using System;
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using System.Collections.Generic;
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using System.Linq;
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using System.Text;
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using System.Threading;
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using OPCAutomation;
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using HalconDotNet;
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using System.Reflection;
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using System.IO;
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using System.Threading.Tasks;
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using HDevEngine;
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using System.Globalization;
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using System.Configuration;
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using Newtonsoft.Json;
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namespace M423project
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{
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/// <summary>
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/// 产品长宽处理类
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/// </summary>
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public class SizeDetection
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{
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#region 尺寸检测相关私有成员
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private OPC opc;
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private ImageProcess imageProcess;
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private ConfigStruct opcConfig;
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private int stationNumber;
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private DetectionType detectionType;
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private HWindow halconWindow;
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private int therold = 30;
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public bool isPick;
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private HDevEngineTool _tool;
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private HTuple rectROI;
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private HTuple rectThreshold;
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#endregion
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/// <summary>
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///类构造函数
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/// </summary>
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/// <param name="_opc">OPC对象引用</param>
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/// <param name="_imageProcess">图象处理对象引用</param>
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/// <param name="_opcConfig">配置信息对象引用</param>
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/// <param name="_stationNumber">对应工位号（4）</param>
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/// <param name="_detectionCollection">检测结果数据存放列表</param>
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/// <param name="_detectionType">检测类型Normal、Repeat、Offline,LastProduct,Manual、BIAS //BIAS</param>
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/// <param name="_halconWindow">图象显示对象</param>
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public SizeDetection(OPC _opc, ImageProcess _imageProcess, ConfigStruct _opcConfig, int _stationNumber,
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DetectionType _detectionType, HWindow _halconWindow, int _therold = 30)
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{
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opc = _opc;
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imageProcess = _imageProcess;
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opcConfig = _opcConfig;
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stationNumber = _stationNumber;
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detectionType = _detectionType;
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halconWindow = _halconWindow;
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therold = _therold;
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//加载hdvp文件
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_tool = new HDevEngineTool(Environment.CurrentDirectory + "\\Vision\\" + "MeasureLW.hdvp");
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//载入hdvp,hdvp的文件名需和内部方法名一致
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_tool.LoadProcedure("MeasureLW");
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SetMinMaxGap();
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#region add by Patrick 2020-2-18
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LoadBatteryCheckSetting();
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CtrlSetBatteryCheckROI.OnSettingSaved += CtrlSetBatteryCheckROI_OnSettingSaved;
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ConfigForm.OnConfigSaved += ConfigForm_OnConfigSaved;
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#endregion
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}
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#region add by Patrick 2020-2-18
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private void CtrlSetBatteryCheckROI_OnSettingSaved(BatteryCheckSetting setting)
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{
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LoadBatteryCheckSetting(setting);
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}
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private void ConfigForm_OnConfigSaved(ConfigStruct config)
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{
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opcConfig = config;
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SetMinMaxGap();
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}
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private void LoadBatteryCheckSetting(BatteryCheckSetting setting = null)
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{
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if (setting == null)
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{
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string path = Path.Combine(AppDomain.CurrentDomain.BaseDirectory, CtrlSetBatteryCheckROI.SettingPath);
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if (File.Exists(path))
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{
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using (StreamReader reader = new StreamReader(path, System.Text.Encoding.UTF8))
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{
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var dataLine = reader.ReadToEnd();
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setting = JsonConvert.DeserializeObject<BatteryCheckSetting>(dataLine);
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}
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}
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else
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{
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setting = new BatteryCheckSetting();
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}
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}
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if (setting.IsEnabled)
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{
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rectROI = new HTuple(setting.StartPoint.Y, setting.StartPoint.X, setting.EndPoint.Y, setting.EndPoint.X);
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rectThreshold = new HTuple((double)setting.MinArea, (double)setting.MaxArea);
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}
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else
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{
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rectROI = new HTuple(0.0, 0.0, 0.0, 0.0);
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rectThreshold = new HTuple(0.0, 0.0);
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}
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}
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#endregion
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const double MAXGAP = 999999;
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const double MINGAP = -999999;
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double maxLength = MAXGAP;
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double maxWidth = MAXGAP;
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public double MaxLength
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{
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get { return maxLength; }
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set
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{
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if (value > 0)
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{
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maxLength = value;
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}
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}
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}
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public double MaxWidth
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{
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get { return maxWidth; }
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set
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{
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if (value > 0)
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{
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maxWidth = value;
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}
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}
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}
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double minLength = MINGAP;
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double minWidth = MINGAP;
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public double MinLength
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{
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get { return minLength; }
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set
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{
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if (value > 0)
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{
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minLength = value;
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}
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}
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}
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public double MinWidth
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{
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get { return minWidth; }
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set
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{
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if (value > 0)
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{
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minWidth = value;
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}
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}
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}
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private void SetMinMaxGap()
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{
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MaxLength = opcConfig.MaxLength;
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MaxWidth = opcConfig.MaxWidth;
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MinLength = opcConfig.MinLength;
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MinWidth = opcConfig.MinWidth;
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// string maxLengthStr = ConfigurationManager.AppSettings["MaxCellLength"];
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// string maxWidthStr = ConfigurationManager.AppSettings["MaxCellWidth"];
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// string minLengthStr = ConfigurationManager.AppSettings["MinCellLength"];
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// string minWidthStr = ConfigurationManager.AppSettings["MinCellWidth"];
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// if (!string.IsNullOrWhiteSpace(maxLengthStr))
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// {
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// if (!(double.TryParse(maxLengthStr, out MaxLength) && MaxLength > 0))
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// {
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// MaxLength = MAXGAP;
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// }
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// }
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// if (!string.IsNullOrWhiteSpace(maxWidthStr))
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// {
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// if (!(double.TryParse(maxWidthStr, out MaxWidth) && MaxWidth > 0))
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// {
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// MaxWidth = MAXGAP;
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// }
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// }
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// if (!string.IsNullOrWhiteSpace(minLengthStr))
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// {
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// if (!(double.TryParse(minLengthStr, out MinLength) && MinLength > 0))
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// {
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// MinLength = MINGAP;
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// }
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// }
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// if (!string.IsNullOrWhiteSpace(minWidthStr))
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// {
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// if (!(double.TryParse(minWidthStr, out MinWidth) && MinWidth > 0))
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// {
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// MinWidth = MINGAP;
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// }
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// }
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}
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public void Execute(int productQty)
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{
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DateTime t1 = DateTime.Now;
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string fileName = string.Empty;
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double btyLength = CommonUtil.InvalidValue, btyWidth = CommonUtil.InvalidValue, btyCellWidhth = CommonUtil.InvalidValue;
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MeasureState ms = MeasureState.NA;
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MeasureState lengthMeasureState = MeasureState.NA;
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MeasureState widthMeasureState = MeasureState.NA;
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double isEmpty = 0;
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//bool isEmpty = false;
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string timeStr = DateTime.Now.ToString("hh:mm:ss fff");
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CommonUtil.WriteLog(LogType.Inf, string.Format("开始检测产品尺寸, 时间：{0}，StepControl:{1} ...",
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timeStr, CommonUtil.StepControl.ToString()));
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HObject hImage = null;
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string tempFileName = "";
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try
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{
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Thread.Sleep(50);
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opc.Write(OPCOutputTag.DetectionStart4, false);
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Thread.Sleep(200);
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int detectID = CommonUtil.StepControl.GetDetectSizeStepID();
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if (detectID < 1)
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{
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return;
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}
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tempFileName = GetCurrentProductSN(detectID);
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string productNo = GetProductNo(detectID);
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int times = 3;
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while (times > 0 && hImage == null)
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{
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GC.Collect();
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imageProcess.GrapSizeAsync();
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int waitCount = 0;
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while (imageProcess.SizeImageCount <= 0 && waitCount < 10)
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{
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Thread.Sleep(50);
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waitCount++;
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}
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if (imageProcess.SizeImageCount > 0)
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hImage = imageProcess.DequeueSizeImage();
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else
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{
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imageProcess.CloseSizeCamera();
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imageProcess.ClearSizeImage();
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Thread.Sleep(1000);
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imageProcess.OpenSizeCamera(CommonUtil.DetectionOption == DetectionOption.doProduct);
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}
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times--;
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}
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if (hImage != null)
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{
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VisionDetect visionDetect = new VisionDetect();
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Dictionary<string, HTuple> tupleDictionary = new Dictionary<string, HTuple>();
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Dictionary<string, HObject> imageDictionary = new Dictionary<string, HObject>();
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double[] lengthArr = null;
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double[] widthArr = null;
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double[] isNaArr = null;
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imageDictionary.Add("INPUT_Image", hImage);
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tupleDictionary.Add("OUTPUT_Length", btyLength);
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tupleDictionary.Add("OUTPUT_Width", btyWidth);
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tupleDictionary.Add("OUTPUT_IsNa", isEmpty);
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tupleDictionary.Add("INPUT_Hwindow", halconWindow);
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#region add by Patrick 2020-2-18
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tupleDictionary.Add("OUTPUT_RectArea", new HTuple());
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tupleDictionary.Add("INPUT_Rect", rectROI);
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tupleDictionary.Add("INPUT_RectThreshold", rectThreshold);
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#endregion
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_tool.SetDictionary(tupleDictionary, imageDictionary);
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//执行
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_tool.RunProcedure();
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lengthArr = _tool.TupleDictionary["OUTPUT_Length"].ToDArr();
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widthArr = _tool.TupleDictionary["OUTPUT_Width"].ToDArr();
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isNaArr = _tool.TupleDictionary["OUTPUT_IsNa"].ToDArr();
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double rectArea = _tool.TupleDictionary["OUTPUT_RectArea"].D;
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btyLength = lengthArr.Length > 0 ? lengthArr[0] : btyLength;
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btyWidth = widthArr.Length > 0 ? widthArr[0] : btyWidth;
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isEmpty = isNaArr.Length > 0 ? isNaArr[0] : isEmpty;
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//switch (CommonUtil.DetectionOption)
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//{
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// case DetectionOption.doProduct:
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// visionDetect.M423MeasureLandWJohnny(hImage, halconWindow, ref btyLength, ref btyWidth,ref isEmpty);
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// break;
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// case DetectionOption.doStandardBlock:
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// visionDetect.M423MeasureLandWJohnny(hImage, halconWindow, ref btyLength, ref btyWidth,ref isEmpty);
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// break;
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//}
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bool isNA = Convert.ToBoolean(isEmpty);
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double compL = 0.0, compW = 0.0;
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//if (!Convert.ToBoolean(isEmpty))
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//{
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if (CommonUtil.DetectionOption == DetectionOption.doProduct)
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{
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Type t = opcConfig.compensationL.GetType();
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FieldInfo fi = t.GetField(string.Format("station{0}", CommonUtil.mainForm.PlateID));
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compL = (double)fi.GetValue(opcConfig.compensationL);
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t = opcConfig.compensationW.GetType();
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fi = t.GetField(string.Format("station{0}", CommonUtil.mainForm.PlateID));
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compW = (double)fi.GetValue(opcConfig.compensationW);
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SaveDualDataAsync(tempFileName, hImage, DateTime.Now, compL, compW, productNo, lengthArr, widthArr, rectArea, isNA);
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btyLength += compL;
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btyWidth += compW;
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//限制精度5位
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btyLength = Math.Round(btyLength, 5);
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btyWidth = Math.Round(btyWidth, 5);
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lengthMeasureState = (btyLength >= opcConfig.batteryLengthLimit.Min && btyLength <= opcConfig.batteryLengthLimit.Max) ? MeasureState.OK : MeasureState.NG;
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widthMeasureState = (btyWidth >= opcConfig.batteryWidthLimit.Min && btyWidth <= opcConfig.batteryWidthLimit.Max) ? MeasureState.OK : MeasureState.NG;
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// 目前逻辑中，如果值OK就认为OK 如果值NG的情况下 根据IsNA判断，区分NG和NA
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if (lengthMeasureState == MeasureState.OK && widthMeasureState == MeasureState.OK)
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{
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ms = MeasureState.OK;
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if (opcConfig.IsSaveSizeOKImage)
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{
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DateTime dt = DateTime.Now;
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if (dt.Second >= 10 && dt.Second <= 15)
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{
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VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + @"\" + tempFileName);
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}
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}
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}
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else
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{
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if (btyLength >= MaxLength || btyLength <= MinLength)
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{
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lengthMeasureState = MeasureState.NA;
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ms = MeasureState.NA;
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}
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if (btyWidth >= MaxWidth || btyWidth <= MinWidth)
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{
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widthMeasureState = MeasureState.NA;
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ms = MeasureState.NA;
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}
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//if (ms != MeasureState.NA)
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//{
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// ms = MeasureState.NG;
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//}
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if (ms != MeasureState.NA)
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{
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if (!isNA)
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{
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ms = MeasureState.NG;
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}
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else
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{
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lengthMeasureState = MeasureState.NA;
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widthMeasureState = MeasureState.NA;
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ms = MeasureState.NA;
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}
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}
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fileName = VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + $"_{ms.ToString()}\\{ tempFileName}");
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}
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}
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else
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{
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Type t = opcConfig.compensationL.GetType();
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FieldInfo fi = t.GetField(string.Format("station{0}", CommonUtil.mainForm.PlateID));
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compL = (double)fi.GetValue(opcConfig.compensationL);
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t = opcConfig.compensationW.GetType();
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fi = t.GetField(string.Format("station{0}", CommonUtil.mainForm.PlateID));
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compW = (double)fi.GetValue(opcConfig.compensationW);
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btyLength += compL;
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btyWidth += compW;
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lengthMeasureState = (btyLength >= opcConfig.standardLengthLimit.Min && btyLength <= opcConfig.standardLengthLimit.Max) ? MeasureState.OK : MeasureState.NG;
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widthMeasureState = (btyWidth >= opcConfig.standardWidthLimit.Min && btyWidth <= opcConfig.standardWidthLimit.Max) ? MeasureState.OK : MeasureState.NG;
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if (lengthMeasureState == MeasureState.OK && widthMeasureState == MeasureState.OK)
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{
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ms = MeasureState.OK;
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VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + @"\" + tempFileName);
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VisionDetect.SaveImageAs(hImage, CommonUtil.ProductSizeImageDir + @"\" + tempFileName);
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}
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else
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{
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ms = MeasureState.NG;
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fileName = VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + @"_NG\" + tempFileName);
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VisionDetect.SaveImageAs(hImage, CommonUtil.ProductSizeImageDir + @"\" + tempFileName);
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}
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}
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timeStr = DateTime.Now.ToString("hh:mm:ss fff");
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CommonUtil.WriteLog(LogType.Inf, string.Format("产品尺寸检测完成：{0:F4}\t{1:F4}, {2}",
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btyLength, btyWidth, timeStr));
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opc.Write(OPCOutputTag.TestResult, true);
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if (FormCheck._totalQty - FormCheck._finishedQty > 0 && FormCheck._pickCount > 0)
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{
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if (FormCheck._lastProductQty + FormCheck._pickCount < productQty + FormCheck._lastBreakProductQty)
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{
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FormCheck._lastProductQty = productQty + FormCheck._lastBreakProductQty;
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}
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if (productQty + FormCheck._lastBreakProductQty == FormCheck._lastProductQty + FormCheck._pickCount)
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{
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//string productNo = GetProductNo(CommonUtil.StepControl.GetDetectSizeStepID());
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if (productNo != "NA" && WeekCompare(productNo))
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{
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isPick = true;
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FormCheck._lastProductQty = productQty + FormCheck._lastBreakProductQty;
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}
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}
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}
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if (ms == MeasureState.OK && isPick)
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{
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FormCheck._finishedQty++;
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}
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if (ms == MeasureState.NG && isPick)
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{
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FormCheck._lastProductQty = FormCheck._lastProductQty - 2;
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}
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}
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else
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{
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opc.Write(OPCOutputTag.TestResult, false);
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CommonUtil.WriteLog(LogType.Inf, string.Format("没有获取到尺寸图像"));
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}
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DateTime t2 = DateTime.Now;
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TimeSpan ts = t2 - CommonUtil.mainForm.TurnDiskReadyTime;
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CommonUtil.mainForm.Invoke(new Action(() => { CommonUtil.mainForm.SetSizeTime((int)Math.Round(ts.TotalMilliseconds)); }));
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}
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catch (Exception ex)
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{
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CommonUtil.WriteLog(LogType.Exc, string.Format("产品尺寸检测出现异常：{0}", ex.Message));
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fileName = VisionDetect.SaveImageAs(hImage, $"{CommonUtil.ProductSizeImageDir}_NA\\{tempFileName}");
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}
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finally
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{
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hImage?.Dispose();
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hImage = null;
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CommonUtil.mainForm.Invoke(new Action(() => CommonUtil.mainForm.SetDetectionSize(btyLength, btyWidth, btyCellWidhth, lengthMeasureState, widthMeasureState, CommonUtil.mainForm.PlateID, fileName, isPick || FormCheck._pickNow)));
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opc.Write(OPCOutputTag.DetectionOK4, true);
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CommonUtil.WriteLog(LogType.Exc, "完成向PLC发送DetectionOK4");
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if (ms == MeasureState.OK && (FormCheck._pickNow || isPick))
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{
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SpotCheckData checkData = new SpotCheckData();
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if (isPick)
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{
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Task.Factory.StartNew(() =>
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{
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FormCheck._detail.Type = "自動拾取";
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checkData.SaveSpotCheckDetail(FormCheck._detail);
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checkData.UpdateFinishedQty();
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checkData.UpdateLastProductQty(FormCheck._lastProductQty);
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checkData.SaveCheckToCsv(FormCheck._detail);
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});
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isPick = false;
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}
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else
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{
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Task.Factory.StartNew(() =>
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{
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FormCheck._detail.Type = "手動拾取";
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checkData.SaveSpotCheckDetail(FormCheck._detail);
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checkData.SaveCheckToCsv(FormCheck._detail);
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});
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FormCheck._pickNow = false;
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}
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}
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}
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}
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#region DualDataCSV 记录两份检测数据的CSV记录
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static object _dualDataLock = new object();
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|
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private void SaveDualDataAsync(string tempFileName, HObject hImage, DateTime now, double compL, double compW, string productNo, double[] lengthArr, double[] widthArr, double area, bool isNA)
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{
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//if (lengthArr.Length < 2 || widthArr.Length < 2 || lengthArr.Length != widthArr.Length)
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// return;
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string data = $"{now.ToString("HH:mm:ss.fff")},{productNo},";
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for (int i = 0; i < lengthArr.Length; i++)
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{
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double length = lengthArr[i];
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double width = widthArr[i];
|
|
if (length != 999.999 && length != -999.999)
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{
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length += compL;
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}
|
if (width != 999.999 && width != -999.999)
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{
|
width += compW;
|
}
|
|
var lengthResult = (length >= opcConfig.batteryLengthLimit.Min && length <= opcConfig.batteryLengthLimit.Max) ? MeasureState.OK : MeasureState.NG;
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var widthResult = (width >= opcConfig.batteryWidthLimit.Min && width <= opcConfig.batteryWidthLimit.Max) ? MeasureState.OK : MeasureState.NG;
|
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data += length.ToString("f5") + ",";
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data += lengthResult.ToString() + ",";
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data += width.ToString("f5") + ",";
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data += widthResult.ToString() + ",";
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data += ((lengthResult == MeasureState.OK && widthResult == MeasureState.OK) ? MeasureState.OK : MeasureState.NG).ToString() + ",";
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if (lengthResult == MeasureState.OK && widthResult == MeasureState.OK)
|
{
|
//VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + @"\" + tempFileName);
|
}
|
else
|
{
|
//string fileName = "";
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//fileName = VisionDetect.SaveImageAs(hImage, CommonUtil.ScreenshotsDir + $"{(i + 1).ToString()}_NG\\{ tempFileName}");
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VisionDetect.SaveWindowImageAs(halconWindow, CommonUtil.ScreenshotsDir + $"_{(i + 1).ToString()}_NG\\{ tempFileName}");
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//VisionDetect.SaveImageAs(hImage, CommonUtil.ProductSizeImageDir + $"_{(i + 1).ToString()}_NG\\{ tempFileName}");
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}
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}
|
|
data += (area.ToString("f5") + ",");
|
data += (isNA ? "NA" : "" + ",");
|
|
data = data.TrimEnd(',');
|
|
lock (_dualDataLock)
|
{
|
string fileName = @"E:\DailyReport";
|
fileName = Path.Combine(fileName, "DualData_" + DateTime.Now.ToString("yyyyMMdd") + ".csv");
|
|
bool isFileExisted = File.Exists(fileName);
|
|
using (StreamWriter writer = new StreamWriter(fileName, true, System.Text.Encoding.UTF8))
|
{
|
if (!isFileExisted)
|
{
|
writer.WriteLine(GetCSVHead(lengthArr.Length));
|
}
|
|
writer.WriteLine(data);
|
writer.Flush();
|
writer.Close();
|
}
|
}
|
|
}
|
|
private string GetCSVHead(int dataNums)
|
{
|
string head = "Time,ProductionNo,";
|
|
for (int i = 1; i <= dataNums; i++)
|
{
|
head += ("Length_" + i + ",");
|
head += ("LengthResult_" + i + ",");
|
head += ("Width_" + i + ",");
|
head += ("WidthResult_" + i + ",");
|
head += ("Result_" + i + ",");
|
}
|
|
head += "Area,IsNA";
|
|
head = head.TrimEnd(',');
|
|
return head;
|
}
|
#endregion
|
|
private string GetCurrentProductSN(int detectID)
|
{
|
var mr = (from x in CommonUtil.mainForm.ProductBindingList
|
where x.DetectID == detectID
|
select x).FirstOrDefault();
|
|
return CommonUtil.mainForm.PlateID.ToString() + "_" + mr.ProductNo.Replace("/", "").Replace("\"", "'") + "_" + DateTime.Now.ToString("HHmmssff") + "_" + detectID.ToString();
|
}
|
|
public string GetProductNo(int detecId)
|
{
|
var mr = (from x in CommonUtil.mainForm.ProductBindingList
|
where x.DetectID == detecId
|
select x).FirstOrDefault();
|
|
return mr.ProductNo.Replace("/", "").Replace("\"", "'");
|
}
|
|
public bool WeekCompare(string productNo)
|
{
|
int result = 0;
|
try
|
{
|
string weekYear = GetWeekYear(DateTime.Now);
|
string weekPPID = productNo.Substring(3, 3);
|
if (weekYear.Substring(0, 1) == weekPPID.Substring(0, 1))
|
{
|
result = Convert.ToInt32(weekYear) - Convert.ToInt32(weekPPID);
|
}
|
else
|
{
|
string lastEnd = GetWeekYear(Convert.ToDateTime((DateTime.Now.Year - 1).ToString() + "-12-31"));
|
result = Convert.ToInt32(lastEnd) - Convert.ToInt32(weekPPID);
|
if (result == 0 && weekYear.Substring(1, 2) == "01")
|
{
|
result = 1;
|
}
|
else
|
{
|
result = 2;
|
}
|
}
|
CommonUtil.WriteLog(LogType.Inf, "WeekCompare判定结果为：" + (result <= 1).ToString() + ",weekYear=" + weekYear + ",weekPPID=" + weekPPID + ",productNo=" + productNo);
|
}
|
catch (Exception ex)
|
{
|
CommonUtil.WriteLog(LogType.Err, string.Format("WeekCompare计算错误：{0}", ex.Message));
|
return false;
|
}
|
|
return result <= 1;
|
}
|
|
public string GetWeekYear(DateTime dt)
|
{
|
GregorianCalendar gc = new GregorianCalendar();
|
int weekOfYear = gc.GetWeekOfYear(dt, CalendarWeekRule.FirstDay, DayOfWeek.Monday);
|
|
var weekPlusStr = ConfigurationManager.AppSettings["WeekPlus"];
|
int weekPlus = 0;
|
if (!int.TryParse(weekPlusStr, out weekPlus))
|
{
|
weekPlus = 0;
|
}
|
weekOfYear += weekPlus;
|
string week = weekOfYear.ToString().Length == 1 ? "0" + weekOfYear.ToString() : weekOfYear.ToString();
|
|
var yearPlusStr = ConfigurationManager.AppSettings["YearPlus"];
|
int yearPlus = 0;
|
if (!int.TryParse(yearPlusStr, out yearPlus))
|
{
|
yearPlus = 0;
|
}
|
string year = dt.Year.ToString().Substring(dt.Year.ToString().Length - 1, 1);
|
year = (int.Parse(year) + yearPlus).ToString();
|
|
return year + week;
|
}
|
}
|
}
|
