A control system input and output module function testing device and testing method

Abstract

The present invention discloses a control system input and output module function test device, including a control cabinet, a network switch, a high-precision multimeter, a channel switch, and a monitoring computer. The control cabinet is connected to the network switch in a two-way communication manner, the network switch is connected to the monitoring computer in a two-way communication manner, the output end of the control cabinet is connected to the input end of the channel switch in a communication manner, the output end of the channel switch is connected to the input end of the high-precision multimeter in a communication manner, and the control cabinet is connected to the high-precision multimeter in a two-way communication manner; the network switch is used for the communication connection between the control cabinet and the monitoring computer, and the high-precision multimeter is used to measure the output signal in the control cabinet and communicate with the control cabinet. The present invention also proposes a control system input and output module function test method, which solves the shortcomings of the existing input and output module function test system and method.

Description

Technical Field

[0001] The invention relates to a control system input and output module function test device and test method, belonging to the technical field of control system online testing. Background Art

[0002] Automatic control systems are widely used in various fields of production and life. The safety and reliability of their operation directly affect the safety of facilities and equipment as well as people's living standards. Input and output modules are the most used components in the control system. They are the connection point between the controller and the field equipment. They collect equipment data and output control instructions, and directly control the field equipment. They play a very important role. The quality of the module ultimately needs to be guaranteed through functional testing.

[0003] At present, many tests of input and output modules of control systems are done manually, which is labor-intensive and cannot guarantee the accuracy and coverage of the tests. There are also some automatic test systems, but the investment cost is very high. The application of automatic control systems includes monitoring systems. The system itself can realize rich control, data recording and display functions. It is an economical and efficient solution to design functional test systems and methods mainly by using its own functions and cooperating with some high-precision meters and switching devices. Summary of the invention

[0004] The present invention aims at the deficiencies of the existing control system input and output module function testing systems and methods, and provides a control system input and output module function testing device, which, in conjunction with a specially designed testing method, implements control system input and output module function testing, improves the test automation level, coverage and accuracy, reduces the labor intensity of testers, and saves investment in automatic testing systems.

[0005] The present invention adopts the following technical scheme: a control system input and output module function test device, characterized in that it includes a control cabinet, a network switch, a high-precision multimeter, a channel switcher, and a monitoring computer.

[0006] The control cabinet is connected to the network switch in a two-way communication manner.

[0007] The network switch is connected to the monitoring computer for bidirectional communication.

[0008] The output end of the control cabinet is communicatively connected with the input end of the channel switch,

[0009] The output end of the channel switch is communicatively connected to the input end of the high-precision multimeter.

[0010] The control cabinet is connected to the high-precision multimeter in a two-way communication manner;

[0011] The network switch is used for communication connection between the control cabinet and the monitoring computer.

[0012] The high-precision multimeter is used to measure the output signal in the control cabinet and to establish communication connection with the control cabinet.

[0013] As a preferred embodiment, the control cabinet includes a power supply module, a controller module, a module to be tested, and a communication module. The power supply module is electrically connected to the controller module, the module to be tested, and the communication module, respectively. The controller module is connected to the module to be tested and the communication module, respectively. The communication module is communicatively connected to the high-precision multimeter to read the measurement value from the high-precision multimeter. The module to be tested includes an analog input module, an analog output module, a switch input module, and a switch output module.

[0014] As a preferred embodiment, the control cabinet also includes a reference module, which includes a reference analog input module, a reference analog output module, a reference switch input module, and a reference switch output module. The reference module is used to test a single type of module to be tested.

[0015] As a preferred embodiment, when testing the analog input module of the module to be tested, the reference analog output module of the reference module or the analog output module of the module to be tested is communicatively connected to the high-precision multimeter, and the reference analog output module of the reference module generates a test signal or the analog output module of the module to be tested generates a test signal which is transmitted to the high-precision multimeter connected in series or in parallel in the loop for measurement.

[0016] As a preferred embodiment, when testing the analog output module of the module to be tested, the analog input module of the reference module or the analog input module of the module to be tested is communicatively connected with the high-precision multimeter, and the reference analog input module of the reference module receives a test signal or the analog input module of the module to be tested receives a test signal and transmits it to the high-precision multimeter connected in series or in parallel in the loop for measurement.

[0017] As a preferred embodiment, when testing the switch quantity input module of the module to be tested, the reference switch quantity output module of the reference module or the switch quantity output module of the module to be tested is communicatively connected to the high-precision multimeter, and the reference switch quantity output module of the reference module generates a test signal or the switch quantity output module of the module to be tested generates a test signal which is transmitted to the high-precision multimeter connected in series or in parallel in the loop for measurement.

[0018] As a preferred embodiment, when testing the switch output module of the module to be tested, the reference switch input module of the reference module or the switch input module of the module to be tested is communicatively connected with the high-precision multimeter, and the reference switch input module of the reference module receives the test signal or the switch input module of the module to be tested receives the test signal and transmits it to the high-precision multimeter connected in series or in parallel in the loop for measurement.

[0019] As a preferred embodiment, the monitoring computer is used for controlling, monitoring and recording data of the control cabinet.

[0020] As a preferred embodiment, the channel switch is used to switch the test channels of a module to be tested having multiple channels.

[0021] The present invention also provides a control system input and output module function testing method, which is characterized by comprising the following steps:

[0022] Step SS1: Start by connecting the output module, channel switch, high-precision multimeter, input module and communication module according to the type of module to be tested, and complete the hardware power-on;

[0023] Step SS2: Select the test case in the monitoring computer and download it to the controller module;

[0024] Step SS3: The controller module converts the test case, issues a control instruction to the output module, the output module outputs a test signal, and the input module receives the test signal to form a loop. If there is a high-precision multimeter in the loop, the controller collects the accurate value measured by it;

[0025] Step SS4: Delay. If there is a channel switch in the loop, the channel switch is controlled manually or the controller module issues a command to control the channel switch, and the process returns to step SS3 to test the next channel. If there is no channel switch in the loop, the process returns directly to step SS3 to test the next channel.

[0026] Step SS5: Return to step SS4 until all channel tests are completed;

[0027] Step SS6: The monitoring computer records and analyzes the data collected from the controller module in the above process and generates a test report using its own reporting function;

[0028] Step SS7: The test ends.

[0029] The beneficial effects achieved by the present invention are:

[0030] First, the present invention realizes automatic testing of control system input and output modules, improves the degree of test automation, coverage and correctness, and reduces the labor intensity of testers;

[0031] The present invention mainly utilizes the functions of the automatic control system and the supporting monitoring system, cooperates with some high-precision meters and switching devices, realizes automatic mutual testing, and reduces the investment in the automatic testing system;

[0032] Third, the test method of the present invention is flexible, and one module can be tested individually or multiple modules can be tested simultaneously, and the test process can be paused, continued and terminated as needed. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the overall circuit structure connection of a first embodiment of a control system input and output module function test device of the present invention.

[0034] Figure 2 It is a schematic diagram of the overall circuit structure connection of the second embodiment of the present invention for simultaneously testing four input and output modules of a control system input and output module function testing device.

[0035] Figure 3 The present invention is a flow chart of a method for simultaneously testing four input and output modules of a control system input and output module function testing method. DETAILED DESCRIPTION

[0036] The following will be combined with the drawings and embodiments in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] Embodiment: The analog input, analog output, switch input and switch output modules of a control system are tested simultaneously.

[0038] like Figure 1As shown, the present invention provides a control system input and output module function test system, including a control cabinet, a network switch, a high-precision multimeter, a channel switch and a monitoring computer, wherein the control cabinet includes a power module V1, a controller module K1, a module to be tested T1, a reference module B1 and a communication module M1, the power module provides a DC power supply for all modules such as the controller module; the controller module collects input module signals and outputs control instructions to the output module after calculation, and also controls the dedicated communication module and communicates with the monitoring computer; the modules to be tested include analog input modules, analog output modules, switch input modules and switch output modules; the reference module The modules are optional and are qualified modules that have passed the test, including reference analog input modules, reference analog output modules, reference switch input modules and reference switch output modules, and are only used when testing a single type of module to be tested; the communication module is used to communicate with the high-precision multimeter via serial port or Ethernet to read the measured values; the network switch S1 is used to connect the control cabinet and the monitoring computer; the high-precision multimeter T1 is used to measure the output signal of the module to be tested and communicate with the communication module; the channel switch C1 is used to switch the test channels of the module to be tested containing multiple channels; the monitoring computer S2 is used to control the control cabinet, monitor and record data.

[0039] Preferably, the present invention provides a multi-purpose functional testing system that can test a single type of module to be tested at one time, or can test all types of modules to be tested at one time, and mainly uses the software and hardware resources of the control system itself.

[0040] Preferably, when testing an analog input module, the present invention can use a reference analog output module to generate a test signal (individual test), or can use an analog output module to be tested to generate a test signal (mutual test). The exact value of the test signal is measured by a high-precision multimeter connected in series or in parallel in the loop, and the measurement of multiple channels is completed by a channel switch.

[0041] Preferably, when testing the analog output module, the reference analog input module can be used to receive the test signal (individual test), or the analog input module to be tested can be used to receive the test signal (mutual test). The accurate value of the test signal is measured by a high-precision multimeter connected in series or parallel in the loop, and the measurement of multiple channels is completed by a channel switch.

[0042] Preferably, when testing the switch quantity input module, the reference switch quantity output module can be used to generate the test signal (individual test), or the switch quantity output module to be tested can be used to generate the test signal (mutual test).

[0043] Preferably, when testing the switch quantity output module, the reference switch quantity input module may be used to receive the test signal (individual test), or the switch quantity input module to be tested may be used to receive the test signal (mutual test).

[0044] Preferably, the switching of the channel switch can be operated manually, or can be controlled by the switch output module to be tested or the reference switch output module.

[0045] Preferably, the monitoring computer uses its own configuration function to download the test case to the controller module, and the controller module controls the output module to generate test signals and control signals, obtain accurate readings of the high-precision multimeter, and transmit them back to the monitoring computer to complete data collection, recording and generate test reports.

[0046] like Figure 2 As shown, this embodiment is a configuration method for automatically testing all types of modules to be tested at one time, including a control cabinet, a network switch, a high-precision multimeter, a channel switcher and a monitoring computer.

[0047] In this embodiment, the control cabinet includes a power supply module V1, a controller module K1, a switch output module T1_DO of a module to be tested, an analog output module T1_AO of a module to be tested, an analog input module T1_AI of a module to be tested, a switch input module T1_DI of a module to be tested and a communication module M1. The power supply module V1 provides a DC power supply for all modules including the controller module K1; the controller module K1 collects input module signals and outputs control instructions to the output module after calculation, and also controls the dedicated communication module M1 and communicates with the monitoring computer S2; this embodiment does not include an optional reference module; the communication module M1 is used to communicate with the high-precision multimeter T1 through a serial port or Ethernet to read the measured value; the network switch Machine S1 connects the controller module K1 and the monitoring computer S2 in the control cabinet; the high-precision multimeter T1 is used to measure the output signal of the module to be tested and communicate with the communication module M1; the channel switcher C1 is used to switch the test channels of the analog input and analog output modules to be tested containing multiple channels. In this embodiment, the output signal of the analog output module to be tested is measured by the high-precision multimeter T1 connected in series in the loop through the channel switcher C1, and finally sent to the analog input module to be tested to form a loop. The switching of the channel switcher C1 is controlled by the switch output module to be tested, and the control signal is simultaneously sent to the switch input module to be tested; the monitoring computer S2 is used to control the control cabinet, monitor data, record and generate test reports.

[0048] Figure 3 The flowchart of the method for testing the function of the input and output modules of a control system of the present invention is shown; it includes the following 7 steps:

[0049] Step SS1: Start by connecting the output module, channel switch C1, high-precision multimeter T1, input module and communication module M1 according to the type of module to be tested. Figure 2 As shown, and complete the hardware power-on;

[0050] Step SS2: Select a test case in the monitoring computer S2, including the configuration of the analog input module, the analog output module, the switch input module, the switch output module and the communication module M1, and download it to the controller module K1;

[0051] Step SS3: The controller module K1 converts the test case and issues a control instruction to the output module. A channel of the analog output module outputs a test signal (0mA, 4mA, 8mA, 12mA, 16mA, 20mA, 24mA, etc.). The input module receives the test signal to form a loop. There is a high-precision multimeter T1 in the loop. The controller module K1 collects the accurate value of its measurement through the communication module M1. The switch output module and the switch input module are interconnected for testing.

[0052] Step SS4: Delay 10 seconds, the switch output module output controls the channel switch C1 to select the next channel, and return to S3 to test this channel;

[0053] Step SS5: Return to step S4 until all channel tests are completed;

[0054] Step SS6: The monitoring computer S2 records and analyzes the data collected from the controller module K1 in the above process and generates a test report using its own reporting function.

[0055] Step SS7: The test ends.

[0056] During the test, the test progress can be monitored by a monitoring computer, and the test can be paused, continued or terminated as needed.

[0057] It should be noted that the hardware entity structures of the control cabinet, controller module, communication module, channel switch, monitoring computer, and network switch involved in the present invention are existing. The core of the present invention is to design the connection relationship between the hardware of the control system and the test logic sequence, analyze the deficiencies of the existing test systems and test methods based on the overall requirements for the functional test of the control system input and output modules, utilize the rich control, data recording and display functions of the automatic control system and the supporting monitoring system, mainly utilize their own functions, cooperate with some high-precision meters and channel switches, solve the deficiencies of the existing control system input and output module function test systems and methods, provide a control system input and output module function test device, cooperate with a specially designed test method, realize the control system input and output module function test, improve the test automation level, coverage and accuracy, reduce the labor intensity of testers, and save the investment in automatic test systems.

[0058] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A control system input and output module function test device, characterized in that: Including control cabinet, network switch, high-precision multimeter, channel switcher, monitoring computer, The control cabinet is connected to the network switch in a two-way communication manner. The network switch is connected to the monitoring computer for bidirectional communication. The output end of the control cabinet is communicatively connected with the input end of the channel switch, The output end of the channel switch is communicatively connected to the input end of the high-precision multimeter. The control cabinet is connected to the high-precision multimeter in a two-way communication manner; The network switch is used for communication connection between the control cabinet and the monitoring computer. The high-precision multimeter is used to measure the output signal in the control cabinet and to establish communication connection with the control cabinet; The control cabinet includes a power supply module, a controller module, a module to be tested, and a communication module. The power supply module is electrically connected to the controller module, the module to be tested, and the communication module respectively. The controller module is connected to the module to be tested and the communication module respectively. The communication module is connected to the high-precision multimeter for communication, and reads the measured value from the high-precision multimeter. The modules to be tested include an analog quantity input module, an analog quantity output module, a switch quantity input module, and a switch quantity output module; The control cabinet also includes a reference module, The reference module includes a reference analog quantity input module, a reference analog quantity output module, a reference switch quantity input module, and a reference switch quantity output module. The reference module is used when testing a single type of module to be tested; When testing the analog quantity input module of the module to be tested, the reference analog quantity output module of the reference module or the analog quantity output module of the module to be tested is connected to the high-precision multimeter for communication, and the reference analog quantity output module of the reference module generates a test signal or the analog quantity output module of the module to be tested generates a test signal which is transmitted to the high-precision multimeter connected in series or in parallel in the loop for measurement; When testing the analog output module of the module to be tested, the analog input module of the reference module or the analog input module of the module to be tested is connected to the high-precision multimeter for communication, and the reference analog input module of the reference module receives a test signal or the analog input module of the module to be tested receives a test signal and transmits it to the high-precision multimeter in series or in parallel with the loop for measurement; When testing the switch quantity input module of the module to be tested, the reference switch quantity output module of the reference module or the switch quantity output module of the module to be tested is connected to the high-precision multimeter for communication, and the reference switch quantity output module of the reference module generates a test signal or the switch quantity output module of the module to be tested generates a test signal and transmits it to the high-precision multimeter connected in series or in parallel in the loop for measurement; When testing the switch output module of the module to be tested, the reference switch input module of the reference module or the switch input module of the module to be tested is connected to the high-precision multimeter for communication, and the reference switch input module of the reference module receives a test signal or the switch input module of the module to be tested receives a test signal and transmits it to the high-precision multimeter in series or in parallel with the loop for measurement; The monitoring computer is used for controlling, monitoring and recording data of the control cabinet; The channel switch is used to switch the test channels of a module to be tested that has multiple channels.

2. A test method based on the control system input and output module function test device according to claim 1, characterized in that: The specific steps include: Step SS1: Start by connecting the output module, channel switch, high-precision multimeter, input module and communication module according to the type of module to be tested, and complete the hardware power-on; Step SS2: Select the test case in the monitoring computer and download it to the controller module; Step SS3: The controller module converts the test case, issues a control instruction to the output module, a channel of the analog output module outputs a test signal, and the input module receives the test signal to form a loop. If there is a high-precision multimeter in the loop, the controller module collects the accurate value of its measurement through the communication module; the switch output module and the switch input module are interconnected and tested; Step SS4: Delay 10 seconds. If there is a channel switch in the loop, the channel switch is manually controlled or the controller module issues a command to control the channel switch, and returns to step SS3 to test the next channel. If there is no channel switch in the loop, it directly returns to step SS3 to test the next channel. Step SS5: Return to step SS4 until all channel tests are completed; Step SS6: The monitoring computer records and analyzes the data collected from the controller module in the above process and generates a test report using its own reporting function; Step SS7: Test ends; During the test, the test progress can be monitored by a monitoring computer, and the test can be paused, continued or terminated as needed.

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