Heater: setpoint ramping to suppress thermal-lag overshoot

This commit is contained in:
2026-10-10 13:59:43 +08:00
parent 5b24b956d2
commit 12ba9de05f
11 changed files with 353 additions and 214 deletions
+188 -93
View File
@@ -5,7 +5,7 @@
协议与串口模块(filmforge_rs485)保持不变, 本文件只做呈现层:
PySide6-Fluent-Widgets 卡片式双栏仪表盘 + 自绘滚动温度曲线(无第三方图表依赖)。
闭环监视 = 实测温度曲线 + 目标温度阶梯线同图 + 加热/上报/传感器状态联动;
设备未开启 M2 上报时可由上位机周期轮询 M1 补齐曲线。
温度监控走固件 M2 周期上报帧(M2S<ms> 开启), M1 仅作手动单点查询。
"""
import ctypes
@@ -60,7 +60,7 @@ import config
import filmforge_rs485 as ff
APP_NAME = "FilmForge"
APP_VERSION = "0.1.0"
APP_VERSION = "0.2.5"
REPO_URL = "https://gitea.hulk.wang/hulk/FilmForge"
MONO = QFont("Consolas", 10)
CHIP_IDLE = "#666666"
@@ -153,7 +153,9 @@ class TemperatureChart(QWidget):
return t_out, v_out
def _target_points(self, t0, t1):
"""目标阶梯线: [(t,v)...] 持有至下一变更时刻, 展开成阶梯点并延伸到右缘"""
"""目标阶梯线: [(t,v)...] 每段从自身时刻起垂直落变并水平延伸至下一变更,
最后一段延伸到右缘。旧实现对"最后一次变更"只画终点, 会从旧值斜拉一条
直线到右缘(实测 57→41 被画成 2 分钟斜坡), 已改为纯阶梯。"""
hist = self._target_hist
if not hist:
return []
@@ -162,10 +164,15 @@ class TemperatureChart(QWidget):
tn = hist[i + 1][0] if i + 1 < len(hist) else t1
if tn < t0 or ti > t1:
continue
b = min(tn, t1)
start, end = max(ti, t0), min(tn, t1)
if not pts:
pts.append((max(ti, t0), vi))
pts.append((b, vi))
pts.append((start, vi))
else:
if pts[-1][0] != start:
pts.append((start, pts[-1][1])) # 空窗: 先延续旧值(防御)
pts.append((start, vi)) # 与上一段终点同 x → 垂直落变
if end > start:
pts.append((end, vi))
if pts and pts[-1][0] < t1:
pts.append((t1, pts[-1][1]))
return pts
@@ -191,7 +198,7 @@ class TemperatureChart(QWidget):
if not self._has_data:
p.setPen(QColor(c["text"]))
p.drawText(self.rect(), Qt.AlignCenter,
"暂无数据 — 连接设备后查询温度(M1)或开启上报(M2S<ms>)")
"暂无数据 — 连接设备后开启周期上报(M2S<ms>)即可实时推送; 单点查询用 M1")
@staticmethod
def _y_range(vis_v, tgt_pts):
@@ -373,9 +380,13 @@ class App(QMainWindow):
self.firmware = None
# 应答 FIFO: 半双工上固件严格按收到顺序应答, 连接序列/连发场景下
# 多个应答可能同时在途, 单 pending 槽会被乱序击穿(实测踩坑)
self._pending = deque() # [{'cmd','kind','t','apply'}]
self._last_poll = 0.0
self._pending = deque() # [{'cmd','kind','t','apply','then'}]
self._frozen_at = None
self._want = False # 连接按钮意图(点击即翻转, 不等线程实际开/关)
self._want_since = None # 意图=连接但实际未建立的起始时刻(丢失判定)
self._last_set = None # 最近一条设定命令(t/cmd/apply): 晚到 ok 补偿
self._resume_report_ms = None # M4 查询前暂停的上报间隔(查询完自动恢复)
self._seq = [] # 连接同步序列剩余步骤
self._last_chart_repaint = 0.0
self._ports = []
self._rx_q = queue.Queue()
@@ -481,8 +492,40 @@ class App(QMainWindow):
scroll.setWidget(host)
return scroll
# ---------------- 左列: 监视 ----------------
# ---------------- 左列: 串口 + 监视 ----------------
def _build_serial_card(self, layout):
"""串口连接卡片(置于左列顶部): 端口/波特率选择 + 连接开关 + 状态行"""
if ff.HAS_SERIAL:
card, body = self._card("串口 · RS485 → FilmForge 温控板")
row = QHBoxLayout()
self.cbo_port = ComboBox(card)
row.addWidget(self.cbo_port, 1)
row.addWidget(self._button("刷新", self._refresh_ports))
self.btn_conn = self._button("连接", self._toggle_connect, True)
row.addWidget(self.btn_conn)
body.addLayout(row)
params = QHBoxLayout()
self.cbo_baud = ComboBox(card)
self.cbo_baud.addItems(["115200", "57600", "38400", "9600"])
self.cbo_baud.setCurrentText(str(config.SERIAL_CFG["baud"]))
params.addWidget(BodyLabel("波特率", card))
params.addWidget(self.cbo_baud)
self.lbl_st = BodyLabel("未连接", card)
self.lbl_st.setWordWrap(True) # 长错误串不得撑大参数行(DLPilot 教训)
params.addWidget(self.lbl_st, 1)
body.addLayout(params)
layout.addWidget(card)
else:
self.cbo_port = None
self.btn_conn = None
self.lbl_st = BodyLabel("未安装 pyserial, 串口功能不可用。", self)
self.lbl_st.setWordWrap(True)
card, body = self._card("串口不可用")
body.addWidget(self.lbl_st)
layout.addWidget(card)
def _build_left(self, layout):
self._build_serial_card(layout)
win_combo = ComboBox(self)
for name, _sec in config.WINDOW_OPTIONS:
win_combo.addItem(name)
@@ -544,47 +587,18 @@ class App(QMainWindow):
# ---------------- 右列: 控制 ----------------
def _build_right(self, layout):
if ff.HAS_SERIAL:
card, body = self._card("串口 · RS485 → FilmForge 温控板")
row = QHBoxLayout()
self.cbo_port = ComboBox(card)
row.addWidget(self.cbo_port, 1)
row.addWidget(self._button("刷新", self._refresh_ports))
self.btn_conn = self._button("连接", self._toggle_connect, True)
row.addWidget(self.btn_conn)
body.addLayout(row)
params = QHBoxLayout()
self.cbo_baud = ComboBox(card)
self.cbo_baud.addItems(["115200", "57600", "38400", "9600"])
self.cbo_baud.setCurrentText(str(config.SERIAL_CFG["baud"]))
params.addWidget(BodyLabel("波特率", card))
params.addWidget(self.cbo_baud)
self.lbl_st = BodyLabel("未连接", card)
self.lbl_st.setWordWrap(True) # 长错误串不得撑大参数行(DLPilot 教训)
params.addWidget(self.lbl_st, 1)
body.addLayout(params)
layout.addWidget(card)
else:
self.cbo_port = None
self.btn_conn = None
self.lbl_st = BodyLabel("未安装 pyserial, 串口功能不可用。", self)
self.lbl_st.setWordWrap(True)
card, body = self._card("串口不可用")
body.addWidget(self.lbl_st)
layout.addWidget(card)
card, body = self._card("温度控制 · 目标 / 加热(固件预留)")
card, body = self._card("温度控制 · 目标 / 加热(PID 闭环)")
row = QHBoxLayout()
self.ent_target = LineEdit(card)
self.ent_target.setPlaceholderText("0~200 整数℃")
self.ent_target.setFixedWidth(110)
self.sld_target = Slider(Qt.Horizontal, card)
self.sld_target.setRange(0, 200)
self.sld_target.setRange(0, 120) # 工况温度 <=120℃; 协议上限 200 仍可手输
self.sld_target.setValue(120)
self.sld_target.valueChanged.connect(lambda v: self.ent_target.setText(str(v)))
row.addWidget(BodyLabel("目标温度", card))
row.addWidget(self.ent_target)
row.addWidget(self._button("查询", lambda: self._query("M4", "target")))
row.addWidget(self._button("查询", self._query_target))
row.addWidget(self._button("设定", self._send_target, True))
body.addLayout(row)
body.addWidget(self.sld_target)
@@ -595,11 +609,12 @@ class App(QMainWindow):
lambda: self._send_set("M3S0", "heater", "OFF")))
row.addStretch(1)
body.addLayout(row)
body.addWidget(self._note(card, "当前固件加热/目标仅维护软件状态(ack+可回读), 硬件执行体"
"待接入; 接入后协议不变, 本页即可直接联调真实控温。"))
body.addWidget(self._note(card, "开启加热后固件按目标温度 PID 闭环真实控温(500ms 周期,"
"慢 PWM 执行); NTC 故障或 ≥150℃ 过温时固件自动断电保护,"
"上电默认关闭。当前占空比无查询命令, 可从温度曲线间接观察。"))
layout.addWidget(card)
card, body = self._card("周期上报 · M2S<ms>")
card, body = self._card("温度监控 · 周期上报 M2S<ms>")
row = QHBoxLayout()
self.ent_report = LineEdit(card)
self.ent_report.setPlaceholderText("100~60000, 10ms 步进")
@@ -612,16 +627,9 @@ class App(QMainWindow):
lambda: self._send_set("M2S0", "report", ("OFF", None))))
row.addWidget(self._button("查状态", lambda: self._query("M2", "report")))
body.addLayout(row)
row = QHBoxLayout()
row.addWidget(BodyLabel("自动轮询 M1", card))
self.cbo_poll = ComboBox(card)
for name, _ms in config.POLL_OPTIONS:
self.cbo_poll.addItem(name)
row.addWidget(self.cbo_poll)
row.addStretch(1)
body.addLayout(row)
body.addWidget(self._note(card, "上报开启时曲线走固件周期帧; 未开启时可由上位机按所选"
"周期自动查询 M1 补点(两条路读同一全局最新温度)。"))
body.addWidget(self._note(card, "温度监控统一走 M2: 开启上报后固件按设定周期主动推送"
"温度帧入曲线; 停止后曲线暂停, 需要单点时用命令区"
" 查温度 M1(两条路读同一全局最新温度)。"))
layout.addWidget(card)
card, body = self._card("命令 · 预设 / 自定义")
@@ -659,7 +667,7 @@ class App(QMainWindow):
body.addWidget(self.txt_log)
self._log(f"帧格式: D5 01 LEN <命令> CRC / B5 TYPE LEN <payload> CRC; "
f"响应超时建议 {ff.REPLY_TIMEOUT * 1000:.0f}ms 重发")
layout.addWidget(card)
layout.addWidget(card, 1) # 弹性填充: 右列底边与左列对齐
card, body = self._card("危险操作 · 会使设备复位")
row = QHBoxLayout()
@@ -684,10 +692,6 @@ class App(QMainWindow):
def _apply_settings(self):
if self.cbo_port is not None and config.SERIAL_CFG["port"]:
self._pick_port(config.SERIAL_CFG["port"])
idx = next((i for i, (_n, ms) in enumerate(config.POLL_OPTIONS)
if ms == config.POLL_MS), 2)
self.cbo_poll.setCurrentIndex(idx) # 先设初值再连信号
self.cbo_poll.currentIndexChanged.connect(self._on_poll_changed)
self.ent_report.editingFinished.connect(self._save_report_pref)
widx = next((i for i, (_n, s) in enumerate(config.WINDOW_OPTIONS)
if s == config.WINDOW_SEC), 1)
@@ -785,26 +789,38 @@ class App(QMainWindow):
connected = self.link.is_connected()
if connected != self._connected:
self._connected = connected
if self.btn_conn is not None:
self.btn_conn.setText("断开" if connected else "连接")
if connected:
if connected and self._want:
self._connect_seq()
else:
elif not connected:
self._pending.clear()
self._last_set = None
self._resume_report_ms = None
# 意图=连接但实际未建立(正在连接)或中途丢失(串口拔出/线程侧异常):
# 2s 宽限后判丢失, 按钮回"连接", 避免界面卡在"断开"与实际状态脱节
if self._want and not connected:
if self._want_since is None:
self._want_since = now
elif now - self._want_since > 2.0:
self._want = False
self._want_since = None
self.btn_conn.setText("连接")
self._pending.clear()
self._last_set = None
self._resume_report_ms = None
self.lbl_st.setText("连接未建立或已丢失, 请重试")
else:
self._want_since = None
# 应答超时: 按发送顺序逐个清理队首过期条目(监视台不自动重发,
# 命令全幂等, 交给用户/自动轮询自然重试)
# 命令全幂等, 交给用户重试; 设定命令的晚到 ok 走补偿, 见 _handle_frame)
while self._pending and now - self._pending[0]["t"] > PENDING_TIMEOUT:
entry = self._pending.popleft()
self._log(f'⏱ {entry["cmd"]} 无响应(>{PENDING_TIMEOUT:.1f}s)')
# 自动轮询 M1: 仅在连接、未开启上报、无未决命令时补点
if (connected and config.POLL_MS > 0
and not (self.report_state and self.report_state[0] == "ON")
and not self._pending
and now - self._last_poll >= config.POLL_MS / 1000.0):
self._last_poll = now
self._send_cmd("M1", "temp")
if entry["kind"] == "target":
self._resume_report() # M4 查询失败也要恢复上报
if entry.get("then"):
entry["then"]() # 链式流程(暂停上报→查目标)继续走
# 曲线时间轴推进 + 窗口统计(节流 0.5s)
if now - self._last_chart_repaint >= 0.5:
@@ -814,8 +830,8 @@ class App(QMainWindow):
def _on_status_main(self, msg):
self.lbl_st.setText(msg)
if msg.startswith("已连接"):
self._log(f"── {msg} ──")
# 连接/断开/丢失全部入日志: 状态标签只留最后一条, 日志才可回溯排查
self._log(f"── {msg} ──")
# ================= 帧派发 =================
def _handle_frame(self, fr, t_rx):
@@ -843,6 +859,7 @@ class App(QMainWindow):
if t_rx - head["t"] <= window:
self._pending.popleft()
self._set_target(t_rx, val)
self._resume_report() # 暂停上报查目标的收尾
return
elif head and head["kind"] == "temp":
self._pending.popleft()
@@ -852,13 +869,28 @@ class App(QMainWindow):
# 非数值成功载荷: ok / ON / OFF / ON <ms> / v*
# 应答形态必须与队首期望匹配才消费, 不匹配记杂散(条目超时自清)
head = self._pending[0] if self._pending else None
pl = fr.payload.strip()
# 晚到 ok 补偿: 设定命令的 ok 延迟超过 1.2s 时已按超时清队(适配器换向
# 实测可 >4s), 迟到的 ok 在此按发送时记录的计划补偿应用, 避免状态
# chip 与设备脱节(实测: M2S100 ok 迟到, 上报 chip 停在 OFF 而设备在报)
if pl == "ok" and not (head and (head.get("apply") or head["kind"] == "ack")):
late = self._last_set
if late and t_rx - late["t"] <= 8.0:
self._last_set = None
self._log(f'⏱→ {late["cmd"]} ok 晚到, 补偿应用')
self._apply_ack({"cmd": late["cmd"], "kind": "ack",
"apply": late["apply"], "t": late["t"]}, t_rx)
elif head is not None:
self._log(f'杂散应答 ok(队首在等 {head["cmd"]})')
return
if head is None:
return
pl = fr.payload.strip()
kind = head["kind"]
if pl == "ok" and (head.get("apply") or kind == "ack"):
self._pending.popleft()
self._apply_ack(head, t_rx)
if self._last_set and self._last_set.get("cmd") == head["cmd"]:
self._last_set = None
elif pl.startswith("v") and kind == "version" and len(pl) <= 16:
self._pending.popleft()
self.firmware = pl
@@ -885,13 +917,16 @@ class App(QMainWindow):
self.lbl_st.setText(f"目标温度已设定 {value} ℃")
elif what == "heater":
self._set_heater(value)
self.lbl_st.setText(f"加热已{'开启' if value == 'ON' else '关闭'}(软件状态)")
self.lbl_st.setText(f"加热已{'开启(PID 闭环)' if value == 'ON' else '关闭'}")
elif what == "report":
state, ms = value
self._set_report_state(state, ms)
self.lbl_st.setText("周期上报已开启" if state == "ON" else "周期上报已停止")
else:
self.lbl_st.setText("设备应答 ok")
then = pending.get("then")
if then:
then()
# ================= 数据通路 =================
def _add_sample(self, t, v):
@@ -947,14 +982,23 @@ class App(QMainWindow):
f"平均 {mean:.1f} ℃ · {len(vals)} 点")
# ================= 发送路径 =================
def _send_cmd(self, cmd, kind, apply_plan=None):
"""带应答跟踪发送: kind 决定应答派发, apply_plan 为 ok 后的本地状态计划。
def _send_cmd(self, cmd, kind, apply_plan=None, then=None):
"""带应答跟踪发送: kind 决定应答派发, apply_plan 为 ok 后的本地状态计划,
then 为 ok 消费后的链式回调(暂停上报→查目标用)。
条目入 FIFO(半双工应答按发送序返回); 队列超长只留最新 8 条防失控"""
if not self.link.is_connected():
self.lbl_st.setText("未连接串口")
return False
# 幂等去重: 同一命令已有未决应答时忽略本次发送(连点"停止/开启"不再堆积,
# 真机实测连点 12 次 M2S0 挤爆 8 条 pending 队列; 协议全幂等, 同命令
# 一条在途足够, 超时自清后自然允许重发)
if any(e["cmd"] == cmd for e in self._pending):
self.lbl_st.setText(f"{cmd} 应答中, 已忽略重复发送")
return True
self._pending.append({"cmd": cmd, "kind": kind, "t": time.time(),
"apply": apply_plan})
"apply": apply_plan, "then": then})
if apply_plan:
self._last_set = {"cmd": cmd, "t": time.time(), "apply": apply_plan}
while len(self._pending) > 8:
dropped = self._pending.popleft()
self._log(f'丢弃积压命令: {dropped["cmd"]}')
@@ -979,8 +1023,9 @@ class App(QMainWindow):
def _heater_on(self):
if not self._confirm("开启加热",
"当前固件加热为预留功能(仅软件状态, 硬件执行体待接入)。\n"
"接入硬件后此操作将真实加热模具, 确认开启?"):
"加热已实装: 开启后固件将按目标温度 PID 闭环真实加热模具,\n"
"表面可达 0~200℃(NTC 故障/过温时固件自动断电保护)。\n"
"确认开启?"):
return
self._send_set("M3S1", "heater", "ON")
@@ -1010,9 +1055,11 @@ class App(QMainWindow):
self._send_set(cmd, "report", ("OFF", None))
elif cmd == "M3S0":
self._send_set(cmd, "heater", "OFF")
elif cmd == "M4":
self._query_target() # 上报开启时需暂停/恢复, 不能直发
else:
kind = {"M1": "temp", "M2": "report", "M3": "heater",
"M4": "target", "M999": "version"}.get(cmd, "ack")
"M999": "version"}.get(cmd, "ack")
self._send_cmd(cmd, kind)
return
@@ -1076,7 +1123,16 @@ class App(QMainWindow):
return label.strip()
def _toggle_connect(self):
if self.link.is_connected():
# 按钮按"意图"立即翻转, 实际开/关由串口线程异步完成并经状态日志反馈;
# 不再用 is_connected() 判断该走哪条分支(线程侧状态滞后会点不动)
if self._want:
self._want = False
self._want_since = None
self.btn_conn.setText("连接")
self.lbl_st.setText("正在断开…")
self._pending.clear()
self._last_set = None
self._resume_report_ms = None
self.link.close()
return
port = self._selected_port()
@@ -1090,6 +1146,10 @@ class App(QMainWindow):
return
config.SERIAL_CFG.update(port=port, baud=baud)
config.save_settings()
self._want = True
self._want_since = time.time()
self.btn_conn.setText("断开")
self.lbl_st.setText("正在连接…")
self.link.open(port, baud)
def _connect_seq_if_connected(self):
@@ -1097,12 +1157,51 @@ class App(QMainWindow):
self._connect_seq()
def _connect_seq(self):
"""连接/复位后状态同步: 版本→上报→加热→目标, 150ms 间隔规避半双工碰撞"""
"""连接/复位后状态同步: 版本→上报→加热→(暂停上报→)目标。
每步发送前确认在线(线程异步打开期间 singleShot 早发会被"未连接串口"丢弃),
150ms 间隔规避半双工碰撞; 目标查询放最后并等 M2 应答消费完(见 _seq_target)"""
self._pending.clear()
self._last_poll = time.time() # 序列期间抑制自动轮询, 防止抢占 M999 位
seq = (("M999", "version"), ("M2", "report"), ("M3", "heater"), ("M4", "target"))
for i, (cmd, kind) in enumerate(seq):
QTimer.singleShot(i * 150, lambda c=cmd, k=kind: self._query(c, k))
self._last_set = None
self._seq = [("M999", "version"), ("M2", "report"), ("M3", "heater")]
QTimer.singleShot(0, self._seq_next)
def _seq_next(self):
if not self._seq:
QTimer.singleShot(0, self._seq_target)
return
if not self.link.is_connected():
return # 连接已断: 序列作废(重连会重跑)
cmd, kind = self._seq.pop(0)
self._query(cmd, kind)
QTimer.singleShot(150, self._seq_next)
def _seq_target(self):
if not self.link.is_connected():
return
if any(e["kind"] == "report" for e in self._pending):
QTimer.singleShot(100, self._seq_target) # 等 M2 应答落地再定分支
return
self._query_target()
def _query_target(self):
"""查询目标温度(M4)。上报开启时 M4 应答与周期温度帧同为 ASCII 浮点,
FIFO 窗口法在 100ms 上报下必现误占(实测目标 chip 显示成实测值)——
改为应答驱动的暂停/恢复: M2S0(ok)→M4→自动 M2S<ms> 恢复。"""
if not (self.report_state and self.report_state[0] == "ON"):
self._send_cmd("M4", "target")
return
self._resume_report_ms = self.report_state[1]
self.lbl_st.setText("查询目标: 先暂停上报…")
self._send_cmd("M2S0", "report", ("OFF", None), then=self._send_m4_after_pause)
def _send_m4_after_pause(self):
if self.link.is_connected():
QTimer.singleShot(120, lambda: self._send_cmd("M4", "target"))
def _resume_report(self):
ms, self._resume_report_ms = self._resume_report_ms, None
if ms and self.link.is_connected():
self._send_cmd(f"M2S{ms}", "report", ("ON", ms))
# ================= 曲线交互 =================
def _on_window(self, idx):
@@ -1189,10 +1288,6 @@ class App(QMainWindow):
f"协议: protocols.md v1.0 (M1~M4 / M888 / M999 / M9999)\n\n{REPO_URL}")
# ================= 设置持久化小项 =================
def _on_poll_changed(self, idx):
config.POLL_MS = config.POLL_OPTIONS[idx][1]
config.save_settings()
def _save_report_pref(self):
try:
config.REPORT_MS = int(self.ent_report.text().strip())