private void checkHeaterTemps( List<ZoneState> zones, double heaterOutputLimit, SystemState state, List<Integer> nodes) { for (ZoneState zone : zones) { Unit unit = zone.getTopUnit(); double setpoint = unit.getSetpoint(); double lowerLimit = setpoint - unit.getLoWarn(); double upperLimit = setpoint + unit.getHiWarn(); double upperAlarm = setpoint + unit.getHiAlarm(); double lowerAlarm = setpoint - unit.getLoAlarm(); // test action with heaterFlag switch (zone.getTopHeaterFlag()) { case OFF: zone.setTopColor(GRAY); yellowFlag = true; break; case SET: zone.setTopColor(WHITE); yellowFlag = true; break; case POWER: zone.setTopColor(WHITE); yellowFlag = true; if (zone.getTopPercentOP() < heaterOutputLimit) zone.setTopHeaterFlag(HeaterFlag.HEATING); break; case HEATING: zone.setTopColor(WHITE); yellowFlag = true; if (zone.getTopTemp() > lowerLimit && zone.getTopTemp() < upperLimit) { zone.setTopHeaterFlag(HeaterFlag.ACTIVE); } break; case ACTIVE: if (zone.getTopTemp() < lowerAlarm || zone.getTopTemp() > upperAlarm) { redZone = true; if (!zone.getTopColor().equals(RED)) { zone.setTopColor(RED); if (state.equals(SystemState.SYSTEM_STATE_RUN_STARTUP) || state.equals(SystemState.SYSTEM_STATE_RUN)) { OvenManager.getInstance().startCooldown(LightTowerState.ALARM_COOLDOWN.getTower()); log.error( "Zone: " + zone.getId() + " top heater out of alarm band: " + zone.getTopTemp()); } } } else if (zone.getTopTemp() < lowerLimit || zone.getTopTemp() > upperLimit) { yellowFlag = true; if (zone.getTopColor().equals(GREEN)) { zone.setTopColor(YELLOW); if (state.equals(SystemState.SYSTEM_STATE_RUN)) { CanComm.sendSystemState( SystemState.SYSTEM_STATE_RUN_PAUSE, Can.OpId.OPER_SET.ordinal(), nodes); CanComm.setLightTower(Equip.LightTowerState.WARNING.getTower()); log.error( "Zone: " + zone.getId() + " top heater out of warning band: " + zone.getTopTemp()); } } } else { zone.setTopColor(GREEN); } break; default: break; } if (zone.isHeatZone()) { unit = zone.getBottomUnit(); setpoint = unit.getSetpoint(); upperLimit = setpoint + unit.getHiWarn(); lowerLimit = setpoint - unit.getLoWarn(); upperAlarm = setpoint + unit.getHiAlarm(); lowerAlarm = setpoint - unit.getLoAlarm(); // test action with heaterFlag switch (zone.getBottomHeaterFlag()) { case OFF: zone.setBottomColor(GRAY); yellowFlag = true; break; case SET: zone.setBottomColor(WHITE); yellowFlag = true; break; case POWER: zone.setBottomColor(WHITE); yellowFlag = true; if (zone.getBottomPercentOP() < heaterOutputLimit) zone.setBottomHeaterFlag(HeaterFlag.HEATING); break; case HEATING: zone.setBottomColor(WHITE); yellowFlag = true; if (zone.getBottomTemp() > lowerLimit && zone.getBottomTemp() < upperLimit) { zone.setBottomHeaterFlag(HeaterFlag.ACTIVE); } break; case ACTIVE: if (zone.getBottomTemp() < lowerAlarm || zone.getBottomTemp() > upperAlarm) { redZone = true; if (!zone.getBottomColor().equals(RED)) { zone.setBottomColor(RED); if (state.equals(SystemState.SYSTEM_STATE_RUN_STARTUP) || state.equals(SystemState.SYSTEM_STATE_RUN)) { OvenManager.getInstance() .startCooldown(LightTowerState.ALARM_COOLDOWN.getTower()); log.error( "Zone: " + zone.getId() + " bottom heater out of alarm band: " + zone.getBottomTemp()); } } } else if (zone.getBottomTemp() < lowerLimit || zone.getBottomTemp() > upperLimit) { yellowFlag = true; if (zone.getBottomColor().equals(GREEN)) { zone.setBottomColor(YELLOW); if (state.equals(SystemState.SYSTEM_STATE_RUN)) { CanComm.sendSystemState( SystemState.SYSTEM_STATE_RUN_PAUSE, Can.OpId.OPER_SET.ordinal(), nodes); CanComm.setLightTower(Equip.LightTowerState.WARNING.getTower()); log.error( "Zone: " + zone.getId() + " bottom heater out of warning band: " + zone.getBottomTemp()); } } } else { zone.setBottomColor(GREEN); } break; default: break; } } } }
@Override public String call() { log.info("OvenCheckThread started..."); List<Integer> nodes = OvenState.getInstance().getNodes(); ParamManager paramManager = new ParamManager(); Config config = OvenState.getInstance().getConfig(); // begin main thread loop to check oven com.heller.oven variables while (OvenState.getInstance().getOvenBoolVar("utility")) { // General Oven parameters needed in thread IoModule ioModule = OvenState.getInstance().getIoModule(); double heaterOutputLimit = ioModule.getGeneralTwo().getHeaterOutputLimit(); double cooldownTemp = ioModule.getGeneralTwo().getCooldown(); // pause thread for specified amount try { Thread.sleep(OVEN_UPDATE_DELAY); } catch (InterruptedException e) { log.error("InterruptedException " + e.getMessage()); } // get references from singleton that might change upon iteration List<ZoneState> zones = OvenState.getInstance().getZones(); List<BeltState> beltStates = OvenState.getInstance().getBeltStates(); List<RailState> railStates = OvenState.getInstance().getRailStates(); SystemState state = OvenState.getInstance().getOvenSystemState(); RecipeFlag recipeFlag = OvenState.getInstance().getRecipeFlag(); // if recipe never loaded, then skip while loop if (OvenState.getInstance().getRecipeFlag() == RecipeFlag.NEVER_LOADED) continue; // If system is in COOLDOWN_DELAYED, test for boards in oven // If/when no boards in oven - start COOLDOWN and change System State if (state == SystemState.SYSTEM_STATE_RUN_COOLDOWN_DELAYED) { // if no boards in oven, change state to RUN_COOLDOWN if (!OvenManager.getInstance().isBoardsInOven()) { CanComm.sendSystemState( SystemState.SYSTEM_STATE_RUN_COOLDOWN, Can.OpId.OPER_SET.ordinal(), nodes); } } else if (state == SystemState.SYSTEM_STATE_RUN_COOLDOWN) { startCooldown( ioModule, paramManager, zones, beltStates, railStates, cooldownTemp, config, nodes); } else if (state.ordinal() >= LOWEST_RUN_STATE && state.ordinal() <= HIGHEST_RUN_STATE) { if (recipeFlag == RecipeFlag.RECIPE_UNLOADABLE) continue; if (recipeFlag == RecipeFlag.RECIPE_LOADING) { // white out heat zones on GUI for (ZoneState zone : zones) { zone.setTopColor(WHITE); if (zone.isHeatZone()) zone.setBottomColor(WHITE); } // white out belts on GUI for (BeltState beltState : beltStates) { beltState.setColor(WHITE); } // gray out rails on GUI for (RailState railState : railStates) { railState.setColor(WHITE); } // skip rest of loop until recipe is loaded. continue; } yellowFlag = false; // check rail position, set sysColor yellow if not ACTIVE within warning band checkRailPosition(railStates, state, nodes); // check belt speed, set sysColor yellow if belt speed out of warning band checkBeltSpeed(beltStates, state, nodes); // iterate through heaters and determine heater colors according to alarm/warning bands checkHeaterTemps(zones, heaterOutputLimit, state, nodes); // if any zone is red, Cooldown should have been called - skip rest of while loop if (redZone) { continue; } if (!yellowFlag) { // set light tower green and change to SYSTEM STATE RUN if in RUN PAUSE (with no warnings) // or RUN START if (state.equals(SystemState.SYSTEM_STATE_RUN_STARTUP)) { CanComm.sendSystemState( SystemState.SYSTEM_STATE_RUN, Can.OpId.OPER_SET.ordinal(), nodes); OvenState.getInstance().setRecipeFlag(RecipeFlag.RECIPE_RUNNING); CanComm.setLightTower(Equip.LightTowerState.EMPTY_OVEN.getTower()); } else if (state.equals(SystemState.SYSTEM_STATE_RUN_PAUSE)) { if (OvenManager.getInstance().isAlarms() == -1 || OvenManager.getInstance().isAlarms() == 2) { OvenManager.getInstance().clearAlarmState(true); CanComm.sendSystemState( SystemState.SYSTEM_STATE_RUN, Can.OpId.OPER_SET.ordinal(), nodes); OvenState.getInstance().setRecipeFlag(RecipeFlag.RECIPE_RUNNING); CanComm.setLightTower(LightTowerState.PRODUCTS_IN_OVEN.getTower()); } } } // pause thread for specified amount try { Thread.sleep(OVEN_UPDATE_DELAY); } catch (InterruptedException e) { log.error("InterruptedException " + e.getMessage()); } } } log.info("OvenCheckThread closed..."); return "thread_closed"; }
private void startCooldown( IoModule ioModule, ParamManager paramManager, List<ZoneState> zones, List<BeltState> beltStates, List<RailState> railStates, double cooldownTemp, Config config, List<Integer> nodes) { if (ioModule.getOutput(Can.OutputIO.IOM_HEAT_CONTACTOR) == 1) { // Turn off heat contactor and disable alarms paramManager.setAlarms(ALARM_DISABLED); CanComm.sendCmdSetpoint( Can.BoardType.BOARD_TYPE_IOM.getStartNum(), 0, Can.CmdSetpoint.SETPOINT_HEAT_CONTACTOR, 0); log.info("Delayed Cooldown -- Heat Contactor Off..."); } // gray out heat zones on GUI for (ZoneState zone : zones) { zone.setTopHeaterFlag(Equip.HeaterFlag.OFF); paramManager.zeroHeaterSetpoint(true, zone); zone.setTopColor(GRAY); if (zone.isHeatZone()) { zone.setBottomHeaterFlag(Equip.HeaterFlag.OFF); paramManager.zeroHeaterSetpoint(false, zone); zone.setBottomColor(GRAY); } } // gray out belts on GUI for (BeltState beltState : beltStates) { beltState.setColor(GRAY); } // gray out rails on GUI for (RailState railState : railStates) { railState.setColor(GRAY); } // test if zone heaters are above cooldown temperature boolean belowTemp = true; for (ZoneState zone : zones) { if (zone.getTopTemp() > cooldownTemp) { belowTemp = false; break; } if (zone.getBottomTemp() > cooldownTemp && zone.isHeatZone()) { belowTemp = false; break; } } if (belowTemp) { // complete cooldown after all zones less than cooldown temp if (OvenState.getInstance().getLightTower() == LightTowerState.COOLDOWN.getTower()) { CanComm.setLightTower(Equip.LightTowerState.TOWER_OFF.getTower()); } // set all belts to speed of zero for (int i = 0; i < config.getNumBelts(); i++) { BeltState beltState = beltStates.get(i); paramManager.zeroBeltSetpoint(beltState); } // turn off fan contactor CanComm.sendCmdSetpoint( Can.BoardType.BOARD_TYPE_IOM.getStartNum(), 0, Can.CmdSetpoint.SETPOINT_FAN_CONTACTOR, 0); CanComm.sendSystemState( SystemState.SYSTEM_STATE_OVEN_OFF, Can.OpId.OPER_SET.ordinal(), nodes); log.info("Cooldown complete - Fan Contactor Off..."); } }