246 lines
9.3 KiB
Python
246 lines
9.3 KiB
Python
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"""
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Modbus TCP Server for Calejo Control Adapter.
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Provides Modbus TCP interface for SCADA systems to access setpoints and status.
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"""
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import asyncio
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from typing import Dict, Optional
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from datetime import datetime
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import structlog
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from pymodbus.server import StartAsyncTcpServer
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from pymodbus.datastore import ModbusSequentialDataBlock
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from pymodbus.datastore import ModbusSlaveContext, ModbusServerContext
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from pymodbus.transaction import ModbusSocketFramer
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from src.core.setpoint_manager import SetpointManager
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logger = structlog.get_logger()
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class ModbusServer:
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"""Modbus TCP Server for Calejo Control Adapter."""
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def __init__(
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self,
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setpoint_manager: SetpointManager,
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host: str = "0.0.0.0",
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port: int = 502,
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unit_id: int = 1
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):
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self.setpoint_manager = setpoint_manager
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self.host = host
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self.port = port
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self.unit_id = unit_id
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self.server = None
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self.context = None
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# Memory mapping
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self.holding_registers = None
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self.input_registers = None
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self.coils = None
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# Register mapping configuration
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self.REGISTER_CONFIG = {
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'SETPOINT_BASE': 0, # Holding register 0-99: Setpoints (Hz * 10)
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'STATUS_BASE': 100, # Input register 100-199: Status codes
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'SAFETY_BASE': 200, # Input register 200-299: Safety status
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'EMERGENCY_STOP_COIL': 0, # Coil 0: Emergency stop status
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'FAILSAFE_COIL': 1, # Coil 1: Failsafe mode status
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}
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# Pump address mapping
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self.pump_addresses = {} # (station_id, pump_id) -> register_offset
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async def start(self):
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"""Start the Modbus TCP server."""
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try:
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# Initialize data blocks
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await self._initialize_datastore()
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# Start server
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self.server = await StartAsyncTcpServer(
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context=self.context,
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framer=ModbusSocketFramer,
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address=(self.host, self.port),
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defer_start=False
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)
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logger.info(
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"modbus_server_started",
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host=self.host,
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port=self.port,
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unit_id=self.unit_id
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)
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# Start background task to update registers
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asyncio.create_task(self._update_registers_loop())
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except Exception as e:
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logger.error("failed_to_start_modbus_server", error=str(e))
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raise
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async def stop(self):
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"""Stop the Modbus TCP server."""
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if self.server:
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# Note: pymodbus doesn't have a direct stop method
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# We'll rely on the task being cancelled
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logger.info("modbus_server_stopping")
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async def _initialize_datastore(self):
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"""Initialize the Modbus data store."""
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# Initialize data blocks
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# Holding registers (read/write): Setpoints
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self.holding_registers = ModbusSequentialDataBlock(
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self.REGISTER_CONFIG['SETPOINT_BASE'],
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[0] * 100 # 100 registers for setpoints
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)
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# Input registers (read-only): Status and safety
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self.input_registers = ModbusSequentialDataBlock(
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self.REGISTER_CONFIG['STATUS_BASE'],
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[0] * 200 # 200 registers for status
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)
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# Coils (read-only): Binary status
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self.coils = ModbusSequentialDataBlock(
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self.REGISTER_CONFIG['EMERGENCY_STOP_COIL'],
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[False] * 10 # 10 coils for binary status
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)
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# Create slave context
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store = ModbusSlaveContext(
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hr=self.holding_registers, # Holding registers
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ir=self.input_registers, # Input registers
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co=self.coils, # Coils
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zero_mode=True
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)
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# Create server context
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self.context = ModbusServerContext(slaves=store, single=True)
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# Initialize pump address mapping
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await self._initialize_pump_mapping()
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async def _initialize_pump_mapping(self):
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"""Initialize mapping between pumps and Modbus addresses."""
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stations = self.setpoint_manager.discovery.get_stations()
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address_counter = 0
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for station in stations:
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station_id = station['station_id']
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pumps = self.setpoint_manager.discovery.get_pumps(station_id)
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for pump in pumps:
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pump_id = pump['pump_id']
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# Assign register addresses
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self.pump_addresses[(station_id, pump_id)] = {
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'setpoint_register': address_counter,
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'status_register': address_counter + self.REGISTER_CONFIG['STATUS_BASE'],
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'safety_register': address_counter + self.REGISTER_CONFIG['SAFETY_BASE']
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}
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address_counter += 1
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# Don't exceed available registers
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if address_counter >= 100:
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logger.warning("modbus_register_limit_reached")
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break
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async def _update_registers_loop(self):
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"""Background task to update Modbus registers periodically."""
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while True:
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try:
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await self._update_registers()
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await asyncio.sleep(5) # Update every 5 seconds
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except Exception as e:
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logger.error("failed_to_update_registers", error=str(e))
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await asyncio.sleep(10) # Wait longer on error
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async def _update_registers(self):
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"""Update all Modbus register values."""
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# Update pump setpoints and status
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for (station_id, pump_id), addresses in self.pump_addresses.items():
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try:
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# Get current setpoint
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setpoint = self.setpoint_manager.get_current_setpoint(station_id, pump_id)
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if setpoint is not None:
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# Convert setpoint to integer (Hz * 10 for precision)
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setpoint_int = int(setpoint * 10)
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# Update holding register (setpoint)
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self.holding_registers.setValues(
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addresses['setpoint_register'],
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[setpoint_int]
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)
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# Determine status code
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status_code = 0 # Normal operation
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safety_code = 0 # Normal safety
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if self.setpoint_manager.emergency_stop_manager.is_emergency_stop_active(station_id, pump_id):
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status_code = 2 # Emergency stop
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safety_code = 1
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elif self.setpoint_manager.watchdog.is_failsafe_active(station_id, pump_id):
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status_code = 1 # Failsafe mode
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safety_code = 2
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# Update input registers (status and safety)
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self.input_registers.setValues(
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addresses['status_register'],
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[status_code]
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)
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self.input_registers.setValues(
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addresses['safety_register'],
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[safety_code]
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)
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except Exception as e:
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logger.error(
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"failed_to_update_pump_registers",
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station_id=station_id,
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pump_id=pump_id,
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error=str(e)
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)
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# Update global status coils
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try:
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# Check if any emergency stops are active
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any_emergency_stop = (
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self.setpoint_manager.emergency_stop_manager.system_emergency_stop or
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len(self.setpoint_manager.emergency_stop_manager.emergency_stop_stations) > 0 or
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len(self.setpoint_manager.emergency_stop_manager.emergency_stop_pumps) > 0
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)
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# Check if any failsafe modes are active
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any_failsafe = any(
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self.setpoint_manager.watchdog.is_failsafe_active(station_id, pump_id)
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for (station_id, pump_id) in self.pump_addresses.keys()
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)
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# Update coils
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self.coils.setValues(
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self.REGISTER_CONFIG['EMERGENCY_STOP_COIL'],
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[any_emergency_stop]
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)
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self.coils.setValues(
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self.REGISTER_CONFIG['FAILSAFE_COIL'],
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[any_failsafe]
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)
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except Exception as e:
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logger.error("failed_to_update_status_coils", error=str(e))
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def get_pump_setpoint_address(self, station_id: str, pump_id: str) -> Optional[int]:
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"""Get Modbus register address for a pump's setpoint."""
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addresses = self.pump_addresses.get((station_id, pump_id))
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return addresses['setpoint_register'] if addresses else None
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def get_pump_status_address(self, station_id: str, pump_id: str) -> Optional[int]:
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"""Get Modbus register address for a pump's status."""
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addresses = self.pump_addresses.get((station_id, pump_id))
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return addresses['status_register'] if addresses else None
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