CN111338322A - Main control cabinet test system and test method - Google Patents
Main control cabinet test system and test method Download PDFInfo
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- CN111338322A CN111338322A CN202010187055.3A CN202010187055A CN111338322A CN 111338322 A CN111338322 A CN 111338322A CN 202010187055 A CN202010187055 A CN 202010187055A CN 111338322 A CN111338322 A CN 111338322A
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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
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R19/00—Arrangements for measuring currents or voltages or for indicating presence or sign thereof
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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
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24065—Real time diagnostics
Abstract
A test system and test method of the master control cabinet, the test system includes the power distribution module, automatic control debug cabinet, PC and needle type frock module; the automatic control debugging cabinet comprises a first air switch, a switching power supply module and a PLC (programmable logic controller); the PLC is used for outputting a control signal to provide a starting test instruction for a loop to be tested in the main control cabinet to be tested when any loop test is carried out on the main control cabinet to be tested, acquiring an output signal corresponding to the loop to be tested, and judging whether the loop to be tested in the main control cabinet to be tested passes the test or not according to the output signal; the pin type tooling module is used for testing a connector between the cabinet and the cabin cabinet to be tested and enabling input/output signals between the main control cabinet to be tested and the PLC to be in a connection and conduction state. The test system automatically completes various function tests of the main control cabinet to be tested, so that frequent wiring and disconnecting work is not required, the test flow is simplified, and the test time of the main control cabinet is greatly reduced.
Description
Technical Field
The invention belongs to the technical field of testing of a main control cabinet of wind power generation equipment, and particularly relates to a main control cabinet testing system and a testing method thereof.
Background
Wind power is the mainstream form of wind energy utilization, and nowadays of global energy crisis, wind power is moving to all countries in the world in one of the power generation forms with the most mature technology and the fastest cost reduction in renewable energy. Meanwhile, various policies of various countries in the world greatly support the wind power industry and develop the wind power technology. In recent years, the wind power industry and the wind power technology in China are rapidly developed, and with the excellent output performance of a megawatt grid-connected wind turbine generator at a power grid end, the wind power technology is continuously breaking through the bottleneck and is developed to a larger megawatt level.
The wind generating set is produced from the beginning of a factory to the on-site grid-connected operation power generation of a wind power plant, the test process comprises the factory test of the whole wind generating set and the wind field test, and the normal operation of the fan is ensured by testing the performance of each electrical functional unit (such as a PLC unit, a current transformation unit, a main control unit, a yaw unit and the like) and mechanical parts of the wind generating set and the reliability of the software logic control regulation function.
At present, in order to ensure the normal operation of the test work of the master control system cabinet, the problems of the master control system are discovered as soon as possible, and the production efficiency is improved. Before assembling the wind turbine generator, the main control cabinet is tested independently. However, in the existing testing method, manual testing is adopted, faults are triggered by disconnecting, short-circuiting and the like, and testing of each loop of the main control system is gradually completed according to a debugging report, so that the problem of complex operation amount is more complicated to locate, human error factors easily exist, and the testing efficiency is not high. In view of the situation, in the wind power industry, many manufacturers research a master control system test system, such as a ZL 201110363480.4 large-scale wind generating set master control test system and method and a ZL201320621814.8 wind generating set pitch system and master control system test device, but in the actual use process, the workload of wiring and disconnecting between test equipment and tested equipment is large, the time is spent, and the improvement on the whole debugging efficiency is limited.
Disclosure of Invention
Objects of the invention
The invention aims to provide a main control cabinet testing system and a testing method, which are used for solving the problems of low debugging efficiency and easy existence of human error factors caused by manually testing and wiring each loop step by step in the existing testing method.
(II) technical scheme
In order to solve the above problems, a first aspect of the present invention provides a test system for a main control cabinet, including a power distribution module, an automatic control debugging cabinet, a PC, and a pin tool module;
the output end of the power distribution module is respectively connected with a main control cabinet to be tested and the automatic control debugging cabinet and is used for supplying power to the main control cabinet to be tested and the automatic control debugging cabinet;
the automatic control debugging cabinet comprises a first air switch, a switching power supply module and a PLC (programmable logic controller); the output end of the power distribution module is connected with the switching power supply module through a first air switch, and the output end of the switching power supply module is connected with the PLC to supply power to the PLC;
the PC is loaded with test software for testing various loops of the main control cabinet to be tested;
the PLC is respectively connected with the PC and the main control cabinet to be tested through the needle type tooling module, and is used for outputting a control signal to provide a starting test instruction for a circuit to be tested in the main control cabinet to be tested when any circuit of the main control cabinet to be tested is tested, acquiring an output signal corresponding to the circuit to be tested, and judging whether the circuit to be tested in the main control cabinet to be tested passes the test according to the output signal.
Further, the needle type tool module comprises a needle type tool body, a handheld fixing unit and a needle type inserting unit;
one end of the handheld fixing unit is firmly welded with the needle type tool body, and the other end of the handheld fixing unit comprises a handheld handle which is used for fixing the whole tool on a metal guide rail to which the terminal row in the main control cabinet to be tested belongs;
the needle type inserting unit comprises a corresponding number of needles, the needles penetrate through the base of the tool and are provided with a certain length at the base, and the elastic elements are arranged in the middle of the needles, so that the needles can be conveniently pressed down by the elastic elements and have corresponding elastic force with the terminals to be tested, and the needles are fully contacted;
the head end of the pin is directly pressed on the terminal to be tested, and the tail end of the pin is welded with the lead-out cable, so that the signal transmission is facilitated.
Furthermore, when the input/output signal of the loop to be tested is connected with the output/input port of the PLC controller and the voltage is suitable, the input/output signal of the corresponding loop to be tested is directly connected with the PLC controller; when the input/output signal of the loop to be tested is connected with the output/input port of the PLC and the voltage is not suitable, the automatic control debugging cabinet further comprises a relay module, the relay module comprises a plurality of relays, and the input/output signal of the loop to be tested is transmitted to the corresponding relay in the relay module through the needle type tool module and is connected with the PLC.
Furthermore, each loop to be tested comprises a communication loop test, a voltage loop test and an analog quantity loop test.
Further, the voltage loop test comprises an alternating current 230V voltage loop test;
the relay module comprises an alternating current 230V voltage loop test unit which is used for carrying out input/output alternating current 230V voltage loop test on a main control cabinet to be tested, the alternating current 230V voltage loop test unit comprises a plurality of relays, coils of the relays are cascaded with corresponding contacts, one end of each relay is connected with the needle type tool module after the cascade connection, normally open contacts of the relays are connected to corresponding PLC controllers, the PLC controllers are electrified and attracted through the corresponding relay coils and receive corresponding signals through the normally open contacts, and therefore the on-off condition of the loop is judged;
the input port of the alternating-current 230V voltage loop of the main control cabinet to be tested is connected with the power distribution module through the second air switch, and the output port of the alternating-current 230V voltage loop of the main control cabinet to be tested is respectively connected with the coils of the plurality of relays through the needle type tooling module.
Further, the voltage loop test comprises a direct current 24V voltage loop test; the needle type tool module comprises a direct current 24V voltage loop test unit and is used for performing input/output direct current 24V voltage loop test on a main control cabinet to be tested;
the direct-current 24V voltage loop test unit comprises a plurality of terminals, a direct-current 24V signal input/output by the main control cabinet to be tested is provided with a corresponding terminal and is transmitted to the PLC through the needle type tooling module, and the PLC judges whether the tested loop is qualified or not through the received direct-current 24V signal.
Furthermore, the relay module comprises an analog quantity loop test unit which is used for testing an analog quantity loop of the main control cabinet to be tested; the analog quantity loop test unit comprises a plurality of relays and corresponding sensors, normally open contacts of the relays in the module share one group of sensors, and the plurality of relays are controlled by a PLC (programmable logic controller) to control whether the sensors are connected into the analog quantity loop to test.
Further, the sensor includes a temperature sensor.
A second aspect of the present invention provides a testing method for the main control cabinet testing system, including the following steps:
connecting the main control cabinet to be tested with the automatic control debugging cabinet through the needle type tool module;
powering on to start the test system and starting the test software of the PC;
sequentially testing all loops of the main control cabinet to be tested, and automatically detecting the next loop if detecting that a certain loop of the main control cabinet to be tested is normal; if one loop is detected to be abnormal, displaying abnormal alarm information, and then continuing to detect the next loop;
and generating a test report after the test of all the loops is completed.
Further, the step of testing each loop of the master control cabinet to be tested in sequence comprises:
testing a communication loop of the main control cabinet to be tested: if the communication loop has no problem, the testing software interface displays the working state and the running data of the communication loop of the main control cabinet to be tested in real time, if the communication loop is abnormal, the testing software interface cannot display the working state and the running data of the communication loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
testing an alternating current 230V voltage loop of the main control cabinet to be tested: if the alternating-current 230V voltage loop has no problem, the testing software interface displays the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested in real time, if the alternating-current 230V voltage loop is abnormal, the testing software interface cannot display the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
testing a direct-current 24V voltage loop of the main control cabinet to be tested: if the direct-current 24V voltage loop has no problem, the test software interface displays the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested in real time, if the direct-current 24V voltage loop is abnormal, the test software interface cannot display the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the test result;
testing an analog quantity loop of the main control cabinet to be tested: if the value measured by the analog quantity loop is within the preset range, the analog quantity loop has no problem, the test software interface displays the working state and the running data of the analog quantity loop of the main control cabinet to be tested in real time, if the value measured by the analog quantity loop is not within the preset range, the analog quantity loop is abnormal, the test software interface cannot display that the value measured by the main control cabinet to be tested is within the preset range, the working state and the running data of the analog quantity loop or display abnormal alarm information, and the test result is recorded.
In summary, the present invention provides a test system and a test method for a main control cabinet, wherein the test system comprises a power distribution module, an automatic control debugging cabinet, a PC and a pin tool module; the automatic control debugging cabinet comprises a first air switch, a switching power supply module and a PLC (programmable logic controller); the PLC is used for outputting a control signal to provide a starting test instruction for a loop to be tested in the main control cabinet to be tested when any loop test is carried out on the main control cabinet to be tested, acquiring an output signal corresponding to the loop to be tested, and judging whether the loop to be tested in the main control cabinet to be tested passes the test or not according to the output signal; the pin type tooling module is used for testing a connector between the cabinet and the cabin cabinet to be tested and enabling input/output signals between the main control cabinet to be tested and the PLC to be in a connection and conduction state. The test system automatically completes various function tests of the main control cabinet to be tested, so that frequent wiring and disconnecting work is not required, the test flow is simplified, and the test time of the main control cabinet is greatly reduced.
(III) advantageous effects
The technical scheme of the invention has the following beneficial technical effects:
the test system only needs to insert the needle type tool module into a main control cabinet to be tested before the test is started, when a certain test is operated, a controller output control signal is utilized to provide a starting test instruction for a loop to be tested in the main control cabinet to be tested, whether the loop to be tested passes the test is judged according to a signal fed back by the loop to be tested, an input/output signal of the loop to be tested is connected with an output/input port of the controller through the needle type tool module, when a signal is collected and is not suitable, the signal matching of the controller and the loop to be tested is realized through the relay module, various function tests of part of the main control cabinet to be tested are automatically completed, and therefore frequent wiring, disconnecting, manual short-circuit and other works are not needed, the test flow is simplified, the test time of the main control cabinet is reduced.
Drawings
FIG. 1 is a schematic diagram of the overall configuration of a test system according to the present invention;
FIG. 2 is a schematic structural diagram of a needle tool module in the test system according to the present invention;
FIG. 3 is a schematic diagram of the overall configuration of a test system including a relay module according to the present invention;
FIG. 4 is a simplified diagram of a fiber optic communication loop of the test system of the present invention;
FIG. 5 is a simplified test circuit diagram of the AC 230V voltage loop of the test system of the present invention;
FIG. 6 is a simplified DC 24V voltage loop test circuit diagram of the test system of the present invention;
FIG. 7 is a simplified diagram of an analog loop test circuit of the test system of the present invention.
FIG. 8 is a flow chart illustrating a testing method of the testing system of the present invention;
fig. 9 is a flowchart illustrating a testing method of a testing system according to an embodiment of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings in conjunction with the following detailed description. It should be understood that the description is intended to be exemplary only, and is not intended to limit the scope of the present invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.
The invention provides a test system of a main control cabinet, as shown in fig. 1, which comprises a power distribution module 1, an automatic control debugging cabinet 2, a PC 3 and a pin tool module 4. The output end of the power distribution module 1 is respectively connected with the main control cabinet 5 to be tested and the automatic control debugging cabinet 2, and is used for supplying power to the main control cabinet 5 to be tested and the automatic control debugging cabinet 2. The automatic control debugging cabinet 2 comprises a first air switch 21, a switching power supply module 22 and a PLC (programmable logic controller) 23; the output end of the power distribution module 1 is connected with a switch power supply module 22 through a first air switch 21, and the output end of the switch power supply module 22 is connected with a PLC (programmable logic controller) 23 to supply power for the PLC 23. The PC 3 is loaded with test software for testing various loops of the main control cabinet to be tested. The PLC controller 23 is respectively connected with the PC 3 and the main control cabinet 5 to be tested through the needle type tooling module 4, and is used for outputting a control signal to provide a starting test instruction for a circuit to be tested in the main control cabinet 5 to be tested when any circuit of the main control cabinet 5 to be tested is tested, acquiring an output signal of a corresponding circuit to be tested, and judging whether the circuit to be tested in the main control cabinet 5 to be tested passes the test according to the output signal. Specifically, the main control cabinet 5 to be tested obtains power from the 400V voltage of the external power distribution module 1 through the second air switch 6. This debugging cabinet 2 gets the electricity from the 400V of outside distribution module 1, through first air switch 21, converts 230V voltage into 24V voltage through switching power supply module 22, provides operating voltage for PLC controller 23. The PLC 23 is connected with the PC 3 through a network cable and establishes communication, and is connected with the main control cabinet 5 to be tested through an optical fiber communication cable and establishes communication, test software is loaded on the PC 3, and the PLC 23 carries out real-time observation on various collected data information of the main control cabinet 5 to be tested through the test software on the PC 3 through a digital input port. The PLC 23 tests the PC 3 through test software, transmits the test software to each loop of the main control cabinet 5 to be tested through the digital output port and the needle type tool module 4, and tests each loop through automatically controlling the working state in the debugging cabinet 2. One end of the needle type tooling module 4 is connected with a wiring terminal in the debugging cabinet 2, and the other end of the needle type tooling module is a connector which can be quickly plugged and pulled out from a terminal in the main control cabinet 5 to be tested.
Further, as shown in fig. 2, the needle tool module 4 includes a needle tool body 41, a handheld fixing unit 42 and a needle inserting unit 43; one end of the handheld fixing unit 42 is firmly welded with the needle type tool body 41, and the other end of the handheld fixing unit comprises a handheld handle which is used for fixing the whole tool on a metal guide rail to which the terminal row in the main control cabinet to be tested belongs; the pin type inserting unit 43 comprises a corresponding number of pins, the pins penetrate through the base of the tool and are provided with a certain length at the base, and an elastic element is arranged in the middle of the pins, so that the pins can be conveniently provided with corresponding elastic force with the terminal to be tested when the pins press the terminal, and the pins can be fully contacted; the head end of the pin is directly pressed on the terminal to be tested, and the tail end of the pin is welded with the lead-out cable, so that the signal transmission is facilitated.
In a specific embodiment, as shown in fig. 3, the automatic control commissioning cabinet 2 further includes a relay module 24, and the other structures are the same as those in fig. 1. When the input/output signal of the loop to be tested is connected with the output/input port of the PLC controller 23 and the voltage is suitable, the input/output signal of the corresponding loop to be tested is directly connected with the PLC controller 23; when the input/output signal of the loop to be tested is connected with the output/input port of the PLC controller 23 and the voltage is not suitable, the automatic control debugging cabinet 2 comprises a relay module 24, the relay module 24 comprises a plurality of relays, and the input/output signal of the loop to be tested is transmitted to the corresponding relay in the relay module 24 through the needle type tool module 4 and is connected with the PLC controller 23. Specifically, the main control cabinet 5 to be tested obtains power from the 400V voltage of the external power distribution module 1 through the second air switch 6. The debugging cabinet 2 gets power from 400V of the external power distribution module 1, and the 230V voltage is converted into 24V voltage through the first air switch 21 and the switch power supply module 22 to provide working voltage for the PLC 23 and the relay module 24; the PLC 23 is connected with the PC 3 through a network cable and establishes communication, and is connected with the main control cabinet 5 to be tested through an optical fiber communication cable and establishes communication, test software is loaded on the PC 3, and the PLC 23 carries out real-time observation on various collected data information of the main control cabinet 5 to be tested through the test software on the PC 3 through a digital input port. The PLC 23 tests the PC 3 through testing software, transmits the test data to each loop of the main control cabinet 5 to be tested through the digital output port and the needle type tool module 4, and tests each loop through automatically controlling the working state of the relay module 24 in the debugging cabinet 2. One end of the needle type tooling module 4 is connected with a wiring terminal in the debugging cabinet 2, and the other end of the needle type tooling module is a connector which can be quickly plugged and pulled out from a terminal in the main control cabinet 5 to be tested.
Furthermore, each loop to be tested comprises a communication loop test, a voltage loop test and an analog quantity loop test. Specifically, the voltage loop test comprises an alternating current 230V voltage loop test and a direct current 24V voltage loop test.
Further, the communication loop of the master control cabinet to be tested is tested, as shown in fig. 4. The PC is connected with the PLC in the debugging cabinet through a network cable, and the main control cabinet to be tested is connected with the PLC in the debugging cabinet through an optical fiber cable. After the test system is powered on and started, if the communication loop is free from problems, the test software interface displays the working state and the operation data of the main control cabinet to be tested in real time, and if the communication loop is abnormal, the test software interface cannot display the working state and the operation data of the main control cabinet to be tested or display abnormal alarm information, and records the test result.
Further, the main control cabinet to be tested is subjected to an ac 230V voltage loop test, as shown in fig. 5. The relay module 24 comprises an alternating current 230V voltage loop test unit for testing an alternating current 230V voltage loop of input/output of the main control cabinet to be tested, the alternating current 230V voltage loop test unit comprises a plurality of relays, coils of the relays are cascaded with corresponding contacts, one end of the cascaded relays is connected with the needle type tool module, normally open contacts of the relays are connected to corresponding PLC controllers, the PLC controllers are electrified and attracted through corresponding relay coils and receive corresponding signals through the normally open contacts, and therefore the on-off condition of the loop is judged. The input port of an alternating-current 230V voltage loop of the main control cabinet to be tested is connected with the power distribution module 1 through the second air switch 6, and the output port of the alternating-current 230V voltage loop of the main control cabinet 5 to be tested is respectively connected with the coils of the plurality of relays through the needle type tooling module 4. Specifically, a three-phase 400V power supply voltage line in the external power distribution module 1 is connected to the corresponding terminal of the main control cabinet 5 to be tested through the first air switch 21 and the three-phase line in the single-phase 230V access debugging cabinet 2, and provides a three-phase 400V working voltage for the main control cabinet 5 to be tested. Meanwhile, an alternating current 230V output signal in the main control cabinet 5 to be tested is connected to a coil A1 terminal of a relay of the corresponding relay module 24 through the needle type tooling module 4, after the automatic test is started through test software, a corresponding contactor in the main control cabinet 5 to be tested is attracted, alternating current 230V voltage is output, the voltage at the moment is connected to a coil of the corresponding relay through the needle type tooling module 4, the relay is attracted, a normally open contact is converted into a normally closed contact, direct current 24V voltage output by the switching power supply module 22 is introduced into a port 11 of the relay, the port 14 of the relay is conducted with the port 11 at the moment, the port 14 is connected to a digital quantity input DI port of the PLC 23, further, the PLC 23 receives direct current 24V signal voltage feedback of the alternating current 230V voltage loop, no problem exists in the loop, and the next step of test is directly carried out; if the line in the main control cabinet 5 to be tested has a problem, the alternating-current 230V voltage fed back to the debugging cabinet 2 by the main control cabinet 5 to be tested is also abnormal, the relays in the debugging cabinet 2 cannot be in a closed state, and the digital input port DI of the PLC controller 23 cannot acquire the corresponding 24V signal voltage, so that the alternating-current 230V voltage loop in the main control cabinet 5 to be tested is abnormal, and meanwhile, the test software interface can also display abnormal alarm information. In a specific embodiment, the relay is of the type PLC-RSP-230 UC/21.
Further, a dc 24V voltage loop test is performed on the master control cabinet 5 to be tested, as shown in fig. 6. The needle type tool module 4 comprises a direct current 24V voltage loop test unit and is used for performing input/output direct current 24V voltage loop test on the main control cabinet 5 to be tested; the direct current 24V voltage loop test unit comprises a plurality of terminals, a direct current 24V signal input/output by the main control cabinet 5 to be tested is provided with a corresponding terminal and is transmitted to the PLC controller 23 through the needle type tooling module 4, and the PLC controller 23 judges whether a tested loop is qualified or not through the received direct current 24V signal. Specifically, as shown in fig. 6, after the alternating current 230V voltage loop test, the direct current 24V voltage loop of the main control cabinet 5 to be tested is continuously tested, at this time, the loop tested by the direct current 24V in the main control cabinet 5 to be tested is connected to the corresponding connection terminal of the debugging cabinet 2 through the needle type tooling module 4, the terminals are respectively connected to the digital input DI and the digital output port DO of the PLC controller 23 according to different testing functions, and further, the PLC controller 23 outputs a control signal to be directly transmitted to a corresponding device in the master control cabinet 5 to be tested, the feedback loop of the device is directly transmitted to a wiring terminal of the debugging cabinet 2 by the needle type tooling module 4, further transmitting the voltage to a DI port of the PLC 23, receiving direct current 24V signal voltage feedback of the loop, and directly carrying out the next test if the loop has no problem; if the line in the main control cabinet 5 to be tested has a problem, the direct current 24V voltage fed back to the debugging cabinet 2 by the main control cabinet 5 to be tested is also abnormal, and the digital input port DI of the PLC controller 23 cannot acquire the corresponding 24V signal voltage, then the direct current 24V voltage test loop in the main control cabinet 5 to be tested is abnormal, and the test software interface also displays abnormal alarm information.
Further, the master control cabinet to be tested is subjected to an analog loop test, as shown in fig. 7. The relay module 24 comprises an analog quantity loop test unit; the analog quantity loop test unit comprises a plurality of relays and corresponding sensors, normally open contacts of the relays in the module share one group of sensors, and the plurality of relays are controlled by the PLC controller to control whether the sensors are connected into the analog quantity loop for testing. Specifically, after the dc 24V voltage loop test, the analog loop of the master control cabinet 5 to be tested is continuously tested. At this time, the analog quantity test loop in the main control cabinet 5 to be tested is connected to the relay contact of the corresponding relay module 24 of the debugging cabinet 2 through the needle type tooling module 4, the a1 coils of the relays are connected and controlled by the digital quantity output end DO of the PLC controller 23, the 11 port and the normally open 14 port of the relays are respectively connected to each analog quantity loop of the main control cabinet to be tested through the needle type tooling module, and the 11 port and the normally open 14 port of the relays are also connected in series with a temperature sensor (taking the temperature sensor as an example, without excluding other analog quantity measuring sensors) in the debugging cabinet 2, further, the PLC controller 23 outputs a control signal to directly control the corresponding relays to be sucked, so that the 11 port and the 14 port of the relays are converted into normally closed contacts, and the temperature sensor is further connected to the PLC analog quantity test module in the main control cabinet 5 to be tested, at this time, the test result of each analog quantity loop can be directly observed through the test software, if the numerical value of the tested loop is kept in a certain range, the loop has no problem, and if the numerical value acquired by the debugging software is not in the specified range, the test software interface can also display abnormal alarm information.
Further, the testing of the analog quantity loop also comprises testing of temperature analog quantity, and the sensor also comprises a temperature sensor.
A second aspect of the present invention provides a testing method of the main control cabinet testing system, as shown in fig. 8, including the following steps:
and S100, connecting the main control cabinet to be tested with the automatic control debugging cabinet through the pin type tool module. Before starting testing, debugging personnel connect all main control cabinet bodies to be tested in the testing system by using an external cable machine needle type tool module.
And step S200, powering on to start the test system, and starting the test software of the PC. And clicking a test starting button, and automatically starting the test of the main control cabinet to be tested by the test system.
Step S300, testing each loop of the main control cabinet to be tested in sequence, and if one loop of the main control cabinet to be tested is detected to be normal, automatically detecting the next loop; if one loop is detected to be abnormal, abnormal alarm information is displayed, and then the detection of the next loop is continued. Specifically, the test system sequentially tests a communication loop, an ac 230V voltage loop, a dc 24V voltage loop, and an analog loop of the main control cabinet to be tested, as shown in fig. 9.
And step S400, generating a test report after the test of all loops is completed. After the test of all the functional loops is completed, the test software generates a test report and records the test result of each functional loop. And (4) the debugging personnel checks the abnormal conditions of the main control cabinet to be tested according to the test report, processes the existing problems and judges whether the main control cabinet to be tested reaches the factory qualified standard.
Further, step S300 of sequentially testing each loop of the master control cabinet to be tested includes:
step S310, testing the communication loop of the main control cabinet to be tested: if the communication loop has no problem, the testing software interface displays the working state and the running data of the communication loop of the main control cabinet to be tested in real time, if the communication loop is abnormal, the testing software interface cannot display the working state and the running data of the communication loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
step S320, testing the alternating current 230V voltage loop of the main control cabinet to be tested: if the alternating-current 230V voltage loop has no problem, the testing software interface displays the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested in real time, if the alternating-current 230V voltage loop is abnormal, the testing software interface cannot display the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
step S330, testing the direct current 24V voltage loop of the main control cabinet to be tested: if the direct-current 24V voltage loop has no problem, the test software interface displays the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested in real time, if the direct-current 24V voltage loop is abnormal, the test software interface cannot display the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the test result;
step S340, testing the analog quantity loop of the main control cabinet to be tested: if the value measured by the analog quantity loop is within the preset range, the analog quantity loop has no problem, the test software interface displays the working state and the running data of the analog quantity loop of the main control cabinet to be tested in real time, if the value measured by the analog quantity loop is not within the preset range, the analog quantity loop is abnormal, the test software interface cannot display that the value measured by the main control cabinet to be tested is within the preset range, the working state and the running data of the analog quantity loop or display abnormal alarm information, and the test result is recorded.
In summary, the present invention provides a test system and a test method for a main control cabinet, wherein the test system comprises a power distribution module, an automatic control debugging cabinet, a PC and a pin tool module; the automatic control debugging cabinet comprises a first air switch, a switching power supply module and a PLC (programmable logic controller); the PLC is used for outputting a control signal to provide a starting test instruction for a loop to be tested in the main control cabinet to be tested when any loop test is carried out on the main control cabinet to be tested, acquiring an output signal corresponding to the loop to be tested, and judging whether the loop to be tested in the main control cabinet to be tested passes the test or not according to the output signal; the pin type tooling module is used for testing a connector between the cabinet and the cabin cabinet to be tested and enabling input/output signals between the main control cabinet to be tested and the PLC to be in a connection and conduction state. The test system automatically completes various function tests of the main control cabinet to be tested, so that frequent wiring and disconnecting work is not required, the test flow is simplified, and the test time of the main control cabinet is greatly reduced. The test system only needs to insert the needle type tool module into a main control cabinet to be tested before the test is started, when a certain test is operated, a controller output control signal is utilized to provide a starting test instruction for a loop to be tested in the main control cabinet to be tested, whether the loop to be tested passes the test is judged according to a signal fed back by the loop to be tested, an input/output signal of the loop to be tested is connected with an output/input port of the controller through the needle type tool module, when a signal is collected and is not suitable, the signal matching of the controller and the loop to be tested is realized through the relay module, various function tests of part of the main control cabinet to be tested are automatically completed, and therefore frequent wiring, disconnecting, manual short-circuit and other works are not needed, the test flow is simplified, the test time of the main control cabinet is reduced.
It is to be understood that the above-described embodiments of the present invention are merely illustrative of or explaining the principles of the invention and are not to be construed as limiting the invention. Therefore, any modification, equivalent replacement, improvement and the like made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention. Further, it is intended that the appended claims cover all such variations and modifications as fall within the scope and boundaries of the appended claims or the equivalents of such scope and boundaries.
Claims (10)
1. A master control cabinet test system is characterized by comprising a power distribution module, an automatic control debugging cabinet, a PC (personal computer) and a needle type tool module;
the output end of the power distribution module is respectively connected with a main control cabinet to be tested and the automatic control debugging cabinet and is used for supplying power to the main control cabinet to be tested and the automatic control debugging cabinet;
the automatic control debugging cabinet comprises a first air switch, a switching power supply module and a PLC (programmable logic controller); the output end of the power distribution module is connected with the switching power supply module through a first air switch, and the output end of the switching power supply module is connected with the PLC to supply power to the PLC;
the PC is loaded with test software for testing various loops of the main control cabinet to be tested;
the PLC is respectively connected with the PC and the main control cabinet to be tested through the needle type tooling module, and is used for outputting a control signal to provide a starting test instruction for a circuit to be tested in the main control cabinet to be tested when any circuit of the main control cabinet to be tested is tested, acquiring an output signal corresponding to the circuit to be tested, and judging whether the circuit to be tested in the main control cabinet to be tested passes the test according to the output signal.
2. The main control cabinet testing system of claim 1, wherein the pin tool module comprises a pin tool body, a handheld fixing unit and a pin plugging unit;
one end of the handheld fixing unit is firmly welded with the needle type tool body, and the other end of the handheld fixing unit comprises a handheld handle which is used for fixing the whole tool on a metal guide rail to which the terminal row in the main control cabinet to be tested belongs;
the needle type inserting unit comprises a corresponding number of needles, the needles penetrate through the base of the tool and are provided with a certain length at the base, and the elastic elements are arranged in the middle of the needles, so that the needles can be conveniently pressed down by the elastic elements and have corresponding elastic force with the terminals to be tested, and the needles are fully contacted;
the head end of the pin is directly pressed on the terminal to be tested, and the tail end of the pin is welded with the lead-out cable, so that the signal transmission is facilitated.
3. The main control cabinet test system according to claim 1 or 2, wherein when the input/output signal of the circuit to be tested is connected with the output/input port of the PLC controller and the voltage is suitable, the input/output signal of the corresponding circuit to be tested is directly connected with the PLC controller; when the input/output signal of the loop to be tested is connected with the output/input port of the PLC and the voltage is not suitable, the automatic control debugging cabinet further comprises a relay module, the relay module comprises a plurality of relays, and the input/output signal of the loop to be tested is transmitted to the corresponding relay in the relay module through the needle type tool module and is connected with the PLC.
4. The main control cabinet test system of claim 3, wherein the loops under test comprise a communication loop test, a voltage loop test and an analog loop test.
5. The master control cabinet test system of claim 4, wherein the voltage loop test comprises an alternating current 230V voltage loop test;
the relay module comprises an alternating current 230V voltage loop test unit which is used for carrying out input/output alternating current 230V voltage loop test on a main control cabinet to be tested, the alternating current 230V voltage loop test unit comprises a plurality of relays, coils of the relays are cascaded with corresponding contacts, one end of each relay is connected with the needle type tool module after the cascade connection, normally open contacts of the relays are connected to corresponding PLC controllers, the PLC controllers are electrified and attracted through the corresponding relay coils and receive corresponding signals through the normally open contacts, and therefore the on-off condition of the loop is judged;
the input port of the alternating-current 230V voltage loop of the main control cabinet to be tested is connected with the power distribution module through the second air switch, and the output port of the alternating-current 230V voltage loop of the main control cabinet to be tested is respectively connected with the coils of the plurality of relays through the needle type tooling module.
6. The master control cabinet test system of claim 4, wherein the voltage loop test comprises a direct current 24V voltage loop test; the needle type tool module comprises a direct current 24V voltage loop test unit and is used for performing input/output direct current 24V voltage loop test on a main control cabinet to be tested;
the direct-current 24V voltage loop test unit comprises a plurality of terminals, a direct-current 24V signal input/output by the main control cabinet to be tested is provided with a corresponding terminal and is transmitted to the PLC through the needle type tooling module, and the PLC judges whether the tested loop is qualified or not through the received direct-current 24V signal.
7. The main control cabinet test system according to claim 4, wherein the relay module comprises an analog loop test unit for performing an analog loop test on the main control cabinet to be tested; the analog quantity loop test unit comprises a plurality of relays and corresponding sensors, normally open contacts of the relays in the module share one group of sensors, and the plurality of relays are controlled by a PLC (programmable logic controller) to control whether the sensors are connected into the analog quantity loop to test.
8. The master control cabinet testing system of claim 7, wherein the sensor comprises a temperature sensor.
9. The method for testing the master control cabinet test system according to any one of claims 1 to 7, comprising the steps of:
connecting the main control cabinet to be tested with the automatic control debugging cabinet through the needle type tool module;
powering on to start the test system and starting the test software of the PC;
sequentially testing all loops of the main control cabinet to be tested, and automatically detecting the next loop if detecting that a certain loop of the main control cabinet to be tested is normal; if one loop is detected to be abnormal, displaying abnormal alarm information, and then continuing to detect the next loop;
and generating a test report after the test of all the loops is completed.
10. The method according to claim 9, wherein the step of sequentially testing the loops of the master control cabinet to be tested comprises:
testing a communication loop of the main control cabinet to be tested: if the communication loop has no problem, the testing software interface displays the working state and the running data of the communication loop of the main control cabinet to be tested in real time, if the communication loop is abnormal, the testing software interface cannot display the working state and the running data of the communication loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
testing an alternating current 230V voltage loop of the main control cabinet to be tested: if the alternating-current 230V voltage loop has no problem, the testing software interface displays the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested in real time, if the alternating-current 230V voltage loop is abnormal, the testing software interface cannot display the working state and the operation data of the alternating-current 230V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the testing result;
testing a direct-current 24V voltage loop of the main control cabinet to be tested: if the direct-current 24V voltage loop has no problem, the test software interface displays the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested in real time, if the direct-current 24V voltage loop is abnormal, the test software interface cannot display the working state and the operation data of the direct-current 24V voltage loop of the main control cabinet to be tested or display abnormal alarm information, and records the test result;
testing an analog quantity loop of the main control cabinet to be tested: if the value measured by the analog quantity loop is within the preset range, the analog quantity loop has no problem, the test software interface displays the working state and the running data of the analog quantity loop of the main control cabinet to be tested in real time, if the value measured by the analog quantity loop is not within the preset range, the analog quantity loop is abnormal, the test software interface cannot display that the value measured by the main control cabinet to be tested is within the preset range, the working state and the running data of the analog quantity loop or display abnormal alarm information, and the test result is recorded.
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