大理片:修改进片逻辑，卧转立启动，详情表中新增一条状态为0的玻璃信息，进片任务完成后将状态改为100 下片：下片异常问题解决

zhoushihao

2024-07-25 73db5fb7f98e13e37ff5f43ec8977fb1f0cfcb9b

 hangzhoumesParent/moduleService/UnLoadGlassModule/src/main/java/com/mes/job/DownLoadCacheGlassTask.java

@@ -4,6 +4,7 @@
import cn.smallbun.screw.core.util.CollectionUtils;
import com.baomidou.mybatisplus.core.conditions.query.LambdaQueryWrapper;
import com.baomidou.mybatisplus.core.conditions.update.LambdaUpdateWrapper;
import com.baomidou.mybatisplus.core.conditions.update.UpdateWrapper;
import com.mes.common.S7object;
import com.mes.common.config.Const;
import com.mes.device.PlcParameterObject;
@@ -29,10 +30,7 @@
import org.springframework.scheduling.annotation.Scheduled;
import org.springframework.stereotype.Component;

import java.util.ArrayList;
import java.util.Date;
import java.util.List;
import java.util.Map;
import java.util.*;
import java.util.stream.Collectors;

/**
@@ -72,8 +70,14 @@
    @Value("${mes.maxHeight}")
    private Integer maxHeight;

    @Value("${mes.minWidth}")
    private Integer minWidth;

    @Scheduled(fixedDelay = 1000)
    @Value("${mes.minHeight}")
    private Integer minHeight;


    @Scheduled(fixedDelay = 300)
    public void plcHomeEdgTask() {
        PlcParameterObject plcParameterObject = S7object.getinstance().PlcMesObject;
        String requestWord = plcParameterObject.getPlcParameter("requestWord").getValue();
@@ -86,6 +90,7 @@
        String confirmationWrodValue = plcParameterObject.getPlcParameter("confirmationWord").getValue();
        String confirmationWrodAddress = plcParameterObject.getPlcParameter("confirmationWord").getAddress();
        String currentSlot = plcParameterObject.getPlcParameter("currentCell").getValue();


        log.info("1、获取到的请求字为：{}，获取到的扫描ID为：{}，获取到的确认字为：{}，获取到的出片状态分别为：g06:{}、g08:{}、g11:{}、g13:{},当前格子号为：{}",
                requestWord, glassIdeValue, confirmationWrodValue, out06Glassstate, out08Glassstate, out11Glassstate, out13Glassstate, currentSlot);
@@ -108,7 +113,7 @@
            inTo(glassIdeValue, requestWord, currentSlot);
        } else if ("2".equals(requestWord)) {
            //09空闲 ：1      10空闲 ：2        都空闲：3    其他0
            log.info("2、出片请求，且确认字为0，执行进片任务");
            log.info("2、出片请求，且确认字为0，执行出片任务");
            outTo(out06Glassstate, out08Glassstate, out11Glassstate, out13Glassstate, glassIdeValue, currentSlot);
        } else if ("3".equals(requestWord)) {
            log.info("2、进片和出片都空闲，执行出片任务");
@@ -135,8 +140,8 @@
        }
        Boolean checkFlag = Boolean.FALSE;
        //玻璃尺寸是否走人工下片
        if (glassInfo.getWidth() > maxWidth || glassInfo.getHeight() > maxHeight) {
            log.info("该玻璃尺寸走人工下片,直接进片");
        if (glassInfo.getWidth() > maxWidth || glassInfo.getHeight() > maxHeight || glassInfo.getWidth() < minWidth || glassInfo.getHeight() < minHeight) {
            log.info("该玻璃尺寸不符合要求，需要走人工下片直接进片");
        } else {
            log.info("该玻璃尺寸非人工下片");
            //获取该玻璃的流程卡是否已绑定架子
@@ -152,14 +157,11 @@
            if (!checkFlag && !isBind) {
                log.info("该玻璃的流程卡未绑定架子，获取是否有空架子");
                List<DownWorkstation> list = downWorkstationService.list(new LambdaQueryWrapper<DownWorkstation>()
                        .isNull(DownWorkstation::getFlowCardId));
                        .isNull(DownWorkstation::getFlowCardId).orderByDesc(DownWorkstation::getWorkstationId));
                if (CollectionUtils.isNotEmpty(list)) {
                    log.info("有空架子,将流程卡与架子好绑定，执行进片任务 结束");
                    //绑定流程卡
                    downWorkstationService.update(new LambdaUpdateWrapper<DownWorkstation>()
                            .set(DownWorkstation::getFlowCardId, glassInfo.getFlowCardId())
                            .set(DownWorkstation::getLayer, glassInfo.getLayer())
                            .eq(DownWorkstation::getWorkstationId, list.get(0).getWorkstationId()));
                    downWorkstationService.updateFlowCardIdAndCount(glassInfo.getFlowCardId(), list.get(0).getWorkstationId(), glassInfo.getLayer());
                    checkFlag = Boolean.TRUE;
                }
            }
@@ -174,27 +176,28 @@
                    endLoop:
                    for (DownGlassInfoDTO e : downGlassInfoDTOList) {
                        List<GlassInfo> glassInfoList = e.getGlassInfoList();
                        for (GlassInfo item : glassInfoList) {
                            if (item.getWidth() == glassInfo.getWidth() && item.getHeight() == glassInfo.getHeight()
                                    && item.getThickness() == glassInfo.getThickness() && item.getFilmsid().equals(glassInfo.getFilmsid())) {
                                //玻璃是否为多层
                                checkFlag = multilayerCheck(item, Boolean.FALSE);
                                if (checkFlag) {
                                    //玻璃替换 仅替换流程卡id及层数
                                    String tempFlowCardId = item.getFlowCardId();
                                    Integer tempLayer = item.getLayer();
                                    String flowCardId = glassInfo.getFlowCardId();
                                    Integer layer = glassInfo.getLayer();
                                    log.info("替换流程卡信息,当前玻璃信息:{}的流程卡号{}及层数{},替换后玻璃信息:{}的流程卡号{}及层数{}",
                                            item, glassInfo, flowCardId, layer, tempFlowCardId, tempLayer);
                                    glassInfo.setFlowCardId(tempFlowCardId);
                                    glassInfo.setLayer(tempLayer);
                                    glassInfoService.updateById(glassInfo);
                                    item.setFlowCardId(flowCardId);
                                    item.setLayer(layer);
                                    glassInfoService.updateById(item);
                                    break endLoop;
                                }
                        Optional<GlassInfo> glassInfoTempOptional = glassInfoList.stream().filter(item -> item.getWidth() == glassInfo.getWidth() && item.getHeight() == glassInfo.getHeight()
                                && item.getThickness() == glassInfo.getThickness() && item.getFilmsid().equals(glassInfo.getFilmsid()))
                                .findFirst();
                        if (glassInfoTempOptional.isPresent()) {
                            GlassInfo item = glassInfoTempOptional.get();
                            //玻璃是否为多层
                            checkFlag = multilayerCheck(item, Boolean.FALSE);
                            if (checkFlag) {
                                //玻璃替换 仅替换流程卡id及层数
                                String tempFlowCardId = item.getFlowCardId();
                                Integer tempLayer = item.getLayer();
                                String flowCardId = glassInfo.getFlowCardId();
                                Integer layer = glassInfo.getLayer();
                                log.info("替换流程卡信息,当前玻璃信息:{}的流程卡号{}及层数{},替换后玻璃信息:{}的流程卡号{}及层数{}",
                                        item, glassInfo, flowCardId, layer, tempFlowCardId, tempLayer);
                                glassInfo.setFlowCardId(tempFlowCardId);
                                glassInfo.setLayer(tempLayer);
                                glassInfoService.updateById(glassInfo);
                                item.setFlowCardId(flowCardId);
                                item.setLayer(layer);
                                glassInfoService.updateById(item);
                                break endLoop;
                            }
                        }
                    }
@@ -207,11 +210,13 @@
        downStorageCageDetails.setState(Const.GLASS_STATE_IN);
        downStorageCageDetails.setSlot(nearestEmpty.getSlot());
        downStorageCageDetailsService.save(downStorageCageDetails);
//        生成进片任务

        //        生成进片任务
        initDownGlassTask(glassInfo, 0, nearestEmpty.getSlot(), Const.GLASS_CACHE_TYPE_IN);
    }

    public Boolean outTo(String glassStatus06, String out08Glassstate, String glassStatus11, String glassStatus13, String glassId, String currentSlot) {
    public Boolean outTo(String glassStatus06, String out08Glassstate, String glassStatus11, String
            glassStatus13, String glassId, String currentSlot) {
        if ("2".equals(glassStatus06) && "2".equals(glassStatus11) && "2".equals(glassStatus13)) {
            log.info("G06、G11、G13分别为{},{}、{}非自动状态，无法出片", glassStatus06, glassStatus11, glassStatus13);
            return Boolean.FALSE;
@@ -236,9 +241,14 @@
            return Boolean.FALSE;
        }
        Boolean flag08 = "1".equals(out08Glassstate) ? Boolean.TRUE : Boolean.FALSE;
        if (!generateTaskByShelf(glassStatus11, flag08, glassStatus13, tempList, cageDetails)) {
            return generateTaskByShelf(glassStatus11, !flag08, glassStatus13, tempList, cageDetails);
        if (!flag08) {
            generateTaskByShelf(glassStatus06, glassStatus11, flag08, glassStatus13, tempList, cageDetails, glassId);
        } else {
            if (!generateTaskByShelf(glassStatus06, glassStatus11, flag08, glassStatus13, tempList, cageDetails, glassId)) {
                return generateTaskByShelf(glassStatus06, glassStatus11, !flag08, glassStatus13, tempList, cageDetails, glassId);
            }
        }

        return Boolean.TRUE;
    }

@@ -279,26 +289,29 @@
        }
    }

    private Boolean generateTaskByShelf(String glassStatus, Boolean flag08, String glassStatus13, List<DownStorageCageDetails> tempList, DownStorageCageDetails cageDetails) {
    private Boolean generateTaskByShelf(String glassStatus06, String glassStatus11, Boolean flag08, String
            glassStatus13, List<DownStorageCageDetails> tempList, DownStorageCageDetails cageDetails, String glassId) {
        //获取2个机械臂范围内的架子绑定的流程卡信息
        List<Integer> workList = new ArrayList();

        if (flag08) {
            if (!"2".equals(glassStatus)) {
            if (!"2".equals(glassStatus11)) {
                workList.addAll(Const.G11_WORK_STATION);
            }
        } else {
            if (!"2".equals(glassStatus)) {
            if (!"2".equals(glassStatus06)) {
                workList.addAll(Const.G06_WORK_STATION);
            }
        }
        List<Integer> workStationAll = Arrays.asList(1, 2, 3, 4, 5, 6);
        List<Integer> offWorkStationList = workStationAll.stream().filter(e -> !workList.contains(e)).collect(Collectors.toList());
        List<DownStorageCageDetails> list = new ArrayList();
        Boolean isEmptyShelf = Boolean.FALSE;
        //对笼内玻璃进行过滤，仅出符合逻辑的玻璃
        if (CollectionUtils.isNotEmpty(workList)) {
            List<DownWorkstation> downWorkstationList = downWorkstationService.list(new LambdaQueryWrapper<DownWorkstation>()
                    .eq(DownWorkstation::getEnableState, 0).in(DownWorkstation::getWorkstationId, workList));
            log.info("架子被禁用，无法出片落架");
                    .eq(DownWorkstation::getEnableState, Const.SLOT_ON).in(DownWorkstation::getWorkstationId, workList));
//            log.info("架子被禁用，无法出片落架");
            if (CollectionUtils.isEmpty(downWorkstationList)) {
                log.info("笼子被禁用，无法走机械臂下片");
                //走人工下片
@@ -306,18 +319,32 @@
                    list = tempList.stream().filter(item -> item.getWidth() > maxWidth || item.getHeight() > maxHeight).collect(Collectors.toList());
                }
            } else {
                //获取可落架的的架子信息（包括空架子）
                List<DownWorkstation> workstationsIsNotBind = downWorkstationList.stream().filter(item -> null == (item.getFlowCardId())).collect(Collectors.toList());
                Map<String, List<DownWorkstation>> listMap = downWorkstationList.stream().collect(Collectors.groupingBy(item -> item.getFlowCardId() + ":" + item.getLayer()));
                //将架子的流程卡号及层数作为key
                if (CollectionUtils.isEmpty(workstationsIsNotBind)) {
                    log.info("不存在未绑定流程卡架子");
                    //筛选出对应架子已绑定流程卡可下片的玻璃
                    Map<String, List<DownWorkstation>> listMap = downWorkstationList.stream()
                            .filter(item -> null != (item.getFlowCardId())).collect(Collectors.groupingBy(item -> item.getFlowCardId() + ":" + item.getLayer()));
                    list = tempList.stream().filter(item -> listMap.containsKey(item.getFlowCardId() + ":" + item.getLayer())).collect(Collectors.toList());
                } else {
                    log.info("存在未绑定流程卡架子，直接获取笼内所有玻璃");
                    log.info("存在未绑定流程卡架子，直接获取笼内所有玻璃,且未绑定架子的玻璃信息");
                    //获取禁用架子的流程号，将笼内绑定架子且架子被禁用的流程卡信息

                    List<DownWorkstation> downWorkstationOffList = downWorkstationService.list(new LambdaQueryWrapper<DownWorkstation>()
                            .and(i -> i.in(DownWorkstation::getWorkstationId, offWorkStationList).or().eq(DownWorkstation::getEnableState, Const.SLOT_OFF)));
                    //获取被禁用的流程卡信息
                    if (CollectionUtils.isEmpty(downWorkstationOffList)) {
                        list = tempList;
                    } else {
                        Map<String, List<DownWorkstation>> listOffMap = downWorkstationOffList.stream().filter(item -> null != (item.getFlowCardId())).collect(Collectors.groupingBy(item -> item.getFlowCardId() + ":" + item.getLayer()));
                        list = tempList.stream().filter(item -> !listOffMap.containsKey(item.getFlowCardId() + ":" + item.getLayer())).collect(Collectors.toList());
                    }
                    isEmptyShelf = Boolean.TRUE;
                    //todo:如果禁用架子已绑定流程卡，因为时间不确定，笼子内的玻璃可重新绑定新架子
//                    list = tempList.stream().filter(item -> !listMap.containsKey(item.getFlowCardId() + ":" + item.getLayer())).collect(Collectors.toList());
                    list = tempList;

                }
            }
        } else {
@@ -343,28 +370,27 @@
            }
        }
        loop:
        if (tempGlassId == null) {
        if (StringUtils.isBlank(tempGlassId)) {
            //获取正在落架的绑定流程卡的信息(流程卡、层数、落架数量)
            List<DownGlassInfoDTO> downGlassInfoDTOList = downGlassInfoService.queryWorkStationIsIn(Boolean.TRUE);
            List<String> downGlassFlowList = downGlassInfoDTOList.stream().map(item -> item.getFlowCardId() + ":" + item.getLayer()).collect(Collectors.toList());
            if (CollectionUtils.isEmpty(downGlassFlowList)) {
                //架子都未绑定流程卡，出笼内子数量最多尺寸最大的玻璃
                DownStorageCageDetails downStorageCageDetails = downStorageCageDetailsService.getGlassInfoMaxCount();
                //绑定流程卡，更新玻璃状态，生成出片任务，
                tempGlassId = downStorageCageDetails.getGlassId();
                //架子都未绑定流程卡，出笼内子数量最多尺寸最大的玻璃id,无  则返回扫描扫到的玻璃id进行出片
                tempGlassId = downStorageCageDetailsService.getGlassInfoMaxCount(glassId, offWorkStationList);

                isBind = Boolean.TRUE;
                break loop;
            }
            //将笼子内的玻璃进行过滤，仅获取无法落架的流程卡玻璃
            List<DownStorageCageDetails> noDownLoadList = list.stream().filter(item -> !downGlassFlowList.contains(item.getFlowCardId() + ":" + item.getLayer())).collect(Collectors.toList());
            List<DownStorageCageDetails> noDownLoadList = list.stream().filter(item -> !downGlassFlowList.contains(item.getFlowCardId() + ":" + item.getLayer()))
                    .collect(Collectors.toList());
            if (CollectionUtils.isNotEmpty(noDownLoadList)) {
                //是否有空架子
//                List<DownWorkstation> emptyShelfList = downWorkstationService.list(new LambdaQueryWrapper<DownWorkstation>()
//                        .isNull(DownWorkstation::getFlowCardId));
                if (isEmptyShelf) {
                    DownStorageCageDetails downStorageCageDetails = downStorageCageDetailsService.getGlassInfoMaxCount();
                    //绑定流程卡，更新玻璃状态，生成出片任务
                    tempGlassId = downStorageCageDetails.getGlassId();
                    //架子都未绑定流程卡，出笼内子数量最多尺寸最大的玻璃id,无  则返回扫描扫到的玻璃id进行出片
                    tempGlassId = downStorageCageDetailsService.getGlassInfoMaxCount(glassId, offWorkStationList);
                    isBind = Boolean.TRUE;
                    break loop;
                }
@@ -412,7 +438,7 @@

            Map<String, List<DownStorageCageDetails>> singleLayerMap = list.stream().filter(item -> item.getTotalLayer() == 1)
                    .collect(Collectors.groupingBy(item -> item.getFlowCardId() + item.getLayer(), Collectors.toList()));
            if (tempGlassId == null) {
            if (StringUtils.isBlank(tempGlassId)) {
                if (CollectionUtils.isNotEmpty(singleLayerMap)) {
                    //获取已落架流程卡信息，按落架数量排序
                    for (DownGlassInfoDTO e : downGlassInfoDTOList) {
@@ -426,36 +452,47 @@
                }
            }
        }
        if (tempGlassId == null) {
        if (StringUtils.isBlank(tempGlassId)) {
            log.info("没有找到可以下片的的玻璃，结束任务");
            return Boolean.FALSE;
        } else {
            //按照出片的玻璃id更新笼内的玻璃状态为已出片
            return generateDownGlassOutTask(tempGlassId, Const.GLASS_CACHE_TYPE_OUT, isBind, cageDetails);
            return generateDownGlassOutTask(tempGlassId, Const.GLASS_CACHE_TYPE_OUT, isBind, cageDetails, workList);
        }
    }

    public Boolean generateDownGlassOutTask(String glassId, Integer taskType, Boolean isBind, DownStorageCageDetails cageDetails) {
    public Boolean generateDownGlassOutTask(String glassId, Integer taskType, Boolean
            isBind, DownStorageCageDetails cageDetails, List<Integer> workList) {
        //按玻璃id获取玻璃信息
        DownStorageCageDetails downStorageCageDetails = null;
        if (glassId.equals(cageDetails.getGlassId())) {
            downStorageCageDetails = cageDetails;
            taskType = 3;
            //将下片玻璃存入笼子详情信息表中
            //将任务插入理片笼详情表
            downStorageCageDetails.setState(Const.GLASS_STATE_OUT);
            downStorageCageDetailsService.save(downStorageCageDetails);
        } else {
            downStorageCageDetails = downStorageCageDetailsService.getOne(new LambdaQueryWrapper<DownStorageCageDetails>()
                    .eq(DownStorageCageDetails::getGlassId, glassId));
                    .eq(DownStorageCageDetails::getGlassId, glassId).eq(DownStorageCageDetails::getState, Const.GLASS_STATE_IN));
            if (downStorageCageDetailsService.update(new LambdaUpdateWrapper<DownStorageCageDetails>()
                    .set(DownStorageCageDetails::getState, Const.GLASS_STATE_OUT).eq(DownStorageCageDetails::getGlassId, glassId))) {
                log.info("更新详情表内的状态成功");
//                return Boolean.TRUE;
            } else {
                log.info("更新详情表内的状态失败");
                return Boolean.FALSE;
            }
        }

        Integer endCell = null;
        if (isBind) {
            //获取空架子信息，将空架子信息绑定流程卡
            DownWorkstation emptyDownWorkstation = downWorkstationService.getOne(new LambdaQueryWrapper<DownWorkstation>()
                    .isNull(DownWorkstation::getFlowCardId).orderByDesc(DownWorkstation::getWorkstationId).last("limit 1"));
                    .isNull(DownWorkstation::getFlowCardId).in(DownWorkstation::getWorkstationId, workList).orderByDesc(DownWorkstation::getWorkstationId).last("limit 1"));
            if (null != emptyDownWorkstation) {
                log.info("获取到空架子信息，绑定流程卡");
                emptyDownWorkstation.setFlowCardId(downStorageCageDetails.getFlowCardId());
                emptyDownWorkstation.setLayer(downStorageCageDetails.getLayer());
                downWorkstationService.updateById(emptyDownWorkstation);
                downWorkstationService.updateFlowCardIdAndCount(downStorageCageDetails.getFlowCardId(), emptyDownWorkstation.getWorkstationId(), downStorageCageDetails.getLayer());
                endCell = emptyDownWorkstation.getWorkstationId();
            } else {
                log.info("没有空架子信息，无法绑定流程卡");
@@ -466,19 +503,20 @@
                    .eq(DownWorkstation::getFlowCardId, downStorageCageDetails.getFlowCardId()).eq(DownWorkstation::getLayer, downStorageCageDetails.getLayer()));
            endCell = workstation.getWorkstationId();
        }
        //更新详情表内的状态
        if (downStorageCageDetailsService.update(new LambdaUpdateWrapper<DownStorageCageDetails>()
                .set(DownStorageCageDetails::getState, Const.GLASS_STATE_OUT).eq(DownStorageCageDetails::getGlassId, glassId))) {
            log.info("更新详情表内的状态成功");
        } else {
            log.info("更新详情表内的状态失败");
            return Boolean.FALSE;
        }
        //更新落架玻璃数量
        if (endCell == 7) {
            downWorkstationService.update(new UpdateWrapper<DownWorkstation>().eq("flow_card_id", downStorageCageDetails.getFlowCardId())
                    .eq("layer", downStorageCageDetails.getLayer()).setSql("other_number = other_number +1"));
        } else {
            downWorkstationService.update(new UpdateWrapper<DownWorkstation>().eq("flow_card_id", downStorageCageDetails.getFlowCardId())
                    .eq("layer", downStorageCageDetails.getLayer()).setSql("racks_number = racks_number +1"));
        }

        //生成任务信息
        DownGlassInfo downGlassInfo = new DownGlassInfo();
        BeanUtils.copyProperties(downStorageCageDetails, downGlassInfo);
        //todo：落架片序
        downGlassInfo.setSequence(downGlassInfoService.queryMaxSequence(downGlassInfo.getFlowCardId(), downGlassInfo.getLayer()));
        downGlassInfoService.save(downGlassInfo);
        //生成任务信息
        GlassInfo glassInfo = new GlassInfo();
@@ -492,12 +530,12 @@
        downGlassTask.setStartCell(startCell);
        downGlassTask.setGlassId(glassInfo.getGlassId());
        downGlassTask.setEndCell(endCell);
        downGlassTask.setTaskType(taskType + "");
        downGlassTask.setTaskType(taskType);
        downGlassTask.setWidth((int) glassInfo.getWidth());
        downGlassTask.setHeight((int) glassInfo.getHeight());
        downGlassTask.setFlowCardId(glassInfo.getFlowCardId());
        downGlassTask.setLayer(glassInfo.getLayer());
        downGlassTask.setTaskStauts(0);
        downGlassTask.setTaskStatus(0);
        downGlassTask.setCreateTime(new Date());
        downGlassTaskService.save(downGlassTask);
        //向plc发送命令
@@ -505,7 +543,8 @@
                startCell, endCell, taskType);
    }

    private Boolean sendMessageToPlc(int width, int height, int thickness, int startCell, int endCell, int taskType) {
    private Boolean sendMessageToPlc(int width, int height, int thickness, int startCell, int endCell,
                                     int taskType) {
        S7control s7control = S7object.getinstance().plccontrol;
        PlcParameterObject plcMesObject = S7object.getinstance().PlcMesObject;
        s7control.writeWord(plcMesObject.getPlcParameter("Glass_width").getAddress(), width);