包装料机器人逻辑

myproject/src/main/java/com/myproject/bean/qisda/InquiryShelfBean.java

@@ -26,6 +26,16 @@ public class InquiryShelfBean {
     public static Map<String,Map<String,ShelfInfo>> hSerialShelfMap = new ConcurrentHashMap<>();
 
     /**
+     * 清理使用过的料架
+     */
+    public static void clearShelf(String hSerial){
+        if(hSerial != null){
+            log.info("清理["+hSerial+"]使用的过料架");
+            hSerialShelfMap.remove(hSerial);
+        }
+    }
+
+    /**
      * 添加限制库位(即库位中只能放入某个条码)
      * @param task
      * @param outItem
@@ -241,12 +251,15 @@ public class InquiryShelfBean {
      * @param packageRfid
      * @return
      */
-    public ShelfInfo findPackageShelf(String packageRfid){
+    public ShelfInfo findPackageShelf(String hSerial, String packageRfid){
         if(packageRfid == null){
             return null;
         }
-        for (Map<String, ShelfInfo> shelfInfoMap : hSerialShelfMap.values()) {
-            for (ShelfInfo shelf : shelfInfoMap.values()) {
+        Map<String, ShelfInfo> shSerialShelfInfoMap = hSerialShelfMap.get(hSerial);
+        if(shSerialShelfInfoMap == null ){
+            return null;
+        }
+        for (ShelfInfo shelf : shSerialShelfInfoMap.values()) {
             String shelfRFID = shelf.getRealRfid();
             if(shelfRFID != null){
                 if(shelfRFID.equals(packageRfid)){
@@ -255,7 +268,6 @@ public class InquiryShelfBean {
                 }
             }
         }
-        }
         return null;
     }
 
@@ -284,6 +296,28 @@ public class InquiryShelfBean {
         return null;
     }
 
+    public ShelfInfo findMaxUsedShelf(String hSerial, String shelfType){
+        Map<String, ShelfInfo> shelfMap = hSerialShelfMap.get(hSerial);
+        ShelfInfo maxLocShelf = null;
+        for (ShelfInfo shelf : shelfMap.values()) {
+            if(StorageConstants.SHEFL_TYPE.judgeType(shelfType, shelf.getShelfType())){
+                //同一种料架
+                if(maxLocShelf == null){
+                    maxLocShelf = shelf;
+                }
+                if(shelf.getUsedLocCount() > maxLocShelf.getUsedLocCount()){
+                    maxLocShelf = shelf;
+                }
+            }
+        }
+        if(maxLocShelf != null){
+            log.info("找到类型为["+shelfType+"]库位最多的同种料架["+maxLocShelf.tempRfid()+"]");
+        }else{
+            log.info("已没有与["+shelfType+"]类型相同的料架");;
+        }
+        return maxLocShelf;
+    }
+
     /**
      * 锁定架位
      */

myproject/src/main/java/com/myproject/bean/update/qisda/OutInfo.java

@@ -177,6 +177,14 @@ public class OutInfo extends BaseMongoBean {
         return getAction().contains("首盘");
     }
 
+
+    /**
+     * 补料需求单
+     */
+    public boolean isTailAction(){
+        return getAction().contains("补料");
+    }
+
     public int getTaskFinishNum() {
         return taskFinishNum;
     }

myproject/src/main/java/com/myproject/webapp/controller/qisda/util/OutInfoCache.java

@@ -26,6 +26,22 @@ public class OutInfoCache {
     //定时查询未完成的需求单
     private static Map<String,OutInfo> outInfoMap = new ConcurrentHashMap<>();
 
+    /**
+     * 当前正在执行的工单需求单(首盘,补料),未完成时,其他工单需求单不可执行
+     */
+    private static String currentOrderHSerial = "";
+
+    public static void setCurrentOrderHSerial(String currentOrderHSerial) {
+        if(currentOrderHSerial == null){
+            currentOrderHSerial = "";
+        }
+        OutInfoCache.currentOrderHSerial = currentOrderHSerial;
+    }
+
+    public String getCurrentOrderHSerial() {
+        return currentOrderHSerial;
+    }
+
     @Autowired
     private IOutInfoDao outInfoDao;
 

myproject/src/main/java/com/myproject/webapp/controller/webService/QisdaApiController.java

@@ -429,17 +429,17 @@ public class QisdaApiController extends BaseController {
     private void realBindReel(OutItem outItem){
         if(!outItem.isCutMaterial()){
             //先从预绑定料盘中进行绑定,如果还有缺料的,从未使用的物料中查找,如果还缺料,从预绑定的物料中查找
-            log.info("绑定非分盘料:So=["+outItem.getSo()+"]hSerial=["+outItem.gethSerial()+"]+refno=["+outItem.getRefno()+"]的slotLoction"+outItem.getSlotlocation()+"]pn=["+outItem.getPn()+"]当前绑定数量["+outItem.getRealLockQty()+"/"+outItem.getQty()+"]");
-
+            log.info("绑定非分盘料:So=["+outItem.getSo()+"]hSerial=["+outItem.gethSerial()+"]+refno=["+outItem.getRefno()+"]的slotLoction"+outItem.getSlotlocation()+"]pn=["+outItem.getPn()+"]当前绑定数量["+outItem.getRealLockQty()+"/"+outItem.getQty()+"]当前出库/发料数量["+outItem.getOutQty()+"/"+outItem.getSendQty()+"]");
 
             List<StoragePos> preBindPosList = storagePosDao.findPreBindList(outItem.getSo(), outItem.getSlotlocation());
             for (StoragePos pos : preBindPosList) {
                 outItem = tryRealBind(pos, outItem);
             }
-            log.info("将预绑定转为真实绑定结束,当前数量:"+ outItem.getRealLockQty() +"/" + outItem.getQty());
-            int needNum = outItem.getQty() - outItem.getRealLockQty();
+            //所需数量=需求单数量-已发料数量-真实绑定数量
+            int needNum = outItem.getQty() - outItem.getSendQty() - outItem.getRealLockQty();
+            log.info("将预绑定转为真实绑定结束,所需数量("+needNum+")=需求单数量("+outItem.getQty()+")-已发料数量("+ outItem.getSendQty()+")-真实绑定数量"+ outItem.getRealLockQty() +")");
             if(needNum >= 0){
-                log.info("预绑定数量不足,查找未绑定料盘进行真实绑定结束,当前数量:"+ outItem.getRealLockQty() +"/" + outItem.getQty());
+                log.info("预绑定数量不足,查找未绑定料盘进行真实绑定结束,当前数量:"+outItem.getSendQty()+"+"+ outItem.getRealLockQty() +"/" + outItem.getQty());
                 while(needNum >= 0){
                     StoragePos pos = storagePosDao.findNoBindMinQty(outItem.getPn(), outItem.getFacility());
                     OutItem resultOutItem = tryRealBind(pos, outItem);
@@ -455,9 +455,9 @@ public class QisdaApiController extends BaseController {
             }
 
 
-            needNum = outItem.getQty() - outItem.getRealLockQty();
+            needNum = outItem.getQty() - outItem.getSendQty() - outItem.getRealLockQty();
             if(needNum >= 0 ){
-                log.info("未绑定料盘数量不足,开始抢其他工单的预绑定物料进行真实绑定,当前数量:"+ outItem.getRealLockQty() +"/" + outItem.getQty());
+                log.info("未绑定料盘数量不足,开始抢其他工单的预绑定物料进行真实绑定,当前数量:"+outItem.getSendQty()+"+"+ outItem.getRealLockQty() +"/" + outItem.getQty());
                 //抢其他工单的预绑定
                 while(needNum >= 0){
                     StoragePos pos = storagePosDao.findOtherPreBindMinQty(outItem.getPn(), outItem.getFacility());
@@ -466,13 +466,13 @@ public class QisdaApiController extends BaseController {
                         break;
                     }
                     outItem = resultOutItem;
-                    if(outItem.getRealLockQty() > outItem.getQty()){
+                    if(outItem.getRealLockQty() + outItem.getSendQty() > outItem.getQty()){
                         //已经满足需求了,直接跳出
                         break;
                     }
                 }
             }
-            log.info("So=["+outItem.getSo()+"]hSerial=["+outItem.gethSerial()+"]+refno=["+outItem.getRefno()+"]的slot"+outItem.getSlotlocation()+"]pn=["+outItem.getPn()+"]真实绑定结束,当前数量:"+ outItem.getRealLockQty() +"/" + outItem.getQty());
+            log.info("So=["+outItem.getSo()+"]hSerial=["+outItem.gethSerial()+"]+refno=["+outItem.getRefno()+"]的slot"+outItem.getSlotlocation()+"]pn=["+outItem.getPn()+"]真实绑定结束,当前数量:"+outItem.getSendQty()+"+"+ outItem.getRealLockQty() +"/" + outItem.getQty());
         }
     }
 
@@ -993,9 +993,10 @@ public class QisdaApiController extends BaseController {
                 tasks.add(task);
             }
         }else{
-            int needNum = outItem.getQty() - outItem.getRealLockQty();
+            //紧急料,未绑定数量=需求单数量-已出库数量-已绑数量
+            int needNum = outItem.getQty() - outItem.getOutQty() - outItem.getRealLockQty();
             if(needNum >= 0){
-                log.info("紧急料,查找未绑定料盘进行出库,当前数量:"+ outItem.getRealLockQty() +"/" + outItem.getQty());
+                log.info("紧急料,查找未绑定料盘进行出库,未绑数量为"+needNum+"=(需求单"+  outItem.getQty() + ") - (已出" + outItem.getOutQty() + ")-已绑(" + outItem.getRealLockQty()+")");
                 while(needNum >= 0){
                     StoragePos pos = storagePosDao.findNoBindMinQty(outItem.getPn(), outItem.getFacility());
                     if(pos != null){
@@ -1139,25 +1140,15 @@ public class QisdaApiController extends BaseController {
             }
         }
 
-        //清理掉已经完成的需求单的料架
-//        Set<String> hserialSet = InquiryShelfBean.hSerialShelfMap.keySet();
-//        for (String hserial : hserialSet) {
-//            OutInfo out = outInfoDao.findByHSerial(hSerial);
-//            if(!outInfo.isReelCutAction() && !outInfo.isUrgentAction()){
-//                log.info("清理需求单["+out.gethSerial()+"]占用的料架");
-//                InquiryShelfBean.hSerialShelfMap.remove(hserial);
-//            }
-//        }
-
 
 
-        //TODO:可以出的时候把之前的料架信息清空
-
-        outInfo.setTaskNum(0);
-        outInfo.setTaskFinishNum(0);
-        outInfo.setOutReelNum(0);
-
-        outInfo = outInfoDao.save(outInfo);
+        //如果是工单需求单,设置当前正在执行的工单需求单
+        if(outInfo.isFirstReelAction() || outInfo.isTailAction()){
+            String oldHSerial = outInfoCache.getCurrentOrderHSerial();
+            log.info("设置当前正在执行的工单料需求为:" + outInfo.gethSerial()+"清理之前["+oldHSerial+"]出库使用的料架");
+            InquiryShelfBean.clearShelf(oldHSerial);
+            outInfoCache.setCurrentOrderHSerial(outInfo.gethSerial());
+        }
 
         List<DataLog> tasks = new ArrayList<>();
 
@@ -1186,8 +1177,12 @@ public class QisdaApiController extends BaseController {
 
         int outReelNum = tasks.size();
         if(outReelNum > 0){
+            log.info("需求单"+outInfo.gethSerial()+"已出("+outInfo.getOutReelNum()+")/已发("+outInfo.getTaskFinishNum()+") 本次出库料盘数量:" + outReelNum);
+            outInfo.setOutReelNum(0);
+            outInfo.setTaskFinishNum(0);
             outInfo.setTaskNum(outReelNum);
             outInfo = outInfoDao.save(outInfo);
+
             //先出小料盘,再出大料盘
             for (DataLog task : tasks) {
                 if(task.isSmallReel()){
@@ -1201,7 +1196,6 @@ public class QisdaApiController extends BaseController {
             }
 
         }
-        log.info("需求单"+outInfo.gethSerial()+" 出库料盘数量:" + outReelNum);
 
         if(outInfo.isReelCutAction() || outInfo.isFirstReelAction()){
             if(outReelNum == 0){

myproject/src/main/java/com/myproject/webapp/controller/webService/QisdaDeviceController.java

@@ -199,10 +199,23 @@ public class QisdaDeviceController extends BaseController {
             String bigRfid = request.getParameter("bigRfid");
             //包装料RFID
             String packageRfid = request.getParameter("packageRfid");
-            log.info("收到包装料摆放位置信息请求:[packageRfid=" + packageRfid + "]bigRfid=" + bigRfid);
-            ShelfInfo packageShelf = inquiryShelfBean.findPackageShelf(packageRfid);
+            String hSerial = outInfoCache.getCurrentOrderHSerial();
+            log.info("收到包装料摆放位置信息请求:[packageRfid=" + packageRfid + "]bigRfid=" + bigRfid + "当前工单料需求:["+hSerial+"]");
+            ShelfInfo packageShelf = inquiryShelfBean.findPackageShelf(hSerial, packageRfid);
+
+            ShelfInfo bigShelf = inquiryShelfBean.findSameShelf(hSerial,bigRfid);
+            //未找到,说明是未绑定过的新料架,找相同类型的进行绑定
+            //未找到已经有实际RFID的料架,查找库位最多的料架
+            if(bigShelf == null){
+                log.info("未找到实际绑定的["+bigRfid+"]料架,开始查找库位最多的C型料架");
+                ShelfInfo maxLocShelf = inquiryShelfBean.findMaxUsedShelf(hSerial, StorageConstants.SHEFL_TYPE.C);
+                if(maxLocShelf != null){
+                    bigShelf = maxLocShelf;
+                }else{
+                    log.info(hSerial + "已没有C型料架");
+                }
+            }
 
-            ShelfInfo bigShelf = inquiryShelfBean.findBigShelf(bigRfid);
             if(bigShelf != null){
                 Collection<DataLog> queueTasks = taskService.getQueueTasks();
                 List<DataLog> allTasks = taskService.getFinishedTasks();
@@ -293,7 +306,8 @@ public class QisdaDeviceController extends BaseController {
                 resultMap.put("packageTask", packageTask +"");
                 resultMap.put("packageRfid", packageRfid);
                 resultMap.put("packageLoc", packageLoc);
-                resultMap.put("bigRfid", bigRfid);
+                resultMap.put("bigRfid", bigShelf.tempRfid());
+                resultMap.put("realBigRfid",bigShelf.getRealRfid());
                 resultMap.put("bigLoc", bigLoc);
 
                 log.info("大料架信息返回:"+resultMap);
@@ -303,8 +317,6 @@ public class QisdaDeviceController extends BaseController {
             }
 
 
-
-
         }catch(Exception e){
             log.error("包装料摆放位置信息获取出错",e);
             return ResultBean.newErrorResult(-1,"包装料摆放位置信息获取出错:" + e.getMessage());
@@ -457,11 +469,13 @@ public class QisdaDeviceController extends BaseController {
      * @param rfid 料架RFID
      * @param rfidLoc 料架位置
      */
-    private void reelPutInFinished(DataLog cacheTask, String rfid, String rfidLoc){
+    private boolean reelPutInFinished(DataLog cacheTask, String rfid, String rfidLoc){
         if(cacheTask != null){
             AppendInfo appendInfo = cacheTask.getAppendInfo();
             boolean putResult = inquiryShelfBean.putInShelf(cacheTask,rfid, Integer.valueOf(rfidLoc));
-            if(!putResult){
+            //紧急料和分盘料放入失败不影响
+            boolean isCutTask = cacheTask.isUrgentReel() || cacheTask.isCutReel();
+            if(!isCutTask && !putResult){
                 //记录日志
                 String errorMsg = "料盘["+cacheTask.getBarcode()+"]放入位置"+rfid+"["+rfidLoc+"],原分配位置"+appendInfo.getTempRfid()+"["+appendInfo.getRfidLoc()+"],不更改状态,不进行发料";
                 log.error(errorMsg);
@@ -475,8 +489,9 @@ public class QisdaDeviceController extends BaseController {
                 alarmInfo.setEndTime(date);
                 alarmInfo.setAlarmMsg(errorMsg);
                 alarmInfoDao.save(alarmInfo);
-                return;
-            }
+                return putResult;
+            }else{
+                log.info("料盘["+cacheTask.getBarcode()+"]放入位置"+rfid+"["+rfidLoc+"]成功");
                 cacheTask.setStatus(StorageConstants.OP_STATUS.FINISHED.name());
                 appendInfo.setRfid(rfid);
                 appendInfo.setRfidLoc(Integer.valueOf(rfidLoc));
@@ -484,8 +499,6 @@ public class QisdaDeviceController extends BaseController {
                 cacheTask = dataLogDao.save(cacheTask);
                 taskService.updateFinishedTask(cacheTask);
 
-
-
                 String hSerial = appendInfo.gethSerial();
                 if(Strings.isNotBlank(hSerial)){
                     OutInfo outInfo = outInfoDao.findByHSerial(hSerial);
@@ -520,6 +533,10 @@ public class QisdaDeviceController extends BaseController {
                     }
                 }
             }
+
+            return putResult;
+        }
+        return false;
     }
     /**
      * 包装线机器人从A包装料架放到C大料架上barcode
@@ -539,9 +556,10 @@ public class QisdaDeviceController extends BaseController {
             if (cacheTask == null) {
                 return ResultBean.newErrorResult(501,"料盘[" + barcode + "]的任务不存在");
             } else {
-                reelPutInFinished(cacheTask,bigRfid, bigLoc);
+                boolean putInResult = reelPutInFinished(cacheTask,bigRfid, bigLoc);
+                if(putInResult){
                     //清理包装料架的位置
-                ShelfInfo packageShelf = inquiryShelfBean.findPackageShelf(packageRfid);
+                    ShelfInfo packageShelf = inquiryShelfBean.findPackageShelf(cacheTask.getAppendInfo().gethSerial(), packageRfid);
                     if(packageShelf != null){
                         Map<Integer, ShelfLoc> packageLocMap = packageShelf.getLocMap();
                         for (ShelfLoc shelfLoc : packageLocMap.values()) {
@@ -558,6 +576,7 @@ public class QisdaDeviceController extends BaseController {
                     }
                 }
             }
+        }
 
         String msg = "包装线机器人放置料盘["+barcode+"]从"+packageRfid+"["+packageLoc+"]=>"+bigRfid+"["+bigLoc+"]失败";
         return ResultBean.newErrorResult(501,msg);
@@ -576,8 +595,6 @@ public class QisdaDeviceController extends BaseController {
 
         try{
 
-
-
             DataLog cacheTask = null;
             if(Strings.isNotBlank(barcode)) {
                 cacheTask = taskService.getFinishedTask(barcode);

myproject/src/main/java/com/myproject/webapp/controller/webService/StorageDataController.java

@@ -584,9 +584,9 @@ public class StorageDataController extends BaseController {
                 }else {
                     StoragePos pos = null;
                     try {
-                        log.info("条码["+barcode.getBarcode()+"]入库,清空Facility入库信息");
-                        barcode.setAppendInfo(null);
-                        barcode = barcodeManager.save(barcode);
+//                        log.info("条码["+barcode.getBarcode()+"]入库,清空Facility入库信息");
+//                        barcode.setAppendInfo(null);
+//                        barcode = barcodeManager.save(barcode);
 
                         pos = taskService.findEmptyPosForPutIn(storageList,barcode, rfid);
                         if(pos != null){

myproject/src/main/java/com/myproject/webapp/controller/webService/TaskService.java

@@ -559,30 +559,28 @@ public class TaskService implements ITaskService {
             }
         }
 
-        //按任务数量从小到大排序
-//        List<Map.Entry<String, Integer>> list = new ArrayList<>(countMap.entrySet());
-//        Collections.sort(list, new Comparator<Map.Entry<String, Integer>>()
-//        {
-//            @Override
-//            public int compare(Map.Entry<String, Integer> o1, Map.Entry<String, Integer> o2)
-//            {
-//                //按照value值，用compareTo()方法默认是从小到大排序
-//                return o1.getValue().compareTo(o2.getValue());
-//            }
-//        });
+        //可用的料仓(在线,且可以放入)
+        List<Storage> availbleStorageList = new ArrayList<>();
 
+        for(Storage storage : storageList){
+            StatusBean status = getStatus(storage.getCid());
+            if(status.timeOut()){
+                continue;
+            }
+            if(storage.canPutIn(barcode.getPlateSize(),barcode.getHeight())){
+                availbleStorageList.add(storage);
+            }
+        }
 
-        //
-        for (Storage storage : storageList) {
+
+        for (Storage storage : availbleStorageList) {
             String storageId = storage.getId();
+
             Integer taskCount = countMap.get(storageId);
             if(taskCount >= 2){
                 continue;
             }
-            StatusBean status = getStatus(storage.getCid());
-            if(status.timeOut()){
-                continue;
-            }
+
             try{
                 log.info("尝试从"+storage.getName()+"["+storage.getCid()+"]查找空位,当前料仓任务数:" + taskCount);
                 return findLineEmptyPosForPutIn(storage,barcode);
@@ -591,6 +589,17 @@ public class TaskService implements ITaskService {
             }
         }
 
+        //只有一个料仓可以入时,只能继续往里面放
+        log.info("可用料仓太少,不按任务数分配,重新查找...");
+        for (Storage storage : availbleStorageList) {
+            try{
+                log.info("尝试从"+storage.getName()+"["+storage.getCid()+"]查找空位,当前料仓任务数");
+                return findLineEmptyPosForPutIn(storage,barcode);
+            }catch(Exception e){
+                log.info("从"+storage.getName()+"["+storage.getCid()+"]查找空位失败:" + e.getMessage());
+            }
+        }
+
         return null;
 
     }
@@ -1027,6 +1036,11 @@ public class TaskService implements ITaskService {
                     }
                 }
                 if(!shelfNameList.contains(storageTask.getAppendInfo().getTempRfid())){
+                    if(storageTask.getAppendInfo().isCShelfTask()){
+                        //大料(C料架)只能同时出一个架子,不然到包装料工位时无法切换
+                        log.info("未完成的工单料架为:["+String.join(",",shelfNameList)+ "]大料架任务["+storageTask.getBarcode()+"]暂停出库,以免包装工位无法切换");
+                        return null;
+                    }
                     //未完成的工单任务料架数量>2,且未包含此任务,任务先不出,等到只有一个料架时再说
                     if(shelfNameList.size() >= 2){
                         log.info("未完成的工单任务料架为:["+String.join(",",shelfNameList)+ "]任务"+storageTask.getBarcode()+"暂停出库");