CN109738847B - Meter calibration method based on meter active self-calibration - Google Patents
Meter calibration method based on meter active self-calibration Download PDFInfo
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Abstract
The invention discloses a meter calibration method based on meter active self-calibration, which adopts a mode of a meter to be calibrated and a calibration device, wherein the meter to be calibrated actively judges whether the calibration is qualified or not according to a meter calibration scheme and parameters stored in the meter to be calibrated by combining test data and upper and lower limits of errors built in the meter to be calibrated, and uploads verification data and a judgment result to a management system. The original passive meter calibration is changed into the active control automatic meter calibration of the calibration device, so that the development and maintenance of meter calibration upper computer software with different protocols are reduced, and meanwhile, the calibration equipment is changed from active to passive, so that the calibration equipment is simplified.
Description
Technical Field
The invention relates to a high-speed meter calibrating method based on meter active self-calibration, which is mainly used for calibrating an intelligent electric energy meter.
Background
With the overall planning of the national network on the next generation smart grid, the large administrative policy of the portable source internet and the requirement of the national network on fine management, the technical complexity of the meter becomes higher and higher, and many small meter enterprises are difficult to bear the continuous high-intensity research and development investment and gradually adopt an OEM mode. After OEMs may gradually become a mainstream business, in order to win orders of OEMs, the automation degree and the production efficiency must be improved, because only the automation degree and the production efficiency are high, the cost is competitive, on the other hand, the manpower cost of china continuously rises, the internal manufacturing cost continuously increases, and the external market competition is more and more intense, so that the reduction and the increase of the number of the members are particularly important, and the requirement of enterprises for improving the production efficiency is more urgent.
The traditional meter calibration mode is that the meter is a passively calibrated product, the calibration stage body and the automatic meter calibration assembly line are active calibration devices, the stage body and the automatic assembly line initiate and control the whole meter calibration process and judgment of a result, and the following two problems exist: 1. the efficiency is low. The table body or the automatic assembly line is active, so that the table body can initiate meter calibration work only after all the meter positions are detected to be in place, the meters of all the meter positions need to be hung in the common table body during meter calibration, the meters of all the meter positions need to be put in bins during meter calibration of the automatic assembly line, waiting time is very long, most time is wasted, and the integral meter calibration efficiency is very low.
2. The equipment or the assembly line is too complex, so that the instability is caused, and the capacity loss is caused. The device is required to output stable voltage, current and phase of a calibration meter, and is also required to have control capability for controlling different calibration gear positions and communication capability of meters with different communication protocols, error calculation capability of the meters with each meter position is required, output capability of isolated current is required for a two-wire single-phase meter, and isolation capability of voltage is required for a calibration table body of a three-phase meter, so that the whole table body or a production line becomes very complex, and in order to meet the requirements, the device is divided into a signal source, a standard meter, a voltage power amplifier, a current power amplifier, an isolated CT (computed tomography), an error calculator, an isolated PT (potential transformer) and other parts and is assembled, and meter calibration software of different meters is required to be installed on a computer; therefore, the whole meter and the table body are very complicated, and once the equipment and the software are complicated, the reliability is reduced, so that the problems of the meter calibration table body and the meter calibration assembly line frequently occur in a workshop, the whole production line is stopped for maintenance, and the production is seriously influenced.
Disclosure of Invention
In order to solve the technical problems, the invention provides a high-speed meter calibrating method based on meter active self-calibration.
The invention adopts the following technical scheme:
a meter calibration method based on meter active self-calibration, the method comprises the following steps:
s1, placing the detected table on a tray, actively reading the template number of the detected table by the management system, and judging the working procedure according to the template number (the template number is the factory internal number, is unique and not repeated, and is similar to the identity card number and used for representing the identity of the identity card); if the process is judged to pass, the tray with the checked meter enters a meter calibration station, and the step S2 is executed; if the process is judged not to pass, the management system commands the PLC control system to output alarm information and distributes the tray to other transportation lines;
s2, after the tray enters the meter calibration station, the PLC control system sends the information that the tray is in place to the management system, and the management system sets parameters of the calibration device (portable source and source for short) corresponding to each meter calibration station according to the information of the checked meter;
s3, the management system sends an output voltage instruction to the checking device, the checking device loads rated voltage for the checked meter to supply power for the checked meter, and the management system commands the checking device to output a normal running state signal of equipment (a station indicator lamp of the checking meter is turned on);
s4, after the detected table is electrified, the verifying device actively sends a command that the detected table is electrified to the management system, the management system receives the command and sends a response to the verifying device, and a table calibrating enabling command is sent to the detected table after a few seconds of delay;
s5, the checked meter sends a parameter packet (the parameter packet contains the meter type, the basic voltage, the current, the output frequency, the output phase sequence, the current direction, the power factor and the like) to the checking device, requests the checking device to load voltage and current signals, automatically judges whether the checking is qualified or not according to the checking meter scheme and the parameter active checking meter stored in the checking device under the condition that the checking device outputs stability by combining the test data and the upper and lower limits of the error built in the checked meter, and uploads the checking data and the judgment result to the management system;
and each meter checking station is correspondingly provided with one checking device, the checking devices are independent from each other and are respectively in communication connection with a management system, and the PLC control system is in communication connection with the management system.
The management system is installed in the PC end, comprises the whole production process of the electric meters, and records which processes each electric meter undergoes in real time, so as to judge whether the current process conforms to the production process.
Further, in step S1, the table to be detected is placed on the tray, and the management system actively reads the template number of the table to be detected, and performs process determination according to the template number, specifically:
the method comprises the following steps that a to-be-detected table is arranged on a tray (the tray is provided with an RFID label for distinguishing identities), the to-be-detected table is electrified through an electrifying station of a previous process, and a management system actively sends an instruction for obtaining a template number of the to-be-detected table to the to-be-detected table; and after receiving the instruction, the detected table sends the template number to the management system, and meanwhile, the management system reads corresponding tray information through the power-on station RFID reader-writer, binds the tray information with the detected table information, and then judges the working procedure according to the acquired template number.
Further, the step S2 specifically includes:
after the tray enters the meter correcting station, the PLC control system sends the information that the tray is in place to the management system, the PLC control system reads the tray information through the meter correcting station RFID reader-writer on each meter correcting station and uploads the tray information to the management system, the management system binds the checked meter information with the calibration device of the meter correcting station according to the corresponding relation between the meter correcting station RFID reader-writer and the calibration device corresponding to the meter correcting station, and parameter setting is carried out on the calibration device corresponding to each meter correcting station according to the binding relation. The binding is to trace and count the subsequent data, and the unqualified table extracted by the subsequent spot check can be checked back to check which checking device is calibrated so as to be processed and maintained in time.
Further, in step S5, after receiving the calibration enabling command, the table to be checked sends a parameter packet to the calibration apparatus, and requests the calibration apparatus to load voltage and current signals, which specifically includes:
after receiving the meter calibration enabling command, the meter to be tested actively sends the command to the calibration device for adjustment according to the scheme and the parameters stored in the meter to be tested, and the calibration device automatically adjusts and outputs the command and outputs voltage and current signals to the meter to be tested.
Still further, in step S5, the method for determining that the output of the verification device is stable includes:
after receiving the voltage and current signals loaded by the verifying device, the checked meter inquires whether the output of the verifying device is stable, and the verifying device feeds a stable result back to the checked meter according to the inquiry;
if the checked table receives the 'adjustment' instruction, the checked table resends the inquiry and waits for the check device to reply;
if the checked meter receives a success command, the meter is automatically calibrated;
if the checked meter receives the 'failure' instruction, the result is sent to the management system, the management system feeds back the result to the checked meter and controls the verification device to power down, the verification device is controlled to output a fault alarm signal, meanwhile, the PLC control system is controlled to conduct line body shunting, and the meter calibration of the meter calibration station is stopped. The line body shunting is that the PLC control system selects where to flow according to the conclusion of a measured table in the tray in the line body, the qualified tray automatically flows to the next work station, and the unqualified tray flows to the maintenance station.
Whether the power value is stable or not is judged by the CPU in the checking device, namely whether the output voltage, the output current and the output power are accurate or not by the CPU, and whether the output power value is stable or not is judged by the CPU, whether the output power value is accurate or not is judged by comparing the source output value with a theoretical value, whether the error range is controlled within +/-0.2%, whether the output power value is stable or not is judged by reading the difference value between the power value and the average value of the internal standard table within a certain time according to continuous seconds of the checking device, and whether the error range is controlled within +/-0.05%, namely, the checking device is stable.
In the existing mode, a software control source of an upper computer at a computer end outputs and reads a voltage value U2, a current value I2 and a power value W2 of a meter calibration device, and sends the voltage value, the current value and the power value W2 to a tested meter, the tested meter calculates according to the voltage value, the current value and the power value which are sampled by the tested meter and U2, I2 and W2, calculates a difference value and a correction coefficient, and writes the difference value and the correction coefficient into a storage chip.
In step S4, the to-be-detected meter actively controls the calibration device to output voltage and current according to the test points in the calibration scheme, after the calibration device is stabilized, the to-be-detected meter reads the voltage value U1, the current value I1 and the power value W1 output by the calibration device, and the to-be-detected meter calculates the difference and the correction coefficient according to the voltage value, the current value and the power value which are sampled by the to-be-detected meter and the values of U1, I1 and W1, and writes the difference and the correction coefficient into the memory chip to complete the calibration.
Preferably, the method for calibrating a meter further comprises:
and S6, the management system feeds back the received judgment result to the checked meter, if the link of the meter calibration is qualified, the checked meter executes the step S5 to automatically calibrate the meter of the next link, if the link of the meter calibration is unqualified, the management system commands the calibration device to be powered off (the power off is that the management system controls the calibration device to reduce the source (the voltage and current output is 0), the calibration device does not supply power to the checked meter) and outputs an unqualified signal, and the management system commands the PLC control system to perform tray shunting and stop the meter calibration.
More preferably, the method further comprises:
and S7, if all the meter calibrating links of the meter to be calibrated are qualified, the management system feeds back the received result to the meter to be calibrated after receiving the judgment result and the qualified total conclusion of the last meter calibrating link, commands the calibration device to be powered down, outputs a qualified signal, completes the meter calibration, and commands the PLC control system to perform tray distribution.
It should be noted that, in the process of calibrating the table (S4-S6), the table to be checked cannot be powered down.
In addition, the invention provides a meter calibrating device, which comprises epitopes for placing a checked meter, wherein each epitope is correspondingly provided with one calibrating device, and each calibrating device is respectively in communication connection with the checked meter on the corresponding epitope; the check devices are independent from each other and are respectively in communication connection with the management system.
Further, in order to facilitate automatic control and reduce labor cost, the meter calibrating device further comprises a PLC control system in communication connection with the management system, and the PLC control system is used for automatically controlling the whole meter calibrating process.
Further, the calibration device is a portable calibration device (portable source, source for short), and is internally provided with a communication conversion module for communication among the calibration device, the to-be-detected meter and the management system, and a power source for outputting voltage and current to the to-be-detected meter.
Compared with the prior art, the invention has the following beneficial effects:
1. the innovation of the calibration mode is that the to-be-tested meter actively controls the calibration device to calibrate the meter automatically, the development and maintenance of meter calibration upper computer software with different protocols are reduced, meanwhile, the calibration equipment is changed from active to passive, and the calibration equipment is simplified.
2. The meter calibration efficiency is high, one meter is used for one source, and all meter positions can be calibrated in parallel without mutual influence.
3. The equipment modularization, degree of automation is high, adopts one table one source mode, and the wiring is simple, and it is convenient to maintain.
4. The meter automatically controls the source to automatically correct the meter according to a built-in scheme, and the meter correcting result meter automatically judges and uploads the upper limit and the lower limit of a built-in error to a management system for real-time monitoring.
Drawings
FIG. 1 is a block diagram of the system of the present invention.
FIG. 2 is a flow chart of the present invention.
Detailed Description
In order to facilitate understanding of the technical solutions of the present invention, the following detailed description is made with reference to the accompanying drawings and specific embodiments.
As shown in FIG. 1, the meter calibration method based on meter active self-calibration according to the present invention is performed in the meter calibration apparatus shown in FIG. 1. The meter checking device comprises a plurality of meter positions for placing the checked meter, each meter position is correspondingly provided with a checking device (portable source and source for short), and each checking device is respectively in communication connection with the checked meter on the corresponding meter position; the check devices are independent from each other and are in communication connection with a management system of the PC terminal respectively. The meter position is provided with a meter position used for hanging the meter and a meter position indicator lamp for displaying the meter hanging state, the checking device further comprises a power source and a communication conversion module, the power source is mainly used for outputting voltage and current to the tested meter and providing the voltage and the current for the tested meter, and the communication conversion module is used for communication scheduling and protocol conversion among the tested meter, the power source and a management system installed at the PC end. Specifically, a HUB (HUB)/switch is arranged between the meter calibration device and the PC end, and network data transmission is realized through a network TCP/IP protocol Socket interface. In addition, a PLC control system is added according to production requirements to control automatic control of the whole process, and the PLC control system and the management system also adopt a network TCP/IP protocol Socket interface to realize network data transmission.
The management system is specifically an MES system installed at a PC end, comprises the whole production flow of the electric meters, and records which flows each electric meter experiences in real time, so as to judge whether the current process accords with the production flow.
As shown in fig. 2, the meter calibrating method based on meter active self-calibration by using the meter calibrating device comprises the following steps:
s1: the method comprises the following steps that a detected table is arranged on a tray, the detected table is electrified through an electrifying station of a previous process, and a management system actively sends an instruction for acquiring a template number of the detected table to the detected table; and after receiving the instruction, the detected table sends the template number to the management system, meanwhile, the management system reads corresponding tray information through the power-on station RFID reader-writer, binds the tray information and the detected table information with the detected table and then judges the process according to the acquired template number. If the task of the meter to be calibrated exists, if the process is judged to pass, the tray containing the checked meter enters a meter calibrating station, and the step S2 is executed; if the task of the meter to be calibrated does not exist, if the process judgment fails, the management system commands the PLC control system to output alarm information and distributes the tray to other transportation lines.
S2: after the tray enters the meter correcting station, the PLC control system sends the information that the tray is in place to the management system, the PLC control system reads the tray information through the meter correcting station RFID reader-writer on each meter correcting station and uploads the tray information to the management system, the management system binds the checked meter information with the calibration device of the meter correcting station according to the corresponding relation between the meter correcting station RFID reader-writer and the calibration device corresponding to the meter correcting station, and parameter setting is carried out on the calibration device corresponding to each meter correcting station according to the binding relation. The binding is for follow-up data tracing and statistics, and the unqualified table extracted by the subsequent spot check can be checked back to check which checking device is calibrated so as to be processed and maintained in time.
S3: the management system sends an output voltage instruction to the checking device, the checking device loads rated voltage for the checked meter to supply power for the checked meter, and simultaneously the management system instructs the checking device to output a normal operation state signal (a green light of a station indicator lamp of the checking meter is on) of the equipment.
S4: after the detected table is electrified, the verification device actively sends a command that the detected table is electrified to the management system, the management system receives the command and sends a response to the verification device, and a table calibration enabling command is sent to the detected table after a few seconds of delay.
S5: after receiving the meter enable command, the meter under test actively sends a command to the checking device to be adjusted according to the internally stored scheme and parameters (the parameters include meter type, basic voltage, current, output frequency, output phase sequence, current direction, power factor, etc.), the checking device automatically adjusts the output according to the command, outputs voltage and current signals to the meter under test, actively checks the meter according to the internally stored meter scheme and parameters under the condition that the output of the checking device is stable, reads the instantaneous voltage value U1, the current value I1 and the power value W1 output by the checking device, calculates the error and the correction coefficient according to the voltage value and the current value which are sampled by the meter under test and the parameters U1, I1 and W1, writes the error and the correction coefficient into the chip, and stores the check data and the result (including the data of the test point and the data of the meter under test and the conclusion whether the meter is qualified or not automatically judged according to the upper and the lower limits of the built-in error, error data refers to the absolute value of the difference between the instantaneous value of the checking device and the instantaneous value of the detected table) and is judged and uploaded to the management system;
the method for judging the output stability of the checking device comprises the following steps: after receiving the voltage and current signals loaded by the checking device, the checked table sends an instruction for inquiring whether the checking device is stable to the checking device, after the checking device receives the instruction, an internal CPU (central processing unit) firstly judges the output accuracy, compares a source output value with a theoretical value, controls an error range to be +/-0.2%, then judges the power stability, reads a difference value between a power value and an average value of an internal standard table according to continuous seconds within a certain time of the checking device, judges that the checking device is stable after the error range is +/-0.05%, and feeds a stable result back to the checked table (the stable result has three states of being adjusted, successful and failed, and 20s of upper limit time of stability), and after receiving the instruction of being adjusted, the checked table resends the inquiry instruction and waits for the checking device to reply; if the checked meter receives a success command, the meter is automatically calibrated; if the checked meter receives the 'failure' instruction, the state of the meter position checking device is determined to be abnormal by default, the state is unqualified and sent to the management system, the management system responds to the checked meter and actively controls the checking device to be powered off, the checking device is controlled to output a fault alarm signal (the red light of the station indicator lamp of the meter checking device is on), the meter checking is stopped, and manual intervention is carried out.
S6: and the management system feeds back the judgment result to the checked meter, if the link of the meter checking is qualified, the checked meter executes the step S5 to automatically check the meter of the next link, if the link of the meter checking is unqualified, the management system commands the calibration device to power down (the power-down indicates to reduce the source of the checked meter and remove the loaded rated voltage) and outputs an unqualified signal (the red light of a station indicator lamp of the meter checking is on), and the management system commands the PLC control system to perform tray shunting and stop the meter checking.
S7: if all the meter calibrating links of the checked meter are qualified, after receiving the judgment result and the total qualified conclusion of the last meter calibrating link, the management system feeds back the received result to the checked meter, commands the calibration device to be powered down, outputs a qualified signal (the green lamp of the meter calibrating station indicator lamp flickers), completes meter calibration, commands the PLC control system to perform tray shunting, and then commands the calibration device to output the state of the meter position vacancy (the yellow lamp of the meter calibrating station indicator lamp is turned on).
It should be noted that in the process of calibrating the table (S4-S7), the power of the table to be checked cannot be cut, otherwise, manual intervention is needed to calibrate the table again. The calibration table of each link needs to inquire whether the calibration device is stable or not.
When the meter calibration is stopped in the meter calibration process and manual intervention is needed, an operator can read the stopping reason from the management system.
The above is only a preferred embodiment of the present invention, and the scope of the present invention is defined by the appended claims, and several modifications and amendments made by those skilled in the art without departing from the spirit and scope of the present invention should be construed as the scope of the present invention.
Claims (10)
1. A meter calibration method based on meter active self-calibration is characterized by comprising the following steps:
s1, placing the table to be detected on the tray, actively reading the template number of the table to be detected by the management system, and judging the working procedure according to the template number; if the process is judged to pass, the tray with the checked meter enters a meter calibration station, and the step S2 is executed; if the process is judged not to pass, the management system commands the PLC control system to output alarm information and shunts the pallet to other transport lines;
s2, after the tray enters the meter calibration station, the PLC control system sends the information that the tray is in place to the management system, and the management system sets parameters of the calibration device corresponding to each meter calibration station according to the information of the checked meter;
s3, the management system sends an output voltage instruction to the checking device, and the checking device loads rated voltage for the detected meter and supplies power to the detected meter;
s4, after the detected table is electrified, the verifying device actively sends a command that the detected table is electrified to the management system, the management system receives the command and sends a response to the verifying device, and a table calibrating enabling command is sent to the detected table after a few seconds of delay;
s5, the checked meter sends a parameter packet to the checking device, requests the checking device to load voltage and current signals, actively checks the meter according to the meter checking scheme and the parameters stored in the checking device under the condition that the output of the checking device is stable, automatically judges whether the checking is qualified or not by combining the test data and the upper and lower limits of the error built in the checked meter, and uploads the checking data and the judgment result to the management system;
and each meter checking station is correspondingly provided with one checking device, the checking devices are independent from each other and are respectively in communication connection with a management system, and the PLC control system is in communication connection with the management system.
2. The method according to claim 1, wherein in step S1, the table to be checked is placed on a tray, and the management system actively reads the template number of the table to be checked and performs process determination according to the template number, specifically:
the method comprises the following steps that a detected table is arranged on a tray, the detected table is electrified through an electrifying station of a previous process, and a management system actively sends an instruction for acquiring a template number of the detected table to the detected table; and after receiving the instruction, the detected table sends the template number to the management system, and meanwhile, the management system reads corresponding tray information through the power-on station RFID reader-writer, binds the tray information with the detected table information, and then judges the working procedure according to the acquired template number.
3. The method according to claim 2, wherein the step S2 specifically comprises:
after the tray enters the meter correcting station, the PLC control system sends the information that the tray is in place to the management system, the PLC control system reads the information of the tray through the meter correcting station RFID reader-writer on each meter correcting station and uploads the information to the management system, the management system binds the checked meter information with the calibration device of the meter correcting station according to the corresponding relation between the meter correcting station RFID reader-writer and the calibration device corresponding to the meter correcting station, and parameter setting is carried out on the calibration device corresponding to each meter correcting station according to the binding relation.
4. The method according to claim 1, wherein in step S5, after receiving the calibration enabling command, the table to be checked sends a parameter packet to the checking apparatus, requesting the checking apparatus to load the voltage and current signals, specifically:
after receiving the meter calibration enabling command, the meter to be tested actively sends the command to the calibration device for adjustment according to the scheme and the parameters stored in the meter to be tested, and the calibration device automatically adjusts and outputs the command and outputs voltage and current signals to the meter to be tested.
5. The method for calibrating a meter according to claim 1, wherein in step S5, the method for determining the output stability of the calibration device comprises:
after receiving the voltage and current signals loaded by the verifying device, the checked meter inquires whether the output of the verifying device is stable, and the verifying device feeds a stable result back to the checked meter according to the inquiry;
if the checked table receives the 'adjustment' instruction, the checked table resends the inquiry and waits for the check device to reply;
if the checked meter receives a success command, the meter is automatically calibrated;
if the checked meter receives the 'failure' instruction, the result is sent to the management system, the management system commands the verification device to power down after responding to the checked meter, commands the verification device to output a fault alarm signal, commands the PLC control system to perform tray shunting, and stops the meter calibration of the meter calibration station.
6. A method for calibrating a table according to claim 1, wherein in step S5, the method for actively calibrating a table according to the table calibrating scheme and parameters stored therein comprises:
the method comprises the steps that a checked table actively controls a checking device to output voltage and current according to a test point in a checking scheme, after the checking device is stabilized, the checked table reads a voltage value U1, a current value I1 and a power value W1 output by the checking device, and meanwhile, the checked table calculates according to the voltage value, the current value and the power value which are sampled by the checked table, the current value and the power value U1, I1 and W1, calculates a difference value and a correction coefficient, and writes the difference value and the correction coefficient into a storage chip to finish checking the table.
7. A method of calibrating a meter as set forth in claim 1, further comprising:
and S6, the management system feeds back the received judgment result to the table to be checked, if the link of the table checking is qualified, the table to be checked executes the step S5 to automatically check the table in the next link, if the link of the table checking is unqualified, the management system commands the checking device to be powered down and outputs an unqualified signal, and the management system commands the PLC control system to carry out tray distribution and stop the table checking.
8. A method of calibrating a meter as set forth in claim 7, said method further comprising:
and S7, if all the meter calibrating links of the meter to be calibrated are qualified, the management system feeds back the received result to the meter to be calibrated after receiving the judgment result and the qualified total conclusion of the last meter calibrating link, commands the calibration device to be powered down, outputs a qualified signal, completes meter calibration, and commands the PLC control system to perform tray distribution.
9. A school table device, includes the epitope that is used for placing the table examined, its characterized in that: each meter position is correspondingly provided with a checking device, and each checking device is respectively in communication connection with the checked meter on the corresponding meter position; the checking devices are independent from each other and are respectively in communication connection with the management system; the meter calibrating device executes the meter calibrating method of any one of claims 1-8.
10. A calibration device according to claim 9, wherein: the meter calibrating device also comprises a PLC control system which is in communication connection with the management system, and the PLC control system is used for automatically controlling the meter calibrating process; the checking device is a portable checking device, a communication conversion module used for mutual communication among the checking device, the checked meter and the management system is arranged in the checking device, and a power source used for outputting voltage and current to the checked meter is arranged in the checking device.
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