CN112379251A - Relay circuit fault testing system and method - Google Patents
Relay circuit fault testing system and method Download PDFInfo
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- CN112379251A CN112379251A CN202011192100.0A CN202011192100A CN112379251A CN 112379251 A CN112379251 A CN 112379251A CN 202011192100 A CN202011192100 A CN 202011192100A CN 112379251 A CN112379251 A CN 112379251A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/327—Testing of circuit interrupters, switches or circuit-breakers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R27/00—Arrangements for measuring resistance, reactance, impedance, or electric characteristics derived therefrom
- G01R27/02—Measuring real or complex resistance, reactance, impedance, or other two-pole characteristics derived therefrom, e.g. time constant
- G01R27/14—Measuring resistance by measuring current or voltage obtained from a reference source
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
- G01R31/52—Testing for short-circuits, leakage current or ground faults
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
- G01R31/54—Testing for continuity
Abstract
The invention relates to a system and a method for testing the circuit fault of a relay, wherein the testing system comprises: tester machine case, man-machine interaction module, test cable. The tester consists of a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate, and the related operation of the test system is realized together; the human-computer interaction module is used for realizing information input and display; and the test cable is used for connecting the test system with the tested product. Wherein, a point to be tested in a tested product is connected to the tester through a testing cable of the access gating module; the drive module supplies power to a relay in a tested product through a drive module test cable. The automatic test system can be used for automatically testing three test states of 'power-on test on', 'power-on test off' and 'power-on test resistance' of any relay circuit, determines faults, and is simple to operate, high in automation degree and high in test efficiency.
Description
Technical Field
The invention relates to a system and a method for testing a relay circuit fault, and belongs to the technical field of automatic testing.
Background
Relays are widely used in various automatic control circuits as a circuit control element. Therefore, the relay circuit fault detection technology plays an important role in ensuring that the circuit achieves the normal function. However, the fault detection of the current relay circuit needs manual testing and manual recording of a test result, and the defects of low working efficiency and high error rate exist.
Disclosure of Invention
The technical problem solved by the invention is as follows: the defects of the prior art are overcome, the relay circuit fault testing system is provided, automatic detection of three relay circuit states can be realized, and the relay circuit fault testing system is simple in operation, high in automation degree and high in testing efficiency.
The technical scheme of the invention is as follows: a relay circuit fault testing system comprising: the device comprises a human-computer interaction module, a tester and a test cable;
a tester, comprising: the system comprises a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate;
the human-computer interaction module is connected with a main control module of the tester to realize information input and display;
the main control module transmits and receives information through the bottom plate, the relay driving module, the access gating module and the access measuring module;
the main control module can send out an instruction and send the instruction to the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module, the access gating module and the access measuring module complete corresponding actions according to the instructions of the main control module and return information to the main control module;
the power supply module supplies power to the main control module, the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module is connected with a relay coil of a tested product through a corresponding test cable and supplies power to a relay in the tested product;
the master control module prestores data of points to be tested of the relay circuit of a tested product and test parameters thereof, and when the master control module sends a gating instruction, the prestored data of the points to be tested of the relay circuit are sent to the access gating module;
the path gating module accesses a point to be measured in the relay circuit into the path measuring module according to prestored point data to be measured of the relay circuit;
and the path measuring module is used for measuring a point to be measured in the relay circuit and sending the measured information to the main control module, and the main control module is used for determining the relay circuit fault according to the measured information, the test state and the prestored test parameters.
Preferably, the main control module stores the name table, the relay table and the test parameter data information of the tested product, can send instructions to the access gating module and the access measuring module in real time, receives and analyzes the test instructions sent by the access measuring module to obtain a calculated resistance value, judges the resistance value according to the test parameters to obtain a test result, and obtains the relay fault in the relay circuit according to the test result; and storing the test result.
Preferably, the relay table stores all the conducting points related to the closing of the relay contacts in the product to be tested and all the breaking points related to the closing of the relay contacts.
Preferably, the power module: and respectively providing working voltage for the main control module, the access gating module, the relay driving module and the access measuring module.
Preferably, the bottom plate can transfer the electricity output by the power supply module and send the electricity to the main control module, the relay driving module, the access gating module and the access measuring module; the bottom plate is provided with a bus; the bus is connected with the main control module, the relay driving module, the access gating module and the access measuring module, and an instruction sent by the main control module is transmitted to the main control module, the relay driving module, the access gating module and the access measuring module through the bus of the bottom plate.
Preferably, the passage gating module comprises a plurality of relays; the access gating module can receive and analyze the instruction of the main control module, and close or open the relay on the access gating module according to the instruction requirement, so that the access or the shift-out of the point to be tested in the relay circuit is realized.
Preferably, the relay driving module comprises a plurality of relays; the relay driving module can receive and analyze the instruction of the main control module, close the corresponding relay according to the instruction requirement and supply power to the relay coil to be tested in the tested product;
preferably, the point to be tested is arranged on a group of contacts in a relay to be tested in a product to be tested or the connecting end of a component directly connected with the contacts; when the point to be measured is arranged on the connecting end of the component directly connected with the contact, one connecting end of the component is connected with one contact in a group of contacts of the relay to be measured, and the other connecting end of the component is the point to be measured; the component comprises a resistor.
Preferably, the path measurement module receives the instruction of the main control module, collects the voltage between the points to be measured, calculates the resistance value according to the voltage as a measured value to form a test instruction, sends the test instruction to the main control module, and returns the measured value.
Preferably, a plurality of signal transmission channels are arranged in the bottom plate and are connected with the main control module, the relay driving module, the access gating module and the access measuring module.
Preferably, a plurality of relays included in each path gating module form 60 test points, and the test points on the tested product can be accessed through cables.
Each relay driving module can drive 48 paths of relays on a tested product at most;
the user can select the number of the access gating modules and the relay driving modules according to the requirement.
Preferably, the test conditions include: the system can test the three states of a relay to be tested in a tested product;
testing parameters, including: conducting parameters, breaking parameters and positive and negative deviations of resistance values;
and testing the electrification state of the power supply, specifically comprising the following steps: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage of a point to be tested in the tested product, the point to be tested is any two of all conducting points involved after the relay contact is closed, and all the conducting points are traversed to obtain a plurality of groups of resistance values; and forming a test instruction, sending the test instruction to the main control module, and judging whether the conduction parameter requirement is met by the main control module.
The test of the power-on test-off state is specifically as follows: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage of a point to be tested in the tested product, the point to be tested is any two of all the break points involved after the relay contact is closed, and all the break points are traversed to obtain a plurality of groups of resistance values; and forming a test instruction, sending the test instruction to the main control module, and judging whether the requirements of the circuit breaking parameters are met by the main control module.
And testing the state of the resistance by applying electricity, specifically: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage between points to be tested in the tested product, and the points to be tested are specifically as follows: one end of the resistor is connected with one contact of a group of contacts in the relay to be tested in the product to be tested, the other end of the resistor is a point to be tested, and one end of the resistor is connected with the other contact of the group of contacts in the relay to be tested in the product to be tested and is another point to be tested; and forming a test instruction by the obtained resistance value, sending the test instruction to the main control module, and judging whether the positive and negative deviation requirements of the resistance value are met by the main control module.
Preferably, two identities of an administrator and an operator can log in the test system; the administrator has the authority to create and modify the test program and can perform product test; the operator can only open the test program for testing. When a test program is created, logging in a test system by using the identity of an administrator; the test program can set the test sequence and the position of the points to be tested in the tested product.
Preferably, the test program creation is specifically as follows:
determining a naming table of a tested product, wherein an administrator needs to fill names and positions of points to be tested and names and positions of test points on a corresponding path gating module into the naming table according to the corresponding relation between the points to be tested on the tested product and the test points on the path gating module;
determining a relay table comprising: the relay testing method comprises the following steps of testing group information, serial numbers and information of relays in a relay driving module, names of relays to be tested on tested products, testing states and information of points to be tested;
wherein, the test group information comprises the group to be tested;
the serial number and information of the relay in the relay driving module are the name, position and number of the relay in the relay driving module which powers the coil of the relay to be tested in the tested product;
the test state is a state in which three tests are required to be carried out on a relay to be tested in a tested product;
when a plurality of relays on the relay driving module need to be closed to finish electrifying the relay coil of the tested product, testing group information needs to be filled, otherwise, the testing group information is null; when the test state is 'power-on resistor testing', the tested resistance value and the positive and negative deviation of the resistance value are filled in the relay table;
and after the test parameters are determined, generating a test program according to the determined relay table and the naming table of the tested product, and sequentially testing the tested product.
A method for testing the fault of a relay circuit comprises the following steps:
(1) the main control module reads the content of the relay table to obtain test group information, relay sequence numbers and information of corresponding actions of the relay driving module and information of points to be tested;
(2) the main control module sends an opening relay driving module, and the relay driving module receives the instruction and opens the relay driving module; the main control module sends an instruction for closing a relay corresponding to the relay driving module, the relay driving module receives the instruction and closes one or more relays of the relay driving module corresponding to the relay to be tested in the tested product, and the relay driving module supplies power to a relay coil to be tested on the tested product through corresponding testing cables;
(3) the main control module searches a path gating module corresponding to the point to be measured according to the information of the point to be measured in the name table and sends an opening instruction to the path gating module; the access gating module receives the instruction of the main control module and opens the main control module; the master control module respectively sends an instruction for accessing the point to be measured to the opened gating module; after receiving the instruction sent by the main control module, the access gating module closes a relay on the access gating module and accesses a point to be tested on a product to be tested into the access measuring module through a test cable;
(4) the main control module sends an instruction for opening the access measurement module, and the access measurement module receives the instruction and opens the access measurement module; the main control module sends a measured value acquisition instruction, and the path measurement module obtains a resistance value between the points to be measured as a measured value by measuring a voltage value between the points to be measured after receiving the measurement instruction and sends the measured value to the main control module;
(5) the main control module receives a measured value returned by the measuring module and judges the fault of the relay circuit according to the test state in the relay table;
when the power-on and power-off state is realized, if the measured value is larger than the conduction parameter, the circuit of the relay to be tested is judged to have an open circuit fault when the circuit is in the power-on and power-off state;
when the power-on test is in the power-on test-off state, the measured value is smaller than the circuit-breaking parameter, and the short-circuit fault exists in the circuit where the relay to be tested is in the power-on test-off state;
when the "resistance on test" state is present, the measured value does not satisfy more than resistance x (1 minus offset) and less than resistance x (1 plus offset); judging that a fault that the resistance precision does not meet the requirement exists when the circuit where the relay to be tested is in the state of power-on resistance measurement;
(6) the main control module sends the information of the point to be tested, the name of the relay to be tested, the measured value and the fault condition of the relay circuit to the man-machine interaction module for displaying, and sends a relay disconnection instruction to the access gating module and the relay driving module respectively, so that one test is completed;
(7) after all test items in the relay table to be tested are completed, the main control module sends a module closing instruction, each module executes the instruction after receiving the instruction, and the relay circuit fault detection is completed.
Compared with the prior art, the invention has the advantages that:
(1) the testing system has simple structure and high integration, and each functional module has small size and is completely arranged in the tester case, so the whole testing system has small volume and is convenient to move;
(2) the test system is simple to operate and convenient to use, and after the administrator fills in the relevant relay information and completes the program creation, the operator opens the program, and the test can be automatically completed without other operations, so that the test system is more time-saving and more reliable compared with the original manual test method;
(3) the test system of the invention has comprehensive test and high reliability, and the test system of the relay fault can automatically realize the fault judgment of three test states, namely 'power-on test on', 'power-on test off' and 'power-on test resistance'.
Drawings
FIG. 1 is a block diagram of the system of the present invention;
FIG. 2 is a schematic diagram of a point to be measured according to the present invention;
FIG. 3 is a schematic diagram of the operation steps of the present invention;
FIG. 4 is a flow chart of the testing steps of the present invention;
FIG. 5 is a circuit configuration diagram of the gating module;
FIG. 6 is a diagram showing the connection relationship between each module and the product under test.
Detailed Description
The invention is described in further detail below with reference to the figures and specific embodiments.
The invention relates to a system and a method for testing the circuit fault of a relay, wherein the testing system comprises: tester machine case, man-machine interaction module, test cable. The tester consists of a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate, and the related operation of the test system is realized together; the human-computer interaction module is used for realizing information input and display; and the test cable is used for connecting the test system with the tested product. Wherein, a point to be tested in a tested product is connected to the tester through a testing cable of the access gating module; the drive module supplies power to a relay in a tested product through a drive module test cable. The automatic test system can be used for automatically testing three test states of 'power-on test on', 'power-on test off' and 'power-on test resistance' of any relay circuit, determines faults, and is simple to operate, high in automation degree and high in test efficiency.
Relays are components often used in automatic control circuits. When the circuit comprising a plurality of relays is subjected to fault detection, different relay coils need to be electrified in sequence, and the measured values of corresponding test points are collected to verify the quality of the partial circuit. The power-on point and the point to be tested need to be continuously replaced during testing, the operation is complex, the efficiency is low, when the tested product contains a large number of related circuits of the relay and the tested product needs to be measured for many times in order to ensure the product quality, the traditional mode is long in time consumption, and the error rate is high. The test system and the test method can quickly and automatically detect the relay circuit fault of the tested product.
When a group of contacts in a relay to be tested in a tested product or the connection ends of components directly connected with the contacts are positioned on an external connector of the tested product, or other relay circuits which can be simplified into the circuits can be tested by using the test system.
Each passage gating module in the test system comprises 60 test points, and each relay driving module can drive 48 paths of relays on a tested product at most. And adjusting the use number of the functional modules according to the scale of the tested product.
The invention relates to a relay circuit fault testing system, which comprises: a human-computer interaction module, a tester and a test cable, wherein the system block diagram is shown in figure 1;
a tester, comprising: the system comprises a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate;
the human-computer interaction module is connected with a main control module of the tester to realize information input and display;
the main control module is a PC104 mainboard and transmits and receives information through a bottom plate, a relay driving module, a channel gating module and a channel measuring module;
the main control module can send out an instruction and send the instruction to the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module, the access gating module and the access measuring module complete corresponding actions according to the instructions of the main control module and return information to the main control module;
the power supply module supplies power to the main control module, the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module is connected with a relay coil of a tested product through a corresponding test cable and supplies power to a relay in the tested product;
the master control module prestores data of points to be tested of the relay circuit of a tested product and test parameters thereof, and when the master control module sends a gating instruction, the prestored data of the points to be tested of the relay circuit are sent to the access gating module;
the path gating module accesses a point to be measured in the relay circuit into the path measuring module according to prestored point data to be measured of the relay circuit;
and the path measurement module is used for measuring a point to be measured in the relay circuit and sending the measured information to the main control module, and the main control module is used for determining the relay fault in the relay circuit according to the measured information, the test state and the prestored test parameters.
The main control module is used for storing a name table, a relay table and test parameter data information of a tested product, sending instructions to the access gating module and the access measuring module in real time, receiving and analyzing the test instructions sent by the access measuring module to obtain a calculated resistance value, judging the resistance value according to the test parameters to obtain a test result, and obtaining a relay fault in the relay circuit according to the test result; storing the test result;
all the conducting points related to the closed relay contacts in the product to be tested and all the breaking points related to the closed relay contacts are stored in the relay table;
a power supply module: and respectively providing working voltage for the main control module, the access gating module, the relay driving module and the access measuring module.
The bottom plate can transfer the electricity output by the power supply module and send the electricity to the main control module, the relay driving module, the access gating module and the access measuring module; the bottom plate is provided with a bus; the bus is connected with the main control module, the relay driving module, the access gating module and the access measuring module, and an instruction sent by the main control module is transmitted to the main control module, the relay driving module, the access gating module and the access measuring module through the bus of the bottom plate;
the passage gating module comprises a plurality of relays; the access gating module can receive and analyze the instruction of the main control module, and close or open the relay on the access gating module according to the instruction requirement, so that the access or the shift-out of the point to be tested in the relay circuit is realized.
A relay driving module including a plurality of relays; the relay driving module can receive and analyze the instruction of the main control module, close the corresponding relay according to the instruction requirement and supply power to the relay coil to be tested in the tested product;
the preferred scheme is as follows: the point to be tested is arranged on a group of contacts in a relay to be tested in a product to be tested or the connecting end of a component directly connected with the contacts; when the point to be measured is arranged on the connecting end of the component directly connected with the contact, one connecting end of the component is connected with one contact in a group of contacts of the relay to be measured, and the other connecting end of the component is the point to be measured; the component comprises a resistor. The points to be tested are connected to the external connectors of the products to be tested through conducting wires or printed wires.
The preferred scheme is as follows: the power-on points are arranged on the contacts of the relay coil to be tested in the tested product or the contacts of other relays directly connected with the contacts, and are connected to the external connector of the tested product through wires or printed lines.
Fig. 2 illustrates the point to be tested and the point to be energized by taking as an example only one set of contacts per relay.
The preferred scheme is as follows: as shown in fig. 2 (a), in the relay K1, X1 is a coil, C1 is a group of contacts, and coil terminals X1_1 and X1_2 and contact terminals C1_1 and C1_2 are all connected to an external connector J1 of a product to be tested. The line packet endpoints X1_1 and X1_2 are power-up points, and C1_1 and C1_2 are to-be-detected points. When relay circuit fault detection is carried out on K1 in a power-on test state, a solenoid terminal X1_1 is connected with a positive power supply in a driving module, a solenoid terminal X1_2 is connected with a negative power supply in the driving module, at the moment, a contact C1 is closed, and a measured value between C1_1 and C1_2 is acquired.
The preferred scheme is as follows: as shown in fig. 2 (b), in the relay K2, X2 is a coil, C2 is a group of contacts, and coil terminals X2_1 and X2_2 and contact terminals C2_1 and C2_2 are all connected to an external connector J2 of a product to be tested. The line packet endpoints X2_1 and X2_2 are power-up points, and C2_1 and C2_2 are to-be-detected points. When relay circuit fault detection is carried out on K2 in a power-on test state, a solenoid terminal X2_1 is connected with a positive power supply in a driving module, a solenoid terminal X2_2 is connected with a negative power supply in the driving module, at the moment, a contact C2 is disconnected, and a measured value between C2_1 and C2_2 is acquired.
The preferred scheme is as follows: as shown in fig. 2 (C), in the relay K3, X3 is a coil, C3 is a set of contacts, and one terminal R1_1 of the resistor R1 is connected to the contact C3_ 2. The coil terminals X3_1 and X3_2, the contact terminal C3_1 and one terminal R1_2 of the resistor R1 are all connected to an external connector J3 of a tested product. The line packet terminals X3_1 and X3_2 are power-up points, and C3_1 and R1_2 are to-be-detected points. When relay circuit fault detection is carried out on K3 in a power-on resistance detection test state, a solenoid terminal X3_1 is connected with a positive power supply in a driving module, a resistor terminal R1_2 is connected with a negative power supply in the driving module, at the moment, a contact C3 is closed, and a measured value between C3_1 and R1_2 is acquired.
The preferred scheme is as follows: as shown in fig. 2 (d), the coil terminal X4_1, the contacts C4_1 and C4_2 of the relay K4, the coil terminals X5_1, X5_1 and the contact C5_2 of the relay K5 are all connected to the external connector J4 of the tested product, and X4_2 is located inside the tested product, so X4_2 cannot be used as a power-up point. One terminal X4_2 of the coil X4 of the relay K4 is connected to one terminal C5_1 of the contact C5 of the relay K5. Therefore, X4_1 and C5_2 are the energizing points of relay K4, and X5_1 and X5_2 of coil X5 of relay K5 are the energizing points of relay K5. Contacts C4_1 and C4_2 of the relay K4 are points to be tested. When relay circuit fault detection is carried out on K4 in a power-on test state, coil terminals X4_1 and X5_1 are connected with a positive power supply in a driving module, a relay contact C4_2 and a coil terminal X5_2 are connected with a negative power supply in the driving module, at the moment, contacts C4 and C5 are closed, and a measured value between C4_1 and C4_2 is acquired.
And the path measuring module is used for receiving the instruction of the main control module, collecting the voltage between the points to be measured, calculating the resistance value according to the voltage to be used as a measured value, forming a test instruction, sending the test instruction to the main control module and returning the measured value.
A plurality of signal transmission channels are arranged in the bottom plate and are connected with the main control module, the relay driving module, the access gating module and the access measuring module
The relays included in each path gating module form 60 test points, and the test points to be tested on the tested product can be accessed through cables.
Each relay driving module can drive 48 paths of relays on a tested product at most;
the user can select the number of the access gating modules and the relay driving modules according to the requirement.
The preferred scheme is as follows: a test state comprising: the system can test the three states of a relay to be tested in a tested product;
testing parameters, including: conducting parameters, breaking parameters and positive and negative deviations of resistance values;
the preferred scheme is as follows: and testing the electrification state of the power supply, specifically comprising the following steps: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage of a point to be tested in the tested product, the point to be tested is any two of all conducting points involved after the relay contact is closed, and all the conducting points are traversed to obtain a plurality of groups of resistance values; and forming a test instruction, sending the test instruction to the main control module, and judging whether the conduction parameter requirement is met by the main control module.
The preferred scheme is as follows: the test of the power-on test-off state is specifically as follows: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage of a point to be tested in the tested product, the point to be tested is any two of all the break points involved after the relay contact is closed, and all the break points are traversed to obtain a plurality of groups of resistance values; and forming a test instruction, sending the test instruction to the main control module, and judging whether the requirements of the circuit breaking parameters are met by the main control module.
The preferred scheme is as follows: and testing the state of the resistance by applying electricity, specifically: the relay on the relay driving module is closed, a relay coil to be tested in a tested product is electrified, the path measuring module obtains a resistance value by measuring the voltage between points to be tested in the tested product, and the points to be tested are specifically as follows: one end of the resistor is connected with one contact of a group of contacts in the relay to be tested in the product to be tested, the other end of the resistor is a point to be tested, and one end of the resistor is connected with the other contact of the group of contacts in the relay to be tested in the product to be tested and is another point to be tested; forming a test instruction by the obtained resistance value, sending the test instruction to the main control module, and judging whether the positive and negative deviation requirements of the resistance value are met by the main control module
The preferred scheme is as follows: an administrator and an operator can log in the test system; the administrator has the authority to create and modify the test program and can perform product test; the operator can only open the test program for testing. When a test program is created, logging in a test system by using the identity of an administrator; the test program can set the test sequence and position of the points to be tested in the tested product;
the preferred scheme is as follows: the test program creation is specifically as follows:
the preferred scheme is as follows: determining a naming table of a tested product, wherein an administrator needs to fill names and positions of points to be tested and names and positions of test points on a corresponding path gating module into the naming table according to the corresponding relation between the points to be tested on the tested product and the test points on the path gating module;
the preferred scheme is as follows: determining a relay table comprising: the relay testing method comprises the following steps of testing group information, serial numbers and information of relays in a relay driving module, names of relays to be tested on tested products, testing states and information of points to be tested;
wherein, the test group information comprises the group to be tested;
the preferred scheme is as follows: the serial number and information of the relay in the relay driving module are the name, position and number of the relay in the relay driving module which powers the coil of the relay to be tested in the tested product;
the test state is a state in which three tests are required to be carried out on a relay to be tested in a tested product;
the preferred scheme is as follows: when a plurality of relays on the relay driving module need to be closed to finish electrifying the relay coil of the tested product, testing group information needs to be filled, otherwise, the testing group information is null; when the test state is 'power-on resistor measurement', a measured resistor value and a positive and negative deviation are required to be filled in the relay table;
the preferred scheme is as follows: after the test parameters are determined, generating a test program according to the determined relay table and the naming table of the tested product, and sequentially testing the tested product;
the invention discloses a method for testing the fault of a relay circuit, which preferably comprises the following steps:
(1) the main control module reads the content of the relay table to obtain test group information, relay sequence numbers and information of corresponding actions of the relay driving module and information of points to be tested;
(2) the main control module sends a command for opening the relay driving module, and the relay driving module receives the command and opens the relay driving module; the main control module sends an instruction for closing a relay corresponding to the relay driving module, the relay driving module receives the instruction and closes one or more relays of the relay driving module corresponding to the relay to be tested in the tested product, and the relay driving module supplies power to a relay coil to be tested on the tested product through corresponding testing cables;
(3) the main control module searches a path gating module corresponding to the point to be measured according to the information of the point to be measured in the name table and sends an opening instruction to the path gating module; the access gating module receives the instruction of the main control module and opens the main control module; the master control module respectively sends an instruction for accessing the point to be measured to the opened gating module; after receiving the instruction sent by the main control module, the access gating module closes a relay on the access gating module and accesses a point to be tested on a product to be tested into the access measuring module through a test cable;
(4) the main control module sends an instruction for opening the access measurement module, and the access measurement module receives the instruction and opens the access measurement module; the main control module sends a measured value acquisition instruction, and the path measurement module obtains a resistance value between the points to be measured as a measured value by measuring a voltage value between the points to be measured after receiving the measurement instruction and sends the measured value to the main control module;
(5) the main control module receives a measured value returned by the measuring module and judges the fault of the relay circuit according to the test state in the relay table;
the preferred scheme is as follows: when the power-on and power-off state is realized, if the measured value is larger than the conduction parameter, the circuit of the relay to be tested is judged to have an open circuit fault when the circuit is in the power-on and power-off state;
the preferred scheme is as follows: when the power-on test is in the power-on test-off state, the measured value is smaller than the circuit-breaking parameter, and the short-circuit fault exists in the circuit where the relay to be tested is in the power-on test-off state;
the preferred scheme is as follows: when the "resistance on test" state is present, the measured value does not satisfy more than resistance x (1 minus offset) and less than resistance x (1 plus offset); judging that a fault that the resistance precision does not meet the requirement exists when the circuit where the relay to be tested is in the state of power-on resistance measurement;
(6) the main control module sends the information of the point to be tested, the name of the relay to be tested, the measured value and the fault condition of the relay circuit to the man-machine interaction module for displaying, and sends a relay disconnection instruction to the access gating module and the relay driving module respectively, so that one test is completed;
(7) after all test items in the relay table to be tested are completed, the main control module sends a module closing instruction, each module executes the instruction after receiving the instruction, and the relay circuit fault detection is completed.
The invention provides a relay circuit fault testing system and method, which are used for automatically testing three testing states of 'power-on testing on', 'power-on testing off' and 'power-on testing resistance' of any relay circuit and generating a testing result.
The preferred scheme is as follows: the test system of the invention comprises: man-machine interaction module, tester, test cable. And the man-machine interaction module and the main control module are used for realizing information input and display. The main control module, the power supply module, the relay driving module, the access gating module, the access measuring module and the bottom plate are arranged in the tester case. The main control module transmits and receives information through the bottom plate, the relay driving module, the access gating module and the access measuring module, and can judge, record and display a test result; the relay driving module receives and analyzes the instruction of the main control module, closes the corresponding relay according to the instruction requirement and supplies power to the relay to be tested in the product to be tested; the access gating module receives and analyzes the instruction of the main control module, closes or opens a relay on the gating module according to the instruction requirement, and accesses a point to be tested on a product to be tested into the tester; the access measurement module collects and returns test information according to the instruction of the main control module; the power module supplies power to other modules through the bottom plate. And the test cable is used for connecting the tester and the tested product. Wherein, a point to be tested in a tested product is connected to the tester through a testing cable of the access gating module; the drive module supplies power to a relay in a tested product through a drive module test cable. Each path gating module in the system comprises 60 test points, and each relay driving module can drive 48 paths of relays on a tested product at most; the user can select the number of each module according to the requirement.
The preferred scheme is as follows: the preferred embodiment of the test method of the present invention is as follows
(1) The operation steps comprise:
before the automatic test, the test program is created according to the following steps.
Logging in the test system by using the identity of an administrator; arranging the one-to-one correspondence between the points to be tested on the tested product and the test points on the tester, and filling a naming table according to the correspondence; filling a relay table, comprising: the relay testing method comprises the following steps of testing group information, relay serial numbers and information of a relay driving module, names of relays to be tested on tested products, testing states, information of points to be tested, resistance values and positive and negative deviations in a power-on resistance testing state and the like; and filling test parameters such as conduction parameters and disconnection parameters to generate a test program.
(2) The testing step comprises the following steps:
the main control module reads the content of the relay meter to obtain test information;
the main control module sends a test instruction to the relay driving module according to the test information, and the relay driving module analyzes the test instruction and executes test actions such as opening the module and closing the relay;
the main control module searches a path gating module corresponding to the point to be measured according to the information of the point to be measured in the name table, and sends instructions of opening the module, closing the test point and the like to the path gating module; the access gating module receives and analyzes the instruction sent by the main control module, opens the module and closes a relay on the module, and accesses a point to be tested on a product to be tested into the access measuring module through a test cable;
the main control module sends an instruction for opening the access measurement module and collecting a measured value, and the access measurement module receives and analyzes the instruction, collects and returns the measured value;
the main control module receives the measured value returned by the measuring module, judges the test result according to the test state and displays the result and the detailed test information.
The main control module respectively sends a relay disconnection instruction and a relay closing instruction to the access gating module and the relay driving module, and sends a module closing instruction to the measurement module.
The preferred scheme is as follows: as shown in fig. 1, the present invention includes: man-machine interaction module, tester, test cable. The human-computer interaction module is used for realizing information input and display; the test cable is used for connecting the tester and a tested product and connecting the point to be tested into the tester; the tester consists of a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate, and related operations of the test system are realized together.
As shown in fig. 3, the present invention has both administrator and operator identities to log in. The administrator has the authority to create and modify the test program and can perform product test; the operator can only open the test program for testing.
When a test program is created, logging in a test system by using the identity of an administrator;
filling a naming table, wherein an administrator needs to arrange the corresponding relation between the points to be tested on the tested product and the test points on the tester, and fills the names of the points to be tested into the naming table;
filling in relay table information, including: the relay testing method comprises the following steps of testing group information, serial numbers and information of relays in a relay driving module, names of relays to be tested on tested products, testing states and information of points to be tested; when a plurality of relays on the relay driving module need to be closed to finish electrifying the relay coil of the tested product, test group information needs to be filled, otherwise, the test group information item is empty; when the test state is 'power-on resistor test', the tested resistor value and the positive and negative deviation are required to be filled;
and filling test parameters such as conduction parameters and disconnection parameters to generate a final test program.
As shown in fig. 4, the preferred testing steps of the test system include:
the main control module reads the content of the relay table to obtain information such as relay serial numbers of corresponding actions of the test group and the relay drive module, names of points to be tested and the like;
the main control module sends a command for opening the relay driving module, and the relay driving module receives the command and opens the relay driving module; the main control module sends an instruction for closing all relays in the same test group of the relay driving module, the relay driving module receives the instruction of the main control module, closes the corresponding relays of the relay driving module, and powers up relay coils on a tested product through test cables;
the main control module searches a path gating module corresponding to the point to be measured according to the information of the point to be measured in the name table, and sends instructions of opening the module, closing the test point and the like to the path gating module; the access gating module receives and analyzes the instruction sent by the main control module, opens the module and closes a relay on the module, and accesses a point to be tested on a product to be tested into the access measuring module through a test cable;
the preferred scheme is as follows: the main control module sends an instruction for opening the access measurement module, and the measurement module receives the instruction and opens the module; the main control module sends a measured value acquisition instruction, and after the measurement module receives the measurement instruction, the voltage values among the test points are acquired and converted into resistance values; the main control module receives the measured value returned by the measuring module and judges the test result according to the following three states: when the power-on and power-off state is realized, if the measured value is larger than the conduction parameter, the circuit of the relay to be tested is judged to have an open circuit fault when the circuit is in the power-on and power-off state; when the power-on test is in the power-on test-off state, the measured value is smaller than the circuit-breaking parameter, and the short-circuit fault exists in the circuit where the relay to be tested is in the power-on test-off state; when the "resistance on test" state is present, the measured value does not satisfy more than resistance x (1 minus offset) and less than resistance x (1 plus offset); judging that a fault that the resistance precision does not meet the requirement exists when the circuit where the relay to be tested is in the state of power-on resistance measurement;
finally, the main control module displays detailed test information and test results, and sends relay disconnection instructions to the access gating module and the relay driving module respectively, so that one test is completed;
after all test items in the relay table to be tested are completed, the main control module sends an instruction for closing each module, each module executes the instruction after receiving the instruction, and the fault detection of the relay circuit is completed.
A block diagram of the circuit structure of the gating module is shown in fig. 5. The module comprises a level conversion part, a power supply part, a control part and a relay array part.
The power supply part supplies 5V and 3.3V voltages to the level conversion part and supplies 5V, 3.3V, 2.5V, 1.8V and 1.2V voltages to the control part.
The level conversion part is connected with the bus and the control part, converts the 5V signal on the bus into a 3.3V signal and transmits information to the FPGA chip of the control part.
The control part comprises an FPGA part, a driving part and a storage part.
The FPGA part receives the bus information processed by the level conversion part, and analyzes the information to obtain the relay serial number of the action required by the test. And the FPGA raises the pin corresponding to the relay to a high level.
The preferred scheme is as follows: the terminal X1_2 of the coil X1 of the relay K1 in FIG. 5 becomes low level, at which time the coil X1 is energized, the contact C1 is closed, at which time the contact C1_1 is connected with the C1_2, and the C1_1 is connected with a test point of a tested product through a test cable, and the test point is accessed to the test system.
The preferred scheme is as follows: the test storage part stores the action times of each relay, and when the service life of each relay reaches 90% of the service life of each relay, the control part sends a reminding instruction to the main control module.
The preferred scheme is as follows: the connection relationship between each module and the tested product is shown in fig. 6. When circuit fault detection is carried out on the relay K4 in a tested product, the driving module receives a main control instruction, points are added to a coil of the relay K4, and the contact of the relay K4 is closed. The gating module receives a master control command to close the relays K1 and K2, contacts C1_1 and C1_2 of the relay K1 are communicated, and contacts C2_1 and C2_2 of the relay K2 are communicated, at the moment, a point C4_1 to be tested is communicated with a contact C1_1 of a relay K1 of the gating module, and a point C4_2 to be tested is communicated with a contact C2_1 of the relay K2 of the gating module, so that a one-to-one corresponding relation is formed. The contacts C1_2 and C2_2 are connected to the measuring module via a bus.
The preferred scheme is as follows: a certain tested product comprises 45 groups of points to be tested, wherein 30 groups of the points to be tested in a 'power-on' state are tested, and the conduction parameters are that the measured values are less than or equal to 2 omega; 11 groups of points to be measured in the state of 'power on and power off', wherein the off parameter is more than or equal to 1M omega; 4 groups of points to be measured in the state of 'resistance measurement on power', the resistance to be measured is respectively 6 omega, 11 omega and 30000 omega, and the positive and negative deviations of the resistance are both 5%. The time for completing the relay circuit fault of the product does not exceed 20s, the average time for one group of tests is about 0.44s, and the fault detection rate is 100%.
The invention realizes the further proposal of improving the test precision: in order to further reduce the test error and improve the test accuracy, the resistance value of each path from the test point to the end of the test cable is counted and measured, and each path resistance value is about 0.486134 Ω, and then the measured value is-0.486134.
The invention realizes a further scheme for improving comprehensive fault judgment: setting the minimum resistance value of the tested product as Rmin omega, and the positive and negative deviation of the resistance value as +/-x%; the maximum resistance value is Rmax omega, and the positive and negative deviation of the resistance value is +/-y%. The maximum value allowed to be set by the conduction test parameter setting is less than Rmin omega (1-x%); the minimum allowed for the open circuit test parameters should be greater than Rmax Ω (1+ y%). Satisfying the optimal parameter constraint condition can realize comprehensive fault judgment.
The testing system has simple structure and high integration, and each functional module has small size and is completely arranged in the tester case, so the whole testing system has small volume and is convenient to move; the test system is simple to operate and convenient to use, and after the administrator fills in the relevant relay information and completes the program creation, the operator opens the program, and the test can be automatically completed without other operations, so that the test system is more time-saving and more reliable compared with the original manual test method;
the test system of the invention has comprehensive test and high reliability, and the test system of the relay fault can automatically realize the fault judgment of three test states, namely 'power-on test on', 'power-on test off' and 'power-on test resistance'.
Claims (10)
1. A relay circuit fault testing system, comprising: the device comprises a human-computer interaction module, a tester and a test cable;
a tester, comprising: the system comprises a main control module, a power supply module, a relay driving module, a channel gating module, a channel measuring module and a bottom plate;
the human-computer interaction module is connected with a main control module of the tester to realize information input and display;
the main control module transmits and receives information through the bottom plate, the relay driving module, the access gating module and the access measuring module;
the main control module can send out an instruction and send the instruction to the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module, the access gating module and the access measuring module complete corresponding actions according to the instructions of the main control module and return information to the main control module;
the power supply module supplies power to the main control module, the relay driving module, the access gating module and the access measuring module through the bottom plate;
the relay driving module is connected with a relay coil of a tested product through a corresponding test cable and supplies power to a relay in the tested product;
the master control module prestores data of points to be tested of the relay circuit of a tested product and test parameters thereof, and when the master control module sends a gating instruction, the prestored data of the points to be tested of the relay circuit are sent to the access gating module;
the path gating module accesses a point to be measured in the relay circuit into the path measuring module according to prestored point data to be measured of the relay circuit;
and the path measuring module is used for measuring a point to be measured in the relay circuit and sending the measured information to the main control module, and the main control module is used for determining the relay circuit fault according to the measured information, the test state and the prestored test parameters.
2. The relay circuit fault testing system of claim 1, wherein: the main control module is used for storing a name table, a relay table and test parameter data information of a tested product, sending instructions to the access gating module and the access measuring module in real time, receiving and analyzing the test instructions sent by the access measuring module to obtain a calculated resistance value, judging the resistance value according to the test parameters to obtain a test result, and obtaining a relay fault in the relay circuit according to the test result; and storing the test result.
3. A relay circuit fault testing system according to claim 2, wherein: all the conducting points related to the closed relay contacts and all the breaking points related to the closed relay contacts in the product to be tested are stored in the relay table.
4. The relay circuit fault testing system of claim 1, wherein: a power supply module: and respectively providing working voltage for the main control module, the access gating module, the relay driving module and the access measuring module.
5. The relay circuit fault testing system of claim 1, wherein: the bottom plate can transfer the electricity output by the power supply module and send the electricity to the main control module, the relay driving module, the access gating module and the access measuring module; the bottom plate is provided with a bus; the bus is connected with the main control module, the relay driving module, the access gating module and the access measuring module, and an instruction sent by the main control module is transmitted to the main control module, the relay driving module, the access gating module and the access measuring module through the bus of the bottom plate.
6. The relay circuit fault testing system of claim 1, wherein: the passage gating module comprises a plurality of relays; the access gating module can receive and analyze the instruction of the main control module, and close or open the relay on the access gating module according to the instruction requirement, so that the access or the shift-out of the point to be tested in the relay circuit is realized.
7. The relay circuit fault testing system of claim 1, wherein: a relay driving module including a plurality of relays; the relay driving module can receive and analyze the instruction of the main control module, close the corresponding relay according to the instruction requirement and supply power to the relay coil to be tested in the tested product.
8. The relay circuit fault testing system of claim 1, wherein: the point to be tested is arranged on a group of contacts in a relay to be tested in a product to be tested or the connecting end of a component directly connected with the contacts; when the point to be measured is arranged on the connecting end of the component directly connected with the contact, one connecting end of the component is connected with one contact in a group of contacts of the relay to be measured, and the other connecting end of the component is the point to be measured; the component comprises a resistor.
9. The relay circuit fault testing system of claim 1, wherein: and the path measuring module is used for receiving the instruction of the main control module, collecting the voltage between the points to be measured, calculating the resistance value according to the voltage to be used as a measured value, forming a test instruction, sending the test instruction to the main control module and returning the measured value.
10. A method for testing the fault of a relay circuit is characterized by comprising the following steps:
(1) the main control module reads the content of the relay table to obtain test group information, relay sequence numbers and information of corresponding actions of the relay driving module and information of points to be tested;
(2) the main control module sends an opening relay driving module, and the relay driving module receives the instruction and opens the relay driving module; the main control module sends an instruction for closing a relay corresponding to the relay driving module, the relay driving module receives the instruction and closes one or more relays of the relay driving module corresponding to the relay to be tested in the tested product, and the relay driving module supplies power to a relay coil to be tested on the tested product through corresponding testing cables;
(3) the main control module searches a path gating module corresponding to the point to be measured according to the information of the point to be measured in the name table and sends an opening instruction to the path gating module; the access gating module receives the instruction of the main control module and opens the main control module; the master control module respectively sends an instruction for accessing the point to be measured to the opened gating module; after receiving the instruction sent by the main control module, the access gating module closes a relay on the access gating module and accesses a point to be tested on a product to be tested into the access measuring module through a test cable;
(4) the main control module sends an instruction for opening the access measurement module, and the access measurement module receives the instruction and opens the access measurement module; the main control module sends a measured value acquisition instruction, and the path measurement module obtains a resistance value between the points to be measured as a measured value by measuring a voltage value between the points to be measured after receiving the measurement instruction and sends the measured value to the main control module;
(5) the main control module receives a measured value returned by the measuring module and judges the fault of the relay circuit according to the test state in the relay table;
when the power-on and power-off state is realized, if the measured value is larger than the conduction parameter, the circuit of the relay to be tested is judged to have an open circuit fault when the circuit is in the power-on and power-off state;
when the power-on test is in the power-on test-off state, the measured value is smaller than the circuit-breaking parameter, and the short-circuit fault exists in the circuit where the relay to be tested is in the power-on test-off state;
when the "resistance on test" state is present, the measured value does not satisfy more than resistance x (1 minus offset) and less than resistance x (1 plus offset); judging that a fault that the resistance precision does not meet the requirement exists when the circuit where the relay to be tested is in the state of power-on resistance measurement;
(6) the main control module sends the information of the point to be tested, the name of the relay to be tested, the measured value and the fault condition of the relay circuit to the man-machine interaction module for displaying, and sends a relay disconnection instruction to the access gating module and the relay driving module respectively, so that one test is completed;
(7) after all test items in the relay table to be tested are completed, the main control module sends a module closing instruction, each module executes the instruction after receiving the instruction, and the relay circuit fault detection is completed.
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