299 lines
12 KiB
C#
299 lines
12 KiB
C#
using System;
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using System.Collections.Concurrent;
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using System.Collections.Generic;
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using System.Configuration;
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using System.Globalization;
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using System.Linq;
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using System.Threading;
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namespace MesWork
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{
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public partial class MesWorkForm
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{
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private class CurveCollectorState
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{
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public string OpName;
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public long CurveId;
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public string ProductNo;
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public Thread WorkerThread;
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public volatile bool IsRunning;
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public bool IsSegmentEnded;
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public bool IsPointValuesSaved;
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public int SeqNo;
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public readonly object BufferLock = new object();
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public readonly List<CurveSamplePoint> Buffer = new List<CurveSamplePoint>();
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public decimal? StableWeight;
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public int? StableStartSeq;
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public int? StableEndSeq;
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public DateTime LastCalibrationErrorLogTime;
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}
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private static readonly ConcurrentDictionary<string, CurveCollectorState> _curveCollectors
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= new ConcurrentDictionary<string, CurveCollectorState>(StringComparer.OrdinalIgnoreCase);
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private static readonly int CurveCollectorSampleIntervalMs = int.TryParse(
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ConfigurationManager.AppSettings["CurveCollectorSampleIntervalMs"], out int _sampleIntervalMs)
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? _sampleIntervalMs : 200;
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private static readonly int CurveStableWindowSize = int.TryParse(
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ConfigurationManager.AppSettings["CurveStableWindowSize"], out int _stableWindowSize)
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? _stableWindowSize : 20;
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/// <summary>
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/// 允许工作后启动曲线采集，每个工位同一时间只保留一个采集段。
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/// </summary>
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private void CurveCollector_Start(string opName, string productNo, string modelNo)
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{
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try
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{
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if (_curveCollectors.TryGetValue(opName, out CurveCollectorState oldState) && !oldState.IsSegmentEnded)
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{
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if (oldState.IsRunning) return;
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CurveCollector_EndSegment(opName, 0); // 清理上一次未正常结束的曲线
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}
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long curveId = B_DB_Opera.CurveRecord_Start(opName, productNo, modelNo, CurveCollectorSampleIntervalMs); // 先建曲线主记录
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if (curveId <= 0)
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{
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WeighingPage?.AppendLog($"[{opName}] 曲线记录创建失败，未启动采集");
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return;
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}
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var state = new CurveCollectorState
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{
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OpName = opName,
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CurveId = curveId,
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ProductNo = productNo,
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IsRunning = true
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};
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state.WorkerThread = new Thread(() => CurveCollector_Work(state))
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{
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IsBackground = true,
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Name = $"CurveCollector_{opName}"
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};
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_curveCollectors[opName] = state;
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state.WorkerThread.Start();
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WeighingPage?.AppendLog($"[{opName}] 实时重量曲线采集启动，记录ID={curveId}");
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}
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catch (Exception err)
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{
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WeighingPage?.AppendLog($"[{opName}] 曲线采集启动异常：{err.Message}");
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}
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}
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/// <summary>
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/// 采集线程：200ms读取一次实时重量，先按工具标定公式计算，再缓存到内存，保存时一次性写库。
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/// </summary>
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private void CurveCollector_Work(CurveCollectorState state)
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{
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while (state.IsRunning)
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{
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try
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{
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decimal rawWeight = Convert.ToDecimal(ReadPLC(100220, state.OpName)); // 实时重量点位
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if (!WeightCalibrationHelper.Apply(state.OpName, rawWeight, out decimal weight, out _, out string msg))
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{
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if ((DateTime.Now - state.LastCalibrationErrorLogTime).TotalSeconds >= 5)
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{
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state.LastCalibrationErrorLogTime = DateTime.Now;
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WeighingPage?.AppendLog($"[{state.OpName}] 曲线采样标定失败：{msg}");
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}
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Thread.Sleep(CurveCollectorSampleIntervalMs);
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continue;
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}
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lock (state.BufferLock)
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{
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state.Buffer.Add(new CurveSamplePoint
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{
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SeqNo = ++state.SeqNo, // 序号用于追溯最终取点区间
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SampleTime = DateTime.Now,
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Weight = weight
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});
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}
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}
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catch (Exception err)
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{
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WeighingPage?.AppendLog($"[{state.OpName}] 曲线采样异常：{err.Message}");
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}
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Thread.Sleep(CurveCollectorSampleIntervalMs);
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}
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}
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/// <summary>
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/// 停止采样线程，但暂不关闭曲线记录，便于保存流程先计算最终重量。
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/// </summary>
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private void CurveCollector_StopSampling(string opName, bool waitingSave = false)
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{
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if (!_curveCollectors.TryGetValue(opName, out CurveCollectorState state)) return;
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state.IsRunning = false;
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if (state.WorkerThread != null && state.WorkerThread.IsAlive)
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{
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state.WorkerThread.Join(2000);
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}
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if (waitingSave)
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{
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CurveCollector_SavePointValues(state, 0, null); // 保存前先把点位字符串落库，供算法读取
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}
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}
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/// <summary>
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/// 保存完成后关闭曲线记录，并关联称重记录ID。
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/// </summary>
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private void CurveCollector_EndSegment(string opName, long weighingRecordId)
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{
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if (!_curveCollectors.TryGetValue(opName, out CurveCollectorState state)) return;
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CurveCollector_StopSampling(opName);
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if (!state.IsSegmentEnded)
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{
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CurveCollector_SavePointValues(state, weighingRecordId, state.StableWeight, state.StableStartSeq, state.StableEndSeq); // 补写称重记录ID和算法依据
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state.IsSegmentEnded = true;
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WeighingPage?.AppendLog($"[{opName}] 实时重量曲线采集结束，记录ID={state.CurveId}，点数={state.SeqNo}");
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}
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_curveCollectors.TryRemove(opName, out _);
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}
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/// <summary>
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/// 优先用已标定曲线点计算稳定重量；失败时调用方继续使用PLC锁定重量。
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/// </summary>
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private bool CurveCollector_TryGetStableWeight(string opName, out decimal weight, out int pointCount, out string msg)
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{
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weight = 0;
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pointCount = 0;
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msg = "未启动曲线采集";
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if (!_curveCollectors.TryGetValue(opName, out CurveCollectorState state))
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{
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return false;
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}
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CurveCollector_SavePointValues(state, 0, null); // 确保数据库已有当前点位字符串
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if (!B_DB_Opera.CurveRecord_QueryLatest(opName, state.ProductNo, out string pointValues, out _))
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{
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msg = "未查询到当前产品曲线记录";
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return false;
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}
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List<decimal> weights = CurveCollector_ParsePointValues(pointValues); // 从数据库点位字符串还原曲线
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pointCount = weights.Count;
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if (CurveCollector_CalculateStableWeight(weights, out weight, out int startSeq, out int endSeq))
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{
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state.StableWeight = weight;
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state.StableStartSeq = startSeq; // 记录最终采用窗口起点
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state.StableEndSeq = endSeq; // 记录最终采用窗口终点
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msg = "";
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return true;
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}
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msg = $"曲线点数不足或无法计算，当前点数={pointCount}";
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return false;
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}
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private List<CurveSamplePoint> CurveCollector_GetPoints(CurveCollectorState state)
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{
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lock (state.BufferLock)
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{
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return state.Buffer.OrderBy(p => p.SeqNo).ToList();
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}
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}
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private string CurveCollector_BuildPointValues(List<CurveSamplePoint> points)
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{
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return string.Join("|", points.Select(p => p.Weight.ToString("F3", CultureInfo.InvariantCulture)));
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}
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private void CurveCollector_SavePointValues(CurveCollectorState state, long weighingRecordId, decimal? finalWeight)
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{
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CurveCollector_SavePointValues(state, weighingRecordId, finalWeight, null, null);
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}
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private void CurveCollector_SavePointValues(CurveCollectorState state, long weighingRecordId,
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decimal? finalWeight, int? finalStartSeq, int? finalEndSeq)
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{
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if (state.IsPointValuesSaved && weighingRecordId <= 0 && !finalWeight.HasValue) return;
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List<CurveSamplePoint> points = CurveCollector_GetPoints(state);
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string pointValues = CurveCollector_BuildPointValues(points); // 例：50.120|50.115|50.118
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B_DB_Opera.CurveRecord_Save(state.CurveId, weighingRecordId, points.Count, pointValues, finalWeight, finalStartSeq, finalEndSeq);
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state.IsPointValuesSaved = true;
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}
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private List<decimal> CurveCollector_ParsePointValues(string pointValues)
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{
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var result = new List<decimal>();
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if (string.IsNullOrWhiteSpace(pointValues)) return result;
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foreach (string item in pointValues.Split('|'))
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{
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if (decimal.TryParse(item, NumberStyles.Number, CultureInfo.InvariantCulture, out decimal value))
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{
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result.Add(value);
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}
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}
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return result;
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}
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/// <summary>
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/// 找连续20点中极差最小的一段，去掉一个最大值和一个最小值后取平均。
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/// </summary>
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private bool CurveCollector_CalculateStableWeight(List<decimal> weights, out decimal stableWeight, out int startSeq, out int endSeq)
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{
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stableWeight = 0;
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startSeq = 0;
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endSeq = 0;
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if (weights == null || weights.Count < CurveStableWindowSize) return false;
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int bestStart = 0; // 0-based窗口起点，保存时转成1-based序号
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decimal bestRange = decimal.MaxValue;
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for (int i = 0; i <= weights.Count - CurveStableWindowSize; i++)
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{
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decimal min = weights[i];
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decimal max = weights[i];
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for (int j = i + 1; j < i + CurveStableWindowSize; j++)
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{
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if (weights[j] < min) min = weights[j];
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if (weights[j] > max) max = weights[j];
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}
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decimal range = max - min;
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if (range <= bestRange)
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{
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bestRange = range;
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bestStart = i; // 极差相同时取靠后窗口，更接近保存时刻
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}
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}
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List<decimal> window = weights.Skip(bestStart).Take(CurveStableWindowSize).ToList();
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decimal windowMin = window.Min();
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decimal windowMax = window.Max();
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bool removedMin = false;
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bool removedMax = false;
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decimal sum = 0;
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int count = 0;
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foreach (decimal value in window)
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{
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if (!removedMin && value == windowMin)
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{
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removedMin = true;
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continue;
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}
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if (!removedMax && value == windowMax)
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{
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removedMax = true; // 只剔除一个最大值，避免过度过滤
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continue;
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}
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sum += value;
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count++;
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}
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if (count <= 0) return false;
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stableWeight = Math.Round(sum / count, 3, MidpointRounding.AwayFromZero); // 剩余18点平均值
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startSeq = bestStart + 1; // 转为数据库可读的1-based序号
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endSeq = bestStart + CurveStableWindowSize;
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return true;
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}
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}
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}
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