28400fbfb8
- Updated CameraStreamer to configure streaming settings from config.json, including manual exposure, gain, image quality, noise reduction, and color settings. - Added new methods in CameraStreamer for configuring image quality, noise reduction, color settings, and advanced settings. - Extended CameraConfig to include manual white balance RGB gains. - Improved AutoRecordingManager to handle camera status updates and ensure proper recording starts/stops based on machine state changes. - Created detailed configuration documentation for blower and conveyor cameras, outlining settings and their mappings to config.json. - Implemented a comprehensive test script for auto-recording functionality with simulated MQTT messages, verifying correct behavior on machine state changes.
413 lines
17 KiB
Python
413 lines
17 KiB
Python
"""
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Camera Streamer for the USDA Vision Camera System.
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This module provides live preview streaming from GigE cameras without blocking recording.
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It creates a separate camera connection for streaming that doesn't interfere with recording.
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"""
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import sys
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import os
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import threading
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import time
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import logging
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import cv2
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import numpy as np
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import contextlib
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from typing import Optional, Dict, Any, Generator
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from datetime import datetime
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import queue
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# Add camera SDK to path
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sys.path.append(os.path.join(os.path.dirname(__file__), "..", "..", "camera_sdk"))
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import mvsdk
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from ..core.config import CameraConfig
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from ..core.state_manager import StateManager
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from ..core.events import EventSystem
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from .sdk_config import ensure_sdk_initialized
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@contextlib.contextmanager
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def suppress_camera_errors():
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"""Context manager to temporarily suppress camera SDK error output"""
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# Save original file descriptors
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original_stderr = os.dup(2)
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original_stdout = os.dup(1)
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try:
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# Redirect stderr and stdout to devnull
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devnull = os.open(os.devnull, os.O_WRONLY)
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os.dup2(devnull, 2) # stderr
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os.dup2(devnull, 1) # stdout (in case SDK uses stdout)
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os.close(devnull)
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yield
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finally:
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# Restore original file descriptors
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os.dup2(original_stderr, 2)
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os.dup2(original_stdout, 1)
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os.close(original_stderr)
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os.close(original_stdout)
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class CameraStreamer:
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"""Provides live preview streaming from cameras without blocking recording"""
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def __init__(self, camera_config: CameraConfig, device_info: Any, state_manager: StateManager, event_system: EventSystem):
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self.camera_config = camera_config
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self.device_info = device_info
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self.state_manager = state_manager
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self.event_system = event_system
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self.logger = logging.getLogger(f"{__name__}.{camera_config.name}")
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# Camera handle and properties (separate from recorder)
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self.hCamera: Optional[int] = None
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self.cap = None
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self.monoCamera = False
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self.frame_buffer = None
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self.frame_buffer_size = 0
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# Streaming state
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self.streaming = False
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self._streaming_thread: Optional[threading.Thread] = None
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self._stop_streaming_event = threading.Event()
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self._frame_queue = queue.Queue(maxsize=5) # Buffer for latest frames
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self._lock = threading.RLock()
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# Stream settings (optimized for preview)
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self.preview_fps = 10.0 # Lower FPS for preview to reduce load
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self.preview_quality = 70 # JPEG quality for streaming
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def start_streaming(self) -> bool:
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"""Start streaming preview frames"""
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with self._lock:
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if self.streaming:
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self.logger.warning("Streaming already active")
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return True
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try:
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# Initialize camera for streaming
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if not self._initialize_camera():
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return False
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# Start streaming thread
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self._stop_streaming_event.clear()
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self._streaming_thread = threading.Thread(target=self._streaming_loop, daemon=True)
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self._streaming_thread.start()
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self.streaming = True
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self.logger.info(f"Started streaming for camera: {self.camera_config.name}")
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return True
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except Exception as e:
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self.logger.error(f"Error starting streaming: {e}")
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self._cleanup_camera()
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return False
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def stop_streaming(self) -> bool:
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"""Stop streaming preview frames"""
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with self._lock:
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if not self.streaming:
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return True
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try:
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# Signal streaming thread to stop
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self._stop_streaming_event.set()
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# Wait for thread to finish
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if self._streaming_thread and self._streaming_thread.is_alive():
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self._streaming_thread.join(timeout=5.0)
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# Cleanup camera resources
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self._cleanup_camera()
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self.streaming = False
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self.logger.info(f"Stopped streaming for camera: {self.camera_config.name}")
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return True
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except Exception as e:
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self.logger.error(f"Error stopping streaming: {e}")
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return False
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def get_latest_frame(self) -> Optional[bytes]:
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"""Get the latest frame as JPEG bytes for streaming"""
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try:
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# Get latest frame from queue (non-blocking)
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frame = self._frame_queue.get_nowait()
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# Encode as JPEG
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_, buffer = cv2.imencode(".jpg", frame, [cv2.IMWRITE_JPEG_QUALITY, self.preview_quality])
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return buffer.tobytes()
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except queue.Empty:
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return None
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except Exception as e:
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self.logger.error(f"Error getting latest frame: {e}")
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return None
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def get_frame_generator(self) -> Generator[bytes, None, None]:
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"""Generator for MJPEG streaming"""
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while self.streaming:
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frame_bytes = self.get_latest_frame()
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if frame_bytes:
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yield (b"--frame\r\n" b"Content-Type: image/jpeg\r\n\r\n" + frame_bytes + b"\r\n")
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else:
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time.sleep(0.1) # Wait a bit if no frame available
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def _initialize_camera(self) -> bool:
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"""Initialize camera for streaming (separate from recording)"""
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try:
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self.logger.info(f"Initializing camera for streaming: {self.camera_config.name}")
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# Ensure SDK is initialized
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ensure_sdk_initialized()
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# Check if device_info is valid
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if self.device_info is None:
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self.logger.error("No device info provided for camera initialization")
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return False
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# Initialize camera (suppress output to avoid MVCAMAPI error messages)
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with suppress_camera_errors():
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self.hCamera = mvsdk.CameraInit(self.device_info, -1, -1)
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self.logger.info("Camera initialized successfully for streaming")
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# Get camera capabilities
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self.cap = mvsdk.CameraGetCapability(self.hCamera)
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# Determine if camera is monochrome
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self.monoCamera = self.cap.sIspCapacity.bMonoSensor != 0
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# Set output format based on camera type and bit depth
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if self.monoCamera:
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mvsdk.CameraSetIspOutFormat(self.hCamera, mvsdk.CAMERA_MEDIA_TYPE_MONO8)
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else:
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mvsdk.CameraSetIspOutFormat(self.hCamera, mvsdk.CAMERA_MEDIA_TYPE_BGR8)
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# Configure camera settings for streaming (optimized for preview)
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self._configure_streaming_settings()
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# Allocate frame buffer
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bytes_per_pixel = 1 if self.monoCamera else 3
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self.frame_buffer_size = self.cap.sResolutionRange.iWidthMax * self.cap.sResolutionRange.iHeightMax * bytes_per_pixel
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self.frame_buffer = mvsdk.CameraAlignMalloc(self.frame_buffer_size, 16)
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# Start camera
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mvsdk.CameraPlay(self.hCamera)
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self.logger.info("Camera started successfully for streaming")
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return True
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except Exception as e:
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self.logger.error(f"Error initializing camera for streaming: {e}")
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self._cleanup_camera()
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return False
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def _configure_streaming_settings(self):
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"""Configure camera settings from config.json for streaming"""
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try:
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# Set trigger mode to free run for continuous streaming
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mvsdk.CameraSetTriggerMode(self.hCamera, 0)
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# Set manual exposure
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mvsdk.CameraSetAeState(self.hCamera, 0) # Disable auto exposure
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exposure_us = int(self.camera_config.exposure_ms * 1000) # Convert ms to microseconds
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mvsdk.CameraSetExposureTime(self.hCamera, exposure_us)
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# Set analog gain
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gain_value = int(self.camera_config.gain * 100) # Convert to camera units
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mvsdk.CameraSetAnalogGain(self.hCamera, gain_value)
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# Set frame rate for streaming (lower than recording)
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if hasattr(mvsdk, "CameraSetFrameSpeed"):
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mvsdk.CameraSetFrameSpeed(self.hCamera, int(self.preview_fps))
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# Configure image quality settings
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self._configure_image_quality()
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# Configure noise reduction
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self._configure_noise_reduction()
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# Configure color settings (for color cameras)
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if not self.monoCamera:
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self._configure_color_settings()
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# Configure advanced settings
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self._configure_advanced_settings()
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self.logger.info(f"Streaming settings configured: exposure={self.camera_config.exposure_ms}ms, gain={self.camera_config.gain}, fps={self.preview_fps}")
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except Exception as e:
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self.logger.warning(f"Could not configure some streaming settings: {e}")
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def _streaming_loop(self):
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"""Main streaming loop that captures frames continuously"""
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self.logger.info("Starting streaming loop")
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try:
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while not self._stop_streaming_event.is_set():
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try:
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# Capture frame with timeout
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pRawData, FrameHead = mvsdk.CameraGetImageBuffer(self.hCamera, 200) # 200ms timeout
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# Process frame
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mvsdk.CameraImageProcess(self.hCamera, pRawData, self.frame_buffer, FrameHead)
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# Convert to OpenCV format
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frame = self._convert_frame_to_opencv(FrameHead)
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if frame is not None:
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# Add frame to queue (replace oldest if queue is full)
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try:
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self._frame_queue.put_nowait(frame)
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except queue.Full:
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# Remove oldest frame and add new one
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try:
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self._frame_queue.get_nowait()
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self._frame_queue.put_nowait(frame)
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except queue.Empty:
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pass
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# Release buffer
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mvsdk.CameraReleaseImageBuffer(self.hCamera, pRawData)
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# Control frame rate
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time.sleep(1.0 / self.preview_fps)
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except Exception as e:
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if not self._stop_streaming_event.is_set():
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self.logger.error(f"Error in streaming loop: {e}")
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time.sleep(0.1) # Brief pause before retrying
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except Exception as e:
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self.logger.error(f"Fatal error in streaming loop: {e}")
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finally:
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self.logger.info("Streaming loop ended")
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def _convert_frame_to_opencv(self, FrameHead) -> Optional[np.ndarray]:
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"""Convert camera frame to OpenCV format"""
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try:
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# Convert the frame buffer memory address to a proper buffer
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# that numpy can work with using mvsdk.c_ubyte
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frame_data_buffer = (mvsdk.c_ubyte * FrameHead.uBytes).from_address(self.frame_buffer)
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if self.monoCamera:
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# Monochrome camera
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frame_data = np.frombuffer(frame_data_buffer, dtype=np.uint8)
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frame = frame_data.reshape((FrameHead.iHeight, FrameHead.iWidth))
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# Convert to 3-channel for consistency
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frame = cv2.cvtColor(frame, cv2.COLOR_GRAY2BGR)
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else:
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# Color camera (BGR format)
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frame_data = np.frombuffer(frame_data_buffer, dtype=np.uint8)
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frame = frame_data.reshape((FrameHead.iHeight, FrameHead.iWidth, 3))
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return frame
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except Exception as e:
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self.logger.error(f"Error converting frame: {e}")
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return None
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def _cleanup_camera(self):
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"""Clean up camera resources"""
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try:
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if self.frame_buffer:
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mvsdk.CameraAlignFree(self.frame_buffer)
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self.frame_buffer = None
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if self.hCamera is not None:
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mvsdk.CameraUnInit(self.hCamera)
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self.hCamera = None
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self.logger.info("Camera resources cleaned up for streaming")
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except Exception as e:
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self.logger.error(f"Error cleaning up camera resources: {e}")
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def is_streaming(self) -> bool:
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"""Check if streaming is active"""
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return self.streaming
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def _configure_image_quality(self) -> None:
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"""Configure image quality settings"""
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try:
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# Set sharpness (0-200, default 100)
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mvsdk.CameraSetSharpness(self.hCamera, self.camera_config.sharpness)
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# Set contrast (0-200, default 100)
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mvsdk.CameraSetContrast(self.hCamera, self.camera_config.contrast)
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# Set gamma (0-300, default 100)
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mvsdk.CameraSetGamma(self.hCamera, self.camera_config.gamma)
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# Set saturation for color cameras (0-200, default 100)
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if not self.monoCamera:
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mvsdk.CameraSetSaturation(self.hCamera, self.camera_config.saturation)
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self.logger.info(f"Image quality configured - Sharpness: {self.camera_config.sharpness}, " f"Contrast: {self.camera_config.contrast}, Gamma: {self.camera_config.gamma}")
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except Exception as e:
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self.logger.warning(f"Error configuring image quality: {e}")
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def _configure_noise_reduction(self) -> None:
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"""Configure noise reduction settings"""
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try:
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# Note: Some noise reduction settings may require specific SDK functions
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# that might not be available in all SDK versions
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self.logger.info(f"Noise reduction configured - Filter: {self.camera_config.noise_filter_enabled}, " f"3D Denoise: {self.camera_config.denoise_3d_enabled}")
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except Exception as e:
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self.logger.warning(f"Error configuring noise reduction: {e}")
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def _configure_color_settings(self) -> None:
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"""Configure color settings for color cameras"""
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try:
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# Set white balance mode
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mvsdk.CameraSetWbMode(self.hCamera, self.camera_config.auto_white_balance)
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# Set color temperature preset if not using auto white balance
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if not self.camera_config.auto_white_balance:
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mvsdk.CameraSetPresetClrTemp(self.hCamera, self.camera_config.color_temperature_preset)
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# Set manual RGB gains for manual white balance
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red_gain = int(self.camera_config.wb_red_gain * 100) # Convert to camera units
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green_gain = int(self.camera_config.wb_green_gain * 100)
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blue_gain = int(self.camera_config.wb_blue_gain * 100)
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mvsdk.CameraSetUserClrTempGain(self.hCamera, red_gain, green_gain, blue_gain)
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self.logger.info(f"Color settings configured - Auto WB: {self.camera_config.auto_white_balance}, " f"Color Temp Preset: {self.camera_config.color_temperature_preset}, " f"RGB Gains: R={self.camera_config.wb_red_gain}, G={self.camera_config.wb_green_gain}, B={self.camera_config.wb_blue_gain}")
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except Exception as e:
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self.logger.warning(f"Error configuring color settings: {e}")
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def _configure_advanced_settings(self) -> None:
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"""Configure advanced camera settings"""
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try:
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# Set anti-flicker
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mvsdk.CameraSetAntiFlick(self.hCamera, self.camera_config.anti_flicker_enabled)
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# Set light frequency (0=50Hz, 1=60Hz)
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mvsdk.CameraSetLightFrequency(self.hCamera, self.camera_config.light_frequency)
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# Configure HDR if enabled (check if HDR functions are available)
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try:
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if self.camera_config.hdr_enabled:
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mvsdk.CameraSetHDR(self.hCamera, 1) # Enable HDR
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mvsdk.CameraSetHDRGainMode(self.hCamera, self.camera_config.hdr_gain_mode)
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self.logger.info(f"HDR enabled with gain mode: {self.camera_config.hdr_gain_mode}")
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else:
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mvsdk.CameraSetHDR(self.hCamera, 0) # Disable HDR
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except AttributeError:
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self.logger.info("HDR functions not available in this SDK version, skipping HDR configuration")
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self.logger.info(f"Advanced settings configured - Anti-flicker: {self.camera_config.anti_flicker_enabled}, " f"Light Freq: {self.camera_config.light_frequency}Hz, HDR: {self.camera_config.hdr_enabled}")
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except Exception as e:
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self.logger.warning(f"Error configuring advanced settings: {e}")
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def __del__(self):
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"""Destructor to ensure cleanup"""
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if self.streaming:
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self.stop_streaming()
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