private void checkRailPosition(
List<RailState> railStates, SystemState state, List<Integer> nodes) {
for (RailState railState : railStates) {
Rail rail = railState.getRail();
double setpoint = railState.getRailWidget().getSetpoint();
double position = railState.getRailPosition();
double home = rail.getHomeDistance();
double tol = rail.getTolPlus();
switch (railState.getRailFlag()) {
case NOT_HOMED:
yellowFlag = true;
railState.setColor(GRAY);
break;
case HOMING:
if (position > home - tol && position < home + tol)
railState.setRailFlag(Equip.RailFlag.HOMED);
yellowFlag = true;
railState.setColor(WHITE);
break;
case HOMED:
yellowFlag = true;
railState.setColor(WHITE);
break;
case SEEKING:
if (position > setpoint - tol && position < setpoint + tol)
railState.setRailFlag(Equip.RailFlag.ACTIVE);
yellowFlag = true;
railState.setColor(WHITE);
break;
case ACTIVE:
railState.setColor(GREEN);
if (position < setpoint - tol || position > setpoint + tol) {
yellowFlag = true;
if (railState.getColor().equals(GREEN)) {
railState.setColor(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("Rail out of tolerance (warning) band...");
}
}
}
break;
default:
break;
}
}
}
private void checkBeltSpeed(List<BeltState> beltStates, SystemState state, List<Integer> nodes) {
for (BeltState beltState : beltStates) {
// determine upper and lower thresholds for alarms and warnings
double setpoint = beltState.getBeltUnit().getSetpoint();
double processValue = beltState.getBeltSpeed();
double upperLimit = setpoint + beltState.getBeltUnit().getHiWarn();
double lowerLimit = setpoint - beltState.getBeltUnit().getLoWarn();
if (setpoint == 0.0) {
yellowFlag = true;
beltState.setColor(WHITE);
continue;
}
switch (beltState.getBeltFlag()) {
case OFF:
yellowFlag = true;
beltState.setColor(GRAY);
break;
case SET:
yellowFlag = true;
beltState.setColor(WHITE);
break;
case SEEKING:
yellowFlag = true;
if (processValue > lowerLimit && processValue < upperLimit)
beltState.setBeltFlag(GenFlag.ACTIVE);
beltState.setColor(WHITE);
break;
case ACTIVE:
beltState.setColor(GREEN);
if (processValue < lowerLimit || processValue > upperLimit) {
yellowFlag = true;
if (beltState.getColor().equals(GREEN)) {
beltState.setColor(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("beltSpeed out of warning band: " + processValue);
}
}
}
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 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;
}
}
}
}
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...");
}
}