Portable industrial equipment detection method and device with charging function

Abstract

The invention relates to the technical field of industrial automation equipment detection and maintenance, in particular to a portable industrial equipment detection method and device with a charging function. The method comprises a power supply mode switching step, an equipment connection and configuration step, a signal processing and conversion step and a result presentation and diagnosis step. According to the invention, the method flow is standardized, dispersed operations depending on personal experience are integrated into a standardized flow covering power supply, wiring, testing and diagnosis, and the reliability and efficiency of detection are greatly improved. The method of switching power supply through a built-in battery thoroughly gets rid of the dependence on a field fixed power supply, and equipment detection at any place and under any working condition is realized. Complex signal interpretation and conversion work is automated, an engineering value is automatically displayed, a standard signal is output, the technical threshold is remarkably reduced, and man-made misjudgment is avoided.

Description

Technical Field

[0001] This invention relates to the field of industrial automation equipment testing and maintenance technology, specifically to a portable, rechargeable industrial equipment testing method and apparatus. Background Technology

[0002] In the field of industrial automation, regular maintenance, in-warehouse calibration, and fault diagnosis of field equipment (such as transmitters, sensors, and frequency converters) are crucial for ensuring production continuity. However, current testing methods still largely rely on the personal experience of technicians and makeshift tools, resulting in the following systemic pain points that urgently need to be addressed: Unable to test due to power failure: Power must be cut off when the equipment is under maintenance, but after the power is cut off, there is no portable power supply for 24V equipment (such as transmitters) to provide working voltage, which makes it impossible to perform functional tests offline; Lack of verification before new equipment is put into storage: The lack of a comprehensive testing platform to verify newly purchased equipment (such as transmitters of different models and parameters) before installation may lead to the equipment being found to be non-functional or having mismatched parameters after it has been installed, increasing maintenance costs and downtime. Difficulty in on-site fault diagnosis: When equipment malfunctions in the field, it is difficult to quickly determine whether the problem lies with the signal source or the equipment itself. There is a lack of a portable source that can provide standard analog signals to quickly locate the fault.

[0003] Therefore, there is an urgent need in this field for a comprehensive detection method that is independent of external conditions, has standardized procedures, integrates power supply, measurement, and signal simulation, and a dedicated device for implementing the method. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides the following technical solution: a portable, rechargeable method for testing industrial equipment, characterized in that the method includes the following steps: S1. Power supply mode switching steps: Based on the availability of external AC power on site, the power supply path is switched by operating the first miniature circuit breaker and the second miniature circuit breaker. The system DC power bus is selectively powered by a switching power supply or a rechargeable power module, and the energy storage battery pack in the rechargeable power module is charged synchronously when powered by the switching power supply. S2. Equipment Connection and Configuration Steps: Provide power to the industrial equipment under test, connect the signal terminal of the industrial equipment under test or control to the corresponding signal channel, and configure the test parameters through the human-machine interface. S3. Signal processing and conversion steps: The core processing unit acquires the input signal and converts the analog input signal into the corresponding engineering value for display. At the same time, the set output command is converted into an analog control signal for output. S4. Result Presentation and Diagnostic Steps: Display the detection status and data on the human-computer interaction interface for operators to analyze and diagnose.

[0005] Preferably, the power supply mode switching step in S1 specifically includes: When no external AC power is available, the second miniature circuit breaker is closed, and the energy storage battery pack supplies power to the system. When an external AC power source is available, the second miniature circuit breaker is disconnected, the external AC power source is connected, and the first miniature circuit breaker is closed. The switching power supply then powers the system and charges the energy storage battery pack.

[0006] Preferably, the device connection and configuration steps in S2 specifically include: Connect the switch signal output terminal and analog signal output terminal of the industrial equipment under test to the digital input channel and analog input channel, respectively. Connect the signal input terminal of the industrial equipment to be controlled to the analog output channel or the digital output channel.

[0007] Preferably, the analog input signal is a 4-20mA current signal or a 0-10V voltage signal; The analog output signal is a 4-20mA current signal or a 0-10V voltage signal.

[0008] Preferably, in the signal processing and conversion step, a linear conversion algorithm is used to convert the engineering value of the analog signal to the original electrical signal value.

[0009] A portable, rechargeable industrial equipment testing device includes a housing, the interior of which is provided with: The core processing unit consists of a CPU module and an AI / AO module connected to the CPU module. The human-computer interaction unit is a touchscreen that is communicatively connected to the CPU module. The power supply module includes a switching power supply, a rechargeable power supply module, a first miniature circuit breaker, and a second miniature circuit breaker. The signal conditioning module includes multiple analog signal isolators. The analog input and output channels of the AI / AO module are respectively connected to the external terminals on the enclosure through the corresponding analog signal isolators. A digital output driver module includes multiple relays. The digital output channel of the CPU module is connected to the coil of the relay, and the external load is driven by the contacts of the relay. The network communication module is a rail-mounted switch connected to the CPU module and is used to expand the communication interface.

[0010] Preferably, the number of analog signal isolators is four.

[0011] Preferably, the number of relays is six; The CPU module itself integrates no fewer than six digital input channels; The AI / AO module provides no fewer than four analog input channels and no fewer than two analog output channels.

[0012] Preferably, the surface of the enclosure is provided with terminal blocks corresponding to all analog input, analog output, digital input, digital output channels and external power supply interfaces.

[0013] Preferably, the power supply module is used to provide DC24V power to the control circuit system, the human-machine interaction unit and the external device under test.

[0014] This invention provides a portable, rechargeable method and apparatus for testing industrial equipment. It offers the following advantages: This invention standardizes the process, integrating fragmented operations reliant on individual experience into a standardized workflow encompassing power supply, wiring, testing, and diagnostics, significantly improving the reliability and efficiency of testing. By using a built-in battery to switch power supplies, it completely eliminates dependence on fixed on-site power sources, enabling equipment testing in any location and under any operating conditions. Furthermore, it automates the complex work of signal interpretation and conversion, automatically displaying engineering values ​​and outputting standard signals, significantly lowering the technical barrier and avoiding human error. One-stop precise diagnostics: Integrating "measurement" and "analysis" functions, it greatly shortens maintenance time. Attached Figure Description

[0015] Figure 1 This is a flowchart of the steps of the method of the present invention; Figure 2 This is a schematic diagram of the power supply module circuit of the present invention; Figure 3 This is a block diagram of the overall structure of the present invention; Figure 4 This is a schematic diagram of the digital input / output principle of the present invention; Figure 5 This is a schematic diagram of the analog input / output (AI / AO) principle of the present invention; Figure 6 This is an external view of the present invention.

[0016] Legend: 1. Enclosure; 2. CPU module; 3. AI / AO module; 4. Touch screen; 5. Switching power supply; 6. Rechargeable power supply module; 7. Analog signal isolator; 8. Relay; 9. DIN rail switch. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1: like Figures 1-5 As shown, this embodiment of the invention provides a portable, rechargeable industrial equipment testing method, characterized in that the method includes the following steps: S1. Power supply mode switching steps: Based on the availability of external AC power on site, the power supply path is switched by operating the first miniature circuit breaker and the second miniature circuit breaker. The system DC power bus is selectively powered by the switching power supply 5 or the rechargeable power module 6, and the energy storage battery pack in the rechargeable power module 6 is charged synchronously when powered by the switching power supply 5. S2. Equipment Connection and Configuration Steps: Provide power to the industrial equipment under test, connect the signal terminal of the industrial equipment under test or control to the corresponding signal channel, and configure the test parameters through the human-machine interface 4. S3. Signal processing and conversion steps: The core processing unit acquires the input signal and converts the analog input signal into the corresponding engineering value for display. At the same time, the set output command is converted into an analog control signal for output. S4. Result Presentation and Diagnostic Steps: Display the detection status and data on the human-computer interaction interface for operators to analyze and diagnose.

[0019] The specific steps for switching power supply modes in S1 include: When there is no available external AC power, close the second miniature circuit breaker QF2 and the energy storage battery pack will power the system. When an external AC power source is available, the second miniature circuit breaker QF2 is disconnected, the external AC power source is connected, and the first miniature circuit breaker QF1 is closed. The switching power supply 5 then supplies power to the system and charges the energy storage battery pack. Specifically, the energy storage battery pack and the charging management module together form a rechargeable power module 6. The charging management module receives electrical energy and performs intelligent charging management of the energy storage battery pack; the energy storage battery pack is used to store electrical energy.

[0020] The specific steps for device connection and configuration in S2 include: Connect the switch signal output terminal and analog signal output terminal of the industrial equipment under test to the digital input channel and analog input channel, respectively. Connect the signal input terminal of the industrial equipment to be controlled to the analog output (AO) channel or the digital output (DO) channel.

[0021] The analog input signal is a 4-20mA current signal or a 0-10V voltage signal; the analog output signal is a 4-20mA current signal or a 0-10V voltage signal.

[0022] In the signal processing and conversion steps, a linear conversion algorithm is used to convert the engineering value of the analog signal into the original electrical signal value. Specifically:

[0023] in The calculated values ​​of engineering physical quantities; This represents the currently acquired raw AD sample value; This is the AD value corresponding to the lower limit of the measurement range; This is the AD value corresponding to the upper limit of the measurement range; The lower limit of the measurement range is the engineering value, such as 0 kPa; This refers to the upper limit of the measurement range, such as 100 kPa.

[0024] Taking the on-site diagnosis of a stopped frequency converter as an example, the method flow of this invention is as follows: S1. Power Supply Mode Autonomous Selection: Upon arrival at the power-off site and determining that no external power source is available, technicians close the second miniature circuit breaker QF2 on the device. The system is then powered by the built-in energy storage battery pack, entering offline operation mode.

[0025] S2. Device Connection and Test Configuration: Connect the DC24V output terminal of the device to the control power supply terminal of the frequency converter.

[0026] Connect the 0-10V terminal of the device's analog output channel to the analog input terminal of the frequency converter.

[0027] Access the AO output settings interface on the touchscreen and set the signal type to "0-10V".

[0028] S3. Signal Processing and Execution: Set the output value to 5.0V on the touchscreen to correspond to the desired frequency of 25Hz.

[0029] The PLC's internal program receives the set value, calls the linear conversion algorithm, calculates the corresponding digital quantity, and generates a precise 5V voltage signal output through the AO module and signal isolator.

[0030] S4. Data Presentation and Diagnosis: Upon observing the inverter's control panel, it was found that its frequency display showed 25Hz and it had started running.

[0031] This result indicates that the inverter itself is functioning normally, and the fault lies in the original signal source, such as the potentiometer. Based on this diagnosis, the faulty potentiometer was replaced, and the system returned to normal.

[0032] Example 2 like Figures 2-6 As shown, a portable measurement control box with charging capability includes a box body 1, which is made of robust engineering plastic or metal material and is equipped with a handle and an airtight lid for easy carrying.

[0033] The control circuit system is installed inside the housing 1 and is mounted on the electrical rail. It includes a PLC as the core processing unit. The PLC consists of a CPU module 2 and an AI / AO module 3 connected to the CPU module 2. The human-machine interface unit is a touchscreen 4 that communicates with the CPU module 2; the housing 1 is equipped with standard electrical rails. All electrical modules are mounted on the rails, with a compact and reasonable layout. Specifically, it includes: a switching power supply 5, a first miniature circuit breaker QF1, a second miniature circuit breaker QF2, the CPU module 2, an AI / AO module 3, four analog signal isolators 7, six relays 8, a rail-mounted switch 9, and a mounting position for a rechargeable power supply module 6. (The last sentence appears to be incomplete and possibly refers to a different unit.) Figure 5 The sliding panel provides protection, and the interior of the housing 1 also houses a touchscreen 4 and a dense array of terminal blocks.

[0034] The input terminal of the switching power supply 5 is selectively connected to an external AC power source via a first miniature circuit breaker; the power output terminal of the rechargeable power module 6 is selectively connected to the system DC power bus via a second miniature circuit breaker. The first and second miniature circuit breakers are configured to have two operating modes: when the first miniature circuit breaker QF1 is closed and the second miniature circuit breaker QF2 is open, the system DC power bus is powered by the switching power supply 5 and simultaneously charges the rechargeable power module 6; when the first miniature circuit breaker QF1 is open and the second miniature circuit breaker QF2 is closed, the system DC power bus is powered by the rechargeable power module 6.

[0035] The analog input and output channels of AI / AO module 3 are connected to the external terminals on the enclosure 1 through the corresponding analog signal isolators 7. The digital output channel of CPU module 2 is connected to the coil of relay 8, and the external load is driven by the contacts of relay 8. The DIN rail switch 9 is connected to the CPU module 2 to expand the communication interface.

[0036] The power supply module is used to provide DC24V power to the control circuit system, human-machine interface unit and external device under test.

[0037] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A portable, rechargeable method for testing industrial equipment, characterized in that, The method includes the following steps: S1. Power supply mode switching steps: Based on the availability of external AC power on site, the power supply path is switched by operating the first miniature circuit breaker and the second miniature circuit breaker. The system DC power bus is selectively powered by a switching power supply or a rechargeable power module, and the energy storage battery pack in the rechargeable power module is charged synchronously when powered by the switching power supply. S2. Equipment Connection and Configuration Steps: Provide power to the industrial equipment under test, connect the signal terminal of the industrial equipment under test or control to the corresponding signal channel, and configure the test parameters through the human-machine interface. S3. Signal processing and conversion steps: The core processing unit acquires the input signal and converts the analog input signal into the corresponding engineering value for display. At the same time, the set output command is converted into an analog control signal for output. S4. Result Presentation and Diagnostic Steps: Display the detection status and data on the human-computer interaction interface for operators to analyze and diagnose.

2. The method for testing industrial equipment with a portable charging port according to claim 1, characterized in that, The power supply mode switching steps in S1 specifically include: When no external AC power is available, the second miniature circuit breaker is closed, and the energy storage battery pack supplies power to the system. When an external AC power source is available, the second miniature circuit breaker is disconnected, the external AC power source is connected, and the first miniature circuit breaker is closed. The switching power supply then powers the system and charges the energy storage battery pack.

3. The method for testing industrial equipment with a portable charging port according to claim 1, characterized in that, The device connection and configuration steps in S2 specifically include: Connect the switch signal output terminal and analog signal output terminal of the industrial equipment under test to the digital input channel and analog input channel, respectively. Connect the signal input terminal of the industrial equipment to be controlled to the analog output channel or the digital output channel.

4. The method for testing industrial equipment with a portable charging port according to claim 1, characterized in that, The analog input signal is a 4-20mA current signal or a 0-10V voltage signal, and the analog output signal is a 4-20mA current signal or a 0-10V voltage signal.

5. The method for testing industrial equipment with a portable charging port according to claim 1, characterized in that, In the signal processing and conversion steps, a linear conversion algorithm is used to convert the engineering value of the analog signal to the original electrical signal value.

6. A portable, rechargeable industrial equipment testing device, comprising the portable, rechargeable industrial equipment testing method according to any one of claims 1-5, characterized in that, Includes a housing, the interior of which is provided with: The core processing unit consists of a CPU module and an AI / AO module connected to the CPU module. The human-computer interaction unit is a touchscreen that is communicatively connected to the CPU module. The power supply module includes a switching power supply, a rechargeable power supply module, a first miniature circuit breaker, and a second miniature circuit breaker. The signal conditioning module includes multiple analog signal isolators. The analog input and output channels of the AI / AO module are respectively connected to the external terminals on the enclosure through the corresponding analog signal isolators. A digital output driver module includes multiple relays. The digital output channel of the CPU module is connected to the coil of the relay, and the external load is driven by the contacts of the relay. The network communication module is a rail-mounted switch connected to the CPU module and is used to expand the communication interface.

7. The portable industrial equipment testing device with rechargeable function according to claim 6, characterized in that, The number of analog signal isolators is four.

8. A portable industrial equipment testing device with rechargeable features according to claim 6, characterized in that, The number of relays is six, the CPU module itself integrates no less than six digital input channels, and the AI / AO module provides no less than four analog input channels and no less than two analog output channels.

9. A portable, rechargeable industrial equipment testing device according to claim 6, characterized in that: The surface of the enclosure is provided with terminal blocks corresponding to all analog input, analog output, digital input, digital output channels, and external power supply interfaces.

10. A portable measurement and control box with charging capability according to claim 6, characterized in that: The power supply module is used to provide DC24V power to the control circuit system, human-machine interaction unit and external device under test.

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