255 lines
8.4 KiB
Python
255 lines
8.4 KiB
Python
"""气体流量闭环控制程序入口。
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示例：
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python main.py --target 50
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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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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
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import logging
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from pathlib import Path
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import sys
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import time
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import config
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from controllers import IncrementalPID
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from data_logger import FlowRunRecorder
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from flow_control import FlowControlFault, FlowControlLoop
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from performance_reporter import PerformanceReporter
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def build_logger():
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log_dir = Path(__file__).resolve().parent / config.LOG_DIRECTORY
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log_dir.mkdir(parents=True, exist_ok=True)
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log_path = log_dir / config.LOG_FILE_NAME
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logger = logging.getLogger("flow_control")
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logger.setLevel(logging.INFO)
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logger.handlers.clear()
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formatter = logging.Formatter(
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"%(asctime)s.%(msecs)03d %(levelname)s %(message)s",
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datefmt="%Y-%m-%d %H:%M:%S",
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)
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file_handler = logging.FileHandler(log_path, encoding="utf-8")
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file_handler.setFormatter(formatter)
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logger.addHandler(file_handler)
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console_handler = logging.StreamHandler()
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console_handler.setFormatter(formatter)
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logger.addHandler(console_handler)
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return logger
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def build_control_loop(hardware, logger):
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pid = IncrementalPID(
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kp=config.PID_KP,
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ki=config.PID_KI,
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kd=config.PID_KD,
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dt=config.CONTROL_PERIOD_S,
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out_min=config.OPENING_MIN_PCT,
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out_max=config.OPENING_MAX_PCT,
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output_rate_limit=config.MAX_OPENING_RATE_PCT_S,
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)
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return FlowControlLoop(
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hardware=hardware,
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pid=pid,
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period_s=config.CONTROL_PERIOD_S,
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flow_channel=config.FLOW_INPUT_CHANNEL,
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pressure_channel=config.PRESSURE_INPUT_CHANNEL,
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motor_channel=config.MOTOR_OUTPUT_CHANNEL,
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motor_open_position=config.MOTOR_OPEN_POSITION,
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motor_closed_position=config.MOTOR_CLOSED_POSITION,
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target_min_slm=config.TARGET_FLOW_MIN_SLM,
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target_max_slm=config.TARGET_FLOW_MAX_SLM,
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zero_flow_threshold_slm=config.ZERO_FLOW_THRESHOLD_SLM,
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flow_valid_min_slm=config.FLOW_VALID_MIN_SLM,
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flow_valid_max_slm=config.FLOW_VALID_MAX_SLM,
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max_pressure_kpa=config.MAX_PRESSURE_KPA,
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max_control_dt_s=config.MAX_CONTROL_DT_S,
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max_consecutive_flow_failures=config.MAX_CONSECUTIVE_FLOW_FAILURES,
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max_consecutive_pressure_failures=(
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config.MAX_CONSECUTIVE_PRESSURE_FAILURES
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),
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logger=logger,
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)
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def parse_args(argv=None):
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parser = argparse.ArgumentParser(description="MT2-AM8 气体流量 PID 控制")
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parser.add_argument(
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"--target",
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type=float,
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required=True,
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help=(
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"目标流量 SLM，允许范围 "
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f"{config.TARGET_FLOW_MIN_SLM}~{config.TARGET_FLOW_MAX_SLM}"
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),
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)
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return parser.parse_args(argv)
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def format_status(result):
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flow_text = (
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"--" if result.measured_flow_slm is None
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else f"{result.measured_flow_slm:.2f}"
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)
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pressure_text = (
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"--" if result.pressure_kpa is None
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else f"{result.pressure_kpa:.2f}"
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)
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return (
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f"状态={result.status} 目标={result.target_flow_slm:.2f} SLM "
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f"实际={flow_text} SLM 压力={pressure_text} kPa "
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f"开度={result.opening_pct:.2f}% "
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f"行程={result.motor_position:.1f} dt={result.actual_dt_s:.3f}s"
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)
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def run(target_flow_slm):
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config.validate_config()
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logger = build_logger()
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try:
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from PcControl import MT2AM8Client
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except ModuleNotFoundError as exc:
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if exc.name and exc.name.startswith("pymodbus"):
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logger.critical(
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"缺少 PcControl.py 所需的 pymodbus；请在运行本工程的 Python "
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"环境中安装与现有硬件代码兼容的 pymodbus 版本"
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)
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return 6
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raise
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hardware = MT2AM8Client(
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host=config.MT2AM8_HOST,
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port=config.MT2AM8_PORT,
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slave_id=config.MT2AM8_SLAVE_ID,
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pressure_range=config.PRESSURE_RANGE_KPA,
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flow_range=config.FLOW_METER_RANGE_SLM,
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)
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controller = build_control_loop(hardware, logger)
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controller.set_target_flow(target_flow_slm)
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connected = False
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recorder = None
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reporter = None
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exit_code = 0
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try:
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logger.info(
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"正在连接 MT2-AM8 %s:%s，目标流量=%.3f SLM",
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config.MT2AM8_HOST,
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config.MT2AM8_PORT,
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target_flow_slm,
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)
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connected = bool(hardware.connect())
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if not connected:
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raise FlowControlFault(
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"DEVICE_CONNECT_FAILED",
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"STARTUP",
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"无法连接 MT2-AM8",
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{
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"host": config.MT2AM8_HOST,
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"port": config.MT2AM8_PORT,
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"slave_id": config.MT2AM8_SLAVE_ID,
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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。
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try:
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initial_flow_slm = hardware.get_flow(config.FLOW_INPUT_CHANNEL)
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except Exception:
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initial_flow_slm = None
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reporter = PerformanceReporter(
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controller.pid,
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window_s=config.STEADY_STATE_WINDOW_S,
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sample_period_s=config.CONTROL_PERIOD_S,
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band_pct=config.STEADY_STATE_BAND_PCT,
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std_pct=config.STEADY_STATE_STD_PCT,
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flow_range_min_slm=config.TARGET_FLOW_MIN_SLM,
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flow_range_max_slm=config.TARGET_FLOW_MAX_SLM,
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initial_flow_slm=initial_flow_slm,
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logger=logger,
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)
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controller.start(initial_opening=config.INITIAL_OPENING_PCT)
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recorder = FlowRunRecorder(
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Path(__file__).resolve().parent / config.DATA_DIRECTORY,
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plot_dpi=config.PLOT_DPI,
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)
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logger.info("逐周期数据将保存到 %s", recorder.csv_path)
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logger.info("闭环控制已启动；按 Ctrl+C 停止")
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next_deadline = time.perf_counter()
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next_status_time = next_deadline
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while True:
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now = time.perf_counter()
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result = controller.step(now=now)
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recorder.record(result)
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reporter.observe(result)
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if config.AUTO_STOP_ON_STEADY and reporter.steady_reached:
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logger.info("已达到稳态，自动停止控制")
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break
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if now >= next_status_time or result.status != "OK":
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logger.info(format_status(result))
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next_status_time = now + config.STATUS_PRINT_PERIOD_S
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next_deadline += config.CONTROL_PERIOD_S
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sleep_s = next_deadline - time.perf_counter()
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if sleep_s > 0:
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time.sleep(sleep_s)
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else:
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# 丢弃已经错过的节拍，避免连续快速补跑 PID。
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next_deadline = time.perf_counter()
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except KeyboardInterrupt:
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logger.info("收到 Ctrl+C，正在停止控制")
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except FlowControlFault as exc:
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exit_code = 2
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logger.critical("控制故障：%s", exc)
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except Exception:
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exit_code = 3
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logger.exception("未处理异常，系统将退出")
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finally:
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if connected:
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try:
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hardware.disconnect()
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except Exception:
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exit_code = max(exit_code, 5)
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logger.exception("断开 MT2-AM8 时发生异常")
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if recorder is not None:
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try:
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image_path = recorder.finalize()
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logger.info("控制数据已保存：%s", recorder.csv_path)
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if image_path is not None:
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logger.info("三联曲线图已保存：%s", image_path)
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else:
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logger.warning("本次运行没有采样点，因此未生成曲线图")
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except Exception:
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recorder.close()
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exit_code = max(exit_code, 7)
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logger.exception("保存控制数据曲线图失败；CSV 数据仍保留")
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if reporter is not None:
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try:
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reporter.finalize()
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except Exception:
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logger.exception("生成控制性能报告时发生异常")
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logger.info("程序结束，退出码=%d", exit_code)
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return exit_code
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def main(argv=None):
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args = parse_args(argv)
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return run(args.target)
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if __name__ == "__main__":
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sys.exit(main())
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