643 lines
25 KiB
C#
643 lines
25 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 RIZO.Admin.WebApi.PLC.Model;
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using RIZO.Common;
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using S7.Net;
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using System;
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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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// PLC地址映射（严格匹配业务地址清单）
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private readonly Dictionary<string, (string Addr, int Len)> _plcStringMap = new()
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{
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{ "LineCode", ("DB1010.DBB50", 14) },
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{ "IpStation", ("DB1010.DBB64", 16) },
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{ "ProductCode", ("DB1010.DBB80", 16) },
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{ "ProductName", ("DB1010.DBB94", 50) },
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{ "PartCode", ("DB1010.DBB144", 16) },
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{ "PartName", ("DB1010.DBB158", 28) },
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{ "ProcessName", ("DB1010.DBB186", 12) },
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{ "ParamName", ("DB1010.DBB198", 12) },
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{ "ParamValue", ("DB1010.DBB210", 14) },
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{ "Static16", ("DB1010.DBB238", 68) }
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};
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private readonly Dictionary<string, string> _plcIntMap = new()
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{
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{ "QualificationFlag", "DB1010.DBW224" },
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{ "ReworkFlag", "DB1010.DBW226" },
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{ "ProductionCycle", "DB1010.DBW228" },
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{ "AutoManual", "DB1010.DBW230" },
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{ "RunStatus", "DB1010.DBW232" }
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};
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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（严格匹配业务地址和解析规则）
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/// </summary>
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/// <param name="ip">PLC IP地址</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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short rack,
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short slot,
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CpuType cpuType = CpuType.S71500)
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{
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// 参数校验
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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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Plc plc = null;
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try
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{
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// 初始化PLC连接
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plc = CreatePlcClient(cpuType, ip, rack, slot);
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await OpenPlcConnectionAsync(plc);
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if (!plc.IsConnected)
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return (false, null, "PLC连接失败");
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// 构建生产数据实体
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var prodData = new PlcProductionData
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{
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PlcIp = ip.Trim(),
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OccurTime = DateTime.Now, // MES自配时间
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// 字符串字段（按规则解析）
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LineCode = await ReadPlcStringAsync(plc, _plcStringMap["LineCode"].Addr, _plcStringMap["LineCode"].Len),
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ProductCode = await ReadPlcStringAsync(plc, _plcStringMap["ProductCode"].Addr, _plcStringMap["ProductCode"].Len),
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ProductName = await ReadPlcStringAsync(plc, _plcStringMap["ProductName"].Addr, _plcStringMap["ProductName"].Len),
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PartCode = await ReadPlcStringAsync(plc, _plcStringMap["PartCode"].Addr, _plcStringMap["PartCode"].Len),
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PartName = await ReadPlcStringAsync(plc, _plcStringMap["PartName"].Addr, _plcStringMap["PartName"].Len),
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ProcessName = await ReadPlcStringAsync(plc, _plcStringMap["ProcessName"].Addr, _plcStringMap["ProcessName"].Len),
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ParamName = await ReadPlcStringAsync(plc, _plcStringMap["ParamName"].Addr, _plcStringMap["ParamName"].Len),
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ParamValue = await ReadPlcStringAsync(plc, _plcStringMap["ParamValue"].Addr, _plcStringMap["ParamValue"].Len),
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// 修复：改为异步读取整数，确保类型兼容
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//合格标志（0默认，1合格，2不合格）
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QualificationFlag = (await ReadPlcIntAsync(plc, _plcIntMap["QualificationFlag"])).ToString(),
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//返工标志（0正常，1返工）
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ReworkFlag = (await ReadPlcIntAsync(plc, _plcIntMap["ReworkFlag"])).ToString(),
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//设备自动手动：0-自动，1-手动
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AutoManual = (await ReadPlcIntAsync(plc, _plcIntMap["AutoManual"])),
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//运行状态:1正常，2异常
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RunStatus = (await ReadPlcIntAsync(plc, _plcIntMap["AutoManual"])),
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//生产节拍秒
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ProductionCycle = await ReadPlcIntAsync(plc, _plcIntMap["ProductionCycle"])
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};
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// 空值兜底（避免入库报错）
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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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// 保存生产数据到MES数据库
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plcProductionDataService.AddPlcProductionData(prodData);
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return (true, prodData, "生产数据读取成功");
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}
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catch (Exception ex)
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{
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return (false, null, $"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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ReleasePlcConnection(plc);
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}
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}
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/// <summary>
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/// 测试单个PLC的连接、读、写功能
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/// </summary>
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/// <param name="config">单个PLC的配置参数</param>
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/// <param name="cancellationToken">取消令牌</param>
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/// <returns>测试结果</returns>
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public async Task<PlcTestResult> TestSinglePlcAsync(PlcConfig config, CancellationToken cancellationToken = default)
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{
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// 参数校验
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if (config == null)
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throw new ArgumentNullException(nameof(config), "PLC测试配置不能为空");
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if (string.IsNullOrWhiteSpace(config.Ip))
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return new PlcTestResult { PlcName = config.PlcName, Ip = config.Ip, ConnectSuccess = false, ConnectMessage = "IP地址为空" };
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var result = new PlcTestResult
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{
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PlcName = config.PlcName,
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Ip = config.Ip
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};
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Plc plc = null;
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try
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{
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// 初始化PLC客户端
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plc = CreatePlcClient(CpuType.S71500, config.Ip, config.Rack, config.Slot);
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// 带超时的连接测试
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var connectTask = OpenPlcConnectionAsync(plc);
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if (await Task.WhenAny(connectTask, Task.Delay(_globalConfig.ReadWriteTimeout, cancellationToken)) != connectTask)
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{
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result.ConnectSuccess = false;
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result.ConnectMessage = $"连接超时（{_globalConfig.ReadWriteTimeout}ms）";
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return result;
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}
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await connectTask;
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// 检查连接状态
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if (plc.IsConnected)
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{
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result.ConnectSuccess = true;
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result.ConnectMessage = "连接成功";
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}
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else
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{
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result.ConnectSuccess = false;
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result.ConnectMessage = "连接失败（PLC未返回连接状态）";
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return result;
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}
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string TestAddress = "DB1010.DBB238"; // 测试地址
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// 读取测试
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if (!string.IsNullOrWhiteSpace(TestAddress))
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{
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try
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{
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var readValue = await Task.Run(() => plc.Read(TestAddress), cancellationToken);
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result.ReadSuccess = true;
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result.ReadValue = FormatPlcValue(readValue);
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result.ReadMessage = "读取成功";
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}
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catch (Exception ex)
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{
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result.ReadSuccess = false;
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result.ReadMessage = $"读取失败：{ex.Message}";
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}
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}
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// 写入测试
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if (!string.IsNullOrWhiteSpace(TestAddress) && !string.IsNullOrWhiteSpace(TestAddress))
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{
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try
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{
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bool writeOk = await Task.Run(() => WritePlcValue(plc, TestAddress, "1"), cancellationToken);
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result.WriteSuccess = writeOk;
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result.WriteMessage = writeOk ? "写入成功" : "写入失败（值类型与地址不匹配）";
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}
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catch (Exception ex)
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{
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result.WriteSuccess = false;
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result.WriteMessage = $"写入失败：{ex.Message}";
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}
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}
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}
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catch (OperationCanceledException)
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{
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result.ConnectSuccess = false;
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result.ConnectMessage = "测试被取消";
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}
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catch (Exception ex)
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{
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result.ConnectSuccess = false;
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result.ConnectMessage = $"连接异常：{ex.Message}";
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}
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finally
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{
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ReleasePlcConnection(plc);
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}
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return result;
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}
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/// <summary>
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/// 批量测试配置文件中所有PLC的读写功能
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/// </summary>
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/// <param name="cancellationToken">取消令牌</param>
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/// <returns>所有PLC的测试结果列表</returns>
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public async Task<List<PlcTestResult>> BatchTestAllPlcAsync(CancellationToken cancellationToken = default)
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{
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if (_plcConfigs == null || _plcConfigs.Count == 0)
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throw new InvalidOperationException("未从配置文件加载到任何PLC参数，请检查PlcConfigs配置");
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// 并行测试所有PLC（带最大并行度限制，避免资源耗尽）
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var testTasks = _plcConfigs
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.Select(config => TestSinglePlcAsync(config, cancellationToken))
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.ToList();
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var results = await Task.WhenAll(testTasks);
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return results.ToList();
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}
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/// <summary>
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/// 单独读取指定PLC的某个地址数据
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/// </summary>
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/// <param name="ip">PLC的IP地址</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="address">读取地址（如DB1.DBD0）</param>
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/// <param name="cpuType">PLC型号</param>
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/// <returns>读取结果（成功状态、值、消息）</returns>
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public async Task<(bool Success, string Value, string Message)> ReadPlcDataAsync(
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string ip,
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short rack,
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short slot,
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string address,
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CpuType cpuType = CpuType.S71500)
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{
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// 参数校验
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if (string.IsNullOrWhiteSpace(ip))
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return (false, "", "PLC IP地址不能为空");
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if (string.IsNullOrWhiteSpace(address))
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return (false, "", "读取地址不能为空");
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Plc plc = null;
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try
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{
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plc = CreatePlcClient(cpuType, ip, rack, slot);
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await OpenPlcConnectionAsync(plc);
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if (!plc.IsConnected)
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return (false, "", "PLC连接失败，请检查IP/机架号/槽位号是否正确");
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var value = await Task.Run(() => plc.Read(address));
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return (true, FormatPlcValue(value), "读取成功");
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}
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catch (Exception ex)
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{
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return (false, "", $"读取失败：{ex.Message}");
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}
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finally
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{
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ReleasePlcConnection(plc);
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}
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}
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/// <summary>
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/// 单独写入数据到指定PLC的某个地址
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/// </summary>
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/// <param name="ip">PLC的IP地址</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="address">写入地址（如DB1.DBD0）</param>
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/// <param name="valueStr">写入的值（字符串格式）</param>
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/// <param name="cpuType">PLC型号</param>
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/// <returns>写入结果（成功状态、消息）</returns>
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public async Task<(bool Success, string Message)> WritePlcDataAsync(
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string ip,
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short rack,
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short slot,
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string address,
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string valueStr,
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CpuType cpuType = CpuType.S71500)
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{
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// 参数校验
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if (string.IsNullOrWhiteSpace(ip))
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return (false, "PLC IP地址不能为空");
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if (string.IsNullOrWhiteSpace(address))
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return (false, "写入地址不能为空");
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if (valueStr == null) // 允许空字符串（如清空值）
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return (false, "写入值不能为null");
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Plc plc = null;
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try
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{
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plc = CreatePlcClient(cpuType, ip, rack, slot);
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await OpenPlcConnectionAsync(plc);
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if (!plc.IsConnected)
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return (false, "PLC连接失败，请检查IP/机架号/槽位号是否正确");
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bool writeOk = await Task.Run(() => WritePlcValue(plc, address, valueStr));
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return (writeOk, writeOk ? "写入成功" : "写入失败（值类型与地址不匹配）");
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}
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catch (Exception ex)
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{
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return (false, $"写入失败：{ex.Message}");
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}
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finally
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{
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ReleasePlcConnection(plc);
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}
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}
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#endregion
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#region 私有辅助方法
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/// <summary>
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/// 创建PLC客户端实例（统一配置超时）
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/// </summary>
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private Plc CreatePlcClient(CpuType cpuType, string ip, short rack, short slot)
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{
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var plc = new Plc(cpuType, ip, rack, slot)
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{
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ReadTimeout = _globalConfig.ReadWriteTimeout,
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WriteTimeout = _globalConfig.ReadWriteTimeout
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};
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return plc;
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}
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/// <summary>
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/// 异步打开PLC连接（封装同步方法为异步）
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/// </summary>
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private async Task OpenPlcConnectionAsync(Plc plc)
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{
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if (plc == null) return;
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await Task.Run(() => plc.Open());
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}
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/// <summary>
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/// 释放PLC连接（安全关闭+资源释放）
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/// </summary>
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private void ReleasePlcConnection(Plc plc)
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{
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if (plc == null) return;
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try
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{
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if (plc.IsConnected)
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plc.Close();
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}
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catch (Exception ex)
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{
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// 记录日志（此处简化为控制台输出，实际项目替换为日志框架）
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Console.WriteLine($"PLC连接关闭失败：{ex.Message}");
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}
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finally
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{
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Dispose();
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}
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}
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/// <summary>
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/// 按业务规则解析PLC字符串（支持中文GBK编码）
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/// </summary>
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private async Task<string> ReadPlcStringAsync(Plc plc, string addr, int maxLen)
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{
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try
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{
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// 解析地址：DB1010.DBB50 → DB编号1010 + 起始字节50
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var parts = addr.Split('.', StringSplitOptions.RemoveEmptyEntries);
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if (parts.Length != 2)
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return string.Empty;
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if (!int.TryParse(parts[0].Replace("DB", ""), out int dbNum) || dbNum <= 0)
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return string.Empty;
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if (!int.TryParse(parts[1].Replace("DBB", ""), out int startByte) || startByte < 0)
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return string.Empty;
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// 读取字节数组
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var bytes = await Task.Run(() => plc.ReadBytes(DataType.DataBlock, dbNum, startByte, maxLen));
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if (bytes == null || bytes.Length < 3)
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return string.Empty;
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// 严格按规则解析：bytes[0]=总长度(备用)、bytes[1]=有效长度、bytes[2+]=内容
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int validLen = Math.Clamp(bytes[1], 0, bytes.Length - 2);
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if (validLen <= 0)
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return string.Empty;
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// 提取有效内容并转字符串（GBK编码支持中文）
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var contentBytes = new byte[validLen];
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Array.Copy(bytes, 2, contentBytes, 0, validLen);
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return Encoding.GetEncoding("GBK").GetString(contentBytes).Trim('\0', ' ', '\t');
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}
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catch
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{
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return string.Empty;
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}
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}
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/// <summary>
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/// 修复版：异步读取PLC整数（DBW地址，16位短整型）
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/// 增强类型兼容、异常日志、地址校验
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/// </summary>
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/// <param name="plc">PLC客户端实例</param>
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/// <param name="addr">读取地址（如DB1010.DBW226）</param>
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/// <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;
|
||
}
|
||
}
|
||
|
||
/// <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;
|
||
}
|
||
}
|
||
}
|
||
} |