#!/usr/bin/env python3 """ Checkweigher HMI - PyQt6 Production Application Replaces Weintek EasyBuilder Pro HMI for Checkweigher machine. Communicates via Modbus RTU (USB-RS485) using minimalmodbus. Architecture: - Theme: Centralized QSS constants (colors, gradients, fonts) - DataModel: Dataclass holding all machine state - ModbusWorker: QThread for non-blocking hardware polling - Simulator: QTimer-based fake data generator (Phase 1 / offline mode) - Widgets: Reusable LCD, StatusBar, StatCard, IndustrialButton - MainWindow: Orchestrates layout and signal/slot wiring """ import sys import random import struct import time from dataclasses import dataclass, field from enum import IntEnum from typing import Optional from PyQt6.QtCore import ( Qt, QTimer, QThread, pyqtSignal, QObject, QSize, QPoint ) from PyQt6.QtGui import ( QFont, QFontDatabase, QPainter, QColor, QLinearGradient, QPen, QBrush, QPalette ) from PyQt6.QtWidgets import ( QApplication, QMainWindow, QWidget, QLabel, QPushButton, QVBoxLayout, QHBoxLayout, QGridLayout, QFrame, QSizePolicy, QSpacerItem, QStackedWidget ) # ───────────────────────────────────────────────────────────────────────────── # SECTION 1 — MODBUS REGISTER MAP (derived from weintek_tags CSV) # ───────────────────────────────────────────────────────────────────────────── class MB: """Modbus register addresses (0-based for minimalmodbus).""" # 3x Input Registers — read only DEVICE_STATUS = 8 # device.status DEVICE_STATE = 11 # device.state CHECK_WEIGHT_VALUE = 13 # device.checkWeightValue (32-bit float, 2 regs) CHECK_WEIGHT_DEVIATION = 15 # device.checkWeightDeviation (32-bit float) CHECK_WEIGHT_STATE = 17 # device.checkWeightState WEIGHER_STATUS = 18 # device.weigher.status WEIGHER_STATE = 21 # device.weigher.state WEIGHER_CURRENT_WEIGHT = 23 # device.weigher.currentWeight (32-bit float) REJECTION_STATUS = 37 # device.rejectionSystem.status REJECTION_STATE = 40 # device.rejectionSystem.state UNDERWEIGHT_WORK_CYCLE = 10547 # device.rejectionSystem.underweightRejectWorkCycle (32-bit) OVERWEIGHT_WORK_CYCLE = 10549 # device.rejectionSystem.overweightRejectWorkCycle (32-bit) HIST_UNDERWEIGHT_COUNT = 1113 # device.historyRecorder.underweightCount (32-bit) HIST_OVERWEIGHT_COUNT = 1115 # device.historyRecorder.overweightCount (32-bit) HIST_PROPER_COUNT = 1119 # device.historyRecorder.properCount (32-bit) HIST_TOTAL_COUNT = 1121 # device.historyRecorder.totalCount (32-bit) HIST_MEAN_WEIGHT = 1109 # device.historyRecorder.meanWeight (32-bit float) HIST_STD_WEIGHT = 1107 # device.historyRecorder.stdWeight (32-bit float) HIST_MIN_WEIGHT = 1101 # device.historyRecorder.minWeight (32-bit float) HIST_MAX_WEIGHT = 1103 # device.historyRecorder.maxWeight (32-bit float) KERNEL_STATE = 5 # kernel.kernelState # 4x Holding Registers — read/write DESIRED_WEIGHT = 25 # device.desiredWeight (32-bit float) UPPER_LIMIT_WEIGHT = 27 # device.upperLimitWeight (32-bit float) LOWER_LIMIT_WEIGHT = 29 # device.lowerLimitWeight (32-bit float) CMD_INPUT_BITS_0 = 889 # commandService.commandInputBits[0] class WeighState(IntEnum): IDLE = 0 RUNNING = 1 OK = 2 OVER = 3 UNDER = 4 TARE = 5 ERROR = 6 # ───────────────────────────────────────────────────────────────────────────── # SECTION 2 — DATA MODEL # ───────────────────────────────────────────────────────────────────────────── @dataclass class MachineData: """Single source of truth for all machine state.""" running: bool = False current_weight: float = 0.0 check_weight: float = 0.0 deviation: float = 0.0 weigh_state: int = WeighState.IDLE total_count: int = 0 proper_count: int = 0 overweight_count: int = 0 underweight_count: int = 0 mean_weight: float = 0.0 std_weight: float = 0.0 min_weight: float = 0.0 max_weight: float = 0.0 desired_weight: float = 100.0 upper_limit: float = 105.0 lower_limit: float = 95.0 tare_offset: float = 0.0 connection_ok: bool = False last_error: str = "" # ───────────────────────────────────────────────────────────────────────────── # SECTION 3 — THEME / QSS # ───────────────────────────────────────────────────────────────────────────── class Theme: # Palette BG_MAIN = "#1A2E3B" BG_PANEL = "#1E3040" BG_PANEL_DARK = "#152535" BG_CARD = "#243444" BORDER_LIGHT = "#3A5A6A" BORDER_DARK = "#0F1E2A" ACCENT_BLUE = "#2A7FBC" ACCENT_CYAN = "#00B4D8" LCD_GREEN = "#00FF41" LCD_DIM = "#004010" LCD_BG = "#000A02" STATUS_OK = "#00C853" STATUS_REJECT = "#D50000" STATUS_WARN = "#FF6D00" STATUS_IDLE = "#546E7A" TEXT_PRIMARY = "#E8F4FD" TEXT_SECONDARY= "#7FB3C8" TEXT_DIM = "#4A6A7A" BTN_START_TOP = "#2E7D32" BTN_START_BOT = "#1B5E20" BTN_STOP_TOP = "#B71C1C" BTN_STOP_BOT = "#7F0000" BTN_TARE_TOP = "#1565C0" BTN_TARE_BOT = "#0D47A1" BTN_RESET_TOP = "#E65100" BTN_RESET_BOT = "#BF360C" BTN_SETUP_TOP = "#4A148C" BTN_SETUP_BOT = "#311B92" FONT_MONO = "Courier New" @staticmethod def global_qss() -> str: return f""" QWidget {{ background-color: {Theme.BG_MAIN}; color: {Theme.TEXT_PRIMARY}; font-family: 'Segoe UI', Arial, sans-serif; }} QFrame[frameRole="panel"] {{ background: qlineargradient(x1:0,y1:0,x2:0,y2:1, stop:0 {Theme.BG_PANEL}, stop:1 {Theme.BG_PANEL_DARK}); border: 1px solid {Theme.BORDER_LIGHT}; border-radius: 6px; }} QFrame[frameRole="card"] {{ background: qlineargradient(x1:0,y1:0,x2:0,y2:1, stop:0 {Theme.BG_CARD}, stop:1 #1A2C3A); border: 1px solid {Theme.BORDER_LIGHT}; border-top: 1px solid #4A7A8A; border-radius: 5px; }} QLabel[role="title"] {{ color: {Theme.TEXT_SECONDARY}; font-size: 11px; font-weight: bold; letter-spacing: 2px; text-transform: uppercase; }} QLabel[role="value"] {{ color: {Theme.TEXT_PRIMARY}; font-size: 22px; font-weight: bold; }} QLabel[role="unit"] {{ color: {Theme.TEXT_DIM}; font-size: 13px; }} QScrollBar {{ width: 0px; height: 0px; }} """ @staticmethod def btn_qss(top: str, bot: str) -> str: r, g, b = int(top[1:3],16), int(top[3:5],16), int(top[5:7],16) shadow = f"#{max(0,r-40):02x}{max(0,g-40):02x}{max(0,b-40):02x}" pressed_top = f"#{max(0,r-50):02x}{max(0,g-50):02x}{max(0,b-50):02x}" return f""" QPushButton {{ background: qlineargradient(x1:0,y1:0,x2:0,y2:1, stop:0 {top}, stop:0.45 {top}, stop:0.5 {bot}, stop:1 {bot}); color: white; border: 1px solid {shadow}; border-top: 1px solid rgba(255,255,255,60); border-radius: 5px; font-size: 14px; font-weight: bold; letter-spacing: 1px; padding: 8px 4px; }} QPushButton:pressed {{ background: qlineargradient(x1:0,y1:0,x2:0,y2:1, stop:0 {pressed_top}, stop:1 {shadow}); border-top: 1px solid rgba(0,0,0,80); padding-top: 10px; padding-bottom: 6px; }} QPushButton:disabled {{ background: #2A3A44; color: #4A6A7A; border: 1px solid #2A3A44; }} """ @staticmethod def lcd_qss() -> str: return f""" QLabel {{ background-color: {Theme.LCD_BG}; color: {Theme.LCD_GREEN}; font-family: '{Theme.FONT_MONO}'; font-size: 72px; font-weight: bold; border: 2px inset #001505; border-radius: 4px; padding: 6px 20px; letter-spacing: 4px; }} """ # ───────────────────────────────────────────────────────────────────────────── # SECTION 4 — CUSTOM WIDGETS # ───────────────────────────────────────────────────────────────────────────── class LcdDisplay(QLabel): """Glowing green LCD-style weight display.""" def __init__(self, parent=None): super().__init__(parent) self.setAlignment(Qt.AlignmentFlag.AlignRight | Qt.AlignmentFlag.AlignVCenter) self.setStyleSheet(Theme.lcd_qss()) self.setMinimumHeight(110) self.setText(" 0.00") self._glow_phase = 0 self._glow_timer = QTimer(self) self._glow_timer.timeout.connect(self._pulse) self._active = False def set_weight(self, value: float): self.setText(f"{value:7.2f}") def set_active(self, active: bool): self._active = active if active: self._glow_timer.start(80) else: self._glow_timer.stop() self._set_color(Theme.LCD_GREEN) def _pulse(self): """Subtle brightness pulse when running.""" import math self._glow_phase = (self._glow_phase + 1) % 20 t = (math.sin(self._glow_phase * 3.14159 / 10) + 1) / 2 brightness = int(180 + t * 75) color = f"#{0:02x}{brightness:02x}{int(brightness * 0.25):02x}" self._set_color(color) def _set_color(self, color: str): self.setStyleSheet( Theme.lcd_qss().replace(Theme.LCD_GREEN, color) ) class StatusBar(QFrame): """Full-width status indicator with gradient flash.""" def __init__(self, parent=None): super().__init__(parent) self.setFixedHeight(48) self.setProperty("frameRole", "card") layout = QHBoxLayout(self) layout.setContentsMargins(16, 0, 16, 0) self._icon = QLabel("●") self._icon.setFixedWidth(28) self._icon.setFont(QFont("Arial", 18)) self._label = QLabel("SYSTEM IDLE") self._label.setFont(QFont("Segoe UI", 16, QFont.Weight.Bold)) self._label.setAlignment(Qt.AlignmentFlag.AlignLeft | Qt.AlignmentFlag.AlignVCenter) self._right = QLabel("") self._right.setAlignment(Qt.AlignmentFlag.AlignRight | Qt.AlignmentFlag.AlignVCenter) self._right.setFont(QFont("Courier New", 13)) self._right.setStyleSheet(f"color: {Theme.TEXT_SECONDARY};") layout.addWidget(self._icon) layout.addWidget(self._label, 1) layout.addWidget(self._right) self._flash_timer = QTimer(self) self._flash_timer.timeout.connect(self._toggle_flash) self._flash_visible = True self.set_idle() def _apply(self, text: str, color: str, icon_color: str, flash=False): self._label.setText(text) self._label.setStyleSheet(f"color: {icon_color}; letter-spacing: 2px;") self._icon.setStyleSheet(f"color: {icon_color};") self.setStyleSheet(f""" QFrame {{ background: qlineargradient(x1:0,y1:0,x2:1,y2:0, stop:0 {color}44, stop:0.6 {color}22, stop:1 transparent); border-left: 4px solid {color}; border-bottom: 1px solid {color}66; border-top: 1px solid {Theme.BORDER_DARK}; border-right: 1px solid {Theme.BORDER_DARK}; border-radius: 4px; }} """) if flash: self._flash_timer.start(600) else: self._flash_timer.stop() self._icon.setVisible(True) def _toggle_flash(self): self._flash_visible = not self._flash_visible self._icon.setVisible(self._flash_visible) def set_idle(self): self._apply("SYSTEM IDLE", Theme.STATUS_IDLE, Theme.STATUS_IDLE) def set_running(self, weight_str=""): self._right.setText(weight_str) self._apply("● RUNNING — WEIGHING", Theme.STATUS_OK, Theme.STATUS_OK) def set_ok(self): self._apply("✔ WEIGHT OK — PASS", Theme.STATUS_OK, Theme.STATUS_OK) def set_overweight(self): self._apply("▲ OVERWEIGHT — REJECT", Theme.STATUS_REJECT, Theme.STATUS_REJECT, flash=True) def set_underweight(self): self._apply("▼ UNDERWEIGHT — REJECT", Theme.STATUS_REJECT, Theme.STATUS_REJECT, flash=True) def set_error(self, msg=""): self._apply(f"⚠ ERROR {msg}", Theme.STATUS_WARN, Theme.STATUS_WARN, flash=True) def set_tare(self): self._apply("TARE IN PROGRESS...", Theme.ACCENT_CYAN, Theme.ACCENT_CYAN) class StatCard(QFrame): """Numeric statistic card with title, large value, and optional unit.""" def __init__(self, title: str, unit: str = "", color: str = None, parent=None): super().__init__(parent) self.setProperty("frameRole", "card") self._color = color or Theme.TEXT_PRIMARY layout = QVBoxLayout(self) layout.setContentsMargins(14, 10, 14, 10) layout.setSpacing(2) title_label = QLabel(title.upper()) title_label.setProperty("role", "title") title_label.setStyleSheet(f"color: {Theme.TEXT_SECONDARY}; font-size: 10px; font-weight: bold; letter-spacing: 1.5px;") title_label.setAlignment(Qt.AlignmentFlag.AlignLeft) row = QHBoxLayout() self._value_label = QLabel("0") self._value_label.setFont(QFont("Courier New", 26, QFont.Weight.Bold)) self._value_label.setStyleSheet(f"color: {self._color};") self._value_label.setAlignment(Qt.AlignmentFlag.AlignRight | Qt.AlignmentFlag.AlignVCenter) unit_label = QLabel(unit) unit_label.setProperty("role", "unit") unit_label.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 12px; padding-top: 6px;") unit_label.setAlignment(Qt.AlignmentFlag.AlignLeft | Qt.AlignmentFlag.AlignBottom) row.addWidget(self._value_label, 1) row.addWidget(unit_label) layout.addWidget(title_label) layout.addLayout(row) def set_value(self, v): if isinstance(v, float): self._value_label.setText(f"{v:.2f}") else: self._value_label.setText(str(v)) def flash_color(self, color: str): self._value_label.setStyleSheet(f"color: {color};") QTimer.singleShot(400, lambda: self._value_label.setStyleSheet(f"color: {self._color};")) class IndustrialButton(QPushButton): """Touch-friendly button with 3D gradient and pressed state.""" def __init__(self, text: str, color_top: str, color_bot: str, icon_text: str = "", parent=None): super().__init__(parent) self.setMinimumHeight(56) self.setSizePolicy(QSizePolicy.Policy.Expanding, QSizePolicy.Policy.Fixed) label = f"{icon_text} {text}" if icon_text else text self.setText(label) self.setStyleSheet(Theme.btn_qss(color_top, color_bot)) self.setCursor(Qt.CursorShape.PointingHandCursor) class DeviationBar(QFrame): """Horizontal bar showing weight deviation from target.""" def __init__(self, parent=None): super().__init__(parent) self.setFixedHeight(30) self._deviation = 0.0 self._limit = 5.0 def set_deviation(self, dev: float, limit: float = 5.0): self._deviation = dev self._limit = limit self.update() def paintEvent(self, event): p = QPainter(self) p.setRenderHint(QPainter.RenderHint.Antialiasing) w, h = self.width(), self.height() mid = w // 2 # Background track p.fillRect(0, h//2-3, w, 6, QColor("#0F1E2A")) p.setPen(QPen(QColor(Theme.BORDER_LIGHT), 1)) p.drawRect(0, h//2-3, w-1, 5) # Center mark p.setPen(QPen(QColor(Theme.TEXT_DIM), 2)) p.drawLine(mid, 4, mid, h-4) # Limit markers if self._limit > 0: lp = int(mid + (self._limit / (self._limit * 2)) * mid * 0.9) rp = int(mid - (self._limit / (self._limit * 2)) * mid * 0.9) p.setPen(QPen(QColor(Theme.STATUS_WARN), 1, Qt.PenStyle.DashLine)) p.drawLine(lp, 2, lp, h-2) p.drawLine(rp, 2, rp, h-2) # Deviation indicator norm = max(-1.0, min(1.0, self._deviation / (self._limit if self._limit else 1.0))) bar_x = int(mid + norm * mid * 0.85) color = QColor(Theme.STATUS_OK) if abs(norm) < 0.8 else QColor(Theme.STATUS_REJECT) p.setPen(Qt.PenStyle.NoPen) p.setBrush(QBrush(color)) p.drawEllipse(bar_x - 7, h//2 - 7, 14, 14) p.end() class ClockLabel(QLabel): """Real-time clock label.""" def __init__(self, parent=None): super().__init__(parent) self.setStyleSheet(f"color: {Theme.TEXT_SECONDARY}; font-family: 'Courier New'; font-size: 13px;") self.setAlignment(Qt.AlignmentFlag.AlignRight | Qt.AlignmentFlag.AlignVCenter) t = QTimer(self) t.timeout.connect(self._tick) t.start(1000) self._tick() def _tick(self): from datetime import datetime self.setText(datetime.now().strftime(" %H:%M:%S %d/%m/%Y")) # ───────────────────────────────────────────────────────────────────────────── # SECTION 5 — SIMULATOR (Phase 1 — no hardware needed) # ───────────────────────────────────────────────────────────────────────────── class Simulator(QObject): """ Generates realistic checkweigher data using a QTimer. Emits new_data signal every 800 ms when running. """ new_data = pyqtSignal(object) # emits MachineData def __init__(self, model: MachineData, parent=None): super().__init__(parent) self._model = model self._timer = QTimer(self) self._timer.timeout.connect(self._tick) self._sample_counter = 0 def start(self): self._model.running = True self._model.connection_ok = True # sim is always "connected" self._timer.start(800) def stop(self): self._model.running = False self._timer.stop() self._model.weigh_state = WeighState.IDLE self.new_data.emit(self._model) def tare(self): self._model.tare_offset = random.uniform(-0.5, 0.5) self._model.weigh_state = WeighState.TARE self.new_data.emit(self._model) QTimer.singleShot(1200, self._finish_tare) def _finish_tare(self): self._model.weigh_state = WeighState.IDLE if not self._model.running else WeighState.RUNNING self.new_data.emit(self._model) def reset_stats(self): self._model.total_count = 0 self._model.proper_count = 0 self._model.overweight_count= 0 self._model.underweight_count=0 self._model.mean_weight = 0.0 self._model.std_weight = 0.0 self._model.min_weight = 0.0 self._model.max_weight = 0.0 self._sample_counter = 0 self.new_data.emit(self._model) def _tick(self): # Simulate a normally-distributed weight with occasional outliers base = self._model.desired_weight sigma = 1.8 w = random.gauss(base, sigma) # 5% chance of deliberate outlier if random.random() < 0.05: w += random.choice([-1, 1]) * random.uniform(6, 12) w = round(w - self._model.tare_offset, 2) self._model.check_weight = w self._model.current_weight = w self._model.deviation = w - base self._model.weigh_state = WeighState.RUNNING # Classify if w > self._model.upper_limit: self._model.weigh_state = WeighState.OVER self._model.overweight_count += 1 elif w < self._model.lower_limit: self._model.weigh_state = WeighState.UNDER self._model.underweight_count += 1 else: self._model.weigh_state = WeighState.OK self._model.proper_count += 1 self._model.total_count += 1 n = self._model.total_count prev_mean = self._model.mean_weight self._model.mean_weight += (w - prev_mean) / n # Welford's online std self._sample_counter += 1 if self._sample_counter == 1: self._model.min_weight = w self._model.max_weight = w self._M2 = 0.0 else: delta = w - prev_mean delta2 = w - self._model.mean_weight self._M2 = getattr(self, '_M2', 0.0) + delta * delta2 self._model.std_weight = (self._M2 / (n - 1)) ** 0.5 if n > 1 else 0.0 self._model.min_weight = min(self._model.min_weight, w) self._model.max_weight = max(self._model.max_weight, w) self.new_data.emit(self._model) # ───────────────────────────────────────────────────────────────────────────── # SECTION 6 — MODBUS WORKER THREAD (Phase 2 — real hardware) # ───────────────────────────────────────────────────────────────────────────── class ModbusWorker(QThread): """ Polls the checkweigher controller via Modbus RTU in a background thread. Set USE_SIMULATION=True (in main) to bypass this entirely. """ new_data = pyqtSignal(object) error_sig = pyqtSignal(str) def __init__(self, port: str, slave_id: int, model: MachineData, parent=None): super().__init__(parent) self._port = port self._slave = slave_id self._model = model self._running = False self._inst = None def run(self): try: import minimalmodbus self._inst = minimalmodbus.Instrument(self._port, self._slave) self._inst.serial.baudrate = 115200 self._inst.serial.timeout = 0.3 self._inst.mode = minimalmodbus.MODE_RTU self._model.connection_ok = True except Exception as e: self.error_sig.emit(f"Modbus connect failed: {e}") self._model.connection_ok = False return self._running = True while self._running: try: self._poll() self.new_data.emit(self._model) except Exception as e: self._model.connection_ok = False self.error_sig.emit(str(e)) time.sleep(0.1) def _read_float(self, reg: int) -> float: """Read a 32-bit IEEE float from two consecutive input registers.""" regs = self._inst.read_registers(reg - 1, 2, functioncode=4) raw = (regs[0] << 16) | regs[1] return struct.unpack('>f', struct.pack('>I', raw))[0] def _read_long(self, reg: int) -> int: """Read a 32-bit unsigned int from two consecutive input registers.""" regs = self._inst.read_registers(reg - 1, 2, functioncode=4) return (regs[0] << 16) | regs[1] def _read_reg(self, reg: int) -> int: return self._inst.read_register(reg - 1, functioncode=4) def _poll(self): m = self._model m.current_weight = self._read_float(MB.WEIGHER_CURRENT_WEIGHT) m.check_weight = self._read_float(MB.CHECK_WEIGHT_VALUE) m.deviation = self._read_float(MB.CHECK_WEIGHT_DEVIATION) m.weigh_state = self._read_reg(MB.CHECK_WEIGHT_STATE) m.total_count = self._read_long(MB.HIST_TOTAL_COUNT) m.proper_count = self._read_long(MB.HIST_PROPER_COUNT) m.overweight_count= self._read_long(MB.HIST_OVERWEIGHT_COUNT) m.underweight_count=self._read_long(MB.HIST_UNDERWEIGHT_COUNT) m.mean_weight = self._read_float(MB.HIST_MEAN_WEIGHT) m.std_weight = self._read_float(MB.HIST_STD_WEIGHT) m.min_weight = self._read_float(MB.HIST_MIN_WEIGHT) m.max_weight = self._read_float(MB.HIST_MAX_WEIGHT) m.connection_ok = True def stop_worker(self): self._running = False self.wait(2000) # ───────────────────────────────────────────────────────────────────────────── # SECTION 7 — LEFT PANEL # ───────────────────────────────────────────────────────────────────────────── class LeftPanel(QFrame): """60% panel: LCD weight, status bar, deviation bar, control buttons.""" sig_start = pyqtSignal() sig_stop = pyqtSignal() sig_tare = pyqtSignal() sig_reset = pyqtSignal() def __init__(self, parent=None): super().__init__(parent) self.setProperty("frameRole", "panel") self._build() def _build(self): root = QVBoxLayout(self) root.setContentsMargins(12, 12, 8, 12) root.setSpacing(8) # ── Header row ────────────────────────────────────────────────────── hdr = QHBoxLayout() title = QLabel("CHECKWEIGHER") title.setStyleSheet(f""" color: {Theme.ACCENT_CYAN}; font-size: 13px; font-weight: bold; letter-spacing: 3px; """) self._conn_label = QLabel("⬤ SIM") self._conn_label.setStyleSheet(f"color: {Theme.STATUS_WARN}; font-size: 11px; font-weight: bold;") hdr.addWidget(title) hdr.addStretch() hdr.addWidget(self._conn_label) root.addLayout(hdr) # ── Weight label ───────────────────────────────────────────────────── wlabel_row = QHBoxLayout() wlabel = QLabel("NET WEIGHT") wlabel.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 10px; letter-spacing: 2px;") self._unit_label = QLabel("g") self._unit_label.setStyleSheet(f"color: {Theme.LCD_DIM}; font-size: 14px; font-weight: bold;") self._unit_label.setAlignment(Qt.AlignmentFlag.AlignRight) wlabel_row.addWidget(wlabel) wlabel_row.addStretch() wlabel_row.addWidget(self._unit_label) root.addLayout(wlabel_row) # ── LCD Display ─────────────────────────────────────────────────────── self.lcd = LcdDisplay() root.addWidget(self.lcd) # ── Limits row ──────────────────────────────────────────────────────── limits_row = QHBoxLayout() self._lo_label = QLabel("▼ LOW: 95.00 g") self._lo_label.setStyleSheet(f"color: {Theme.STATUS_WARN}; font-size: 11px; font-weight: bold;") self._tgt_label = QLabel("◎ TGT: 100.00 g") self._tgt_label.setStyleSheet(f"color: {Theme.TEXT_SECONDARY}; font-size: 11px;") self._tgt_label.setAlignment(Qt.AlignmentFlag.AlignHCenter) self._hi_label = QLabel("HIGH: 105.00 g ▲") self._hi_label.setStyleSheet(f"color: {Theme.STATUS_WARN}; font-size: 11px; font-weight: bold;") self._hi_label.setAlignment(Qt.AlignmentFlag.AlignRight) limits_row.addWidget(self._lo_label) limits_row.addStretch() limits_row.addWidget(self._tgt_label) limits_row.addStretch() limits_row.addWidget(self._hi_label) root.addLayout(limits_row) # ── Deviation bar ───────────────────────────────────────────────────── dev_label = QLabel("DEVIATION FROM TARGET") dev_label.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 9px; letter-spacing: 2px;") root.addWidget(dev_label) self.dev_bar = DeviationBar() root.addWidget(self.dev_bar) # ── Status bar ──────────────────────────────────────────────────────── self.status_bar = StatusBar() root.addWidget(self.status_bar) # ── Mini stats row ──────────────────────────────────────────────────── mini_row = QHBoxLayout() mini_row.setSpacing(6) self._mean_card = self._mini_card("MEAN", "g", Theme.ACCENT_CYAN) self._std_card = self._mini_card("STD DEV","g", Theme.TEXT_SECONDARY) self._min_card = self._mini_card("MIN", "g", Theme.STATUS_WARN) self._max_card = self._mini_card("MAX", "g", Theme.STATUS_WARN) for c in [self._mean_card, self._std_card, self._min_card, self._max_card]: mini_row.addWidget(c) root.addLayout(mini_row) root.addStretch() # ── Control buttons ─────────────────────────────────────────────────── separator = QFrame() separator.setFrameShape(QFrame.Shape.HLine) separator.setStyleSheet(f"color: {Theme.BORDER_LIGHT};") root.addWidget(separator) btn_row1 = QHBoxLayout() btn_row1.setSpacing(8) self.btn_start = IndustrialButton("START", Theme.BTN_START_TOP, Theme.BTN_START_BOT, "▶") self.btn_stop = IndustrialButton("STOP", Theme.BTN_STOP_TOP, Theme.BTN_STOP_BOT, "■") self.btn_stop.setEnabled(False) btn_row1.addWidget(self.btn_start) btn_row1.addWidget(self.btn_stop) btn_row2 = QHBoxLayout() btn_row2.setSpacing(8) self.btn_tare = IndustrialButton("TARE", Theme.BTN_TARE_TOP, Theme.BTN_TARE_BOT, "⊖") self.btn_reset = IndustrialButton("RESET", Theme.BTN_RESET_TOP, Theme.BTN_RESET_BOT, "↺") btn_row2.addWidget(self.btn_tare) btn_row2.addWidget(self.btn_reset) root.addLayout(btn_row1) root.addLayout(btn_row2) # Wire buttons self.btn_start.clicked.connect(self.sig_start) self.btn_stop.clicked.connect(self.sig_stop) self.btn_tare.clicked.connect(self.sig_tare) self.btn_reset.clicked.connect(self.sig_reset) def _mini_card(self, title: str, unit: str, color: str) -> QFrame: f = QFrame() f.setProperty("frameRole", "card") v = QVBoxLayout(f) v.setContentsMargins(8, 6, 8, 6) v.setSpacing(0) tl = QLabel(title) tl.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 9px; letter-spacing: 1px;") tl.setAlignment(Qt.AlignmentFlag.AlignCenter) vl = QLabel("0.00") vl.setStyleSheet(f"color: {color}; font-size: 13px; font-weight: bold; font-family: 'Courier New';") vl.setAlignment(Qt.AlignmentFlag.AlignCenter) ul = QLabel(unit) ul.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 9px;") ul.setAlignment(Qt.AlignmentFlag.AlignCenter) v.addWidget(tl) v.addWidget(vl) v.addWidget(ul) f._value_label = vl return f # ── Public update slot ─────────────────────────────────────────────────── def update_data(self, d: MachineData): self.lcd.set_weight(d.current_weight) self.dev_bar.set_deviation(d.deviation, d.upper_limit - d.desired_weight) self.lcd.set_active(d.running) # Connection indicator if d.connection_ok and not d.running: self._conn_label.setText("⬤ CONNECTED") self._conn_label.setStyleSheet(f"color: {Theme.STATUS_OK}; font-size: 11px; font-weight: bold;") elif d.running: self._conn_label.setText("⬤ LIVE") self._conn_label.setStyleSheet(f"color: {Theme.LCD_GREEN}; font-size: 11px; font-weight: bold;") # Limits self._lo_label.setText(f"▼ LOW: {d.lower_limit:.2f} g") self._tgt_label.setText(f"◎ TGT: {d.desired_weight:.2f} g") self._hi_label.setText(f"HIGH: {d.upper_limit:.2f} g ▲") # Status bar state = d.weigh_state if state == WeighState.IDLE or not d.running: self.status_bar.set_idle() elif state == WeighState.TARE: self.status_bar.set_tare() elif state == WeighState.OK: self.status_bar.set_ok() elif state == WeighState.OVER: self.status_bar.set_overweight() elif state == WeighState.UNDER: self.status_bar.set_underweight() else: self.status_bar.set_running() # Mini stat cards self._mean_card._value_label.setText(f"{d.mean_weight:.2f}") self._std_card._value_label.setText(f"{d.std_weight:.2f}") self._min_card._value_label.setText(f"{d.min_weight:.2f}" if d.min_weight else "—") self._max_card._value_label.setText(f"{d.max_weight:.2f}" if d.max_weight else "—") # Button states self.btn_start.setEnabled(not d.running) self.btn_stop.setEnabled(d.running) self.btn_tare.setEnabled(True) def set_sim_mode(self, sim: bool): if sim: self._conn_label.setText("⬤ SIMULATION") self._conn_label.setStyleSheet(f"color: {Theme.STATUS_WARN}; font-size: 11px; font-weight: bold;") # ───────────────────────────────────────────────────────────────────────────── # SECTION 8 — RIGHT PANEL # ───────────────────────────────────────────────────────────────────────────── class RightPanel(QFrame): """40% panel: statistics, product info, and Setup button.""" sig_setup = pyqtSignal() def __init__(self, parent=None): super().__init__(parent) self.setProperty("frameRole", "panel") self._build() def _build(self): root = QVBoxLayout(self) root.setContentsMargins(8, 12, 12, 12) root.setSpacing(8) # ── Header ──────────────────────────────────────────────────────────── hdr = QHBoxLayout() title = QLabel("STATISTICS") title.setStyleSheet(f"color: {Theme.ACCENT_CYAN}; font-size: 13px; font-weight: bold; letter-spacing: 3px;") self._clock = ClockLabel() hdr.addWidget(title) hdr.addStretch() hdr.addWidget(self._clock) root.addLayout(hdr) # ── Separator ───────────────────────────────────────────────────────── sep = QFrame() sep.setFrameShape(QFrame.Shape.HLine) sep.setStyleSheet(f"color: {Theme.BORDER_LIGHT};") root.addWidget(sep) # ── Primary stat cards (2-col grid) ────────────────────────────────── grid = QGridLayout() grid.setSpacing(6) self._total_card = StatCard("Total Samples", "", Theme.TEXT_PRIMARY) self._ok_card = StatCard("Pass (OK)", "", Theme.STATUS_OK) self._over_card = StatCard("Overweight", "", Theme.STATUS_REJECT) self._under_card = StatCard("Underweight", "", Theme.STATUS_REJECT) grid.addWidget(self._total_card, 0, 0) grid.addWidget(self._ok_card, 0, 1) grid.addWidget(self._over_card, 1, 0) grid.addWidget(self._under_card, 1, 1) root.addLayout(grid) # ── Yield / Reject rate ─────────────────────────────────────────────── rate_frame = QFrame() rate_frame.setProperty("frameRole", "card") rate_layout = QHBoxLayout(rate_frame) rate_layout.setContentsMargins(14, 8, 14, 8) yield_col = QVBoxLayout() yield_title = QLabel("YIELD RATE") yield_title.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 10px; letter-spacing: 1px;") self._yield_label = QLabel("—") self._yield_label.setFont(QFont("Courier New", 28, QFont.Weight.Bold)) self._yield_label.setStyleSheet(f"color: {Theme.STATUS_OK};") yield_col.addWidget(yield_title) yield_col.addWidget(self._yield_label) reject_col = QVBoxLayout() reject_col.setAlignment(Qt.AlignmentFlag.AlignRight) reject_title = QLabel("REJECT RATE") reject_title.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 10px; letter-spacing: 1px; text-align: right;") reject_title.setAlignment(Qt.AlignmentFlag.AlignRight) self._reject_label = QLabel("—") self._reject_label.setFont(QFont("Courier New", 28, QFont.Weight.Bold)) self._reject_label.setStyleSheet(f"color: {Theme.STATUS_REJECT};") self._reject_label.setAlignment(Qt.AlignmentFlag.AlignRight) reject_col.addWidget(reject_title) reject_col.addWidget(self._reject_label) rate_layout.addLayout(yield_col, 1) rate_layout.addLayout(reject_col, 1) root.addWidget(rate_frame) # ── Weight histogram bar (simple) ───────────────────────────────────── hist_frame = QFrame() hist_frame.setProperty("frameRole", "card") hist_layout = QVBoxLayout(hist_frame) hist_layout.setContentsMargins(10, 8, 10, 8) hist_title = QLabel("WEIGHT DISTRIBUTION") hist_title.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 9px; letter-spacing: 2px;") self._hist_widget = HistogramWidget() hist_layout.addWidget(hist_title) hist_layout.addWidget(self._hist_widget) root.addWidget(hist_frame) # ── Product info card ───────────────────────────────────────────────── prod_frame = QFrame() prod_frame.setProperty("frameRole", "card") prod_layout = QGridLayout(prod_frame) prod_layout.setContentsMargins(14, 8, 14, 8) prod_layout.setHorizontalSpacing(8) prod_layout.setVerticalSpacing(4) def _kv(k, v_init="—"): kl = QLabel(k) kl.setStyleSheet(f"color: {Theme.TEXT_DIM}; font-size: 10px;") vl = QLabel(v_init) vl.setStyleSheet(f"color: {Theme.TEXT_PRIMARY}; font-size: 12px; font-weight: bold; font-family: 'Courier New';") vl.setAlignment(Qt.AlignmentFlag.AlignRight) return kl, vl k1, self._prd_name = _kv("Product:") k2, self._prd_target = _kv("Target Weight:") k3, self._prd_tol = _kv("Tolerance:") k4, self._prd_last = _kv("Last Weight:") prod_layout.addWidget(k1, 0, 0); prod_layout.addWidget(self._prd_name, 0, 1) prod_layout.addWidget(k2, 1, 0); prod_layout.addWidget(self._prd_target, 1, 1) prod_layout.addWidget(k3, 2, 0); prod_layout.addWidget(self._prd_tol, 2, 1) prod_layout.addWidget(k4, 3, 0); prod_layout.addWidget(self._prd_last, 3, 1) root.addWidget(prod_frame) root.addStretch() # ── Setup button ────────────────────────────────────────────────────── sep2 = QFrame() sep2.setFrameShape(QFrame.Shape.HLine) sep2.setStyleSheet(f"color: {Theme.BORDER_LIGHT};") root.addWidget(sep2) self.btn_setup = IndustrialButton("SETTING UP", Theme.BTN_SETUP_TOP, Theme.BTN_SETUP_BOT, "⚙") self.btn_setup.setMinimumHeight(56) root.addWidget(self.btn_setup) self.btn_setup.clicked.connect(self.sig_setup) # ── Public update slot ─────────────────────────────────────────────────── def update_data(self, d: MachineData): self._total_card.set_value(d.total_count) self._ok_card.set_value(d.proper_count) self._over_card.set_value(d.overweight_count) self._under_card.set_value(d.underweight_count) if d.total_count > 0: yield_r = d.proper_count / d.total_count * 100 reject_r = (d.overweight_count + d.underweight_count) / d.total_count * 100 self._yield_label.setText(f"{yield_r:.1f}%") self._reject_label.setText(f"{reject_r:.1f}%") else: self._yield_label.setText("—") self._reject_label.setText("—") self._prd_target.setText(f"{d.desired_weight:.2f} g") tol = d.upper_limit - d.desired_weight self._prd_tol.setText(f"± {tol:.2f} g") self._prd_last.setText(f"{d.check_weight:.2f} g") self._hist_widget.push(d.check_weight, d.lower_limit, d.upper_limit) # Flash reject cards on new rejects if d.weigh_state == WeighState.OVER: self._over_card.flash_color(Theme.STATUS_REJECT) elif d.weigh_state == WeighState.UNDER: self._under_card.flash_color(Theme.STATUS_REJECT) def set_product_name(self, name: str): self._prd_name.setText(name) class HistogramWidget(QFrame): """Mini live histogram of recent 40 weight samples.""" def __init__(self, parent=None): super().__init__(parent) self.setFixedHeight(60) self._samples = [] self._lo = 95.0 self._hi = 105.0 def push(self, value: float, lo: float, hi: float): self._lo = lo self._hi = hi self._samples.append(value) if len(self._samples) > 60: self._samples.pop(0) self.update() def paintEvent(self, event): if not self._samples: return p = QPainter(self) p.setRenderHint(QPainter.RenderHint.Antialiasing) w, h = self.width(), self.height() n = len(self._samples) bar_w = max(3, w // n) span = (self._hi - self._lo) * 1.5 center = (self._hi + self._lo) / 2 vmin = center - span / 2 vmax = center + span / 2 rng = vmax - vmin if vmax != vmin else 1.0 for i, val in enumerate(self._samples): bh = int(((val - vmin) / rng) * (h - 6)) + 3 bh = max(2, min(h - 2, bh)) x = i * (w / n) if val > self._hi: color = QColor(Theme.STATUS_REJECT) elif val < self._lo: color = QColor(Theme.STATUS_WARN) else: age = i / max(n - 1, 1) g = int(60 + age * 195) color = QColor(0, g, int(g * 0.25)) p.fillRect(int(x) + 1, h - bh, max(2, int(bar_w) - 1), bh - 1, color) # Limit lines def y_for(v): return h - int(((v - vmin) / rng) * (h - 6)) - 3 p.setPen(QPen(QColor(Theme.STATUS_WARN), 1, Qt.PenStyle.DashLine)) p.drawLine(0, y_for(self._hi), w, y_for(self._hi)) p.drawLine(0, y_for(self._lo), w, y_for(self._lo)) p.end() # ───────────────────────────────────────────────────────────────────────────── # SECTION 9 — TITLE BAR # ───────────────────────────────────────────────────────────────────────────── class TitleBar(QWidget): """Custom frameless title bar with machine info.""" def __init__(self, parent=None): super().__init__(parent) self.setFixedHeight(36) self.setStyleSheet(f""" QWidget {{ background: qlineargradient(x1:0,y1:0,x2:1,y2:0, stop:0 #0F1E2A, stop:0.5 #162535, stop:1 #0F1E2A); border-bottom: 1px solid {Theme.BORDER_LIGHT}; }} """) layout = QHBoxLayout(self) layout.setContentsMargins(14, 0, 14, 0) logo = QLabel("⚖") logo.setStyleSheet(f"color: {Theme.ACCENT_CYAN}; font-size: 18px;") machine_name = QLabel("CHECKWEIGHER CONTROL SYSTEM | CW-2000") machine_name.setStyleSheet(f"color: {Theme.TEXT_PRIMARY}; font-size: 12px; font-weight: bold; letter-spacing: 2px;") mode_badge = QLabel("● SIMULATION MODE") mode_badge.setObjectName("mode_badge") mode_badge.setStyleSheet(f""" color: {Theme.STATUS_WARN}; font-size: 10px; font-weight: bold; background: #1A2E00; border: 1px solid {Theme.STATUS_WARN}; border-radius: 3px; padding: 2px 8px; """) layout.addWidget(logo) layout.addSpacing(8) layout.addWidget(machine_name) layout.addStretch() layout.addWidget(mode_badge) # Drag support self._drag_pos = None def mousePressEvent(self, event): if event.button() == Qt.MouseButton.LeftButton: self._drag_pos = event.globalPosition().toPoint() - self.window().frameGeometry().topLeft() def mouseMoveEvent(self, event): if self._drag_pos and event.buttons() & Qt.MouseButton.LeftButton: self.window().move(event.globalPosition().toPoint() - self._drag_pos) # ───────────────────────────────────────────────────────────────────────────── # SECTION 10 — MAIN WINDOW # ───────────────────────────────────────────────────────────────────────────── class MainWindow(QMainWindow): # ── Toggle this to True for real hardware ─────────────────────────────── USE_SIMULATION = True MODBUS_PORT = "/dev/ttyUSB0" MODBUS_SLAVE = 1 def __init__(self): super().__init__() self._model = MachineData() self._model.desired_weight = 100.0 self._model.upper_limit = 105.0 self._model.lower_limit = 95.0 self._setup_window() self._build_ui() self._connect_signals() if self.USE_SIMULATION: self._sim = Simulator(self._model, self) self._sim.new_data.connect(self._on_new_data) self.left.set_sim_mode(True) else: self._worker = ModbusWorker( self.MODBUS_PORT, self.MODBUS_SLAVE, self._model, self ) self._worker.new_data.connect(self._on_new_data) self._worker.error_sig.connect(self._on_error) self._worker.start() def _setup_window(self): self.setWindowTitle("Checkweigher HMI") self.setWindowFlags(Qt.WindowType.FramelessWindowHint) self.showFullScreen() self.setMinimumSize(QSize(1024, 600)) self.setStyleSheet(Theme.global_qss()) def _build_ui(self): central = QWidget() self.setCentralWidget(central) root = QVBoxLayout(central) root.setContentsMargins(0, 0, 0, 0) root.setSpacing(0) # Title bar self.title_bar = TitleBar(self) root.addWidget(self.title_bar) # Main content content = QHBoxLayout() content.setContentsMargins(8, 8, 8, 8) content.setSpacing(8) self.left = LeftPanel(self) self.right = RightPanel(self) self.right.set_product_name("PRODUCT A") content.addWidget(self.left, 60) content.addWidget(self.right, 40) root.addLayout(content, 1) def _connect_signals(self): self.left.sig_start.connect(self._on_start) self.left.sig_stop.connect(self._on_stop) self.left.sig_tare.connect(self._on_tare) self.left.sig_reset.connect(self._on_reset) self.right.sig_setup.connect(self._on_setup) # ── Slots ───────────────────────────────────────────────────────────────── def _on_start(self): if self.USE_SIMULATION: self._sim.start() else: # In real mode: write START command to Modbus pass # TODO: self._worker.write_command(CMD_START) self._model.running = True self.left.update_data(self._model) def _on_stop(self): if self.USE_SIMULATION: self._sim.stop() self._model.running = False self.left.update_data(self._model) def _on_tare(self): if self.USE_SIMULATION: self._sim.tare() def _on_reset(self): if self.USE_SIMULATION: self._sim.reset_stats() self.right.update_data(self._model) self.left.update_data(self._model) def _on_setup(self): # Placeholder — open settings dialog in future phases self.left.status_bar.set_error("Settings page not yet implemented") QTimer.singleShot(3000, self.left.status_bar.set_idle) def _on_new_data(self, data: MachineData): self.left.update_data(data) self.right.update_data(data) def _on_error(self, msg: str): self._model.connection_ok = False self.left.status_bar.set_error(msg[:40]) def keyPressEvent(self, event): # ESC exits fullscreen for development; remove for production if event.key() == Qt.Key.Key_Escape: self.close() # ───────────────────────────────────────────────────────────────────────────── # SECTION 11 — ENTRY POINT # ───────────────────────────────────────────────────────────────────────────── def main(): app = QApplication(sys.argv) app.setStyle("Fusion") # Force dark palette at Qt level (fallback for any un-styled widgets) palette = QPalette() palette.setColor(QPalette.ColorRole.Window, QColor(Theme.BG_MAIN)) palette.setColor(QPalette.ColorRole.WindowText, QColor(Theme.TEXT_PRIMARY)) palette.setColor(QPalette.ColorRole.Base, QColor(Theme.BG_PANEL)) palette.setColor(QPalette.ColorRole.Text, QColor(Theme.TEXT_PRIMARY)) palette.setColor(QPalette.ColorRole.Button, QColor(Theme.BG_CARD)) palette.setColor(QPalette.ColorRole.ButtonText, QColor(Theme.TEXT_PRIMARY)) palette.setColor(QPalette.ColorRole.Highlight, QColor(Theme.ACCENT_BLUE)) app.setPalette(palette) win = MainWindow() win.show() sys.exit(app.exec()) if __name__ == "__main__": main()