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异常情况兜底不中断信号流程

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This commit is contained in:
XingCheng3
2026-05-12 15:55:42 +08:00
parent 2d5f260201
commit 24e1fa423a
3 changed files with 164 additions and 65 deletions
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163
SCADA/Funtion/MIS_Funtion.cs
View File

@@ -152,6 +152,18 @@ namespace MesWork
return !string.IsNullOrWhiteSpace(productNo);
}
/// <summary>
/// 业务资料异常时只记录兜底日志，PLC交互仍尽量继续，避免现场流程被MES辅助数据卡住。
/// </summary>
private void LogWeighingFallback(string opName, string productNo, string flowName, string reason, long AID)
{
string safeProductNo = string.IsNullOrWhiteSpace(productNo) ? "未知产品" : productNo;
string msg = $"【{opName}】兜底放行：产品={safeProductNo}，流程={flowName}，原因={reason}";
B_DB_Opera.SaveLog_Response(msg, AID);
WeighingPage?.AppendLog($"[{opName}] {msg}");
}
/// <summary>
/// 处理请求工作信号 (tagTypeCodeID=44)
/// 流程：读取工件信息 → 查询参数 → 写过站记录 → 按类型处理称重记录 → 回写允许工作
@@ -166,7 +178,8 @@ namespace MesWork
string modelNo = PLC_R.GetString_CleanGarbled(ReadPLC(11, opName)); // 机型号
string orderNo = PLC_R.GetString_CleanGarbled(ReadPLC(39, opName)); // 工单号
string palletNo = PLC_R.GetString_CleanGarbled(ReadPLC(80, opName)); // 托盘号
// 解析代码串格式: 0/DHN2.5Q0219-36/D426E016767 或 DHH02K0014-400/B726E00584555
string rawCodeBlock = engineNo;
// 解析代码串格式: 0/DHN2.5Q0219-36/D426E016767 或 DHH02K0014-400/B726E00584555
if (TryConvertCodeBlockData(engineNo, out string parsedOrderNo, out string parsedProductNo))
{
if (!string.IsNullOrWhiteSpace(parsedOrderNo))
@@ -175,19 +188,21 @@ namespace MesWork
}
engineNo = parsedProductNo;
int stIdx = WeighingPage?.GetStationIndex(opName) ?? 1;
if (!B_DB_Opera.QueryWorkpieceByOrderNo(orderNo, out string matchedModelNo, out decimal addOilQty, out decimal extractOilQty, out decimal density,
out decimal residualOilUpperLimit, out decimal residualOilLowerLimit)) // 根据订货号 查询基本参数
{
WritePLC_IF(112, opName, 3); // 报警代码=3，机型错误
B_DB_Opera.SaveLog_Response($"【{opName}】工件管理中未找到订货号[{orderNo}]的匹配规则，发动机={engineNo}", AID);
WeighingPage?.AppendLog($"[{opName}] 订货号[{orderNo}]未匹配到工件参数");
return;
}
modelNo = matchedModelNo;
B_DB_Opera.SaveLog_Response($"【{opName}】读取工件：发动机={engineNo}，机型={modelNo}，订货号={orderNo}，托盘={palletNo}", AID);
WeighingPage?.UpdateStationInfo(stIdx, engineNo, modelNo, orderNo);
WeighingPage?.AppendLog($"[{opName}] 读取工件：{engineNo}，机型={modelNo}");
int stIdx = WeighingPage?.GetStationIndex(opName) ?? 1;
if (!B_DB_Opera.QueryWorkpieceByOrderNo(orderNo, out string matchedModelNo, out decimal addOilQty, out decimal extractOilQty, out decimal density,
out decimal residualOilUpperLimit, out decimal residualOilLowerLimit)) // 根据订货号 查询基本参数
{
WritePLC_IF(112, opName, 3); // 报警代码=3，机型错误
LogWeighingFallback(opName, engineNo, "请求工作", $"订货号[{orderNo}]未匹配到工件参数，使用PLC机型[{modelNo}]继续允许工作", AID);
// 兜底机制：参数资料缺失不再卡PLC，请求保存时若无法正常更新记录会生成异常完成记录。
WritePLC_IF(66, opName, true);
CurveCollector_Start(opName, engineNo, modelNo);
return;
}
modelNo = matchedModelNo;
B_DB_Opera.SaveLog_Response($"【{opName}】读取工件：发动机={engineNo}，机型={modelNo}，订货号={orderNo}，托盘={palletNo}", AID);
WeighingPage?.UpdateStationInfo(stIdx, engineNo, modelNo, orderNo);
WeighingPage?.AppendLog($"[{opName}] 读取工件：{engineNo}，机型={modelNo}");
WeighingPage?.UpdateOilInfo(stIdx, addOilQty, extractOilQty, density, 0, 0);
string weighType = GetWeighingType(opName); // 地面/放油前/放油后
string stationName = weighType; // 工位名称直接用称重类型名
@@ -199,9 +214,7 @@ namespace MesWork
if (!B_DB_Opera.QueryWeighingBeforeOil(engineNo, out _, out decimal preWeight, out _, out _, out _))
{
WritePLC_IF(112, opName, 3);
B_DB_Opera.SaveLog_Response($"【{opName}】未找到发动机[{engineNo}]的空中称重记录", AID);
WeighingPage?.AppendLog($"[{opName}] 未找到[{engineNo}]放油前记录，进站失败");
return;
LogWeighingFallback(opName, engineNo, "请求工作-放油后", "未找到放油前记录，继续允许工作，保存时按异常放油后记录处理", AID);
}
else
{
@@ -223,8 +236,11 @@ namespace MesWork
else
{
WritePLC_IF(112, opName, 1); // 报警代码=1，获取数据失败
B_DB_Opera.SaveLog_Response($"【{opName}】码块数据转换失败：原始码值=[{engineNo}]", AID);
WeighingPage?.AppendLog($"[{opName}] 码块数据转换失败：{engineNo}");
engineNo = string.IsNullOrWhiteSpace(rawCodeBlock) ? $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}" : rawCodeBlock.Trim();
LogWeighingFallback(opName, engineNo, "请求工作", $"码块数据转换失败，原始码值=[{rawCodeBlock}]，仍允许工作", AID);
// 兜底机制：产品解析失败时仍给允许工作，后续保存阶段会按异常产品记录并判不合格。
WritePLC_IF(66, opName, true);
CurveCollector_Start(opName, engineNo, modelNo);
}
}
catch (Exception err)
@@ -251,27 +267,34 @@ namespace MesWork
{
engineNo = parsedProductNo;
}
else if (string.IsNullOrWhiteSpace(engineNo))
{
engineNo = $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}";
LogWeighingFallback(opName, engineNo, "请求保存", "保存时产品编号为空，使用临时产品号继续保存", AID);
}
if (CurveCollector_TryGetStableWeight(opName, out decimal curveWeight, out int curvePointCount, out string curveMsg))
{
weight = curveWeight; // 曲线采样点已按工具标定公式处理，稳定重量不再二次标定
B_DB_Opera.SaveLog_Response($"【{opName}】标定曲线重量={curveWeight:F3}kg，PLC锁定重量={plcWeight:F3}kg，点数={curvePointCount}", AID);
}
else
{
B_DB_Opera.SaveLog_Response($"【{opName}】曲线重量不可用，使用PLC锁定重量={plcWeight:F3}kg，原因={curveMsg}", AID);
decimal rawWeight = plcWeight;
if (!WeightCalibrationHelper.Apply(opName, rawWeight, out decimal calibratedWeight, out string calibrationFormula, out string calibrationMsg))
{
throw new Exception($"工具标定公式处理失败：{calibrationMsg}");
}
weight = calibratedWeight;
B_DB_Opera.SaveLog_Response($"【{opName}】PLC锁定重量标定：原始重量={rawWeight:F3}kg，公式={calibrationFormula}，标定后={weight:F3}kg", AID);
WeighingPage?.AppendLog($"[{opName}] PLC锁定重量标定：原始={rawWeight:F3}kg，公式={calibrationFormula}，结果={weight:F3}kg");
}
long curveWeighingRecordId = 0;
B_DB_Opera.UpdateStationComplete(engineNo, opName, weight); // 过站记录保存最终采用重量
if (CurveCollector_TryGetStableWeight(opName, out decimal curveWeight, out int curvePointCount, out string curveMsg))
{
weight = curveWeight; // 曲线采样点已按工具标定公式处理，稳定重量不再二次标定
B_DB_Opera.SaveLog_Response($"【{opName}】标定曲线重量={curveWeight:F3}kg，PLC锁定重量={plcWeight:F3}kg，点数={curvePointCount}", AID);
}
else
{
B_DB_Opera.SaveLog_Response($"【{opName}】曲线重量不可用，使用PLC锁定重量={plcWeight:F3}kg，原因={curveMsg}", AID);
decimal rawWeight = plcWeight;
if (!WeightCalibrationHelper.Apply(opName, rawWeight, out decimal calibratedWeight, out string calibrationFormula, out string calibrationMsg))
{
LogWeighingFallback(opName, engineNo, "请求保存", $"工具标定公式处理失败：{calibrationMsg}，使用PLC原始重量继续保存", AID);
calibrationFormula = "未标定兜底";
calibratedWeight = rawWeight;
}
weight = calibratedWeight;
B_DB_Opera.SaveLog_Response($"【{opName}】PLC锁定重量标定：原始重量={rawWeight:F3}kg，公式={calibrationFormula}，标定后={weight:F3}kg", AID);
WeighingPage?.AppendLog($"[{opName}] PLC锁定重量标定：原始={rawWeight:F3}kg，公式={calibrationFormula}，结果={weight:F3}kg");
}
long curveWeighingRecordId = 0;
B_DB_Opera.UpdateStationComplete(engineNo, opName, weight); // 过站记录保存最终采用重量
string weighType = GetWeighingType(opName);
decimal oilReleaseQty = 0;
decimal residualOilQty = 0;
@@ -280,29 +303,53 @@ namespace MesWork
if (weighType == "地面")
{
// 地面：查最新记录 → 放油量=重量/密度 → 标记完成
B_DB_Opera.QueryLatestRecord(opName, engineNo,
out long recordId, out _, out decimal addOil, out decimal extractOil, out decimal dens);
curveWeighingRecordId = recordId; // 曲线记录最终关联这条称重记录
oilReleaseQty = dens > 0 ? weight / dens : 0; // 地面：油桶重量/密度=放油量
residualOilQty = addOil - extractOil - oilReleaseQty; // 残油=加油-抽油-放油
B_DB_Opera.UpdateWeighingComplete(recordId, "地面", opName,
weight, oilReleaseQty, residualOilQty, waterContent, out finalQualityFlag, out qualityMsg);
B_DB_Opera.SaveLog_Response(
$"【{opName}】地面保存完成：发动机={engineNo}，重量={weight}kg，放油量={oilReleaseQty:F4}L，残油量={residualOilQty:F4}L，合格标志={finalQualityFlag}，{qualityMsg}", AID);
WeighingPage?.UpdateOilResult(WeighingPage?.GetStationIndex(opName) ?? 1, oilReleaseQty, residualOilQty);
WeighingPage?.AppendLog($"[{opName}] 保存完成：{engineNo}，重量={weight:F2}kg，放油量={oilReleaseQty:F4}L");
if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
out long recordId, out _, out decimal addOil, out decimal extractOil, out decimal dens))
{
curveWeighingRecordId = recordId; // 曲线记录最终关联这条称重记录
oilReleaseQty = dens > 0 ? weight / dens : 0; // 地面：油桶重量/密度=放油量
residualOilQty = addOil - extractOil - oilReleaseQty; // 残油=加油-抽油-放油
B_DB_Opera.UpdateWeighingComplete(recordId, "地面", opName,
weight, oilReleaseQty, residualOilQty, waterContent, out finalQualityFlag, out qualityMsg);
B_DB_Opera.SaveLog_Response(
$"【{opName}】地面保存完成：发动机={engineNo}，重量={weight}kg，放油量={oilReleaseQty:F4}L，残油量={residualOilQty:F4}L，合格标志={finalQualityFlag}，{qualityMsg}", AID);
WeighingPage?.UpdateOilResult(WeighingPage?.GetStationIndex(opName) ?? 1, oilReleaseQty, residualOilQty);
WeighingPage?.AppendLog($"[{opName}] 保存完成：{engineNo}，重量={weight:F2}kg，放油量={oilReleaseQty:F4}L");
}
else
{
// 兜底机制：请求工作阶段资料异常可能没有占位记录，保存时补一条异常完成记录，避免PLC等不到保存完成。
curveWeighingRecordId = B_DB_Opera.InsertWeighingRecord(opName, "地面", engineNo, "", "", "",
0, weight, 0, 0, 0, 0, 0, 0, 0, 2, waterContent,
opName, Curr_UserName, isComplete: 1);
finalQualityFlag = 2;
qualityMsg = "未找到请求工作占位记录，已按异常地面记录保存";
LogWeighingFallback(opName, engineNo, "请求保存-地面", qualityMsg, AID);
}
}
else if (weighType == "放油前")
{
// 空中放油前：查最新记录 → 仅写入进站重量，不标记完成
B_DB_Opera.QueryLatestRecord(opName, engineNo,
out long recordId, out _, out _, out _, out _);
curveWeighingRecordId = recordId; // 放油前曲线也关联同一条称重记录
B_DB_Opera.UpdateWeighingComplete(recordId, "空中放油前", opName,
weight, 0, 0, waterContent, out finalQualityFlag, out qualityMsg);
B_DB_Opera.SaveLog_Response(
$"【{opName}】空中放油前保存完成：发动机={engineNo}，进站重量={weight}kg，合格标志={finalQualityFlag}，{qualityMsg}", AID);
WeighingPage?.AppendLog($"[{opName}] 放油前保存：{engineNo}，重量={weight:F2}kg");
if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
out long recordId, out _, out _, out _, out _))
{
curveWeighingRecordId = recordId; // 放油前曲线也关联同一条称重记录
B_DB_Opera.UpdateWeighingComplete(recordId, "空中放油前", opName,
weight, 0, 0, waterContent, out finalQualityFlag, out qualityMsg);
B_DB_Opera.SaveLog_Response(
$"【{opName}】空中放油前保存完成：发动机={engineNo}，进站重量={weight}kg，合格标志={finalQualityFlag}，{qualityMsg}", AID);
WeighingPage?.AppendLog($"[{opName}] 放油前保存：{engineNo}，重量={weight:F2}kg");
}
else
{
// 兜底机制：没有占位记录时补异常记录并完成握手，后续放油后仍可按异常链路继续。
curveWeighingRecordId = B_DB_Opera.InsertWeighingRecord(opName, "空中", engineNo, "", "", "",
weight, 0, 0, 0, 0, 0, 0, 0, 0, 2, waterContent,
opName, Curr_UserName, isComplete: 1);
finalQualityFlag = 2;
qualityMsg = "未找到请求工作占位记录，已按异常放油前记录保存";
LogWeighingFallback(opName, engineNo, "请求保存-放油前", qualityMsg, AID);
}
}
else // 放油后
{

58
SCADA/Pages/UC_Report.cs
View File

@@ -38,14 +38,13 @@ namespace MesWork.Pages
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "发动机号", HeaderText = "发动机号", DataPropertyName = "发动机号", FillWeight = 100 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "机型号", HeaderText = "机型号", DataPropertyName = "机型号", FillWeight = 80 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "订单号", HeaderText = "订单号", DataPropertyName = "订单号", FillWeight = 80 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "称重类型", HeaderText = "称重类型", DataPropertyName = "称重类型", FillWeight = 70 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "托盘号", HeaderText = "托盘号", DataPropertyName = "托盘号", FillWeight = 60 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "进站重量", HeaderText = "进站重量(KG)", DataPropertyName = "进站重量", FillWeight = 80 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "离站重量", HeaderText = "离站重量(KG)", DataPropertyName = "离站重量", FillWeight = 80 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "加油量", HeaderText = "加油量", DataPropertyName = "加油量", FillWeight = 60 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "抽油量", HeaderText = "抽油量", DataPropertyName = "抽油量", FillWeight = 60 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "放油量", HeaderText = "放油量", DataPropertyName = "放油量", FillWeight = 70 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "残留量", HeaderText = "残留量", DataPropertyName = "残留量", FillWeight = 60 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "残油量上下限", HeaderText = "残油量上下限", DataPropertyName = "残油量上下限", FillWeight = 90 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "油密度", HeaderText = "油密度", DataPropertyName = "油密度", FillWeight = 60 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "合格标志", HeaderText = "合格", DataPropertyName = "合格标志", FillWeight = 50 });
dgv_Data.Columns.Add(new DataGridViewTextBoxColumn { Name = "操作员", HeaderText = "操作员", DataPropertyName = "操作员", FillWeight = 60 });
@@ -81,7 +80,11 @@ namespace MesWork.Pages
itemCountParam
};
SqlOperation.ExecuteStoredProcedure("称重记录_分页查询", parms, out DataTable dt, out string err);
if (dt != null) dgv_Data.DataSource = dt;
if (dt != null)
{
AddResidualOilLimitColumn(dt);
dgv_Data.DataSource = dt;
}
_pager.UpdateState(pageCountParam, itemCountParam);
}
catch (Exception ex)
@@ -90,6 +93,53 @@ namespace MesWork.Pages
}
}
/// <summary>
/// 将残油量上下限合并为报表显示列。
/// </summary>
private void AddResidualOilLimitColumn(DataTable dt)
{
if (!dt.Columns.Contains("残油量上下限"))
{
dt.Columns.Add("残油量上下限", typeof(string));
}
if (dt.Columns.Contains("残留量"))
{
dt.Columns["残油量上下限"].SetOrdinal(dt.Columns["残留量"].Ordinal + 1);
}
foreach (DataRow row in dt.Rows)
{
row["残油量上下限"] = $"{FormatLimit(row, "残油量下限")}~{FormatLimit(row, "残油量上限")}";
}
}
private string FormatLimit(DataRow row, string columnName)
{
if (!row.Table.Columns.Contains(columnName) || row[columnName] == DBNull.Value)
{
return "";
}
if (decimal.TryParse(row[columnName].ToString(), out decimal value))
{
return value.ToString("0.###");
}
return row[columnName].ToString();
}
private void RemoveHiddenExportColumns(DataTable dt)
{
string[] hiddenColumns = { "称重类型", "托盘号", "残油量上限", "残油量下限" };
foreach (string columnName in hiddenColumns)
{
if (dt.Columns.Contains(columnName))
{
dt.Columns.Remove(columnName);
}
}
}
/// <summary>
/// 导出 Excel（重新查询全量数据后导出）
/// </summary>
@@ -126,6 +176,8 @@ namespace MesWork.Pages
if (dt != null && dt.Rows.Count > 0)
{
AddResidualOilLimitColumn(dt);
RemoveHiddenExportColumns(dt);
bool exported = NPOITest.ExeclHelper.DataTableToExcel(dt, "称重记录", sfd.FileName);
if (exported)
{

8
SCADA/WC_GKJ_OIL.csproj
View File

@@ -165,9 +165,9 @@
</Reference>
</ItemGroup>
<ItemGroup>
<Compile Include="Core\SqlOperation.cs" />
<Compile Include="Core\WeightCalibrationHelper.cs" />
<Compile Include="Frm_Login.cs">
<Compile Include="Core\SqlOperation.cs" />
<Compile Include="Core\WeightCalibrationHelper.cs" />
<Compile Include="Frm_Login.cs">
<SubType>Form</SubType>
</Compile>
<Compile Include="Frm_Login.Designer.cs">
@@ -364,4 +364,4 @@
</PackageReference>
</ItemGroup>
<Import Project="$(MSBuildToolsPath)\Microsoft.CSharp.targets" />
</Project>
</Project>