PunkHPX8/PunkHPX8_RT/Modules/PlatingCell/PlatingCellDepositionRoutine.cs

using Aitex.Core.RT.Device;
using Aitex.Core.RT.Log;
using Aitex.Core.RT.Routine;
using Aitex.Core.Util;
using MECF.Framework.Common.Alarm;
using MECF.Framework.Common.Beckhoff.Station;
using MECF.Framework.Common.CommonData.PowerSupplier;
using MECF.Framework.Common.RecipeCenter;
using MECF.Framework.Common.Routine;
using MECF.Framework.Common.Utilities;
using PunkHPX8_Core;
using PunkHPX8_RT.Devices.AXIS;
using PunkHPX8_RT.Devices.PlatingCell;
using System;
using System.Collections.Generic;
using System.Diagnostics;
using System.Linq;
using System.Text;
using System.Threading.Tasks;

namespace PunkHPX8_RT.Modules.PlatingCell
{
    public class PlatingCellDepositionRoutine : RoutineBase, IRoutine
    {
        private enum RunRecipeStep
        {
            RunPowerStep,
            RunPowerStepWait,
            LoopRotationStart,
            LoopVerticalGotoOffSet,
            LoopVerticalGotoOffSetCheck,

            LoopRecordRotationStartTime,
            LoopRotationStartIfCurrentIsStoped,//如果当前电机是停止状态，启动起来
            LoopRotationChangeSpeed,
            LoopCalculateRotationDelayTime,
            LoopRotationDelay,

            LoopRotationStopIfCurrentIsRuning, //如果当前电机是启动状态，则停止
            LoopRotationStopCheck,
            LoopRotationBiRotation,
            LoopRotationBiRotationCheck,

            LoopEnd,
            RotationStartIfCurrentIsStoped,
            End
        }
        #region 常量
        /// <summary>
        /// ROTATION电机转速比例
        /// </summary>
        private const int SPEED_RATIO = 1;
        private const int ROTATION_FAR_POSITION = 12 * 60 * 60 * 500 * 6; //以500rmp 运行12个小时的位置
        #endregion

        /// <summary>
        /// recipe
        /// </summary>
        private DepRecipe _recipe;
        /// <summary>
        /// Rotation axis
        /// </summary>
        private JetAxisBase _rotationAxis;
        /// <summary>
        /// Platingcell device
        /// </summary>
        private PlatingCellDevice _device;
        /// <summary>
        /// vertical axis entity
        /// </summary>
        private PlatingCellVerticalEntity _verticalEntity;
        /// <summary>
        /// 不通电
        /// </summary>
        private bool _isZeroCurrent = false;
        /// <summary>
        /// 是否启动smart spin
        /// </summary>
        private bool _isSmartSpin = false;
        /// <summary>
        /// Power step集合
        /// </summary>
        List<PowerSupplierStepPeriodData> _powerSupplierStepPeriodDatas = new List<PowerSupplierStepPeriodData>();
        /// <summary>
        /// 双向旋转routine
        /// </summary>
        private RotationBiDirectionRoutine _rotationBiDirectionRoutine;
        /// <summary>
        /// 电镀单步延迟等待时间（recipe的时间减去rotation启动的时间,单位ms）
        /// </summary>
        private int _singalStepDelayTime;
        /// <summary>
        /// 当前执行到电镀步骤的索引
        /// </summary>
        private int _depositionStepIndex = 0;
        /// <summary>
        /// 计时器
        /// </summary>
        private Stopwatch _stopwatch = new Stopwatch();
        /// <summary>
        /// 构造函数
        /// </summary>
        /// <param name="module"></param>
        public PlatingCellDepositionRoutine(string module) : base(module)
        {
            _rotationBiDirectionRoutine = new RotationBiDirectionRoutine(module);
        }
        /// <summary>
        /// 中止
        /// </summary>
        public void Abort()
        {
            Runner.Stop("Manual Abort");
        }
        /// <summary>
        /// 监控
        /// </summary>
        /// <returns></returns>
        public RState Monitor()
        {               //没有上电保护，此刻给电
            Runner.RunIf(RunRecipeStep.RunPowerStep, _recipe.IsEntryTypeCold, StartPowerStep, _delay_1ms)
                //检验步阶电流是否完成
                .WaitWithStopCondition(RunRecipeStep.RunPowerStepWait, CheckRecipeStepEndStatus, CheckRecipeStepStopStatus, false, _delay_10s)
                .LoopStart(RunRecipeStep.LoopRotationStart, "Start rotation cycle",_recipe.DepStepCount,NullFun)
                //vertical 调整位置(第一步不用调，entry过程已经走到位置了)
                .LoopRunIf(RunRecipeStep.LoopVerticalGotoOffSet, _recipe.DepSteps[_depositionStepIndex].PlatingZoffset!=0 && _depositionStepIndex!=0, () => StartVertical("Plate", _recipe.DepSteps[_depositionStepIndex].PlatingZoffset),_delay_1ms)
                .LoopRunIfWithStopStatus(RunRecipeStep.LoopVerticalGotoOffSetCheck, _recipe.DepSteps[_depositionStepIndex].PlatingZoffset!=0 && _depositionStepIndex != 0, CheckVerticalEnd, CheckVerticalError)

                  //不带双向旋转，时间到了直接变速(如果当前电机是停止状态，启动起来)
                .LoopRunIf(RunRecipeStep.LoopRecordRotationStartTime, !_recipe.DepSteps[_depositionStepIndex].BiDireaction,
                   () => { return StartRecordTime(); }, _delay_1ms)
                .LoopRunIf(RunRecipeStep.LoopRotationStartIfCurrentIsStoped, CheckRotationIsIdle() && !_recipe.DepSteps[_depositionStepIndex].BiDireaction,
                   () => { return StartRotation(ROTATION_FAR_POSITION, _recipe.DepSteps[_depositionStepIndex].PlatingSpeed); }, _delay_1ms)
                .LoopRunIf(RunRecipeStep.LoopRotationChangeSpeed, !_recipe.DepSteps[_depositionStepIndex].BiDireaction && !CheckRotationIsIdle(), () => ChangeRotationSpeed(_recipe.DepSteps[_depositionStepIndex].PlatingSpeed),_delay_1ms)
                .LoopRunIf(RunRecipeStep.LoopCalculateRotationDelayTime, !_recipe.DepSteps[_depositionStepIndex].BiDireaction , CalculateActualDepStepTime, _delay_1ms)
                .LoopDelayIf(RunRecipeStep.LoopRotationDelay, !_recipe.DepSteps[_depositionStepIndex].BiDireaction, _recipe.DepSteps[_depositionStepIndex].DurartionSeconds * 1000 - _singalStepDelayTime)
                
                //带双向旋转，启动双向旋转的routine(如果当前电机是启动状态，则停止)
                .LoopRunIf(RunRecipeStep.LoopRotationStopIfCurrentIsRuning, checkRotationIsRunning() && _recipe.DepSteps[_depositionStepIndex].BiDireaction,
                    _rotationAxis.StopPositionOperation, _delay_1ms)
                .LoopRunIfWithStopStatus(RunRecipeStep.LoopRotationStopCheck, checkRotationIsRunning() && _recipe.DepSteps[_depositionStepIndex].BiDireaction,
                    CheckRotationIsIdle, CheckRotationPositionRunStop)
                .LoopRunIf(RunRecipeStep.LoopRotationBiRotation, _recipe.DepSteps[_depositionStepIndex].BiDireaction, 
                    () => _rotationBiDirectionRoutine.Start(_recipe.DepSteps[_depositionStepIndex].DurartionSeconds, _recipe.DepSteps[_depositionStepIndex].BiDFrequency, _recipe.DepSteps[_depositionStepIndex].PlatingSpeed) == RState.Running,_delay_1ms)
                .LoopRunIfWithStopStatus(RunRecipeStep.LoopRotationBiRotationCheck, _recipe.DepSteps[_depositionStepIndex].BiDireaction, 
                        () => CommonFunction.CheckRoutineEndState(_rotationBiDirectionRoutine), 
                        () => CommonFunction.CheckRoutineStopState(_rotationBiDirectionRoutine))
                .LoopEnd(RunRecipeStep.LoopEnd, UpdateDepositionIndex, _delay_1ms)
                //如果电镀最后一步带双向旋转，后续电机会停止，需要再把电机启动起来(用Reclaim的速度)
                .RunIf(RunRecipeStep.RotationStartIfCurrentIsStoped, CheckRotationIsIdle(), () => { return StartRotation(ROTATION_FAR_POSITION,_recipe.ReclaimSpeed); }, _delay_1ms)
                .End(RunRecipeStep.End, NullFun);
            return Runner.Status;
        }
        /// <summary>
        /// 开始计时
        /// </summary>
        /// <returns></returns>
        private bool StartRecordTime()
        {
            _stopwatch.Restart();
            return true;
        }
        /// <summary>
        /// 计算当前电镀步骤的真正用时（减掉了rotation的启动时间）
        /// </summary>
        /// <returns>返回值单位ms</returns>
        /// <param name="recipetime"> 单位ms</param>
        private bool CalculateActualDepStepTime()
        {
            _stopwatch.Stop();
            _singalStepDelayTime =  (int)_stopwatch.ElapsedMilliseconds;
            return true;
        }
        /// <summary>
        /// 判断当前电机是否在转
        /// </summary>
        /// <returns></returns>
        private bool checkRotationIsRunning()
        {
            return _rotationAxis.Status == RState.Running;
        }
        /// <summary>
        /// 判断电机当前状态是否停止
        /// </summary>
        /// <returns></returns>
        private bool CheckRotationIsIdle()
        {
            return _rotationAxis.Status == RState.End;
        }
        /// <summary>
        /// 检验Rotation是否运动失败
        /// </summary>
        /// <returns></returns>
        private bool CheckRotationPositionRunStop()
        {
            return _rotationAxis.Status == RState.Failed || _rotationAxis.Status == RState.Timeout;
        }
        /// <summary>
        /// 更新电镀步骤索引
        /// </summary>
        /// <returns></returns>
        private bool UpdateDepositionIndex()
        {
            if (_depositionStepIndex < _recipe.DepStepCount - 1)
            {
                _depositionStepIndex++;
            }
            return true;
        }
        /// <summary>
        /// 启动PowerSupplier
        /// </summary>
        /// <returns></returns>
        private bool StartPowerStep()
        {
            bool result = _device.PowerSupplier.StartSetStepPeriodNoWaitEnd(_powerSupplierStepPeriodDatas);
            if (!result)
            {
                _device.PowerSupplier.DisableOperation("", null);
                return false;
            }
            return true;
        }
        /// <summary>
        /// 检验Powerstep是否启动完成
        /// </summary>
        /// <returns></returns>
        private bool CheckRecipeStepEndStatus()
        {
            if (_isZeroCurrent)
            {
                return true;
            }
            return _device.PowerSupplier.Status == RState.End;

        }
        /// <summary>
        /// 检验Powerstep是否启动失败
        /// </summary>
        /// <returns></returns>
        private bool CheckRecipeStepStopStatus()
        {
            if (_isZeroCurrent)
            {
                return false;
            }
            return _device.PowerSupplier.Status == RState.Failed || _device.PowerSupplier.Status == RState.Timeout;
        }
        /// <summary>
        /// rotation开始旋转
        /// </summary>
        /// <param name="param"></param>
        /// <returns></returns>
        private bool StartRotation(int targetPosition,int speed)
        {
            bool result = _rotationAxis.ProfilePosition(targetPosition, speed * SPEED_RATIO * 6, 0, 0); //rpm->deg/s
            if (!result)
            {
                NotifyError(eEvent.ERR_PLATINGCELL, "Start Rotation is failed", 0);
                return false;
            }
            return true;
        }
        /// <summary>
        /// rotation改变速度
        /// </summary>
        /// <param name="speed"></param>
        /// <returns></returns>
        private bool ChangeRotationSpeed(int speed)
        {
            double _scale = _rotationAxis.ScaleFactor;
            speed = (int)Math.Round(_scale * BeckhoffVelocityUtil.ConvertVelocityToDegPerSecondByRPM(speed), 0);
            return _rotationAxis.ChangeSpeed(speed);
        }
        /// <summary>
        /// vertical 运行
        /// </summary>
        /// <param name="positionName"></param> 目标位置名称
        /// <param name="offset"></param> 偏移量
        /// <returns></returns>
        private bool StartVertical(string positionName, double offset)
        {
            return _verticalEntity.CheckToPostMessage<PlatingCellVerticalState, PlatingCellVerticalEntity.VerticalMsg>(eEvent.INFO_PLATINGCELL,
                    _verticalEntity.Module.ToString(), (int)PlatingCellVerticalEntity.VerticalMsg.Position, positionName, offset);
        }
        /// <summary>
        /// 检验垂直电机是否运动完成
        /// </summary>
        /// <returns></returns>
        private bool CheckVerticalEnd()
        {
            return _verticalEntity.IsIdle;
        }
        /// <summary>
        /// 检验垂直是否出现错误
        /// </summary>
        /// <returns></returns>
        private bool CheckVerticalError()
        {
            return _verticalEntity.IsError;
        }
        /// <summary>
        /// 检验电流和电压合理性
        /// </summary>
        /// <param name="current"></param>
        /// <param name="voltage"></param>
        /// <param name="side"></param>
        /// <returns></returns>
        private bool CheckSidePowerInvalid(double current, double voltage)
        {
            double maxVoltage = _recipe.DepMaxVoltageFault;
            double warnVoltage = _recipe.DepMaxVoltageWarning;
            if (voltage > maxVoltage)
            {
                NotifyError(eEvent.ERR_PLATINGCELL, $" voltage {voltage} is large than recipe max voltage {maxVoltage}", 0);
                return true;
            }
            if (voltage > warnVoltage)
            {
                string str = $" voltage is {voltage} in warning";
                if (AlarmListManager.Instance.AddWarn(Module, $"voltage", str))
                {
                    LOG.WriteLog(eEvent.WARN_METAL, Module, str);
                }
            }
            double maxErrorCurrent = _powerSupplierStepPeriodDatas[_depositionStepIndex].Current * (double)(1 + _recipe.DepCurrentFault * 0.01);
            double minErrorCurrent = _powerSupplierStepPeriodDatas[_depositionStepIndex].Current * (double)(1 - _recipe.DepCurrentFault * 0.01);
            double maxWarnCurrent = _powerSupplierStepPeriodDatas[_depositionStepIndex].Current * (double)(1 + _recipe.DepCurrentWarning * 0.01);
            double minWarnCurrent = _powerSupplierStepPeriodDatas[_depositionStepIndex].Current * (double)(1 - _recipe.DepCurrentWarning * 0.01);
            if (current > maxErrorCurrent)
            {
                NotifyError(eEvent.ERR_PLATINGCELL, $" current {current} is large than recipe max current {maxErrorCurrent}", 0);
                return true;
            }
            if (current < minErrorCurrent)
            {
                NotifyError(eEvent.ERR_PLATINGCELL, $" current {current} is less than recipe min current {minErrorCurrent}", 0);
                return true;
            }

            if ((current <= maxErrorCurrent && current >= maxWarnCurrent) || (current >= minErrorCurrent && current <= minWarnCurrent))
            {
                string str = $" current {current} is in warning";
                if (AlarmListManager.Instance.AddWarn(Module, $" current", str))
                {
                    LOG.WriteLog(eEvent.ERR_PLATINGCELL, Module, str);
                }
            }
            return false;
        }

        /// <summary>
        /// 启动
        /// </summary>
        /// <param name="objs"></param>
        /// <returns></returns>
        public RState Start(params object[] objs)
        {
            _recipe = (DepRecipe)objs[0];
            _isZeroCurrent = (bool)objs[1];
            _powerSupplierStepPeriodDatas = (List<PowerSupplierStepPeriodData>)objs[2];
            _rotationAxis = DEVICE.GetDevice<JetAxisBase>($"{Module}.Rotation");
            _device = DEVICE.GetDevice<PlatingCellDevice>(Module);
            _depositionStepIndex = 0;
            //获取vertical entity
            string vertical = ModuleMatcherManager.Instance.GetPlatingVerticalByCell(Module);
            _verticalEntity = Singleton<RouteManager>.Instance.GetModule<PlatingCellVerticalEntity>(vertical);
            return Runner.Start(Module, "start Deposition routine");
        }
    }
}