异常情况兜底不中断信号流程
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XingCheng3
@@ -152,6 +152,18 @@ namespace MesWork
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return !string.IsNullOrWhiteSpace(productNo);
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}
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/// <summary>
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/// 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。
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/// </summary>
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private void LogWeighingFallback(string opName, string productNo, string flowName, string reason, long AID)
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{
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string safeProductNo = string.IsNullOrWhiteSpace(productNo) ? "未知产品" : productNo;
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string msg = $"【{opName}】兜底放行：产品={safeProductNo}，流程={flowName}，原因={reason}";
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B_DB_Opera.SaveLog_Response(msg, AID);
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WeighingPage?.AppendLog($"[{opName}] {msg}");
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}
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/// <summary>
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/// 处理请求工作信号 (tagTypeCodeID=44)
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/// 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
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@@ -166,7 +178,8 @@ namespace MesWork
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string modelNo = PLC_R.GetString_CleanGarbled(ReadPLC(11, opName)); // 机型号
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string orderNo = PLC_R.GetString_CleanGarbled(ReadPLC(39, opName)); // 工单号
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string palletNo = PLC_R.GetString_CleanGarbled(ReadPLC(80, opName)); // 托盘号
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// 解析代码串格式: 0/DHN2.5Q0219-36/D426E016767 或 DHH02K0014-400/B726E00584555
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string rawCodeBlock = engineNo;
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// 解析代码串格式: 0/DHN2.5Q0219-36/D426E016767 或 DHH02K0014-400/B726E00584555
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if (TryConvertCodeBlockData(engineNo, out string parsedOrderNo, out string parsedProductNo))
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{
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if (!string.IsNullOrWhiteSpace(parsedOrderNo))
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@@ -175,19 +188,21 @@ namespace MesWork
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}
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engineNo = parsedProductNo;
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int stIdx = WeighingPage?.GetStationIndex(opName) ?? 1;
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if (!B_DB_Opera.QueryWorkpieceByOrderNo(orderNo, out string matchedModelNo, out decimal addOilQty, out decimal extractOilQty, out decimal density,
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out decimal residualOilUpperLimit, out decimal residualOilLowerLimit)) // 根据订货号 查询基本参数
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{
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WritePLC_IF(112, opName, 3); // 报警代码=3，机型错误
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B_DB_Opera.SaveLog_Response($"【{opName}】工件管理中未找到订货号[{orderNo}]的匹配规则，发动机={engineNo}", AID);
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WeighingPage?.AppendLog($"[{opName}] 订货号[{orderNo}]未匹配到工件参数");
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return;
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}
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modelNo = matchedModelNo;
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B_DB_Opera.SaveLog_Response($"【{opName}】读取工件：发动机={engineNo}，机型={modelNo}，订货号={orderNo}，托盘={palletNo}", AID);
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WeighingPage?.UpdateStationInfo(stIdx, engineNo, modelNo, orderNo);
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WeighingPage?.AppendLog($"[{opName}] 读取工件：{engineNo}，机型={modelNo}");
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int stIdx = WeighingPage?.GetStationIndex(opName) ?? 1;
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if (!B_DB_Opera.QueryWorkpieceByOrderNo(orderNo, out string matchedModelNo, out decimal addOilQty, out decimal extractOilQty, out decimal density,
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out decimal residualOilUpperLimit, out decimal residualOilLowerLimit)) // 根据订货号 查询基本参数
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{
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WritePLC_IF(112, opName, 3); // 报警代码=3，机型错误
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LogWeighingFallback(opName, engineNo, "请求工作", $"订货号[{orderNo}]未匹配到工件参数，使用PLC机型[{modelNo}]继续允许工作", AID);
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// 兜底机制：参数资料缺失不再卡PLC，请求保存时若无法正常更新记录会生成异常完成记录。
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WritePLC_IF(66, opName, true);
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CurveCollector_Start(opName, engineNo, modelNo);
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return;
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}
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modelNo = matchedModelNo;
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B_DB_Opera.SaveLog_Response($"【{opName}】读取工件：发动机={engineNo}，机型={modelNo}，订货号={orderNo}，托盘={palletNo}", AID);
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WeighingPage?.UpdateStationInfo(stIdx, engineNo, modelNo, orderNo);
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WeighingPage?.AppendLog($"[{opName}] 读取工件：{engineNo}，机型={modelNo}");
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WeighingPage?.UpdateOilInfo(stIdx, addOilQty, extractOilQty, density, 0, 0);
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string weighType = GetWeighingType(opName); // 地面/放油前/放油后
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string stationName = weighType; // 工位名称直接用称重类型名
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@@ -199,9 +214,7 @@ namespace MesWork
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if (!B_DB_Opera.QueryWeighingBeforeOil(engineNo, out _, out decimal preWeight, out _, out _, out _))
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{
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WritePLC_IF(112, opName, 3);
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B_DB_Opera.SaveLog_Response($"【{opName}】未找到发动机[{engineNo}]的空中称重记录", AID);
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WeighingPage?.AppendLog($"[{opName}] 未找到[{engineNo}]放油前记录，进站失败");
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return;
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LogWeighingFallback(opName, engineNo, "请求工作-放油后", "未找到放油前记录，继续允许工作，保存时按异常放油后记录处理", AID);
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}
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else
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{
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@@ -223,8 +236,11 @@ namespace MesWork
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else
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{
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WritePLC_IF(112, opName, 1); // 报警代码=1，获取数据失败
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B_DB_Opera.SaveLog_Response($"【{opName}】码块数据转换失败：原始码值=[{engineNo}]", AID);
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WeighingPage?.AppendLog($"[{opName}] 码块数据转换失败：{engineNo}");
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engineNo = string.IsNullOrWhiteSpace(rawCodeBlock) ? $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}" : rawCodeBlock.Trim();
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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);
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// 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。
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WritePLC_IF(66, opName, true);
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CurveCollector_Start(opName, engineNo, modelNo);
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}
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}
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catch (Exception err)
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@@ -251,27 +267,34 @@ namespace MesWork
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{
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engineNo = parsedProductNo;
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}
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else if (string.IsNullOrWhiteSpace(engineNo))
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{
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engineNo = $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}";
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LogWeighingFallback(opName, engineNo, "请求保存", "保存时产品编号为空，使用临时产品号继续保存", AID);
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}
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if (CurveCollector_TryGetStableWeight(opName, out decimal curveWeight, out int curvePointCount, out string curveMsg))
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{
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weight = curveWeight; // 曲线采样点已按工具标定公式处理，稳定重量不再二次标定
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B_DB_Opera.SaveLog_Response($"【{opName}】标定曲线重量={curveWeight:F3}kg，PLC锁定重量={plcWeight:F3}kg，点数={curvePointCount}", AID);
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}
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else
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{
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B_DB_Opera.SaveLog_Response($"【{opName}】曲线重量不可用，使用PLC锁定重量={plcWeight:F3}kg，原因={curveMsg}", AID);
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decimal rawWeight = plcWeight;
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if (!WeightCalibrationHelper.Apply(opName, rawWeight, out decimal calibratedWeight, out string calibrationFormula, out string calibrationMsg))
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{
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throw new Exception($"工具标定公式处理失败：{calibrationMsg}");
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}
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weight = calibratedWeight;
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B_DB_Opera.SaveLog_Response($"【{opName}】PLC锁定重量标定：原始重量={rawWeight:F3}kg，公式={calibrationFormula}，标定后={weight:F3}kg", AID);
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WeighingPage?.AppendLog($"[{opName}] PLC锁定重量标定：原始={rawWeight:F3}kg，公式={calibrationFormula}，结果={weight:F3}kg");
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}
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long curveWeighingRecordId = 0;
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B_DB_Opera.UpdateStationComplete(engineNo, opName, weight); // 过站记录保存最终采用重量
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if (CurveCollector_TryGetStableWeight(opName, out decimal curveWeight, out int curvePointCount, out string curveMsg))
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{
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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
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B_DB_Opera.SaveLog_Response($"【{opName}】标定曲线重量={curveWeight:F3}kg，PLC锁定重量={plcWeight:F3}kg，点数={curvePointCount}", AID);
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}
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else
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{
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B_DB_Opera.SaveLog_Response($"【{opName}】曲线重量不可用，使用PLC锁定重量={plcWeight:F3}kg，原因={curveMsg}", AID);
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decimal rawWeight = plcWeight;
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if (!WeightCalibrationHelper.Apply(opName, rawWeight, out decimal calibratedWeight, out string calibrationFormula, out string calibrationMsg))
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{
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LogWeighingFallback(opName, engineNo, "请求保存", $"工具标定公式处理失败：{calibrationMsg}，使用PLC原始重量继续保存", AID);
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calibrationFormula = "未标定兜底";
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calibratedWeight = rawWeight;
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}
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weight = calibratedWeight;
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B_DB_Opera.SaveLog_Response($"【{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);
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WeighingPage?.AppendLog($"[{opName}] PLC锁定重量标定：原始={rawWeight:F3}kg，公式={calibrationFormula}，结果={weight:F3}kg");
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}
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long curveWeighingRecordId = 0;
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B_DB_Opera.UpdateStationComplete(engineNo, opName, weight); // 过站记录保存最终采用重量
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string weighType = GetWeighingType(opName);
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decimal oilReleaseQty = 0;
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decimal residualOilQty = 0;
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@@ -280,29 +303,53 @@ namespace MesWork
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if (weighType == "地面")
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{
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// 地面：查最新记录 → 放油量=重量/密度 → 标记完成
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B_DB_Opera.QueryLatestRecord(opName, engineNo,
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out long recordId, out _, out decimal addOil, out decimal extractOil, out decimal dens);
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curveWeighingRecordId = recordId; // 曲线记录最终关联这条称重记录
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oilReleaseQty = dens > 0 ? weight / dens : 0; // 地面：油桶重量/密度=放油量
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residualOilQty = addOil - extractOil - oilReleaseQty; // 残油=加油-抽油-放油
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B_DB_Opera.UpdateWeighingComplete(recordId, "地面", opName,
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weight, oilReleaseQty, residualOilQty, waterContent, out finalQualityFlag, out qualityMsg);
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B_DB_Opera.SaveLog_Response(
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$"【{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);
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WeighingPage?.UpdateOilResult(WeighingPage?.GetStationIndex(opName) ?? 1, oilReleaseQty, residualOilQty);
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WeighingPage?.AppendLog($"[{opName}] 保存完成：{engineNo}，重量={weight:F2}kg，放油量={oilReleaseQty:F4}L");
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if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
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out long recordId, out _, out decimal addOil, out decimal extractOil, out decimal dens))
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{
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curveWeighingRecordId = recordId; // 曲线记录最终关联这条称重记录
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oilReleaseQty = dens > 0 ? weight / dens : 0; // 地面：油桶重量/密度=放油量
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residualOilQty = addOil - extractOil - oilReleaseQty; // 残油=加油-抽油-放油
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B_DB_Opera.UpdateWeighingComplete(recordId, "地面", opName,
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weight, oilReleaseQty, residualOilQty, waterContent, out finalQualityFlag, out qualityMsg);
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B_DB_Opera.SaveLog_Response(
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$"【{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);
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WeighingPage?.UpdateOilResult(WeighingPage?.GetStationIndex(opName) ?? 1, oilReleaseQty, residualOilQty);
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WeighingPage?.AppendLog($"[{opName}] 保存完成：{engineNo}，重量={weight:F2}kg，放油量={oilReleaseQty:F4}L");
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}
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else
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{
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// 兜底机制：请求工作阶段资料异常可能没有占位记录，保存时补一条异常完成记录，避免PLC等不到保存完成。
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curveWeighingRecordId = B_DB_Opera.InsertWeighingRecord(opName, "地面", engineNo, "", "", "",
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0, weight, 0, 0, 0, 0, 0, 0, 0, 2, waterContent,
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opName, Curr_UserName, isComplete: 1);
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finalQualityFlag = 2;
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qualityMsg = "未找到请求工作占位记录，已按异常地面记录保存";
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LogWeighingFallback(opName, engineNo, "请求保存-地面", qualityMsg, AID);
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}
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}
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else if (weighType == "放油前")
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{
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// 空中放油前：查最新记录 → 仅写入进站重量，不标记完成
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B_DB_Opera.QueryLatestRecord(opName, engineNo,
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out long recordId, out _, out _, out _, out _);
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curveWeighingRecordId = recordId; // 放油前曲线也关联同一条称重记录
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B_DB_Opera.UpdateWeighingComplete(recordId, "空中放油前", opName,
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weight, 0, 0, waterContent, out finalQualityFlag, out qualityMsg);
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B_DB_Opera.SaveLog_Response(
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$"【{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);
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WeighingPage?.AppendLog($"[{opName}] 放油前保存：{engineNo}，重量={weight:F2}kg");
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if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
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out long recordId, out _, out _, out _, out _))
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{
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curveWeighingRecordId = recordId; // 放油前曲线也关联同一条称重记录
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B_DB_Opera.UpdateWeighingComplete(recordId, "空中放油前", opName,
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weight, 0, 0, waterContent, out finalQualityFlag, out qualityMsg);
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B_DB_Opera.SaveLog_Response(
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$"【{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);
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WeighingPage?.AppendLog($"[{opName}] 放油前保存：{engineNo}，重量={weight:F2}kg");
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}
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else
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{
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// 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。
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curveWeighingRecordId = B_DB_Opera.InsertWeighingRecord(opName, "空中", engineNo, "", "", "",
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weight, 0, 0, 0, 0, 0, 0, 0, 0, 2, waterContent,
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opName, Curr_UserName, isComplete: 1);
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finalQualityFlag = 2;
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qualityMsg = "未找到请求工作占位记录，已按异常放油前记录保存";
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LogWeighingFallback(opName, engineNo, "请求保存-放油前", qualityMsg, AID);
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}
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}
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else // 放油后
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{
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Block a user