStr)
|
||
{
|
||
// 双字（DBD/DD）：浮点数或32位整数
|
||
if (address.Contains("DBD") || address.Contains("DD"))
|
||
{
|
||
if (float.TryParse(valueStr, out float f))
|
||
{
|
||
plc.Write(address, f);
|
||
return true;
|
||
}
|
||
else if (int.TryParse(valueStr, out int i))
|
||
{
|
||
plc.Write(address, i);
|
||
return true;
|
||
}
|
||
}
|
||
// 字（DBW/DW）：16位整数
|
||
else if (address.Contains("DBW") || address.Contains("DW"))
|
||
{
|
||
if (short.TryParse(valueStr, out short s))
|
||
{
|
||
plc.Write(address, s);
|
||
return true;
|
||
}
|
||
}
|
||
// 字节（DBB/DB）：8位整数
|
||
else if (address.Contains("DBB") || address.Contains("DB"))
|
||
{
|
||
if (byte.TryParse(valueStr, out byte b))
|
||
{
|
||
plc.Write(address, b);
|
||
return true;
|
||
}
|
||
}
|
||
// 位（DBX）：布尔值（兼容0/1输入）
|
||
else if (address.Contains("DBX"))
|
||
{
|
||
if (bool.TryParse(valueStr, out bool bl))
|
||
{
|
||
plc.Write(address, bl);
|
||
return true;
|
||
}
|
||
else if (valueStr == "0")
|
||
{
|
||
plc.Write(address, false);
|
||
return true;
|
||
}
|
||
else if (valueStr == "1")
|
||
{
|
||
plc.Write(address, true);
|
||
return true;
|
||
}
|
||
}
|
||
|
||
// 不匹配的类型
|
||
return false;
|
||
}
|
||
#endregion
|
||
|
||
#region 资源释放
|
||
/// <summary>
|
||
/// 实现IDisposable接口，释放资源
|
||
/// </summary>
|
||
public void Dispose()
|
||
{
|
||
Dispose(true);
|
||
GC.SuppressFinalize(this); // 通知GC无需调用终结器
|
||
}
|
||
|
||
/// <summary>
|
||
/// 实际释放资源的逻辑（区分托管/非托管资源）
|
||
/// </summary>
|
||
/// <param name="disposing">是否释放托管资源</param>
|
||
protected virtual void Dispose(bool disposing)
|
||
{
|
||
if (_disposed) return; // 避免重复释放
|
||
|
||
// 释放托管资源
|
||
if (disposing)
|
||
{
|
||
// 此处无长期持有的PLC连接，若有可在此统一释放
|
||
}
|
||
|
||
// 标记为已释放
|
||
_disposed = true;
|
||
}
|
||
|
||
/// <summary>
|
||
/// 终结器（防忘记手动Dispose）
|
||
/// </summary>
|
||
~PlcService()
|
||
{
|
||
Dispose(false);
|
||
}
|
||
#endregion
|
||
|
||
private List<PlcConfig> initPlcConfigs(List<PlcConfig> result)
|
||
{
|
||
var defaultResult = result ?? new List<PlcConfig>();
|
||
try
|
||
{
|
||
List<PlcConfig> query = _plantWorkstationService.Queryable()
|
||
.Where(it => it.Status == 1)
|
||
.Select(it => new PlcConfig
|
||
{
|
||
PlcName = it.WorkstationCode,
|
||
Ip = it.PlcIP,
|
||
Rack = (short)it.Rack, // 直接强制转换（it.Rack是int，非空）
|
||
Slot = (short)it.Slot // 同理，it.Slot是int，非空
|
||
})
|
||
.ToList();
|
||
return query.Count > 0 ? query : defaultResult;
|
||
}
|
||
catch (Exception ex)
|
||
{
|
||
Console.WriteLine($"初始化PLC配置异常：{ex.Message}");
|
||
return defaultResult;
|
||
}
|
||
}
|
||
}
|
||
} |