365 lines
13 KiB
Python
365 lines
13 KiB
Python
"""气体流量闭环控制程序入口。
|
||
|
||
示例：
|
||
python main.py --target 50
|
||
|
||
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
|
||
其他异常会断开 MT2-AM8；阀门不被驱动时默认回到全开。
|
||
"""
|
||
|
||
import argparse
|
||
import logging
|
||
from pathlib import Path
|
||
import sys
|
||
import time
|
||
|
||
try:
|
||
import msvcrt # Windows 专用：非阻塞键盘输入，用于运行中切换目标流量
|
||
except ImportError: # 非 Windows 平台无此模块，退化为仅周期控制
|
||
msvcrt = None
|
||
|
||
import config
|
||
from controllers import IncrementalPID
|
||
from data_logger import FlowRunRecorder
|
||
from flow_control import FlowControlFault, FlowControlLoop
|
||
from performance_reporter import PerformanceReporter
|
||
|
||
|
||
class ConsoleGate(logging.Filter):
|
||
"""终端输出闸门：输入模式下挡住终端日志，文件日志不受影响。"""
|
||
|
||
def __init__(self):
|
||
super().__init__()
|
||
self.blocked = False
|
||
|
||
def filter(self, _record):
|
||
return not self.blocked
|
||
|
||
|
||
def build_logger():
|
||
log_dir = Path(__file__).resolve().parent / config.LOG_DIRECTORY
|
||
log_dir.mkdir(parents=True, exist_ok=True)
|
||
log_path = log_dir / config.LOG_FILE_NAME
|
||
|
||
logger = logging.getLogger("flow_control")
|
||
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)
|
||
console_gate = ConsoleGate()
|
||
console_handler.addFilter(console_gate)
|
||
logger.addHandler(console_handler)
|
||
return logger, console_gate
|
||
|
||
|
||
def build_control_loop(hardware, logger):
|
||
pid = IncrementalPID(
|
||
kp=config.PID_FAR_KP,
|
||
ki=config.PID_FAR_KI,
|
||
kd=config.PID_FAR_KD,
|
||
dt=config.CONTROL_PERIOD_S,
|
||
out_min=config.OPENING_MIN_PCT,
|
||
out_max=config.OPENING_MAX_PCT,
|
||
output_rate_limit=config.MAX_OPENING_RATE_FAR_PCT_S,
|
||
)
|
||
return FlowControlLoop(
|
||
hardware=hardware,
|
||
pid=pid,
|
||
period_s=config.CONTROL_PERIOD_S,
|
||
flow_channel=config.FLOW_INPUT_CHANNEL,
|
||
pressure_channel=config.PRESSURE_INPUT_CHANNEL,
|
||
motor_channel=config.MOTOR_OUTPUT_CHANNEL,
|
||
motor_open_position=config.MOTOR_OPEN_POSITION,
|
||
motor_closed_position=config.MOTOR_CLOSED_POSITION,
|
||
target_min_slm=config.TARGET_FLOW_MIN_SLM,
|
||
target_max_slm=config.TARGET_FLOW_MAX_SLM,
|
||
zero_flow_threshold_slm=config.ZERO_FLOW_THRESHOLD_SLM,
|
||
flow_valid_min_slm=config.FLOW_VALID_MIN_SLM,
|
||
flow_valid_max_slm=config.FLOW_VALID_MAX_SLM,
|
||
max_pressure_kpa=config.MAX_PRESSURE_KPA,
|
||
max_control_dt_s=config.MAX_CONTROL_DT_S,
|
||
max_consecutive_flow_failures=config.MAX_CONSECUTIVE_FLOW_FAILURES,
|
||
max_consecutive_pressure_failures=(
|
||
config.MAX_CONSECUTIVE_PRESSURE_FAILURES
|
||
),
|
||
pid_far_gains=(
|
||
config.PID_FAR_KP,
|
||
config.PID_FAR_KI,
|
||
config.PID_FAR_KD,
|
||
),
|
||
pid_near_gains=(
|
||
config.PID_NEAR_KP,
|
||
config.PID_NEAR_KI,
|
||
config.PID_NEAR_KD,
|
||
),
|
||
opening_rate_far_pct_s=config.MAX_OPENING_RATE_FAR_PCT_S,
|
||
opening_rate_near_pct_s=config.MAX_OPENING_RATE_NEAR_PCT_S,
|
||
pid_near_error_min_slm=config.PID_NEAR_ERROR_MIN_SLM,
|
||
pid_near_error_target_ratio=(
|
||
config.PID_NEAR_ERROR_TARGET_RATIO
|
||
),
|
||
pid_far_error_min_slm=config.PID_FAR_ERROR_MIN_SLM,
|
||
pid_far_error_target_ratio=config.PID_FAR_ERROR_TARGET_RATIO,
|
||
pid_mode_switch_confirm_cycles=(
|
||
config.PID_MODE_SWITCH_CONFIRM_CYCLES
|
||
),
|
||
logger=logger,
|
||
)
|
||
|
||
|
||
def parse_args(argv=None):
|
||
parser = argparse.ArgumentParser(description="MT2-AM8 气体流量 PID 控制")
|
||
parser.add_argument(
|
||
"--target",
|
||
type=float,
|
||
required=True,
|
||
help=(
|
||
"目标流量 SLM，允许范围 "
|
||
f"{config.TARGET_FLOW_MIN_SLM}~{config.TARGET_FLOW_MAX_SLM}"
|
||
),
|
||
)
|
||
return parser.parse_args(argv)
|
||
|
||
|
||
def format_status(result):
|
||
flow_text = (
|
||
"--" if result.measured_flow_slm is None
|
||
else f"{result.measured_flow_slm:.2f}"
|
||
)
|
||
pressure_text = (
|
||
"--" if result.pressure_kpa is None
|
||
else f"{result.pressure_kpa:.2f}"
|
||
)
|
||
return (
|
||
f"状态={result.status} 目标={result.target_flow_slm:.2f} SLM "
|
||
f"实际={flow_text} SLM 压力={pressure_text} kPa "
|
||
f"开度={result.opening_pct:.2f}% "
|
||
f"行程={result.motor_position:.1f} dt={result.actual_dt_s:.3f}s"
|
||
)
|
||
|
||
|
||
def run(target_flow_slm):
|
||
config.validate_config()
|
||
logger, console_gate = 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,
|
||
)
|
||
controller = build_control_loop(hardware, logger)
|
||
controller.set_target_flow(target_flow_slm)
|
||
|
||
connected = False
|
||
recorder = None
|
||
reporter = None
|
||
exit_code = 0
|
||
try:
|
||
logger.info(
|
||
"正在连接 MT2-AM8 %s:%s，目标流量=%.3f SLM",
|
||
config.MT2AM8_HOST,
|
||
config.MT2AM8_PORT,
|
||
target_flow_slm,
|
||
)
|
||
connected = bool(hardware.connect())
|
||
if not connected:
|
||
raise FlowControlFault(
|
||
"DEVICE_CONNECT_FAILED",
|
||
"STARTUP",
|
||
"无法连接 MT2-AM8",
|
||
{
|
||
"host": config.MT2AM8_HOST,
|
||
"port": config.MT2AM8_PORT,
|
||
"slave_id": config.MT2AM8_SLAVE_ID,
|
||
},
|
||
)
|
||
|
||
# 控制前读取一次当前流量，作为超调量方向的基准。
|
||
try:
|
||
initial_flow_slm = hardware.get_flow(config.FLOW_INPUT_CHANNEL)
|
||
except Exception:
|
||
initial_flow_slm = None
|
||
|
||
reporter = PerformanceReporter(
|
||
controller.pid,
|
||
window_s=config.STEADY_STATE_WINDOW_S,
|
||
sample_period_s=config.CONTROL_PERIOD_S,
|
||
band_pct=config.STEADY_STATE_BAND_PCT,
|
||
std_pct=config.STEADY_STATE_STD_PCT,
|
||
flow_range_min_slm=config.TARGET_FLOW_MIN_SLM,
|
||
flow_range_max_slm=config.TARGET_FLOW_MAX_SLM,
|
||
initial_flow_slm=initial_flow_slm,
|
||
logger=logger,
|
||
)
|
||
|
||
controller.start(initial_opening=config.INITIAL_OPENING_PCT)
|
||
recorder = FlowRunRecorder(
|
||
Path(__file__).resolve().parent / config.DATA_DIRECTORY,
|
||
plot_dpi=config.PLOT_DPI,
|
||
)
|
||
logger.info("逐周期数据将保存到 %s", recorder.csv_path)
|
||
logger.info(
|
||
"闭环控制已启动；按 Ctrl+C 停止，按 %s 切换目标流量",
|
||
config.TARGET_SWITCH_KEY.upper(),
|
||
)
|
||
|
||
input_mode = False
|
||
input_buf = ""
|
||
|
||
def apply_target():
|
||
"""把输入缓冲区解析为新的目标流量并生效。"""
|
||
raw = input_buf.strip()
|
||
if not raw:
|
||
logger.warning("未输入目标流量，已忽略")
|
||
return
|
||
try:
|
||
value = float(raw)
|
||
except ValueError:
|
||
logger.warning("无法解析目标流量 %r，已忽略", raw)
|
||
return
|
||
try:
|
||
controller.set_target_flow(value)
|
||
except ValueError as exc:
|
||
logger.warning("目标流量设置失败：%s", exc)
|
||
return
|
||
reporter.reset()
|
||
logger.info("目标流量已切换为 %.3f SLM", value)
|
||
|
||
def process_keys():
|
||
"""非阻塞处理键盘输入；输入模式下控制循环照常运行。"""
|
||
nonlocal input_mode, input_buf
|
||
if msvcrt is None:
|
||
return
|
||
while msvcrt.kbhit():
|
||
ch = msvcrt.getch()
|
||
if not input_mode:
|
||
if ch == b"\x03": # Ctrl+C，交给外层 KeyboardInterrupt 处理
|
||
raise KeyboardInterrupt
|
||
key = ch.decode("ascii", errors="ignore").lower()
|
||
if key == config.TARGET_SWITCH_KEY:
|
||
input_mode = True
|
||
input_buf = ""
|
||
console_gate.blocked = True
|
||
print(
|
||
f"当前目标={controller.target_flow_slm:.2f} SLM，"
|
||
f"请输入新目标流量 (回车确认, Esc 取消): ",
|
||
end="",
|
||
flush=True,
|
||
)
|
||
else:
|
||
if ch in (b"\r", b"\n"):
|
||
print()
|
||
console_gate.blocked = False
|
||
input_mode = False
|
||
apply_target()
|
||
elif ch == b"\x1b": # Esc 取消
|
||
console_gate.blocked = False
|
||
input_mode = False
|
||
print(" (已取消)")
|
||
elif ch in (b"\x08", b"\x7f"): # 退格删除最后一位
|
||
if input_buf:
|
||
input_buf = input_buf[:-1]
|
||
print("\b \b", end="", flush=True)
|
||
else:
|
||
text = ch.decode("ascii", errors="ignore")
|
||
if text and text.isprintable():
|
||
input_buf += text
|
||
print(text, end="", flush=True)
|
||
|
||
next_deadline = time.perf_counter()
|
||
next_status_time = next_deadline
|
||
while True:
|
||
now = time.perf_counter()
|
||
process_keys()
|
||
result = controller.step(now=now)
|
||
recorder.record(result)
|
||
reporter.observe(result)
|
||
|
||
if config.AUTO_STOP_ON_STEADY and reporter.steady_reached:
|
||
logger.info("已达到稳态，自动停止控制")
|
||
break
|
||
|
||
if now >= next_status_time or result.status != "OK":
|
||
logger.info(format_status(result))
|
||
next_status_time = now + config.STATUS_PRINT_PERIOD_S
|
||
|
||
next_deadline += config.CONTROL_PERIOD_S
|
||
sleep_s = next_deadline - time.perf_counter()
|
||
if sleep_s > 0:
|
||
time.sleep(sleep_s)
|
||
else:
|
||
# 丢弃已经错过的节拍，避免连续快速补跑 PID。
|
||
next_deadline = time.perf_counter()
|
||
|
||
except KeyboardInterrupt:
|
||
console_gate.blocked = False
|
||
logger.info("收到 Ctrl+C，正在停止控制")
|
||
except FlowControlFault as exc:
|
||
console_gate.blocked = False
|
||
exit_code = 2
|
||
logger.critical("控制故障：%s", exc)
|
||
except Exception:
|
||
console_gate.blocked = False
|
||
exit_code = 3
|
||
logger.exception("未处理异常，系统将退出")
|
||
finally:
|
||
console_gate.blocked = False
|
||
if connected:
|
||
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("控制数据已保存：%s", recorder.csv_path)
|
||
if image_path is not None:
|
||
logger.info("三联曲线图已保存：%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("保存控制数据曲线图失败；CSV 数据仍保留")
|
||
|
||
if reporter is not None:
|
||
try:
|
||
reporter.finalize()
|
||
except Exception:
|
||
logger.exception("生成控制性能报告时发生异常")
|
||
|
||
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.target)
|
||
|
||
|
||
if __name__ == "__main__":
|
||
sys.exit(main())
|