CN114721360A - Automatic testing device and method for aircraft engine controller - Google Patents
Automatic testing device and method for aircraft engine controller Download PDFInfo
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- CN114721360A CN114721360A CN202210571084.9A CN202210571084A CN114721360A CN 114721360 A CN114721360 A CN 114721360A CN 202210571084 A CN202210571084 A CN 202210571084A CN 114721360 A CN114721360 A CN 114721360A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0256—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
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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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to an automatic testing device and method of an aircraft engine controller.A computer is provided with an analog-digital conversion plate, a digital-analog conversion plate, a digital quantity input plate and a serial port communication plate, and an adapter plate is integrated with a power supply control and detection circuit, a rotating speed sensor analog circuit, a temperature sensor analog circuit, a pressure sensor analog circuit, a testing channel gating circuit and a switching value output circuit; the analog-digital conversion board, the digital-analog conversion board, the digital quantity input board and the serial port communication board are connected with the adapting board, the serial port communication board is connected with the adapting board through the serial-parallel conversion board, the adapting board is connected with the end connector of the controller, the self-checking output signal end of the controller is connected with the optocoupler in series between the LED indicating lamps on the adapting board, and the optocoupler is connected with the digital quantity input board; the adapter plate is connected with the digital multimeter and the oscilloscope through the test wiring terminal, and the computer is connected with the digital multimeter and the oscilloscope. When the device is used for carrying out automatic testing, the repeated labor is reduced, and the labor intensity is reduced.
Description
Technical Field
The invention belongs to the field of design and test of aircraft engine controllers, and particularly relates to an automatic test device and method of an aircraft engine controller.
Background
The aircraft engine controller is a complex whole machine product, and the interior of the aircraft engine controller consists of a secondary power supply module, a calculation and communication module, a self-checking module, a sensor acquisition and conversion module and an electromagnetic valve driving module. The performance test of the controller is needed in the production process of the controller and before delivery, and the test items comprise power supply test, self-checking test, communication test, sensor interface test and load output characteristic test. The power supply test is to electrify the controller and detect whether the working current and the secondary power supply output are normal; the self-checking test is to electrify the controller and detect whether the self-checking signal output by the controller is normal or not; the communication test is that the controller and the upper computer carry out serial port communication, and whether the communication function is normal is verified through data comparison of an upper serial port and a lower serial port; the sensor interface test is to provide a sensor analog signal for the controller and detect whether the output of the controller is normal; the load output characteristic test is to connect the output of the controller with a simulation load, detect the output waveform of the controller by an oscilloscope, extract the signal characteristics and judge whether the output waveform is normal or not.
The existing testing method of the engine controller is completed manually, specifically, an operator manually gives various testing input excitations, manually measures product output and records data and states, and completes data interpretation. Generally, two persons, namely an operator and a recorder, are required to form a group of persons to cooperate, and if a plurality of products are tested simultaneously, a plurality of groups of persons are required to be invested to work in parallel.
In the manual testing process of the aircraft engine controller, an operator is the most important factor, the testing process has higher requirements on the operator, the technical level and the working state of the operator have larger influence on the testing speed and the testing quality, and further the testing progress and the testing quality are influenced.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the automatic testing device and the method for the aircraft engine controller, which have the advantages of low cost, capability of reducing the participation degree and the specific gravity of operators in the testing and testing links, capability of solving the current situation that the testing process is seriously dependent on people, capability of reducing the repeated labor of data inspection and filing and labor intensity reduction.
The invention is realized by the following technical scheme:
an automatic testing device of an aircraft engine controller comprises a computer, a serial-parallel conversion board, an adapter board, a digital multimeter and a digital oscilloscope;
the computer is provided with an analog-digital conversion plate, a digital-analog conversion plate, a digital quantity input plate and a serial port communication plate, and the adapter plate comprises a printed circuit board, and a power supply control and detection circuit, a rotating speed sensor analog circuit, a temperature sensor analog circuit, a pressure sensor analog circuit, a test channel gating circuit and a switching value output circuit which are integrated on the printed circuit board;
the serial-parallel conversion board is integrated with a serial communication chip, an FPGA and a driver, an acquisition channel of the analog-digital conversion board, an output channel of the digital-analog conversion board, an input channel of the digital quantity input board and a part of serial communication ports of the serial communication board are connected with a printed circuit board, the other serial communication port of the serial communication board is connected with the input end of the serial communication chip, the output end of the serial communication chip is connected with the input end of the FPGA, the output end of the FPGA is connected with the input end of the driver, the driver is connected with the printed circuit board, the printed circuit board is connected with 2 aircraft engine controller end connectors, each aircraft engine controller end connector is used for being connected with the aircraft engine controller, the printed circuit board is connected with an LED indicator lamp, a primary optical coupler is connected in series between a signal end of the self-checking output of the aircraft engine controller and the LED indicator lamp, the output end of the optical coupler is connected with the input end of the digital quantity input plate;
the computer is connected with the digital multimeter and the digital oscilloscope through the switch respectively.
Preferably, the analog-digital conversion plate has 32 acquisition channels, the digital-analog conversion plate has 32 output channels, the digital quantity input plate has 32 input channels, the serial communication plate has 9 serial communication ports, each 4 acquisition channels in the analog-digital conversion plate, each 4 output channels in the digital-analog conversion plate, each 4 input channels in the digital quantity input plate and each 1 serial communication port in the serial communication plate are connected with 1 printed circuit board through a computer end connector, and the analog-digital conversion plate, the digital-analog conversion plate, the digital quantity input plate and the serial communication plate are connected with 8 aircraft engine controller end connectors through 4 printed circuit boards.
Furthermore, the 4 printed circuit boards are arranged at intervals, each printed circuit board is respectively connected with the driver in an up-and-down stacked mode through an inter-board connector, and each printed circuit board is connected with the 2 aircraft engine controller end connectors through an on-board connector;
the analog-digital conversion plate, the digital-analog conversion plate, the digital input plate and the serial port communication plate are connected with the same computer end connector, and the computer end connector is connected with the printed circuit board through 1 on-board connector.
Preferably, the power supply control and detection circuit comprises a power module, the output end of the power module is connected with a button switch, the button switch is connected with the input end of a power supply relay, the output end of the power supply relay is connected with the input end of a Hall current sensor, and the output end of the Hall current sensor is connected with an end connector of the aircraft engine controller.
Preferably, the analog circuit of the revolution speed sensor comprises an operational amplifier, the input end of the operational amplifier is connected with 1 output channel of the digital-to-analog conversion board, the output end of the operational amplifier is connected with the input end of the voltage-to-frequency converter, the output end of the voltage-to-frequency converter is connected with the input end of the driving amplifier, and the output end of the driving amplifier is connected with the connector of the controller end of the aircraft engine.
Preferably, the temperature sensor analog circuit comprises an operational amplifier N1, an operational amplifier N2, a triode V1 and an impedance matching resistor R6;
1 output channel of the digital-to-analog conversion board is connected with the positive input electrode of an operational amplifier N2 through a resistor R8, the output end of the operational amplifier N2 is connected with the b electrode of a triode V1, the e electrode of the triode V1 is connected with one end of a resistor R7, the other end of the resistor R7 is respectively connected with one end of a relay and one end of an impedance matching resistor R6, the relay is connected with the current source input end of an aircraft engine controller through a digital multimeter and an aircraft engine controller end connector in sequence, and the other end of the impedance matching resistor R6 is connected with the current source input end of the aircraft engine controller through an aircraft engine controller end connector;
one end of the R7 is connected with the input cathode of the instrument operational amplifier N1 through a current-limiting resistor R3, the other end of the R7 is connected with the input anode of the instrument operational amplifier N1 through a current-limiting resistor R4, one end of the R2 is connected with the output end of the operational amplifier N1, and the other end of the R2 is connected with 1 acquisition channel of the analog-digital conversion board.
Furthermore, the temperature sensor analog circuit further comprises a resistor R5 and a gain resistor R1, one end of the resistor R5 is connected to the input negative electrode of the operational amplifier N2, the other end of the resistor R5 is connected to one end of the resistor R9, the other end of the resistor R9 is connected to the power supply end, the c electrode of the triode V1 is connected to one end of the resistor R9, and two ends of the gain resistor R1 are respectively connected to the gain interface of the operational amplifier N1.
Preferably, the analog circuit of the pressure sensor is connected with 2 output channels of a digital-to-analog conversion plate; the switching value output circuit comprises an electromagnetic relay, the output end of the driver is connected with the input end of the electromagnetic relay, and the output end of the electromagnetic relay is connected with the connector of the aircraft engine controller.
Preferably, the test channel gating circuit comprises an electromagnetic relay and 2 8-channel analog switches, and the driver is respectively connected with the electromagnetic relay and the analog switches.
An automatic testing method of an aircraft engine controller is based on the automatic testing device of the aircraft engine controller, and comprises the following steps:
when a power supply test is carried out, the computer controls the serial-parallel conversion board to be connected with a power supply control and detection circuit through a serial port, the analog-digital conversion board converts the collected current and voltage into a current value, and finally whether the obtained current value is normal is judged;
when the self-checking test is carried out, the 1 st output channel of the digital-to-analog conversion plate outputs, and the rotating speed sensor analog circuit is controlled to generate a sine wave signal of 2100 +/-100 Hz, and Vrms is more than 1V; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output, and the analog circuit of the pressure sensor is controlled to output 2.75-3V direct-current voltage; the 3 rd output channel of the digital-to-analog conversion board controls the temperature sensor analog circuit to generate a current signal of-288.2 muA; the computer controls the serial-parallel conversion board to be communicated with the power supply control and detection circuit through a serial port, and a self-detection signal output by the aircraft engine controller passes through the optocoupler and the LED indicator lamp to judge whether the signal is normal or not;
when a communication test is carried out, the computer sends instructions to the aircraft engine controller at intervals through the serial port, the aircraft engine controller transmits back, and the computer compares the sent and received serial port data to judge whether the serial port data are normal or not;
when a sensor interface is tested, the 3 rd output channel of the digital-to-analog conversion board outputs, a temperature sensor analog circuit is controlled to generate a current signal of-273.2 muA, a computer controls the serial-to-parallel conversion board to control the gating of the test channel gating circuit through a serial port, a temperature sensor telemetering channel is connected, and the analog-to-digital conversion board acquires and measures and records a controller telemetering value 1; in the same manner current signals of-288.2 μ A and-303.2 μ A were generated, and the corresponding controller telemetry 2 and controller telemetry 3 were measured and recorded; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output 1V, the computer controls the serial-to-parallel conversion plate to control the gating of the testing channel gating circuit through the serial port, the pressure sensor telemetering channel is connected, and the analog-to-digital conversion plate measures a controller telemetering value 4; the 2 nd and 4 th DAC channels of the digital-to-analog conversion plate output 3V, the computer controls the serial-to-parallel conversion plate to control the analog circuit of the pressure sensor to be gated through a serial port, and the remote measurement value 5 of the controller is measured; finally, judging whether the controller telemetering value 1, the controller telemetering value 2, the controller telemetering value 3, the controller telemetering value 4 and the controller telemetering value 5 are normal or not;
when a power supply test is carried out, the 1 st channel of the digital-to-analog conversion plate outputs, and the analog circuit of the rotating speed sensor is controlled to generate a sine wave signal of 2100 +/-100 Hz, Vrms is more than 1V; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output, and the analog circuit of the pressure sensor is controlled to output 3V direct-current voltage; the 3 rd output channel of the digital-to-analog conversion board controls the temperature sensor analog circuit to generate a current signal of-288.2 muA; the computer controls the serial-parallel conversion board to be connected with the test channel gating circuit through the serial port, the output of the aircraft engine controller is switched to the test wiring terminal, the computer controls the digital oscilloscope to acquire a drive output waveform, and the frequency and the peak-to-peak value of the drive output are extracted; and adjusting a 1 st output channel of the digital-to-analog conversion plate to enable the analog circuit of the rotating speed sensor to generate sine wave signals of 3000 +/-100 Hz and Vrms & gt 1V, and controlling the digital oscilloscope by the computer to acquire driving output waveforms, extract the frequencies and peak-to-peak values of the driving output waveforms and judge whether the frequencies and the peak-to-peak values are normal or not.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention relates to an automatic testing device of an aircraft engine controller, wherein an analog-digital conversion plate, a digital-analog conversion plate, a digital quantity input plate and a serial port communication plate are arranged on a computer, the digital-analog conversion plate can provide direct-current voltage input for a measured controller and complete the input setting of the measured controller, 1 serial communication port of the serial port communication plate can complete power supply control, switching value configuration and test channel gating, and the other serial communication ports complete point-to-point data communication with the aircraft engine controller, the analog-digital conversion plate can collect the direct-current voltage output of the aircraft engine controller, the switching value output state of the aircraft engine controller can be collected by the digital quantity input plate, and the computer can complete the control and collection of a digital multimeter and a digital oscilloscope by an LAN (local area network) communication protocol; the output point of the aircraft engine controller can be connected to a test wiring terminal through an aircraft engine controller end connector by gating a test channel on the adapter plate, the voltage with the precision of 0.1mV and the current with the precision of 0.01 muA are collected by using a digital multimeter, and the peak-to-peak value and the frequency of an output signal are collected by using a digital oscilloscope; the computer can send the control instruction to the serial port communication chip of the serial-parallel conversion board, the serial port communication chip transmits the control instruction to the FPGA, the FPGA solidifies the logic of serial port communication protocol analysis and can analyze the control instruction of the computer into a switching value output state, the driver completes instruction decoding according to the serial port communication protocol and respectively outputs the instruction to the rotating speed sensor analog circuit, the temperature sensor analog circuit, the pressure sensor analog circuit, the test channel gating circuit and the switching value output circuit on the printed circuit board, and the rotating speed sensor simulation, the voltage type pressure sensor simulation, the current type temperature sensor simulation, the test channel gating, the switching value output and the switching value input conversion are completed; the printed circuit board is connected with an LED indicator light, a primary optocoupler is connected in series between a signal end of the self-checking output of the aircraft engine controller and the LED indicator light, and an output end of the optocoupler is connected with an input end of the digital input board. The invention completes the manual signal setting, software configuration, lamp interpretation, multimeter measurement, signal parameter extraction, data inspection, recording and copying operations by an automatic test device according to a preset flow, forms electronic data, and generates an electronic file with a WORD format consistent with paper records for printing and filing, thereby realizing the automatic test of the controller. After the automatic testing device is put into use, the number of testers is reduced to 1, and the operators do not directly participate in the test of the whole machine except the connection and replacement of the tested product, the starting test and the periodic inspection. The automatic testing device replaces repetitive manual labor, greatly reduces the input and consumption of manpower, is easy to use on equipment, reduces the capability requirement of operators, can continuously work for a long time, and improves the testing efficiency and speed. The invention replaces the manual testing work with the machine operation which can be quantized and standardized, and because the manual work does not directly intervene in the testing process, the random error and mistake caused by the manual operation can be reduced, and the consistency of the test is improved.
The invention relates to an automatic test method of an aircraft engine controller, which is mainly suitable for full-parameter automatic test of the controller, and particularly during power supply test, a computer can control a serial-parallel conversion board to be connected with a power supply control and detection circuit through a serial port, and an analog-digital conversion board converts acquired current and voltage into current values firstly and then converts the current and the voltage into the current values; when the self-checking test is carried out, a 1 st output channel of the digital-to-analog conversion plate outputs, a rotating speed sensor analog circuit is controlled to generate a sine wave signal of 2100 +/-100 Hz, Vrms is larger than 1V, 2 nd and 4 th output channels output, a pressure sensor analog circuit is controlled to output 2.75-3V direct current voltage, a 3 rd output channel outputs, a temperature sensor analog circuit is controlled to generate a current signal of-288.2 mu A, a computer controls and switches on a power supply control and detection circuit through a serial port, and a self-checking signal output by a controller is judged through an optical coupler and an LED indicator light; when in communication test, the computer sends instructions to the aircraft engine controller at intervals through the serial port, the controller returns back, and the computer compares the sent and received serial port data; when a sensor interface is tested, a 3 rd output channel of the digital-to-analog conversion plate outputs, a temperature sensor analog circuit is controlled to generate a current signal of-273.2 muA, a computer controls a test channel gating circuit to gate through a serial port, a temperature sensor remote measuring channel is switched on, an analog-to-digital conversion plate collects and measures and records a controller remote measuring value 1, corresponding controller remote measuring values 2 and 3 can be recorded in a similar way, the 2 nd and 4 th output channels of the digital-to-analog conversion plate output 1V, the computer controls the test channel gating circuit to gate through the serial port, a pressure sensor remote measuring channel is switched on, and the analog-to-digital conversion plate measures a controller remote measuring value 4; the 2 nd and 4 th DAC channels output 3V, the computer controls the serial-parallel conversion plate to control the analog circuit of the pressure sensor to be gated through a serial port, and the remote measurement value 5 of the measurement controller is obtained; when a power supply is used for testing, a 1 st output channel of the digital-to-analog conversion board outputs, a rotating speed sensor analog circuit is controlled to generate a 2100 +/-100 Hz sine wave signal, Vrms is larger than 1V, a pressure sensor analog circuit is controlled to output 3V direct current voltage, a temperature sensor analog circuit is controlled to generate a current signal of-288.2 muA, a computer is controlled by a serial port to connect a test channel gating circuit, the output of the controller is switched to a test wiring terminal, a digital oscilloscope obtains a driving output waveform, extracts frequency and peak value, adjusts the 1 st output channel to enable the rotating speed sensor analog circuit to generate a 3000 +/-100 Hz sine wave signal, and extracts the frequency and the peak value of the driving output waveform, and the computer controls the digital oscilloscope to obtain the driving output waveform and extract the frequency and the peak value of the driving output waveform. The invention can collect and record data in real time and complete online interpretation during testing, can complete full parameter testing of the whole production process of the controller, realizes automatic recording of data in the testing process, forms a testing data packet, has high testing efficiency and comprehensive testing coverage, eliminates random errors and errors introduced by manual operation, realizes electronization of data management, and meets the requirement of mass production of the controller.
Drawings
FIG. 1 is a schematic block diagram of an automated testing apparatus according to the present invention.
Fig. 2 is a schematic block diagram of a 28V power supply circuit according to the present invention.
Fig. 3 is a schematic block diagram of the adapter plate according to the present invention.
Fig. 4 is a schematic diagram of an analog circuit of the tachometer sensor according to the present invention.
Fig. 5 is a schematic block diagram of an analog circuit of the temperature sensor according to the present invention.
FIG. 6 is a flow chart of a power supply test according to the present invention.
Fig. 7 is a flow chart of the self-test according to the present invention.
Fig. 8 is a flow chart of the communication test according to the present invention.
FIG. 9 is a flow chart of a sensor interface test according to the present invention.
Fig. 10 is a flowchart illustrating a load output characteristic test according to the present invention.
Detailed Description
The present invention will now be described in further detail with reference to specific examples, which are intended to be illustrative, but not limiting, of the invention.
The invention relates to an automatic testing device and method of an aircraft engine controller, which are applied to testing and experiment of the aircraft engine controller. The automated testing device is shown in fig. 1 and comprises a computer, an adaptive conditioning box and a meter. Referring to the computer in fig. 1, the expansion board card installed in the computer includes an analog-to-digital conversion board, a digital-to-analog conversion board, a digital quantity input board, and a serial communication board. The analog-digital conversion board is abbreviated as ADC and is provided with 32 acquisition channels, and the voltage input range is-10V- + 10V; the digital-to-analog conversion plate is abbreviated as DAC, 32 output channels are provided, and the voltage output range is-10V- + 10V; the digital quantity input board is abbreviated as DI, has 32 input channels and is used for optical coupling isolation input; the serial communication board has 9 serial communication ports, 8 of them serial communication ports carry out point-to-point communication with 8 controllers under test respectively, and the remaining 1 serial communication port carries out communication with the serial-parallel conversion board that is fit for the adjustment box. The acquisition channels of the ADC, the output channels of the DAC, the input channels of the DI and the serial communication ports of the serial communication board are evenly distributed to 1 to 8 tested controllers, and 1 computer can meet the test requirements of 8 controllers, so that the test of one controller needs to be completed by using 4 acquisition channels of the ADC, 4 output channels of the DAC, 4 input channels of the DI and 1 serial communication port of the serial communication board.
Referring to the adapting conditioning box in fig. 1, the adapting conditioning box is designed as a metal box body, a panel of the box body is integrated with a button switch, a testing wiring terminal, a computer end connector, 8 tested controller end connectors, a power supply socket and 16 groups of LED indicating lamps, wherein each group of LED indicating lamps is 2, and the power supply socket is used for supplying power to a power module and can meet the test of 8 tested products. The inside power module, 1 piece of deserializing board, 4 adaptation boards of still installing of adaptation regulation case.
ADC, DAC, DI, the serial port communication board of computer installation, through the inside line of taking care of adaptation case, 32 ADC's collection passageway, 32 DAC's output channel, 32 DI's input channel, 8 serial communication ports of serial port communication board, 16 LED pilot lamps of group are evenly distributed to adaptation board 1-adaptation board 4. The principle and the function of 4 adapter plates are completely the same, 4 adapter plates are distributed at intervals, every adapter plate is respectively stacked up and down with the serial-parallel conversion plate through the inter-plate connector and fixedly installed in the adapter adjustment box, and 1 adapter plate can complete the connection and the interface adaptation of 2 measured controllers.
Taking 1 adapter plate as an example, the following is described: the adapter board is connected with the computer end connector through an on-board connector, and the circuits are distinguished on the printed board, so that 8 ADC acquisition channels, 8 DAC output channels, 8 DI input channels and 2 serial communication ports of the serial communication board are accessed; the adapter plate is connected with the 2 measured controller end connectors on the box body through the on-board connectors; the adapter board is wired inside the adapter box and connected with 4 groups of LED indicating lamps on the LED board, so that the state display of 2 measured controllers can be realized; through controlling the switching circuit on the adapter plate and the wiring inside the adapter box, signals of 2 measured controllers can be switched to the test wiring terminal on the case, and the signal leading-out of 2 measured controllers is realized.
Referring to the meter in fig. 1, a probe of the digital multimeter, which is also called a stylus, and a probe of the digital oscilloscope are both connected with a test connection terminal of the adaptation conditioning box. The computer is connected with the switch through a network interface by using a network cable, the switch is connected with the digital multimeter and the digital oscilloscope by using the network cable through an LAN communication protocol, and networking of the computer, the digital multimeter and the digital oscilloscope is realized.
The adaptive adjusting box switches the outputs of different tested controllers to the testing wiring terminal of the chassis panel in a time-sharing manner, and the computer sets and reads the digital oscilloscope and the digital multimeter to obtain the useful information output by the controller. The controller automatic test of the invention designs corresponding test software according to the power supply test flow, the self-checking test flow, the communication test flow, the sensor interface flow and the load output characteristic test flow of the tested controller through the hardware platform, and the test software is installed in a computer, thereby realizing the following processes:
firstly, the computer provides direct current voltage input for the measured controller through a digital-to-analog conversion plate and an adaptive adjusting box, and input setting of the measured controller is completed.
And secondly, the computer completes power supply control, switching value configuration and test channel gating suitable for the conditioning box through 1 serial communication port of the serial communication board, and completes point-to-point data communication with the measured controller through the other 8 serial communication ports.
Thirdly, the computer collects the direct current voltage output of the controller to be tested through the analog-to-digital conversion board.
Fourthly, the computer collects the switching value output state of the controller to be monitored through a digital input board.
Fifthly, the computer completes the control and acquisition of the digital multimeter and the digital oscilloscope through an LAN communication protocol; the output point of the measured controller can be connected to the test wiring terminal through the measured controller end connector and the adapter plate by gating the test channel on each adapter plate, the voltage with the precision of 0.1mV and the current with the precision of 0.01 muA are acquired by using a digital multimeter, and the peak-to-peak value and the frequency of an output signal are acquired by using a digital oscilloscope.
Besides, the software also provides a login interface for the five tests, and records the serial number of the tested controller and the test time information.
The serial-parallel conversion board is a functional single board and consists of a serial communication chip, an FPGA and a driver, wherein the driver comprises a TTL gate circuit and a Darlington transistor. The computer sends the control instruction to the serial communication chip of the serial-parallel conversion board, the serial communication chip transmits the control instruction to the FPGA, the FPGA solidifies the logic of serial communication protocol analysis and can analyze the control instruction of the computer into a switching value output state, the TTL gate circuit and the Darlington transistor finish instruction decoding according to the serial communication protocol and respectively output the instruction decoding to 4 adapting boards, and the control of each circuit mentioned later on the adapting boards is realized.
As shown in fig. 3, the adapter board is a functional board integrated with each circuit, and specifically includes a power supply control and detection circuit, a rotation speed sensor analog circuit, a temperature sensor analog circuit, a pressure sensor analog circuit, a test channel gating circuit, a switching value output circuit, and a switching value input conversion circuit. The adapter board receives the control instruction output by the serial-parallel conversion board, and completes power supply control and detection, rotation speed sensor simulation, voltage type pressure sensor simulation, current type temperature sensor simulation, test channel gating, switching value output and switching value input conversion.
Taking the interface adaptation of 1 controller as an example, the following is described:
the power module specifically selects an AC/DC converter, as a power supply control and monitoring circuit shown in fig. 2 and fig. 3, the power module can convert an externally input alternating current 220V into direct currents 5V and 28V, 5V supplies power to a serial-parallel conversion plate and 4 adapter plates through a button switch, 28V supplies power to the 4 adapter plates through the button switch, 28V is controlled by a power supply relay on the adapter plates, a product working current is converted into a voltage signal through a Hall current sensor, and a direct current voltage is collected by an analog-to-digital conversion plate of a computer, so that the on-off control, the current and the voltage monitoring of a measured controller are realized. The rated voltage power supply of 28V can be converted into external input through the switching button switch, and an external independent power supply is used for completing the test. The direct current acquisition test of 1 measured controller occupies 1 acquisition channel of the analog-to-digital conversion board.
Fig. 4 shows a schematic diagram of a tachometer sensor analog circuit, and a voltage-to-frequency converter of ICL8038 is used to generate a tachometer sensor analog signal. The analog circuit of the revolution speed transducer uses 1 output channel of the digital-to-analog conversion board of the computer, the output voltage of the digital-to-analog conversion board is changed by the operational amplifier, the voltage-frequency converter realizes the sine wave voltage with the frequency range of 300 Hz-6000 Hz and the effective value larger than 1V, and finally the sine wave voltage is output by the driving amplifier.
The pressure sensor analog circuit (voltage type) simulates the output of the voltage type sensor by using 2 output channels of the digital-to-analog conversion plate and provides test input for the tested controller.
In the analog circuit (current mode) of the temperature sensor shown in fig. 5, the DACIN terminal is connected to the digital-to-analog converter board through the terminal connector of the computer, the output of the digital-to-analog converter board continuously changes to realize the continuous adjustment of the current, i.e. 1 channel current source is controlled by using 1 channel signal output by the digital-to-analog converter board, and the current signal with continuously adjustable range of-350 mua to-250 mua is generated through the precise resistance sampling and the operational amplifier amplification in the circuit, the typical values are-273.2 mua, -288.2 mua and-303.2 mua respectively, so as to realize the simulation of the current mode temperature sensor, provide mua class current excitation for the temperature sensor acquisition and conversion module of the controller to be monitored, and realize the current recovery by 1 acquisition channel of the analog-to-digital converter board. DMM-EN is a digital multimeter switch-on enabling signal sent by a serial-parallel conversion board, and realizes access selection of the digital multimeter; the OUTPUT end is connected with the current source input end of the measured controller; the DMM-IN + end and the DMM-IN-end are respectively connected with the anode and the cathode of a current measurement input end of the digital multimeter; the ADC-IN end is connected with an analog-to-digital conversion plate.
For further analysis, in fig. 5, the operational amplifier N2, the transistors V1, R9, R5, and R8 form a voltage follower, wherein one end of R8 is connected to the DAC, the other end of R8 is connected to the positive input terminal of the operational amplifier N2, one end of R5 is connected to the negative input terminal of the operational amplifier N2, the other end of R5 is connected to one end of R9, the other end of R9 is connected to the negative terminal of the power supply voltage, the output of the operational amplifier N2 is connected to the b terminal of the transistor V1, and the c-pole voltage of the transistor V1 follows the voltage change at the DACIN terminal; r7 is a high-precision resistor, one end of R7 is connected with the e pole of the triode V1, and the other end is connected with the current source input end of the measured controller; the e-voltage of the triode V1 passes through R7, and the conversion of continuous variable voltage/continuous variable current is realized. K1 is the contact of the relay, R6 is an impedance matching resistor, and the resistance value of R6 is the same as the internal resistance in the current gear of the digital multimeter. When K1 is disconnected, the current on R7 is input to the current source input end of the measured controller through R6; when K1 is attracted, the current on R7 is input to the current source input end of the controller to be monitored through the digital multimeter, the accurate collection of the output current can be realized through the digital multimeter with the model of 33461A at the moment, and the DACIN voltage value is adjusted for further correction. The two ends of the R7 are respectively connected with the input cathode and the input anode of the instrument operational amplifier N1 through a current-limiting resistor R3 and a current-limiting resistor R4, the output of the N1 can be collected through an analog-to-digital conversion board, the voltage at the two ends of the R7 is monitored, and the current set value is obtained. R1 is the gain resistance of instrument operational amplifier N1, and both ends are connected respectively in the gain interface of operational amplifier N1, and one end and the output of operational amplifier N1 of R2 are connected, and the analog-to-digital conversion board is connected to the other end of R2. The DAC output precision of the digital-to-analog conversion board is 0.1mV, the DAC output precision is changed within the range of 0-10V, the precision of the digital multimeter is 6-bit and half, a relay K1 is attracted, the digital multimeter is connected in series into a loop, accurate current measurement and correction are carried out through a multimeter current gear, and the precision output by the temperature simulation circuit reaches 0.03 muA within an effective output range.
The switching value input conversion circuit is used for detecting self-checking signals of the measured controller and comprises a current-limiting resistor, an optical coupler and an LED indicator lamp. The self-checking output circuit of the tested controller is an open collector circuit with a current-limiting resistor, and the self-checking state is detected by lighting an LED indicator lamp during manual testing. A primary optical coupler is connected in series between a signal end of the self-checking output of the monitored controller and the LED indicator lamp, and the output end of the optical coupler is connected with the input end of the digital quantity input plate. When the self-checking signal output of the input controller to be tested is effective, the LED indicating lamp on the panel can be lightened, the optocoupler can output, the computer refreshes and acquires the state of the digital quantity input board at regular time, and the self-checking signal of the controller to be tested is detected and recorded.
The switching value output circuit provides a contact switch input signal required by the test for the tested controller by using an electromagnetic relay. The computer controls the serial-parallel conversion board through the serial port, and the serial-parallel conversion board controls the electromagnetic relay to complete switching value output.
The test channel gating circuit uses an analog switch and an electromagnetic relay to complete the gating of different types of signals. The gating of the analog switch uses 2 8-channel analog switches to realize the gating of 16 direct current signals in the voltage range of-10V to + 10V. The computer controls the serial-parallel conversion board through a serial port, and the serial-parallel conversion board controls the analog switch on the adapter board, so that 16 input channels are gated. The 16 input channels collect in a time-sharing mode, and 2 ADC collecting channels of the analog-to-digital conversion board finish voltage collection. The relay gating uses an electromagnetic relay to complete the time-sharing gating of 14 output points of the tested controller and the testing wiring terminal of the chassis panel. The computer controls the serial-parallel conversion board through the serial port, and the serial-parallel conversion board controls the relay to complete relay gating.
Taking 1 product as an example, when performing a power supply test, as shown in fig. 6, the automatic test method for an aircraft engine controller according to the present invention, based on the automatic test apparatus, includes the following steps:
When the self-test is performed, as shown in fig. 7, the automatic test method for the aircraft engine controller according to the invention is based on the automatic test device, and comprises the following steps:
and 2, starting test software, starting self-checking test by the test software, and switching on a button switch on the adapter box. The 1 st path of DAC output of the DAC channel controls a rotating speed sensor analog circuit of the adapter plate to generate sine wave signals of (2100 +/-100) Hz and Vrms more than 1V; the 2 nd DAC channel and the 4 th DAC channel output control the analog circuit of the pressure sensor to output (2.75-3) V direct-current voltage; and 3, outputting a DAC, and controlling a temperature sensor analog circuit of the adapter board to generate a current signal of-288.2 muA. The computer passes through serial ports control deserialize board switch-on power supply relay on the adapter plate, and the self-checking signal of controller output is judged through switching value input converting circuit self-checking, and effective then LED pilot lamp on the panel can be lighted, and effectual self-checking is gathered simultaneously to DI, and the self-checking test passes, and invalid then LED pilot lamp on the panel is not lighted, and the self-checking test does not pass.
When a communication test is performed, as shown in fig. 8, the automatic testing method for the aircraft engine controller according to the present invention includes the following steps based on the automatic testing apparatus:
and 3, starting the test software, starting the communication test by the test software, and connecting a button switch on the adapter box. The computer sends a 7e 7e 0304040008 instruction to the controller through the serial port every 100ms, and the instruction is transmitted back by the controller. And the computer compares the sent and received serial port data and judges whether the serial port data are consistent or not, if so, the communication test is passed, and if not, the communication test is not passed, so that the communication test is finished.
When the sensor interface test is performed, as shown in fig. 9, the automatic test method for the aircraft engine controller according to the invention is based on the automatic test device, and comprises the following steps:
and 4, starting test software, starting the sensor interface test by the test software, and switching on a button switch on the adapter box. And the 3 rd DAC output of the DAC channel of the digital-to-analog conversion plate controls the temperature sensor analog circuit of the adapter plate to generate a current signal of-273.2 muA. The computer controls the serial-parallel conversion board to control the gating of a test channel gating circuit on the adapter board through a serial port, and the temperature sensor telemetering channel is switched on, is collected by the computer analog-digital conversion board, and measures and records a controller telemetering value 1;
the 3 rd DAC output of the DAC channel of the digital-to-analog conversion plate generates a current signal of-288.2 muA by the temperature sensor analog circuit. The computer controls the serial-parallel conversion board to control the gating of a testing channel gating circuit on the adapter board through a serial port, the temperature sensor telemetering channel is connected, the temperature sensor telemetering channel is collected by the computer analog-digital conversion board, and the controller telemetering value 2 is measured and recorded;
the 3 rd DAC output of the DAC channel of the digital-to-analog conversion plate is output, and the temperature sensor analog circuit generates a current signal of-303.2 muA. The computer controls the serial-parallel conversion board to control the gating of a testing channel gating circuit on the adapter board through a serial port, the temperature sensor telemetering channel is connected, the temperature sensor telemetering channel is collected by the computer analog-digital conversion board, and the controller telemetering value 3 is measured and recorded;
the 2 nd DAC channel and the 4 th DAC channel of the digital-to-analog conversion plate output 1V, the computer controls the serial-parallel conversion plate to control the gating of a testing channel gating circuit on the adapter plate through a serial port, a pressure sensor telemetering channel is connected, and a computer analog-to-digital conversion plate measures a controller telemetering value 4;
and the 2 nd DAC channel and the 4 th DAC channel of the digital-to-analog conversion plate output 3V, the computer controls the serial-parallel conversion plate to control the gating of a pressure sensor analog circuit on the adapter plate through a serial port, the measuring controller telemetering value is 5, and the sensor interface test is finished.
In the load output characteristic test, as shown in fig. 10, the automatic test method for the aircraft engine controller according to the present invention includes the following steps:
and 5, starting test software, starting load output characteristic test by the test software, and switching on a button switch on the adapter box. The 1 st path of DAC output of the DAC channel controls a rotating speed sensor analog circuit of the adapter plate to generate sine wave signals (2100 +/-100) Hz, and Vrms is larger than 1V; the 2 nd DAC channel and the 4 th DAC channel output control the pressure sensor analog circuit to output 3V direct-current voltage; and 3, outputting a DAC channel, and controlling a temperature sensor analog circuit of the adapter board to generate a current signal of-288.2 muA. The computer controls the serial-parallel conversion board to be connected with a test channel gating circuit on the adapter board through the serial port, the output of the controller is switched to the panel test point, the computer controls the oscilloscope to obtain the driving output waveform, and the frequency and the peak-to-peak value of the driving output waveform are extracted.
And adjusting the 1 st path of DAC output of the DAC channel of the digital-to-analog conversion plate to enable the analog circuit of the rotating speed sensor of the adapter plate to generate sine wave signals of (3000 +/-100) Hz and Vrms & gt 1V, and controlling the oscilloscope by the computer to acquire driving output waveforms and extract the frequency and peak-to-peak value of the driving output waveforms.
Claims (10)
1. An automatic testing device of an aircraft engine controller is characterized by comprising a computer, a serial-parallel conversion board, an adapter board, a digital multimeter and a digital oscilloscope;
the computer is provided with an analog-digital conversion plate, a digital-analog conversion plate, a digital quantity input plate and a serial port communication plate, and the adapter plate comprises a printed circuit board, and a power supply control and detection circuit, a rotating speed sensor analog circuit, a temperature sensor analog circuit, a pressure sensor analog circuit, a test channel gating circuit and a switching value output circuit which are integrated on the printed circuit board;
the serial-parallel conversion board is integrated with a serial communication chip, an FPGA and a driver, an acquisition channel of the analog-digital conversion board, an output channel of the digital-analog conversion board, an input channel of the digital quantity input board and a part of serial communication ports of the serial communication board are connected with a printed circuit board, the other serial communication port of the serial communication board is connected with the input end of the serial communication chip, the output end of the serial communication chip is connected with the input end of the FPGA, the output end of the FPGA is connected with the input end of the driver, the driver is connected with the printed circuit board, the printed circuit board is connected with 2 aircraft engine controller end connectors, each aircraft engine controller end connector is used for being connected with the aircraft engine controller, the printed circuit board is connected with an LED indicator lamp, a primary optical coupler is connected in series between a signal end of the self-checking output of the aircraft engine controller and the LED indicator lamp, the output end of the optical coupler is connected with the input end of the digital quantity input plate;
the computer is connected with the digital multimeter and the digital oscilloscope through the switch respectively.
2. The automatic test device for the aircraft engine controller according to claim 1, wherein the analog-to-digital conversion board has 32 acquisition channels, the digital-to-analog conversion board has 32 output channels, the digital quantity input board has 32 input channels, the serial communication board has 9 serial communication ports, every 4 acquisition channels in the analog-to-digital conversion board, every 4 output channels in the digital-to-analog conversion board, every 4 input channels in the digital quantity input board and every 1 serial communication port in the serial communication board are connected to 1 printed circuit board through a computer end connector, and the analog-to-digital conversion board, the digital quantity input board and the serial communication board are connected to 8 aircraft engine controller end connectors through 4 printed circuit boards.
3. The automatic testing device for the aircraft engine controller according to claim 2, wherein the 4 printed circuit boards are arranged at intervals, each printed circuit board is respectively connected with the driver in an up-and-down stacked manner through an inter-board connector, and each printed circuit board is connected with 2 aircraft engine controller end connectors through an on-board connector;
the analog-digital conversion plate, the digital-analog conversion plate, the digital input plate and the serial port communication plate are connected with the same computer end connector, and the computer end connector is connected with the printed circuit board through 1 on-board connector.
4. The automatic testing device of the aircraft engine controller according to claim 1, wherein the power supply control and detection circuit comprises a power module, a button switch is connected to an output end of the power module, the button switch is connected to an input end of a power supply relay, an output end of the power supply relay is connected to an input end of a hall current sensor, and an output end of the hall current sensor is connected to an end connector of the aircraft engine controller.
5. The automatic testing device for the aircraft engine controller according to claim 1, wherein the analog circuit of the rotation speed sensor comprises an operational amplifier, an input end of the operational amplifier is connected with 1 output channel of the digital-to-analog conversion board, an output end of the operational amplifier is connected with an input end of the voltage-to-frequency converter, an output end of the voltage-to-frequency converter is connected with an input end of the driving amplifier, and an output end of the driving amplifier is connected with an aircraft engine controller end connector.
6. The automated test equipment of an aircraft engine controller according to claim 1, wherein the temperature sensor analog circuit comprises an operational amplifier N1, an operational amplifier N2, a triode V1 and an impedance matching resistor R6;
1 output channel of the digital-to-analog conversion board is connected with the positive input electrode of an operational amplifier N2 through a resistor R8, the output end of the operational amplifier N2 is connected with the b electrode of a triode V1, the e electrode of the triode V1 is connected with one end of a resistor R7, the other end of the resistor R7 is respectively connected with one end of a relay and one end of an impedance matching resistor R6, the relay is connected with the current source input end of an aircraft engine controller through a digital multimeter and an aircraft engine controller end connector in sequence, and the other end of the impedance matching resistor R6 is connected with the current source input end of the aircraft engine controller through an aircraft engine controller end connector;
one end of the R7 is connected with the input cathode of the instrument operational amplifier N1 through a current-limiting resistor R3, the other end of the R7 is connected with the input anode of the instrument operational amplifier N1 through a current-limiting resistor R4, one end of the R2 is connected with the output end of the operational amplifier N1, and the other end of the R2 is connected with 1 acquisition channel of the analog-digital conversion board.
7. The automatic test device of the aircraft engine controller according to claim 6, wherein the temperature sensor analog circuit further comprises a resistor R5 and a gain resistor R1, one end of the resistor R5 is connected to the negative input terminal of the operational amplifier N2, the other end of the resistor R5 is connected to one end of the resistor R9, the other end of the resistor R9 is connected to the power supply terminal, the c pole of the triode V1 is connected to one end of the resistor R9, and the two ends of the gain resistor R1 are respectively connected to the gain interface of the operational amplifier N1.
8. The automatic testing device of the aircraft engine controller according to claim 1, wherein the pressure sensor analog circuit is connected with 2 output channels of a digital-to-analog conversion plate; the switching value output circuit comprises an electromagnetic relay, the output end of the driver is connected with the input end of the electromagnetic relay, and the output end of the electromagnetic relay is connected with the connector of the aircraft engine controller.
9. The automated test equipment of an aircraft engine controller according to claim 1, wherein the test channel gating circuit comprises an electromagnetic relay and 2 8-channel analog switches, and the driver is connected with the electromagnetic relay and the analog switches respectively.
10. An automatic testing method of an aircraft engine controller, characterized in that the automatic testing device of the aircraft engine controller based on any one of claims 1 to 9 comprises the following steps:
when a power supply test is carried out, the computer controls the serial-parallel conversion board to be connected with a power supply control and detection circuit through a serial port, the analog-digital conversion board converts the collected current and voltage into a current value, and finally whether the obtained current value is normal is judged;
when the self-checking test is carried out, the 1 st channel of the digital-to-analog conversion plate outputs, and the analog circuit of the rotating speed sensor is controlled to generate a sine wave signal of 2100 +/-100 Hz, and Vrms is more than 1V; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output, and the analog circuit of the pressure sensor is controlled to output 2.75-3V direct-current voltage; the 3 rd output channel of the digital-to-analog conversion board controls the temperature sensor analog circuit to generate a current signal of-288.2 muA; the computer controls the serial-parallel conversion board to be communicated with the power supply control and detection circuit through a serial port, and a self-detection signal output by the aircraft engine controller passes through the optocoupler and the LED indicator lamp to judge whether the signal is normal or not;
when a communication test is carried out, the computer sends instructions to the aircraft engine controller at intervals through the serial port, the aircraft engine controller transmits back, and the computer compares the sent and received serial port data to judge whether the serial port data are normal or not;
when a sensor interface is tested, the 3 rd output channel of the digital-to-analog conversion board outputs, a temperature sensor analog circuit is controlled to generate a current signal of-273.2 muA, a computer controls the serial-to-parallel conversion board to control the gating of the test channel gating circuit through a serial port, a temperature sensor telemetering channel is connected, and the analog-to-digital conversion board acquires and measures and records a controller telemetering value 1; in the same manner current signals of-288.2 μ A and-303.2 μ A were generated, and the corresponding controller telemetry 2 and controller telemetry 3 were measured and recorded; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output 1V, the computer controls the serial-to-parallel conversion plate to control the gating of the testing channel gating circuit through the serial port, the pressure sensor telemetering channel is connected, and the analog-to-digital conversion plate measures a controller telemetering value 4; the 2 nd and 4 th DAC channels of the digital-to-analog conversion plate output 3V, the computer controls the serial-to-parallel conversion plate to control the analog circuit of the pressure sensor to be gated through a serial port, and the remote measurement value 5 of the controller is measured; finally, judging whether the controller telemetering value 1, the controller telemetering value 2, the controller telemetering value 3, the controller telemetering value 4 and the controller telemetering value 5 are normal or not;
when a power supply test is carried out, the 1 st output channel of the digital-to-analog conversion plate outputs, and the rotating speed sensor analog circuit is controlled to generate a sine wave signal of 2100 +/-100 Hz, and Vrms is more than 1V; the 2 nd and 4 th output channels of the digital-to-analog conversion plate output, and the analog circuit of the pressure sensor is controlled to output 3V direct-current voltage; the 3 rd output channel of the digital-to-analog conversion board controls the temperature sensor analog circuit to generate a current signal of-288.2 muA; the computer controls the serial-parallel conversion board to be connected with the test channel gating circuit through the serial port, the output of the aircraft engine controller is switched to the test wiring terminal, the computer controls the digital oscilloscope to acquire a drive output waveform, and the frequency and the peak-to-peak value of the drive output are extracted; and adjusting a 1 st output channel of the digital-to-analog conversion plate to enable the analog circuit of the rotating speed sensor to generate sine wave signals of 3000 +/-100 Hz and Vrms & gt 1V, and controlling the digital oscilloscope by the computer to acquire driving output waveforms, extract the frequencies and peak-to-peak values of the driving output waveforms and judge whether the frequencies and the peak-to-peak values are normal or not.
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| CN116578072A (en) * | 2023-07-13 | 2023-08-11 | 西安康创电子科技有限公司 | Testing device and method for electronic anti-asthma controller |
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