1.原先程序启动后会先下发关闭位置，再开始闭环，现在启动后直接从当前阀门开度（默认全开）开始闭环。删除了safe_close相关的代码
2.新增open_loop.py进行开环控制，记录控流阀前后流量和压力数据，方便后面辨识拟合，以及观察动态特性。 3.新增README.md
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# 气体流量闭环控制系统
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基于 **MT2-AM8 模拟量采集/输出模块** 的单回路气体流量 PID 闭环控制程序。
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程序以 10 Hz 周期读取流量（可选读取压力），经增量式 PID 计算阀门开度，
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映射为电机行程后通过 Modbus TCP 下发给执行机构，并在每次运行结束后自动
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保存逐周期数据、生成三联曲线图与一次性的控制性能报告。
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## 硬件与通讯
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- 采集/输出模块：艾莫迅 **MT2-AM8**（Modbus TCP，默认 `192.168.1.12:502`，站号 1）
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- 模拟量输入（AI）：地址 `0x00~0x03`，0~4095 对应 0~10V / 0~20mA
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- 模拟量输出（AO）：保持寄存器 `0x00~0x03`
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- 流量计量程默认 300 SLM，压力表量程默认 400 kPa
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- 电机行程与开度**反向作用**：行程越大开度越小，
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`opening=0% → MOTOR_CLOSED_POSITION`，`opening=100% → MOTOR_OPEN_POSITION`
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> 所有地址、通道、量程、行程端值均在 [config.py](config.py) 中集中配置，
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> 首次连接真实设备前必须核对。
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## 架构与模块职责
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| 文件 | 职责 |
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| --- | --- |
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| [main.py](main.py) | 程序入口：解析参数、装配日志/控制器/记录器/报告器、主循环与安全退出 |
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| [flow_control.py](flow_control.py) | 闭环控制层：`读取传感器 → PID → 开度/行程映射 → 下发电机位置`，含全部安全处理 |
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| [controllers.py](controllers.py) | 通用增量式 PID 控制器 `IncrementalPID`（输出限幅 + 输出变化率限幅） |
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| [config.py](config.py) | 集中配置与 `validate_config()` 启动前校验 |
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| [data_logger.py](data_logger.py) | `FlowRunRecorder`：逐周期写 CSV，运行结束生成三联曲线图 |
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| [performance_reporter.py](performance_reporter.py) | `PerformanceReporter`：滑窗稳态判定，输出一次性性能报告 |
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| [PcControl.py](PcControl.py) | 硬件层：`MT2AM8Client` 等 Modbus 客户端（本项目实际使用 `MT2AM8Client`） |
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### 控制回路流程
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```
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读取流量/压力 (MT2-AM8)
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│
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▼
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IncrementalPID.update() ──► 开度百分比 0~100%
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│
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▼
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opening_to_motor_position() ──► 反向行程 0~1000
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│
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▼
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hardware.set_motor_position() ──► Modbus TCP 写 AO
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```
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`error = setpoint - measurement`；PID 输出累加后统一映射为阀门开度百分比，
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再做行程换算，因此 PID 与执行机构解耦。
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## 快速开始
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```bash
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python main.py --target 50
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```
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- `--target`：目标流量（SLM），必须在 `[TARGET_FLOW_MIN_SLM, TARGET_FLOW_MAX_SLM]` 内。
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- 启动流程：连接 MT2-AM8 → 确认阀门关闭 → 读取初始流量 → 启动闭环。
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- 停止：`Ctrl+C`；控制故障、未处理异常同样会触发安全关阀并断开设备。
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## 运行输出
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1. **终端/日志**：周期状态行（状态、目标/实际流量、压力、开度、行程、实际 dt），
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日志同时写入 [logs/flow_control.log](logs/flow_control.log)。
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2. **逐周期数据**：每次运行生成 `data/flow_run_<时间戳>.csv`。
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3. **曲线图**：与 CSV 同名的 PNG 三联图（流量响应 / 阀门开度 / 压力）。
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4. **性能报告**：首次达到稳态时打印一次，包含：
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- 本次 PID 参数（Kp / Ki / Kd）
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- 调节时间（至稳态，秒）
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- 超调量（绝对 SLM + 相对目标百分比）
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- 本次控制范围
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稳态判定为两个条件**同时**满足：滑窗均值落在目标 ±`STEADY_STATE_BAND_PCT`% 误差带内，
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且滑窗标准差低于 `STEADY_STATE_STD_PCT`% 目标流量阈值。
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## 安全机制
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- **启动前安全关阀**：控制开始前先确认阀门已关闭。
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- **流量/压力越限关阀**：读数超出 `FLOW_VALID_*` 或超过 `MAX_PRESSURE_KPA` 立即关阀。
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- **连续读取失败关阀**：短暂读取失败保持上一输出；连续达到阈值后关阀。
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- **控制循环超时保护**：实际周期超过 `MAX_CONTROL_DT_S` 判定超时。
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- **输出变化率限幅**：`MAX_OPENING_RATE_PCT_S` 限制开度变化速度，防止阀门阶跃冲击。
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- **退出安全关阀**：任何退出路径（含异常）都会再次尝试关阀并断开设备。
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## 关键配置项
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见 [config.py](config.py)，常用项：
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| 配置 | 默认值 | 说明 |
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| --- | --- | --- |
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| `MT2AM8_HOST` / `MT2AM8_PORT` / `MT2AM8_SLAVE_ID` | `192.168.1.12` / `502` / `1` | 模块地址 |
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| `FLOW_INPUT_CHANNEL` / `PRESSURE_INPUT_CHANNEL` / `MOTOR_OUTPUT_CHANNEL` | `1` / `0` / `0` | AI/AO 通道（0 起始） |
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| `FLOW_METER_RANGE_SLM` / `PRESSURE_RANGE_KPA` | `300` / `400` | 量程 |
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| `CONTROL_PERIOD_S` | `0.1` | 控制周期（100 ms，10 Hz） |
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| `PID_KP` / `PID_KI` / `PID_KD` | `0.5` / `0.1` / `0.0` | 安全起步 PI 参数，需现场整定 |
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| `MOTOR_CLOSED_POSITION` / `MOTOR_OPEN_POSITION` | `1000` / `0` | 行程端值 |
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| `MAX_PRESSURE_KPA` | `400` | 压力上限，须按管路额定压力确认 |
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| `STEADY_STATE_WINDOW_S` / `STEADY_STATE_BAND_PCT` / `STEADY_STATE_STD_PCT` | `2.0` / `2.0` / `2.0` | 稳态判定参数 |
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## 依赖
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- Python 3
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- [pymodbus](https://pymodbus.readthedocs.io/)（`PcControl.py` 的 Modbus TCP 通讯）
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- [matplotlib](https://matplotlib.org/)（曲线图生成，使用 `Agg` 后端，无显示器环境也可保存）
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## 项目结构
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```
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flow_control/
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├── main.py # 程序入口
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├── flow_control.py # 闭环控制层
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├── controllers.py # 增量式 PID
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├── config.py # 集中配置与校验
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├── data_logger.py # CSV 记录 + 曲线图
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├── performance_reporter.py # 稳态判定 + 性能报告
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├── PcControl.py # Modbus 硬件客户端
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├── data/ # 每次运行的 CSV / PNG
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└── logs/ # 运行日志
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```
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@@ -19,7 +19,7 @@ FLOW_METER_RANGE_SLM = 300.0
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# AI/AO 通道均从 0 开始。AI0 和 AO0 属于不同的寄存器区，可以同时使用。
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# AI/AO 通道均从 0 开始。AI0 和 AO0 属于不同的寄存器区，可以同时使用。
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FLOW_INPUT_CHANNEL = 1
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FLOW_INPUT_CHANNEL = 1
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PRESSURE_INPUT_CHANNEL = 0 # 没有压力传感器时改为 None
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PRESSURE_INPUT_CHANNEL = 0 # 没有压力传感器时改为 None
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MOTOR_OUTPUT_CHANNEL = 0
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MOTOR_OUTPUT_CHANNEL = 1
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# ---------------------------------------------------------------------------
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# ---------------------------------------------------------------------------
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# 控制目标和控制周期
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# 控制目标和控制周期
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@@ -62,18 +62,21 @@ STEADY_STATE_STD_PCT = 2.0 # 滑窗标准差阈值（相对目标百分比
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# opening=0% -> MOTOR_CLOSED_POSITION（完全关闭）
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# opening=0% -> MOTOR_CLOSED_POSITION（完全关闭）
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# opening=100% -> MOTOR_OPEN_POSITION（打开端/机械死区边界）
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# opening=100% -> MOTOR_OPEN_POSITION（打开端/机械死区边界）
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MOTOR_CLOSED_POSITION = 1000.0
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MOTOR_CLOSED_POSITION = 1000.0
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MOTOR_OPEN_POSITION = 240.0
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MOTOR_OPEN_POSITION = 0.0
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# 控制启动时的阀门初始开度；增量 PID 从该开度开始累加 Δu。
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INITIAL_OPENING_PCT = 100.0
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# ---------------------------------------------------------------------------
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# ---------------------------------------------------------------------------
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# 安全阈值
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# 安全阈值
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# ---------------------------------------------------------------------------
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# ---------------------------------------------------------------------------
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# 物理读数允许范围；超过范围立即关阀。
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# 物理读数允许范围；超过范围立即报故障停机（阀门不被驱动时回到全开）。
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FLOW_VALID_MIN_SLM = 0.0
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FLOW_VALID_MIN_SLM = 0.0
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FLOW_VALID_MAX_SLM = 300.0
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FLOW_VALID_MAX_SLM = 300.0
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MAX_PRESSURE_KPA = 400 # 必须按实际管路额定压力确认
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MAX_PRESSURE_KPA = 400 # 必须按实际管路额定压力确认
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# 短暂读取失败时保持上一输出，不下发新位置；连续达到阈值后关阀。
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# 短暂读取失败时保持上一输出，不下发新位置；连续达到阈值后报故障停机。
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MAX_CONSECUTIVE_FLOW_FAILURES = 3
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MAX_CONSECUTIVE_FLOW_FAILURES = 3
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MAX_CONSECUTIVE_PRESSURE_FAILURES = 3
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MAX_CONSECUTIVE_PRESSURE_FAILURES = 3
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+2
-40
@@ -166,12 +166,9 @@ class FlowControlLoop:
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self.faulted = False
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self.faulted = False
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self.running = True
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self.running = True
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def stop(self, close_valve=True):
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def stop(self):
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"""停止 PID；默认同时安全关阀。"""
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"""停止 PID；阀门保持当前开度（默认全开）。"""
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self.running = False
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self.running = False
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self.pid.reset(initial_output=0.0)
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if close_valve:
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return self.safe_close("STOP_REQUESTED")
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return True
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return True
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def step(self, now=None):
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def step(self, now=None):
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@@ -290,39 +287,6 @@ class FlowControlLoop:
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actual_dt_s=actual_dt,
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actual_dt_s=actual_dt,
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)
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)
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def safe_close(self, reason="UNSPECIFIED"):
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"""尝试把阀门置于关闭端；失败时返回 False 并详细记录。"""
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try:
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success = bool(
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self.hardware.set_motor_position(
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self.motor_closed_position,
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channel=self.motor_channel,
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)
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)
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except Exception as exc:
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self._log(
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"critical",
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"SAFE_CLOSE_FAILED reason=%s exception=%s context=%s",
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reason,
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repr(exc),
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self._context(),
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)
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return False
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if success:
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self.last_opening_pct = 0.0
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self.last_motor_position = self.motor_closed_position
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self._log("warning", "阀门已安全关闭，原因=%s", reason)
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return True
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self._log(
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"critical",
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"SAFE_CLOSE_FAILED reason=%s hardware_return=False context=%s",
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reason,
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self._context(),
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)
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return False
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def _read_flow(self):
|
def _read_flow(self):
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try:
|
try:
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value = self.hardware.get_flow(self.flow_channel)
|
value = self.hardware.get_flow(self.flow_channel)
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@@ -409,8 +373,6 @@ class FlowControlLoop:
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context.update(extra_context or {})
|
context.update(extra_context or {})
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self.faulted = True
|
self.faulted = True
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self.running = False
|
self.running = False
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close_ok = self.safe_close(code)
|
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context["safe_close_success"] = close_ok
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fault = FlowControlFault(code, stage, message, context)
|
fault = FlowControlFault(code, stage, message, context)
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self._log("critical", "%s", fault)
|
self._log("critical", "%s", fault)
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raise fault
|
raise fault
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@@ -0,0 +1,5 @@
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|
2026-08-19 14:22:33.301 CRITICAL 缺少 PcControl.py 所需的 pymodbus；请在运行本工程的 Python 环境中安装与现有硬件代码兼容的 pymodbus 版本
|
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|
2026-08-19 14:23:00.260 INFO 开度扫描顺序（已打乱）: 70.0%, 30.0%, 20.0%, 80.0%, 50.0%, 60.0%, 90.0%, 40.0%, 0.0%, 10.0%, 100.0%
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|
2026-08-19 14:23:00.260 INFO 正在连接 MT2-AM8 192.168.1.12:502
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|
2026-08-19 14:23:03.274 CRITICAL 无法连接 MT2-AM8，实验中止
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|
2026-08-19 14:23:03.274 INFO 程序结束，退出码=2
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@@ -3,8 +3,8 @@
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示例：
|
示例：
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python main.py --target 50
|
python main.py --target 50
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|
|
||||||
程序启动后会先下发关闭位置，再开始闭环。Ctrl+C、控制故障或其他异常都会
|
程序启动后直接从当前阀门开度（默认全开）开始闭环。Ctrl+C、控制故障或
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再次尝试关阀并断开 MT2-AM8。
|
其他异常会断开 MT2-AM8；阀门不被驱动时默认回到全开。
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"""
|
"""
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import argparse
|
import argparse
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@@ -156,14 +156,6 @@ def run(target_flow_slm):
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},
|
},
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)
|
)
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|
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if not controller.safe_close("STARTUP"):
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raise FlowControlFault(
|
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"SAFE_CLOSE_FAILED",
|
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"STARTUP",
|
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"启动前无法确认阀门关闭命令已成功写入",
|
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{"motor_closed_position": config.MOTOR_CLOSED_POSITION},
|
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)
|
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|
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# 控制前读取一次当前流量，作为超调量方向的基准。
|
# 控制前读取一次当前流量，作为超调量方向的基准。
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try:
|
try:
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initial_flow_slm = hardware.get_flow(config.FLOW_INPUT_CHANNEL)
|
initial_flow_slm = hardware.get_flow(config.FLOW_INPUT_CHANNEL)
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@@ -181,7 +173,7 @@ def run(target_flow_slm):
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logger=logger,
|
logger=logger,
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)
|
)
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|
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controller.start(initial_opening=0.0)
|
controller.start(initial_opening=config.INITIAL_OPENING_PCT)
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recorder = FlowRunRecorder(
|
recorder = FlowRunRecorder(
|
||||||
Path(__file__).resolve().parent / config.DATA_DIRECTORY,
|
Path(__file__).resolve().parent / config.DATA_DIRECTORY,
|
||||||
plot_dpi=config.PLOT_DPI,
|
plot_dpi=config.PLOT_DPI,
|
||||||
@@ -216,13 +208,9 @@ def run(target_flow_slm):
|
|||||||
logger.critical("控制故障：%s", exc)
|
logger.critical("控制故障：%s", exc)
|
||||||
except Exception:
|
except Exception:
|
||||||
exit_code = 3
|
exit_code = 3
|
||||||
logger.exception("未处理异常，系统将进入安全关闭")
|
logger.exception("未处理异常，系统将退出")
|
||||||
finally:
|
finally:
|
||||||
if connected:
|
if connected:
|
||||||
close_ok = controller.safe_close("PROGRAM_EXIT")
|
|
||||||
if not close_ok:
|
|
||||||
exit_code = max(exit_code, 4)
|
|
||||||
logger.critical("程序退出时安全关阀失败，请立即人工检查")
|
|
||||||
try:
|
try:
|
||||||
hardware.disconnect()
|
hardware.disconnect()
|
||||||
except Exception:
|
except Exception:
|
||||||
|
|||||||
+648
@@ -0,0 +1,648 @@
|
|||||||
|
"""气体流量开环扫点实验（不参与闭环反馈，也不被 main.py 导入）。
|
||||||
|
|
||||||
|
本模块可独立运行，用于阀门开度—流量特性的开环标定/扫点。程序会：
|
||||||
|
|
||||||
|
1. 生成 0%~100%（默认 10% 间隔）共 11 个开度值并随机打乱；
|
||||||
|
2. 逐个开度：写入电机行程 → 以固定周期采集控流阀前后 4 个传感器
|
||||||
|
（前压力、前流量、后压力、后流量）→ 等待“控流阀后流量”进入稳态后
|
||||||
|
切换到下一个开度；
|
||||||
|
3. 全程逐周期写 CSV，结束后在单个窗口内输出两张子图（前后压力、前后流量），
|
||||||
|
保存到工程目录下的 open_loop_data/。
|
||||||
|
|
||||||
|
示例：
|
||||||
|
python open_loop.py
|
||||||
|
python open_loop.py --seed 42 # 复现同一种打乱顺序
|
||||||
|
python open_loop.py --min 0 --max 100 --step 5
|
||||||
|
|
||||||
|
量程、行程端值、稳态窗口等沿用 config.py；本文件顶部的常量可在不修改
|
||||||
|
config.py 的前提下覆盖实验相关参数（尤其是四个传感器通道映射）。
|
||||||
|
"""
|
||||||
|
|
||||||
|
import argparse
|
||||||
|
import csv
|
||||||
|
import logging
|
||||||
|
import math
|
||||||
|
import random
|
||||||
|
import statistics
|
||||||
|
import time
|
||||||
|
from collections import deque
|
||||||
|
from pathlib import Path
|
||||||
|
|
||||||
|
import config
|
||||||
|
from flow_control import opening_to_motor_position
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 实验参数（可在本文件修改，不影响 config.py）
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
# 四个传感器的 AI 通道（0 起始，MT2-AM8 AI0~AI3）。
|
||||||
|
# “后”= 控流阀出口侧（靠近流量计/负载一侧），沿用 config 的原始通道；
|
||||||
|
# “前”= 控流阀入口侧（靠近减压阀一侧），为本次新增传感器，请按实际接线确认。
|
||||||
|
PRESSURE_AFTER_CHANNEL = config.PRESSURE_INPUT_CHANNEL # 后压力，默认 0
|
||||||
|
FLOW_AFTER_CHANNEL = config.FLOW_INPUT_CHANNEL # 后流量，默认 1
|
||||||
|
PRESSURE_BEFORE_CHANNEL = 2 # 前压力（新增，需确认）
|
||||||
|
FLOW_BEFORE_CHANNEL = 3 # 前流量（新增，需确认）
|
||||||
|
|
||||||
|
MOTOR_CHANNEL = config.MOTOR_OUTPUT_CHANNEL # AO 通道
|
||||||
|
|
||||||
|
# 开度扫描：0%~100%，默认 10% 间隔，共 11 个开度值，随机打乱。
|
||||||
|
OPENING_MIN_PCT = 0.0
|
||||||
|
OPENING_MAX_PCT = 100.0
|
||||||
|
OPENING_STEP_PCT = 10.0
|
||||||
|
RANDOM_SEED = 42 # 设为整数可复现同一打乱顺序
|
||||||
|
|
||||||
|
# 采样与稳态判定
|
||||||
|
SAMPLE_PERIOD_S = 0.1 # 采样周期（秒）
|
||||||
|
STEADY_STATE_WINDOW_S = config.STEADY_STATE_WINDOW_S # 滑窗长度，复用 config
|
||||||
|
STEADY_STATE_STD_PCT = config.STEADY_STATE_STD_PCT # 相对标准差阈值（%）
|
||||||
|
MAX_WAIT_S = 60.0 # 单个开度的最长等待时间
|
||||||
|
MIN_ABS_STD_SLM = 0.05 # 近零流量时的绝对标准差下限
|
||||||
|
MAX_CONSECUTIVE_READ_FAILURES = 5 # 后流量连续读取失败判定设备断开
|
||||||
|
|
||||||
|
# 安全阈值（沿用 config 的闭环安全值；0% 开度时近零噪声若略为负，可放宽流量下限）
|
||||||
|
SAFETY_FLOW_MIN_SLM = config.FLOW_VALID_MIN_SLM
|
||||||
|
SAFETY_FLOW_MAX_SLM = config.FLOW_VALID_MAX_SLM
|
||||||
|
SAFETY_MAX_PRESSURE_KPA = config.MAX_PRESSURE_KPA
|
||||||
|
|
||||||
|
# 输出
|
||||||
|
OUTPUT_DIRECTORY = "open_loop_data" # 相对工程目录
|
||||||
|
PLOT_DPI = config.PLOT_DPI
|
||||||
|
ANNOTATE_STEPS = True # 曲线上标注开度步
|
||||||
|
|
||||||
|
|
||||||
|
CSV_FIELDS = (
|
||||||
|
"time_s",
|
||||||
|
"step_index",
|
||||||
|
"opening_pct",
|
||||||
|
"motor_position",
|
||||||
|
"flow_before_slm",
|
||||||
|
"flow_after_slm",
|
||||||
|
"pressure_before_kpa",
|
||||||
|
"pressure_after_kpa",
|
||||||
|
)
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 稳态判定
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
class SteadyStateDetector:
|
||||||
|
"""滑动窗口稳态判定，复用 PerformanceReporter 的滑窗标准差思路。
|
||||||
|
|
||||||
|
闭环有目标流量，所以用“均值落在目标 ±band”+“标准差低于阈值”两个条件；
|
||||||
|
开环没有目标，因此只保留“滑窗相对标准差足够小”这一条，表示信号不再
|
||||||
|
明显变化：
|
||||||
|
|
||||||
|
std <= max(STD_PCT% * |mean|, MIN_ABS_STD_SLM)
|
||||||
|
|
||||||
|
近零流量时以绝对下限兜底，避免除以零。
|
||||||
|
"""
|
||||||
|
|
||||||
|
def __init__(self, window_s, std_pct, sample_period_s=0.1, min_abs_std_slm=0.05):
|
||||||
|
self.window_s = float(window_s)
|
||||||
|
self.std_pct = float(std_pct)
|
||||||
|
self.sample_period_s = float(sample_period_s)
|
||||||
|
self.min_abs_std_slm = float(min_abs_std_slm)
|
||||||
|
self._window = deque() # 元素为 (elapsed_s, flow_slm)
|
||||||
|
|
||||||
|
def reset(self):
|
||||||
|
self._window.clear()
|
||||||
|
|
||||||
|
def observe(self, elapsed_s, flow_slm):
|
||||||
|
"""喂入一个样本；达到稳态返回 True，否则返回 False。"""
|
||||||
|
if flow_slm is None or not math.isfinite(float(flow_slm)):
|
||||||
|
return False
|
||||||
|
|
||||||
|
self._window.append((float(elapsed_s), float(flow_slm)))
|
||||||
|
cutoff = float(elapsed_s) - self.window_s
|
||||||
|
while self._window and self._window[0][0] < cutoff:
|
||||||
|
self._window.popleft()
|
||||||
|
|
||||||
|
if len(self._window) < 2:
|
||||||
|
return False
|
||||||
|
# 滑窗覆盖时长需至少达到 window_s。真实时间戳带抖动，若严格比较
|
||||||
|
# span < window_s，几乎总差一个采样间隙而永远无法判定；放宽一个
|
||||||
|
# 采样周期的余量。
|
||||||
|
min_span = max(0.0, self.window_s - self.sample_period_s)
|
||||||
|
if self._window[-1][0] - self._window[0][0] < min_span:
|
||||||
|
return False
|
||||||
|
|
||||||
|
flows = [item[1] for item in self._window]
|
||||||
|
mean = statistics.mean(flows)
|
||||||
|
std = statistics.pstdev(flows)
|
||||||
|
threshold = max(self.std_pct / 100.0 * abs(mean), self.min_abs_std_slm)
|
||||||
|
return std <= threshold
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 数据记录与绘图
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
class OpenLoopRecorder:
|
||||||
|
"""逐周期写 CSV，结束时输出两张子图（前后压力、前后流量）。"""
|
||||||
|
|
||||||
|
def __init__(self, output_directory, *, plot_dpi=160):
|
||||||
|
output_dir = Path(output_directory)
|
||||||
|
output_dir.mkdir(parents=True, exist_ok=True)
|
||||||
|
|
||||||
|
run_id = time.strftime("%Y%m%d_%H%M%S")
|
||||||
|
self.csv_path = output_dir / f"open_loop_{run_id}.csv"
|
||||||
|
self.image_path = output_dir / f"open_loop_{run_id}.png"
|
||||||
|
self.plot_dpi = int(plot_dpi)
|
||||||
|
|
||||||
|
self._file = self.csv_path.open("w", newline="", encoding="utf-8-sig")
|
||||||
|
self._writer = csv.DictWriter(self._file, fieldnames=CSV_FIELDS)
|
||||||
|
self._writer.writeheader()
|
||||||
|
self._file.flush()
|
||||||
|
|
||||||
|
self.sample_count = 0
|
||||||
|
self.steps = [] # 每个开度步的 (time_s, opening_pct)
|
||||||
|
self._last_step_index = None
|
||||||
|
self._closed = False
|
||||||
|
|
||||||
|
def record(
|
||||||
|
self,
|
||||||
|
*,
|
||||||
|
time_s,
|
||||||
|
step_index,
|
||||||
|
opening_pct,
|
||||||
|
motor_position,
|
||||||
|
flow_before_slm,
|
||||||
|
flow_after_slm,
|
||||||
|
pressure_before_kpa,
|
||||||
|
pressure_after_kpa,
|
||||||
|
):
|
||||||
|
if self._closed:
|
||||||
|
raise RuntimeError("记录器已关闭")
|
||||||
|
|
||||||
|
self._writer.writerow(
|
||||||
|
{
|
||||||
|
"time_s": self._fmt(time_s),
|
||||||
|
"step_index": int(step_index),
|
||||||
|
"opening_pct": self._fmt(opening_pct),
|
||||||
|
"motor_position": self._fmt(motor_position),
|
||||||
|
"flow_before_slm": self._fmt(flow_before_slm),
|
||||||
|
"flow_after_slm": self._fmt(flow_after_slm),
|
||||||
|
"pressure_before_kpa": self._fmt(pressure_before_kpa),
|
||||||
|
"pressure_after_kpa": self._fmt(pressure_after_kpa),
|
||||||
|
}
|
||||||
|
)
|
||||||
|
self._file.flush()
|
||||||
|
self.sample_count += 1
|
||||||
|
|
||||||
|
if step_index != self._last_step_index:
|
||||||
|
self.steps.append((float(time_s), float(opening_pct)))
|
||||||
|
self._last_step_index = step_index
|
||||||
|
|
||||||
|
def finalize(self):
|
||||||
|
"""关闭 CSV 并生成 PNG；无采样点时只保留 CSV。"""
|
||||||
|
self.close()
|
||||||
|
if self.sample_count == 0:
|
||||||
|
return None
|
||||||
|
self._create_plot()
|
||||||
|
return self.image_path
|
||||||
|
|
||||||
|
def close(self):
|
||||||
|
if not self._closed:
|
||||||
|
self._file.flush()
|
||||||
|
self._file.close()
|
||||||
|
self._closed = True
|
||||||
|
|
||||||
|
def _create_plot(self):
|
||||||
|
# 无界面后端，保证终端/无显示器环境也能保存图片。
|
||||||
|
import matplotlib
|
||||||
|
|
||||||
|
matplotlib.use("Agg")
|
||||||
|
import matplotlib.pyplot as plt
|
||||||
|
|
||||||
|
time_s = []
|
||||||
|
flow_before = []
|
||||||
|
flow_after = []
|
||||||
|
pressure_before = []
|
||||||
|
pressure_after = []
|
||||||
|
|
||||||
|
with self.csv_path.open("r", newline="", encoding="utf-8-sig") as file:
|
||||||
|
for row in csv.DictReader(file):
|
||||||
|
time_s.append(float(row["time_s"]))
|
||||||
|
flow_before.append(self._float_or_nan(row["flow_before_slm"]))
|
||||||
|
flow_after.append(self._float_or_nan(row["flow_after_slm"]))
|
||||||
|
pressure_before.append(
|
||||||
|
self._float_or_nan(row["pressure_before_kpa"])
|
||||||
|
)
|
||||||
|
pressure_after.append(
|
||||||
|
self._float_or_nan(row["pressure_after_kpa"])
|
||||||
|
)
|
||||||
|
|
||||||
|
figure, axes = plt.subplots(
|
||||||
|
2,
|
||||||
|
1,
|
||||||
|
figsize=(12, 9),
|
||||||
|
sharex=True,
|
||||||
|
constrained_layout=True,
|
||||||
|
)
|
||||||
|
figure.suptitle("Open-loop Valve Sweep", fontsize=15)
|
||||||
|
|
||||||
|
self._plot_series(
|
||||||
|
axes[0], time_s, pressure_before,
|
||||||
|
"Pressure before valve", "#1565C0",
|
||||||
|
)
|
||||||
|
self._plot_series(
|
||||||
|
axes[0], time_s, pressure_after,
|
||||||
|
"Pressure after valve", "#D84315",
|
||||||
|
)
|
||||||
|
axes[0].set_ylabel("Pressure (kPa)")
|
||||||
|
axes[0].set_title("Pressure across control valve")
|
||||||
|
axes[0].legend(loc="best")
|
||||||
|
|
||||||
|
self._plot_series(
|
||||||
|
axes[1], time_s, flow_before,
|
||||||
|
"Flow before valve", "#2E7D32",
|
||||||
|
)
|
||||||
|
self._plot_series(
|
||||||
|
axes[1], time_s, flow_after,
|
||||||
|
"Flow after valve", "#6A1B9A",
|
||||||
|
)
|
||||||
|
axes[1].set_ylabel("Flow (SLM)")
|
||||||
|
axes[1].set_xlabel("Time (s)")
|
||||||
|
axes[1].set_title("Flow across control valve")
|
||||||
|
axes[1].legend(loc="best")
|
||||||
|
|
||||||
|
if ANNOTATE_STEPS and self.steps:
|
||||||
|
y_top = axes[1].get_ylim()[1]
|
||||||
|
for step_time, opening in self.steps:
|
||||||
|
for axis in axes:
|
||||||
|
axis.axvline(
|
||||||
|
step_time,
|
||||||
|
color="0.5",
|
||||||
|
linestyle="--",
|
||||||
|
linewidth=0.7,
|
||||||
|
alpha=0.6,
|
||||||
|
)
|
||||||
|
axes[1].text(
|
||||||
|
step_time,
|
||||||
|
y_top,
|
||||||
|
f"{opening:.0f}%",
|
||||||
|
rotation=90,
|
||||||
|
fontsize=7,
|
||||||
|
ha="left",
|
||||||
|
va="bottom",
|
||||||
|
color="0.3",
|
||||||
|
)
|
||||||
|
|
||||||
|
for axis in axes:
|
||||||
|
axis.grid(True, alpha=0.3, linestyle="--")
|
||||||
|
axis.margins(x=0)
|
||||||
|
|
||||||
|
figure.savefig(self.image_path, dpi=self.plot_dpi, bbox_inches="tight")
|
||||||
|
plt.close(figure)
|
||||||
|
|
||||||
|
@staticmethod
|
||||||
|
def _plot_series(axis, time_s, series, label, color):
|
||||||
|
if any(math.isfinite(value) for value in series):
|
||||||
|
axis.plot(time_s, series, color=color, linewidth=1.4, label=label)
|
||||||
|
else:
|
||||||
|
axis.text(
|
||||||
|
0.5,
|
||||||
|
0.5,
|
||||||
|
f"No data: {label}",
|
||||||
|
transform=axis.transAxes,
|
||||||
|
ha="center",
|
||||||
|
va="center",
|
||||||
|
color="gray",
|
||||||
|
)
|
||||||
|
|
||||||
|
@staticmethod
|
||||||
|
def _fmt(value):
|
||||||
|
if value is None:
|
||||||
|
return ""
|
||||||
|
number = float(value)
|
||||||
|
return "" if not math.isfinite(number) else f"{number:.6f}"
|
||||||
|
|
||||||
|
@staticmethod
|
||||||
|
def _float_or_nan(value):
|
||||||
|
if value in (None, ""):
|
||||||
|
return math.nan
|
||||||
|
try:
|
||||||
|
return float(value)
|
||||||
|
except (TypeError, ValueError):
|
||||||
|
return math.nan
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 硬件读写辅助
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
def _safe_read(channel, read_fn):
|
||||||
|
"""读取单路传感器；通道为 None 或读取失败时返回 None，不抛异常。"""
|
||||||
|
if channel is None:
|
||||||
|
return None
|
||||||
|
try:
|
||||||
|
return read_fn(channel)
|
||||||
|
except Exception:
|
||||||
|
return None
|
||||||
|
|
||||||
|
|
||||||
|
def read_sensors(hardware):
|
||||||
|
"""读取控流阀前后四个传感器，返回 (前压, 前流量, 后压, 后流量)。"""
|
||||||
|
pressure_before = _safe_read(PRESSURE_BEFORE_CHANNEL, hardware.get_pressure)
|
||||||
|
flow_before = _safe_read(FLOW_BEFORE_CHANNEL, hardware.get_flow)
|
||||||
|
pressure_after = _safe_read(PRESSURE_AFTER_CHANNEL, hardware.get_pressure)
|
||||||
|
flow_after = _safe_read(FLOW_AFTER_CHANNEL, hardware.get_flow)
|
||||||
|
return pressure_before, flow_before, pressure_after, flow_after
|
||||||
|
|
||||||
|
|
||||||
|
def check_safety(pressure_before, flow_before, pressure_after, flow_after):
|
||||||
|
"""越限检查，返回故障描述字符串；正常返回 None。
|
||||||
|
|
||||||
|
沿用闭环 FlowControlLoop 的安全阈值：流量超出
|
||||||
|
[SAFETY_FLOW_MIN_SLM, SAFETY_FLOW_MAX_SLM]，或任一压力超过
|
||||||
|
SAFETY_MAX_PRESSURE_KPA 时判定为故障（顺带识别未接线通道的负读数）。
|
||||||
|
"""
|
||||||
|
if (
|
||||||
|
flow_after is not None
|
||||||
|
and not SAFETY_FLOW_MIN_SLM <= flow_after <= SAFETY_FLOW_MAX_SLM
|
||||||
|
):
|
||||||
|
return f"FLOW_AFTER_OUT_OF_RANGE({flow_after:.3f} SLM)"
|
||||||
|
if (
|
||||||
|
flow_before is not None
|
||||||
|
and not SAFETY_FLOW_MIN_SLM <= flow_before <= SAFETY_FLOW_MAX_SLM
|
||||||
|
):
|
||||||
|
return f"FLOW_BEFORE_OUT_OF_RANGE({flow_before:.3f} SLM)"
|
||||||
|
if pressure_after is not None and pressure_after > SAFETY_MAX_PRESSURE_KPA:
|
||||||
|
return f"PRESSURE_AFTER_OVER_LIMIT({pressure_after:.3f} kPa)"
|
||||||
|
if pressure_before is not None and pressure_before > SAFETY_MAX_PRESSURE_KPA:
|
||||||
|
return f"PRESSURE_BEFORE_OVER_LIMIT({pressure_before:.3f} kPa)"
|
||||||
|
return None
|
||||||
|
|
||||||
|
|
||||||
|
def set_opening(hardware, opening_pct):
|
||||||
|
"""把 0~100% 开度换算成反向电机行程并下发给 MT2-AM8。"""
|
||||||
|
position = opening_to_motor_position(
|
||||||
|
opening_pct,
|
||||||
|
config.MOTOR_OPEN_POSITION,
|
||||||
|
config.MOTOR_CLOSED_POSITION,
|
||||||
|
)
|
||||||
|
return bool(
|
||||||
|
hardware.set_motor_position(position, channel=MOTOR_CHANNEL)
|
||||||
|
), position
|
||||||
|
|
||||||
|
|
||||||
|
def generate_openings(min_pct, max_pct, step_pct, seed):
|
||||||
|
"""生成 [min, max] 内 step 间隔的开度序列并随机打乱。"""
|
||||||
|
count = int(round((max_pct - min_pct) / step_pct)) + 1
|
||||||
|
openings = [round(min_pct + i * step_pct, 6) for i in range(count)]
|
||||||
|
# step 不能整除区间时，自动补上 max 端点，保证上下限都被覆盖。
|
||||||
|
if not openings or abs(openings[-1] - max_pct) > 1e-6:
|
||||||
|
openings.append(float(max_pct))
|
||||||
|
rng = random.Random(seed)
|
||||||
|
rng.shuffle(openings)
|
||||||
|
return openings
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 日志
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
def build_logger():
|
||||||
|
log_dir = Path(__file__).resolve().parent / config.LOG_DIRECTORY
|
||||||
|
log_dir.mkdir(parents=True, exist_ok=True)
|
||||||
|
log_path = log_dir / "open_loop.log"
|
||||||
|
|
||||||
|
logger = logging.getLogger("open_loop")
|
||||||
|
logger.setLevel(logging.INFO)
|
||||||
|
logger.handlers.clear()
|
||||||
|
|
||||||
|
formatter = logging.Formatter(
|
||||||
|
"%(asctime)s.%(msecs)03d %(levelname)s %(message)s",
|
||||||
|
datefmt="%Y-%m-%d %H:%M:%S",
|
||||||
|
)
|
||||||
|
file_handler = logging.FileHandler(log_path, encoding="utf-8")
|
||||||
|
file_handler.setFormatter(formatter)
|
||||||
|
logger.addHandler(file_handler)
|
||||||
|
|
||||||
|
console_handler = logging.StreamHandler()
|
||||||
|
console_handler.setFormatter(formatter)
|
||||||
|
logger.addHandler(console_handler)
|
||||||
|
return logger
|
||||||
|
|
||||||
|
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
# 主流程
|
||||||
|
# ---------------------------------------------------------------------------
|
||||||
|
|
||||||
|
def parse_args(argv=None):
|
||||||
|
parser = argparse.ArgumentParser(description="MT2-AM8 气体流量开环扫点实验")
|
||||||
|
parser.add_argument("--min", type=float, default=OPENING_MIN_PCT,
|
||||||
|
help="扫描起始开度（%%），默认 %.0f" % OPENING_MIN_PCT)
|
||||||
|
parser.add_argument("--max", type=float, default=OPENING_MAX_PCT,
|
||||||
|
help="扫描结束开度（%%），默认 %.0f" % OPENING_MAX_PCT)
|
||||||
|
parser.add_argument("--step", type=float, default=OPENING_STEP_PCT,
|
||||||
|
help="开度间隔（%%），默认 %.0f" % OPENING_STEP_PCT)
|
||||||
|
parser.add_argument("--seed", type=int, default=RANDOM_SEED,
|
||||||
|
help="随机种子，默认 None（每次打乱顺序不同）")
|
||||||
|
args = parser.parse_args(argv)
|
||||||
|
if args.step <= 0:
|
||||||
|
parser.error("--step 必须大于 0")
|
||||||
|
if not (0 <= args.min < args.max <= 100):
|
||||||
|
parser.error("必须满足 0 <= --min < --max <= 100")
|
||||||
|
return args
|
||||||
|
|
||||||
|
|
||||||
|
def run(args):
|
||||||
|
config.validate_config()
|
||||||
|
logger = build_logger()
|
||||||
|
|
||||||
|
try:
|
||||||
|
from PcControl import MT2AM8Client
|
||||||
|
except ModuleNotFoundError as exc:
|
||||||
|
if exc.name and exc.name.startswith("pymodbus"):
|
||||||
|
logger.critical(
|
||||||
|
"缺少 PcControl.py 所需的 pymodbus；请在运行本工程的 Python "
|
||||||
|
"环境中安装与现有硬件代码兼容的 pymodbus 版本"
|
||||||
|
)
|
||||||
|
return 6
|
||||||
|
raise
|
||||||
|
|
||||||
|
hardware = MT2AM8Client(
|
||||||
|
host=config.MT2AM8_HOST,
|
||||||
|
port=config.MT2AM8_PORT,
|
||||||
|
slave_id=config.MT2AM8_SLAVE_ID,
|
||||||
|
pressure_range=config.PRESSURE_RANGE_KPA,
|
||||||
|
flow_range=config.FLOW_METER_RANGE_SLM,
|
||||||
|
)
|
||||||
|
|
||||||
|
openings = generate_openings(
|
||||||
|
args.min, args.max, args.step, args.seed
|
||||||
|
)
|
||||||
|
logger.info(
|
||||||
|
"开度扫描顺序（已打乱）: %s",
|
||||||
|
", ".join(f"{o:.1f}%" for o in openings),
|
||||||
|
)
|
||||||
|
|
||||||
|
connected = False
|
||||||
|
recorder = None
|
||||||
|
exit_code = 0
|
||||||
|
|
||||||
|
try:
|
||||||
|
logger.info("正在连接 MT2-AM8 %s:%s", config.MT2AM8_HOST, config.MT2AM8_PORT)
|
||||||
|
connected = bool(hardware.connect())
|
||||||
|
if not connected:
|
||||||
|
logger.critical("无法连接 MT2-AM8，实验中止")
|
||||||
|
exit_code = 2
|
||||||
|
return exit_code
|
||||||
|
|
||||||
|
# 启动前先关阀。
|
||||||
|
ok, _ = set_opening(hardware, 0.0)
|
||||||
|
if not ok:
|
||||||
|
logger.critical("启动前关阀失败，实验中止")
|
||||||
|
exit_code = 2
|
||||||
|
return exit_code
|
||||||
|
|
||||||
|
recorder = OpenLoopRecorder(
|
||||||
|
Path(__file__).resolve().parent / OUTPUT_DIRECTORY,
|
||||||
|
plot_dpi=PLOT_DPI,
|
||||||
|
)
|
||||||
|
logger.info("逐周期数据将保存到 %s", recorder.csv_path)
|
||||||
|
|
||||||
|
detector = SteadyStateDetector(
|
||||||
|
STEADY_STATE_WINDOW_S,
|
||||||
|
STEADY_STATE_STD_PCT,
|
||||||
|
sample_period_s=SAMPLE_PERIOD_S,
|
||||||
|
min_abs_std_slm=MIN_ABS_STD_SLM,
|
||||||
|
)
|
||||||
|
|
||||||
|
run_start = time.perf_counter()
|
||||||
|
read_failures = 0
|
||||||
|
|
||||||
|
for step_index, opening in enumerate(openings):
|
||||||
|
ok, position = set_opening(hardware, opening)
|
||||||
|
if not ok:
|
||||||
|
logger.critical(
|
||||||
|
"写入开度 %.1f%% 对应行程 %.1f 失败，实验中止", opening, position
|
||||||
|
)
|
||||||
|
exit_code = 2
|
||||||
|
break
|
||||||
|
|
||||||
|
logger.info(
|
||||||
|
"步 %d/%d：设置开度 %.1f%%（行程 %.1f），等待后流量稳定…",
|
||||||
|
step_index + 1, len(openings), opening, position,
|
||||||
|
)
|
||||||
|
|
||||||
|
detector.reset()
|
||||||
|
step_start = time.perf_counter()
|
||||||
|
next_sample = step_start
|
||||||
|
stable = False
|
||||||
|
|
||||||
|
while True:
|
||||||
|
now = time.perf_counter()
|
||||||
|
elapsed_s = now - run_start
|
||||||
|
|
||||||
|
pressure_before, flow_before, pressure_after, flow_after = (
|
||||||
|
read_sensors(hardware)
|
||||||
|
)
|
||||||
|
recorder.record(
|
||||||
|
time_s=elapsed_s,
|
||||||
|
step_index=step_index,
|
||||||
|
opening_pct=opening,
|
||||||
|
motor_position=position,
|
||||||
|
flow_before_slm=flow_before,
|
||||||
|
flow_after_slm=flow_after,
|
||||||
|
pressure_before_kpa=pressure_before,
|
||||||
|
pressure_after_kpa=pressure_after,
|
||||||
|
)
|
||||||
|
|
||||||
|
fault = check_safety(
|
||||||
|
pressure_before, flow_before, pressure_after, flow_after
|
||||||
|
)
|
||||||
|
if fault is not None:
|
||||||
|
logger.critical("安全阈值触发：%s，实验中止并关阀", fault)
|
||||||
|
exit_code = 2
|
||||||
|
break
|
||||||
|
|
||||||
|
if flow_after is None:
|
||||||
|
read_failures += 1
|
||||||
|
else:
|
||||||
|
read_failures = 0
|
||||||
|
if read_failures >= MAX_CONSECUTIVE_READ_FAILURES:
|
||||||
|
logger.critical(
|
||||||
|
"控流阀后流量连续 %d 次读取失败，判定设备断开，实验中止",
|
||||||
|
read_failures,
|
||||||
|
)
|
||||||
|
exit_code = 2
|
||||||
|
break
|
||||||
|
|
||||||
|
if detector.observe(elapsed_s, flow_after):
|
||||||
|
stable = True
|
||||||
|
settle_s = now - step_start
|
||||||
|
flow_text = "--" if flow_after is None else f"{flow_after:.3f}"
|
||||||
|
logger.info(
|
||||||
|
"步 %d 完成：开度 %.1f%% 后流量稳定 %s SLM，耗时 %.2f s",
|
||||||
|
step_index + 1, opening, flow_text, settle_s,
|
||||||
|
)
|
||||||
|
break
|
||||||
|
|
||||||
|
if now - step_start >= MAX_WAIT_S:
|
||||||
|
logger.warning(
|
||||||
|
"开度 %.1f%% 在 %.1f s 内未稳定，强制进入下一开度",
|
||||||
|
opening, MAX_WAIT_S,
|
||||||
|
)
|
||||||
|
break
|
||||||
|
|
||||||
|
next_sample += SAMPLE_PERIOD_S
|
||||||
|
sleep_s = next_sample - time.perf_counter()
|
||||||
|
if sleep_s > 0:
|
||||||
|
time.sleep(sleep_s)
|
||||||
|
else:
|
||||||
|
next_sample = time.perf_counter()
|
||||||
|
|
||||||
|
if exit_code != 0:
|
||||||
|
break
|
||||||
|
|
||||||
|
except KeyboardInterrupt:
|
||||||
|
logger.info("收到 Ctrl+C，正在停止实验")
|
||||||
|
except Exception:
|
||||||
|
exit_code = 3
|
||||||
|
logger.exception("未处理异常，实验进入收尾")
|
||||||
|
finally:
|
||||||
|
if connected:
|
||||||
|
try:
|
||||||
|
close_ok, _ = set_opening(hardware, 0.0)
|
||||||
|
if not close_ok:
|
||||||
|
exit_code = max(exit_code, 4)
|
||||||
|
logger.critical("收尾安全关阀失败，请立即人工检查")
|
||||||
|
except Exception:
|
||||||
|
exit_code = max(exit_code, 4)
|
||||||
|
logger.exception("收尾安全关阀时发生异常")
|
||||||
|
try:
|
||||||
|
hardware.disconnect()
|
||||||
|
except Exception:
|
||||||
|
exit_code = max(exit_code, 5)
|
||||||
|
logger.exception("断开 MT2-AM8 时发生异常")
|
||||||
|
|
||||||
|
if recorder is not None:
|
||||||
|
try:
|
||||||
|
image_path = recorder.finalize()
|
||||||
|
logger.info("开环数据已保存：%s", recorder.csv_path)
|
||||||
|
if image_path is not None:
|
||||||
|
logger.info("曲线图已保存：%s", image_path)
|
||||||
|
else:
|
||||||
|
logger.warning("本次运行没有采样点，因此未生成曲线图")
|
||||||
|
except Exception:
|
||||||
|
recorder.close()
|
||||||
|
exit_code = max(exit_code, 7)
|
||||||
|
logger.exception("保存曲线图失败；CSV 数据仍保留")
|
||||||
|
|
||||||
|
logger.info("程序结束，退出码=%d", exit_code)
|
||||||
|
return exit_code
|
||||||
|
|
||||||
|
|
||||||
|
def main(argv=None):
|
||||||
|
args = parse_args(argv)
|
||||||
|
return run(args)
|
||||||
|
|
||||||
|
|
||||||
|
if __name__ == "__main__":
|
||||||
|
import sys
|
||||||
|
|
||||||
|
sys.exit(main())
|
||||||
Reference in New Issue
Block a user