异常情况兜底不中断信号流程

SCADA/Funtion/MIS_Funtion.cs

@@ -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
@@ -166,6 +178,7 @@ 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
+                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))
                 {
@@ -180,8 +193,10 @@ namespace MesWork
                         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);
+                        LogWeighingFallback(opName, engineNo, "请求工作", $"订货号[{orderNo}]未匹配到工件参数，使用PLC机型[{modelNo}]继续允许工作", AID);
-                        WeighingPage?.AppendLog($"[{opName}] 订货号[{orderNo}]未匹配到工件参数");
+                        // 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;
@@ -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($"【{opName}】未找到发动机[{engineNo}]的空中称重记录", AID);
+                            LogWeighingFallback(opName, engineNo, "请求工作-放油后", "未找到放油前记录，继续允许工作，保存时按异常放油后记录处理", AID);
-                            WeighingPage?.AppendLog($"[{opName}] 未找到[{engineNo}]放油前记录，进站失败");
-                            return;
                         }
                         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);
+                    engineNo = string.IsNullOrWhiteSpace(rawCodeBlock) ? $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}" : rawCodeBlock.Trim();
-                    WeighingPage?.AppendLog($"[{opName}] 码块数据转换失败：{engineNo}");
+                    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)
@@ -251,6 +267,11 @@ 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))
                 {
@@ -263,7 +284,9 @@ namespace MesWork
                     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}");
+                        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);
@@ -280,8 +303,9 @@ 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,
+                    if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
-                        out long recordId, out _, out decimal addOil, out decimal extractOil, out decimal dens);
+                        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
@@ -292,11 +316,23 @@ namespace MesWork
                         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,
+                    if (B_DB_Opera.QueryLatestRecord(opName, engineNo,
-                        out long recordId, out _, out _, out _, out _);
+                        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);
@@ -304,6 +340,17 @@ namespace MesWork
                             $"【{opName}】空中放油前保存完成：发动机={engineNo}，进站重量={weight}kg，合格标志={finalQualityFlag}，{qualityMsg}", AID);
                         WeighingPage?.AppendLog($"[{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
                 {
                     // 空中放油后：查最新放油前记录（无论是否完成），计算放油量更新到该记录

SCADA/Pages/UC_Report.cs

@@ -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)
                             {