217 lines
8.0 KiB
Python
217 lines
8.0 KiB
Python
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"""产线联动引擎：计划上线 / 上卷鞍座 / 生产实绩 / 停机自动检测。
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状态流转：
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ready(准备好) --自动--> online(在线, 队首唯一) --移动--> 上卷鞍座(staged)
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--有速度/投入生产--> producing(生产中) --带头2000m--> produced(生产完成,产生实绩)
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停机：当产线无生产(速度=0)持续超过 10min，自动新增一条未结束停机记录；
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恢复速度后自动结束该记录，原因由用户后续补充录入。
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"""
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from datetime import datetime
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from sqlalchemy import select, asc
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from sqlalchemy.ext.asyncio import AsyncSession
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from loguru import logger
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from app.models.plan import ProductionPlan
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from app.models.production import ProductionRecord
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from app.models.downtime import DowntimeRecord
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from app.models.line_state import LineState
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# ── 仿真参数 ──
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TARGET_LENGTH_M = 2000.0 # 带头目标长度（生产完成阈值）
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SIM_SPEED_M_MIN = 600.0 # 仿真线速度 m/min（2000m ≈ 200s）
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DOWNTIME_THRESHOLD_S = 600 # 速度为0持续超过该秒数判定停机（10min）
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def _shift_of(dt: datetime) -> str:
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return "甲" if 8 <= dt.hour < 20 else "乙"
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async def _saddle_plan(db: AsyncSession):
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res = await db.execute(select(ProductionPlan).where(ProductionPlan.on_saddle == 1))
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return res.scalars().first()
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async def ensure_online(db: AsyncSession):
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"""保证恰好一条 online（队首，最早录入的 ready）。"""
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res = await db.execute(select(ProductionPlan).where(ProductionPlan.status == "online"))
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online = list(res.scalars())
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if len(online) > 1:
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# 仅保留最早的一条为 online，其余回退 ready
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online.sort(key=lambda p: (p.plan_date or datetime.max, p.id))
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for p in online[1:]:
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p.status = "ready"
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online = online[:1]
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if not online:
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res = await db.execute(
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select(ProductionPlan)
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.where(ProductionPlan.status == "ready")
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.order_by(asc(ProductionPlan.plan_date), asc(ProductionPlan.id))
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.limit(1)
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)
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head = res.scalar_one_or_none()
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if head:
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head.status = "online"
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async def move_to_saddle(db: AsyncSession, plan: ProductionPlan):
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"""把在线计划移动到上卷鞍座（staged，等待速度/投入生产）。"""
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occupied = await _saddle_plan(db)
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if occupied and occupied.id != plan.id:
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raise ValueError("上卷鞍座已被占用，请等待当前钢卷生产完成")
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plan.on_saddle = 1
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plan.saddle_at = datetime.now()
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plan.run_started_at = None
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plan.run_speed = 0
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plan.run_length_m = 0
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if plan.status not in ("producing", "produced"):
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plan.status = "online"
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await ensure_online(db)
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async def commit_plan(db: AsyncSession, plan: ProductionPlan):
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"""投入生产：鞍座计划有速度 → 生产中。"""
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if plan.on_saddle != 1:
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await move_to_saddle(db, plan)
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if plan.run_started_at is None:
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plan.run_started_at = datetime.now()
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plan.run_speed = SIM_SPEED_M_MIN
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plan.status = "producing"
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await ensure_online(db)
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async def _produce(db: AsyncSession, plan: ProductionPlan):
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"""带头到达目标长度 → 生产完成，并生成实绩记录。"""
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now = datetime.now()
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plan.status = "produced"
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plan.produced_at = now
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plan.on_saddle = 0
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plan.run_speed = 0
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plan.run_length_m = TARGET_LENGTH_M
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weight = plan.incoming_weight or plan.plan_weight or 0
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length = TARGET_LENGTH_M
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rec = ProductionRecord(
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coil_no=plan.cold_coil_no or plan.plan_no,
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sub_coil_no=plan.cold_coil_no,
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hot_coil_no=plan.hot_coil_no,
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plan_id=plan.id,
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shift=_shift_of(now),
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steel_grade=plan.steel_grade,
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incoming_thickness=plan.incoming_thickness,
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outlet_thickness=plan.product_thickness,
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deviation_upper=plan.deviation_upper,
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deviation_lower=plan.deviation_lower,
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incoming_width=plan.incoming_width,
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outlet_width=plan.product_width,
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incoming_weight=weight,
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weighed_weight=round(weight * 0.985, 4) if weight else None,
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packaging_req=plan.packaging_req,
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trim_req=plan.trim_req,
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surface_quality="合格",
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product_quality=99.0,
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product_length=length,
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length_per_ton=round(length / weight, 2) if weight else None,
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offline_time=now,
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status="PRODUCT",
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shift_date=now,
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start_time=plan.run_started_at or now,
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end_time=now,
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process_length=length,
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process_weight=weight,
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avg_speed=SIM_SPEED_M_MIN,
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max_speed=round(SIM_SPEED_M_MIN * 1.05, 1),
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inlet_thickness=plan.incoming_thickness,
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inlet_width=plan.incoming_width,
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quality_grade="A",
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operator="系统",
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)
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db.add(rec)
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logger.info(f"生产完成并产生实绩: {plan.cold_coil_no or plan.plan_no}")
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async def advance_saddle(db: AsyncSession):
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"""推进鞍座计划：staged 自动获得速度 → 生产中；累计长度到 2000m → 完成。"""
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plan = await _saddle_plan(db)
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if not plan:
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return
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now = datetime.now()
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# staged（在线且在鞍座）自动获得速度，模拟 PLC 速度信号
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if plan.status == "online" and plan.run_started_at is None:
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plan.run_started_at = now
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plan.run_speed = SIM_SPEED_M_MIN
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plan.status = "producing"
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await ensure_online(db)
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if plan.status == "producing" and plan.run_started_at:
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elapsed = (now - plan.run_started_at).total_seconds()
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plan.run_length_m = min(TARGET_LENGTH_M, (plan.run_speed or 0) / 60.0 * elapsed)
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if plan.run_length_m >= TARGET_LENGTH_M:
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await _produce(db, plan)
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async def _get_line_state(db: AsyncSession) -> LineState:
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st = await db.get(LineState, 1)
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if not st:
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st = LineState(id=1, speed=0)
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db.add(st)
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await db.flush()
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return st
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async def detect_downtime(db: AsyncSession):
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"""速度为0持续超过阈值 → 自动新增停机；恢复速度 → 自动结束。"""
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res = await db.execute(select(ProductionPlan).where(ProductionPlan.status == "producing"))
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running = res.scalars().first() is not None
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now = datetime.now()
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st = await _get_line_state(db)
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if running:
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st.speed = SIM_SPEED_M_MIN
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st.zero_since = None
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if st.open_downtime_id:
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rec = await db.get(DowntimeRecord, st.open_downtime_id)
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if rec and rec.end_time is None:
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rec.end_time = now
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rec.duration = round((now - rec.start_time).total_seconds() / 60.0, 1)
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st.open_downtime_id = None
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else:
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st.speed = 0
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if st.zero_since is None:
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st.zero_since = now
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elif st.open_downtime_id is None and (now - st.zero_since).total_seconds() >= DOWNTIME_THRESHOLD_S:
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rec = DowntimeRecord(
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category_code="AUTO",
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category_name="待定",
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shift=_shift_of(now),
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shift_date=now,
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start_time=st.zero_since,
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fault_desc="线速度为0持续超过10分钟（系统自动检测，原因待补充）",
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reporter="系统",
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is_planned=0,
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)
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db.add(rec)
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await db.flush()
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st.open_downtime_id = rec.id
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logger.info("自动检测到停机，已新增待补充停机记录")
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async def tick(db: AsyncSession):
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"""引擎单步：上线 + 推进鞍座 + 停机检测。"""
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await ensure_online(db)
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await advance_saddle(db)
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await detect_downtime(db)
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async def run_engine_loop(interval_s: int = 15):
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"""后台循环，使联动在无人查看时也能自动推进。"""
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import asyncio
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from app.database import AsyncSessionLocal
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while True:
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try:
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async with AsyncSessionLocal() as db:
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await tick(db)
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await db.commit()
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except Exception as e: # noqa
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logger.warning(f"line engine tick 失败: {e}")
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await asyncio.sleep(interval_s)
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