Analog load testing device and system

Abstract

The utility model discloses an analog load testing arrangement and system. Analog load testing arrangement includes: first resistance device, second resistance device, transmission shaft, manual control subassembly, automatic control subassembly and controller, and first resistance device and second resistance device are coaxial connection through transmission shaft, and transmission shaft connects manual control subassembly and automatic control subassembly, and transmission shaft is used for adjusting first resistance device and second resistance device, and first resistance device connects analog load signal end, and second resistance device is electrically connected with controller, and controller is also electrically connected with automatic control subassembly, and controller controls automatic control subassembly to adjust first resistance device and second resistance device, and the resistance of detecting second resistance device. The utility model discloses technical scheme, through resistance device, transmission shaft and control subassembly etc. simple device, has solved the inconvenient carrying and high cost problem of current testing arrangement, can simplify the test step of complex load scene.

Description

Technical Field

[0001] This utility model relates to the field of controller testing technology, and in particular to a simulated load testing device and system. Background Technology

[0002] Hardware-in-the-Loop (HIL) testing is a widely used technique in the testing and verification of controller products. Its core idea is to connect the actual controller hardware to a simulation test environment consisting of a real-time simulation computer and signal interface devices. By simulating various sensor signals and actuator loads required by the controller, the controller is tested under laboratory conditions.

[0003] Currently, HIL test systems are typically implemented based on large, integrated test benches. The core components of these benches include high-performance real-time simulation computers and a range of highly specialized interface boards. Among these, the resistance and voltage simulation boards used to simulate sensor signals are particularly critical. These boards can generate programmable resistance and voltage signals required by the controller to simulate the outputs of various physical sensors such as temperature sensors, position sensors, and pressure sensors.

[0004] However, the existing HIL testing model, based on large fixed test benches and dedicated boards, suffers from drawbacks such as poor portability, limited flexibility, and high cost. This makes it inconvenient to use when testing controllers in scenarios requiring mobile testing or on-site debugging. Utility Model Content

[0005] This utility model provides a simulated load testing device and system to solve the problems of existing testing devices being inconvenient to carry and costly.

[0006] According to one aspect of the present invention, a simulated load testing device is provided, comprising: a first resistive device, a second resistive device, a transmission shaft, a manual control component, an automatic control component, and a controller;

[0007] The first resistor and the second resistor are coaxially connected via the drive shaft. One end of the drive shaft is connected to the manual control component, and the other end is connected to the automatic control component. The drive shaft is used to adjust the first resistor and the second resistor. The first resistor is connected to an analog load signal terminal, and the second resistor is electrically connected to the controller. The controller is also electrically connected to the automatic control component. The controller is used to control the automatic control component to adjust the first resistor and the second resistor, and to detect the resistance of the second resistor.

[0008] Optionally, a damping connector is provided between the second resistive device and the automatic control component.

[0009] Optionally, the simulated load testing device further includes a display device electrically connected to the controller, the display device being used to display simulated load data.

[0010] Optionally, the controller includes at least a communication unit, a storage unit, and an analog-to-digital converter (ADC). The ADC is connected to the second resistor and the communication unit. The communication unit is electrically connected to the automatic control component and the storage unit. The ADC is used to convert the resistance value of the second resistor into a digital signal. The storage unit is used to store the data of the second resistor. The communication unit is used to transmit the data of the second resistor to a display device and the storage unit, and to control the automatic control component based on the data from the display device or the storage unit.

[0011] Optionally, the communication unit includes at least one wired interface or wireless protocol.

[0012] Optionally, the simulated load testing device also includes a housing that encapsulates a first resistive device, a second resistive device, a drive shaft, a manual control component, an automatic control component, and a controller.

[0013] Optionally, the analog load signal terminal includes at least a first analog load signal terminal and a second analog load signal terminal. The first analog load signal terminal is used to connect to an analog resistance signal; the second analog load signal terminal is used to connect to an analog voltage signal; wherein, when the first resistor is connected to the second analog load signal terminal, a reference voltage is connected to both ends of the first resistor.

[0014] Optionally, the first resistive device includes a first potentiometer, the second resistive device includes a second potentiometer, the first potentiometer and the second potentiometer are coaxially connected via the drive shaft, the first potentiometer is electrically connected to the analog load signal terminal, and the second potentiometer is electrically connected to the controller.

[0015] Optionally, the automatic control component includes at least one of a stepper motor or a DC motor.

[0016] According to another aspect of the present invention, a simulated load testing system is also provided, comprising at least two simulated load testing devices as described in any of the above embodiments.

[0017] The technical solution of this utility model embodiment, by setting a first resistive device and a second resistive device and connecting the two resistive devices through a transmission shaft, ensures that the first and second resistive devices change synchronously. The controller detects the second resistance value in real time and provides feedback for adjustment, ensuring load stability. Operators can directly adjust the two resistive devices by controlling the transmission shaft through manual and automatic control components, making the operation intuitive and responsive. This utility model's technical solution, using simple components such as resistive devices, a transmission shaft, and control components, solves the problems of inconvenience and high cost of existing testing devices, simplifying the testing steps for complex load scenarios.

[0018] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this utility model, nor is it intended to limit the scope of this utility model. Other features of this utility model will become readily apparent from the following description. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a simulated load testing device provided in an embodiment of this utility model;

[0021] Figure 2 This is a schematic diagram of another simulated load testing device provided in this embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram of the structure of another simulated load testing device provided in this embodiment of the utility model;

[0023] Figure 4 This is a graph showing the correspondence between the voltage value and the pressure value of the analog voltage signal provided in this embodiment of the invention.

[0024] Figure 5 This is a schematic diagram of the structure of a simulated load testing system provided in an embodiment of this utility model. Detailed Implementation

[0025] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. 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 should fall within the protection scope of the present invention.

[0026] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0027] Figure 1 This is a schematic diagram of a simulated load testing device provided in an embodiment of the present invention. This embodiment is applicable to scenarios requiring flexible configuration, portability, and real-time feedback in load simulation, such as thermal management systems. Figure 1 As shown, the simulated load testing device includes: a first resistive device 101, a second resistive device 102, a drive shaft 103, a manual control component 104, an automatic control component 105, and a controller 106.

[0028] The first resistor 101 and the second resistor 102 are coaxially connected via a drive shaft 103. One end of the drive shaft 103 is connected to a manual control component 104, and the other end is connected to an automatic control component 105. The drive shaft 103 is used to adjust the first resistor 101 and the second resistor 102. The first resistor 101 is connected to the analog load signal terminal Pin, and the second resistor 102 is electrically connected to a controller 106. The controller 106 is also electrically connected to the automatic control component 106. The controller 106 is used to control the automatic control component 105 to adjust the first resistor 101 and the second resistor 102, and to detect the resistance of the second resistor 102.

[0029] The first resistor 101 is a simulated load element that can simulate a real load condition. The first resistor 101 can be connected to the output terminal of the device under test, i.e., the simulated load signal terminal Pin. The simulated load signal terminal Pin can be connected to a simulated resistance signal or a simulated voltage signal. The first resistor 101 and the second resistor 102 are coaxially connected via a drive shaft 103, causing the resistance of the second resistor 102 to change synchronously with the resistance of the first resistor 101. Furthermore, the second resistor 102 is electrically connected to the controller 106; therefore, the resistance value of the second resistor 102 can represent the resistance value of the first resistor 101 in real time and is transmitted to the controller 106. The drive shaft 103 acts as a mechanical linkage device, coaxially connecting the first resistor 101 and the second resistor 102. When the drive shaft 103 rotates, it simultaneously and synchronously changes the resistance values ​​of the first resistor 101 and the second resistor 102. The resistance change of the second resistor 102 is synchronous and proportional to the resistance change of the first resistor 101, which can be 1:1 or other proportional relationships. One end of the drive shaft 103 is connected to the manual control component 104, and the other end is connected to the automatic control component 105. The manual control component 104 allows the operator to manually rotate the drive shaft 103, and can be a knob or handle. By rotating the manual control component 104, the operator can directly change the resistance values ​​of the two resistors. The automatic control component 105 can automatically rotate the drive shaft 103 under the command of the controller 106. The automatic control component 105 can be a motor that can receive signals from the controller 106 and control the drive shaft 103 to rotate by a corresponding angle. The controller 106 can continuously detect the resistance value of the second resistor 102. Since the second resistor 102 changes synchronously with the first resistor 101, the resistance value of the first resistor 101 can be determined by detecting the resistance value of the second resistor 102.

[0030] Specifically, the first resistor 101 is connected to the analog load signal pin, which is connected to an analog resistance signal or an analog voltage signal. The operator operates the manual control component 101, or the controller 106 issues a command to drive the automatic control component 105, directly driving the drive shaft 103. The drive shaft 103 simultaneously changes the resistance values ​​of the first resistor 101 and the second resistor 102. The controller 106 continuously monitors the current resistance value of the second resistor 102. Because the first resistor 101 and the second resistor 102 are coaxially linked through the drive shaft 103, their resistance changes are synchronous and proportional. The obtained resistance value of the second resistor 102 can determine the resistance value of the first resistor 101, i.e., the actual simulated load condition. Simultaneously, the operator can use the resistance value of the second resistor 102 obtained by the controller 106 to obtain the current simulated load status, such as temperature or pressure data, through table lookup or other methods. At the same time, the controller 106 sends a signal to the automatic control component 105, which drives the transmission shaft 103 to rotate, adjusting the resistance values ​​of the first resistor 101 and the second resistor 102 to form a closed-loop feedback.

[0031] The technical solution of this utility model embodiment, by setting a first resistive device and a second resistive device and connecting the two resistive devices through a transmission shaft, ensures that the first and second resistive devices change synchronously. The controller detects the second resistance value in real time and provides feedback for adjustment, ensuring load stability. Operators can directly adjust the two resistive devices by controlling the transmission shaft through manual and automatic control components, making the operation intuitive and responsive. This utility model's technical solution, using simple components such as resistive devices, a transmission shaft, and control components, solves the problems of inconvenience and high cost of existing testing devices, simplifying the testing steps for complex load scenarios.

[0032] Figure 2 This is a schematic diagram of another simulated load testing device provided in an embodiment of this utility model. In some optional embodiments of this utility model, such as... Figure 2 As shown, a damping connector 107 is provided between the second resistive device 102 and the automatic control component 105.

[0033] The damping connector 107 generates controllable resistance through its built-in mechanical structure. When the resistance of the first resistive device 101 and the second resistive device 102 is adjusted via the manual control component 104, the automatic control component 105 may be damaged due to the reverse force caused by manual intervention. When switching between the manual control component 104 and the automatic control component 105, the damping connector 107 prevents the bidirectional force from clashing, thus avoiding damage to the automatic control component 105.

[0034] In some optional embodiments of this utility model, reference continues to be made. Figure 2 The simulated load testing device also includes a display device 108, which is electrically connected to the controller 106, and the display device 109 is used to display simulated load data.

[0035] The display device 108 can directly receive data transmitted by the controller 106 and display it in digital form. The display device 108 can be a host computer. The display device 108 allows users to send commands to the controller 106 via a touch screen or buttons, thereby controlling the automatic control component 105 to adjust the first resistor device 101 and the second resistor device 102.

[0036] In some optional embodiments of this utility model, reference continues to be made. Figure 2 The controller 106 includes at least a communication unit 1061, a storage unit 1062, and an analog-to-digital converter 1063. The analog-to-digital converter 1063 is connected to the second resistor device 102 and the communication unit 1061. The communication unit 1061 is electrically connected to the automatic control component 105 and the storage unit 1062. The analog-to-digital converter 1063 is used to convert the resistance value of the second resistor device 102 into a digital signal. The storage unit 1062 is used to store the data of the second resistor device 102. The communication unit 1061 is used to transmit the data of the second resistor device 102 to the display device 108 and the storage unit 1062, and to control the automatic control component 105 according to the data of the display device 108 or the storage unit 1062.

[0037] The analog-to-digital converter 1063 converts the resistance value of the second resistor 102 into a digital signal that can be processed by the digital system. The communication unit 1061 receives the digital signal converted by the analog-to-digital converter 1063 in real time and transmits the digital signal to the display device 108 and the storage unit 1062. The display device 108 enables visual monitoring. The storage unit 1062 stores the data from the second resistor 1062.

[0038] Specifically, the resistance value of the second resistor 101 is converted into a digital signal by the analog-to-digital converter 1063 and then sent to the communication unit 1061. The communication unit 1061 sends the received data from the second resistor 102 to the display device 108 for real-time display of the resistance value or the corresponding physical quantity. It also sends the received data from the second resistor 102 to the storage unit 1062 for storage. Simultaneously, the communication unit 1061 generates control commands based on instructions received from the display device 108 or based on data stored in the storage unit 1062, and sends these commands to the automatic control component 105 to adjust the resistance value of the second resistor 102.

[0039] In some alternative embodiments of this utility model, the communication unit includes at least one wired interface or wireless protocol.

[0040] Wired interfaces refer to hardware ports and corresponding communication standards / protocols that enable connection and data transmission via physical lines, such as CAN bus interfaces, LIN bus interfaces, and serial ports. Wireless protocols refer to the communication rules, standards, and technologies followed for wireless data transmission via radio waves, such as Wi-Fi and Bluetooth.

[0041] Figure 3 This is a schematic diagram of another simulated load testing device provided in an embodiment of the present invention. In some optional embodiments of the present invention, such as... Figure 3 As shown, the simulated load testing device 10 also includes a housing 109, which encapsulates a first resistive device 101, a second resistive device 102, a drive shaft 103, a manual control component 104, an automatic control component 105, and a controller 106.

[0042] The housing 109 can encapsulate the first resistor 101, the second resistor 102, the drive shaft 103, the manual control component 104, the automatic control component 105, and the controller 106.

[0043] In some optional embodiments of this utility model, the analog load signal terminal Pin includes at least a first analog load signal terminal Pin1 and a second analog load signal terminal Pin2. The first analog load signal terminal Pin1 is used to connect to an analog resistance signal; the second analog load signal terminal Pin2 is used to connect to an analog voltage signal; wherein, when the first resistor device 101 is connected to the second analog load signal terminal Pin2, a reference voltage is connected to both ends of the first resistor device 101.

[0044] The first analog load signal terminal, Pin 1, can be connected to an analog resistance signal. The analog resistance signal can be a resistance value; for example, in a temperature sensor with an actual negative temperature coefficient (NTC), different resistance values ​​correspond to different temperature values. The second analog load signal terminal, Pin 2, is used to connect to an analog voltage signal. The analog voltage signal can be a voltage value; for example, in a pressure sensor, the analog voltage signal corresponds to the pressure value. When an analog voltage signal is connected, a reference voltage is connected across the first resistor device 101, at which point the first resistor device 101 can act as a voltage divider.

[0045] In some optional embodiments of this utility model, the first resistor device 101 includes a first potentiometer 1011, the second resistor device 102 includes a second potentiometer 1021, the first potentiometer 1011 and the second potentiometer 1021 are coaxially connected through a drive shaft 103, the first potentiometer 1011 is electrically connected to the analog load signal terminal Pin, and the second potentiometer 1021 is electrically connected to the controller 106.

[0046] The first potentiometer 1011 and the second potentiometer 1021 can be variable resistors or voltage dividers. The first potentiometer 1011 and the second potentiometer 1021 can be rotary potentiometers with three terminals. When the first potentiometer 1011 and the second potentiometer 1021 function as variable resistors, only the control terminal and one fixed terminal are used. When rotated, the resistance value between the control terminal and the fixed terminal can vary from near 0Ω to the maximum resistance. When the first potentiometer 1011 and the second potentiometer 1021 function as voltage dividers, all three terminals are used. A reference voltage is applied between the first potentiometer 1011 and the second potentiometer 1021 and the two fixed terminals. The output voltage between the control terminal and one of the fixed terminals changes proportionally to the position of the control terminal, ranging from 0V to the maximum voltage. Both potentiometers need to be calibrated before adjusting their resistance using the manual control component 104 or the automatic control component 105. The rotation of the two potentiometers from their minimum to maximum values ​​can be controlled manually via component 104 or automatically via component 105. Data is collected from the first potentiometer 1011 starting at its initial position and continuing until its final position. Multiple calibration points are selected, and the data from both potentiometers is recorded. The corresponding relationship is stored in the storage unit 1062 of the controller 106. The first potentiometer 1011 and the second potentiometer 1021 are mechanically connected via a drive shaft 102 to ensure absolute synchronization of the rotation angle. The resistance ranges of the first potentiometer 1011 and the second potentiometer 1021 can be the same or different. For example, when the drive shaft rotates 30°, the resistance value of the first potentiometer 1011 changes from 10Ω to 20Ω, and the resistance value of the second potentiometer 1021 simultaneously changes from 10Ω to 20Ω.

[0047] In some alternative embodiments of this invention, the automatic control component includes at least one of a stepper motor or a DC motor.

[0048] Stepper motors can precisely convert electrical pulse signals into angular or linear displacement, rotating step by step by sequentially energizing the coils within the motor. They feature precise position control, simple open-loop control, and high torque at low speeds. DC motors operate using DC power, and their speed and direction can be easily controlled by changing the input voltage or current. Common types include brushed DC motors and brushless DC motors. They are characterized by relatively simple control, fast response, low cost, and a wide speed range. Automatic control components must be equipped with at least one type of motor for performing the action.

[0049] The working principle of this utility model can be found by referring to [reference here]. Figure 3When an analog resistance signal is connected through the first analog load signal terminal Pin1, the analog resistance signal is realized through one of the fixed terminals and the control terminal of the first potentiometer 1011. The first potentiometer 1011 and the second potentiometer 1021 are coaxially connected through the drive shaft 103, enabling synchronous rotation. During rotation, the second potentiometer 1021 can provide feedback on the state of the first potentiometer 1011 and transmit it to the controller 106, which further transmits it to the display device 108. The operator can refer to a table to determine the current temperature data. Simultaneously, the resistance value of the second potentiometer 1021 can be sampled and transmitted to the display device 108 through the manual control component 104 or the automatic control component 105. For example, Table 1 shows the correspondence between temperature and the resistance range of the second potentiometer 1021; when the resistance value of the second potentiometer 1021 is 241.0 KΩ, the temperature is -35℃. When the resistance of the second potentiometer 1021 is 5KΩ, and the temperature is between 40℃ and 45℃, the temperature can be calculated to be 41.7℃ by linear interpolation based on R(t)Normal. The resistance-temperature relationship of a real NTC temperature sensor may be non-linear, but linear interpolation can be used for calculations within a small temperature range.

[0050] When an analog voltage signal is input through the second analog load signal terminal Pin2, a reference voltage is applied to the two fixed terminals of the first potentiometer 1011, and the output voltage signal is adjusted by the control terminal. The first potentiometer 1011 and the second potentiometer 1021 are coaxially connected, enabling synchronous rotation. During rotation, the second potentiometer 1021 can provide feedback on the state of the first potentiometer 1011 and transmit it to the controller 106. Simultaneously, pressure data can be determined based on the data from the display device 108 and the correspondence between the analog voltage signal and the pressure value. For example, Figure 4 The diagram illustrates the correspondence between the voltage value and pressure value of an analog voltage signal. When the voltage value is 1.5V, the pressure is 7.8Bar.

[0051] Table 1. Correspondence between temperature and resistance range of the second potentiometer

[0052]

[0053] Figure 5 This is a schematic diagram of the structure of a simulated load testing system provided in an embodiment of this utility model, as shown below. Figure 5 As shown, the simulated load testing system 20 includes at least two simulated load testing devices 10 as described in any of the above embodiments.

[0054] The simulated load test system 20 may include multiple simulated load test devices 10, and any number can be added according to actual needs. Multiple simulated resistance signals or simulated voltage signals can be superimposed without quantity limit, thereby shortening the test cycle.

[0055] It should be understood that the various forms of the process shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this utility model can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this utility model can be achieved, and this is not limited herein.

[0056] The specific embodiments described above do not constitute a limitation on the scope of protection of this utility model. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A simulated load testing device, characterized in that, include: First resistive device, second resistive device, drive shaft, manual control assembly, automatic control assembly and controller; The first resistor and the second resistor are coaxially connected via the drive shaft. One end of the drive shaft is connected to the manual control component, and the other end is connected to the automatic control component. The drive shaft is used to adjust the first resistor and the second resistor. The first resistor is connected to an analog load signal terminal, and the second resistor is electrically connected to the controller. The controller is also electrically connected to the automatic control component. The controller is used to control the automatic control component to adjust the first resistor and the second resistor, and to detect the resistance of the second resistor.

2. The simulated load testing device according to claim 1, characterized in that, A damping connector is provided between the second resistive device and the automatic control component.

3. The simulated load testing device according to claim 1, characterized in that, It also includes a display device electrically connected to the controller, the display device being used to display analog load data.

4. The simulated load testing device according to claim 1, characterized in that, The controller includes at least a communication unit, a storage unit, and an analog-to-digital converter (ADC). The ADC is connected to the second resistor and the communication unit. The communication unit is electrically connected to the automatic control component and the storage unit. The ADC is used to convert the resistance value of the second resistor into a digital signal. The storage unit is used to store the data of the second resistor. The communication unit is used to transmit the data of the second resistor to a display device and the storage unit, and to control the automatic control component based on the data from the display device or the storage unit.

5. The simulated load testing device according to claim 4, characterized in that, The communication unit includes at least one wired interface or wireless protocol.

6. The simulated load testing device according to claim 1, characterized in that, It also includes a housing that encapsulates a first resistive device, a second resistive device, a drive shaft, a manual control component, an automatic control component, and a controller.

7. The simulated load testing device according to claim 1, characterized in that, The analog load signal terminal includes at least a first analog load signal terminal and a second analog load signal terminal. The first analog load signal terminal is used to connect to an analog resistance signal; the second analog load signal terminal is used to connect to an analog voltage signal; wherein, when the first resistor is connected to the second analog load signal terminal, a reference voltage is connected to both ends of the first resistor.

8. The simulated load testing device according to claim 1, characterized in that, The first resistive device includes a first potentiometer, and the second resistive device includes a second potentiometer. The first potentiometer and the second potentiometer are coaxially connected via the drive shaft. The first potentiometer is electrically connected to the analog load signal terminal, and the second potentiometer is electrically connected to the controller.

9. The simulated load testing device according to claim 1, characterized in that, The automatic control component includes at least one of a stepper motor or a DC motor.

10. A simulated load testing system, characterized in that, It includes at least two simulated load testing devices as described in any one of claims 1-9.

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