CN106950464B - Armored car cable fault detection system based on path optimization - Google Patents

Abstract

A cable fault detection system based on path optimization consists of a host computer, a public interface, a tested cable, a connecting cable and an auxiliary computer, wherein the system has preliminary fault diagnosis capability, further controls related hardware equipment, realizes control of a main relay array and an auxiliary relay array, enables a cable core, a voltage source and a sampling circuit which are connected with contacts of the main relay array to be connected and switched in a regular manner, acquires signals, conditions and displays the signals, and simultaneously optimizes the next test path continuously so as to quickly judge and position all faults. The system can dynamically optimize the test path in the detection process, stably and reliably work and improve the cable fault detection efficiency.

Description

Armored car cable fault detection system based on path optimization

Technical Field

The invention belongs to the technical field of intelligent detection and control, and relates to a detection system for cable faults in an armored car based on path optimization.

Background

Cables of various kinds and diameters, which are as long as tens of kilometers, are distributed inside a certain armored vehicle, and are used for conveying power sources, control signals and data information to various parts in the vehicle. The cable system is limited by the internal space of the vehicle body, and is often influenced by strong external force impact, cold and hot, pollution, electrochemistry and other factors in the combat and training process, so that potential faults of the cable system are increased, one fault phenomenon can have a plurality of different fault points, and one fault point can also generate a plurality of different fault phenomena. At present, no cable detection system specially aiming at a certain type of armored vehicle exists, the traditional cable detection device basically adopts a method for testing the whole cable system one by one to find faults, certain blindness consumes time, and if all cables are subjected to pressure resistance test one by one, damage to the insulativity of the cables is enlarged; the traditional detection device generally adopts an integrated structure, and is not convenient for detecting cables with fixed positions and relatively dispersed distribution in a certain armored vehicle; in addition, CPLD is mostly adopted in the common cable detection device, and the control scale is large and fast, but the cost is high, the stability is difficult to meet the requirement of military products, and the system redundancy is caused; in addition, the other detection devices can only perform single on-off detection, and cannot perform insulation, short circuit detection and fault positioning at the same time. Therefore, a detection system for quickly detecting and positioning cable faults in situ of the original vehicle needs to be developed.

Disclosure of Invention

The invention aims to solve the problems of the prior art, improve the defects and shortcomings of the prior art and provide a cable fault detection system based on path optimization.

The technical scheme adopted by the invention is as follows:

the detection system comprises a touch screen industrial personal computer 1, a main relay array 2, a secondary relay array 3, a chargeable power supply 4, an MSP430 singlechip 5, a high-voltage module 6, an electric quantity detection module 7, an overcurrent/overload protection module 8, a level conversion and voltage stabilization circuit 9, a sampling circuit 10, a main relay array driving circuit 11 and a secondary relay array driving circuit 12; MSP430 singlechip 5 links to each other with main relay array drive circuit 11 and vice relay array drive circuit 12 respectively, main relay array drive circuit 11 links to each other with main relay array 2, vice relay array drive circuit 12 links to each other with vice relay array 3, industrial computer 1 communicates with MSP430 singlechip 5 links to each other, electric quantity detection module 7, overcurrent/overload protection module 8, level conversion and voltage stabilizing circuit 9 all link to each other with chargeable power supply 4's output, high-voltage module 6 and sampling circuit 10 link to each other with the 61 core aviation plug common port of slave computer and host computer through the normally open contact of relay respectively.

The relay array and the driving circuit adopt solid state relays with high stability, and the relay array is driven by adopting two stages of chips; the first-stage driving chip adopts four 74HC138D 3 to 8 line decoders, and drives eight 8 output decoders 74HC4051 of the second-stage chip, and the driving circuits in the main machine and the auxiliary machine jointly drive the relay array to control the connection and disconnection of the aviation socket 61 core.

The power management system comprises a level conversion and voltage stabilization filter circuit and a power supply control circuit, wherein the level conversion and voltage stabilization filter circuit consists of a 12V chargeable direct current power supply, an overcurrent/overload protection module, an electric quantity detection module, chips 7805-SOT223 and LM1117, and the power supply control circuit consists of a high-voltage source for HVWG24X direct current boosting and an auxiliary machine power supply control circuit.

The control part of the armored car cable fault detection system is developed based on the king and IAR platform, and realizes cooperative control of the relay array; the device comprises the following functional modules: the system comprises a common function module (I), a cable category and number selection module (II), a data management and query module (III), a fault library and optimization path display module (IV), an initialization and electric quantity detection module (V), a signal acquisition and conditioning module (VI), a path optimization algorithm module (VII) and a communication protocol module (VIII).

The common function module I consists of interfaces such as a configuration Wang Dengliu management interface, a help menu, power supply and electric quantity display, a state indication and the like, wherein the help menu comprises a real vehicle cable distribution model, a use connection and an operation instruction, and related operations are limited under different state indications; the cable type and number selection module II is divided into fire control, gun control, automatic loading machine and grounding cable type selection, each type of cable is further selected in a plurality of groups, and the topology structure diagram of the cable can be displayed after the corresponding cable is selected; the data management and query module III stores the detection data of the tested cable every time and provides fault data analysis and query for maintenance personnel; the fault library and the optimized path display module IV comprise cable fault phenomena and mapping relations between the fault phenomena and fault reasons, the fault rules are written and extracted by maintenance personnel with rich experience to detect historical data of the system, a fault range can be primarily diagnosed, and an optimal path of the cable fault is searched in the optimized path display detection process. The initialization and electric quantity detection module V initializes an I/O port, a USART communication serial port, an A/D conversion and a timer and the like of the lower computer, acquires power supply electric quantity change through the lower computer, sends a Wang Shishi animation display of the configuration and reminds of low-electric quantity charging; the signal acquisition and conditioning module VI enables the relay array to be connected into the detection loop according to a certain number sequence, acquires the on-resistance, the insulation resistance (voltage-resistant grade) and the short circuit condition of the tested cable, conditions the signal into the range which can be processed by the singlechip, and performs multiple measurement and average value; the path optimization algorithm module VII performs weighted traversal on the cable network in the fault occurrence area, specifically, the last detection result is combined with the occurrence rate of the cable fault part to give the next optimal detection path, the cable fault part and the occurrence rate thereof in the refined historical data are taken as weighted values, and the occurrence rate is updated after each time of fault detection; the communication protocol module VIII realizes the efficient and stable transmission of data between the configuration king and the singlechip.

The communication protocol module (VIII) is a communication mode of the singlechip and the configuration Wang Caiyong RS-232, communication parameters and byte data format are determined by the singlechip programming, the communication parameters set in the configuration king are consistent with the communication parameters, and the register data address defined in the configuration king corresponds to the data address of the singlechip; the basic format of the communication read-write command is as follows: header + device address + flag + data address + data byte number + data + exclusive or + CR; when the communication is normal and abnormal, the response format of the lower computer is slightly changed; the process of reading data from the singlechip by the configuration king is as follows: the configuration Wang Fasong reads the command data stream, the singlechip verifies the equipment address, if the equipment address is met, the data address is continuously verified, otherwise, the singlechip sends communication abnormality to the configuration king, if the address is in the RAM of the singlechip, the singlechip receives the command and performs CRC (cyclic redundancy check), otherwise, the singlechip sends the communication abnormality to the configuration king, and if the verification is successful, the singlechip sends the data in the address to the configuration king; the data writing process of the configuration king to the singlechip is as follows: the configuration Wang Fasong writes the command data stream, the singlechip verifies the equipment address, if the equipment address is met, the data address is continuously verified, otherwise, the singlechip sends communication abnormality to the configuration king, if the address is in the RAM of the singlechip, the singlechip receives the data and performs CRC (cyclic redundancy check), otherwise, the singlechip sends the communication abnormality to the configuration king, and if the verification is successful, the singlechip stores the received data in the address.

After the detection system is used, when the electric quantity is too low, the host computer displays an alarm of the too low electric quantity, and the battery should be charged immediately. Clicking a slave to supply power, selecting a fault phenomenon in a fault list, inquiring, primarily obtaining the fault reason and range of a cable, selecting a certain serial cable of a corresponding category to start detection, continuously transmitting data to a lower computer by a configuration king, when the lower computer receives a signal, firstly executing a serial port interrupt subroutine, analyzing the data according to a communication protocol, then jumping to execute a timer interrupt subroutine to detect a corresponding cable group according to an analyzed data command, jumping to a relay array driving subroutine to control a corresponding relay to be closed by the subroutine, and then executing an on-resistance detection acquisition subroutine and an insulation resistance detection acquisition subroutine respectively. After the acquired data are conditioned, a path optimization program is executed to analyze historical fault data and combine the cable which has been detected to obtain the category and number data of the cable to be detected next time. And finally, packaging all data according to a communication protocol, sending the data to the configuration king, and analyzing and displaying a report and optimizing a detection path according to the configuration Wang Duishu.

Compared with a method for detecting cable faults of certain armored vehicles one by utilizing CPLD and integrated detection equipment, the armored vehicle cable fault detection system has the advantages of higher efficiency detection performance, better stability and portability, low power consumption and strong endurance capacity, is simple and efficient in program, and can realize the training requirement of quickly and accurately positioning the cable system faults in situ of the original vehicle.

Drawings

FIG. 1 is a connection diagram of a cable detection system.

Fig. 2 is a schematic diagram of a cable detection system.

Fig. 3 is a block diagram of a decoder circuit.

Fig. 4 is a schematic diagram of a relay array access cable.

Fig. 5 is a schematic diagram of insulation resistance measurement.

Fig. 6 is a schematic diagram of a filter circuit.

Fig. 7 is a schematic diagram of a power management system.

FIG. 8 is a block diagram of a system.

Fig. 9 is a flowchart of a main routine.

FIG. 10 is a flow chart of continuity detection.

Fig. 11 is a flowchart of insulation resistance detection.

In the figure: 1 touch screen industrial personal computer, 2 main relay array, 3 auxiliary relay array, 4 chargeable power supply,

5 MSP430 singlechip, 6 high-voltage module, 7 electric quantity detection module, 8 overcurrent/overload protection module,

9 level switching and voltage stabilizing circuits, 10 sampling circuits, 11 main relay array driving circuits,

12 pairs of relay array driving circuits.

Description of the embodiments

The following detailed description of the invention refers to the accompanying drawings

In an example implementation, as shown in fig. 1, a cable detection system is a connection diagram, where the detection system is composed of a host, an auxiliary machine, a connection cable and a transfer cable. The connection definition of the transfer cable and the cable system inside a certain type of armored car is matched, the transfer cable is manufactured according to the optimal test principle along with the classification of the cable to be tested, each class is divided into a plurality of groups, and each group is paired. First, the host provides power and transmits control signals to the slave computer through the connection cable. And the main machine and the auxiliary machine are respectively provided with a 61-core aviation socket connection switching cable, and the 61-core aviation socket meets the maximum requirement of single-time tested cable core number. In addition, the host is provided with an interface for connecting a cable, a USB interface, a storage battery charging interface, a power switch and an indicator lamp. The tested cable is connected between the main machine and the auxiliary machine through the transfer cable, the relay arrays are distributed in the main machine and the auxiliary machine, the relays can be divided into two types, the first type of relay arrays control the connection and disconnection of all pins in 61-core sockets on the main machine and the auxiliary machine, and the second type of relays control the connection of an overcurrent/overload protection circuit, a main machine and auxiliary machine power supply, a +5V constant voltage source, a high-voltage direct current source and a resistance sampling circuit.

In the hardware block diagram of the detection system of fig. 2, the host comprises a touch screen industrial personal computer and a singlechip. The detection system written by the configuration king is used as an interface of man-machine interaction, the configuration king has the functions of rich equipment drivers, flexible configuration modes, visual operation interfaces, historical data query and management and the like, and is very suitable for development of the detection system. A16-bit ultra-low power consumption singlechip MSP430F149 of TI company is adopted as a controller, the controller has various low power consumption modes, the wake-up time is short, the power supply voltage is 3.3V, 12-bit high-precision AD acquisition conversion is integrated in a chip, 32I/O ports are matched with a specific driving circuit to control the on-off of 131 relays in the detection system, and the singlechip and the configuration king are communicated through an RS232 bus. The relay driving circuits of fig. 3 and 4 are formed by two-stage chip expansion, wherein first 12I/O ports drive four 3-to-8-wire decoders 74HC138D, and the standard outputs of the four 74HC138D decoders drive eight 8-output decoders 74HC4051. Eight 74HC4051 have 64 outputs and are connected with corresponding triodes to control 61 relays.

Fig. 7 is a schematic diagram of a power management system, including a battery charging and supplying module, an overcurrent/overload protection module, an electric quantity detection module, a level conversion and voltage stabilization circuit, a high voltage power supply module, and a main and auxiliary machine power supply control circuit. The power supply voltage of the storage battery is direct current 12V, the battery capacity is 10AH, the charging current is less than 5A, the stable working current is less than 10A, the maximum instantaneous current is 15A, and the working temperature is-20-60 ℃. Overcurrent/overload protection module: when the discharge current of the storage battery is detected to be continuously larger than a certain upper limit, the output signal end DOUT outputs a high level, the normally closed contact of the relay is disconnected by 12VGD, the normally open contact is closed, the pin of the singlechip P57 is connected with a high level, a power-off alarm signal is transmitted to the singlechip, when the current is recovered to be normal, the relay is automatically reset, the delay action time of the relay can be set, the output oscillation is prevented, and the whole circuit is damaged. The electric quantity detection module is used for detecting the change of electric quantity by collecting the output voltage of the power supply to be detected, and can lighten diodes with different colors, meanwhile, five single-chip microcomputer I/O ports P5.0-P5.4 are connected, and the king displays the residual electric quantity of the battery through analyzing the level change animation of the single-chip microcomputer I/O ports. Level conversion and voltage stabilizing circuit: the +12V direct current supplied by the battery is changed into +5V and +3.3 power supplies in sequence through level conversion chips 7805-SOT223, LM1117-3.3 and a voltage stabilizing and filtering circuit, so that different electricity requirements are met. The high-voltage power supply module HVWG24X is a 12V direct-current boost power supply, the input ends MV2 and MV3 are controlled by the relay CQ64 to be connected with low level, and the direct-current high voltage of +250V and +500V can be output in a switching mode.

Fig. 8 the control part of the present invention is divided into the following modules. The upper computer: the system comprises a common function module I, a cable category and number selection module II, a data management and query module III, a fault library and an optimized path display module IV. The lower computer: the system comprises an initialization and electric quantity detection module V, a signal acquisition and conditioning module VI, a path optimization algorithm module VII and a communication protocol module VIII.

Fig. 9, 10, 11 detection flow: the login configuration Wang Jiance interface is used for selecting corresponding fault phenomena in a fault list, clicking and inquiring to obtain possible fault reasons, range and cable category numbers suggested to be detected, supplying power to an auxiliary machine, continuously sending data to a lower computer by a configuration king, selecting a cable model and a group after connecting cables to be detected, clicking a start detection button, respectively connecting a constant voltage source and a collection circuit to the first common end and the second common end of all the detected core wires by a relay when detecting the conduction condition of the cables, sequentially connecting all the detected core wires to a loop, collecting conduction resistance, and calculating and averaging; fig. 5 is an insulation resistance detection schematic diagram, in which a high voltage source and an acquisition circuit are connected to a common end of a tested cable respectively during insulation detection, insulation grades of core wires can be detected by switching different high voltage sources, then all core wires of the tested cable are sequentially connected to a host end, after each core wire is connected, the rest core wires are connected to a secondary end one by one, insulation resistance between any two core wires in the tested cable is acquired, calculation processing is performed to obtain an average value, and insulation between the core wires, a short circuit condition and a short circuit wire number are judged according to resistance orders. Such an n-core cable would be tested n x (n-1)/2 times in total. And then, path optimization is carried out to obtain the number of the next detection cable, finally, all data are sent to an upper computer according to the format of a communication protocol between the detection cable and the configuration king, the upper computer analyzes and displays conduction, short circuit and insulativity between the detection cable and the current cable core wire of the next optimal path in the form of report patterns and the like, and the detection cable and the current cable core wire can be saved in a historical database. The next detection path is continuously optimized in such a way that the weighting traverses and its neighboring cables of the same hierarchy, its connection cables to the front piece and its connection cables to the back piece. Until all faults are detected.

The cable fault detection system can be used for carrying out in-situ rapid detection and fault positioning on the original vehicle on the on-off, short circuit and insulativity of the cable of the whole armored vehicle, and has the advantages of flexible operation, low power consumption, stability and reliability.

Claims (1)

1. The armored vehicle cable fault detection system based on path optimization is characterized by comprising a touch screen industrial personal computer (1), a main relay array (2), an auxiliary relay array (3), a chargeable power supply (4), an MSP430 singlechip (5), a high-voltage module (6), an electric quantity detection module (7), an overcurrent/overload protection module (8), a level conversion and voltage stabilization circuit (9), a sampling circuit (10), a main relay array driving circuit (11) and an auxiliary relay array driving circuit (12);

the MSP430 singlechip (5) is respectively connected with the main relay array driving circuit (11) and the auxiliary relay array driving circuit (12), the main relay array driving circuit (11) is connected with the main relay array (2), the auxiliary relay array driving circuit (12) is connected with the auxiliary relay array (3), the industrial personal computer (1) and the MSP430 singlechip (5) are connected through an RS232 interface for communication, the electric quantity detection module (7), the overcurrent/overload protection module (8) and the level conversion and voltage stabilizing circuit (9) are connected with the output end of the chargeable power supply (4) for managing the power supply, and the high-voltage module (6) and the sampling circuit (10) are respectively connected with the common end of the 61-core aviation plugs of the slave computer and the host computer through normally open contacts of the relay;

the relay array and the driving circuit adopt solid state relays with high stability, and the relay array is driven by adopting two stages of chips; the first-stage driving chip adopts four 74HC138D 3 to 8 line decoders, then drives eight 8 output decoders 74HC4051 of the second-stage chip, and the driving circuits in the main machine and the auxiliary machine jointly drive the relay array to control the connection and disconnection of the aviation socket 61 core;

the power management system comprises a level conversion and voltage stabilization filter circuit and a power supply control circuit, wherein the level conversion and voltage stabilization filter circuit consists of a 12V chargeable direct current power supply, an overcurrent/overload protection module, an electric quantity detection module, chips 7805-SOT223 and LM1117, and the power supply control circuit consists of a high-voltage source for HVWG24X direct current boosting and an auxiliary machine power supply control circuit;

the control part of the armored vehicle cable fault detection system is developed based on the king and IAR platform, and realizes cooperative control of the relay array; the device comprises the following functional modules: the system comprises a common functional module (I), a cable category and number selection module (II), a data management and query module (III), a fault library and optimization path display module (IV), an initialization and electric quantity detection module (V), a signal acquisition and conditioning module (VI), a path optimization algorithm module (VII) and a communication protocol module (VIII);

the common function module (I) comprises login management, a help menu, power supply and electric quantity display, state indication and result storage, wherein the help menu comprises a real vehicle cable distribution model, use connection and operation instructions, and related operations are limited under different state indications; the module mainly performs a management function on a host;

the cable type and number selecting module (II) is used for selecting types and numbers of fire control, gun control, automatic loading machine and grounding cables, and displaying the connection mode of the cables in a test state and a topological structure diagram thereof after selecting the cables with corresponding numbers, so that a tester can conveniently know the cable structure and locate and search cable faults;

the data management and query module (III) displays and stores reports of the data of each test cable, can query the fault condition of the cable, statistics historical data to obtain the cable with multiple fault types and positions, improves the maintenance efficiency and pertinence, performs operations such as deleting, modifying and inserting the data, and improves the expandability of the system;

the fault library and the optimized path display module (IV) comprise all possible cable fault phenomena and the corresponding relations between the fault phenomena and fault reasons, the fault rules are compiled by experienced maintenance personnel and are obtained by continuously refining historical data of the detection system, the initial determination of the fault range is facilitated, and the optimal path of the cable fault is searched in the optimized path display detection process;

the initialization and electric quantity detection module (V) initializes an I/O port, a USART communication serial port, an A/D conversion and timer and the like of the lower computer; the electric quantity detection program acquires the electric quantity change of a power supply in real time through a lower computer, the level change of I/O ports of five single-chip computers P5.0-P5.4 represents different percentages of the residual electric quantity, and the module displays five-level electric quantity;

after the upper computer sends a command for detecting a certain cable, the signal acquisition and conditioning module jumps to execute a corresponding statement, so that a corresponding relay is closed according to a formulated sequence, a core wire to be detected is connected between a constant voltage source, a high voltage source and a signal acquisition circuit to form a loop, and then corresponding data are acquired for multiple times, signal conditioning and average value taking are carried out;

the path optimization algorithm module (VII) is used for obtaining the next optimal detection path cable by taking the occurrence rate of the cable fault part as a weight value according to all the completed detection results, carrying out weighted traversal on the cable network of the fault occurrence area, extracting the cable fault part and the occurrence rate thereof from historical data, and updating the fault occurrence rate after detecting the fault every time;

the communication protocol module (VIII) is a communication mode of the singlechip and the configuration Wang Caiyong RS-232, communication parameters and byte data format are determined by the singlechip programming, the communication parameters set in the configuration king are consistent with the communication parameters, and the register data address defined in the configuration king corresponds to the data address of the singlechip; the basic format of the communication read-write command is as follows: header + device address + flag + data address + data byte number + data + exclusive or + CR; when the communication is normal and abnormal, the response format of the lower computer is slightly changed; the process of reading data from the singlechip by the configuration king is as follows: the configuration Wang Fasong reads the command data stream, the singlechip verifies the equipment address, if the equipment address is met, the data address is continuously verified, otherwise, the singlechip sends communication abnormality to the configuration king, if the address is in the RAM of the singlechip, the singlechip receives the command and performs CRC (cyclic redundancy check), otherwise, the singlechip sends the communication abnormality to the configuration king, and if the verification is successful, the singlechip sends the data in the address to the configuration king; the data writing process of the configuration king to the singlechip is as follows: the configuration Wang Fasong writes the command data stream, the singlechip verifies the equipment address, if the equipment address is met, the data address is continuously verified, otherwise, the singlechip sends communication abnormality to the configuration king, if the address is in the RAM of the singlechip, the singlechip receives the data and performs CRC (cyclic redundancy check), otherwise, the singlechip sends the communication abnormality to the configuration king, and if the verification is successful, the singlechip stores the received data in the address.

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