Integrated testing jig, testing method and device for numerical control machine tool

Abstract

This application discloses an integrated testing fixture, testing method, and apparatus for CNC machine tools. The integrated testing fixture includes a power supply configured to supply power to a power supply module; multiple motors, each corresponding to a multiple drive modules, with each motor connected to the power output port of its corresponding drive module; and a controller configured to acquire feedback information from the control module and issue commands to the control module to control the power supply and the operation of the motors. This application, through integrated testing of CNC machine tools, can fully simulate energy feedback and bus voltage surges under real common bus conditions. It also fully considers communication protocol matching and pre-charging logic coordination between modules, and can simulate phase loss faults in the power grid, effectively improving testing efficiency, accuracy, and fault coverage, while avoiding the problems of traditional discrete testing.

Description

Technical Field

[0001] This application belongs to the field of CNC machine tool testing technology, specifically relating to an integrated testing fixture, testing method and device for CNC machine tools. Background Technology

[0002] Common bus power supply technology is widely used in multi-axis CNC systems due to its advantages such as high energy efficiency and simple wiring. These systems typically consist of an independent power supply module, multiple drive modules, and a control module. Functional verification of these modules is crucial in product development, factory quality inspection, and after-sales maintenance.

[0003] Traditional testing methods mainly use discrete testing, which involves separating the various modules of a common bus CNC machine tool and testing them with separate power supplies, signal generators, and loads. This results in distorted test scenarios, failing to simulate energy feedback and bus voltage surges under real common bus operating conditions. Furthermore, it easily overlooks systemic faults such as communication protocol matching of modules, bus pre-charging logic coordination, and the power supply module's response to grid phase loss, leading to incomplete fault coverage. Summary of the Invention

[0004] The purpose of this application is to provide an integrated testing fixture, testing method and related device for CNC machine tools, so as to solve the problems of test scenario distortion and incomplete test fault coverage in the existing discrete testing methods.

[0005] To achieve the above objectives, a first aspect of this application provides an integrated testing fixture for a CNC machine tool. The CNC machine tool includes a power supply module, multiple drive modules, and a control module connected via a control bus. The power supply module and the multiple drive modules are connected via a power bus, and the control module is connected to each drive module and the power supply module via a communication interface. The integrated testing fixture includes:

[0006] The power supply is configured to supply power to the power supply module;

[0007] Multiple motors are associated with multiple drive modules, and each motor is connected to the power output port of the corresponding drive module.

[0008] The controller is configured to acquire information fed back by the control module and to issue commands to the control module to control the power supply and the operation of the motor.

[0009] In one or more embodiments, at least one phase of the power supply is connected in series with a contactor, and the integrated test fixture further includes an expansion module configured to control the on / off state of the contactor. The controller is also configured to issue instructions to the expansion module to simulate a phase loss environment.

[0010] To achieve the above objectives, a second aspect of this application provides an integrated testing method for CNC machine tools, applied to the controller of the integrated testing fixture described in any of the above embodiments, the integrated testing method comprising:

[0011] In response to the start test command, the bus status value fed back by the power supply module is obtained, and it is determined whether there is an initial bus status abnormality or a control power supply fault.

[0012] If not, send a pre-charge command to the power supply module to control the power supply module to supply power, wait for a preset time, obtain the power bus voltage fed back by the power supply module and the drive module, and determine whether there is a pre-charge fault;

[0013] If not, send a run command to the control module so that the control module responds to the run command and controls the motor to run through the drive module;

[0014] During operation, the fault register of the driver module is read in real time to determine whether the driver module is working properly;

[0015] During operation, the power bus status value fed back by the power supply module is acquired in real time, and it is determined whether the power supply module is working properly.

[0016] After the operation is completed, a power-off command is sent to the power supply module to control the power supply module to stop supplying power. The alarm information of the power supply module is monitored to determine whether there is an abnormality in the regenerative discharge function of the power supply module. After waiting for a preset time, the power bus voltage fed back by the power supply module is obtained, and it is determined whether there is a discharge circuit fault in the power supply module.

[0017] In one or more embodiments, the bus status values ​​include power bus voltage, power bus current, and control bus voltage;

[0018] The steps for determining whether there are initial busbar status abnormalities and control power supply faults include:

[0019] Determine whether the power bus voltage is less than a first threshold and whether the power bus current is less than a second threshold;

[0020] If so, then there is no anomaly in the initial busbar state;

[0021] Calculate the first difference between the control bus voltage and the preset value, and determine whether the absolute value of the first difference is less than the third threshold.

[0022] If so, then there is no control power supply failure.

[0023] In one or more embodiments, the step of determining whether a precharge fault exists includes:

[0024] Calculate the second difference between the power bus voltage fed back by the power supply module and the rated value from the power bus voltage of the drive module, and determine whether the absolute value of the second difference is less than the fourth threshold.

[0025] If so, then there is no pre-charge fault.

[0026] In one or more embodiments, the step of sending an operation command to the control module, so that the control module controls the motor to operate via the drive module in response to the operation command, includes:

[0027] A first operating command is sent to the control module, so that the control module responds to the first operating command by sequentially sending a motor enable command, a motor phase-finding command, and a position closed-loop mode command to each of the drive modules;

[0028] A second operating command is sent to the control module, so that the control module, in response to the second operating command, controls the motor to alternately rotate forward and reverse at a preset speed through the drive module.

[0029] In one or more embodiments, the power bus status values ​​include power bus current and power bus voltage;

[0030] The steps of acquiring the power bus status value fed back by the power supply module in real time during operation and determining whether the power supply module is working properly include:

[0031] The theoretical bus current is calculated based on the theoretical load torque of all motors during operation.

[0032] Calculate the third difference between the power bus current and the theoretical bus current, and determine whether the absolute value of the third difference is less than the fifth threshold.

[0033] If so, calculate the fourth difference between the peak voltage and the steady-state voltage of the power bus voltage, and determine whether the fourth difference is less than the sixth threshold.

[0034] If so, then the power supply module is working normally.

[0035] In one or more embodiments, at least one phase of the power supply is connected in series with a contactor, and the integrated test fixture further includes an expansion module configured to control the on / off state of the contactor. The controller is also used to issue instructions to the expansion module to simulate a phase loss environment.

[0036] The integrated testing method also includes:

[0037] During operation, a phase loss command is sent to the expansion module to disconnect at least one phase of the power supply connected in series with the contactor. After waiting for a preset time, the alarm information of the power supply module is listened to to determine whether the phase loss detection function of the power supply module is effective.

[0038] If so, a reset command is sent to the expansion module to close the contactor. After waiting for a preset time, the alarm information of the power supply module is monitored to determine whether the fault self-recovery function of the power supply module is effective.

[0039] In one or more embodiments, the step of obtaining the power bus voltage fed back by the power supply module and determining whether the power supply module has a discharge circuit fault includes:

[0040] Determine whether the power bus voltage is less than the seventh threshold;

[0041] If so, then the power supply module does not have a discharge circuit fault.

[0042] To achieve the above objectives, a third aspect of this application provides an integrated testing device for CNC machine tools, applied in the controller of the integrated testing fixture described in any of the above embodiments, the integrated testing device comprising:

[0043] The pre-inspection module is used to respond to the start test command, obtain the bus status value fed back by the power supply module, and determine whether there is an initial bus status abnormality or control power supply failure.

[0044] The pre-charge detection module is used to send a pre-charge command to the power supply module when there is no abnormality in the initial bus state or control power failure, so as to control the power supply module to supply power. After waiting for a preset time, it obtains the power bus voltage fed back by the power supply module and the drive module, and determines whether there is a pre-charge failure.

[0045] The test control module is used to send a run command to the control module when there is no pre-charge fault, so that the control module responds to the run command and controls the motor to run through the drive module;

[0046] The driver detection module is used to read the fault register of the driver module in real time during operation and determine whether the driver module is working properly.

[0047] The power supply detection module is used to acquire the power bus status value fed back by the power supply module in real time during operation, and to determine whether the power supply module is working properly.

[0048] The power failure detection module is used to send a power failure command to the power supply module after operation is completed, so as to control the power supply module to stop supplying power, listen to the alarm information of the power supply module, determine whether there is an abnormality in the regenerative discharge function of the power supply module, wait for a preset time, obtain the power bus voltage fed back by the power supply module, and determine whether there is a discharge circuit fault in the power supply module.

[0049] The advantages of this application, which differ from existing technologies, are:

[0050] This application can fully simulate the energy feedback and bus voltage impulse under real common bus conditions by performing integrated testing on CNC machine tools. At the same time, it fully considers the communication protocol matching between modules, the pre-charging logic coordination, etc., and can simulate the phase loss fault of the power grid, effectively improving the testing efficiency, testing accuracy and testing fault coverage, and avoiding the problems of traditional discrete testing. Attached Figure Description

[0051] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 This is a schematic diagram of one embodiment of the integrated testing fixture for CNC machine tools according to this application;

[0053] Figure 2 This is a flowchart illustrating one embodiment of the integrated testing method for CNC machine tools according to this application;

[0054] Figure 3 yes Figure 2 A flowchart of one embodiment corresponding to S100;

[0055] Figure 4 yes Figure 2 A flowchart illustrating one embodiment corresponding to S300;

[0056] Figure 5 yes Figure 2 A flowchart of one embodiment corresponding to S500;

[0057] Figure 6 This is a schematic diagram of one embodiment of the integrated testing device for CNC machine tools according to this application.

[0058] Explanation of key figure labels:

[0059] CNC machine tool 100; power supply module 101; control module 102; drive module 103; power bus 104; control bus 105;

[0060] Integrated test fixture 200; power supply 201; contactor 2011; motor 202; controller 203; expansion module 204. Detailed Implementation

[0061] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0062] With the improvement of industrial automation, the development of electrical components for CNC machine tools is trending towards higher integration and higher power density; common bus power supply technology is widely used in multi-axis CNC systems due to its advantages such as high energy utilization and simple wiring.

[0063] Traditional testing methods for CNC machine tools with common bus power supply mainly employ discrete testing. For example, a laboratory adjustable power supply is used to power the drive module, a signal generator is used to simulate control signals, and a high-power resistor or motor is used as a load on the platform to test the drive module's load-carrying capacity separately. This testing method cannot simulate energy feedback and bus voltage fluctuations under real common bus conditions. When testing the power supply module separately, it cannot simulate the impact of sudden acceleration or deceleration of the drive module on the bus. Furthermore, it easily overlooks systemic faults such as communication protocol matching between modules, bus pre-charging logic coordination, and the power supply module's response to grid phase loss.

[0064] To address the aforementioned issues, the applicant has developed a novel integrated testing fixture for CNC machine tools. This fixture enables integrated testing of CNC machine tools without requiring testing of individual modules, effectively resolving the problems of distorted test scenarios and incomplete fault coverage in existing testing methods.

[0065] Specifically, please refer to Figure 1 , Figure 1 This is a schematic diagram of one embodiment of the integrated testing fixture for CNC machine tools according to this application.

[0066] like Figure 1As shown, the fixture is applied in a CNC machine tool 100 having a power supply module 101, a control module 102, and multiple drive modules 103. The power supply module 101, multiple drive modules 103, and control module 102 are connected through a control bus 105 to power the controllers 203 in the drive modules 103 and the control module 102. The power supply module 101 and multiple drive modules 103 are connected through a power bus 104 to power the power components in the drive modules 103.

[0067] The control module 102 is also connected to each drive module 103 and power supply module 101 via a communication interface to enable internal communication.

[0068] Specifically, in one embodiment, the power bus 104 may be supplied with a voltage of 310V and the control bus 105 may be supplied with a voltage of 24V.

[0069] In one embodiment, the control module 102 can be connected to each drive module 103 via a serial optical port to issue drive commands. The control module 102 can also be connected to the power supply module 101 via an EtherCAT bus to receive real-time status information fed back by the power supply module 101.

[0070] The integrated test fixture 200 of this application is described in detail below, such as... Figure 1 As shown, the test fixture includes a power supply 201, multiple motors 202, and a controller 203. The power supply 201 is used to supply power to the power supply module 101. The multiple motors 202 correspond one-to-one with the multiple drive modules 103. Each motor 202 is connected to the power output port of the corresponding drive module 103. The controller 203 is used to obtain information fed back by the control module 102 and to issue commands to the control module 102 to control the power supply and the operation of the motors 202.

[0071] Based on the above scheme, the controller 203 sends instructions to the control module 102 to control the power supply and power-off of the CNC machine tool 100 and the operation of each drive module 103. The power supply module 101 and the drive module 103 can feed back the real-time status values ​​of the power bus 104 and the control bus 105 to the control module 102. The controller 203 can obtain the real-time status values ​​of the power bus 104 and the control bus 105 from the control module 102 to realize the abnormal judgment of each component of the CNC machine tool 100. At the same time, in the integrated test, it can fully simulate the energy feedback and bus voltage fluctuation under the real common bus condition, avoiding the test environment distortion problem of discrete test.

[0072] In addition, since the modules of the CNC machine tool 100 are in a communication connection state during testing, it can simulate fault testing under various real-world conditions, effectively avoiding the problem of incomplete fault coverage that exists in discrete testing.

[0073] Furthermore, in this embodiment, at least one phase of the power supply 201 is connected in series with a contactor 2011, and the integrated test fixture 200 also includes an expansion module 204. The expansion module 204 is configured to control the on / off state of the contactor 2011, and the controller 203 is also used to issue instructions to the expansion module 204 to simulate a phase loss environment.

[0074] Based on the above scheme, the controller 203 sends instructions to the expansion module 204 to control the on / off state of the contactor 2011, simulating a phase loss environment in the power grid, in order to determine whether the phase loss detection function and fault self-recovery function of the power supply module 101 are effective, which helps to further improve the test fault coverage.

[0075] This application also provides an integrated testing method for CNC machine tools, which is applied to the controller of the integrated testing fixture in any of the above embodiments. Please refer to [link to relevant documentation]. Figure 2 , Figure 2 This is a flowchart illustrating one implementation method of the integrated testing method for CNC machine tools according to this application.

[0076] like Figure 2 As shown, the method includes:

[0077] S100: In response to the start test command, obtain the bus status value fed back by the power supply module, and determine whether there is an initial bus status abnormality or control power supply failure.

[0078] First, when the power supply module is not powered on, the system is in standby mode and the power supply module does not output power to the power bus. At this time, the machine tool pre-inspection process can be carried out to determine whether the test conditions are met, that is, whether there is an abnormality in the initial bus status and a control power supply failure.

[0079] Specifically, in one embodiment, bus status values ​​may include power bus voltage, power bus current, and control bus voltage. (See [link to relevant documentation]). Figure 3 , Figure 3 yes Figure 2 A flowchart of one embodiment corresponding to S100.

[0080] like Figure 3 As shown, methods for determining whether there are initial bus condition anomalies and control power supply faults may include:

[0081] S101. Determine whether the power bus voltage is less than the first threshold and whether the power bus current is less than the second threshold.

[0082] If so, then:

[0083] S102a, There is no abnormality in the initial busbar status.

[0084] If not, then:

[0085] S102b, An initial busbar anomaly exists; test ends.

[0086] Understandably, when the power supply module is not outputting high voltage to the drive module, the power bus voltage and power bus current should theoretically be close to 0. By judging whether the actual power bus voltage fed back by the power supply module is less than the first threshold and whether the power bus current is less than the second threshold, it can be determined whether the initial bus state is abnormal.

[0087] The first threshold and the second threshold can be adjusted based on the actual working conditions. For example, the first threshold and the second threshold can be values ​​slightly greater than 0, such as the first threshold being 0.1V and the second threshold being 0.1A.

[0088] S103. Calculate the first difference between the control bus voltage and the preset value, and determine whether the absolute value of the first difference is less than the third threshold.

[0089] If so, then:

[0090] S104a, There is no control power supply fault.

[0091] If not, then:

[0092] S104b, Control power supply failure exists, test ends.

[0093] Furthermore, when the power supply module does not output high voltage to the drive module, the control bus voltage should remain at a preset value. By calculating the difference between the actual control bus voltage fed back by the power supply module and the preset value, it can be determined whether there is a control power supply fault.

[0094] When the first difference is greater than or equal to the third threshold, it indicates that the control bus voltage deviation is large, which may be due to a fault in the control power supply of the power supply module. At this point, the test ends.

[0095] When the first difference is less than the third threshold, it means that the deviation of the control bus voltage from the preset value is within a reasonable range. At this time, the control power supply can be considered normal and the test can continue.

[0096] The preset value can be 24V, and the third threshold can be adjusted based on the actual working conditions. For example, the third threshold can be a value slightly greater than 0, such as 0.5V.

[0097] After the CNC machine tool passes the pre-inspection, the method also includes:

[0098] S200: Send a pre-charge command to the power supply module to control the power supply module to supply power. After waiting for a preset time, obtain the power bus voltage fed back by the power supply module and the drive module, and determine whether there is a pre-charge fault.

[0099] Furthermore, a pre-charge test can be performed after the pre-inspection. The controller can send a pre-charge command to the power supply module. At this time, the power supply module outputs high power to the power bus and waits for a preset time for pre-charging. After that, the controller can obtain the power bus voltage fed back by the power supply module and each drive module, and then determine whether there is a voltage abnormality. Based on whether the voltage of each module is abnormal, it can be determined whether there is a pre-charge fault.

[0100] Specifically, the judgment method can be:

[0101] Calculate the second difference between the power bus voltage fed back by the power supply module and the drive module and the rated value, and determine whether the absolute value of the second difference is less than the fourth threshold.

[0102] If so, then there is no pre-charge fault.

[0103] The preset waiting time can be adjusted based on the actual working conditions; for example, the preset time can be 3 seconds. The fourth threshold can also be adjusted based on the actual working conditions; for example, it can be 0.5V.

[0104] If a pre-charge fault exists, it indicates that the operating conditions are not met, and the test can be terminated; if no pre-charge fault exists, the motor operation test can be further performed, including:

[0105] S300: Send a run command to the control module so that the control module responds to the run command and controls the motor to run through the drive module.

[0106] The controller sends a run command to the control module. After receiving the run command, the control module can control the operation of each motor through the drive module to start the motor operation.

[0107] Specifically, please refer to Figure 4 , Figure 4 yes Figure 2 A flowchart of one embodiment corresponding to S300 is shown below. Figure 4 As shown, methods for controlling motor operation may include:

[0108] S301. Send a first running command to the control module, so that the control module responds to the first running command by sequentially sending a motor enable command, a motor phase finding command, and a position closed-loop mode command to each drive module.

[0109] First, a first running command can be sent to control the motor to sequentially enable, initialize the rotor position, and switch to position closed-loop mode standby, waiting for subsequent commands.

[0110] S302. Send a second running command to the control module so that the control module responds to the second running command by controlling the motor to alternately rotate forward and reverse at a preset speed through the drive module.

[0111] Then a second running command can be sent to control the motor to alternately rotate forward and reverse, in order to simulate the motor's rapid acceleration and deceleration working state under actual working conditions.

[0112] The preset speed can be adjusted based on actual working conditions. For example, the motor can run at 100 rpm forward for 30 seconds, then reverse for 30 seconds, and then the power is cut off.

[0113] S400 reads the fault register of the driver module in real time during operation and determines whether the driver module is working properly.

[0114] When the motor is running, the fault register of the drive module is read in real time, and the information stored in the fault register is used to determine whether the drive module is working properly.

[0115] For example, it can be determined whether there is overcurrent, overvoltage, encoder error, etc. in the fault register. If not, the driver module is working normally; if so, the driver module has a fault, and the test ends.

[0116] S500: During operation, the power bus status value fed back by the power supply module is obtained in real time, and it is determined whether the power supply module is working properly.

[0117] When the motor is running, the power bus status value can be monitored in real time to determine whether the power supply module is working properly. Specifically, this means checking whether the power supply module has a normal load-carrying capacity and whether the power supply module's discharge circuit is normal.

[0118] Please see Figure 5 , Figure 5 yes Figure 2 A flowchart of one embodiment corresponding to S500.

[0119] like Figure 5 As shown, the methods for determining whether the power supply module is working properly during motor operation include:

[0120] S501. Based on the theoretical load torque of all motors during operation, the theoretical bus current is calculated.

[0121] First, the theoretical bus current can be calculated. This theoretical bus current is based on the power voltage and the theoretical load torque of all motors. The specific calculation process is as follows:

[0122] The mechanical power of the motor is calculated based on the theoretical load torque and given speed of the motor.

[0123] Based on the mechanical power and theoretical efficiency of the motor and the theoretical conversion efficiency of the drive module, the total input electrical power of the drive module is calculated.

[0124] Based on the total input electrical power and power voltage of the drive module, the theoretical bus current can be calculated.

[0125] S502. Calculate the third difference between the power bus current and the theoretical bus current, and determine whether the absolute value of the third difference is less than the fifth threshold.

[0126] If so, then:

[0127] S503. Calculate the fourth difference between the peak voltage and the steady-state voltage of the power bus voltage, and determine whether the fourth difference is less than the sixth threshold.

[0128] If so, then:

[0129] S504, the power supply module is working normally.

[0130] Specifically, by judging the error between the power bus current and the theoretical bus current, it can be determined whether the load-carrying capacity of the power supply module is normal or whether there are hidden dangers in the energy conversion efficiency of the drive module. When a problem is found, the test ends.

[0131] When the absolute value of the third difference between the two is less than the fifth threshold, it can be determined that the load-carrying capacity of the power supply module and the energy conversion efficiency of the drive module are normal. It can be further determined whether the difference between the peak voltage and steady-state voltage of the power bus is within a reasonable range, thereby reflecting whether the fluctuation of the power bus voltage during the rapid acceleration and deceleration of the motor is reasonable. When the difference is within a reasonable range, it can be determined that the discharge circuit of the power supply module is working normally. When there is a problem, the test ends.

[0132] Furthermore, to simulate a phase-deficient environment for testing, the method also includes:

[0133] S600: During operation, a phase loss command is sent to the expansion module to disconnect at least one phase of the power supply contactor connected in series. After waiting for a preset time, the alarm information of the power supply module is listened to to determine whether the phase loss detection function of the power supply module is effective.

[0134] First, a command can be sent to the expansion module to disconnect at least one of the contactors connected in series with the power supply. When the contactor is disconnected, a phase loss environment of the power grid can be simulated. After waiting for a preset time, the alarm information of the power supply module can be listened to. If the power supply module does not send an "input phase loss" fault, it can be considered that the phase loss detection function of the power supply module has failed, and the test can be ended at this time.

[0135] If the power supply module sends an "input phase loss" fault, the phase loss detection function of the power supply module is effective and may also include:

[0136] S700 sends a reset command to the expansion module to close the contactor. After waiting for a preset time, it listens for alarm information from the power supply module to determine whether the power supply module's fault self-recovery function is effective.

[0137] Furthermore, by issuing a command to the expansion module to close the contactor and restore the normal power grid environment, the alarm information of the power supply module can be listened to after a preset time. If the "input phase loss" fault flag of the power supply module is not cleared, it can be determined that the fault self-recovery function of the power supply module has failed, and the test can be ended at this time.

[0138] If the "input phase loss" fault flag of the power supply module has been cleared, the fault self-recovery function of the power supply module can be considered effective, and subsequent power-off tests can continue, including:

[0139] After S800 completes operation, it sends a power-off command to the power supply module to control the power supply module to stop supplying power, listens for alarm information from the power supply module, determines whether there is an abnormality in the regenerative discharge function of the power supply module, waits for a preset time, obtains the power bus voltage fed back by the power supply module, and determines whether there is a discharge circuit fault in the power supply module.

[0140] Specifically, after the motor has finished running, the power supply module can be controlled to stop supplying power, and the alarm information of the power supply module can be listened to. If the power supply module reports "abnormal regenerative discharge alarm", it can be determined that the power supply module has an abnormal regenerative discharge function.

[0141] If no feedback is received, there is no abnormality in the regeneration and discharge function.

[0142] Furthermore, after a preset time has elapsed and the circuit is fully discharged, the presence of a discharge circuit fault can be determined based on the power bus voltage fed back by the power supply module. Specifically, this includes:

[0143] Determine whether the power bus voltage is less than the seventh threshold;

[0144] If so, then there is no discharge circuit fault in the power supply module.

[0145] Understandably, when the power supply module stops supplying power and discharges completely, the power bus voltage should be close to 0V. When it is greater than the seventh threshold, it can be determined that there is a discharge circuit fault; when it is less than the seventh threshold, it can be determined that there is no discharge circuit fault, thus completing the entire test process.

[0146] The seventh threshold can be adjusted based on actual operating conditions; for example, the seventh threshold can be 0.5V.

[0147] Based on the methods described above, integrated testing can fully simulate energy feedback and bus voltage surges under real common bus conditions. It also fully considers communication protocol matching and pre-charging logic coordination between modules, and can simulate power grid phase loss faults, effectively improving testing efficiency, testing accuracy, and testing fault coverage.

[0148] This application also provides an integrated testing device for CNC machine tools; please refer to [link / reference]. Figure 6 , Figure 6 This is a schematic diagram of one embodiment of the integrated testing device for CNC machine tools according to this application.

[0149] like Figure 6 As shown, the device is applied in the controller of the integrated test fixture in any of the above embodiments, and includes a pre-inspection module 21, a pre-charge detection module 22, a test control module 23, a drive detection module 24, a power supply detection module 25, a phase loss detection module 26, and a power failure detection module 27.

[0150] The pre-inspection module 21 is used to respond to the start test command, obtain the bus status value fed back by the power supply module, and determine whether there is an initial bus status abnormality or control power supply failure.

[0151] The pre-charge detection module 22 is used to send a pre-charge command to the power supply module to control the power supply module to supply power when there is no abnormality in the initial bus state or control power failure. After waiting for a preset time, it obtains the power bus voltage fed back by the power supply module and the drive module and determines whether there is a pre-charge failure.

[0152] The test control module 23 is used to send a running command to the control module when there is no pre-charge fault, so that the control module responds to the running command and controls the motor to run through the drive module;

[0153] The drive detection module 24 is used to read the fault register of the drive module in real time during operation and determine whether the drive module is working properly.

[0154] The power supply detection module 25 is used to acquire the power bus status value fed back by the power supply module in real time during operation and to determine whether the power supply module is working properly.

[0155] The phase loss detection module 26 is used to send a phase loss command to the expansion module during operation to disconnect at least one phase of the power supply connected in series with the contactor, wait for a preset time, listen to the alarm information of the power supply module, determine whether the phase loss detection function of the power supply module is effective, and when the phase loss detection function is effective, send a reset command to the expansion module to close the contactor, wait for a preset time, listen to the alarm information of the power supply module, and determine whether the fault self-recovery function of the power supply module is effective.

[0156] The power failure detection module 27 is used to send a power failure command to the power supply module after the operation is completed, so as to control the power supply module to stop supplying power, listen to the alarm information of the power supply module, determine whether there is an abnormality in the regenerative discharge function of the power supply module, wait for a preset time, obtain the power bus voltage fed back by the power supply module, and determine whether there is a discharge circuit fault in the power supply module.

[0157] As per the above reference Figures 1 to 5 This specification describes an integrated testing method for CNC machine tools according to embodiments thereof. The details mentioned in the above description of the method embodiments also apply to the integrated testing apparatus for CNC machine tools according to embodiments thereof. The above-described integrated testing apparatus for CNC machine tools can be implemented in hardware, software, or a combination of hardware and software.

[0158] Those skilled in the art will understand that the various embodiments disclosed above can be modified and varied without departing from the spirit of the invention. Therefore, the scope of protection of this specification should be defined by the appended claims.

[0159] It should be noted that not all steps and units in the above process and system structure diagrams are mandatory; some steps or units can be omitted according to actual needs. The execution order of each step is not fixed and can be determined as needed. The device structure described in the above embodiments can be a physical structure or a logical structure. That is, some units may be implemented by the same physical client, or some units may be implemented by multiple physical clients, or they may be jointly implemented by certain components in multiple independent devices.

[0160] In the above embodiments, the hardware units or modules can be implemented mechanically or electrically. For example, a hardware unit, module, or processor may include permanent dedicated circuitry or logic (such as a dedicated processor, FPGA, or ASIC) to perform the corresponding operation. The hardware unit or processor may also include programmable logic or circuitry (such as a general-purpose processor or other programmable processor), which can be temporarily configured by software to perform the corresponding operation. The specific implementation method (mechanical, dedicated permanent circuitry, or temporarily configured circuitry) can be determined based on cost and time considerations.

[0161] The specific embodiments described above with reference to the accompanying drawings are exemplary embodiments, but do not represent all embodiments that can be implemented or fall within the scope of the claims. The term "exemplary" as used throughout this specification means "serving as an example, instance, or illustration" and does not imply that it is "preferred" or "advantageous" compared to other embodiments. Specific details are included to provide an understanding of the described techniques. However, these techniques can be practiced without these specific details. In some instances, well-known structures and apparatuses are shown in block diagram form to avoid obscuring the concepts of the described embodiments.

[0162] The foregoing description of this disclosure is provided to enable any person skilled in the art to implement or use this disclosure. Various modifications to this disclosure will be apparent to those skilled in the art, and the general principles applicable herein can be applied to other variations without departing from the scope of this disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but is consistent with the widest scope of the principles and novel features disclosed herein.

Claims

1. An integrated testing fixture for CNC machine tools, characterized in that, The CNC machine tool has a power supply module, multiple drive modules, and a control module connected via a control bus. The power supply module and the multiple drive modules are connected via a power bus, and the control module is connected to each drive module and the power supply module via a communication interface. The integrated test fixture includes: The power supply is configured to supply power to the power supply module; Multiple motors are associated with multiple drive modules, and each motor is connected to the power output port of the corresponding drive module. The controller is configured to acquire information fed back by the control module and to issue commands to the control module to control the power supply and the operation of the motor.

2. The integrated testing fixture according to claim 1, characterized in that, At least one phase of the power supply is connected in series with a contactor. The integrated test fixture also includes an expansion module configured to control the on / off state of the contactor. The controller is also used to issue instructions to the expansion module to simulate a phase loss environment.

3. An integrated testing method for CNC machine tools, characterized in that, The integrated testing method, applied in the controller of the integrated test fixture according to claim 1 or 2, comprises: In response to the start test command, the bus status value fed back by the power supply module is obtained, and it is determined whether there is an initial bus status abnormality or a control power supply fault. If not, send a pre-charge command to the power supply module to control the power supply module to supply power, wait for a preset time, obtain the power bus voltage fed back by the power supply module and the drive module, and determine whether there is a pre-charge fault; If not, send a run command to the control module so that the control module responds to the run command and controls the motor to run through the drive module; During operation, the fault register of the driver module is read in real time to determine whether the driver module is working properly; During operation, the power bus status value fed back by the power supply module is acquired in real time, and it is determined whether the power supply module is working properly. After the operation is completed, a power-off command is sent to the power supply module to control the power supply module to stop supplying power. The alarm information of the power supply module is monitored to determine whether there is an abnormality in the regenerative discharge function of the power supply module. After waiting for a preset time, the power bus voltage fed back by the power supply module is obtained, and it is determined whether there is a discharge circuit fault in the power supply module.

4. The integrated testing method according to claim 3, characterized in that, The bus status values ​​include power bus voltage, power bus current, and control bus voltage; The steps for determining whether there are initial busbar status abnormalities and control power supply faults include: Determine whether the power bus voltage is less than a first threshold and whether the power bus current is less than a second threshold; If so, then there is no anomaly in the initial busbar state; Calculate the first difference between the control bus voltage and the preset value, and determine whether the absolute value of the first difference is less than the third threshold. If so, then there is no control power supply failure.

5. The integrated testing method according to claim 3, characterized in that, The step of determining whether a pre-charge fault exists includes: Calculate the second difference between the power bus voltage fed back by the power supply module and the rated value from the power bus voltage of the drive module, and determine whether the absolute value of the second difference is less than the fourth threshold. If so, then there is no pre-charge fault.

6. The integrated testing method according to claim 3, characterized in that, The step of sending a run command to the control module, so that the control module controls the motor to operate via the drive module in response to the run command, includes: A first operating command is sent to the control module, so that the control module responds to the first operating command by sequentially sending a motor enable command, a motor phase-finding command, and a position closed-loop mode command to each of the drive modules; A second operating command is sent to the control module, so that the control module, in response to the second operating command, controls the motor to alternately rotate forward and reverse at a preset speed through the drive module.

7. The integrated testing method according to claim 3, characterized in that, The power bus status values ​​include power bus current and power bus voltage; The steps of acquiring the power bus status value fed back by the power supply module in real time during operation and determining whether the power supply module is working properly include: The theoretical bus current is calculated based on the theoretical load torque of all motors during operation. Calculate the third difference between the power bus current and the theoretical bus current, and determine whether the absolute value of the third difference is less than the fifth threshold. If so, calculate the fourth difference between the peak voltage and the steady-state voltage of the power bus voltage, and determine whether the fourth difference is less than the sixth threshold. If so, then the power supply module is working normally.

8. The integrated testing method according to claim 3, characterized in that, At least one phase of the power supply is connected in series with a contactor. The integrated test fixture also includes an expansion module configured to control the on / off state of the contactor. The controller is also used to issue instructions to the expansion module to simulate a phase loss environment. The integrated testing method also includes: During operation, a phase loss command is sent to the expansion module to disconnect at least one phase of the power supply connected in series with the contactor. After waiting for a preset time, the alarm information of the power supply module is listened to to determine whether the phase loss detection function of the power supply module is effective. If so, a reset command is sent to the expansion module to close the contactor. After waiting for a preset time, the alarm information of the power supply module is monitored to determine whether the fault self-recovery function of the power supply module is effective.

9. The integrated testing method according to claim 3, characterized in that, The steps of obtaining the power bus voltage fed back by the power supply module and determining whether the power supply module has a discharge circuit fault include: Determine whether the power bus voltage is less than the seventh threshold; If so, then the power supply module does not have a discharge circuit fault.

10. An integrated testing device for CNC machine tools, characterized in that, The integrated testing device, used in the controller of the integrated testing fixture according to claim 1 or 2, comprises: The pre-inspection module is used to respond to the start test command, obtain the bus status value fed back by the power supply module, and determine whether there is an initial bus status abnormality or control power supply failure. The pre-charge detection module is used to send a pre-charge command to the power supply module when there is no abnormality in the initial bus state or control power failure, so as to control the power supply module to supply power. After waiting for a preset time, it obtains the power bus voltage fed back by the power supply module and the drive module, and determines whether there is a pre-charge failure. The test control module is used to send a run command to the control module when there is no pre-charge fault, so that the control module responds to the run command and controls the motor to run through the drive module; The driver detection module is used to read the fault register of the driver module in real time during operation and determine whether the driver module is working properly. The power supply detection module is used to acquire the power bus status value fed back by the power supply module in real time during operation, and to determine whether the power supply module is working properly. The power failure detection module is used to send a power failure command to the power supply module after operation is completed, so as to control the power supply module to stop supplying power, listen to the alarm information of the power supply module, determine whether there is an abnormality in the regenerative discharge function of the power supply module, wait for a preset time, obtain the power bus voltage fed back by the power supply module, and determine whether there is a discharge circuit fault in the power supply module.

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