using ExternalDataSync; using System; using DC_A95; /// /// /// namespace MesWork { /// /// 处理MIS逻辑 /// public partial class MesWorkForm { /// /// PLC信号变化处理入口 /// 当Bool型信号值变化时由框架自动触发 /// /// private void MIS_Funtion(object e) { try { var msgEvent = (DeviceDriver_BasicData.CustomeEvetnArgs)e; if (msgEvent.TagValue == null) return; var tagID = msgEvent.TagID.ToString(); var opName = msgEvent.OpName.ToString(); var tagTypeCodeID = (int)msgEvent.TagTypeCodeID; var tagTypeID = (EnumTagTypeID)msgEvent.TagTypeID; var isFirstValue = msgEvent.IsFirstValue.ToString().ToLower(); var alarmLevel = msgEvent.ShaftID.ToString(); var alarmMsg = msgEvent.ItemName.ToString(); string tagValue; switch (tagTypeID) { case EnumTagTypeID.BOOL: tagValue = (Convert.ToInt32(msgEvent.TagValue)).ToString(); break; default: tagValue = msgEvent.TagValue.ToString(); break; } // ── 监控变量变化记录(首次值及心跳除外,不影响主流程)── if (!ValueT(isFirstValue) && tagTypeCodeID != 14) { var signalName = string.IsNullOrWhiteSpace(alarmMsg) ? tagID : alarmMsg; SaveSignalChangeLog(opName, tagTypeCodeID, signalName, tagValue); } // ── 报警处理(编码900~2000)── if (tagTypeCodeID >= 900 & tagTypeCodeID < 2000) { if (ValueT(isFirstValue)) { //不处理第一次变化的值 return; } var opNameNew = opName.Replace("_Alarm", ""); if (tagValue == "1") { B_DB_Opera.Event_Alarm_Start(opNameNew, tagTypeCodeID, alarmMsg, alarmLevel, tagID); } else { B_DB_Opera.Event_Alarm_End(opNameNew, tagTypeCodeID, alarmMsg, alarmLevel, tagID); } } // ── 信号分发 ── switch (tagTypeCodeID) { case 2: // 工件到位/离开 // WritePLC_IF(112, opName, 0); // 报警代码清空 ClearStationDisplay(opName); break; case 14: // PLC心跳 → 回写PC心跳 WritePLC_IF(15, opName, tagValue); break; case 44: // 请求工作 if (ValueT(isFirstValue)) return; if (tagValue == "1") { WeighingPage?.AppendLog($"[{opName}] PLC请求工作,开始处理..."); Weighing_HandleRequestWork(opName, tagID); } else { WritePLC_IF(66, opName, false); //允许工作 } break; case 19: // 请求保存 if (ValueT(isFirstValue)) return; if (tagValue == "1") { CurveCollector_StopSampling(opName, true); // 先停止采样,保存完成后再关联称重记录ID WeighingPage?.AppendLog($"[{opName}] PLC请求保存数据..."); Weighing_HandleRequestSave(opName, tagID); } else { WritePLC_IF(20, opName, false); //保存完成 WritePLC_IF(21, opName, false); //合格标志 } break; case 203: // 设备状态 B_DB_Opera.Event_DeviceStatus_Change(opName, tagValue); break; default: break; } } catch (Exception err) { string errMsg = $"PLC信号处理异常:{err.Message}"; B_DB_Opera.SaveLog_Request("", Log_Type.ZK_MesHandler, "MIS_Function", Log_FromAndTo.ZK, Log_FromAndTo.ZK, errMsg, out long AID); B_DB_Opera.SaveLog_Response(errMsg, AID); WeighingPage?.AppendLog(errMsg); } } /// /// 记录监控变量变化,异常不影响PLC主流程。 /// private void SaveSignalChangeLog(string opName, int tagTypeCodeID, string signalName, string tagValue) { try { B_DB_Opera.Event_Signal_Log(opName, tagTypeCodeID, signalName, tagValue); } catch { // 变化记录失败不干涉PLC信号主流程 } } // ==================================================================== // 称重交互核心方法 // ==================================================================== /// /// 获取称重类型:地面/放油前/放油后 /// Ground模式:统一返回"地面" /// Hanging模式:工位1=放油前,工位2=放油后 /// private string GetWeighingType(string opName) { if (WeighingType == "Ground") return "地面"; if (string.Equals(opName, Station1OpName, StringComparison.OrdinalIgnoreCase)) return "放油前"; if (string.Equals(opName, Station2OpName, StringComparison.OrdinalIgnoreCase)) return "放油后"; throw new InvalidOperationException($"工位号[{opName}]未匹配到App.config中的Station1OpName/Station2OpName,请检查工位配置"); } /// /// 清除工位显示信息(工件离开时调用) /// private void ClearStationDisplay(string opName) { try { int stIdx = WeighingPage?.GetStationIndex(opName) ?? 1; // 清除工件信息 WeighingPage?.UpdateStationInfo(stIdx, "", "", ""); // 清除油量参数信息 WeighingPage?.UpdateOilInfo(stIdx, 0, 0, 0, 0, 0); // 清除结果信息 WeighingPage?.UpdateOilResult(stIdx, 0, 0); } catch (Exception err) { WeighingPage?.AppendLog($"[{opName}] 清除显示异常:{err.Message}"); } } /// /// 码块数据转换:将产品编号统一转大写,并拆分出订货号与产品编号 /// 支持格式: /// 0/DHN2.5Q0219-36/D426E016767 /// DHH02K0014-400/B726E00584555 /// CodeBlockOrderNoReverse=0:订货号/流水号;CodeBlockOrderNoReverse=1:流水号/订货号 /// private bool TryConvertCodeBlockData(string codeBlock, out string orderNo, out string productNo) { orderNo = ""; productNo = ""; if (string.IsNullOrWhiteSpace(codeBlock)) { return false; } string normalizedCode = codeBlock.Trim().ToUpperInvariant(); string[] parts = normalizedCode.Split('/'); if (parts.Length >= 2) { if (CodeBlockOrderNoReverse == 1) { productNo = parts[parts.Length - 2].Trim(); orderNo = parts[parts.Length - 1].Trim(); } else { orderNo = parts[parts.Length - 2].Trim(); productNo = parts[parts.Length - 1].Trim(); } } else { productNo = normalizedCode; } return !string.IsNullOrWhiteSpace(productNo); } /// /// 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。 /// 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}"); } /// /// 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 /// private void Weighing_HandleRequestWork(string opName, string tagID) { B_DB_Opera.SaveLog_Request(opName, Log_Type.ZK_MesHandler, "MIS_Function", Log_FromAndTo.ZK, Log_FromAndTo.ZK, $"触发信号【44-请求工作】", out long AID); try { string engineNo = PLC_R.GetString_CleanGarbled(ReadPLC(10, opName)); // 原始代码串 0/dhn2.5q0219-36/d426e016767 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)) { if (!string.IsNullOrWhiteSpace(parsedOrderNo)) { orderNo = parsedOrderNo; } 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 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($"[{opName}] 读取工件:{engineNo},机型={modelNo}"); WeighingPage?.UpdateOilInfo(stIdx, addOilQty, extractOilQty, density, 0, 0); string weighType = GetWeighingType(opName); // 地面/放油前/放油后 string stationName = weighType; // 工位名称直接用称重类型名 B_DB_Opera.InsertStationRecord(engineNo, modelNo, orderNo, palletNo, opName, stationName, addOilQty, extractOilQty, density, Curr_UserName); // 请求工作成功先写到站记录 if (weighType == "放油后") { // 空中放油后:查找最新放油前记录(无论是否完成,支持多次测量) if (!B_DB_Opera.QueryWeighingBeforeOil(engineNo, out _, out decimal preWeight, out _, out _, out _)) { // WritePLC_IF(112, opName, 3); LogWeighingFallback(opName, engineNo, "请求工作-放油后", "未找到放油前记录,继续允许工作,保存时按异常放油后记录处理", AID); } else { B_DB_Opera.SaveLog_Response($"【{opName}】空中放油后准备完成,发动机={engineNo},机型={modelNo},放油前重量={preWeight}kg", AID); } } else { // 地面 或 空中放油前:每次都新建称重记录(支持同一产品多次测量取最新) string recordType = weighType == "地面" ? "地面" : "空中"; B_DB_Opera.InsertWeighingRecord(opName, recordType, engineNo, modelNo, orderNo, palletNo, 0, 0, addOilQty, extractOilQty, density, residualOilUpperLimit, residualOilLowerLimit, 0, 0, 0, 0, opName, Curr_UserName, isComplete: 0); // 放油前/地面先占位,保存时回填重量结果 B_DB_Opera.SaveLog_Response($"【{opName}】{weighType}准备完成,发动机={engineNo},机型={modelNo},残油量范围={residualOilLowerLimit:F4}-{residualOilUpperLimit:F4}L", AID); } WritePLC_IF(66, opName, true); CurveCollector_Start(opName, engineNo, modelNo); // 允许工作后开始记录本次曲线 } else { // WritePLC_IF(112, opName, 1); // 报警代码=1,获取数据失败 engineNo = string.IsNullOrWhiteSpace(rawCodeBlock) ? $"未知产品_{opName}_{DateTime.Now:yyyyMMddHHmmss}" : rawCodeBlock.Trim(); LogWeighingFallback(opName, engineNo, "请求工作", $"码块数据转换失败,原始码值=[{rawCodeBlock}],仍允许工作", AID); // 兜底机制:产品解析失败时仍给允许工作,后续保存阶段会按异常产品记录并判不合格。 WritePLC_IF(66, opName, true); CurveCollector_Start(opName, engineNo, modelNo); } } catch (Exception err) { //WritePLC_IF(112, opName, 1); // 报警代码=1,获取数据失败 B_DB_Opera.SaveLog_Response($"【{opName}】请求工作处理失败:{err.Message}", AID); } } /// /// 处理请求保存信号 (tagTypeCodeID=19) /// 流程:读取称重数据 → 更新过站记录 → 按类型处理称重记录 → 回写保存完成 /// private void Weighing_HandleRequestSave(string opName, string tagID) { B_DB_Opera.SaveLog_Request(opName, Log_Type.ZK_MesHandler, "MIS_Function", Log_FromAndTo.ZK, Log_FromAndTo.ZK, $"触发信号【19-请求保存】", out long AID); try { decimal plcWeight = Convert.ToDecimal(ReadPLC(100140, opName)); // PLC锁定重量,曲线无效时兜底使用 decimal weight = plcWeight; // 默认使用PLC锁定重量,曲线算法成功后覆盖 decimal waterContent = Convert.ToDecimal(ReadPLC(100180, opName)); // 水含量 string engineNo = PLC_R.GetString_CleanGarbled(ReadPLC(10, opName)); // 原始代码串/产品编号 string modelNo = PLC_R.GetString_CleanGarbled(ReadPLC(11, opName)); // 机型号 string orderNo = PLC_R.GetString_CleanGarbled(ReadPLC(39, opName)); // 工单号/订货号 string palletNo = PLC_R.GetString_CleanGarbled(ReadPLC(80, opName)); // 托盘号 if (TryConvertCodeBlockData(engineNo, out string parsedOrderNo, out string parsedProductNo)) { if (!string.IsNullOrWhiteSpace(parsedOrderNo)) { orderNo = parsedOrderNo; } 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)) { 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; string weighType = GetWeighingType(opName); decimal addOilQty = 0; decimal extractOilQty = 0; decimal density = 0; decimal residualOilUpperLimit = 0; decimal residualOilLowerLimit = 0; if (!string.IsNullOrWhiteSpace(orderNo) && B_DB_Opera.QueryWorkpieceByOrderNo(orderNo, out string matchedModelNo, out decimal matchedAddOilQty, out decimal matchedExtractOilQty, out decimal matchedDensity, out decimal matchedResidualOilUpperLimit, out decimal matchedResidualOilLowerLimit)) { modelNo = matchedModelNo; addOilQty = matchedAddOilQty; extractOilQty = matchedExtractOilQty; density = matchedDensity; residualOilUpperLimit = matchedResidualOilUpperLimit; residualOilLowerLimit = matchedResidualOilLowerLimit; } if (!B_DB_Opera.UpdateStationComplete(engineNo, opName, weight, modelNo, orderNo, palletNo, weighType, addOilQty, extractOilQty, density, Curr_UserName)) // 过站记录保存最终采用重量;找不到则由SP补异常完成记录 { LogWeighingFallback(opName, engineNo, "请求保存-过站", "未找到请求工作过站记录,已补异常过站完成记录", AID); } decimal oilReleaseQty = 0; decimal residualOilQty = 0; int finalQualityFlag = 1; string qualityMsg = ""; if (weighType == "地面") { // 地面:查最新记录 → 放油量=重量/密度 → 标记完成 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, modelNo, orderNo, palletNo, 0, weight, addOilQty, extractOilQty, density, residualOilUpperLimit, residualOilLowerLimit, 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 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, modelNo, orderNo, palletNo, weight, 0, addOilQty, extractOilQty, density, residualOilUpperLimit, residualOilLowerLimit, 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 if (B_DB_Opera.QueryWeighingBeforeOil(engineNo, out long recordId, out decimal preWeight, out decimal addOil, out decimal extractOil, out decimal dens)) { curveWeighingRecordId = recordId; // 放油后回填放油前创建的称重记录 oilReleaseQty = dens > 0 ? (preWeight - weight) / dens : 0; // 空中:前后重量差/密度=放油量 residualOilQty = addOil - extractOil - oilReleaseQty; // 残油=加油-抽油-放油 B_DB_Opera.UpdateWeighingComplete(recordId, "空中放油后", opName, weight, oilReleaseQty, residualOilQty, waterContent, out finalQualityFlag, out qualityMsg); B_DB_Opera.SaveLog_Response( $"【{opName}】空中放油后保存完成:发动机={engineNo},放油前={preWeight}kg,放油后={weight}kg,放油量={oilReleaseQty:F4}L,残油量={residualOilQty:F4}L,合格标志={finalQualityFlag},{qualityMsg}", AID); WeighingPage?.UpdateOilResult(WeighingPage?.GetStationIndex(opName) ?? 1, oilReleaseQty, residualOilQty); WeighingPage?.AppendLog($"[{opName}] 放油后保存:{engineNo},放油量={oilReleaseQty:F4}L,残油量={residualOilQty:F4}L"); } else { // 找不到放油前记录(可能直接进放油后工位):创建一条放油后记录并标记完成 curveWeighingRecordId = B_DB_Opera.InsertWeighingRecord(opName, "空中放油后", engineNo, modelNo, orderNo, palletNo, 0, weight, addOilQty, extractOilQty, density, residualOilUpperLimit, residualOilLowerLimit, 0, 0, 2, waterContent, opName, Curr_UserName, isComplete: 1); // 异常兜底记录,质量直接判不合格 finalQualityFlag = 2; qualityMsg = "未找到放油前记录"; B_DB_Opera.SaveLog_Response( $"【{opName}】放油后保存(无放油前记录):发动机={engineNo},放油后重量={weight}kg", AID); WeighingPage?.AppendLog($"[{opName}] ⚠️ 放油后保存:{engineNo}(无放油前记录,已新建)"); } } CurveCollector_EndSegment(opName, curveWeighingRecordId); // 保存点位、最终重量和取点区间 // TODO: MES接口数据上传(接口对接后实现) if (finalQualityFlag == 2 && !string.IsNullOrWhiteSpace(qualityMsg)) { WeighingPage?.AppendLog($"[{opName}] 判定不合格:{qualityMsg}"); } // 4. 先回写上位机判定的合格标志,再回写保存完成 WritePLC_IF(21, opName, finalQualityFlag); // 合格标志 WritePLC_IF(20, opName, true); // 保存完成 } catch (Exception err) { CurveCollector_EndSegment(opName, 0); // WritePLC_IF(112, opName, 2); // 报警代码=2,保存失败 B_DB_Opera.SaveLog_Response($"【{opName}】保存处理失败:{err.Message}", AID); WeighingPage?.AppendLog($"[{opName}] ❌ 保存异常:{err.Message}"); } } // ==================================================================== // 扫码枪业务处理 // ==================================================================== /// /// 扫码枪扫码完成后的业务处理 /// 将码值写入PLC地址102500,触发完成信号100016=1,1秒后复位 /// /// 工位号,由COM口绑定决定 /// 扫到的条码值 public void Barcode_HandleScan(string opName, string barcode) { B_DB_Opera.SaveLog_Request(opName, Log_Type.ZK_MesHandler, "MIS_Function", Log_FromAndTo.ZK, Log_FromAndTo.ZK, $"扫码枪触发【{opName}】码值={barcode}", out long AID); try { // 1. 写入码值到 PLC 地址 102500(PLC_PC_扫码枪值) WritePLC_IF(102500, opName, barcode); // 2. 写入扫码完成信号 100016 = 1(PC_PLC_扫码枪扫码完成) WritePLC_IF(100016, opName, true); // 3. 日志 B_DB_Opera.SaveLog_Response($"【{opName}】扫码完成:码值={barcode}", AID); WeighingPage?.AppendLog($"[{opName}] 触发扫码 码值:{barcode}"); // 4. 1秒后复位 100016 = 0 System.Threading.Tasks.Task.Delay(1000).ContinueWith(_ => { try { WritePLC_IF(100016, opName, false); } catch { } }); } catch (Exception err) { B_DB_Opera.SaveLog_Response($"【{opName}】扫码处理失败:{err.Message}", AID); WeighingPage?.AppendLog($"[{opName}] ❌ 扫码处理异常:{err.Message}"); } } } }