OP130/src/com/mes/util/PlcService.java

package com.mes.util;

import com.github.xingshuangs.iot.protocol.s7.enums.EPlcType;
import com.github.xingshuangs.iot.protocol.s7.service.S7PLC;
import org.slf4j.Logger;
import org.slf4j.LoggerFactory;

import java.nio.charset.StandardCharsets;

/**
 * 西门子 S7-200 SMART PLC 通信服务。
 * <p>
 * 使用 iot-communication 库的 S200_SMART 协议（支持 V 区原生地址，如 V2800.3、VB3000）。
 * s7connector 不支持 S7-200 SMART，请勿混用。
 */
public class PlcService {

    public static final Logger log = LoggerFactory.getLogger(PlcService.class);

    private static S7PLC s7PLC;
    private static String plcIp = "192.168.2.1";
    private static int rack = 0;
    private static int slot = 0;
    private static volatile boolean connected = false;

    public static void setPlcIp(String ip) {
        if (ip != null && !ip.trim().isEmpty()) {
            plcIp = ip.trim();
        }
    }

    public static void setConnectionParams(int rackNo, int slotNo) {
        rack = rackNo;
        slot = slotNo;
    }

    public static String getPlcIp() {
        return plcIp;
    }

    public static boolean isConnected() {
        return connected;
    }

    public static synchronized boolean connect() {
        disconnect();
        try {
            s7PLC = new S7PLC(EPlcType.S200_SMART, plcIp, 102, rack, slot);
            s7PLC.setPersistence(true);
            s7PLC.setConnectTimeout(3000);
            s7PLC.setReceiveTimeout(3000);
            s7PLC.connect();
            s7PLC.readBoolean(addr(QmPlcPoint.STATUS_BYTE, QmPlcPoint.DATA_READY_BIT));
            connected = true;
            log.info("S7-200 SMART PLC连接成功: {} rack={} slot={}", plcIp, rack, slot);
            return true;
        } catch (Exception e) {
            connected = false;
            closeQuietly();
            log.info("S7-200 SMART PLC连接失败: {} - {}", plcIp, e.getMessage());
            return false;
        }
    }

    public static synchronized void disconnect() {
        connected = false;
        closeQuietly();
        s7PLC = null;
    }

    private static void closeQuietly() {
        if (s7PLC != null) {
            try {
                s7PLC.close();
            } catch (Exception ignored) {
            }
        }
    }

    public static synchronized boolean ensureConnected() {
        if (connected && s7PLC != null) {
            try {
                if (s7PLC.checkConnected()) {
                    s7PLC.readBoolean(addr(QmPlcPoint.STATUS_BYTE, QmPlcPoint.DATA_READY_BIT));
                    return true;
                }
            } catch (Exception e) {
                connected = false;
            }
        }
        return connect();
    }

    public static byte[] readStatusByte() {
        ensureConnectedOrThrow();
        return s7PLC.readByte("V" + QmPlcPoint.STATUS_BYTE, 1);
    }

    public static byte[] readMesDataBlock() {
        ensureConnectedOrThrow();
        return s7PLC.readByte("V" + QmPlcPoint.DATA_OFFSET, QmPlcPoint.DATA_LENGTH);
    }

    public static boolean isDataReady(byte[] statusByte) {
        return QmPlcPoint.readBool(statusByte, 0, QmPlcPoint.DATA_READY_BIT);
    }

    public static boolean readDataReady() {
        ensureConnectedOrThrow();
        return s7PLC.readBoolean(addr(QmPlcPoint.STATUS_BYTE, QmPlcPoint.DATA_READY_BIT));
    }

    public static boolean setCollectComplete(boolean complete) {
        return writeVBit(QmPlcPoint.STATUS_BYTE, QmPlcPoint.COLLECT_COMPLETE_BIT, complete);
    }

    /**
     * 上位机采集完成反馈：V2800.3 写1并保持1~3秒后复位为0。
     */
    public static boolean pulseCollectComplete() {
        if (!setCollectComplete(true)) {
            return false;
        }
        try {
            Thread.sleep(QmPlcPoint.COLLECT_COMPLETE_PULSE_MS);
        } catch (InterruptedException e) {
            Thread.currentThread().interrupt();
            log.info("V2800.3脉冲被中断");
            return false;
        }
        return setCollectComplete(false);
    }

    public static boolean isQrMatchComplete(byte[] statusByte) {
        return QmPlcPoint.readBool(statusByte, 0, QmPlcPoint.QR_MATCH_BIT);
    }

    public static boolean setMesConnected(boolean connectedFlag) {
        return writeVBit(QmPlcPoint.STATUS_BYTE, QmPlcPoint.MES_CONNECTED_BIT, connectedFlag);
    }

    public static String readMesData() {
        byte[] data = readMesDataBlock();
        if (data == null) {
            log.warn("读取VB3000失败: 返回null");
            return "";
        }
        log.info("读取VB3000完成, byteLength={}", data.length);
        return QmPlcPoint.readPlcString(data);
    }

    /**
     * 质量校验通过后，将扫码内容写入 VB3500（纯 ASCII 原始字符串，无长度字节前缀）。
     */
    public static boolean writeScanCode(String barcode) {
        if (!ensureConnected()) {
            return false;
        }
        if (barcode == null || barcode.trim().isEmpty()) {
            log.info("二维码为空，无法写入VB3500");
            return false;
        }
        try {
            String code = barcode.trim();
            byte[] codeBytes = code.getBytes(StandardCharsets.US_ASCII);
            byte[] buffer = new byte[QmPlcPoint.SCAN_CODE_LENGTH];
            int copyLen = Math.min(codeBytes.length, buffer.length);
            if (codeBytes.length > buffer.length) {
                log.info("二维码长度超过VB3500容量({}字节)，已截断", QmPlcPoint.SCAN_CODE_LENGTH);
            }
            System.arraycopy(codeBytes, 0, buffer, 0, copyLen);
            s7PLC.writeByte("V" + QmPlcPoint.SCAN_CODE_OFFSET, buffer);
            log.info("S7-200 SMART 写入 VB3500 二维码(ASCII): {}", code);
            return true;
        } catch (Exception e) {
            connected = false;
            log.info("写入VB3500失败: {}", e.getMessage());
            return false;
        }
    }

    /** 复位 VB3500 扫码区 */
    public static boolean clearScanCode() {
        if (!ensureConnected()) {
            return false;
        }
        try {
            byte[] empty = new byte[QmPlcPoint.SCAN_CODE_LENGTH];
            s7PLC.writeByte("V" + QmPlcPoint.SCAN_CODE_OFFSET, empty);
            log.info("S7-200 SMART 已清空 VB3500");
            return true;
        } catch (Exception e) {
            connected = false;
            log.info("清空VB3500失败: {}", e.getMessage());
            return false;
        }
    }

    private static boolean writeVBit(int byteOffset, int bitOffset, boolean value) {
        if (!ensureConnected()) {
            return false;
        }
        try {
            String address = addr(byteOffset, bitOffset);
            s7PLC.writeBoolean(address, value);
            log.info("S7-200 SMART 写入 {} = {}", address, value);
            return true;
        } catch (Exception e) {
            connected = false;
            log.info("S7-200 SMART PLC写入失败: {}", e.getMessage());
            return false;
        }
    }

    private static String addr(int byteOffset, int bitOffset) {
        return "V" + byteOffset + "." + bitOffset;
    }

    private static void ensureConnectedOrThrow() {
        if (!ensureConnected()) {
            throw new IllegalStateException("PLC未连接");
        }
    }
}