package com.jeesite.modules.scheduling;
import com.github.xingshuangs.iot.protocol.s7.enums.EPlcType;
import com.github.xingshuangs.iot.protocol.s7.service.S7PLC;
import com.jeesite.common.config.Global;
import com.jeesite.common.lang.ObjectUtils;
import com.jeesite.common.lang.StringUtils;
import com.jeesite.modules.mes.entity.MesLine;
import com.jeesite.modules.mes.entity.MesProduct;
import com.jeesite.modules.mes.entity.MesProductRecord;
import com.jeesite.modules.mes.entity.MesProductTj;
import com.jeesite.modules.mes.resp.BindMaterialResp;
import com.jeesite.modules.mes.resp.ParamsResp;
import com.jeesite.modules.mes.service.MesLineService;
import com.jeesite.modules.mes.service.MesProductRecordService;
import com.jeesite.modules.mes.service.MesProductService;
import com.jeesite.modules.mes.service.MesProductTjService;
import com.jeesite.modules.mes.util.CommonUitl;
import com.jeesite.modules.mes.web.MesProductRecordController;
import org.slf4j.Logger;
import org.slf4j.LoggerFactory;
import org.springframework.beans.factory.annotation.Autowired;
import org.springframework.context.annotation.Configuration;
import org.springframework.scheduling.annotation.EnableScheduling;
import org.springframework.scheduling.annotation.Scheduled;
import java.util.ArrayList;
import java.util.List;
import java.util.concurrent.atomic.AtomicBoolean;
/**
* 涂胶 S7 采集与质量握手（OP220，固定工位号）。
*
* DB1300 点位：
* 0.0 框架码 String[30]
* 64.0 扫码反馈信号
* 64.2 质量校验通过反馈（校验通过 MES 写 true，工位完成后 MES 写 false）
* 64.4 涂胶数据采集触发
* 64.5 整体完成信号（true 时提交工位 OK 并回查确认落库，成功后将 64.2 置 false）
* 66.0 涂胶序号 Word
* 68.0 涂胶速度 Real
* 72.0 涂胶长度 Word
*
* 配置（application.yml）：
* mes.tj.enabled 是否启用（默认 false）
* mes.tj.plc.ip PLC IP，默认 10.0.40.100
* mes.tj.lineSn 产线编号，默认 XT
*
*/
@Configuration
@EnableScheduling
public class ProductTjScheduling {
private static final Logger logger = LoggerFactory.getLogger(ProductTjScheduling.class);
private static final String ADDR_SN = "DB1300.0.0";
private static final int SN_LENGTH = 30;
private static final String ADDR_SCAN_FEEDBACK = "DB1300.64.0";
private static final String ADDR_QUALITY_PASS = "DB1300.64.2";
private static final String ADDR_GLUE_COLLECT = "DB1300.64.4";
private static final String ADDR_COMPLETE = "DB1300.64.5";
private static final String ADDR_GLUE_SEQ = "DB1300.66.0";
private static final String ADDR_GLUE_SPEED = "DB1300.68.0";
private static final String ADDR_GLUE_LENGTH = "DB1300.72.0";
private static final String DEFAULT_PLC_IP = "10.0.40.100";
private static final String OPRNO = "OP220";
private static final String DEFAULT_LINE_SN = "XT";
@Autowired
private MesProductRecordController mesProductRecordController;
@Autowired
private MesProductService mesProductService;
@Autowired
private MesLineService mesLineService;
@Autowired
private MesProductTjService mesProductTjService;
@Autowired
private MesProductRecordService mesProductRecordService;
private final AtomicBoolean running = new AtomicBoolean(false);
private volatile String lastKnownSn;
private volatile String lastCompletedSn;
@Scheduled(fixedRate = 100)
public void collect() {
String enabled = Global.getConfig("mes.tj.enabled");
if (StringUtils.isBlank(enabled) || !"true".equalsIgnoreCase(enabled.trim())) {
return;
}
runOnce();
}
/**
* 直接执行一轮（供测试调用）
*/
public void runOnce() {
if (!running.compareAndSet(false, true)) {
return;
}
String ip = getPlcIp();
S7PLC s7PLC = null;
try {
s7PLC = new S7PLC(EPlcType.S1200, ip);
handleScanFeedback(s7PLC);
handleGlueCollect(s7PLC);
handleComplete(s7PLC);
} catch (Exception e) {
logger.error("涂胶S7任务失败[{}]：{}", ip, e.getMessage());
} finally {
if (s7PLC != null) {
try {
s7PLC.close();
} catch (Exception ignore) {
}
}
running.set(false);
}
}
/**
* 扫码反馈为 true：读框架码 → 质量校验 → 通过则写 DB1300.64.2=true
*/
private void handleScanFeedback(S7PLC s7PLC) {
if (!s7PLC.readBoolean(ADDR_SCAN_FEEDBACK)) {
lastCompletedSn = null;
return;
}
String sn = readWorkpieceCode(s7PLC);
if (StringUtils.isBlank(sn)) {
return;
}
lastKnownSn = sn;
boolean pass = doQualityCheck(sn);
if (pass) {
s7PLC.writeBoolean(ADDR_QUALITY_PASS, true);
logger.info("涂胶质量校验通过 sn={}，已写 {}=true", sn, ADDR_QUALITY_PASS);
} else {
logger.warn("涂胶质量校验未通过 sn={}", sn);
}
}
/**
* 涂胶采集触发为 true：读涂胶参数 → 落库 mes_product_tj → 清触发位
*/
private void handleGlueCollect(S7PLC s7PLC) {
if (!s7PLC.readBoolean(ADDR_GLUE_COLLECT)) {
return;
}
String sn = readWorkpieceCode(s7PLC);
if (StringUtils.isBlank(sn)) {
sn = lastKnownSn;
}
if (StringUtils.isBlank(sn)) {
logger.error("涂胶数据采集失败：无工件码，保持 {}=true 待重试", ADDR_GLUE_COLLECT);
return;
}
lastKnownSn = sn;
int glueSeq = s7PLC.readUInt16(ADDR_GLUE_SEQ);
float glueSpeed = s7PLC.readFloat32(ADDR_GLUE_SPEED);
int glueLength = s7PLC.readUInt16(ADDR_GLUE_LENGTH);
logger.info("涂胶数据采集 sn={} 序号={} 速度={} 长度={}", sn, glueSeq, glueSpeed, glueLength);
if (!saveTjData(sn, glueSeq, glueSpeed, glueLength)) {
logger.error("涂胶数据保存失败，保持 {}=true 待重试 sn={}", ADDR_GLUE_COLLECT, sn);
return;
}
s7PLC.writeBoolean(ADDR_GLUE_COLLECT, false);
logger.info("涂胶数据采集完成 sn={} 序号={}，已将 {} 置 false", sn, glueSeq, ADDR_GLUE_COLLECT);
}
/**
* DB1300.64.5 整体完成信号为 true：提交工位 OK → 成功后将 DB1300.64.2 置 false
*/
private void handleComplete(S7PLC s7PLC) {
if (!s7PLC.readBoolean(ADDR_COMPLETE)) {
return;
}
String sn = readWorkpieceCode(s7PLC);
if (StringUtils.isBlank(sn)) {
sn = lastKnownSn;
}
if (StringUtils.isBlank(sn)) {
logger.error("涂胶工位完成提交失败：无工件码，保持 {}=true 待重试", ADDR_COMPLETE);
return;
}
if (sn.equals(lastCompletedSn)) {
return;
}
if (!submitStationResult(sn, "OK")) {
logger.error("涂胶工位结果提交失败，保持信号待重试 sn={}", sn);
return;
}
s7PLC.writeBoolean(ADDR_QUALITY_PASS, false);
lastCompletedSn = sn;
logger.info("涂胶工位完成 sn={}，已提交 OK 并将 {} 置 false", sn, ADDR_QUALITY_PASS);
}
private boolean saveTjData(String sn, int glueSeq, float glueSpeed, int glueLength) {
try {
MesProductTj entity = new MesProductTj();
entity.setSn(sn);
entity.setOprno(OPRNO);
entity.setTjData(String.valueOf(glueSeq));
entity.setTjSpeed(fmt(glueSpeed));
entity.setTjLength(String.valueOf(glueLength));
mesProductTjService.save(entity);
return true;
} catch (Exception e) {
logger.error("涂胶数据保存异常 sn={}：{}", sn, e.getMessage());
return false;
}
}
/**
* 直接提交工位结果（供测试 / 手工触发），不读写 PLC 信号。
* 逻辑与 64.5 完成时的 submitStationResult 相同（含回查与强制落库）。
*
* @param sn 工件码
* @param result 结果，通常为 OK
* @return true=craft=100000 已确认为目标结果
*/
public boolean submitStationResultNow(String sn, String result) {
if (StringUtils.isBlank(sn)) {
logger.error("涂胶工位结果提交跳过：工件码为空");
return false;
}
return submitStationResult(sn.trim(), StringUtils.isBlank(result) ? "OK" : result.trim());
}
/**
* 提交工位结果为 OK，并回查 craft=100000 确认已落库。
* updateRecordResult 在单部件工位或缺少总结果行时可能静默跳过，此时改走 updateRecord 强制更新。
*/
private boolean submitStationResult(String sn, String result) {
String oldOprno = OPRNO + "A";
String lineSn = getLineSn(sn);
if (StringUtils.isBlank(lineSn)) {
logger.warn("涂胶工位结果提交失败：无法解析产线编号 sn={}", sn);
return false;
}
try {
List params = new ArrayList<>();
List bmlists = new ArrayList<>();
mesProductRecordService.updateRecordResult(sn, oldOprno, "100000", "", result,
"", params, lineSn, true, bmlists, null);
if (isStationMainResult(sn, lineSn, result)) {
logger.info("涂胶工位结果已提交 sn={} oprno={} result={}", sn, oldOprno, result);
return true;
}
logger.warn("updateRecordResult 未真正更新 craft=100000，改为 updateRecord 强制提交 sn={} oprno={}",
sn, oldOprno);
mesProductRecordService.updateRecord(sn, oldOprno, "100000", "", result, "", lineSn);
if (!isStationMainResult(sn, lineSn, result)) {
logger.error("涂胶工位结果强制提交后仍未落库 sn={} oprno={} lineSn={}", sn, oldOprno, lineSn);
return false;
}
logger.info("涂胶工位结果已强制提交 sn={} oprno={} result={}", sn, oldOprno, result);
return true;
} catch (Exception e) {
logger.error("涂胶工位结果提交异常 sn={}：{}", sn, e.getMessage());
return false;
}
}
/** 回查工位总结果行 craft=100000 是否已为指定结果 */
private boolean isStationMainResult(String sn, String lineSn, String expectContent) {
String fOprno = CommonUitl.formatOprno(OPRNO + "A");
MesProductRecord query = new MesProductRecord();
query.setSn(sn);
query.setOprno(fOprno);
query.setCraft("100000");
query.setLineSn(lineSn);
List list = mesProductRecordService.findList(query);
if (list == null || list.isEmpty()) {
return false;
}
return expectContent.equals(list.get(0).getContent());
}
private boolean doQualityCheck(String sn) {
String oldOprno = OPRNO + "A";
String lineSn = getLineSn(sn);
if (StringUtils.isBlank(lineSn)) {
logger.warn("涂胶质量校验失败：无法解析产线编号 sn={}", sn);
return false;
}
try {
String ret = mesProductRecordController.checkQualityCommon(oldOprno, sn, lineSn, "");
if (StringUtils.isBlank(ret) || ret.length() < 5) {
return false;
}
return "UD".equals(ret.substring(3, 5));
} catch (Exception e) {
logger.error("涂胶质量校验异常 sn={}：{}", sn, e.getMessage());
return false;
}
}
private String getLineSn(String sn) {
String lineSn = Global.getConfig("mes.tj.lineSn");
if (StringUtils.isNotBlank(lineSn)) {
return lineSn.trim();
}
MesProduct product = mesProductService.findBySn(sn);
if (ObjectUtils.isEmpty(product) || StringUtils.isBlank(product.getCate())) {
return DEFAULT_LINE_SN;
}
MesLine query = new MesLine();
query.setProductCate(product.getCate());
query.setStatus("0");
MesLine line = mesLineService.findInfo(query);
if (ObjectUtils.isEmpty(line) || StringUtils.isBlank(line.getSn())) {
return DEFAULT_LINE_SN;
}
return line.getSn();
}
private String readWorkpieceCode(S7PLC s7PLC) {
String raw = s7PLC.readString(ADDR_SN, SN_LENGTH);
if (StringUtils.isBlank(raw)) {
return null;
}
StringBuilder sb = new StringBuilder(raw.length());
for (int i = 0; i < raw.length(); i++) {
char c = raw.charAt(i);
if (c == 0 || c == ' ') {
continue;
}
if (c >= 32 && c < 127) {
sb.append(c);
}
}
return sb.toString().trim();
}
private String getPlcIp() {
String ip = Global.getConfig("mes.tj.plc.ip");
return StringUtils.isBlank(ip) ? DEFAULT_PLC_IP : ip.trim();
}
private static String fmt(float val) {
return String.format("%.3f", val);
}
}