WeldRobotBean.cs
23.5 KB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
using log4net;
using URSoldering.Common;
using System;
using System.Collections.Generic;
using System.Linq;
using System.Reflection;
using System.Text;
using System.Threading;
using URSoldering.LoadCSVLibrary;
using System.Threading.Tasks;
namespace URSoldering.DeviceLibrary
{
public partial class WeldRobotBean
{
public static bool HasSoldering = ConfigAppSettings.GetBoolValue(Setting_Init.HasSoldering);
public static bool IsFirstStart = false;
public static string WarnMsg = "";
public static readonly ILog LOGGER = LogManager.GetLogger(MethodBase.GetCurrentMethod().DeclaringType);
private static System.Timers.Timer mainTimer = new System.Timers.Timer();
public static URPointValue HomePoint = new URPointValue();
public static URPointValue Clear1Point = new URPointValue();
public static URPointValue Clear2Point = new URPointValue();
public static URPointValue RobotMin = new URPointValue();
public static URPointValue RobotMax = new URPointValue();
//休眠的秒数,<=0不需要休眠
public static int SleepSeconds = ConfigAppSettings.GetIntValue(Setting_Init.SleepSeconds);
public static bool isHighSpeed = ConfigAppSettings.GetIntValue(Setting_Init.Robot_IsHigh) == 1;
//public static int ClearMSenconds = ConfigAppSettings.GetIntValue(Setting_Init.Clear_Time);
private static string RobotName = "【焊接】";
/// <summary>
/// 机械臂是否在运行中
/// </summary>
public static bool ISRun = false;
/// <summary>
/// 是否在急停中
/// </summary>
public static bool IsInSudden = false;
/// <summary>
/// 是否没有气压信号
/// </summary>
public static bool IsNoAir = false;
/// <summary>
/// 焊接步骤
/// </summary>
public static WeldStepBean WeldMoveStep = new WeldStepBean();
//public static int ClearCount = ConfigAppSettings.GetIntValue(Setting_Init.Weld_Clear_Count);
public static int WeldCount = 0;
private static bool isInit = false;
public static AlarmType alarmType = AlarmType.None;
//记录是否空闲中,如果空闲并且超过三分钟,就关闭烙铁,下次启动时需要打卡
private static bool IsFree = false;
private static DateTime BeginFreeTime = DateTime.Now;
private static bool SolderSleep = false;
static WeldRobotBean()
{
mainTimer = new System.Timers.Timer();
mainTimer.Interval = 300;
mainTimer.AutoReset = true;
mainTimer.Elapsed += mainTimer_Elapsed;
mainTimer.Enabled = false;
Clear1Point = LoadPoint(Setting_Init.Soldering_Clear1Point);
Clear2Point = LoadPoint(Setting_Init.Soldering_Clear2Point);
HomePoint = LoadPoint(Setting_Init.Soldering_HomePoint);
RobotMin = LoadPoint(Setting_Init.Soldering_RobotMin);
RobotMax = LoadPoint(Setting_Init.Soldering_RobotMax);
}
private static URPointValue LoadPoint(string configStr)
{
URPointValue p = new URPointValue();
string configP = ConfigAppSettings.GetValue(configStr);
if (String.IsNullOrEmpty(configP))
{
ConfigAppSettings.SaveValue(configStr, p.ToJosonStr());
}
else
{
p = URPointValue.ToObject(configP);
}
return p;
}
public static SolderingRobotConfig RobotConfig = null;
public static void InitData(SolderingRobotConfig config)
{
RobotConfig = config;
}
/// <summary>
/// 初始化
/// </summary>
public static void Init()
{
StartURRobot();
SolderingManager.Init(RobotConfig.JBC_Soldering_Port, RobotConfig.JBC_Soldering_Num);
SendWireManager.Init(RobotConfig.JBC_SendWire_Port);
isInit = true;
}
private static void StartURRobot()
{
if (!URRobotControl.IsRun)
{
Task.Factory.StartNew(delegate ()
{
bool result = URRobotControl.StartRobot();
if (!result)
{
WarnMsg = "连接UR机器人失败";
}
});
}
}
public static void ResetInit()
{
StartURRobot();
SendWireManager.Init(RobotConfig.JBC_SendWire_Port);
SolderingManager.Init(RobotConfig.JBC_Soldering_Port, RobotConfig.JBC_Soldering_Num);
}
/// <summary>
/// 开始运行
/// </summary>
/// <returns></returns>
public static string StartRun()
{
LogUtil.info(RobotName + "开始启动");
IsFirstStart = true;
return GoHome();
}
public static string Reset()
{
StopSleep();
WeldMoveStep.EndMove();
WarnMsg = "";
if (!isInit)
{
Init();
}
else
{
ResetInit();
}
//Thread.Sleep(1000);
//if (!URRobotControl.IsRun)
//{
// Thread.Sleep(2000);
//}
if (!URRobotControl.PointIsValid(HomePoint))
{
LogUtil.info(RobotName + "开始启动失败:原点坐标无效");
return "原点坐标无效";
}
if ((!URRobotControl.PointIsValid(Clear1Point)) || (!URRobotControl.PointIsValid(Clear2Point)))
{
LogUtil.info(RobotName + "开始启动失败:清洗点坐标无效");
return "清洗点坐标无效";
}
if (HasSoldering)
{
if (!SolderingManager.IsRun)
{
LogUtil.info(RobotName + "开始启动:烙铁没有连接上");
return "烙铁没有连接上!";
}
if (!SendWireManager.IsRun)
{
LogUtil.info(RobotName + "开始启动:JBC送丝器没有连接上");
return "JBC送丝器没有连接上!";
}
}
IsInSudden = false;
IsNoAir = false;
//开始运行
alarmType = AlarmType.None;
//锁定轴
URRobotControl.LockAxis();
//烙铁温度=0, 送丝上升,机器复位
SolderingUp(false);
SendWireWork(false);
ISRun = true;
mainTimer.Enabled = true;
return "";
}
public static void StopWeld()
{
LogUtil.info(RobotName + "停止当前焊接");
WeldMoveStep.EndMove();
}
/// <summary>
/// 停止所有运动
/// </summary>
public static void StopMove()
{
StopWeld();
LogUtil.info(RobotName + "停止所有运动");
//烙铁温度=0,烙铁上升,送丝上升,机器复位
SolderingUp(false);
SendWireWork(false);
SendWireManager.StopSend();
SolderingManager.Release();
}
/// <summary>
/// 停止运行
/// </summary>
public static void StopRun()
{
IsFree = false;
SolderSleep = false;
StopMove();
mainTimer.Enabled = false;
ISRun = false;
LogUtil.info(LOGGER, RobotName + "停止运行");
}
private static bool IsTimerProcess = false;
static void mainTimer_Elapsed(object sender, System.Timers.ElapsedEventArgs e)
{
if (IsTimerProcess)
{
return;
}
IsTimerProcess = true;
try
{
if (WeldMoveStep.moveType.Equals(MoveType.None))
{
IOTimeOutProcess();
//处理休眠
if (IsFree)
{
//如果超过配置的时间,关闭烙铁头
TimeSpan span = DateTime.Now - BeginFreeTime;
if (SleepSeconds > 0 && span.TotalSeconds > SleepSeconds && (SolderSleep.Equals(false)))
{
LogUtil.info(RobotName + ",已经空闲【" + (int)span.TotalSeconds + "】秒,开始休眠烙铁");
SolderSleep = true;
SolderingManager.Release();
}
}
else
{
IsFree = true;
BeginFreeTime = DateTime.Now;
}
}
else if (WeldMoveStep.moveType.Equals(MoveType.Weld))
{
IsFree = false;
if (alarmType.Equals(AlarmType.None) || alarmType.Equals(AlarmType.StepTimeOut))
{
WeldProcess();
}
}
else if (WeldMoveStep.moveType.Equals(MoveType.GoHome))
{
GoHomeProcess();
}
if (HasSoldering)
{
CheckSolderingAlarm();
}
if ((!WeldMoveStep.moveType.Equals(MoveType.Weld)) || WeldMoveStep.ResetCount >= 3)
{
CheckSendWireAlarm();
}
if (!WeldMoveStep.moveType.Equals(MoveType.GoHome))
{
CheckRobotAlarm();
}
}
catch (Exception ex)
{
LogUtil.error(RobotName + "定时器出错:" + ex.ToString());
}
IsTimerProcess = false;
}
private static void CheckRobotAlarm()
{
if (alarmType.Equals(AlarmType.RobotError))
{
return;
}
if (URRobotControl.WarnMsg.Equals(""))
{
if (URRobotControl.IsRun.Equals(false))
{
WarnMsg = "机械臂连接断开";
LogUtil.error("检测到" + WarnMsg);
Alarm(AlarmType.RobotError);
}
}
else
{
WarnMsg = URRobotControl.WarnMsg;
LogUtil.error("检测到" + WarnMsg);
Alarm(AlarmType.RobotError);
}
}
//烙铁停止休眠
private static void StopSleep()
{
IsFree = false;
if (SolderSleep)
{
SolderingManager.Init(RobotConfig.JBC_Soldering_Port, RobotConfig.JBC_Soldering_Num);
SolderSleep = false;
}
}
private static DateTime preCheckSendWireTime = DateTime.Now;
private static DateTime lastSendWireOkTime = DateTime.Now;
/// <summary>
/// 检测送丝错误
/// </summary>
private static void CheckSendWireAlarm()
{
preCheckSendWireTime = DateTime.Now;
//如果休眠了不需要处理
if (SendWireManager.IsAlarm())
{
SendWireManager.Reset();
if (SendWireManager.IsAlarm())
{
//停止送丝器
SendWireManager.StopSend();
WarnMsg = "送丝器报警";
Alarm(AlarmType.SendWireAlarm);
LogUtil.error(RobotName + WarnMsg);
}
}
else
{
if (alarmType.Equals(AlarmType.SendWireAlarm) && IsInSudden.Equals(false) && IsNoAir.Equals(false))
{
TimeSpan span = DateTime.Now - lastSendWireOkTime;
int needSeconds = ConfigAppSettings.GetIntValue(Setting_Init.SendWireRecoverSeconds);
if (span.TotalSeconds > needSeconds)
{
WarnMsg = "";
alarmType = AlarmType.None;
WarnMsg = "";
LogUtil.info(RobotName + "送丝器已恢复超过【" + needSeconds + "】秒,消除送丝器报警!");
}
}
}
}
/// <summary>
/// 卡丝恢复功能,只有手动点了才会继续,当前焊点会重新焊接
/// </summary>
public static bool SendWireRecover()
{
if (SendWireManager.IsAlarm())
{
LogUtil.info(RobotName + "卡丝恢复失败,仍在报警中!");
}
else
{
if (alarmType.Equals(AlarmType.SendWireAlarm) && IsInSudden.Equals(false) && IsNoAir.Equals(false))
{
if (WeldMoveStep.moveType.Equals(MoveType.Weld))
{
LogUtil.info(RobotName + "开始卡丝恢复,重新此焊点的焊接 !");
WeldMoveStep.NextMoveStep(MoveStep.Wait);
}
lastSendWireOkTime = DateTime.Now;
LogUtil.info(RobotName + "开始卡丝恢复!");
return true;
}
}
return false;
}
/// <summary>IsNeedMsg
/// 送丝报警恢复前是否需要弹出提示信息
/// </summary>
/// <returns></returns>
public static bool IsNeedMsg()
{
if (alarmType.Equals(AlarmType.SendWireAlarm) && IsInSudden.Equals(false) && IsNoAir.Equals(false))
{
//判断是否在焊接中
if (WeldMoveStep.moveType.Equals(MoveType.Weld))
{
return true;
}
}
return false;
}
private static DateTime preCheckSolderingTime = DateTime.Now;
private static int preSolderingRet = -1;
/// <summary>
/// 检查烙铁报警
/// </summary>
private static void CheckSolderingAlarm()
{
//10秒钟检测一次
TimeSpan span = DateTime.Now - preCheckSolderingTime;
if (span.TotalSeconds > 10)
{
preCheckSolderingTime = DateTime.Now;
//如果休眠了不需要处理
int ErrorCode = SolderingManager.ReadPortError();
//添加验证,需要连续两次都是同一个值才算有效,跳过不稳定的错误
if (!ErrorCode.Equals(preSolderingRet))
{
LOGGER.Info(RobotName + "烙铁PortError更改,本次读取的值:" + ErrorCode + ",上次的值:" + preSolderingRet + "");
preSolderingRet = ErrorCode;
}
if (ErrorCode > 0)
{
string str = SolderingManager.GetErrorStr(ErrorCode);
WarnMsg = "烙铁报警:" + str;
Alarm(AlarmType.SolderingAlarm);
LogUtil.error(RobotName + WarnMsg);
}
else
{
if (alarmType.Equals(AlarmType.SolderingAlarm) && IsInSudden.Equals(false) && IsNoAir.Equals(false))
{
WarnMsg = "";
alarmType = AlarmType.None;
WarnMsg = "";
LogUtil.error(RobotName + "消除烙铁报警!");
}
}
}
}
/// <summary>
/// io检测异常,如果所有的步骤已经完成,表示信号超时异常已经结束
/// </summary>
private static DateTime preIoTimerOutTime = DateTime.Now;
private static void IOTimeOutProcess()
{
try
{
TimeSpan span = DateTime.Now - preIoTimerOutTime;
if (span.TotalSeconds > 1)
{
preIoTimerOutTime = DateTime.Now;
if (IsInSudden || IsNoAir)
{
return;
}
if (alarmType.Equals(AlarmType.IoSingleTimeOut) || alarmType.Equals(AlarmType.StepTimeOut))
{
if (WeldMoveStep.IsInWait == false)
{
LogUtil.info(RobotName + "之前有IO超时异常,清理信号超时异常!");
WarnMsg = "";
alarmType = AlarmType.None;
//RobotBean.KNDIOMove(IO_Type.Device_NG, IO_VALUE.HIGH);
}
}
}
}
catch (Exception ex)
{
LogUtil.error(LOGGER, "IOTimeOutProcess出错:" + ex.ToString());
}
}
public static void Alarm(AlarmType alarm)
{
LogUtil.error(LOGGER, RobotName + "收到报警:" + alarm);
alarmType = alarm;
//RobotBean.KNDIOMove(IO_Type.Device_NG, IO_VALUE.LOW);
if (alarmType.Equals(AlarmType.IoSingleTimeOut))
{
}
else if (alarmType.Equals(AlarmType.SuddenStop) || alarmType.Equals(AlarmType.NoAirCheck) || alarm.Equals(AlarmType.RobotError))
{
if (alarmType.Equals(AlarmType.SuddenStop))
{
IsInSudden = true;
}
else if (alarmType.Equals(AlarmType.NoAirCheck))
{
IsNoAir = true;
}
//急停之后需要机械臂重连
URRobotControl.StopRobot();
//停止所有运行
StopMove();
}
}
public static string GoHome()
{
string msg = Reset();
if (!msg.Equals(""))
{
WarnMsg = msg;
return msg;
}
WeldMoveStep.NewWeld(MoveType.GoHome);
WeldMoveStep.NextMoveStep(MoveStep.Home_Reset);
SolderingUp(true);
SendWireWork(true);
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitRobotRun());
return "";
}
public static void GoHomeProcess()
{
if (WeldMoveStep.IsInWait)
{
CheckWait();
}
if (WeldMoveStep.IsInWait)
{
return;
}
if (WeldMoveStep.moveStep.Equals(MoveStep.Home_Reset))
{
WeldMoveStep.NextMoveStep(MoveStep.Home_1_RobotMove);
if (IsFirstStart)
{
if (BoardManager.CurrBoard != null && BoardManager.CurrBoard.pointList.Count > 0)
{
int time = (int)(BoardManager.CurrBoard.pointList[0].preheatTime * 1000);
int temp = BoardManager.CurrBoard.pointList[0].preheatTemperature;
int maxTemp = BoardManager.CurrBoard.pointList[0].preheatTemperatureMax;
int minTemp = BoardManager.CurrBoard.pointList[0].preheatTemperatureMin;
SolderingManager.setTemp(temp.ToString());
WeldLog("设置烙铁温度" + temp + "");
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitTemperature(temp, maxTemp, minTemp));
}
}
MoveToOrg();
}
else if (WeldMoveStep.moveStep.Equals(MoveStep.Home_1_RobotMove))
{
if (IsFirstStart)
{
IsFirstStart = false;
WeldMoveStep.NextMoveStep(MoveStep.Home_3_StartClear);
SendWireUpToClear1();
}
else
{
WeldLog("回原点结束,机械臂回到待机点 ");
WarnMsg = "";
WeldMoveStep.EndMove();
}
}
else if (WeldMoveStep.moveStep.Equals(MoveStep.Home_3_StartClear))
{
WeldMoveStep.NextMoveStep(MoveStep.Home_4_ToClear2);
MoveToClear2(RobotConfig.ClearMSenconds);
}
else if (WeldMoveStep.moveStep.Equals(MoveStep.Home_4_ToClear2))
{
WeldMoveStep.NextMoveStep(MoveStep.Home_5_ToOrg);
MoveToOrg();
}
else if (WeldMoveStep.moveStep.Equals(MoveStep.Home_5_ToOrg))
{
WeldLog("回原点结束,清洗完成 ,送丝上升到位 ");
WarnMsg = "";
WeldMoveStep.EndMove();
}
}
private static void MoveToPoint(WeldPointInfo p, bool IsHigh)
{
SendWireWork(true);
SolderingDown(true);
URPointValue point = p.GetURPoint();
WeldLog("移动到焊点【" + WeldMoveStep.CurrPoint.pointName + "】:" + point.ToShowStr());
URRobotControl.MoveTo(point, isHighSpeed);
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitRobotPoint(point));
}
private static void MoveToOrg()
{
SolderingUp(true);
SendWireWork(true);
WeldLog("送丝上升,机械臂走到待机点 ");
URRobotControl.MoveTo(HomePoint, isHighSpeed);
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitRobotPoint(HomePoint));
}
private static void SendWireUpToClear1()
{
SolderingUp(true);
SendWireClear(true);
Thread.Sleep(100);
WeldCount = 0;
WeldLog("送丝上升,打开清洗装置,机械臂走到清洗点1 ");
URRobotControl.MoveTo(Clear1Point, isHighSpeed);
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitRobotPoint(Clear1Point));
}
private static void MoveToClear2(int mSenconds)
{
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitTime(mSenconds));
WeldLog("机械臂走到清洗点2 ,打开清洗装置,清洗时间:" + mSenconds + " ");
URRobotControl.MoveTo(Clear2Point, isHighSpeed);
WeldMoveStep.WaitList.Add(WaitResultInfo.WaitRobotPoint(Clear2Point));
}
//更新原点
public static void UpdateOrgPoint(URPointValue point)
{
WeldRobotBean.HomePoint = point;
string str = point.ToJosonStr();
ConfigAppSettings.SaveValue(Setting_Init.Soldering_HomePoint, str);
}
public static void UpdateClear1Point(URPointValue point)
{
WeldRobotBean.Clear1Point = point;
string str = point.ToJosonStr();
ConfigAppSettings.SaveValue(Setting_Init.Soldering_Clear1Point, str);
}
public static void UpdateClear2Point(URPointValue point)
{
WeldRobotBean.Clear2Point = point;
string str = point.ToJosonStr();
ConfigAppSettings.SaveValue(Setting_Init.Soldering_Clear2Point, str);
}
/// <summary>
/// 验证机器人是否超出活动范围
/// </summary>
/// <param name="point"></param>
/// <returns></returns>
public static string CheckEpsonPoint(URPointValue point)
{
return "";
}
}
}