louis
cfeedcf887
- 前馈冻结改用可配置的 3 秒流量绝对误差滑窗，修复采样抖动造成的重复解冻，并保留下游扰动后的自动更新 - 支持非单调阀特性反解、最小可测面积以下直接全关，以及闭阀端精细扫点与辨识开关 - 调整双压力判稳、最长等待时间、在线入口全开收尾和闭环四联图 - 更新配置、README、阀模型及离线测试，归档本轮实验数据与诊断产物
428 lines
14 KiB
Python
428 lines
14 KiB
Python
"""手动设置阀门开度，并每秒显示阀前、阀后传感器数据和电机行程。"""
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import contextlib
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import csv
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from datetime import datetime
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import io
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import math
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from pathlib import Path
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import sys
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import time
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try:
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import msvcrt
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except ImportError: # 本项目的交互方式仅适用于 Windows 终端
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msvcrt = None
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import config
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from flow_control import opening_to_motor_position
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SAMPLE_PERIOD_S = 1.0
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KEY_POLL_PERIOD_S = 0.05
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INITIAL_OPENING_PCT = 100.0
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OUTPUT_DIRECTORY = Path(__file__).resolve().parent / "test_valve_data"
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class ManualValveRecorder:
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"""逐次保存手动测试数据，并在结束时生成三联图。"""
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CSV_FIELDS = (
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"time_s",
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"timestamp",
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"flow_after_slm",
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"opening_pct",
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"pressure_before_kpa",
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"pressure_after_kpa",
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"motor_position",
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)
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def __init__(self, output_directory):
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output_directory.mkdir(parents=True, exist_ok=True)
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run_id = datetime.now().strftime("%Y%m%d_%H%M%S")
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self.csv_path = output_directory / f"test_valve_{run_id}.csv"
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self.image_path = output_directory / f"test_valve_{run_id}.png"
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self._file = self.csv_path.open("w", newline="", encoding="utf-8-sig")
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self._writer = csv.DictWriter(self._file, fieldnames=self.CSV_FIELDS)
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self._writer.writeheader()
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self._file.flush()
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self._start_time = None
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self.sample_count = 0
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self._closed = False
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def record(
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self,
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sample_time,
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flow_after,
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opening,
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pressure_before,
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pressure_after,
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position,
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):
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if self._start_time is None:
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self._start_time = sample_time
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self._writer.writerow(
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{
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"time_s": f"{sample_time - self._start_time:.6f}",
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"timestamp": datetime.now().isoformat(timespec="milliseconds"),
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"flow_after_slm": self._format_number(flow_after),
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"opening_pct": self._format_number(opening),
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"pressure_before_kpa": self._format_number(pressure_before),
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"pressure_after_kpa": self._format_number(pressure_after),
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"motor_position": self._format_number(position),
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}
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)
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self._file.flush()
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self.sample_count += 1
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def finalize(self):
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self.close()
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if self.sample_count == 0:
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return None
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self._create_plot()
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return self.image_path
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def close(self):
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if not self._closed:
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self._file.flush()
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self._file.close()
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self._closed = True
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def _create_plot(self):
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import matplotlib
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matplotlib.use("Agg")
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import matplotlib.pyplot as plt
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time_s = []
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flow_after = []
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opening = []
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pressure_before = []
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pressure_after = []
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with self.csv_path.open("r", newline="", encoding="utf-8-sig") as file:
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for row in csv.DictReader(file):
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time_s.append(float(row["time_s"]))
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flow_after.append(self._float_or_nan(row["flow_after_slm"]))
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opening.append(self._float_or_nan(row["opening_pct"]))
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pressure_before.append(
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self._float_or_nan(row["pressure_before_kpa"])
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)
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pressure_after.append(
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self._float_or_nan(row["pressure_after_kpa"])
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)
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figure, axes = plt.subplots(
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3,
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1,
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figsize=(12, 10),
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sharex=True,
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constrained_layout=True,
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)
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figure.suptitle("Manual Valve Test", fontsize=15)
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axes[0].plot(time_s, flow_after, color="#1565C0", linewidth=1.4)
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axes[0].set_ylabel("Flow after valve (SLM)")
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axes[0].set_title("Flow after valve")
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axes[1].plot(time_s, opening, color="#2E7D32", linewidth=1.4)
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axes[1].set_ylabel("Opening (%)")
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axes[1].set_title("Valve opening")
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axes[1].set_ylim(-2, 102)
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axes[2].plot(
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time_s,
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pressure_before,
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color="#6A1B9A",
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linewidth=1.4,
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label="Pressure before valve",
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)
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axes[2].plot(
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time_s,
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pressure_after,
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color="#D84315",
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linewidth=1.4,
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label="Pressure after valve",
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)
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axes[2].set_ylabel("Pressure (kPa)")
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axes[2].set_xlabel("Time (s)")
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axes[2].set_title("Pressure before and after valve")
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axes[2].legend()
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for axis in axes:
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axis.grid(True, alpha=0.3, linestyle="--")
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axis.margins(x=0)
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figure.savefig(self.image_path, dpi=config.PLOT_DPI, bbox_inches="tight")
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plt.close(figure)
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@staticmethod
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def _format_number(value):
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if value is None:
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return ""
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try:
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number = float(value)
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except (TypeError, ValueError):
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return ""
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return f"{number:.6f}" if math.isfinite(number) else ""
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@staticmethod
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def _float_or_nan(value):
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try:
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return float(value)
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except (TypeError, ValueError):
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return math.nan
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def format_value(value, unit):
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"""将传感器读数格式化；读取失败时显示 --。"""
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if value is None:
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return f"-- {unit}"
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try:
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number = float(value)
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except (TypeError, ValueError):
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return f"-- {unit}"
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if not math.isfinite(number):
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return f"-- {unit}"
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return f"{number:.2f} {unit}"
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def format_analog_raw(value, physical_range, analog_raw_max):
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"""把物理量反算为 PLC 的 0~analog_raw_max 模拟量原始值。"""
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try:
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number = float(value)
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full_scale = float(physical_range)
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raw_maximum = float(analog_raw_max)
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except (TypeError, ValueError):
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return "--"
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if (
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not math.isfinite(number)
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or not math.isfinite(full_scale)
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or not math.isfinite(raw_maximum)
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or full_scale <= 0.0
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or raw_maximum <= 0.0
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):
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return "--"
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return str(round(number / full_scale * raw_maximum))
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def motor_position_for(opening_pct):
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return opening_to_motor_position(
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opening_pct,
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config.MOTOR_OPEN_POSITION,
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config.MOTOR_CLOSED_POSITION,
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)
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def set_opening(hardware, opening_pct):
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"""校验并下发开度，成功时返回对应的电机行程。"""
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opening = float(opening_pct)
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if not math.isfinite(opening) or not 0.0 <= opening <= 100.0:
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raise ValueError("开度必须是 0~100 之间的有限数值")
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position = motor_position_for(opening)
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if not hardware.set_motor_position(
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position,
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channel=config.MOTOR_OUTPUT_ADDR,
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):
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raise RuntimeError("电机位置写入失败")
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return opening, position
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def read_sensors(hardware, quiet=False):
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"""读取阀后流量及阀前、阀后压力；输入模式中隐藏硬件输出。"""
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output = io.StringIO()
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stream = output if quiet else sys.stdout
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with contextlib.redirect_stdout(stream):
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flow_after = hardware.get_flow(config.FLOW_AFTER_ADDR)
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pressure_before = (
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None
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if config.PRESSURE_BEFORE_ADDR is None
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else hardware.get_pressure(config.PRESSURE_BEFORE_ADDR)
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)
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pressure_after = (
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None
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if config.PRESSURE_AFTER_ADDR is None
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else hardware.get_pressure(config.PRESSURE_AFTER_ADDR)
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)
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return flow_after, pressure_before, pressure_after
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def main():
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if msvcrt is None:
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print("本程序需要在 Windows 终端中运行。")
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return 1
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try:
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from PcControl import Easy521ModbusClient, raw_max as analog_raw_max
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except ModuleNotFoundError as exc:
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print(f"无法导入硬件客户端: {exc}")
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return 2
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hardware = Easy521ModbusClient(
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host=config.PLC_HOST,
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port=config.PLC_PORT,
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slave_id=config.PLC_SLAVE_ID,
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flow_addr=config.FLOW_AFTER_ADDR,
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flow_range=config.FLOW_AFTER_RANGE_SLM,
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pressure_before_addr=config.PRESSURE_BEFORE_ADDR,
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pressure_before_range=config.PRESSURE_BEFORE_RANGE_KPA,
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pressure_after_addr=config.PRESSURE_AFTER_ADDR,
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pressure_after_range=config.PRESSURE_AFTER_RANGE_KPA,
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motor_output_addr=config.MOTOR_OUTPUT_ADDR,
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)
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connected = False
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opening = INITIAL_OPENING_PCT
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position = motor_position_for(opening)
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input_mode = False
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input_buffer = ""
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recorder = None
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exit_code = 0
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try:
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print(
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f"正在连接 PLC {config.PLC_HOST}:{config.PLC_PORT} ..."
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)
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connected = bool(hardware.connect())
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if not connected:
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print("连接失败。")
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return 3
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# 先全开，再创建记录器和启动采样计时。
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opening, position = set_opening(hardware, 100.0)
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print(
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f"连接后已设置为 100% 开度（行程 {position:.1f}），"
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"不计入采样计时。"
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)
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recorder = ManualValveRecorder(OUTPUT_DIRECTORY)
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print("手动阀门控制已启动：按 S 输入新开度，按 Ctrl+C 退出。")
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print(
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f"连接时按已知状态记录：开度 {opening:.2f}%（行程 {position:.1f}）；"
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"未向电机写入位置。"
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)
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print(f"CSV 将保存到：{recorder.csv_path}")
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next_sample_time = time.perf_counter()
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while True:
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while msvcrt.kbhit():
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ch = msvcrt.getch()
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if not input_mode:
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if ch == b"\x03":
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raise KeyboardInterrupt
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if ch.decode("ascii", errors="ignore").lower() == "s":
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input_mode = True
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input_buffer = ""
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print(
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f"当前开度={opening:.2f}%，请输入新开度 0~100 "
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"(回车确认, Esc 取消): ",
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end="",
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flush=True,
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)
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continue
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if ch in (b"\r", b"\n"):
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print()
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input_mode = False
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raw = input_buffer.strip()
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if not raw:
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print("未输入开度，保持原开度。")
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continue
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try:
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opening, position = set_opening(hardware, float(raw))
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except (ValueError, RuntimeError) as exc:
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print(f"开度切换失败：{exc}；保持原开度。")
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else:
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print(
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f"开度已切换为 {opening:.2f}%"
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f"（行程 {position:.1f}）。"
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)
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elif ch == b"\x1b":
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input_mode = False
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print(" (已取消，保持原开度)")
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elif ch in (b"\x08", b"\x7f"):
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if input_buffer:
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input_buffer = input_buffer[:-1]
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print("\b \b", end="", flush=True)
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elif ch == b"\x03":
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raise KeyboardInterrupt
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else:
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text = ch.decode("ascii", errors="ignore")
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if text and text.isprintable():
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input_buffer += text
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print(text, end="", flush=True)
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now = time.perf_counter()
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if now >= next_sample_time:
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flow_after, pressure_before, pressure_after = read_sensors(
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hardware, quiet=input_mode
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)
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recorder.record(
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now,
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flow_after,
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opening,
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pressure_before,
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pressure_after,
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position,
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)
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if not input_mode:
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timestamp = time.strftime("%H:%M:%S")
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print(
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f"[{timestamp}] "
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f"阀后流量={format_value(flow_after, 'SLM')}"
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f"（模拟量={format_analog_raw(flow_after, config.FLOW_AFTER_RANGE_SLM, analog_raw_max)}） "
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f"阀前压力={format_value(pressure_before, 'kPa')}"
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f"（模拟量={format_analog_raw(pressure_before, config.PRESSURE_BEFORE_RANGE_KPA, analog_raw_max)}） "
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f"阀后压力={format_value(pressure_after, 'kPa')}"
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f"（模拟量={format_analog_raw(pressure_after, config.PRESSURE_AFTER_RANGE_KPA, analog_raw_max)}） "
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f"开度={opening:.2f}% 行程={position:.1f}"
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)
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# 不追补错过的终端输出；输入期间的样本只写入 CSV。
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next_sample_time = time.perf_counter() + SAMPLE_PERIOD_S
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time.sleep(KEY_POLL_PERIOD_S)
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except KeyboardInterrupt:
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if input_mode:
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print()
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print("收到 Ctrl+C，正在保存数据并退出；不改变当前阀门开度。")
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except Exception as exc:
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if input_mode:
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print()
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print(f"程序异常：{exc}")
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exit_code = 4
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finally:
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if connected:
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try:
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opening, position = set_opening(hardware, 100.0)
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print(
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f"断开前已设置为 100% 开度（行程 {position:.1f}），"
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"不计入采样计时。"
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)
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except Exception as exc:
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print(f"警告：断开前设置阀门 100% 开度失败：{exc}")
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exit_code = max(exit_code, 4)
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try:
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hardware.disconnect()
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except Exception as exc:
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print(f"警告：断开设备失败：{exc}")
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exit_code = max(exit_code, 5)
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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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print(f"CSV 已保存：{recorder.csv_path}")
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if image_path is not None:
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print(f"三联图已保存：{image_path}")
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except Exception as exc:
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recorder.close()
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print(f"警告：生成图表失败：{exc}")
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exit_code = max(exit_code, 6)
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return exit_code
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if __name__ == "__main__":
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raise SystemExit(main())
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