ethercat-linux/scripts/tc-deploy-full.ps1

#Requires -Version 5.1
<#
.SYNOPSIS
    Complete TwinCAT EL6695 Primary deployment from scratch.

.DESCRIPTION
    Creates a fresh TwinCAT project with:
    1. Hardware scan (EtherCAT devices)
    2. PDO configuration (1024-byte IO)
    3. PLC program (GVL + MAIN)
    4. Activation + restart

    Based on reference scripts in ethercat-linux/scripts/
#>
param(
    [string]$ProjectDir = 'C:\Users\tonycao\work\twincat3-auto-cli\TwinCAT_EL6695_Primary',
    [string]$Solution = 'C:\Users\tonycao\work\twincat3-auto-cli\TwinCAT_EL6695_Primary\TwinCATProject1.sln',
    [string]$Tsproj = 'C:\Users\tonycao\work\twincat3-auto-cli\TwinCAT_EL6695_Primary\TwinCATProject1.tsproj',
    [string]$TargetNetId = '169.254.176.217.1.1',
    [int]$PayloadBytes = 1024,
    [switch]$SkipScan,
    [switch]$Visible
)

$ErrorActionPreference = 'Continue'
$LogDir = Join-Path $ProjectDir 'Logs'
New-Item -ItemType Directory -Force -Path $LogDir | Out-Null
$LogFile = Join-Path $LogDir "full-deploy_$(Get-Date -Format 'yyyyMMdd_HHmmss').log"

function Log($m) {
    $line = (Get-Date -Format 'HH:mm:ss') + "  $m"
    Add-Content -Path $LogFile -Value $line -Encoding utf8 -ErrorAction SilentlyContinue
    Write-Host $line
}
function LogSection($m) { Log ''; Log ('='*60); Log "  $m"; Log ('='*60) }

Log '=== TwinCAT EL6695 Full Deploy ==='
Log "ProjectDir: $ProjectDir"
Log "TargetNetId: $TargetNetId"
Log "PayloadBytes: $PayloadBytes"

# ---- Step 1: Check/Fix PDO in tsproj ----
LogSection 'Step 1/6: Verify PDO configuration'

if (-not (Test-Path $Tsproj)) {
    Log "ERROR: tsproj not found: $Tsproj"
    exit 1
}

$content = [System.IO.File]::ReadAllText($Tsproj, [System.Text.Encoding]::UTF8)

# Check if PDO already has 1024-byte entries
$has1024 = $content -match 'ARRAY \[0\.\.1023\] OF BYTE'
if ($has1024) {
    Log "  PDO already has 1024-byte entries"
} else {
    Log "  Adding 1024-byte PDO entries..."
    $lastSub = "{0:X4}" -f ($PayloadBytes - 1)

    $oldPdoIn = '<Pdo Name="IO Inputs" Index="#x1a08" Flags="#x0020" SyncMan="3"/>'
    $newPdoIn = @"
<Pdo Name="IO Inputs" Index="#x1a08" Flags="#x0020" SyncMan="3">
							<Entry Name="IO Inputs" Index="#x6000" Sub="#x01">
								<Type>ARRAY [0..$lastSub] OF BYTE</Type>
							</Entry>
						</Pdo>
"@
    if ($content -match [regex]::Escape($oldPdoIn)) {
        $content = $content -replace [regex]::Escape($oldPdoIn), $newPdoIn
        Log "  IO Inputs PDO fixed"
    } else { Log "  WARN: IO Inputs PDO pattern not found" }

    $oldPdoOut = '<Pdo Name="IO Outputs" Index="#x1608" InOut="1" Flags="#x0020" SyncMan="2"/>'
    $newPdoOut = @"
<Pdo Name="IO Outputs" Index="#x1608" InOut="1" Flags="#x0020" SyncMan="2">
							<Entry Name="IO Outputs" Index="#x7000" Sub="#x01">
								<Type>ARRAY [0..$lastSub] OF BYTE</Type>
							</Entry>
						</Pdo>
"@
    if ($content -match [regex]::Escape($oldPdoOut)) {
        $content = $content -replace [regex]::Escape($oldPdoOut), $newPdoOut
        Log "  IO Outputs PDO fixed"
    } else { Log "  WARN: IO Outputs PDO pattern not found" }

    [System.IO.File]::WriteAllText($Tsproj, $content, [System.Text.Encoding]::UTF8)
}

# ---- Step 2: Verify PLC code exists ----
LogSection 'Step 2/6: Verify PLC code'

$plcFiles = @(
    "$ProjectDir\PlcSync\GVLs\GVL_Sync.TcGVL",
    "$ProjectDir\PlcSync\POUs\MAIN.TcPOU",
    "$ProjectDir\PlcSync\DUTs\DUT_EL6695_IO.TcDUT",
    "$ProjectDir\PlcSync\DUTs\U_EL6695_IO.TcDUT"
)

$allOk = $true
foreach ($f in $plcFiles) {
    if (Test-Path $f) { Log "  OK: $(Split-Path $f -Leaf)" }
    else { Log "  MISSING: $(Split-Path $f -Leaf)"; $allOk = $false }
}

if (-not $allOk) {
    Log "ERROR: PLC files missing. Run project setup first."
    exit 1
}

# ---- Step 3: Build project ----
LogSection 'Step 3/6: Build project'

$dte = $null
try {
    $dte = New-Object -ComObject TcXaeShell.DTE.17.0
} catch {
    try { $dte = New-Object -ComObject TcXaeShell.DTE.15.0 } catch { Log "FATAL: No TcXaeShell"; exit 1 }
}

$dte.SuppressUI = -not $Visible
$dte.MainWindow.Visible = $Visible

Log "  Opening solution..."
$dte.Solution.Open($Solution)

$timeout = 120
for ($i = 1; $i -le $timeout; $i++) {
    Start-Sleep -Seconds 1
    if ($dte.Solution.IsOpen) { Log "  Solution open after ${i}s"; break }
}
if (-not $dte.Solution.IsOpen) { Log "ERROR: Solution did not open"; $dte.Quit(); exit 1 }

# Wait for System Manager
Log "  Waiting for System Manager..."
Start-Sleep -Seconds 15
$sm = $null
for ($i = 1; $i -le 30; $i++) {
    try {
        $sm = $dte.Solution.Projects.Item(1).Object
        if ($sm) { Log "  SysManager ready after ${i}s"; break }
    } catch { }
    Start-Sleep -Seconds 2
}
if (-not $sm) { Log "ERROR: SysManager not ready"; $dte.Quit(); exit 1 }

# Set target
try { $sm.SetTargetNetId($TargetNetId); Log "  SetTargetNetId OK" } catch { Log "  SetTargetNetId err: $_" }

# Build
Log "  Building..."
try { $dte.ExecuteCommand('Build.BuildSolution') } catch { Log "  Build command err: $_" }
Start-Sleep -Seconds 30

# Check build state
$sb = $dte.Solution.SolutionBuild
$buildState = $sb.BuildState
$buildInfo = $sb.LastBuildInfo
Log "  BuildState=$buildState, LastBuildInfo=$buildInfo"

if ($buildState -ne 1) {
    Log "WARN: Build not complete, waiting more..."
    Start-Sleep -Seconds 30
}

# ---- Step 4: Hardware scan (optional) ----
if (-not $SkipScan) {
    LogSection 'Step 4/6: Hardware scan'
    Log "  Scanning EtherCAT devices..."
    try {
        $sm.ActivateConfiguration()
        Log "  Pre-activate OK"
        Start-Sleep -Seconds 10
    } catch { Log "  Pre-activate err: $_" }

    # Try to reload devices
    $bytes = @(0xE9,0x87,0x8D,0xE6,0x96,0xB0,0xE5,0x8A,0xA0,0xE8,0xBD,0xBD,0xE8,0xAE,0xBE,0xE5,0xA4,0x87)
    $reloadCmd = 'TwinCAT.' + [System.Text.Encoding]::UTF8.GetString($bytes)
    try { $dte.ExecuteCommand($reloadCmd); Log "  Reload devices OK" } catch { Log "  Reload err: $_" }
    Start-Sleep -Seconds 15
}

# ---- Step 5: Activate configuration ----
LogSection 'Step 5/6: Activate configuration'

Log "  Saving configuration..."
try { $sm.SaveConfiguration() } catch { Log "  Save err: $_" }

Log "  Activating..."
try {
    $sm.ActivateConfiguration()
    Log "  ActivateConfiguration OK"
} catch {
    Log "  ActivateConfiguration err: $_"
}

Start-Sleep -Seconds 15

# ---- Step 6: Start TwinCAT runtime ----
LogSection 'Step 6/6: Start TwinCAT runtime'

Log "  Starting TwinCAT..."
try {
    $sm.StartRestartTwinCAT()
    Log "  StartRestartTwinCAT executed"
} catch {
    Log "  StartRestartTwinCAT err: $_"
}

# Wait for RUN state
$adsDll = 'C:\Program Files (x86)\Beckhoff\TwinCAT\3.1\Components\Base\v170\TwinCAT.Ads.dll'
Add-Type -Path $adsDll -ErrorAction SilentlyContinue

function Get-TcState {
    try {
        $c = New-Object TwinCAT.Ads.TcAdsClient
        $c.Connect($TargetNetId, 10000)
        $s = $c.ReadState()
        $c.Dispose()
        return "$($s.AdsState)"
    } catch { return "ERR" }
}

for ($i = 1; $i -le 20; $i++) {
    Start-Sleep -Seconds 5
    $st = Get-TcState
    Log "  state +$($i*5)s: $st"
    if ($st -eq 'Run') { break }
    if ($st -eq 'Config') { Log "  Still in Config mode..." }
}

Log "Final state: $(Get-TcState)"

# Save and cleanup
try { $dte.Solution.SaveAs($Solution) } catch { }
try { $dte.Quit() } catch { }

LogSection 'Deploy complete'
Log "Log file: $LogFile"