FootwearTest-20260602/Footwear Test methodsfor wholeshoe Slipresistanceperformance/Services/SlipResistanceDeviceService.cs

using Footwear_Test_methodsfor_wholeshoe_Slipresistanceperformance.Models;
using NModbus;
using NModbus.IO;
using Serilog;
using System;
using System.Globalization;
using System.IO.Ports;
using System.Threading;
using System.Threading.Tasks;

namespace Footwear_Test_methodsfor_wholeshoe_Slipresistanceperformance.Services
{
    public sealed class SlipResistanceDeviceService : IDisposable
    {
        private const byte SlaveId = 1;
        private const ushort PlcDisplacementRegister = 402;
        private const ushort PlcStateCoilStart = 81;
        private const ushort StartTestCoil = 80;
        private const ushort StopTestCoil = 83;
        private const ushort ResetCoil = 90;
        private const ushort MoveLeftCoil = 1;
        private const ushort MoveRightCoil = 2;
        private const ushort LowerCoil = 4;
        private const ushort LiftCoil = 5;
        private const ushort ManualSpeedRegister = 302;
        private const ushort TestSpeedRegister = 310;
        private const ushort ManualDisplacementRegister = 320;

        private readonly object sync = new();
        private readonly ModbusFactory modbusFactory = new();

        private CancellationTokenSource? cancellationTokenSource;
        private Task? adcTask;
        private Task? plcTask;
        private SerialPort? plcPort;
        private SerialPort? adcPort;
        private IModbusSerialMaster? plcMaster;
        private IModbusSerialMaster? adcMaster;
        private DeviceSettings settings = new("0.00", "0.00", "0.30", "0", "0.00", "0", "0.00", "0", "0.00", "COM7", "COM8", 115200);
        private SlipDeviceSnapshot snapshot = SlipDeviceSnapshot.Offline();
        private DateTime lastAdcErrorLoggedAt = DateTime.MinValue;
        private DateTime lastPlcErrorLoggedAt = DateTime.MinValue;

        private double verticalLoadN;
        private double horizontalFrictionN;
        private double displacementMm;
        private int pressureRawValue;
        private int frictionRawValue1;
        private int frictionRawValue2;
        private bool hasAdcRawValues;
        private bool isTestRunning;
        private bool isResetting;
        private bool isConnected;
        private string lastError = string.Empty;

        public SlipDeviceSnapshot CurrentSnapshot
        {
            get
            {
                lock (sync)
                {
                    return snapshot;
                }
            }
        }

        public void Start(DeviceSettings deviceSettings)
        {
            settings = deviceSettings;
            Stop();

            try
            {
                Log.Information(
                    "启动防滑测试设备连接：PLC={PlcPort}, ADC={AdcPort}, BaudRate={BaudRate}, SlaveId={SlaveId}",
                    settings.PlcPortName,
                    settings.AdcPortName,
                    settings.BaudRate,
                    SlaveId);

                plcPort = CreatePort(settings.PlcPortName, settings.BaudRate);
                adcPort = CreatePort(settings.AdcPortName, settings.BaudRate);
                plcPort.Open();
                adcPort.Open();

                plcMaster = modbusFactory.CreateRtuMaster(new SerialPortResource(plcPort));
                adcMaster = modbusFactory.CreateRtuMaster(new SerialPortResource(adcPort));
                plcMaster.Transport.ReadTimeout = 2000;
                adcMaster.Transport.ReadTimeout = 2000;

                cancellationTokenSource = new CancellationTokenSource();
                var token = cancellationTokenSource.Token;
                SetConnected(true, string.Empty);
                adcTask = Task.Run(() => PollAdc(token), token);
                plcTask = Task.Run(() => PollPlc(token), token);
                Log.Information("防滑测试设备连接成功，ADC/PLC 轮询已启动");
            }
            catch (Exception ex)
            {
                Log.Error(
                    ex,
                    "防滑测试设备连接失败：PLC={PlcPort}, ADC={AdcPort}, BaudRate={BaudRate}",
                    settings.PlcPortName,
                    settings.AdcPortName,
                    settings.BaudRate);
                SetConnected(false, ex.Message);
                Stop();
            }
        }

        public void UpdateSettings(DeviceSettings deviceSettings)
        {
            settings = deviceSettings;
            Log.Debug(
                "设备设置已更新：PLC={PlcPort}, ADC={AdcPort}, BaudRate={BaudRate}, TestSpeed={TestSpeed}, ManualSpeed={ManualSpeed}, ManualDisplacement={ManualDisplacement}",
                settings.PlcPortName,
                settings.AdcPortName,
                settings.BaudRate,
                settings.TestSpeed,
                settings.ManualSpeed,
                settings.ManualDisplacement);
        }

        public Task PulseStartTestAsync() => PulseCoilAsync(StartTestCoil);

        public Task PulseStopTestAsync() => PulseCoilAsync(StopTestCoil);

        public Task PulseResetAsync() => PulseCoilAsync(ResetCoil);

        public async Task StartLiftAsync()
        {
            await WriteCoilAsync(LowerCoil, false);
            await WriteCoilAsync(LiftCoil, true);
            Log.Information("提升按下运行：M{LiftCoil}=1, M{LowerCoil}=0", LiftCoil, LowerCoil);
        }

        public async Task StopLiftAsync()
        {
            await WriteCoilAsync(LiftCoil, false);
            Log.Information("提升松开停止：M{LiftCoil}=0", LiftCoil);
        }

        public async Task StartLowerAsync()
        {
            await WriteCoilAsync(LiftCoil, false);
            await WriteCoilAsync(LowerCoil, true);
            Log.Information("下降按下运行：M{LowerCoil}=1, M{LiftCoil}=0", LowerCoil, LiftCoil);
        }

        public async Task StopLowerAsync()
        {
            await WriteCoilAsync(LowerCoil, false);
            Log.Information("下降松开停止：M{LowerCoil}=0", LowerCoil);
        }

        public async Task StartMoveLeftAsync()
        {
            await WriteCoilAsync(MoveRightCoil, false);
            await WriteCoilAsync(MoveLeftCoil, true);
            Log.Information("左移按下运行：M{MoveLeftCoil}=1, M{MoveRightCoil}=0", MoveLeftCoil, MoveRightCoil);
        }

        public async Task StopMoveLeftAsync()
        {
            await WriteCoilAsync(MoveLeftCoil, false);
            Log.Information("左移松开停止：M{MoveLeftCoil}=0", MoveLeftCoil);
        }

        public async Task StartMoveRightAsync()
        {
            await WriteCoilAsync(MoveLeftCoil, false);
            await WriteCoilAsync(MoveRightCoil, true);
            Log.Information("右移按下运行：M{MoveRightCoil}=1, M{MoveLeftCoil}=0", MoveRightCoil, MoveLeftCoil);
        }

        public async Task StopMoveRightAsync()
        {
            await WriteCoilAsync(MoveRightCoil, false);
            Log.Information("右移松开停止：M{MoveRightCoil}=0", MoveRightCoil);
        }

        public async Task StopAllMotionAsync()
        {
            await WriteCoilAsync(LiftCoil, false);
            await WriteCoilAsync(LowerCoil, false);
            await WriteCoilAsync(MoveLeftCoil, false);
            await WriteCoilAsync(MoveRightCoil, false);
            Log.Information("全部运动停止：M{LiftCoil}=0, M{LowerCoil}=0, M{MoveLeftCoil}=0, M{MoveRightCoil}=0", LiftCoil, LowerCoil, MoveLeftCoil, MoveRightCoil);
        }

        public Task WriteManualSpeedAsync(double value) => WriteFloatRegisterAsync(ManualSpeedRegister, value);

        public Task WriteTestSpeedAsync(double value) => WriteFloatRegisterAsync(TestSpeedRegister, value);

        public Task WriteManualDisplacementAsync(double value) => WriteFloatRegisterAsync(ManualDisplacementRegister, value);

        public Task<PlcDeviceParameters> ReadDeviceParametersAsync() =>
            Task.Run(() =>
            {
                var master = plcMaster ?? throw new InvalidOperationException("PLC 未连接");
                var manualSpeedWords = master.ReadHoldingRegisters(SlaveId, ManualSpeedRegister, 2);
                var manualDisplacementWords = master.ReadHoldingRegisters(SlaveId, ManualDisplacementRegister, 2);
                var testSpeedWords = master.ReadHoldingRegisters(SlaveId, TestSpeedRegister, 2);
                var parameters = new PlcDeviceParameters(
                    UshortToFloat(manualSpeedWords[1], manualSpeedWords[0]),
                    UshortToFloat(manualDisplacementWords[1], manualDisplacementWords[0]),
                    UshortToFloat(testSpeedWords[1], testSpeedWords[0]));

                Log.Information(
                    "读取 PLC 参数完成：D{ManualSpeedRegister}={ManualSpeed:F3}, D{ManualDisplacementRegister}={ManualDisplacement:F3}, D{TestSpeedRegister}={TestSpeed:F3}",
                    ManualSpeedRegister,
                    parameters.ManualSpeed,
                    ManualDisplacementRegister,
                    parameters.ManualDisplacement,
                    TestSpeedRegister,
                    parameters.TestSpeed);
                return parameters;
            });

        public AdcZeroCalibration CaptureCurrentAdcZero()
        {
            lock (sync)
            {
                if (!hasAdcRawValues)
                {
                    throw new InvalidOperationException("ADC 尚未读取到有效原始数据");
                }

                Log.Information(
                    "采集 ADC 零点：NormalPressureZero={NormalPressureZero}, FrictionZero1={FrictionZero1}, FrictionZero2={FrictionZero2}",
                    pressureRawValue,
                    frictionRawValue1,
                    frictionRawValue2);
                return new AdcZeroCalibration(pressureRawValue, frictionRawValue1, frictionRawValue2);
            }
        }

        public void Stop()
        {
            Log.Information("停止防滑测试设备连接与轮询");
            cancellationTokenSource?.Cancel();

            try
            {
                adcTask?.Wait(200);
                plcTask?.Wait(200);
            }
            catch
            {
            }

            cancellationTokenSource?.Dispose();
            cancellationTokenSource = null;
            adcTask = null;
            plcTask = null;

            plcMaster?.Dispose();
            adcMaster?.Dispose();
            plcMaster = null;
            adcMaster = null;

            ClosePort(plcPort);
            ClosePort(adcPort);
            plcPort = null;
            adcPort = null;
        }

        public void Dispose()
        {
            Stop();
        }

        private static SerialPort CreatePort(string portName, int baudRate) =>
            new(portName, baudRate, Parity.None, 8, StopBits.One)
            {
                ReadTimeout = 2000,
                WriteTimeout = 2000
            };

        private static void ClosePort(SerialPort? port)
        {
            if (port is null)
            {
                return;
            }

            try
            {
                if (port.IsOpen)
                {
                    port.Close();
                }
            }
            catch
            {
            }

            port.Dispose();
        }

        private void PollAdc(CancellationToken token)
        {
            while (!token.IsCancellationRequested)
            {
                try
                {
                    var master = adcMaster;
                    if (master is null)
                    {
                        return;
                    }

                    var data = master.ReadHoldingRegisters(SlaveId, 0, 8);
                    var pressureRaw = UshortToInt(data[0], data[1]);
                    var friction1Raw = UshortToInt(data[6], data[7]);
                    var friction2Raw = UshortToInt(data[2], data[3]);

                    var pressure = ConvertAdc(pressureRaw, settings.NormalPressureZero, settings.NormalPressureCoefficient);

                    // Keep the old instrument channel wiring: ADC 6/7 uses zero 1 with coefficient 2,
                    // and ADC 2/3 uses zero 2 with coefficient 1.
                    var friction1 = ConvertAdc(friction1Raw, settings.FrictionZero1, settings.FrictionCoefficient2);
                    var friction2 = ConvertAdc(friction2Raw, settings.FrictionZero2, settings.FrictionCoefficient1);
                    var friction = (friction1 + friction2) * -1.0;

                    lock (sync)
                    {
                        pressureRawValue = pressureRaw;
                        frictionRawValue1 = friction1Raw;
                        frictionRawValue2 = friction2Raw;
                        hasAdcRawValues = true;
                        verticalLoadN = pressure;
                        horizontalFrictionN = friction;
                        lastError = string.Empty;
                        isConnected = true;
                        RefreshSnapshotLocked();
                    }

                    Thread.Sleep(10);
                }
                catch (Exception ex)
                {
                    LogPollingError("ADC", ex, ref lastAdcErrorLoggedAt);
                    SetConnected(false, ex.Message);
                    Thread.Sleep(250);
                }
            }
        }

        private void PollPlc(CancellationToken token)
        {
            while (!token.IsCancellationRequested)
            {
                try
                {
                    var master = plcMaster;
                    if (master is null)
                    {
                        return;
                    }

                    var displacementWords = master.ReadHoldingRegisters(SlaveId, PlcDisplacementRegister, 2);
                    var coils = master.ReadCoils(SlaveId, PlcStateCoilStart, 10);

                    lock (sync)
                    {
                        displacementMm = UshortToFloat(displacementWords[1], displacementWords[0]);
                        isTestRunning = coils.Length > 0 && coils[0];
                        isResetting = coils.Length > 9 && coils[9];
                        lastError = string.Empty;
                        isConnected = true;
                        RefreshSnapshotLocked();
                    }

                    Thread.Sleep(10);
                }
                catch (Exception ex)
                {
                    LogPollingError("PLC", ex, ref lastPlcErrorLoggedAt);
                    SetConnected(false, ex.Message);
                    Thread.Sleep(250);
                }
            }
        }

        private async Task PulseCoilAsync(ushort coil)
        {
            Log.Information("发送 PLC 脉冲线圈：M{Coil}", coil);
            await WriteCoilAsync(coil, true);
            await Task.Delay(80);
            await WriteCoilAsync(coil, false);
        }

        private Task ToggleCoilAsync(ushort coil) =>
            Task.Run(() =>
            {
                var master = plcMaster ?? throw new InvalidOperationException("PLC 未连接");
                var current = master.ReadCoils(SlaveId, coil, 1)[0];
                master.WriteSingleCoil(SlaveId, coil, !current);
                Log.Information("切换 PLC 线圈：M{Coil}, Before={Before}, After={After}", coil, current, !current);
            });

        private Task WriteCoilAsync(ushort coil, bool value) =>
            Task.Run(() =>
            {
                var master = plcMaster ?? throw new InvalidOperationException("PLC 未连接");
                master.WriteSingleCoil(SlaveId, coil, value);
                Log.Debug("写入 PLC 线圈：M{Coil}={Value}", coil, value);
            });

        private Task WriteFloatRegisterAsync(ushort register, double value) =>
            Task.Run(() =>
            {
                var master = plcMaster ?? throw new InvalidOperationException("PLC 未连接");
                master.WriteMultipleRegisters(SlaveId, register, SplitFloatToUShortArray((float)value));
                Log.Information("写入 PLC 浮点寄存器：D{Register}={Value:F3}", register, value);
            });

        private void LogPollingError(string source, Exception exception, ref DateTime lastLoggedAt)
        {
            var now = DateTime.UtcNow;
            if (now - lastLoggedAt < TimeSpan.FromSeconds(5))
            {
                return;
            }

            lastLoggedAt = now;
            Log.Error(
                exception,
                "{Source} 轮询失败：PLC={PlcPort}, ADC={AdcPort}, BaudRate={BaudRate}",
                source,
                settings.PlcPortName,
                settings.AdcPortName,
                settings.BaudRate);
        }

        private void SetConnected(bool connected, string error)
        {
            lock (sync)
            {
                isConnected = connected;
                lastError = error;
                RefreshSnapshotLocked();
            }
        }

        private void RefreshSnapshotLocked()
        {
            snapshot = new SlipDeviceSnapshot(
                DateTime.Now,
                verticalLoadN,
                horizontalFrictionN,
                displacementMm,
                isTestRunning,
                isResetting,
                isConnected,
                lastError);
        }

        private static double ConvertAdc(int rawValue, string zeroText, string coefficientText)
        {
            var zero = ParseDouble(zeroText);
            var coefficient = ParseDouble(coefficientText);
            if (Math.Abs(coefficient) < 0.0001)
            {
                return 0;
            }

            return (rawValue - zero) / coefficient;
        }

        private static double ParseDouble(string value) =>
            double.TryParse(value, NumberStyles.Float, CultureInfo.InvariantCulture, out var invariantValue)
                ? invariantValue
                : double.TryParse(value, NumberStyles.Float, CultureInfo.CurrentCulture, out var localValue)
                    ? localValue
                    : 0;

        private static int UshortToInt(ushort first, ushort second)
        {
            var bytes = new byte[4];
            BitConverter.GetBytes(first).CopyTo(bytes, 0);
            BitConverter.GetBytes(second).CopyTo(bytes, 2);
            return BitConverter.ToInt32(bytes, 0);
        }

        private static float UshortToFloat(ushort first, ushort second)
        {
            var intSign = first / 32768;
            var intSignRest = first % 32768;
            var intExponent = intSignRest / 128;
            var intExponentRest = intSignRest % 128;
            var digit = (float)(intExponentRest * 65536 + second) / 8388608;
            return (float)Math.Pow(-1, intSign) * (float)Math.Pow(2, intExponent - 127) * (digit + 1);
        }

        private static ushort[] SplitFloatToUShortArray(float value)
        {
            var bytes = BitConverter.GetBytes(value);
            return
            [
                BitConverter.ToUInt16(bytes, 0),
                BitConverter.ToUInt16(bytes, 2)
            ];
        }

        private sealed class SerialPortResource(SerialPort serialPort) : IStreamResource
        {
            public int InfiniteTimeout => SerialPort.InfiniteTimeout;

            public int ReadTimeout
            {
                get => serialPort.ReadTimeout;
                set => serialPort.ReadTimeout = value;
            }

            public int WriteTimeout
            {
                get => serialPort.WriteTimeout;
                set => serialPort.WriteTimeout = value;
            }

            public void DiscardInBuffer() => serialPort.DiscardInBuffer();

            public int Read(byte[] buffer, int offset, int count) => serialPort.Read(buffer, offset, count);

            public void Write(byte[] buffer, int offset, int count) => serialPort.Write(buffer, offset, count);

            public void Dispose()
            {
            }
        }
    }
}