A programmable sensor module automatic testing method and device

Abstract

The present invention provides a method and device for automatically testing a programmable sensor module, which includes a power module, a CAN module, a FLASH module, an MCU module, a serial port conversion module, a programmable digitally controlled potentiometer module, and an indicator light module arranged on a circuit board. The method is simple to operate and highly efficient. When in use, all programmable sensor interfaces can be tested by simply connecting the programmable sensor module interface and the CAN interface. The software performs the test automatically, which not only accurately tests but also greatly saves test time. Secondly, the curve can be freely set. Programmable sensor modules with different sensor characteristic curves can be programmed in the FLASH module. Thirdly, the method has good protection. During the automated detection process, no human intervention is required, which can prevent damage to the generator set controller caused by misoperation by the tester. At the same time, the method is small in size and easy to carry, which can provide convenience for the tester. At the same time, it has multiple sensor interfaces and can be tested simultaneously.

Description

Technical Field

[0001] The present invention relates to the field of programmable sensors, and in particular to an automatic testing method and device for a programmable sensor module. Background Art

[0002] A diesel generator set is a mechatronic device consisting of three major components: a diesel engine, an AC generator, and a generator set electrical control system. It includes a front-end fuel supply system and a back-end power supply system, forming a complete energy power supply management system.

[0003] The generator set controller is the core component of the generator set's electrical control system. It collects the generator set's operating parameters to achieve various control effects on the diesel generator set. It includes functions such as power generation monitoring, mains power monitoring, and automatic switching control. It is an integrated power generation and mains power control and monitoring system.

[0004] The programmable sensor module is an information acquisition module in the generator set controller. The module usually has five detection interfaces, which detect temperature sensors, oil pressure sensors, liquid level sensors, and two sensors whose parameters and sensor types can be freely set through programming. The name of the programmable sensor module comes from this.

[0005] The programmable sensor module collects resistance data from various sensors on the diesel generator set and, using the sensor type's curve, determines the generator set's internal temperature, operating oil pressure, fuel storage level, and other parameters. This information then determines the generator set's operating parameters and implements protective functions. In practical applications, diesel generator set operating parameters are crucial. The generator set controller uses these parameters to determine whether the generator set is operating normally. If the operating parameters deviate significantly from the normal operating parameters, the generator set controller will force the generator set to shut down and issue an alarm. During the development process, programmable sensor modules require testing to verify the accuracy of their data acquisition capabilities. This ensures that the generator set can be shut down promptly if operating conditions deteriorate, preventing potentially dangerous situations. Therefore, the accuracy of the programmable sensor module's detection is crucial.

[0006] In existing testing methods, workers use sensors to test the functionality of programmable sensor modules to verify their functionality. Because each sensor type can only provide one set of data, programmable sensor modules with different detection ranges require replacement sensors. Programmable sensor modules with numerous interfaces require multiple tests. This not only increases worker workload, but also reduces testing efficiency and increases work time. Summary of the Invention

[0007] The purpose of the present invention is to provide an automated testing method and device for a programmable sensor module, so as to solve the problem that when testing the functions of a programmable sensor module, one type of sensor can only provide one set of data. When a programmable sensor module has many interfaces, multiple tests are required, which not only increases the workload of the staff, but also reduces the test efficiency and increases the working time.

[0008] In order to achieve the above object, the present invention adopts the following technical solutions:

[0009] A programmable sensor module automatic testing device includes a power supply module, a CAN module, a FLASH module, an MCU module, a serial port conversion module, a programmable digitally controlled potentiometer module and an indicator light module arranged on a circuit board;

[0010] The power supply module is used to supply power to the CAN module, FLASH module, MCU module, serial port conversion module, programmable digital control potentiometer module and indicator light module;

[0011] The CAN module is connected to the MCU module and the generator set controller via a CAN signal. The CAN module is used to receive a parameter signal sent by the generator set controller and call the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module;

[0012] The output end of the FLASH module is connected to the programmable digital control potentiometer module through the serial port conversion module. The FLASH module is also connected to the MCU module for communication. The FLASH module is used to set the corresponding parameter value according to the characteristic curve of different sensors.

[0013] The programmable digitally controlled potentiometer module includes a plurality of digitally controlled potentiometers, and the plurality of digitally controlled potentiometers are connected to the programmable sensor module interface of the generator set controller via a programmable sensor module interface;

[0014] The control input end of the indicator light module is connected to the output end of the MCU module.

[0015] The indicator light module is composed of a yellow LED lamp and a red LED lamp, which are respectively used to emit yellow light and red light under the control of the MCU module.

[0016] It also includes a USB module, which is communicatively connected to the FLASH module and is used to write data to the FLASH module through an external input device.

[0017] The power module is also provided with an external charging interface.

[0018] A programmable sensor module automated testing method comprises the following steps:

[0019] Step 1: Setting corresponding parameter values ​​in the FLASH module according to the characteristic curves of different sensors, wherein the characteristic curves of different sensors are the actual characteristic curves of each sensor working in the programmable sensor module of the diesel generator, and the parameter values ​​include the seven random resistance values ​​recorded on the characteristic curve of each sensor and their corresponding parameter values;

[0020] Step 2: The generator set controller is powered on. The generator set controller sends parameter signals of different interfaces of the programmable sensor module through CAN signals. The CAN module receives the parameter signals sent by the generator set controller and sends them to the MCU module.

[0021] Step 3: The MCU module calls the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module to simulate the resistance values ​​corresponding to the 7 different parameter values ​​of the corresponding sensor;

[0022] Step 4: The MCU module compares the seven different parameter values ​​of the corresponding sensor with the corresponding parameter values ​​in the FLASH module. If the two sets of data are the same, the MCU module controls the indicator light module to emit a yellow light signal; if the two sets of data are different, the MCU module controls the indicator light module to emit a red light signal;

[0023] Step 5: Repeat steps 1 to 4 until the MCU module completes the test of all programmable sensor module interfaces.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] First, the operation is simple and efficient. When using it, you only need to connect the programmable sensor module interface and the CAN interface to test all programmable sensor interfaces. The software will test automatically, which is not only accurate but also greatly saves test time.

[0026] Secondly, the curve can be set freely; programmable sensor modules with different sensor characteristic curves can be programmed in the FLASH module;

[0027] Secondly, it has good protection. During the automated testing process, no human intervention is required, which can prevent damage to the generator controller caused by tester misoperation.

[0028] At the same time, it is small in size and easy to carry, which provides convenience for testers; it also has a multi-channel sensor interface, which can be tested simultaneously, avoiding the trouble of rewiring every time a sensor is replaced in traditional testing methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0030] Figure 1 It is a structural schematic diagram of the present invention;

[0031] Figure 2 Flow chart of the method of the present invention. DETAILED DESCRIPTION

[0032] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0033] like Figure 1 As shown: A programmable sensor module automatic testing device according to the present invention includes a power module, a CAN module, a FLASH module, an MCU module, a serial port conversion module, a programmable digitally controlled potentiometer module and an indicator light module arranged on a circuit board;

[0034] The power supply module is used to supply power to the CAN module, FLASH module, MCU module, serial port conversion module, programmable digital control potentiometer module and indicator light module;

[0035] The CAN module is connected to the MCU module and the generator set controller via a CAN signal. The CAN module is used to receive a parameter signal sent by the generator set controller and call the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module;

[0036] The output end of the FLASH module is connected to the programmable digital control potentiometer module through the serial port conversion module. The FLASH module is also connected to the MCU module for communication. The FLASH module is used to set the corresponding parameter value according to the characteristic curve of different sensors.

[0037] The programmable digitally controlled potentiometer module includes a plurality of digitally controlled potentiometers, and the plurality of digitally controlled potentiometers are connected to the programmable sensor module interface of the generator set controller via a programmable sensor module interface;

[0038] The control input end of the indicator light module is connected to the output end of the MCU module.

[0039] Preferably, the indicator light module is composed of a yellow LED lamp and a red LED lamp, which are used to emit yellow light and red light respectively under the control of the MCU module.

[0040] Preferably, it further comprises a USB module, which is communicatively connected to the FLASH module and is used to write data to the FLASH module via an external input device, so that the device can be used in different test environments.

[0041] Preferably, the power module is also provided with an external charging interface to facilitate charging the power module so as to achieve repeated use and long-term battery life.

[0042] The working principle of the programmable sensor module automatic testing device described in the present invention is:

[0043] Based on the number of programmable sensor module interfaces on the generator set controller, a corresponding number of digital potentiometers are selected, with each digital potentiometer corresponding to one programmable sensor module interface. The circuit board is connected to the generator set controller using the CAN interface. When the generator set controller is powered on, the parameter signal is sent from the generator set controller to the MCU module via the CAN signal. The MCU module then calls the corresponding parameter value in the FLASH module based on the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module. The MCU module compares the different parameter values ​​of the corresponding sensors with the corresponding parameter values ​​in the FLASH module. If the two sets of data are the same, the MCU module controls the indicator light module to emit a yellow light signal; if the two sets of data are different, the MCU module controls the indicator light module to emit a red light signal until the MCU module completes the testing of all programmable sensor module interfaces.

[0044] like Figure 2 A programmable sensor module automated testing method includes the following steps:

[0045] Step 1: Setting corresponding parameter values ​​in the FLASH module according to the characteristic curves of different sensors, wherein the characteristic curves of different sensors are the actual characteristic curves of each sensor working in the programmable sensor module of the diesel generator, and the parameter values ​​include the seven random resistance values ​​recorded on the characteristic curve of each sensor and their corresponding parameter values;

[0046] Step 2: The generator set controller is powered on. The generator set controller sends parameter signals of different interfaces of the programmable sensor module through CAN signals. The CAN module receives the parameter signals sent by the generator set controller and sends them to the MCU module.

[0047] Step 3: The MCU module calls the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module to simulate the resistance values ​​corresponding to the 7 different parameter values ​​of the corresponding sensor;

[0048] Step 4: The MCU module compares the seven different parameter values ​​of the corresponding sensor with the corresponding parameter values ​​in the FLASH module. If the two sets of data are the same, the MCU module controls the indicator light module to emit a yellow light signal; if the two sets of data are different, the MCU module controls the indicator light module to emit a red light signal;

[0049] Step 5: Repeat steps 1 to 4 until the MCU module completes the test of all programmable sensor module interfaces.

[0050] Example:

[0051] In order to facilitate those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below with specific embodiments:

[0052] In this embodiment, it is necessary to consider the maximum detection range of different programmable sensor modules. Since a digital potentiometer with a smaller resistance range has higher precision, it is necessary to use a digital potentiometer with a detection range close to the programmable sensor module's to improve test accuracy. Furthermore, an appropriate number of digital potentiometers can be selected based on the maximum number of interfaces on the programmable sensor module. This embodiment uses a three-channel programmable sensor module as an example for detailed description.

[0053] The characteristic curves of commonly used temperature sensors are as follows:

[0054] 0Ω 32Ω 64Ω 96Ω 128Ω 192Ω 256Ω 480Ω 163° 110° 85° 73° 64° 53° 44° 35°

[0055] Table 1 Temperature sensor characteristic curve Common oil pressure sensor characteristic curves are as follows:

[0056] 0Ω 16Ω 32Ω 48Ω 64Ω 96Ω 128Ω 176Ω 0kp 0kp 179kp 241kp 338kp 503kp 703kp 1034kp

[0057] Table 2 Oil pressure sensor characteristic curve Common liquid level sensor characteristic curves are as follows:

[0058] 4Ω 29Ω 53Ω 71Ω 107Ω 127Ω 166Ω 181Ω 0％ 14％ 28％ 42％ 57％ 71％ 85％ 100％

[0059] Table 3 Liquid level sensor characteristic curve

[0060] Step 1: According to the characteristic curves of the three sensors, write the characteristic curves of the three common sensors into the FLASH module. Each curve records 7 resistance values ​​and their corresponding parameter values.

[0061] Step 2: The generator set controller is powered on. The generator set controller sends parameter signals of different interfaces of the programmable sensor module through CAN signals. The CAN module receives the parameter signals sent by the generator set controller and sends them to the MCU module.

[0062] Step 3: The MCU module calls the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module to simulate the resistance values ​​corresponding to the seven different parameter values ​​of the corresponding sensor. For example, as shown in Table 1, the MCU controls the digital potentiometer to simulate the different resistance values ​​of the seven parameter nodes of the temperature sensor. For example, if the first temperature node is 0Ω, the MCU controls the digital potentiometer to adjust it to 0Ω, and the corresponding temperature should be 163°.

[0063] Step 4: The MCU module compares the seven different parameter values ​​of the corresponding sensor with the corresponding parameter values ​​in the FLASH module. If the two sets of data are the same, the MCU module controls the indicator light module to emit a yellow light signal; if the two sets of data are different, the MCU module controls the indicator light module to emit a red light signal;

[0064] Step 5: Repeat steps 1 to 4 until the MCU module completes the test of all programmable sensor module interfaces.

[0065] The beneficial effects of the present invention are:

[0066] First, the operation is simple and efficient. When using it, you only need to connect the programmable sensor module interface and the CAN interface to test all programmable sensor interfaces. The software will test automatically, which is not only accurate but also greatly saves test time.

[0067] Secondly, the curve can be set freely; programmable sensor modules with different sensor characteristic curves can be programmed in the FLASH module;

[0068] Secondly, it has good protection. During the automated testing process, no human intervention is required, which can prevent damage to the generator controller caused by tester misoperation.

[0069] At the same time, it is small in size and easy to carry, which provides convenience for testers; it also has a multi-channel sensor interface, which can be tested simultaneously, avoiding the trouble of rewiring every time a sensor is replaced in traditional testing methods.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A programmable sensor module automated testing device, characterized in that: It includes a power supply module, a CAN module, a FLASH module, an MCU module, a serial port conversion module, a programmable digital control potentiometer module and an indicator light module arranged on a circuit board; The power supply module is used to supply power to the CAN module, FLASH module, MCU module, serial port conversion module, programmable digital control potentiometer module and indicator light module; The CAN module is connected to the MCU module and the generator set controller via a CAN signal. The CAN module is used to receive a parameter signal sent by the generator set controller and call the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module; The output end of the FLASH module is connected to the programmable digital control potentiometer module through the serial port conversion module. The FLASH module is also connected to the MCU module for communication. The FLASH module is used to set the corresponding parameter value according to the characteristic curve of different sensors. The programmable digitally controlled potentiometer module includes a plurality of digitally controlled potentiometers, and the plurality of digitally controlled potentiometers are connected to the programmable sensor module interface of the generator set controller via a programmable sensor module interface; The control input end of the indicator light module is connected to the output end of the MCU module; The indicator light module is composed of a yellow LED light and a red LED light, which are used to emit yellow light and red light respectively under the control of the MCU module; It also includes a USB module, which is communicatively connected to the FLASH module and is used to write data to the FLASH module through an external input device.

2. The programmable sensor module automatic testing device according to claim 1, characterized in that: The power module is also provided with an external charging interface.

3. A programmable sensor module automatic testing method performed by a programmable sensor module automatic testing device according to claim 1, characterized in that: The following steps are involved: Step 1: Setting corresponding parameter values ​​in the FLASH module according to the characteristic curves of different sensors, wherein the characteristic curves of different sensors are the actual characteristic curves of each sensor working in the programmable sensor module of the diesel generator, and the parameter values ​​include the seven random resistance values ​​recorded on the characteristic curve of each sensor and their corresponding parameter values; Step 2: The genset controller is powered on. The genset controller sends parameter signals of different interfaces of the programmable sensor module through CAN signals. The CAN module receives the parameter signals sent by the genset controller and sends them to the MCU module. Step 3: The MCU module calls the corresponding parameter value in the FLASH module according to the parameter signal to control the resistance value of the corresponding digital potentiometer in the programmable digital potentiometer module to simulate the resistance values ​​corresponding to the 7 different parameter values ​​of the corresponding sensor; Step 4: The MCU module compares the seven different parameter values ​​of the corresponding sensor with the corresponding parameter values ​​in the FLASH module. If the two sets of data are the same, the MCU module controls the indicator light module to emit a yellow light signal; if the two sets of data are different, the MCU module controls the indicator light module to emit a red light signal; Step 5: Repeat steps 1 to 4 until the MCU module completes the test of all programmable sensor module interfaces.

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