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refactor(ocp): lots of work for rfid and dyco contorl

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This commit is contained in:
Blake Matthes
2025-03-27 21:12:22 -05:00
parent 27d6b6e884
commit ba3d721940
19 changed files with 360 additions and 162 deletions
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45
server/services/ocp/controller/specialProcesses/dyco/plcConnection.ts
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@@ -2,13 +2,14 @@ import { Controller, Tag } from "st-ethernet-ip";
import { createLog } from "../../../../logger/logger.js";
import { labelerTagRead } from "./plcTags/labelerTag.js";
import { palletSendTag } from "./plcTags/palletSendTag.js";
import { strapperFaults } from "./plcTags/strapperFault.js";
let PLC = new Controller();
let isDycoRunning = false;
// PLC address
let plcAddress = "10.44.5.4";
let isReading = false;
// Initialize the interval variable outside the function
let plcCycle: any;
let plcInterval = 500;
@@ -31,17 +32,42 @@ export const dycoConnect = async () => {
await PLC.connect(plcAddress, 0).then(async () => {
createLog("info", "dyco", "ocp", `We are connected to the dyco.`);
isDycoRunning = true;
let buffer = "";
plcCycle = setInterval(async () => {
await PLC.readTag(labelerTag);
await PLC.readTag(palletSend);
if (isReading) {
createLog(
"warn",
"dyco",
"ocp",
"Skipping cycle: previous read still in progress."
);
return;
}
isReading = true; // Set flag
try {
await PLC.readTag(labelerTag);
await PLC.readTag(palletSend);
await PLC.readTag(strapperError);
// send the labeler tag data over
labelerTagRead(labelerTag);
// strapper check
strapperFaults(strapperError);
// send the end of line check over.
palletSendTag(palletSend);
}, 500);
// send the labeler tag data over
labelerTagRead(labelerTag);
// send the end of line check over.
palletSendTag(palletSend);
} catch (error: any) {
createLog(
"error",
"dyco",
"ocp",
`Error reading PLC tag: ${error.message}`
);
} finally {
isReading = false; // Reset flag
}
}, plcInterval);
});
} catch (error) {
createLog(
@@ -50,6 +76,7 @@ export const dycoConnect = async () => {
"ocp",
`There was an error in the dyco: ${error}`
);
await PLC.disconnect();
isDycoRunning = false;
}
};

50
server/services/ocp/controller/specialProcesses/dyco/plcTags/labelerTag.ts
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@@ -4,7 +4,10 @@ import { tryCatch } from "../../../../../../globalUtils/tryCatch.js";
import { createLog } from "../../../../../logger/logger.js";
import { readTags } from "../../../../../rfid/controller/readTags.js";
import { labelingProcess } from "../../../labeling/labelProcess.js";
import { stapperFaulted, strapperFaults } from "./strapperFault.js";
export let cameraPalletCheck = 20;
export let currentPalletCheck = 0;
let lastProcessedTimestamp = 0;
export const labelerTagRead = async (tagData: any) => {
@@ -41,11 +44,48 @@ export const labelerTagRead = async (tagData: any) => {
// Only process if this is a new timestamp within the last 5 seconds
if (tagTime !== lastProcessedTimestamp && Date.now() - tagTime <= 5000) {
lastProcessedTimestamp = tagTime;
//console.log(numericString, tagData.state.timestamp);
/**
* add logic in to see if this is the first time we run this so we return an error to validate we are in sync.
*/
createLog(
"info",
"dyco",
"ocp",
`Current pallet at the wrapper is: ${numericString}`
);
if (dycoPrint[0].value === "1") {
createLog("info", "dyco", "ocp", "Dyco will be printing the label");
// send over to print.
labelingProcess({ line: numericString });
// if (!dycoControlCheck) {
// createLog(
// "error",
// "dyco",
// "ocp",
// `Dyco was switch to be the printer guys. please validate the line is in sync, Current line is ${numericString}`
// );
// dycoControlCheck = true;
// return;
// }
// check the stapper error logic.
if (stapperFaulted) {
createLog("error", "dyco", "ocp", `Strapper is faulted.`);
return;
}
// check if we need to manual check due to 20 pallets.
if (currentPalletCheck <= cameraPalletCheck) {
currentPalletCheck = currentPalletCheck + 1;
labelingProcess({ line: numericString });
} else {
currentPalletCheck = 0;
createLog(
"error",
"dyco",
"ocp",
`You have reached 20 pallets since the last check please validate the labeler is still in sync.`
);
}
}
if (dycoPrint[0].value === "0") {
@@ -56,7 +96,9 @@ export const labelerTagRead = async (tagData: any) => {
"Rfid system is contorlling the printing"
);
// trigger the reader so we can get the label from the tag readers.
await readTags("wrapper1");
setTimeout(async () => {
await readTags("wrapper1");
}, 2 * 1000);
}
}
};

72
server/services/ocp/controller/specialProcesses/dyco/plcTags/strapperFault.ts Normal file
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@@ -0,0 +1,72 @@
import { db } from "../../../../../../../database/dbclient.js";
import { settings } from "../../../../../../../database/schema/settings.js";
import { tryCatch } from "../../../../../../globalUtils/tryCatch.js";
import { createLog } from "../../../../../logger/logger.js";
// strapper related issues
export let strapperActive = true;
export let stapperFaulted = false;
export let strapperFaultCount = 3; // move to db so we can control it outside the app
export const strapperFaults = async (tagData: any) => {
const { data, error } = await tryCatch(db.select().from(settings));
if (error) {
return { success: false, message: "Failed to get settings." };
}
if (strapperActive) {
// monitor strapper
//console.log(`Strapper fault is ${strapperError.value}`);
if (tagData.value && strapperFaultCount > 0) {
// strapper faulted we want to start the trigger to force the check
if (!stapperFaulted) {
createLog(
"error",
"dyco",
"ocp",
`Strapper errored triggering manual checks will be required for the next ${strapperFaultCount}`
);
}
stapperFaulted = true;
// change move fault count to db....
strapperFaultCount = 3;
}
}
const strapperCheckSetting = data.filter((n) => n.name === "strapperCheck");
if (strapperCheckSetting[0]?.value === "1") {
if (stapperFaulted && strapperFaultCount > 0) {
createLog(
"warn",
"dyco",
"ocp",
`There was a strapper error, remaining pallets to check ${strapperFaultCount}.`
);
strapperFaultCount = strapperFaultCount - 1;
return {
success: false,
message: `There was a strapper error, remaining pallets to check ${strapperFaultCount}.`,
};
} else {
createLog(
"debug",
"dyco",
"ocp",
`Strapper check is active but not faulted, remaining pallets to check ${strapperFaultCount}.`
);
// reset everything
stapperFaulted = false;
strapperFaultCount = 3; // move to db as well
return {
success: true,
message: `Strapper check is active but not faulted, remaining pallets to check ${strapperFaultCount}.`,
};
}
}
};