CN111427329B - Automatic detection system and method for controller - Google Patents
Automatic detection system and method for controller Download PDFInfo
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- CN111427329B CN111427329B CN202010180580.2A CN202010180580A CN111427329B CN 111427329 B CN111427329 B CN 111427329B CN 202010180580 A CN202010180580 A CN 202010180580A CN 111427329 B CN111427329 B CN 111427329B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
Abstract
The invention discloses an automatic detection system of a controller, which comprises a stabilized voltage power supply, a controller connector module, a heater host, a 12V/24V voltage switching module, a PLC (programmable logic controller) and a human-computer interface, wherein the stabilized voltage power supply is used for power supply and voltage regulation of the automatic detection system of the controller; the controller connector module is used for inserting the controller; the heater host is used for receiving the signal of the controller, and if the interior of the heater host runs normally, the controller sends out a control signal; if the heater host machine operates abnormally, the controller cannot send out a control signal; the 12V/24V voltage switching module is used for detecting signals sent by controllers driven by different voltages, and the controller connector module is respectively connected with the heater host and the 12V/24V voltage switching module; and the PLC communication port is connected with the human-computer interface communication port. The technical problems that the existing controller is not comprehensive in detection items, poor in product traceability and incapable of meeting automation and intelligent requirements can be solved.
Description
Technical Field
The invention relates to the technical field of controller detection, in particular to an automatic detection system and method for a controller.
Background
In the application field of the controller, as the controller is a key component, all signals are output to a mechanical structure by the controller to control the action of the mechanical structure, all functions and performances of a product are closely related to the controller, and if the controller fails or an internal program is not matched with the model of the whole machine, the quality of the product is seriously influenced, customers complain, and brand influence is reduced. It is particularly important and necessary to perform a verification test after the controller is fabricated. At present, a controller is connected with a complete machine to start a switch, then the controller is detected, whether part of main parts (including a main motor, a water pump and an ignition plug) on the complete machine act or not is observed through visual sense and auditory sense, and then whether the controller outputs signals or not is judged.
The existing controller cannot detect whether all main parts have signal output or not, detect whether an internal program is correct or not, detect incomplete items and poor product traceability, and cannot meet the requirements of automation and intellectualization.
An effective solution to the problems in the related art has not been proposed yet.
Disclosure of Invention
Aiming at the technical problems in the related art, the invention provides an automatic detection system and method for a controller, which can solve the technical problems that the existing controller is incomplete in detection items, poor in product traceability and incapable of meeting the requirements of automation and intellectualization.
In order to achieve the technical purpose, the technical scheme of the invention is realized as follows:
an automatic detection system of a controller comprises a voltage-stabilized power supply, a controller connector module, a heater host, a 12V/24V voltage switching module, a PLC controller and a human-computer interface, wherein,
the voltage-stabilizing power supply is used for power supply voltage regulation of the automatic detection system of the controller;
the controller connector module is used for inserting the controller;
the heater host is used for receiving the signal of the controller, and if the interior of the heater host runs normally, the controller sends out a control signal; if the heater host runs abnormally, the controller cannot send out a control signal;
the 12V/24V voltage switching module is used for detecting signals sent by controllers driven by different voltages and sending the signals to the 12 VPNP-to-24 VNPN module and the 24 VPNP-to-24 VNPN module;
the controller connector module is respectively connected with the heater host and the 12V/24V voltage switching module;
the normally open end and the normally closed end of the 12V/24V voltage switching module are respectively connected with a 12 VPNP-to-24 VNPN module input end and a 24 VPNP-to-24 VNPN module input end;
the input end of the PLC controller is respectively connected with the output end of a module for converting 12VPNP into 24VNPN and the output end of the module for converting 24VPNP into 24 VNPN;
and the PLC communication port is connected with the human-computer interface communication port.
Furthermore, the output end of the PLC is respectively connected with a load indication module and a seal driving module.
Furthermore, the load indication module sequentially detects a main motor signal, a water pump signal, an ignition plug signal and an electromagnetic pump signal.
Further, the 12 VPNP-24 VNPN module and the 24 VPNP-24 VNPN module are configured to convert a high level signal output by the controller into a low level signal at an input end of the PLC controller through optical coupling isolation processing.
Further, the output end of the voltage-stabilized power supply is connected with a switch module.
Further, the output end of the PLC is connected with a buzzer.
In another aspect of the present invention, an automatic detection method for a controller is provided, which includes the following steps:
s1, calling the product model stored in the system on a human-computer interface, and setting the detection parameters of the corresponding controller;
s2, starting the switch module, and converting the high level signal into the low level signal after the controller sends the high level signal through the voltage switching module and the optical coupling isolation high-low level conversion module;
s3, the PLC receives a low level signal sent by the controller, detects each path of signal of the controller according to a control program, judges and drives an indicator light in a corresponding load indicating module to light up according to the signal, the detection sequence is a main motor signal, a water pump signal, an ignition plug signal and an electromagnetic pump signal, the corresponding load indicating light is a green light, a blue light, a red light and a yellow light in sequence, the indicator light corresponding to each path of load lights up, the PLC sends a control command, and the command on the corresponding load indicating module is communicated to a human-machine interface;
s4, when the load indicator lamps are not lightened according to the quantity specified by the program within the set time, the PLC sends a command to the buzzer to alarm, and the controller is prompted to be unqualified; the load indicating lamps are all sequentially lighted within the set time, a high-speed counting module in the PLC starts to count pulse signals sent by the controller, the PLC performs analysis and calculation to obtain a real-time oil consumption value, and the PLC communicates a pulse counting value and the oil consumption value to a human-computer interface;
and S5, stopping counting by the high-speed counting module, analyzing and judging by the PLC according to the product model, the on-off condition of each loop load and the oil consumption value, detecting whether the controller is qualified, communicating the judgment result to a human-computer interface, and recording and storing the detection result.
S6, if the PLC controller judges that the seal is qualified, the seal driving module is driven to act, a qualified mark is made on the shell of the controller, and the seal driving module is reset; and if the LC controller judges that the seal module is not qualified, the seal module is driven to have no action.
The invention has the beneficial effects that:
the automatic alarm and automatic recording and storage of the detected defective products are realized through the PLC and the human-computer interface, the upgrading conversion from the judgment of the qualification of the products by people to the automatic judgment of the system is realized, the detection items are supplemented and perfected, the visualization of the monitoring of the load running state is realized, the adjustment of the detection parameters of the products with different models is realized, and the automatic and intelligent detection of the controller is realized;
the detection precision is improved by perfecting the supplement of the detection items, the product quality is improved, complaints of customers are reduced, the rework and maintenance cost is reduced, the dependence on people is reduced through automatic alarm, and the traceability of the product is improved through automatic recording and storing of data.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
Fig. 1 is a schematic diagram of an automatic detection system of a controller according to an embodiment of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.
As shown in fig. 1, an automatic controller detection system according to an embodiment of the present invention is characterized by comprising a regulated power supply, a controller connector module, a heater host, a 12V/24V voltage switching module, a PLC controller and a human-machine interface, wherein,
the voltage-stabilizing power supply is used for power supply voltage regulation of the automatic detection system of the controller;
the controller connector module is used for inserting the controller;
the heater host is used for receiving the signal of the controller, and if the interior of the heater host runs normally, the controller sends out a control signal; if the heater host runs abnormally, the controller cannot send out a control signal;
the 12V/24V voltage switching module is used for detecting signals sent by controllers driven by different voltages and sending the signals to the 12 VPNP-to-24 VNPN module and the 24 VPNP-to-24 VNPN module;
the controller connector module is respectively connected with the heater host and the 12V/24V voltage switching module;
the normally open end and the normally closed end of the 12V/24V voltage switching module are respectively connected with a 12 VPNP-to-24 VNPN module input end and a 24 VPNP-to-24 VNPN module input end;
the input end of the PLC controller is respectively connected with the output end of a module for converting 12VPNP into 24VNPN and the output end of the module for converting 24VPNP into 24 VNPN;
and the PLC communication port is connected with the human-computer interface communication port.
In a specific embodiment of the present invention, the output end of the PLC controller is respectively connected to a load indication module and a stamp driving module.
In an embodiment of the present invention, the load indication module detects a main motor signal, a water pump signal, an ignition plug signal and an electromagnetic pump signal in sequence.
In an embodiment of the present invention, the 12VPNP to 24VNPN module and the 24VPNP to 24VNPN module are configured to convert a high level signal output by the controller into a low level signal at an input end of the PLC controller through optical coupling isolation processing.
In an embodiment of the invention, the output end of the voltage-stabilized power supply is connected with a switch module.
In a specific embodiment of the invention, the output end of the PLC controller is connected with a buzzer.
In another aspect of the present invention, an automatic detection method for a controller is provided, which is characterized by comprising the following steps:
s1, calling the product model stored in the system on a human-computer interface, and setting the detection parameters of the corresponding controller;
s2, starting the switch module, and converting the high level signal into the low level signal after the controller sends the high level signal through the voltage switching module and the optical coupling isolation high-low level conversion module;
s3, the PLC receives a low level signal sent by the controller, detects each path of signal of the controller according to a control program, judges and drives an indicator light in a corresponding load indicating module to light up according to the signal, the detection sequence is a main motor signal, a water pump signal, an ignition plug signal and an electromagnetic pump signal, the corresponding load indicating light is a green light, a blue light, a red light and a yellow light in sequence, the indicator light corresponding to each path of load lights up, the PLC sends a control command, and the command on the corresponding load indicating module is communicated to a human-machine interface; and if the air heating controller is detected, the water pump signal is not detected.
S4, when the load indicator lamps are not lightened according to the quantity specified by the program within the set time, the PLC sends a command to the buzzer to alarm, and the controller is prompted to be unqualified; the load indicating lamps are all sequentially lighted within the set time, a high-speed counting module in the PLC starts to count pulse signals sent by the controller, the PLC performs analysis and calculation to obtain a real-time oil consumption value, and the PLC communicates a pulse counting value and the oil consumption value to a human-computer interface;
and S5, stopping counting by the high-speed counting module, analyzing and judging by the PLC according to the product model, the on-off condition of each loop load and the oil consumption value, detecting whether the controller is qualified, communicating the judgment result to a human-computer interface, and recording and storing the detection result.
S6, if the PLC controller judges that the seal is qualified, the seal driving module is driven to act, a qualified mark is made on the shell of the controller, and the seal driving module is reset; and if the LC controller judges that the seal module is not qualified, the seal module is driven to have no action.
In order to facilitate understanding of the above-described technical aspects of the present invention, the above-described technical aspects of the present invention will be described in detail below in terms of specific usage.
And the touch screen on the human-computer interface is used for calling the stored material model, setting corresponding detection parameters, displaying the load running state of each path, judging whether the controller is qualified or not and recording and storing the detection result.
The 12 VPNP-to-24 VNPN module and the 24 VPNP-to-24 VNPN module are used for converting a high level signal output by the controller into a PLC input end low level signal through optical coupling isolation processing, and if controllers driven by different voltages are detected, the 12V/24V voltage switching module needs to be started.
The controller is connected with the connector module, the controller performs self-checking firstly after the switch module is started, if all main parts of the heater host are normal, the controller can send a control signal, the detection system works normally, if the main parts of the heater host are abnormal, the controller cannot send the control signal, the detection system cannot work, and therefore the heater host is used for self-checking of the controller, and meanwhile, the controller also detects whether the heater host is normal or not.
When the seal box is used specifically, after the PLC receives a signal sent by the controller, the PLC sends a control command to the load indication module, the seal driving module and the human-computer interface. The PLC controller receives the controller signal, judges and drives the indicator lamps in the corresponding load indicating modules to light up according to the signal (when a certain loop has a signal, the corresponding load indicator lamps light up, a certain loop has no signal, and the corresponding load indicator lamps do not light up), and when the corresponding load indicator lamps do not light up according to the specified quantity of the program within the specified time, the PLC controller sends a command to the buzzer to alarm, and the controller is prompted to be unqualified; when the controller sends out a pulse signal, the PLC controller counts pulses through an internal high-speed counter, the pulse counting is finished within a specified time, the oil consumption value of the controller is obtained through the analysis and calculation of the PLC controller, and the oil consumption value is displayed on a human-computer interface.
In summary, by means of the technical scheme of the invention, upgrading transition from the condition that whether products are qualified is judged by people to the condition that the products are judged automatically by a system is realized, visualization of load running state monitoring is realized, adjustability of detection parameters of products of different models is realized, automatic and intelligent detection of a controller is realized, supplement and perfection of detection items are realized, detection accuracy is improved, product quality is improved, complaints of customers are reduced, and rework and maintenance cost is reduced.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (1)
1. An automatic detection method of a controller is characterized by comprising the following steps,
s1, calling the product model stored in the system on a human-computer interface, and setting the detection parameters of the corresponding controller;
s2, starting the switch module, and converting the high level signal into the low level signal after the controller sends the high level signal through the voltage switching module and the optical coupling isolation high-low level conversion module;
s3, the PLC receives a low level signal sent by the controller, detects each path of signal of the controller according to a control program, judges and drives an indicator light in a corresponding load indicating module to light up according to the signal, the detection sequence is a main motor signal, a water pump signal, an ignition plug signal and an electromagnetic pump signal, the corresponding load indicating light is a green light, a blue light, a red light and a yellow light in sequence, the indicator light corresponding to each path of load lights up, the PLC sends a control command, and the command on the corresponding load indicating module is communicated to a human-machine interface;
s4, when the load indicator lamps are not lightened according to the quantity specified by the program within the set time, the PLC sends a command to the buzzer to alarm, and the controller is prompted to be unqualified; the load indicating lamps are all sequentially lighted within the set time, a high-speed counting module in the PLC starts to count pulse signals sent by the controller, the PLC performs analysis and calculation to obtain a real-time oil consumption value, and the PLC communicates a pulse counting value and the oil consumption value to a human-computer interface;
s5, stopping counting by the high-speed counting module, analyzing and judging by the PLC according to the product model, the on-off condition of each loop load and the oil consumption value, detecting whether the controller is qualified, communicating the judgment result to a human-computer interface, and recording and storing the detection result;
s6, if the PLC controller judges that the seal is qualified, the seal driving module is driven to act, a qualified mark is made on the shell of the controller, and the seal driving module is reset; and if the PLC judges that the seal module is not qualified, the seal module is driven to have no action.
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