Automatic debugging device for tilt angle sensor

Abstract

The invention relates to an automatic debugging device for a tilt angle sensor. The automatic debugging device comprises a cabinet, wherein the cabinet is composed of a cabinet main body, a tool assembly and a rotary table assembly arranged in the cabinet main body; and the hardware control system comprises an upper computer communicating with the remote server and a plurality of functional modules mounted in the cabinet main body, and is used for realizing signal control, power supply control and state monitoring of automatic debugging of the tilt angle sensor product to be tested. Compared with the prior art, the method has the advantages of wide applicability, high reliability, automation, convenience in operation and the like.

Description

Technical Field

[0001] The invention relates to the field of intelligent sensor production and manufacturing, and in particular to an automatic debugging device for an inclination sensor. Background Art

[0002] In the production process of inclination sensors, product debugging is a crucial link. At present, in the debugging process of inclination sensor products, since different types of inclination sensor products have different working voltages, signal outputs, detection axes and shell shapes, it is necessary to customize corresponding debugging tools and host computers for each type of product, and the debugging personnel are required to operate frequently during the debugging process, including disassembling and assembling product cables, recording debugging data, etc. For a large number of inclination sensor products to be tested, this debugging method is extremely inefficient, manual operation is very cumbersome and prone to errors, and tooling for products of different models cannot be universal. Therefore, there is a need for an automatic debugging device that can adapt to inclination sensors of different models and specifications and can improve debugging efficiency and accuracy. Summary of the invention

[0003] In order to solve the technical problems in the background technology, the present invention provides an automatic debugging device for a tilt sensor, the device comprising:

[0004] Cabinet: It is composed of a cabinet body, tooling components, and a turntable component arranged in the cabinet body;

[0005] Hardware control system: includes a host computer that communicates with a remote server and multiple functional modules installed in the cabinet body, which are used to realize signal control, power supply control and status monitoring for automatic debugging of the inclination sensor product to be tested.

[0006] Furthermore, the cabinet body is composed of a front panel, a rear panel, an upper top panel, a left side panel and a right side panel, and a support beam and an electrical installation plate are installed in the cabinet body for installing and fixing the multiple functional modules of the hardware control system. The support beam in the cabinet body is also provided with a slip ring mounting plate for fixing and installing a conductive slip ring.

[0007] Furthermore, the turntable assembly includes a marble adjustment frame, a marble horizontally arranged on the marble adjustment frame, and a high-precision turntable arranged on the marble, and the tooling assembly is installed on a mounting disk surface of the high-precision turntable.

[0008] Furthermore, the tooling assembly is divided into a horizontal tooling assembly, a vertical tooling assembly and a disc tooling assembly according to the installation method of the inclination sensor product to be measured. The horizontal tooling assembly, the vertical tooling assembly and the disc tooling assembly all include a mounting plate, an elbow clamp arranged on the mounting plate through an elbow clamp pad, and a terminal block and a 24PIN quick-connect terminal installed on the mounting plate.

[0009] Furthermore, the multiple functional modules of the hardware control system specifically include an industrial control touch screen all-in-one computer as the host computer, an angle digital display and a three-color sound and light alarm light arranged on the cabinet body, and a first system interface conversion board, a second system interface conversion board, a network switch, a serial port server, an 8PIN quick-connect terminal, an analog quantity collector, an NPN output module, a first network relay control board, a second network relay control board, a servo control board, a splitter, a terminal block, a first switching power supply, a second switching power supply and a servo motor driver installed on the electrical installation board.

[0010] Furthermore, the power supply control of the device specifically includes:

[0011] The first power supply line: the 220V interactive component power supply interface is used to supply power to the industrial control touch screen all-in-one computer and the angle digital display meter;

[0012] Second power supply line: a 220V system power interface passes through an emergency stop button and a splitter in sequence to supply power to the first switch power supply, the second switch power supply and the servo motor driver respectively;

[0013] The third power supply line:

[0014] The first switching power supply converts 220V into 24V to supply power to the servo control board. In addition, the first switching power supply converts 220V into 12V and 24V to supply power to the inclination sensor product to be tested.

[0015] Fourth power supply line:

[0016] The second switching power supply converts 220V into 12V and supplies power to the first system interface conversion board, the second system interface conversion board, the network switch, the serial port server, the NPN output module and the first network relay control board respectively. The first network relay control board supplies power to the second network relay control board and the analog quantity collector respectively.

[0017] Further, when the inclination sensor product to be tested requires an internal 12V or 24V power supply, the first switch power supply sequentially supplies 12V or 24V power through the terminal block, the first network relay control board, the 8PIN quick-connect terminal, the conductive slip ring, the 24PIN quick-connect terminal and the terminal block;

[0018] When the inclination sensor product to be tested requires an external non-12V and non-24V power supply, the external power supply sequentially supplies power through the 8PIN quick-connect terminal, the conductive slip ring, the 24PIN quick-connect terminal and the terminal block.

[0019] Furthermore, the signal control circuit of the device specifically includes:

[0020] Turntable control sub-circuit: the host computer controls the rotation angle of the high-precision turntable through the servo control board and the servo motor driver in turn, and reads the current angle of the high-precision turntable in real time through the angle digital display and feeds back to the host computer;

[0021] Product control sub-loop:

[0022] For digital inclination sensor products: the host computer establishes a connection with the digital inclination sensor product to be tested through the network switch, the serial port server, the system interface conversion board, the 8PIN quick-connect terminal, the conductive slip ring, the 24PIN quick-connect terminal and the terminal block in sequence, reads the real-time output data of the digital inclination sensor product to be tested and sends a control signal, and the host computer switches the working mode of the system interface conversion board through the NPN output module to convert it into a corresponding communication mode, including TTL, RS232, RS485 and CAN;

[0023] For a switch tilt sensor product: the host computer establishes a connection with the switch tilt sensor product to be tested through the network switch, the first network relay control board, the 8PIN quick-connect terminal, the conductive slip ring, the 24PIN quick-connect terminal and the terminal block in sequence, sends a control signal, and the host computer obtains real-time output switch data of the switch sensor product to be tested from the first network relay control board through the network switch;

[0024] For analog inclination sensor products: the host computer establishes connection with the analog inclination sensor product to be measured through the network switch, the second network relay control board, the 8PIN quick-connect terminal, the conductive slip ring, the 24PIN quick-connect terminal and the terminal block in sequence, sends a control signal, and the host computer reads the real-time output analog data of the analog sensor product to be measured collected by the analog quantity collector through the network switch and the first network relay control board in sequence, and the host computer controls the analog quantity collector to switch the current analog quantity or voltage analog quantity signal through the second network relay control board.

[0025] Furthermore, the data output types of the tilt sensor product to be tested include digital quantity, switch quantity and analog quantity. When the data output type is digital quantity, the data communication mode includes TTL, RS232, RS485 and CAN bus.

[0026] Furthermore, the steps of using the device to automatically debug the tilt sensor product include:

[0027] 1) Device startup: After the host computer is initialized, the product debugging file corresponding to the inclination sensor product to be tested is loaded, and the connection between the host computer and each functional module is automatically completed. The product debugging file contains the relevant parameters of the data parsing method of the inclination sensor product to be tested, the parameter information of each functional module and the corresponding debugging step information;

[0028] 2) Input information: After all functional modules are connected normally, enter the product numbers, device addresses, customer SN codes and other information of multiple tilt sensor products to be debugged into the host computer by scanning the QR code or manually entering;

[0029] 3) Install the product: install the inclination sensor to be debugged on the corresponding tooling assembly and connect the power supply line and signal line;

[0030] 4) Start automatic debugging: After confirming that the power supply and communication are normal, start the automatic debugging. The host computer controls the entire automatic debugging device and the inclination sensor product to be tested according to the step information in the product debugging configuration file. The debugging content includes axis zero point calibration, accuracy calibration and accuracy inspection;

[0031] 5) End of automatic debugging: When the host computer completes all debugging steps according to the relevant parameters of the product debugging configuration file, the automatic debugging process ends; after the automatic debugging process of the inclination sensor product to be tested is completed, the host computer automatically uploads the result data of the product debugging inspection, that is, the debugging index data to the remote server, and also uploads the product parameter backup data, the debugging process prompt data file and the debugging process product communication file to the remote server; finally, the power of the host computer and the entire automatic debugging device is turned off to complete the automatic debugging of the inclination sensor product to be tested of the current batch and model.

[0032] Compared with the prior art, the present invention has the following advantages:

[0033] The automatic debugging device for an inclination sensor provided by the present invention is used for automatic debugging of various inclination sensors. It can automatically, reliably and efficiently debug inclination products of different models (single-axis / dual-axis inclination sensors, inclination switches), different output data types (digital quantity, analog quantity, switch quantity output), different installation methods (horizontal installation, vertical installation) and different working voltages. During the debugging process, there is no need for frequent operations by the debugging personnel, and the device can automatically record data and debugging results. The operation is simple, efficient and reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a front structural schematic diagram of the automatic debugging device for the inclination sensor;

[0035] Figure 2 It is a side structural schematic diagram of the automatic debugging device for the inclination sensor;

[0036] Figure 3 This is a schematic diagram of the external structure of the back of the automatic debugging device for the inclination sensor;

[0037] Figure 4 This is a schematic diagram of the internal structure of the back of the automatic debugging device for the inclination sensor;

[0038] Figure 5 This is a schematic diagram of the installation structure of the marble turntable;

[0039] Figure 6 It is a schematic diagram of the structure for installing the horizontal tooling assembly;

[0040] Figure 7 It is a schematic diagram of the structure for installing the vertical tooling assembly;

[0041] Figure 8 It is a schematic diagram of the structure of the installation disc tooling assembly;

[0042] Fig. 9 A block diagram of the principles for powering the device hardware;

[0043] Fig.10 A block diagram of the principle of externally powering the device hardware;

[0044] Fig.11 This is the principle block diagram of the device control;

[0045] Fig.12 This is a debugging / testing flow chart for the automatic debugging device using the inclination sensor.

[0046] Description of reference numerals:

[0047] 101, top plate, 102, upper front panel, 103, left front baffle, 104, left side panel, 105, lower front panel, 106, Fomar caster, 107, right front baffle, 108, right side panel, 109, upper rear panel, 110, lower rear panel, 111, slip ring mounting plate, 112, electrical mounting plate, 113, support beam;

[0048] 201, three-color sound and light alarm light, 202, angle digital display, 203, industrial control touch screen all-in-one computer, 204, start button, 205, pause button, 206, reset button, 207, emergency stop button, 208, network interface, 209, external power supply interface, 210, system power interface, 211, interactive component power interface, 212, grounding column, 213, display rotating frame;

[0049] 301, first system interface conversion board, 302, second system interface conversion board, 303, industrial-grade network switch, 304, RS232 / RS485 / RS422 serial port server, 305, 8PIN quick-connect terminal, 306, analog quantity collector, 307, NPN output module, 308, first network relay control board, 309, second network relay control board, 310, servo control board, 311, industrial wire trough, 312, splitter, 313, terminal block, 314, first switch power supply, 315, second switch power supply, 316, servo motor driver;

[0050] 401, elbow clamp, 402, terminal block, 403, elbow clamp pad, 404, 24PIN quick-connect terminal, 410, horizontal tooling assembly, 420, vertical tooling assembly, 430, disc tooling assembly;

[0051] 510. High-precision turntable. 520. Conductive slip ring. 530. Marble adjustment frame. 540. Marble. DETAILED DESCRIPTION

[0052] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0053] It should be noted that in this specification, similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings.

[0054] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0055] The terms “first”, “second”, etc. are only used for distinguishing descriptions and should not be understood as indicating or implying relative importance.

[0056] In the description of this embodiment, it should also be noted that, unless otherwise clearly specified and limited, the terms "set", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, and it can be the internal communication of two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this embodiment can be understood in specific circumstances.

[0057] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0058] Example

[0059] The present invention provides an automatic debugging device for an inclination sensor, which is used for debugging tasks of inclination products such as single-axis and dual-axis inclination sensors. Up to 8 products can be clamped and debugged at the same time each time. The device is mainly composed of a cabinet and tooling components, and a hardware control system. The present invention is introduced in detail below.

[0060] 1. Cabinet and tooling components

[0061] like Figure 1-5 As shown, the cabinet mainly includes an upper top plate 101, an upper front panel 102, a left front baffle 103, a left side panel 104, a lower front panel 105, a Forma caster 106, a right front baffle 107, a right side panel 108, an upper rear panel 109, a lower rear panel 110, an electrical installation board 112 and a support beam 113, wherein the upper front panel 102, the left front baffle 103, the lower front panel 105 and the right front baffle 107 together constitute a front panel, the upper rear panel 109 and the lower rear panel 110 together constitute a rear panel, the front panel, the rear panel, the upper top plate 101, the left side panel 104 and the right side panel 108 together constitute a main body of the cabinet, and the electrical installation board 112 and the support beam 113 are arranged inside the main body;

[0062] The support beams 113 are divided into horizontal beams, longitudinal beams and columns according to different installation positions. The support beams are connected by iron tees and fixed with screws. The electrical installation board 112 is installed between the support beams to install the functional modules of the hardware control system.

[0063] The components installed on the main body of the cabinet include a three-color sound and light alarm lamp 201, an angle digital display 202, an industrial control touch screen all-in-one computer 203, a start button 204, a pause button 205, a reset button 206, an emergency stop button 207, a network interface 208, an external power supply interface 209, a system power interface 210, an interactive component power interface 211, a grounding column 212 and a display rotating frame 213; wherein the three-color sound and light alarm lamp 201 is installed on the upper top plate 101, and the angle digital display 202 is installed on the upper top plate 101. 202 is installed on the upper part of the upper front panel 102, the industrial control touch screen all-in-one computer 203 is rotatably installed on the upper part of the right side panel 108 through the display rotating frame 213, the start button 204, the pause button 205, the reset button 206 and the emergency stop button 207 are arranged in a vertical row on the right side panel 108, and the network interface 208, the external power supply interface 209, the system power interface 210, the interactive component power interface 211 and the grounding column 212 are also respectively arranged at the corresponding positions of the right side panel 108.

[0064] A marble adjustment frame 530 is provided inside the main body of the cabinet, on which a marble 540 is placed horizontally, and a high-precision turntable 510 (a single-axis high-precision turntable is used in the present invention, with a measuring range of 0-360°, a digital display resolution of 1″, and a division accuracy of 6″) is placed horizontally on the plane of the marble 540. A conductive slip ring 520 is installed on a beam inside the cabinet body through a slip ring mounting plate 111 to achieve communication connection between the inclination sensor to be measured and the hardware control system, and the back of the high-precision turntable 510 is fixed to the same beam inside the cabinet body by bolts to prevent the high-precision turntable 510 from being accidentally touched and dropped to cause a safety accident.

[0065] The installation disk of the high-precision turntable 510 with a T-groove extends out of the front panel of the cabinet, and the tooling assembly is fixed on the installation disk of the high-precision turntable 510. The tooling assembly is divided into horizontal tooling assembly, vertical tooling assembly and disc tooling assembly according to the different installation methods of the products. The three tooling assemblies can be switched according to different usage scenarios. Multiple inclination sensors to be measured are installed and fixed on the tooling assembly. For example, for inclination products with horizontal installation and shells (single-axis, double-axis, three-axis, etc.), horizontal tooling assemblies are suitable; for inclination products with vertical installation and shells (single-axis, double-axis, three-axis, long-angle, etc.), horizontal and vertical tooling assemblies are suitable; and the disc tooling assembly is compatible with all inclination products with shells except vertically installed products, especially products with circular plastic / metal shells (such as inclination switches, etc.). In addition, the present invention can also debug bare board products. It only needs to add an adapter plate assembly that can be used for bare board debugging to the tooling assembly, and other wiring and fixing methods remain unchanged.

[0066] like Figure 6-8As shown, the three tooling assemblies all include a tooling plate and elbow clamps 401 (8 are provided in the present invention, and software and hardware expansion can also be performed as needed) respectively installed on the tooling plate, an elbow clamp pad 403, a terminal block 402 and a 24PIN quick-connect terminal 404. The tooling plate is fixedly connected to the T-groove on the mounting plate surface through a T-nut, and the tooling plates of the horizontal tooling assembly, the vertical tooling assembly and the disc tooling assembly respectively adopt a horizontal square plate, a vertical square plate and a circular plate. The elbow clamp pad 403 is arranged between the elbow clamp 401 and the tooling plate to adjust the installation position of the elbow clamp 401 , and can be adjusted with the elbow clamp 401 to be compatible with inclination sensor products of different heights; the 24PIN quick-connect terminal 404 is used to connect the terminal block 402 and the rotor wire of the conductive slip ring 520, and can realize the interchange between different tooling components. The stator wire of the conductive slip ring is connected to the hardware control system through the 8PIN quick-connect terminal 305. The conductive slip ring 520 can realize continuous and reliable communication between the tooling component and the host computer during the rotation of the high-precision turntable 510, prevent the communication power supply line from being entangled when the high-precision turntable 510 rotates, and enable the high-precision turntable 510 to rotate without restriction.

[0067] The tooling assembly can be installed with the corresponding toggle clamp pad 403 according to the different models of the inclination sensor products to be tested, and the toggle clamp 401 is used together to clamp the product. At the same time, a positioning block (horizontal tooling assembly, vertical tooling assembly) or a positioning column (disc tooling assembly) is provided on the mounting position of the mounting plate for positioning. When debugging a single-axis inclination sensor product, the horizontal tooling assembly and the vertical tooling assembly only need to be clamped once to complete the entire debugging process. For a dual-axis inclination sensor product, after debugging one axis, the product needs to be rotated 90° and clamped again for the other axis. The disc tooling assembly is compatible with the debugging of single-axis and dual-axis products. The single-axis inclination sensor product can complete the entire debugging process with one clamping. The dual-axis inclination sensor product needs to rotate the circular plate 90° after debugging one axis to complete the debugging of the other axis. The disc tooling assembly is equipped with a 90° limit and locking mechanism, so you only need to rotate the circular plate 90° to complete the reversal of the test axis, and there is no need to clamp the dual-axis inclination sensor product for the second time. This can greatly save the time spent on disassembling and assembling the product, thereby improving the debugging efficiency.

[0068] 2. Hardware control system

[0069] The hardware control system includes a host computer and multiple functional modules installed on the electrical installation board 112, specifically including a first system interface conversion board 301, a second system interface conversion board 302, an industrial-grade network switch 303, an RS232 / RS485 / RS422 serial port server 304, an analog quantity collector 306, an NPN output module 307, a first network relay control board 308, a second network relay control board 309, a servo control board 310, a first switching power supply 314, a second switching power supply 315, a servo motor driver 316 and auxiliary wiring components, the auxiliary wiring components include 8PIN quick-connect terminals 305, industrial wire troughs 311, splitters 312 and terminal blocks 313.

[0070] The host computer includes an industrial control touch screen all-in-one computer 203 as hardware and an automatic host computer program installed and running on the industrial control touch screen all-in-one computer 203 .

[0071] 2.1 Hardware module system and host computer power supply description

[0072] like Fig. 9 As shown, the cabinet is provided with two 220V power interfaces, namely a system power interface 210 for powering the functional modules and products of the entire hardware control system, and an interactive component power interface 211 for powering the interactive components.

[0073] The interactive component includes an industrial control touch screen all-in-one computer 203 and an angle digital display 202, and is directly powered by a 220V AC power supply of the interactive component power supply interface 211; the 220V AC power supply of the system power supply interface 210 is sequentially supplied to the first switch power supply 314, the second switch power supply 315 and the servo motor driver 316 through the emergency stop button 207 and the splitter 312 respectively. The first switch power supply 314 and the second switch power supply 315 can both convert the 220V AC power supply into 5V, 12V and 24V DC power supplies to meet the power supply requirements of different voltages, and separate the product power supply and the device power supply. In the present invention, the first switch power supply 314 converts the 220V AC power supply into 12V and 24V DC power supplies to power the servo control board and the inclination sensor product to be measured, and the second switch power supply 315 converts the 220V AC power supply into a 12V DC power supply to power each functional module.

[0074] The first switch power supply 314 converts the first 220V AC power into 24V DC power, and then supplies power to the servo control board through the terminal block 313. In addition, the first switch power supply 314 converts the first 220V AC power into 12V and 24V DC power, and then sequentially provides 12V and 24V power to the inclination sensor product to be measured through the first network relay control board 308, the 8PIN quick-connect terminal 305, the conductive slip ring 520, the 24PIN quick-connect terminal 404, and the terminal block 402;

[0075] The second switching power supply 315 converts the second 220V AC power into 12V DC power, and then supplies power to the first network relay control board 308, the first system interface conversion board 301, the second system interface conversion board 302, the industrial-grade network switch 303, the RS232 / RS485 / RS422 serial port server 304, and the NPN output module 307 through the terminal block 313; the first network relay control board 308 supplies power to the second network relay control board 309 and the analog quantity collector 306 after conversion through its own circuit.

[0076] like Fig.10 As shown, the inclination sensor product to be tested uses the system 12V or 24V power supply by default. If the power supply requirement of the product to be tested is non-12V and non-24V, an external power supply is used. When selecting external power supply, the power supply option needs to be selected as external power supply on the host computer. At this time, the 12V in the circuit of the first network relay control board 308 only supplies power to the second network relay control board 309 and the analog quantity collector 306, and the power input end of the 8PIN quick-connect terminal 305 is connected to the external power supply.

[0077] 2.2 Hardware module system control description

[0078] like Fig.11 As shown, the industrial control touch screen all-in-one computer 203, the servo control board 310, the servo motor driver 316, the high-precision turntable 510, and the angle digital display 202 constitute a complete feedback system. The host computer (the industrial control touch screen all-in-one computer 203) sends instructions to the servo control board 310, and the servo control board 310 converts the instructions sent by the host computer into a format recognizable by the servo motor driver 316, and then sends it to the servo motor driver 316. After receiving the instructions, the servo motor driver 316 controls the high-precision turntable 510 to rotate to a set angle. The angle digital display 202 reads the angle of the turntable through the optical encoder installed inside the high-precision turntable 510, and then converts it into displayable information and displays it; the angle digital display 202 and the industrial control touch screen all-in-one computer 203 are connected through a serial port data cable, and the industrial control touch screen all-in-one computer 203 sends instructions to read the display value of the angle digital display 202.

[0079] The industrial control touch screen integrated computer 203 communicates with the industrial-grade network switch 303 through a network cable, and the industrial-grade network switch 303 communicates with the NPN output module 307, the RS232 / RS485 / RS422 serial port server 304, the first network relay control board 308, and the second network relay control board 309 respectively, and the NPN output module 307 communicates with the first system interface conversion board 301 and the second system interface conversion board 302 respectively, and the RS232 / RS485 / RS422 serial port server 304 communicates with the first system interface conversion board 301 and the second system interface conversion board 302 respectively, and the analog quantity collector 306 communicates with the first network relay control board 308 and the second network relay control board 309 respectively; 8PI Channels 1 and 2 of the N quick-connect terminal 305 are power channels, channels 3 and 4 are digital signal channels, channels 5 and 6 are switch signal channels, and channels 7 and 8 are analog signal channels; the digital signal channels of the first system interface conversion board 301 and the second system interface conversion board 302 are connected to channels 3 and 4 of the 8PIN quick-connect terminal, the switch signal channel on the first network relay control board 308 is connected to channels 5 and 6 of the 8PIN quick-connect terminal, the analog signal channel on the analog collector 306 is connected to channels 7 and 8 of the 8PIN quick-connect terminal, and the 8PIN quick-connect terminal 305 is finally connected to the inclination sensor product to be measured through the conductive slip ring, the 24PIN quick-connect terminal 404 and the terminal block 402 in sequence.

[0080] The three-color sound and light alarm lamp 201 is connected to the first network relay control board 308. The host computer controls the light color and sound of the three-color sound and light alarm lamp 201 through the first network relay control board 308 according to the debugging status of the tilt sensor product:

[0081] (1) During the normal debugging process, the green light flashes;

[0082] (2) When human operation is required during the debugging process, the red and green lights flash and a buzzer sounds. After the set time, the red light goes out and the buzzer turns off;

[0083] (3) When debugging is completed, the red and green lights flash and a buzzer sounds. After the set time, the red light goes out and the buzzer turns off.

[0084] The start button 204, the pause button 205 and the reset button 206 on the cabinet communicate with the second network relay control board 309 respectively to achieve linkage control with the host computer.

[0085] 2.3 Hardware module system main hardware module function description

[0086] Host computer: including the industrial control touch screen all-in-one computer 203 and the automatic host computer running on the industrial control touch screen all-in-one computer 203, used to control all the hardware in the entire automatic debugging device, dynamically adjust the operating parameters of each hardware, control the behavior of each hardware, and monitor the operating status of each hardware at all times;

[0087] Servo control board 310: used to communicate with the host computer, parse the instructions sent by the host computer, generate corresponding instructions, and send them to the servo motor driver 316;

[0088] Servo motor driver 316: receives the instruction sent by servo control board 310, generates corresponding instruction after parsing, and then controls the operation of high-precision turntable 510;

[0089] High-precision turntable 510: Install the tooling assembly on the high-precision turntable 510, and then install the inclination sensor product to be debugged on the tooling assembly. When the host computer controls the operation of the high-precision turntable, it is equivalent to controlling the rotation angle, rotation direction and operation trajectory of the inclination sensor product to be debugged. In other words, the output data of the inclination sensor product to be debugged will change with the change of the high-precision turntable 510, and in the automatic debugging process of the inclination sensor product to be debugged, the most important step is to send different debugging instructions to the product when the inclination sensor product to be debugged is at different angles, and the realization of this process depends on the operation of the high-precision turntable 510.

[0090] Angle digital display 202: The angle digital display 202 will always read the current rotation angle of the high-precision turntable 510 and exchange data with the host computer. The host computer will compare the rotation angle of the turntable sent by the angle digital display 202 with the target angle cached in the host computer, and then dynamically and real-time adjust the operating parameters of the high-precision turntable 510, such as the operating direction (clockwise or counterclockwise), the operating speed (the closer the rotation angle of the turntable is to the target angle, the lower the operating speed will be), so as to accurately control the high-precision turntable 510 to run to the target angle in the best way;

[0091] Industrial-grade network switch 303: used to establish the internal LAN of the automatic debugging device, so that the functional modules in the entire device are connected to the same LAN, which is convenient for the host computer to uniformly dispatch the functional modules;

[0092] NPN output module 307: used to control the operation mode of the system interface conversion board. The host computer can adjust the DO output of the module through the network interface of the industrial-grade network switch 303, thereby switching the operation mode of the system interface conversion board;

[0093] System interface conversion board: In the present invention, there are two system interface conversion boards (a first system interface conversion board 301 and a second system interface conversion board 302). One end of the system interface conversion board is connected to the inclination sensor product to be measured through a conductive slip ring, a 24PIN quick-connect terminal 404 and a terminal block 402 in sequence, and is compatible with four common communication interfaces: TTL, RS232, RS485 and CAN bus. The specific communication method to be used when communicating with the product is controlled by the constraints of the NPN output module; the other end is connected to the serial port server, and the system interface conversion board will convert the data sent by the inclination sensor product to be measured into serial port binary data and forward it to the serial port server. At the same time, the system interface conversion board will also convert the data sent by the serial port server into a data format that can be correctly received by the corresponding product;

[0094] Serial port server: The present invention adopts RS232 / RS485 / RS422 serial port server 304, which is a multi-channel data conversion module. Its main function is to package and convert the data sent by the system interface conversion board into network data of corresponding format, and send it to the host computer through the network interface of the industrial-grade network switch 303. At the same time, the module will package the data sent by the host computer into data that can be parsed by the system interface conversion board and forward it to the system interface conversion board;

[0095] The first network relay control board 308: This module can control the power supply of other modules, and can collect the switch signal output by the tilt sensor product to be measured, and send it to the host computer. In addition, one end of the module communicates with the analog quantity collector 306 through RS485 with stronger anti-interference ability, so as to convert the received data packet into a network signal and send it to the host computer, while the other end of the module communicates with the host computer through the industrial-grade network switch 303, converts the relevant data sent by the host computer into RS485 signals, and then sends them to the analog quantity collector 306;

[0096] The second network relay control board 309: the host computer can control the DO output of the module through the network interface of the industrial-grade network switch 303. The module is connected to the analog quantity collector 306 and can control the switching of the analog quantity collection type of the multi-channel analog quantity collector 306 to voltage or current;

[0097] Analog quantity collector 306: is a multi-channel analog quantity acquisition module, which can switch the type of analog quantity to be collected through the second network relay control board 309, and the analog quantity collection range of the module is adjusted through the first network relay control board 308. The analog quantity collection range supported by the module is shown in Table 1;

[0098] Table 1 Analog quantity acquisition range supported by analog quantity collector

[0099] Collection Type Collection range Collection Type Collection range Voltage -10V~+10V Voltage 1V~5V Voltage -5V~+5V Voltage -2.5V~+2.5V Voltage -1V~+1V Voltage 0V~2.5V Voltage -500mV~+500mV Current -20mA~20mA Voltage -150mV~+150mV Current 0mA~20mA Voltage 0V~10V Current 4mA~20mA Voltage 0V~5V Current 0mA~22mA

[0100] like Fig.12 As shown in the figure, the operation process of the operator when using the automatic debugging device to batch debug the inclination products is as follows:

[0101] 1) Device startup: Start the automatic host computer in the host computer and log in, load the product debugging file corresponding to the inclination sensor product to be tested after initialization, and automatically complete the connection between the host computer and each functional module, including the relay control module (the first network relay control board 308, the second network relay control board 309), the serial port server (RS232 / RS485 / RS422 serial port server 304), the digital communication related module (analog quantity collector 306), the digital communication related module (the first system interface conversion board 301, the second system interface conversion board 302), the turntable control related module (servo control board 310, servo motor driver 316), the product debugging file contains the relevant parameters of the data parsing method of the inclination sensor product to be tested, the parameter information of each functional module and the corresponding debugging step information;

[0102] 2) Input information: After all functional modules are connected normally, enter the product numbers, device addresses, customer SN codes and other information of multiple tilt sensor products to be debugged into the host computer by scanning the QR code or manually entering;

[0103] 3) Install the product: select the corresponding tooling assembly according to the model of the inclination sensor to be debugged, install the inclination sensor to be debugged on the tooling assembly and connect the power supply line and signal line. For example, single-axis inclination sensor products and inclination switch products can use horizontal tooling assemblies or vertical tooling assemblies, and dual-axis inclination sensor products can use disc tooling assemblies;

[0104] 4) Start automatic debugging: After confirming that the power supply and communication are normal, start the automatic debugging function of the automatic host computer. The host computer controls the entire automatic debugging device and the inclination sensor product to be tested according to the step information in the product debugging configuration file, including command reception and transmission and parameter configuration. In addition, when controlling the operation of the high-precision turntable, the host computer sends debugging and calibration related instructions to the product in a timely manner. The debugging content includes axis zero point calibration, accuracy calibration and accuracy inspection;

[0105] Generally, the debugging process of the inclination sensor product to be tested does not require human intervention. However, in some special cases, the system will remind the user that human intervention is required by making a beep and flashing the indicator light, such as when the inclination sensor product to be debugged has poor communication, data errors, or the product to be debugged needs to be reversing.

[0106] 5) End of automatic debugging: When the host computer completes all debugging steps according to the relevant parameters of the product debugging configuration file, the automatic debugging process ends; after the automatic debugging process of the inclination sensor product to be tested is completed, the host computer automatically uploads the result data of the product debugging inspection, that is, the debugging index data to the remote server, and also uploads the product parameter backup data, the debugging process prompt data file and the debugging process product communication file to the remote server; finally, the automatic host computer is turned off, and the power of the host computer and the entire automatic debugging device is turned off to complete the automatic debugging of the inclination sensor product to be tested of the current batch and model.

[0107] For the debugging and calibration process of the above products, if all on-site production staff need to perform manual operations according to the debugging instructions, it will not only be very time-consuming, but also have a high probability of error. Moreover, only one product can be debugged and calibrated at a time, which leads to low production efficiency. By using the automatic debugging device to debug and calibrate the product, production efficiency is greatly improved, and the occurrence of errors caused by human participation is reduced. On-site production staff only need to perform the following operations:

[0108] 1) Install the horizontal tooling assembly on the high-precision turntable;

[0109] 2) Load the product debugging file to the host computer;

[0110] 3) Scan the product numbers of 8 products to be debugged;

[0111] 4) Install 8 products to be debugged on the horizontal tooling assembly;

[0112] 5) Click "Auto Debug" on the host computer;

[0113] 6) After the automatic debugging is completed, check the integrity and correctness of the data;

[0114] 7) Remove the debugged product from the tooling assembly and keep it properly.

[0115] To sum up, the automatic debugging device for the inclination sensor provided by the present invention is used for the automatic debugging of various inclination sensors. It can automatically, reliably and efficiently debug inclination products of different models (single-axis / dual-axis inclination sensors, inclination switches), different output data types (digital quantity, analog quantity, switch output), different installation methods (horizontal installation, vertical installation), and different working voltages. During the debugging process, there is no need for frequent operations by the debugging personnel, and the device can automatically record data and debugging results. The operation is simple, efficient and reliable.

[0116] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. An automatic debugging device for an inclination sensor, characterized in that: The device includes: Cabinet: It is composed of a cabinet body, tooling components, and a turntable component arranged in the cabinet body; Hardware control system: includes a host computer that communicates with a remote server and multiple functional modules installed in the cabinet body, which are used to realize signal control, power supply control and status monitoring for automatic debugging of the inclination sensor product to be tested.

2. The automatic debugging device for an inclination sensor according to claim 1, characterized in that: The cabinet body is composed of a front panel, a rear panel, an upper top plate (101), a left side plate (104) and a right side plate (108), and a support beam (113) and an electrical installation plate (112) are installed in the cabinet body for installing and fixing the plurality of functional modules of the hardware control system. The support beam (113) in the cabinet body is also provided with a slip ring installation plate (111) for fixing and installing a conductive slip ring (520).

3. The automatic debugging device for an inclination sensor according to claim 2, characterized in that: The turntable assembly comprises a marble adjustment frame (530), a marble (540) horizontally arranged on the marble adjustment frame (530), and a high-precision turntable (510) arranged on the marble (540), and the tooling assembly is installed on a mounting plate surface of the high-precision turntable (510).

4. The automatic debugging device for an inclination sensor according to claim 3, characterized in that: The tooling assembly is divided into a horizontal tooling assembly, a vertical tooling assembly and a disc tooling assembly according to the installation method of the inclination sensor product to be measured. The horizontal tooling assembly, the vertical tooling assembly and the disc tooling assembly all include a mounting plate, a toggle clamp (401) arranged on the mounting plate through a toggle clamp pad (403), and a terminal block (402) and a 24PIN quick-connect terminal (404) installed on the mounting plate.

5. The automatic debugging device for the inclination sensor according to claim 4, characterized in that: The multiple functional modules of the hardware control system specifically include an industrial control touch screen all-in-one computer (203) as the host computer, an angle digital display (202) and a three-color sound and light alarm lamp (201) arranged on the cabinet body, and a first system interface conversion board (301), a second system interface conversion board (302), a network switch, a serial port server, an 8PIN quick-connect terminal (305), an analog quantity collector (306), an NPN output module (307), a first network relay control board (308), a second network relay control board (309), a servo control board (310), a splitter (311), a terminal block (313), a first switch power supply (314), a second switch power supply (315) and a servo motor driver (316) installed on the electrical installation board (112).

6. The automatic debugging device for an inclination sensor according to claim 5, characterized in that: The power supply control of the device specifically includes: First power supply line: a 220V interactive component power supply interface (211) for respectively supplying power to the industrial control touch screen all-in-one computer (203) and the angle digital display meter (202); Second power supply line: a 220V system power interface (210) passes through an emergency stop button (207) and a splitter (312) in sequence to supply power to the first switch power supply (314), the second switch power supply (315) and the servo motor driver (316); The third power supply line: The first switching power supply (314) converts 220V into 24V to supply power to the servo control board (310); in addition, the first switching power supply (314) converts 220V into 12V and 24V to supply power to the inclination sensor product to be tested; Fourth power supply line: The second switching power supply (315) converts 220V into 12V and supplies power to the first system interface conversion board (301), the second system interface conversion board (302), the network switch, the serial port server, the NPN output module (307) and the first network relay control board (308), respectively. The first network relay control board (308) supplies power to the second network relay control board (309) and the analog quantity collector (306).

7. The automatic debugging device for an inclination sensor according to claim 6, characterized in that: When the tilt sensor product to be tested requires an internal 12V or 24V power supply, the first switch power supply (314) sequentially supplies 12V or 24V power through the terminal block (313), the first network relay control board (308), the 8PIN quick-connect terminal (305), the conductive slip ring (520), the 24PIN quick-connect terminal (404) and the terminal block (402); When the inclination sensor product to be measured requires an external non-12V and non-24V power supply, the external power supply sequentially supplies power through the 8PIN quick-connect terminal (305), the conductive slip ring (520), the 24PIN quick-connect terminal (404) and the terminal block (402).

8. The automatic debugging device for an inclination sensor according to claim 5, characterized in that: The signal control circuit of the device specifically includes: Turntable control sub-circuit: the host computer sequentially controls the rotation angle of the high-precision turntable (510) through the servo control board (310) and the servo motor driver (316), and reads the current angle of the high-precision turntable (510) in real time through the angle digital display (202) and feeds back to the host computer; Product control sub-loop: For a digital tilt sensor product: the host computer sequentially establishes a connection with the digital tilt sensor product to be tested through the network switch, the serial port server, the system interface conversion board, the 8PIN quick-connect terminal (305), the conductive slip ring (520), the 24PIN quick-connect terminal (404) and the terminal block (402), reads the real-time output data of the digital tilt sensor product to be tested and sends a control signal, and the host computer switches the working mode of the system interface conversion board through the NPN output module (307) to convert it into a corresponding communication mode, including TTL, RS232, RS485 and CAN; For a switch value inclination sensor product: the host computer sequentially establishes a connection with the switch value inclination sensor product to be tested through the network switch, the first network relay control board (308), the 8PIN quick-connect terminal (305), the conductive slip ring (520), the 24PIN quick-connect terminal (404) and the terminal block (402), sends a control signal, and the host computer obtains real-time output switch value data of the switch value sensor product to be tested from the first network relay control board (308) through the network switch; For an analog tilt sensor product: the host computer sequentially establishes a connection with the analog tilt sensor product to be measured through the network switch, the second network relay control board (309), the 8PIN quick-connect terminal (305), the conductive slip ring (520), the 24PIN quick-connect terminal (404) and the terminal block (402), and sends a control signal. The host computer sequentially reads the real-time output analog data of the analog sensor product to be measured collected by the analog quantity collector (306) through the network switch and the first network relay control board (308), and the host computer controls the analog quantity collector (306) to switch the current analog quantity signal or the voltage analog quantity signal through the second network relay control board (309).

9. The automatic debugging device for an inclination sensor according to claim 1, characterized in that: The data output types of the tilt sensor product to be tested include digital quantity, switch quantity and analog quantity. When the data output type is digital quantity, the data communication mode includes TTL, RS232, RS485 and CAN bus.

10. The automatic debugging device for an inclination sensor according to claim 1, characterized in that: The steps of using the device to automatically debug the inclination sensor product include: 1) Device startup: After the host computer is initialized, the product debugging file corresponding to the inclination sensor product to be tested is loaded, and the connection between the host computer and each functional module is automatically completed. The product debugging file contains the relevant parameters of the data parsing method of the inclination sensor product to be tested, the parameter information of each functional module and the corresponding debugging step information; 2) Input information: After all functional modules are connected normally, enter the product numbers, device addresses, customer SN codes and other information of multiple tilt sensor products to be debugged into the host computer by scanning the QR code or manually entering; 3) Install the product: install the inclination sensor to be debugged on the corresponding tooling assembly and connect the power supply line and signal line; 4) Start automatic debugging: After confirming that the power supply and communication are normal, start the automatic debugging. The host computer controls the entire automatic debugging device and the inclination sensor product to be tested according to the step information in the product debugging configuration file. The debugging content includes axis zero point calibration, accuracy calibration and accuracy inspection; 5) End of automatic debugging: When the host computer completes all debugging steps according to the relevant parameters of the product debugging configuration file, the automatic debugging process ends; after the automatic debugging process of the inclination sensor product to be tested is completed, the host computer automatically uploads the result data of the product debugging inspection, that is, the debugging index data to the remote server, and also uploads the product parameter backup data, the debugging process prompt data file and the debugging process product communication file to the remote server; finally, the power of the host computer and the entire automatic debugging device is turned off to complete the automatic debugging of the inclination sensor product to be tested of the current batch and model.

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