427 lines
17 KiB
C#
427 lines
17 KiB
C#
using System.Diagnostics;
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using System.IO;
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using Microsoft.Extensions.Logging;
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using Microsoft.Extensions.Options;
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using SSPCTester.Devices.Config;
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using SSPCTester.Devices.Interfaces;
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namespace SSPCTester.UI.Services;
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public sealed class SafetyMonitorService : IDisposable
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{
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private readonly ISafetyDio _safetyDio;
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private readonly IPowerSupply _power;
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private readonly ILoad _load;
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private readonly ISspc _sspc;
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private readonly DeviceOptions _options;
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private readonly UiLogSink _log;
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private readonly ILogger<SafetyMonitorService> _logger;
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private readonly SemaphoreSlim _gate = new(1, 1);
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private readonly string _traceLogPath;
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private readonly object _traceLock = new();
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private Timer? _timer;
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private bool _handlingEmergency;
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private bool _softwareEmergencyActive;
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private bool _hardwareEmergencyLatched;
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private bool _disposed;
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private long _pollSequence;
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private long _pollGateBusyCount;
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private string? _lastStatusSnapshot;
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private string? _lastPollSnapshot;
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public SafetyMonitorService(
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ISafetyDio safetyDio,
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IPowerSupply power,
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ILoad load,
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ISspc sspc,
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IOptions<DeviceOptions> options,
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UiLogSink log,
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ILogger<SafetyMonitorService> logger)
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{
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_safetyDio = safetyDio;
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_power = power;
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_load = load;
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_sspc = sspc;
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_options = options.Value;
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_log = log;
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_logger = logger;
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string logDir = Path.Combine(
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Environment.GetFolderPath(Environment.SpecialFolder.LocalApplicationData),
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"SSPCTester",
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"Logs");
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Directory.CreateDirectory(logDir);
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_traceLogPath = Path.Combine(logDir, $"safety-trace-{DateTime.Now:yyyyMMdd-HHmmss}.log");
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Trace($"Safety trace started. UseMock={_options.Pci2312.UseMock}, AutoConnect={_options.Pci2312.AutoConnect}, Enabled={_options.Pci2312.Enabled}, PollIntervalMs={_options.Pci2312.PollIntervalMs}");
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}
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public bool IsEmergencyActive { get; private set; }
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public bool IsAlarmOutputOn { get; private set; }
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public string StatusText { get; private set; } = "设备故障";
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public string DetailText { get; private set; } = "设备安全监控未启动";
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public event EventHandler? StatusChanged;
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public void Start()
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{
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if (_timer is not null) return;
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var options = _options.Pci2312;
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Trace($"Start() called. Enabled={options.Enabled}, AutoConnect={options.AutoConnect}, DeviceId={options.DeviceId}, DI={options.EmergencyInputChannel}, DO={options.AlarmOutputChannel}, PollIntervalMs={options.PollIntervalMs}");
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if (!options.Enabled)
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{
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SetStatus(false, false, "设备故障", "PCI2312 安全监控未启用");
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return;
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}
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int interval = Math.Clamp(options.PollIntervalMs, 50, 10000);
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_timer = new Timer(OnTimer, null, TimeSpan.Zero, TimeSpan.FromMilliseconds(interval));
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SetStatus(false, false, "设备正常", "正在监控 PCI2312 急停输入");
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_log.Add(UiLogLevel.Info, $"安全观测日志已启用：{_traceLogPath}");
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}
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public async Task TriggerSoftwareEmergencyAsync(CancellationToken ct = default)
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{
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var sw = Stopwatch.StartNew();
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Trace("TriggerSoftwareEmergencyAsync enter.");
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await _gate.WaitAsync(ct).ConfigureAwait(false);
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try
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{
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_softwareEmergencyActive = true;
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_handlingEmergency = true;
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SetStatus(true, IsAlarmOutputOn, "软件急停已触发", "正在执行软件急停安全关断");
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_log.Add(UiLogLevel.Error, "软件触发报警急停，开始执行报警灯、电源、负载关断。");
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await EnsureSafetyDioConnectedAsync(ct).ConfigureAwait(false);
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await SetAlarmOutputAsync(true, ct).ConfigureAwait(false);
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await TryShutdownSspcAsync().ConfigureAwait(false);
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await TryShutdownPowerAsync().ConfigureAwait(false);
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await TryShutdownLoadAsync().ConfigureAwait(false);
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SetStatus(true, true, "软件急停已触发", "报警灯已接通，SSPC 通道已全部关断，电源输出和负载输入已发送关闭指令");
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Trace($"TriggerSoftwareEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
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}
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catch (Exception ex)
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{
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_softwareEmergencyActive = false;
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_handlingEmergency = false;
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_logger.LogError(ex, "Software emergency shutdown failed.");
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_log.Add(UiLogLevel.Error, $"软件急停执行异常：{ex.Message}");
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SetStatus(true, IsAlarmOutputOn, "设备故障", ex.Message);
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Trace($"TriggerSoftwareEmergencyAsync failed in {sw.ElapsedMilliseconds}ms. {ex.GetType().Name}: {ex.Message}");
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throw;
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}
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finally
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{
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_gate.Release();
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}
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}
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public async Task<SafetyResetResult> ResetAsync(CancellationToken ct = default)
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{
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await _gate.WaitAsync(ct).ConfigureAwait(false);
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try
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{
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return await ResetCoreAsync(ct).ConfigureAwait(false);
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}
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finally
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{
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_gate.Release();
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}
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}
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private async Task<SafetyResetResult> ResetCoreAsync(CancellationToken ct)
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{
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Trace("ResetCoreAsync enter.");
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var options = _options.Pci2312;
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await EnsureSafetyDioConnectedAsync(ct).ConfigureAwait(false);
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if (await IsEmergencyInputActiveAsync(options, ct).ConfigureAwait(false))
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{
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const string message = "硬件急停按钮仍处于触发状态，无法执行状态重置。请先旋转或释放设备上的急停按钮，确认急停输入复位后再重试。";
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SetStatus(true, IsAlarmOutputOn, "急停已触发", message);
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Trace("ResetCoreAsync blocked: emergency input still active.");
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return new SafetyResetResult(false, message);
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}
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await SetAlarmOutputAsync(false, ct).ConfigureAwait(false);
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_softwareEmergencyActive = false;
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_hardwareEmergencyLatched = false;
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_handlingEmergency = false;
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SetStatus(false, false, "设备正常", "急停状态已重置，报警灯已关闭，正在监控 PCI2312 输入");
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Trace("ResetCoreAsync success.");
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return new SafetyResetResult(true, "急停状态已重置。");
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}
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private void OnTimer(object? state)
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{
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if (_disposed) return;
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_ = PollAsync();
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}
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private async Task PollAsync()
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{
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if (!await _gate.WaitAsync(0).ConfigureAwait(false))
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{
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long skipped = Interlocked.Increment(ref _pollGateBusyCount);
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if (skipped % 20 == 0)
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Trace($"PollAsync skipped by gate contention. skipped={skipped}");
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return;
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}
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try
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{
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long seq = Interlocked.Increment(ref _pollSequence);
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var options = _options.Pci2312;
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if (!options.Enabled) return;
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if (options.AutoConnect && !_safetyDio.IsConnected)
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{
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Trace($"Poll#{seq}: attempting auto connect for safety DIO.");
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await _safetyDio.ConnectAsync().ConfigureAwait(false);
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}
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bool active = await IsEmergencyInputActiveAsync(options, CancellationToken.None).ConfigureAwait(false);
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string snapshot = $"poll={seq},active={active},handling={_handlingEmergency},soft={_softwareEmergencyActive},latched={_hardwareEmergencyLatched},emergency={IsEmergencyActive},alarm={IsAlarmOutputOn},dioConnected={_safetyDio.IsConnected}";
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if (!string.Equals(_lastPollSnapshot, snapshot, StringComparison.Ordinal))
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{
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_lastPollSnapshot = snapshot;
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Trace($"Poll snapshot: {snapshot}");
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}
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if (active)
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{
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_hardwareEmergencyLatched = true;
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Trace($"Poll#{seq}: branch=ACTIVE -> HandleEmergencyAsync");
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await HandleEmergencyAsync().ConfigureAwait(false);
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}
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else if (_hardwareEmergencyLatched)
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{
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Trace($"Poll#{seq}: branch=HardwareLatchedClear -> ClearHardwareEmergencyAsync");
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await ClearHardwareEmergencyAsync(options).ConfigureAwait(false);
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}
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else if (_softwareEmergencyActive)
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{
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Trace($"Poll#{seq}: branch=SoftwareActiveWaitReset");
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SetStatus(true, IsAlarmOutputOn, "软件急停已触发", "等待状态重置，电源和负载不会自动恢复");
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}
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else if (IsEmergencyActive || IsAlarmOutputOn)
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{
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Trace($"Poll#{seq}: branch=CleanupByStatus -> ClearHardwareEmergencyAsync");
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await ClearHardwareEmergencyAsync(options).ConfigureAwait(false);
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}
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else
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{
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SetStatus(false, false, "设备正常", $"DI{options.EmergencyInputChannel} 未触发");
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}
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}
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catch (Exception ex)
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{
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_logger.LogWarning(ex, "Safety monitor poll failed.");
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SetStatus(IsEmergencyActive, IsAlarmOutputOn, "设备故障", ex.Message);
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Trace($"PollAsync failed. {ex.GetType().Name}: {ex.Message}");
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}
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finally
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{
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_gate.Release();
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}
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}
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private async Task HandleEmergencyAsync()
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{
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if (_handlingEmergency)
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{
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Trace("HandleEmergencyAsync skipped because _handlingEmergency=true.");
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return;
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}
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var sw = Stopwatch.StartNew();
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_handlingEmergency = true;
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SetStatus(true, IsAlarmOutputOn, "急停已触发", "正在执行安全关断");
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_log.Add(UiLogLevel.Error, "检测到急停输入接通，开始执行报警灯、电源、负载关断。");
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Trace("HandleEmergencyAsync begin.");
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try
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{
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var step = Stopwatch.StartNew();
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await SetAlarmOutputAsync(true, CancellationToken.None).ConfigureAwait(false);
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Trace($"HandleEmergencyAsync step SetAlarmOutputAsync OK in {step.ElapsedMilliseconds}ms.");
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step.Restart();
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await TryShutdownSspcAsync().ConfigureAwait(false);
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Trace($"HandleEmergencyAsync step TryShutdownSspcAsync done in {step.ElapsedMilliseconds}ms.");
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step.Restart();
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await TryShutdownPowerAsync().ConfigureAwait(false);
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Trace($"HandleEmergencyAsync step TryShutdownPowerAsync done in {step.ElapsedMilliseconds}ms.");
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step.Restart();
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await TryShutdownLoadAsync().ConfigureAwait(false);
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Trace($"HandleEmergencyAsync step TryShutdownLoadAsync done in {step.ElapsedMilliseconds}ms.");
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SetStatus(true, true, "急停已触发", "报警灯已接通，SSPC 通道已全部关断，电源输出和负载输入已发送关闭指令");
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Trace($"HandleEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
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}
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catch (Exception ex)
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{
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_logger.LogError(ex, "Emergency shutdown failed.");
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_log.Add(UiLogLevel.Error, $"急停关断执行异常：{ex.Message}");
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SetStatus(true, IsAlarmOutputOn, "设备故障", ex.Message);
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_handlingEmergency = false;
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Trace($"HandleEmergencyAsync failed in {sw.ElapsedMilliseconds}ms. {ex.GetType().Name}: {ex.Message}");
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}
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}
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private async Task ClearHardwareEmergencyAsync(Pci2312Options options)
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{
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var sw = Stopwatch.StartNew();
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Trace("ClearHardwareEmergencyAsync begin.");
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if (IsAlarmOutputOn)
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await SetAlarmOutputAsync(false, CancellationToken.None).ConfigureAwait(false);
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_handlingEmergency = false;
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_softwareEmergencyActive = false;
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_hardwareEmergencyLatched = false;
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SetStatus(false, false, "设备正常", $"DI{options.EmergencyInputChannel} 已复位，硬件急停已解除，报警灯已关闭，设备输出不会自动恢复");
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_log.Add(UiLogLevel.Info, "硬件急停输入已复位，软件急停状态和报警灯已自动解除。");
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Trace($"ClearHardwareEmergencyAsync success in {sw.ElapsedMilliseconds}ms.");
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}
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private async Task TryShutdownSspcAsync()
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{
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try
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{
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if (!_sspc.IsConnected && _options.Sspc.AutoConnect)
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{
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Trace("TryShutdownSspcAsync: auto-connecting SSPC.");
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await _sspc.ConnectAsync().ConfigureAwait(false);
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}
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if (_sspc.IsConnected)
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{
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for (int ch = 1; ch <= _sspc.ChannelCount; ch++)
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{
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try { await _sspc.TurnOffAsync(ch).ConfigureAwait(false); }
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catch (Exception ex) { _logger.LogWarning(ex, "急停关断 SSPC CH{Ch} 失败。", ch); }
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}
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_log.Add(UiLogLevel.Warning, $"SSPC 全部 {_sspc.ChannelCount} 个通道已发送关断指令。");
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}
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else
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{
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_log.Add(UiLogLevel.Warning, "SSPC 未连接，跳过通道关断。");
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}
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}
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catch (Exception ex)
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{
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_logger.LogWarning(ex, "SSPC 批量关断失败。");
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_log.Add(UiLogLevel.Error, $"SSPC 通道批量关断失败：{ex.Message}");
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Trace($"TryShutdownSspcAsync failed. {ex.GetType().Name}: {ex.Message}");
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}
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}
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private async Task TryShutdownPowerAsync()
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{
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try
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{
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if (!_power.IsConnected && _options.PowerSupply.AutoConnect)
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{
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Trace("TryShutdownPowerAsync: auto-connecting power supply.");
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await _power.ConnectAsync().ConfigureAwait(false);
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}
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if (_power.IsConnected)
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await _power.OutputAsync(false).ConfigureAwait(false);
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_log.Add(UiLogLevel.Warning, "UDP5080 电源输出已发送关闭指令。");
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}
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catch (Exception ex)
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{
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_logger.LogWarning(ex, "Power shutdown failed.");
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_log.Add(UiLogLevel.Error, $"UDP5080 电源关闭失败：{ex.Message}");
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Trace($"TryShutdownPowerAsync failed. {ex.GetType().Name}: {ex.Message}");
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}
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}
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private async Task TryShutdownLoadAsync()
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{
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try
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{
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if (!_load.IsConnected && _options.Load.AutoConnect)
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{
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Trace("TryShutdownLoadAsync: auto-connecting load.");
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await _load.ConnectAsync().ConfigureAwait(false);
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}
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if (_load.IsConnected)
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await _load.InputAsync(false).ConfigureAwait(false);
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_log.Add(UiLogLevel.Warning, "IT8702P 负载输入已发送关闭指令。");
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}
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catch (Exception ex)
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{
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_logger.LogWarning(ex, "Load shutdown failed.");
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_log.Add(UiLogLevel.Error, $"IT8702P 负载关闭失败：{ex.Message}");
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Trace($"TryShutdownLoadAsync failed. {ex.GetType().Name}: {ex.Message}");
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}
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}
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private async Task<bool> IsEmergencyInputActiveAsync(Pci2312Options options, CancellationToken ct)
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{
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bool value = await _safetyDio.ReadInputAsync(options.EmergencyInputChannel, ct).ConfigureAwait(false);
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return options.EmergencyInputActiveHigh ? value : !value;
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}
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private async Task SetAlarmOutputAsync(bool on, CancellationToken ct)
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{
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var options = _options.Pci2312;
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bool outputValue = options.AlarmOutputActiveHigh ? on : !on;
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await _safetyDio.WriteOutputAsync(options.AlarmOutputChannel, outputValue, ct).ConfigureAwait(false);
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IsAlarmOutputOn = on;
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}
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private async Task EnsureSafetyDioConnectedAsync(CancellationToken ct)
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{
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var options = _options.Pci2312;
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if (!options.Enabled)
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throw new InvalidOperationException("PCI2312 安全输入输出未启用，无法控制报警灯。");
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if (!_safetyDio.IsConnected)
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{
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Trace("EnsureSafetyDioConnectedAsync: connecting safety DIO.");
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await _safetyDio.ConnectAsync(ct).ConfigureAwait(false);
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}
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}
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private void SetStatus(bool emergencyActive, bool alarmOutputOn, string statusText, string detailText)
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{
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string snapshot = $"emergency={emergencyActive},alarm={alarmOutputOn},status={statusText},detail={detailText}";
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if (!string.Equals(_lastStatusSnapshot, snapshot, StringComparison.Ordinal))
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{
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_lastStatusSnapshot = snapshot;
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Trace($"SetStatus changed: {snapshot}");
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}
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IsEmergencyActive = emergencyActive;
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IsAlarmOutputOn = alarmOutputOn;
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StatusText = statusText;
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DetailText = detailText;
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StatusChanged?.Invoke(this, EventArgs.Empty);
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}
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public void Dispose()
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{
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Trace("Dispose() called. Safety monitor disposed.");
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_disposed = true;
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_timer?.Dispose();
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_gate.Dispose();
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}
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private void Trace(string message)
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{
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string line = $"{DateTime.Now:yyyy-MM-dd HH:mm:ss.fff} [T{Environment.CurrentManagedThreadId}] {message}{Environment.NewLine}";
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try
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{
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lock (_traceLock)
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{
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File.AppendAllText(_traceLogPath, line);
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}
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}
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catch
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{
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// Temporary diagnostic trace should never break runtime behavior.
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}
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}
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}
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public sealed record SafetyResetResult(bool Success, string Message);
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