迁移最新的压力调节算法

InkJetPrinter.cpp

@@ -745,6 +745,38 @@ float PID_realize(float speed, float act){
 }
 #endif
 
+float PID_realize2(float speed, float act){
+    pid.Kp = 0.08f;
+    pid.Ki = 0.003f;   // 0.015 * (100ms/500ms) = 0.003，防积分饱和
+    pid.Kd = 0.0f;
+    pid.SetSpeed    = speed;
+    pid.ActualSpeed = act;
+    pid.err         = pid.SetSpeed - pid.ActualSpeed;
+
+    // 增量式PID差分公式：Δu = Kp*(e[k]-e[k-1]) + Ki*e[k] + Kd*(e[k]-2*e[k-1]+e[k-2])
+    // e[k-2] 用 voltage 字段暂存
+    float delta_u = pid.Kp * (pid.err - pid.err_last)
+                  + pid.Ki * pid.err
+                  + pid.Kd * (pid.err - 2.0f * pid.err_last + pid.voltage);
+
+    // 自适应步长：误差大时快速逼近，误差小时精细调节
+    float absErr = (pid.err < 0) ? -pid.err : pid.err;
+    float maxStep, minStep;
+    if(absErr > 50.0f) {
+        maxStep = 6.0f;  minStep = -10.0f;  // 大误差：快速逼近
+    } else if(absErr > 20.0f) {
+        maxStep = 3.0f;  minStep = -5.0f;   // 中误差：适中
+    } else {
+        maxStep = 1.5f;  minStep = -2.5f;   // 小误差：精细调节
+    }
+    if(delta_u >  maxStep) delta_u =  maxStep;
+    if(delta_u <  minStep) delta_u =  minStep;
+
+    pid.voltage  = pid.err_last;  // 暂存 e[k-2]
+    pid.err_last = pid.err;
+    return delta_u;
+}
+
 #if 0
 struct _pid{
     float SetSpeed;            //定义设定值
@@ -783,69 +815,186 @@ float PID_realize(float speed, float act){
 
 void InkJetPrinter::pressureAdj(int type)
 {
-    //float u, actual;
+    if(sysPara->status.gearPumpRunStopFlag || sysPara->status.flagOfSpeedAlarm)
-    signed short delta_u;
+    {
-    signed short old = (signed short)sysPara->para.gearPumpValue;
+        sysPara->para.gearPumpValue = 0;
-    static unsigned int oldPressure = 0;
+        u              = 0.0f;
-    static qint32 printOut = 0;
+        m_rampDone     = false;
-    if(printOut++%2 !=0) {
+        m_adjSkip      = 0;
+        m_lastAvgPressure = 0;
+        m_bufValidCount = 0;
+        for(int i = 0; i < 20; i++) m_pressureBuf[i] = 0;
+        m_bufIdx = 0;
+        sysPara->devOp->WriteMoterPump();
         return;
     }
 
-    int oldTargetPresuure = sysPara->para.pressure;
+    if(!sysPara->para.gearPumpEnable)
-    if(type == 1){
-        sysPara->para.pressure = sysPara->para.pressure*1.2;
-    }
-    if(!sysPara->status.gearPumpRunStopFlag)
     {
-        if(u > 0 || ((sysPara->para.pressure - sysPara->status.PRESSURE) > 0) )
+        // 非齿轮泵模式：沿用原有位置式PID
-        {
+        if(u > 0 || ((sysPara->para.pressure - sysPara->status.PRESSURE) > 0))
-            u=PID_realize((float)sysPara->para.pressure,(float)sysPara->status.PRESSURE);
+            u = PID_realize((float)sysPara->para.pressure, (float)sysPara->status.PRESSURE);
+        sysPara->para.gearPumpValue = (u > 0) ? (unsigned short)u : 0;
+        if(sysPara->para.gearPumpValue > 800)
+            sysPara->para.gearPumpValue = 800;
+        sysPara->devOp->WriteMoterPump();
+        return;
     }
+
+    //回收泵模式限速
+    int maxValue = sysPara->para.flagOfReclaimPumEnable ? 420 : 800;
+    if(maxValue < 60) maxValue = 60;
+
+    int maxSpeed = (int)sysPara->para.gearPumpSpeedAlarm;
+
+    int actual = sysPara->status.PRESSURE;
+    int target = (int)sysPara->para.pressure;
+    int cur;
+
+    //每次进入都更新滑动平均缓冲
+    m_pressureBuf[m_bufIdx] = actual;
+    m_bufIdx = (m_bufIdx + 1) % 20;
+    if(m_bufValidCount < 20) m_bufValidCount++;  // 累积有效点数
+
+    // 优化：缓冲区未满时只对有效数据求平均，避免0值拉低平均值
+    int avgPressure = 0;
+    for(int i = 0; i < m_bufValidCount; i++) {
+        avgPressure += m_pressureBuf[i];
     }
-    //u=PID_realize(350.0,(float)sysPara->status.PRESSURE);
+    avgPressure /= m_bufValidCount;
-    if(u > 0)
+
+    //硬保护：压力超过目标+50，立即强制减速，优先级最高
+    if(actual > target + 50)
     {
-        sysPara->para.gearPumpValue = (unsigned short)u;
+        float overErr = (float)(actual - (target + 50));
+        float delta   = -0.1f * overErr;
+        if(delta < -15.0f) delta = -15.0f;
+        u += delta;
+        if(u < 60.0f)           u = 60.0f;
+        if(u > (float)maxValue) u = (float)maxValue;
+        m_lastAvgPressure = actual;
+        sysPara->para.gearPumpValue = (unsigned short)(int)u;
+        sysPara->devOp->WriteMoterPump();
+        return;
+    }
+
+    // 软启动：自适应步长，每 800ms 一次
+    // 自检期间也走此逻辑，自检完成后重置重新收敛
+    // 软启动阶段不做压力稳定检测，优先快速收敛
+    if(!m_rampDone)
+    {
+        if(++m_adjSkip < 8)
+        {
+            sysPara->para.gearPumpValue = (unsigned short)(int)u;
+            sysPara->devOp->WriteMoterPump();
+            return;
+        }
+        m_adjSkip = 0;
+
+        int err = target - actual;
+
+        if(err < 0)
+        {
+            // 超压：小步减速
+            u -= 1.0f;
         }
         else
         {
-        sysPara->para.gearPumpValue = 0;
+            // 自适应步长：差得远步子大，差得近步子小
+            float step;
+            if     (err > 200) step = 5.0f;
+            else if(err > 100) step = 3.0f;
+            else if(err > 50)  step = 2.0f;
+            else               step = 1.0f;
+            u += step;
         }
 
-    if(sysPara->para.gearPumpValue>800) {
+        if(u < 60.0f)           u = 60.0f;
-        sysPara->para.gearPumpValue = 800;
+        if(u > (float)maxValue) u = (float)maxValue;
-    }
-    /*********************改回收泵后压力调整*********************************/
-    if(sysPara->para.gearPumpValue && sysPara->para.flagOfReclaimPumEnable){
-        sysPara->para.gearPumpValue = (sysPara->para.gearPumpValue + old)/2;
-        if(sysPara->status.selfCheckDone){
-            float ratio;
-            float ratio_c;
-            ratio = (float)sysPara->status.PRESSURE/sysPara->para.pressure;
-            if(sysPara->status.PRESSURE < oldPressure){
-                if((ratio > 1.02 && ratio < 1.8) ||
-                        (ratio > 0.2 && ratio < 0.98)){
-                    ratio_c = ratio*1.15;
-                    sysPara->para.gearPumpValue = (int)(sysPara->para.gearPumpValue*ratio_c);
-                }
-            }
-        }
-        if(sysPara->para.gearPumpValue < 60){
-            sysPara->para.gearPumpValue = 75;
-        }
-    }
-    /************************************************************/
 
-    if(sysPara->status.gearPumpRunStopFlag)
+        // 转速上限保护：VX4特有，防止回收泵模式下转速超标
+        if(sysPara->para.flagOfReclaimPumEnable &&
+           sysPara->status.gearPumpRunSpeed >= maxSpeed)
         {
-        sysPara->para.gearPumpValue = 0;
+            u -= 3.0f;
+            if(u < 60.0f)           u = 60.0f;
+            if(u > (float)maxValue) u = (float)maxValue;
         }
-    if(sysPara->status.flagOfSpeedAlarm)
+
-        sysPara->para.gearPumpValue = 0;
+        cur = (int)u;
+
+        // 进入闭环条件：压力已接近目标±30以内
+        if(sysPara->status.selfCheckDone && err >= -30 && err <= 30)
+        {
+            m_rampDone = true;
+            m_adjSkip  = 0;
+        }
+
+        sysPara->para.gearPumpValue = (unsigned short)cur;
         sysPara->devOp->WriteMoterPump();
-    oldPressure = sysPara->status.PRESSURE;
+        return;
-    sysPara->para.pressure = oldTargetPresuure;
+    }
+
+    //闭环：使用实时压力做快速小步修正，每200ms调整一次
+    {
+        m_adjSkip++;
+        if(m_adjSkip < 2)
+        {
+            sysPara->para.gearPumpValue = (unsigned short)(int)u;
+            sysPara->devOp->WriteMoterPump();
+            return;
+        }
+        m_adjSkip = 0;
+
+        float err = (float)(target - actual);
+        float absErr = err;
+        if(absErr < 0.0f) absErr = -absErr;
+
+        if(absErr < 0.5f)
+        {
+            m_lastAvgPressure = actual;
+            sysPara->para.gearPumpValue = (unsigned short)(int)u;
+            sysPara->devOp->WriteMoterPump();
+            return;
+        }
+
+        int pressureChange = actual - m_lastAvgPressure;
+        m_lastAvgPressure = actual;
+
+        float delta_u;
+        if(absErr <= 5.0f &&
+           ((err > 0.0f && pressureChange > 0) ||
+            (err < 0.0f && pressureChange < 0)))
+        {
+            delta_u = -0.20f * (float)pressureChange;
+        }
+        else
+        {
+            delta_u = 0.05f * err - 0.20f * (float)pressureChange;
+        }
+
+        float maxDelta;
+        if(absErr > 30.0f)      maxDelta = 1.0f;
+        else if(absErr > 10.0f) maxDelta = 0.6f;
+        else                    maxDelta = 0.3f;
+
+        if(delta_u > maxDelta)  delta_u = maxDelta;
+        if(delta_u < -maxDelta) delta_u = -maxDelta;
+
+        if(sysPara->para.flagOfReclaimPumEnable &&
+           sysPara->status.gearPumpRunSpeed >= maxSpeed)
+        {
+            if(delta_u > 0.0f) delta_u = 0.0f;
+        }
+
+        u += delta_u;
+        if(u < 60.0f)           u = 60.0f;
+        if(u > (float)maxValue) u = (float)maxValue;
+        cur = (int)u;
+
+        sysPara->para.gearPumpValue = (unsigned short)cur;
+        sysPara->devOp->WriteMoterPump();
+    }
 }
 
 void InkJetPrinter::DacAdjustStore()
@@ -1163,6 +1312,20 @@ void InkJetPrinter::timerHandler(void){
             ControledSwitchFlag = false;
             pulse_3s = 0;
         }
+        // 直接恢复压力控制，不走 gearPumpStartFlag 的 3s 等待
+        // 平滑切换，避免手动操作后自动恢复时出现压力突变
+        if(m_lastByHand && !sysPara->status.isPumpValveControledByHand)
+        {
+            ControledSwitchFlag = true;
+            u              = (float)sysPara->para.gearPumpValue; // 同步当前转速，避免突变
+            m_rampDone     = false;  // 重新软启动，适应切换后的压力状态
+            m_adjSkip      = 0;
+            m_lastAvgPressure = 0;
+            m_bufValidCount = 0;
+            for(int i = 0; i < 20; i++) m_pressureBuf[i] = 0;
+            m_bufIdx = 0;
+        }
+        m_lastByHand = sysPara->status.isPumpValveControledByHand;
         if(!(sysPara->status.statWarn & WARN_STATUS_INK_SWINT)){//墨线开关,压力抖动
             InkSwintFlag = true;
         }
@@ -1530,11 +1693,19 @@ void InkJetPrinter::timerHandler(void){
                     if(sysPara->status.selfCheckCnt >= MAX_SELF_CHECK_CNT)
                     {
                         sysPara->status.selfCheckDone = 1;
+                        // 自检完成平滑进入闭环，不强制跳转造成扰动
+                        m_rampDone = true;
+                        m_adjSkip  = 0;
+                        // 同步 gearPumpValue 与 u，防止两者不一致
+                        sysPara->para.gearPumpValue = (unsigned short)u;
                         LogInfo::setRunStatusText(tr("自检完成!!!"));
                         ui->tabMainWindow->setRunStatus(tr("自检完成!!!"));
                         qDebug()<<"自检完成!!!";
                         ui->tabPrintSetting->PrintSettingLog();
                         ui->tabMainWindow->enableReclaimCtrlButton(true);
+
+                        // 先让软件更新泵/阀的期望状态
+                        autoControlValvePump();
                         sysPara->devOp->mainInkCtrl();
                         sysPara->status.canRunAirPushing = true;
                         if(sysPara->para.Reciclar)
@@ -1552,7 +1723,28 @@ void InkJetPrinter::timerHandler(void){
                     if (!sysPara->status.airPushing || ui->tabMainWindow->m_2sFlag) {
                         autoControlValvePump();
                     }
-                    if(sysPara->para.gearPumpEnable && !sysPara->status.isPumpValveControledByHand && ControledSwitchFlag) {
+                    // 检测回收泵模式切换，切换时重置泄漏保护学习状态和软启动状态
+                    if(m_lastReclaimMode != sysPara->para.flagOfReclaimPumEnable)
+                    {
+                        m_lastReclaimMode      = sysPara->para.flagOfReclaimPumEnable;
+                        gearPumpRunNormalFlag  = false;   // 泄漏保护重新学习
+                        gearPumpRunNormalValue = 0.0f;
+
+                        // 仅在压力偏离目标较大时才重置软启动
+                        // 避免模式抖动导致反复重新爬坡
+                        int err = (int)sysPara->para.pressure - sysPara->status.PRESSURE;
+                        if(err < -100 || err > 100) {
+                            m_rampDone     = false;       // 误差大时重新软启动
+                            m_adjSkip      = 0;
+                            m_lastAvgPressure = 0;
+                            m_bufValidCount = 0;
+                            for(int i = 0; i < 20; i++) m_pressureBuf[i] = 0;
+                            m_bufIdx = 0;
+                        }
+                        // 否则保持当前控制状态，只更新maxValue限制
+                    }
+                    // 压力调节改为100ms调用一次
+                    if(pulse_100ms && sysPara->para.gearPumpEnable && !sysPara->status.isPumpValveControledByHand && ControledSwitchFlag) {
                         pressureAdj(0);
                     }
                 }

InkJetPrinter.h

@@ -132,6 +132,16 @@ private:
     bool pushButtonStartFlag;
 
     unsigned char rWarnViscoReady;
+
+    //压力控制相关状态变量
+    bool   m_rampDone     = false;  // 软启动完成标志
+    int    m_adjSkip      = 0;      // 节拍计数（闭环500ms周期）
+    int    m_lastAvgPressure = 0;   // 上次平均压力（微分项用）
+    int    m_pressureBuf[20] = {};  // 压力滑动平均缓冲（20点=2s）
+    int    m_bufIdx       = 0;      // 滑动平均写入索引
+    int    m_bufValidCount = 0;     // 缓冲区有效数据点数（0~20）
+    bool   m_lastReclaimMode = false; // 上次 flagOfReclaimPumEnable 状态
+    bool   m_lastByHand     = false;  // 上次 isPumpValveControledByHand 状态
 };
 
 #endif // INKJETPRINTER_H