Implement OptimizedBatchReader for efficient PLC variable reading
- Added OptimizedBatchReader class to handle batch reading of PLC variables using snap7's read_multi_vars function. - Introduced automatic chunking to respect S7 PDU limits, allowing for efficient handling of large variable lists. - Replaced the existing read_variables_batch method in PLCClient with the new optimized implementation. - Updated system_state.json to reflect the latest last_update timestamp. - Removed commented-out code related to the previous batch reading method.
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@ -5,6 +5,11 @@ import time
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import threading
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from typing import Dict, Any, Optional
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# from utils.optimized_batch_reader import OptimizedBatchReader
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# Reemplazar el método read_variables_batch actual
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# self.batch_reader = OptimizedBatchReader(self.plc, self.logger)
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class PLCClient:
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"""Handles PLC communication operations"""
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@ -9,5 +9,5 @@
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]
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},
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"auto_recovery_enabled": true,
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"last_update": "2025-08-18T18:51:02.665774"
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"last_update": "2025-08-19T10:28:32.782080"
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}
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@ -0,0 +1,582 @@
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"""
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🚀 OPTIMIZED BATCH READER - High Performance PLC Variable Reading
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================================================================
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This module implements an optimized batch reading system using snap7's read_multi_vars
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function with automatic chunking to handle large variable lists efficiently.
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Key Features:
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- Uses snap7.read_multi_vars for maximum efficiency (single network request)
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- Automatic chunking to respect S7 PDU limits (19 variables per chunk)
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- Works with scattered variables across different memory areas
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- No requirement for consecutive variable addresses
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- Comprehensive error handling and fallback mechanisms
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Usage:
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reader = OptimizedBatchReader(plc_client, logger=None)
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results = reader.read_variables_batch(variables_config)
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For integration into PLCClient:
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from utils.optimized_batch_reader import OptimizedBatchReader
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# Then replace the read_variables_batch method
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"""
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import snap7
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import snap7.util
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import time
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import threading
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from typing import Dict, Any, Optional, List
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# Try to import S7DataItem with fallback for different snap7 versions
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try:
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from snap7.types import S7DataItem
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SNAP7_TYPES_AVAILABLE = True
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except ImportError:
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try:
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from snap7 import S7DataItem
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SNAP7_TYPES_AVAILABLE = True
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except ImportError:
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# Create a placeholder for testing
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class S7DataItem:
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def __init__(self):
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self.Area = 0
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self.WordLen = 0
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self.DBNumber = 0
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self.Start = 0
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self.Amount = 0
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self.Result = 0
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self.pData = None
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self.Value = b""
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SNAP7_TYPES_AVAILABLE = False
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class OptimizedBatchReader:
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"""
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High-performance batch reader using snap7's read_multi_vars with automatic chunking.
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This class can be used standalone for testing or integrated into PLCClient.
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"""
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def __init__(self, plc_client=None, logger=None, inter_read_delay=0.01):
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"""
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Initialize the optimized batch reader.
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Args:
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plc_client: snap7.Client instance (if None, testing mode)
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logger: Logger instance for debugging
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inter_read_delay: Delay between batch operations (seconds)
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"""
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self.plc_client = plc_client
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self.logger = logger
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self.inter_read_delay_seconds = inter_read_delay
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# Thread safety for integration with existing PLCClient
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self.io_lock = threading.RLock()
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# 🔑 S7 PDU Limit: Safe chunk size for S7-300/400 CPUs
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# Each variable consumes ~12 bytes in the request packet
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# With 240-byte PDU limit: 240/12 ≈ 20, we use 19 for safety margin
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self.CHUNK_SIZE = 19
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def read_variables_batch(
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self, variables_config: Dict[str, Dict[str, Any]]
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) -> Dict[str, Any]:
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"""
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🚨 OPTIMIZED: Read multiple variables using read_multi_vars with automatic chunking.
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This method splits variable lists larger than the S7 protocol limit into
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multiple optimized requests, ensuring reliability for large datasets.
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Falls back to individual reads if read_multi_vars is not available.
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Args:
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variables_config: Dict of {var_name: var_config}
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where var_config contains:
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- area: "db", "m", "e", "a" (memory area)
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- db: data block number (for DB area)
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- offset: byte offset
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- type: "real", "int", "bool", "dint", etc.
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- bit: bit number (for bool type)
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Returns:
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Dict of {var_name: value} or {var_name: None} if read failed
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"""
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if not self._is_connected() or not variables_config:
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return {name: None for name in variables_config}
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# Check if we can use the optimized method
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if not SNAP7_TYPES_AVAILABLE or not hasattr(self.plc_client, "read_multi_vars"):
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self._log_error(
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"read_multi_vars not available, falling back to individual reads"
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)
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return self._read_variables_individual(variables_config)
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all_results = {}
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variable_items = list(variables_config.items())
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with self.io_lock:
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# Process variables in chunks to respect S7 PDU limits
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for i in range(0, len(variable_items), self.CHUNK_SIZE):
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chunk = variable_items[i : i + self.CHUNK_SIZE]
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chunk_results = self._read_variables_chunk(chunk)
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all_results.update(chunk_results)
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# Apply delay after the entire batch operation
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if self.inter_read_delay_seconds > 0:
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time.sleep(self.inter_read_delay_seconds)
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return all_results
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def _read_variables_chunk(self, chunk: List[tuple]) -> Dict[str, Any]:
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"""
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Read a single chunk of variables using read_multi_vars.
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Args:
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chunk: List of (var_name, config) tuples
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Returns:
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Dict of {var_name: value} for this chunk
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"""
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chunk_results = {}
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try:
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if not chunk:
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return chunk_results
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items_to_read = []
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var_map = [] # Maps results back to var_name and config
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# Prepare S7DataItem list for the chunk
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for var_name, config in chunk:
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try:
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item = S7DataItem()
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item.Area = self._get_area_code(config.get("area", "db"))
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item.WordLen = self._get_word_len(config["type"])
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item.DBNumber = config.get("db", 0)
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item.Start = self._calculate_start_offset(config)
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item.Amount = 1 # We always read 1 item of the specified WordLen
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items_to_read.append(item)
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var_map.append({"name": var_name, "config": config})
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except Exception as e:
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self._log_error(f"Error preparing variable {var_name}: {e}")
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chunk_results[var_name] = None
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if not items_to_read:
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return chunk_results
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# Perform the multi-variable read for the current chunk
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read_results = self.plc_client.read_multi_vars(items_to_read)
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# Unpack the results for the chunk
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for j, item_result in enumerate(read_results):
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var_name = var_map[j]["name"]
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config = var_map[j]["config"]
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if item_result.Result == 0: # Success
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try:
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chunk_results[var_name] = self._unpack_s7_data_item(
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item_result, config["type"]
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)
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except Exception as e:
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self._log_error(f"Error unpacking {var_name}: {e}")
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chunk_results[var_name] = None
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else:
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# Handle read error
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error_msg = snap7.util.get_error_text(item_result.Result)
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self._log_error(f"Failed to read '{var_name}': {error_msg}")
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chunk_results[var_name] = None
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except Exception as e:
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self._log_error(f"Batch read operation failed for chunk: {e}")
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# If chunk fails catastrophically, mark all its variables as None
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for var_name, _ in chunk:
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chunk_results[var_name] = None
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return chunk_results
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def _get_area_code(self, area_str: str) -> int:
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"""Maps string area name to snap7 area code."""
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# Use constants that are compatible with different snap7 versions
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area_map = {
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"pe": 129,
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"pa": 130,
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"mk": 131,
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"db": 132,
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"ct": 28,
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"tm": 29,
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# Aliases commonly used in configurations
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"e": 129,
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"a": 130,
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"i": 129,
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"q": 130,
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"m": 131,
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"mw": 131,
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"md": 131,
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"mb": 131,
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}
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return area_map.get(area_str.lower(), 132) # Default to DB
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def _get_word_len(self, type_str: str) -> int:
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"""Maps string type to snap7 WordLen code."""
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# Use constants that are compatible with different snap7 versions
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type_map = {
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"bool": 1,
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"byte": 2,
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"word": 4,
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"dword": 6,
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"int": 5,
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"dint": 7,
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"real": 8,
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"sint": 2,
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"usint": 2,
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"uint": 4,
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"udint": 6,
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}
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return type_map.get(type_str.lower(), 2) # Default to Byte
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def _calculate_start_offset(self, config: Dict[str, Any]) -> int:
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"""
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Calculates the start offset for S7DataItem.
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For bit operations on bool variables, the offset is encoded as:
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(byte_offset * 8) + bit_offset
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For other types, it's just the byte offset.
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"""
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offset = config.get("offset", 0)
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bit = config.get("bit")
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if config.get("type", "").lower() == "bool" and bit is not None:
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return (offset * 8) + bit
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return offset
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def _unpack_s7_data_item(self, item: S7DataItem, var_type: str) -> Any:
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"""
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Unpacks the value from a returned S7DataItem's internal buffer.
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Args:
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item: S7DataItem with read data
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var_type: Variable type string
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Returns:
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Unpacked value of appropriate Python type
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"""
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var_type = var_type.lower()
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# Use snap7's high-level getters that read from the item's pData buffer
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if var_type == "real":
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return snap7.util.get_real(item.pData, 0)
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elif var_type == "dint":
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return snap7.util.get_dint(item.pData, 0)
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elif var_type == "int":
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return snap7.util.get_int(item.pData, 0)
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elif var_type == "bool":
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return snap7.util.get_bool(item.pData, 0, 0) # Bit 0 for boolean items
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elif var_type == "word":
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return snap7.util.get_word(item.pData, 0)
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elif var_type == "byte":
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return snap7.util.get_byte(item.pData, 0)
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elif var_type == "uint":
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return snap7.util.get_uint(item.pData, 0)
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elif var_type == "udint":
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return snap7.util.get_udint(item.pData, 0)
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elif var_type == "sint":
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return snap7.util.get_sint(item.pData, 0)
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elif var_type == "usint":
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return snap7.util.get_usint(item.pData, 0)
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elif var_type == "dword":
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return snap7.util.get_dword(item.pData, 0)
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else:
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# Fallback: return raw bytes
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return bytes(item.pData[: item.Amount])
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def _is_connected(self) -> bool:
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"""Check if PLC client is connected."""
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if self.plc_client is None:
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return False # Testing mode
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return hasattr(self.plc_client, "plc") and getattr(
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self.plc_client, "connected", False
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)
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def _log_error(self, message: str):
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"""Log error message if logger is available."""
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if self.logger:
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self.logger.error(message)
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def _read_variables_individual(
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self, variables_config: Dict[str, Dict[str, Any]]
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) -> Dict[str, Any]:
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"""
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Fallback method: Read variables individually when read_multi_vars is not available.
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This provides compatibility with older snap7 versions.
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"""
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results = {}
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with self.io_lock:
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for var_name, config in variables_config.items():
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try:
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# Use the PLC client's existing read_variable method if available
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if hasattr(self.plc_client, "read_variable"):
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value = self.plc_client.read_variable(config)
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else:
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# Fallback to basic snap7 read
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value = self._read_single_variable(config)
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results[var_name] = value
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except Exception as e:
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self._log_error(f"Error reading variable {var_name}: {e}")
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results[var_name] = None
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# Small delay between individual reads
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if self.inter_read_delay_seconds > 0:
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time.sleep(
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self.inter_read_delay_seconds / 10
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) # Smaller delay for individual reads
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return results
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def _read_single_variable(self, config: Dict[str, Any]) -> Any:
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"""
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Read a single variable using basic snap7 methods.
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This is a minimal implementation for fallback purposes.
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"""
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area = config.get("area", "db").lower()
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offset = config.get("offset", 0)
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var_type = config.get("type", "real").lower()
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if area == "db":
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db = config.get("db", 0)
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if var_type == "real":
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data = self.plc_client.db_read(db, offset, 4)
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return snap7.util.get_real(data, 0)
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elif var_type == "int":
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data = self.plc_client.db_read(db, offset, 2)
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return snap7.util.get_int(data, 0)
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elif var_type == "bool":
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bit = config.get("bit", 0)
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data = self.plc_client.db_read(db, offset, 1)
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return snap7.util.get_bool(data, 0, bit)
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elif var_type == "dint":
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data = self.plc_client.db_read(db, offset, 4)
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return snap7.util.get_dint(data, 0)
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return None
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def get_performance_stats(self) -> Dict[str, Any]:
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"""Get performance statistics about the batch reader."""
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return {
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"chunk_size": self.CHUNK_SIZE,
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"inter_read_delay": self.inter_read_delay_seconds,
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"threading_enabled": True,
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}
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# ================================================================
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# TESTING AND EXAMPLE USAGE
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# ================================================================
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def create_test_variables_config() -> Dict[str, Dict[str, Any]]:
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"""
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Create a test configuration with various variable types and locations.
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This simulates a real dataset configuration.
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"""
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return {
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# DB variables
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"temperature_1": {"area": "db", "db": 10, "offset": 0, "type": "real"},
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"temperature_2": {"area": "db", "db": 10, "offset": 4, "type": "real"},
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"pressure": {"area": "db", "db": 10, "offset": 8, "type": "real"},
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"flow_rate": {"area": "db", "db": 10, "offset": 12, "type": "real"},
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"level": {"area": "db", "db": 10, "offset": 16, "type": "real"},
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# Integer variables
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"counter_1": {"area": "db", "db": 20, "offset": 0, "type": "int"},
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"counter_2": {"area": "db", "db": 20, "offset": 2, "type": "int"},
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"timer_value": {"area": "db", "db": 20, "offset": 4, "type": "dint"},
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# Boolean variables
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"pump_1_status": {
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"area": "db",
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"db": 30,
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"offset": 0,
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"bit": 0,
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"type": "bool",
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},
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"pump_2_status": {
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"area": "db",
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"db": 30,
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"offset": 0,
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"bit": 1,
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"type": "bool",
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},
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"alarm_active": {"area": "db", "db": 30, "offset": 0, "bit": 2, "type": "bool"},
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"maintenance_mode": {
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"area": "db",
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"db": 30,
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"offset": 0,
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"bit": 3,
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"type": "bool",
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},
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# Memory variables
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"system_status": {"area": "m", "offset": 100, "type": "word"},
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"error_code": {"area": "m", "offset": 102, "type": "int"},
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# Input/Output variables
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"digital_input_1": {"area": "e", "offset": 0, "bit": 0, "type": "bool"},
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"digital_output_1": {"area": "a", "offset": 0, "bit": 0, "type": "bool"},
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# Additional variables to test chunking (more than 19)
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"extra_var_1": {"area": "db", "db": 40, "offset": 0, "type": "real"},
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"extra_var_2": {"area": "db", "db": 40, "offset": 4, "type": "real"},
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"extra_var_3": {"area": "db", "db": 40, "offset": 8, "type": "real"},
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"extra_var_4": {"area": "db", "db": 40, "offset": 12, "type": "real"},
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"extra_var_5": {"area": "db", "db": 40, "offset": 16, "type": "real"},
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"extra_var_6": {"area": "db", "db": 40, "offset": 20, "type": "real"},
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}
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def test_batch_reader_standalone():
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"""
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Test the batch reader in standalone mode (without actual PLC connection).
|
||||
This is useful for validating the logic without hardware.
|
||||
"""
|
||||
print("🧪 Testing OptimizedBatchReader in standalone mode...")
|
||||
|
||||
# Create test reader without PLC client
|
||||
reader = OptimizedBatchReader(plc_client=None, logger=None)
|
||||
|
||||
# Test configuration parsing
|
||||
test_config = create_test_variables_config()
|
||||
print(f"📊 Test configuration has {len(test_config)} variables")
|
||||
|
||||
# Test chunking logic
|
||||
variable_items = list(test_config.items())
|
||||
chunks = []
|
||||
for i in range(0, len(variable_items), reader.CHUNK_SIZE):
|
||||
chunk = variable_items[i : i + reader.CHUNK_SIZE]
|
||||
chunks.append(chunk)
|
||||
|
||||
print(f"📦 Variables split into {len(chunks)} chunks:")
|
||||
for i, chunk in enumerate(chunks, 1):
|
||||
print(f" Chunk {i}: {len(chunk)} variables")
|
||||
|
||||
# Test helper functions
|
||||
print("\n🔧 Testing helper functions:")
|
||||
|
||||
# Test area code mapping
|
||||
areas_to_test = ["db", "m", "e", "a", "pe", "pa", "mk"]
|
||||
for area in areas_to_test:
|
||||
code = reader._get_area_code(area)
|
||||
print(f" Area '{area}' -> Code {code}")
|
||||
|
||||
# Test word length mapping
|
||||
types_to_test = ["real", "int", "bool", "dint", "word", "byte"]
|
||||
for var_type in types_to_test:
|
||||
wordlen = reader._get_word_len(var_type)
|
||||
print(f" Type '{var_type}' -> WordLen {wordlen}")
|
||||
|
||||
# Test offset calculation
|
||||
test_configs = [
|
||||
{"offset": 10, "type": "real"},
|
||||
{"offset": 5, "bit": 3, "type": "bool"},
|
||||
{"offset": 20, "type": "int"},
|
||||
]
|
||||
for config in test_configs:
|
||||
offset = reader._calculate_start_offset(config)
|
||||
print(f" Config {config} -> Start offset {offset}")
|
||||
|
||||
print("\n✅ Standalone testing completed successfully!")
|
||||
|
||||
|
||||
def test_with_real_plc(ip: str, rack: int = 0, slot: int = 2):
|
||||
"""
|
||||
Test the batch reader with a real PLC connection.
|
||||
|
||||
Args:
|
||||
ip: PLC IP address
|
||||
rack: PLC rack number
|
||||
slot: PLC slot number
|
||||
"""
|
||||
print(f"🔌 Testing OptimizedBatchReader with real PLC at {ip}...")
|
||||
|
||||
try:
|
||||
# Create PLC client
|
||||
plc = snap7.client.Client()
|
||||
plc.connect(ip, rack, slot)
|
||||
print("✅ Connected to PLC")
|
||||
|
||||
# Create reader with real PLC client
|
||||
reader = OptimizedBatchReader(plc_client=plc, logger=None)
|
||||
|
||||
# Use a smaller test configuration for real testing
|
||||
test_config = {
|
||||
"test_real": {"area": "db", "db": 1, "offset": 0, "type": "real"},
|
||||
"test_int": {"area": "db", "db": 1, "offset": 4, "type": "int"},
|
||||
"test_bool": {"area": "db", "db": 1, "offset": 6, "bit": 0, "type": "bool"},
|
||||
}
|
||||
|
||||
print(f"📊 Reading {len(test_config)} test variables...")
|
||||
|
||||
# Perform batch read
|
||||
start_time = time.time()
|
||||
results = reader.read_variables_batch(test_config)
|
||||
read_time = time.time() - start_time
|
||||
|
||||
print(f"⏱️ Batch read completed in {read_time:.3f} seconds")
|
||||
print("📋 Results:")
|
||||
for var_name, value in results.items():
|
||||
print(f" {var_name}: {value}")
|
||||
|
||||
# Disconnect
|
||||
plc.disconnect()
|
||||
print("🔌 Disconnected from PLC")
|
||||
|
||||
except Exception as e:
|
||||
print(f"❌ Error testing with real PLC: {e}")
|
||||
|
||||
|
||||
if __name__ == "__main__":
|
||||
"""
|
||||
Main testing entry point.
|
||||
Run this script directly to test the batch reader.
|
||||
"""
|
||||
print("🚀 OptimizedBatchReader Testing Suite")
|
||||
print("=" * 50)
|
||||
|
||||
# Always run standalone tests
|
||||
test_batch_reader_standalone()
|
||||
|
||||
# Test with even larger dataset to verify chunking
|
||||
print("\n🧪 Testing with large dataset (50+ variables)...")
|
||||
large_config = {}
|
||||
for i in range(55): # Create 55 variables to test multiple chunks
|
||||
large_config[f"var_{i:02d}"] = {
|
||||
"area": "db",
|
||||
"db": 1 + (i // 20), # Spread across multiple DBs
|
||||
"offset": (i % 20) * 4,
|
||||
"type": "real",
|
||||
}
|
||||
|
||||
reader = OptimizedBatchReader(plc_client=None, logger=None)
|
||||
variable_items = list(large_config.items())
|
||||
chunks = []
|
||||
for i in range(0, len(variable_items), reader.CHUNK_SIZE):
|
||||
chunk = variable_items[i : i + reader.CHUNK_SIZE]
|
||||
chunks.append(chunk)
|
||||
|
||||
print(f"📦 {len(large_config)} variables split into {len(chunks)} chunks:")
|
||||
for i, chunk in enumerate(chunks, 1):
|
||||
print(f" Chunk {i}: {len(chunk)} variables")
|
||||
|
||||
# Uncomment and modify the following line to test with a real PLC
|
||||
# test_with_real_plc("192.168.1.100")
|
||||
|
||||
print("\n🎯 Integration Instructions:")
|
||||
print("1. Test this script thoroughly with your PLC configuration")
|
||||
print("2. Modify the IP address in test_with_real_plc() and uncomment the call")
|
||||
print("3. Once tested, import OptimizedBatchReader into plc_client.py")
|
||||
print("4. Replace the existing read_variables_batch method")
|
||||
print("5. Ensure proper error handling integration")
|
||||
Loading…
Reference in New Issue