6月29日崩溃前缓存

InkJetPrinter.cpp

@@ -387,102 +387,228 @@ float PID_realize(float speed, float act){
 }
 
 float PID_realize2(float speed, float act){
-    pid.Kp = 0.8;
-    pid.Ki = 0.02;
-    pid.Kd = 0.5;
-    pid.integral_max = 12000;
-    pid.SetSpeed=speed;
+    // 增量式 PID：Δu = Kp*(e[k]-e[k-1]) + Ki*e[k]
+    pid.Kp = 0.15f;
+    pid.Ki = 0.02f;
+    pid.Kd = 0.0f;
+    pid.SetSpeed    = speed;
     pid.ActualSpeed = act;
-    pid.err=pid.SetSpeed-pid.ActualSpeed;
+    pid.err         = pid.SetSpeed - pid.ActualSpeed;
 
-    float Pout = pid.Kp * pid.err;
-    pid.integral += pid.err;
-    if (pid.integral > pid.integral_max) {
-            pid.integral = pid.integral_max;
-        } else if (pid.integral < -pid.integral_max) {
-            pid.integral = -pid.integral_max;
-        }
-    float Iout = pid.Ki * pid.integral;
-    float Dout = pid.Kd * ((pid.err + pid.err_last)/2 - pid.err_last);
+    float delta_u = pid.Kp * (pid.err - pid.err_last)
+            + pid.Ki * pid.err;
 
-    pid.voltage = Pout + Iout + Dout;
-    pid.err_last=pid.err;
-    return pid.voltage;
+    // 自适应非对称限幅：
+    // 压力严重偏高（err < -30）：允许快速减速，限制慢速加速
+    // 压力严重偏低（err > 50）：允许正常加速，限制减速（避免过度降速）
+    // 接近目标：小步长，平稳调节
+    if(pid.err < -30.0f) {
+        if(delta_u >  1.0f) delta_u =  1.0f;
+        if(delta_u < -6.0f) delta_u = -6.0f;
+    } else if(pid.err > 50.0f) {
+        if(delta_u >  3.0f) delta_u =  3.0f;
+        if(delta_u < -2.0f) delta_u = -2.0f;
+    } else {
+        if(delta_u >  3.0f) delta_u =  3.0f;
+        if(delta_u < -3.0f) delta_u = -3.0f;
+    }
+
+    pid.err_last = pid.err;
+    return delta_u;
 }
 
 void InkJetPrinter::pressureAdj()
 {
-    //float u, actual;
-    signed short delta_u;
-    signed short old = (signed short)sysPara->para.gearPumpValue;
-    static unsigned int oldPressure = 0;
-    static qint32 printOut = 0;
-    if(printOut++%2 !=0) {
+    if(sysPara->status.gearPumpRunStopFlag || sysPara->status.flagOfSpeedAlarm)
+    {
+        sysPara->para.gearPumpValue = 0;
+        u              = 0.0f;
+        m_rampDone     = false;
+        m_adjSkip      = 0;
+        m_lastPressure = 0;
+        m_stableCount  = 0;
+        for(int i = 0; i < 10; i++) m_pressureBuf[i] = 0;
+        m_bufIdx = 0;
+        sysPara->devOp->WriteMoterPump();
         return;
     }
-    static qint32 dbgCnt = 0;
-    if(++dbgCnt % 50 == 0){
-        // qDebug()<<"[pressureAdj] pressure="<<sysPara->para.pressure
-        //         <<" PRESSURE="<<sysPara->status.PRESSURE
-        //         <<" gearPumpValue="<<sysPara->para.gearPumpValue
-        //         <<" u="<<u
-        //         <<" flagOfReclaimPumEnable="<<sysPara->para.flagOfReclaimPumEnable
-        //         <<" gearPumpSpeedAlarm="<<sysPara->para.gearPumpSpeedAlarm
-        //         <<" gearPumpRunStopFlag="<<sysPara->status.gearPumpRunStopFlag
-        //         <<" flagOfSpeedAlarm="<<sysPara->status.flagOfSpeedAlarm;
+
+    if(!sysPara->para.gearPumpEnable)
+    {
+        if(u > 0 || ((sysPara->para.pressure - sysPara->status.PRESSURE) > 0))
+            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;
     }
 
-    if(!sysPara->status.gearPumpRunStopFlag)
+    int maxValue = sysPara->para.flagOfReclaimPumEnable ? 420 : 800;
+    if(maxValue < 60) maxValue = 60;
+
+    int maxSpeed = (int)sysPara->para.gearPumpSpeedAlarm;
+
+    auto clampU = [&]() {
+        if(u < 60.0f)           u = 60.0f;
+        if(u > (float)maxValue) u = (float)maxValue;
+    };
+
+    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（软启动用瞬时值，闭环用平均值）
+    m_pressureBuf[m_bufIdx] = actual;
+    m_bufIdx = (m_bufIdx + 1) % 10;
+    int avgPressure = 0;
+    for(int i = 0; i < 10; i++) avgPressure += m_pressureBuf[i];
+    avgPressure /= 10;
+
+    // ---------------------------------------------------------------
+    // 硬保护：压力超过目标+50，立即强制减速，优先级最高
+    // 覆盖自检、软启动、闭环所有阶段
+    // ---------------------------------------------------------------
+    if(actual > target + 50)
     {
-        if(sysPara->para.gearPumpEnable && sysPara->para.flagOfReclaimPumEnable)
+        float overErr = (float)(actual - (target + 50));
+        float delta   = -0.1f * overErr;
+        if(delta < -15.0f) delta = -15.0f;
+        u += delta;
+        clampU();
+        m_lastPressure = actual;
+        sysPara->para.gearPumpValue = (unsigned short)(int)u;
+        sysPara->devOp->WriteMoterPump();
+        return;
+    }
 
-
-            u=PID_realize2((float)sysPara->para.pressure,(float)sysPara->status.PRESSURE);
-
-        else if(u > 0 || ((sysPara->para.pressure - sysPara->status.PRESSURE) > 0) )
+    // ---------------------------------------------------------------
+    // 软启动：自适应步长，每 800ms 一次
+    // 自检期间也走此逻辑（硬保护兜底），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)
         {
-            //
-            u=PID_realize((float)sysPara->para.pressure,(float)sysPara->status.PRESSURE);
+            sysPara->para.gearPumpValue = (unsigned short)(int)u;
+            sysPara->devOp->WriteMoterPump();
+            return;
         }
-    }
+        m_adjSkip = 0;
 
-    if(u > 0)
-    {
-        sysPara->para.gearPumpValue = (unsigned short)u;
-    }
-    else
-    {
-        sysPara->para.gearPumpValue = 0;
-    }
-    if(sysPara->para.gearPumpValue>800) {
-        sysPara->para.gearPumpValue = 800;
-    }
-    /*********************改回收泵后压力调整*********************************/
-    if(sysPara->para.gearPumpValue && sysPara->para.flagOfReclaimPumEnable){
-        int maxValue;
-        if(sysPara->para.gearPumpSpeedAlarm <= 1200){
-            maxValue = 200 + (sysPara->para.pressure - 500)*0.1;
-            if(maxValue > 260) maxValue = 260;
-        }else{
-            maxValue = 350 + (sysPara->para.pressure - 500)*0.1;
-            if(maxValue > 420) maxValue = 420;
+        int err = target - actual;
+
+        if(err < 0)
+        {
+            // 超压：小步减速
+            u -= 1.0f;
+        }
+        else
+        {
+            // 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 < 60)
-            sysPara->para.gearPumpValue = 75;
-        else if(sysPara->para.gearPumpValue > maxValue)
-            sysPara->para.gearPumpValue = maxValue;
-    }
-    /************************************************************/
+        clampU();
 
-    if(sysPara->status.gearPumpRunStopFlag)
+        // 转速上限保护
+        if(sysPara->para.flagOfReclaimPumEnable &&
+                sysPara->status.gearPumpRunSpeed >= maxSpeed)
+        {
+            u -= 3.0f;
+            clampU();
+        }
+
+        cur = (int)u;
+
+        // 进入闭环条件：压力已稳定在目标±50以内
+        if(sysPara->status.selfCheckDone && err >= -50 && err <= 50)
+        {
+            m_rampDone = true;
+            m_adjSkip  = 0;
+        }
+
+        sysPara->para.gearPumpValue = (unsigned short)cur;
+        sysPara->devOp->WriteMoterPump();
+        return;
+    }
+
+    // ---------------------------------------------------------------
+    // 闭环：等压力稳定后再调速，自适应管路响应时间
+    //
+    // 每100ms采样一次，连续3次压力变化<15认为稳定，才执行调速
+    // 最长等待5s（50次）兜底，防止管路持续抖动导致永远不调
+    //
+    // 调速后立即重置稳定计数，重新等待下一次稳定
+    //
+    // 分区Kp：误差大步子大，误差小步子小
+    //   |err| > 100 → Kp=0.05，限幅±5
+    //   |err| 50~100→ Kp=0.04，限幅±4
+    //   |err| < 50  → Kp=0.03，限幅±3
+    // ---------------------------------------------------------------
     {
-        sysPara->para.gearPumpValue = 0;
+        // 稳定检测用平均值，滤掉传感器噪声
+        int pressureChange = avgPressure - m_lastPressure;
+        if(pressureChange < 0) pressureChange = -pressureChange;
+        m_lastPressure = avgPressure;
+        m_adjSkip++;  // 复用为超时计数
+
+        bool stable  = (pressureChange < 10);
+        bool timeout = (m_adjSkip >= 50);  // 5s兜底
+
+        if(stable)
+            m_stableCount++;
+        else
+            m_stableCount = 0;
+
+        bool readyToAdj = (m_stableCount >= 15) || timeout;
+
+        if(!readyToAdj)
+        {
+            sysPara->para.gearPumpValue = (unsigned short)(int)u;
+            sysPara->devOp->WriteMoterPump();
+            return;
+        }
+
+        // 平均压力已稳定（或超时兜底），执行调速，重置计数
+        m_adjSkip     = 0;
+        m_stableCount = 0;
+
+        // 误差用平均值计算，避免瞬时噪声影响调速幅度
+        float absErr = (float)(target - avgPressure);
+        if(absErr < 0.0f) absErr = -absErr;
+
+        float kp, capDelta;
+        if(absErr > 100.0f)      { kp = 0.05f; capDelta = 5.0f; }
+        else if(absErr > 50.0f)  { kp = 0.04f; capDelta = 4.0f; }
+        else                     { kp = 0.03f; capDelta = 3.0f; }
+
+        float err     = (float)(target - avgPressure);
+        float delta_u = kp * err;
+
+        if(delta_u >  capDelta) delta_u =  capDelta;
+        if(delta_u < -capDelta) delta_u = -capDelta;
+
+        // 转速上限软限制：转速已达上限时禁止继续加速
+        if(sysPara->para.flagOfReclaimPumEnable &&
+                sysPara->status.gearPumpRunSpeed >= maxSpeed)
+        {
+            if(delta_u > 0.0f) delta_u = 0.0f;
+        }
+
+        u += delta_u;
+        clampU();
+        cur = (int)u;
+
+        sysPara->para.gearPumpValue = (unsigned short)cur;
+        sysPara->devOp->WriteMoterPump();
     }
-    if(sysPara->status.flagOfSpeedAlarm)
-        sysPara->para.gearPumpValue = 0;
-    sysPara->devOp->WriteMoterPump();
-    oldPressure = sysPara->status.PRESSURE;
 }
 
 
@@ -580,10 +706,11 @@ void InkJetPrinter::timerHandler(void){
             if(!(sysPara->status.statWarn & WARN_STATUS_INK_WARN) && !gearPumpRunFlag && !sysPara->status.isPumpValveControledByHand)//刚启动前3秒
             {
                 if(sysPara->para.gearPumpEnable) {
-                    sysPara->para.gearPumpValue = 150;
-                    if(tempFlag){
+                    // 确保开机时控制字从 0 开始，让 pressureAdj 软启动从 0 爬坡，避免突变到高转速
+                    if(sysPara->para.gearPumpValue != 0) {
+                        sysPara->para.gearPumpValue = 0;
+                        u = 0.0f;
                         sysPara->devOp->WriteMoterPump();
-                        tempFlag=0;
                     }
                     gearPumpStartFlag = true;
                 }
@@ -613,6 +740,19 @@ void InkJetPrinter::timerHandler(void){
             ControledSwitchFlag = false;
             pulse_3s = 0;
         }
+        // 检测手动→自动边沿，直接恢复压力控制，不走 gearPumpStartFlag 的 3s 等待
+        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_lastPressure = 0;
+            m_stableCount  = 0;
+            for(int i = 0; i < 10; 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;
         }
@@ -654,6 +794,19 @@ void InkJetPrinter::timerHandler(void){
             test_flag = 0;
         }
         if(pulse_1s) {
+            // 回收泵模式切换时重置软启动和泄漏保护学习状态
+            if(m_lastReclaimMode != sysPara->para.flagOfReclaimPumEnable)
+            {
+                m_lastReclaimMode      = sysPara->para.flagOfReclaimPumEnable;
+                gearPumpRunNormalFlag  = false;
+                gearPumpRunNormalValue = 0.0f;
+                m_rampDone     = false;
+                m_adjSkip      = 0;
+                m_lastPressure = 0;
+                m_stableCount  = 0;
+                for(int i = 0; i < 10; i++) m_pressureBuf[i] = 0;
+                m_bufIdx = 0;
+            }
             if(sysPara->status.selfCheckDone && sysPara->para.gearPumpEnable && sysPara->para.flagOfReclaimPumEnable)
                 checkPressureControl();
             if((QTime::currentTime()>=QTime(00,00,00))&&(QTime::currentTime()<=QTime(00,00,02))&&sysPara->para.Reciclar){
@@ -881,6 +1034,15 @@ void InkJetPrinter::timerHandler(void){
                     if(sysPara->status.selfCheckCnt >= MAX_SELF_CHECK_CNT)
                     {
                         sysPara->status.selfCheckDone = 1;
+                        // 自检完成后管道恢复正常阻力，重置软启动让压力重新平稳收敛
+                        // 不清零 u，从当前控制字开始，避免突变
+                        u = (float)sysPara->para.gearPumpValue;
+                        m_rampDone     = false;
+                        m_adjSkip      = 0;
+                        m_lastPressure = 0;
+                        m_stableCount  = 0;
+                        for(int i = 0; i < 10; i++) m_pressureBuf[i] = 0;
+                        m_bufIdx = 0;
                         LogInfo::setRunStatusText(tr("自检完成!!!"));
                         m_MainWidget->setRunStatus(tr("自检完成!!!"));
                         qDebug()<<"自检完成!!!";