A Flexible Automated Test System for Avionics Batch Production Testing

Abstract

The present invention discloses a flexible automated test system for avionics mass production testing, which includes a server side and several test stations. The server side is deployed with a first remote management module, and the test stations are deployed with a main control module, a general simulation module, and a general interface module. The first remote management module automatically issues the test engine and test cases of the product under test to the test stations according to the product under test identified by the characteristics of the product under test provided by the main control module on each test station, and defines the signals on the test stations. The main control module provides services such as signal definition, test engine, test management, access identification, etc. The general simulation module provides slots and driver adaptation for the simulation board cards, and provides a keyword-based test interface for the main control module. The general interface module is used to connect the product under test, forward simulation test data between the main control module and the product under test, and support resource expansion at the same time. The present invention improves the flexibility of the test system and can be extended to be compatible with the testing of more newly developed products.

Description

Technical Field

[0001] The present invention belongs to the field of avionics product testing, and relates to a flexible automated testing system for avionics mass production testing. Background Art

[0002] Avionics testing systems usually implement the function and performance testing of avionics products based on key technologies such as signal simulation, virtual instruments, and automated testing engines. Since testing is the most important means of quality control, avionics testing systems are the most important industrial equipment to ensure the high-quality delivery of weaponry.

[0003] The development of avionics testing systems has closely followed the development of measuring instruments, going through the eras of analog testing systems, digital testing systems, virtualized instrument testing systems, and distributed testing systems. The virtualized instrument testing system is the basis of modern testing systems. The testing system constructs the testing hardware through bus modular testing instruments such as PXI / VXI, and realizes complex simulation and automated testing through software. The system architecture and software functions are gradually converging. Thanks to the emergence of standardized testing instruments, the upgrade and iteration cost of the testing system has gradually decreased, the function expansion is more convenient, and the generalization degree has been greatly improved. Excellent general testing systems and platforms such as TestStand, ATEC-6, and EITS Global have emerged in the international market. With the increasing complexity of airborne system functions and the increasing cross-linking between subsystems, distributed testing systems have also gradually developed. Distributed testing eliminates the space limitation of large system testing and realizes the centralized control of distributed resources through the distributed deployment of testing resources and the networked access to the upper computer control system.

[0004] Although the current avionics testing system has a certain degree of generalization and automation, it lacks targeted design for the scenario of automated production testing of avionics products with the characteristics of small batches and multiple varieties, resulting in difficult improvement of production efficiency. Specifically, it is reflected in:

[0005] 1. The flexibility of the testing system is insufficient. When the existing simulation resources cannot meet the testing of new products, it is impossible to quickly expand the resources.

[0006] 2. The testing system cannot automatically match the product under test and execute the testing task. Key testing processes such as testing execution and report collection still require personnel participation, which is not conducive to the automation of the production testing process.

[0007] 3. The testing system lacks remote control and management capabilities. The existing testing system does not consider the needs of networked management in the software and hardware design, and does not have the capabilities of remote access and dynamic switching of the testing engine.

[0008] 4. The test system lacks the ability of health diagnosis. At present, the sources of domestic shelf test resources are diverse, and there is a lack of a unified health monitoring software for different manufacturers' resources to monitor the health status of the test system in real time, which is not conducive to the production scheduling personnel to quickly obtain the equipment status and is also not conducive to the rapid troubleshooting of the system. Summary of the Invention

[0009] The object of the present invention is to provide a flexible automated test system for avionics mass production testing. By adding an extended resource component, the flexibility of the test system is improved. In addition, it can automatically match the product under test and execute test tasks, and support remote monitoring and health diagnosis.

[0010] The object of the present invention is achieved by the following technical solutions:

[0011] A flexible automated test system for avionics mass production testing includes a server side and a number of test stations. The server side is deployed with a first remote management module, and the test stations are deployed with a main control module, a general simulation module, and a general interface module;

[0012] The first remote management module automatically sends the test engine and test cases of the product under test to the test station according to the product under test identified by the characteristics of the product under test provided by the main control module on each test station; remotely defines the signals on the test station; monitors the test tasks, collects and manages the test data;

[0013] The main control module includes a signal definition component, a test engine component, a test management component, and an access identification component;

[0014] The signal definition component generates a configuration table according to the signal definition set in the first remote management module by software-defined hardware interface. The configuration table includes the correspondence between the simulation card channels and the data ICD;

[0015] The test engine component is responsible for parsing the test keywords in the test cases into test instructions, reading the configuration table when calling the test keywords, and automatically matching the corresponding message channels based on the ICD fields, so as to send the test instructions to the simulation board card, and then receive the test data returned by the simulation board card and return the test results to the test management component according to the pass criteria;

[0016] The test management component is used to receive the test engine and test cases sent by the first remote management module, dynamically execute the test cases, and at the same time summarize the test results of the cases, generate a test report and upload it to the first remote management module;

[0017] The access identification component is used to measure the characteristics of the product under test connected to the general interface module and report it to the remote management module for matching the product model of the product under test;

[0018] The general simulation module provides slots and driver adaptation for simulation boards, and provides a keyword-based test interface for the main control module;

[0019] The general interface module is used to connect the product under test, forward simulation test data between the main control module and the product under test, and support resource expansion at the same time.

[0020] Preferably, the first remote management module includes a management service component and a permission management component;

[0021] The management service component provides a Git server application, supports database functions, stores information about the product under test, and the matching information between the product under test, the test engine, and test cases; it also supports file management functions for storing different versions of the test engine, test case scripts, and test data.

[0022] The permission management component is used to set and control user permissions.

[0023] Preferably, the test station further includes a second remote management module. The second remote management module includes a browser component, which communicates with the management service component on the first remote management module, allowing test managers to monitor test tasks and perform device management at the test site;

[0024] The management service component provides a server program for the user interface for the browser component on the second remote management module, generating data for display.

[0025] Preferably, the general simulation module uses a PXI industrial computer, including a main simulation resource component and a first hardware virtualization component;

[0026] The main simulation resource component provides PXI / CPCI hybrid slots, compatible with the mixed insertion of most off-the-shelf simulation boards. The main simulation resource component needs to select and install resource types and quantities that cover most product test requirements according to actual needs. If a single industrial computer chassis cannot meet the requirements, a cascading card is used to expand the measurement and control chassis;

[0027] The first hardware virtualization component is custom-developed using the ZeroRPC module of Python, provides an embedded or non-embedded system environment, runs the simulation board driver and driver adaptation software. Through the driver adaptation software, it unifies the driver interfaces of different manufacturers and types of boards, and connects to the test engine component of the main control module through the ZeroRPC service, providing a unified driver interface.

[0028] Preferably, the general interface module includes an identification resistor component, an extended resource component, a second hardware virtualization component, and an interface adaptation component;

[0029] The recognition resistor component uses an electronic resistor, provides a serial port for writing the resistor value, and uses the resistance value as the feature of the product under test for the first remote management module to identify the product under test;

[0030] The extended resource component provides PXI / CPCI hybrid slots. When the number or type of interfaces provided by the main simulation resource cannot meet the needs of new products, the extended slots are used for resource expansion;

[0031] The second hardware virtualization component provides an embedded or non-embedded system environment, runs the simulation board driver and driver adaptation software, and connects to the test engine component of the main control module through the RPC service;

[0032] The interface adaptation component provides a matrix-type general array interface, connects to the UUT externally and connects to the main simulation resource component and the extended resource component internally. Among them, the interfaces corresponding to the main simulation resource component are arranged in a fixed layout, and the interfaces corresponding to the extended resource component are adjusted as needed through reserved spare interface units. The signal definition is set by the signal definition component of the main control module.

[0033] Preferably, the test station also includes an alarm module, and the main control module also includes a health monitoring component. The health monitoring component is developed based on the VISA standard protocol to read the basic information of all simulation board cards compatible with the VISA standard; at the same time, the health monitoring component encapsulates the self-test interface of the simulation board card, supports single simulation board card self-test and one-key self-test of the hardware in the flexible automated test system. The status information of the simulation board card and the hardware of the flexible automated test system will be transmitted to the alarm component through the serial port and reported to the first remote management module.

[0034] The alarm module is used to generate an alarm notification when the device self-test reports a fault or the main control system hardware fails, so that maintenance personnel can quickly respond to troubleshoot.

[0035] Preferably, the test station also includes a power supply module, which is used to provide working power input for the main control module, the general simulation module, the general interface module, and the alarm module, and includes a power supply, a main power switch, an emergency stop button, and a sequencer.

[0036] The beneficial effects of the present invention are as follows:

[0037] 1. By adding an extended resource component, the flexibility of the test system is improved, and more new research products can be tested through expansion;

[0038] 2. The test system can automatically match the product under test by recognizing the resistor and execute the test task. Key test processes such as test execution and report collection do not require personnel participation, effectively improving the automation level of production testing;

[0039] 3. The main control module of the test station provides an external interface, and the test system provides a remote management module, which has the ability to remotely access and dynamically switch the test engine and test cases;

[0040] 4. The main control module has a health monitoring component, which can provide a unified health monitoring software for different manufacturers' resources to monitor the health status of the test system in real time, and can give real-time alarms, which is beneficial for production scheduling personnel to quickly obtain the device status and quickly locate faults in the test system. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 is the structural block diagram of the flexible automated test system of the present invention

[0042] Figure 2 is the schematic structural diagram of an embodiment of the flexible automated test system of the present invention

[0043] Figure 3 is the system working flow chart of an embodiment of the flexible automated test system of the present invention DETAILED DESCRIPTION OF THE EMBODIMENTS

[0044] The present invention will be further described in detail below with reference to the drawings and embodiments.

[0045] Refer to Figure 1 、 Figure 2 As shown, a flexible automated test system for avionics batch production testing shown in this embodiment includes a server side and several test stations. The server side is deployed with a first remote management module 1, and the test stations are deployed with a second remote management module 7, a main control module 2, a general simulation module 3, a general interface module 4, an alarm module 5, a power supply module 6, etc.

[0046] The first remote management module uses a rack-mounted server. According to the measured products identified by the characteristics (such as resistance value) of the measured products provided by the main control module on each test station, it automatically distributes the test engine and test cases of the measured products to the test stations, remotely defines the signals on the test stations, monitors the test tasks, collects and manages the test data, etc. At the same time, it remotely monitors according to the health status reported by the main control module on each test station and assigns user permissions, etc. The first remote management module is deployed with a management service component and a permission management component.

[0047] The management service component provides a Git server application, provides a server program for the user interface for the browser component on the second remote management module, and generates data for display; at the same time, it supports database functions, stores information about the measured products, and the matching information between the measured products and the test engine and test cases; it also needs to support file management functions for storing different versions of the test engine, test case scripts, and test data.

[0048] The permission management component is used to set and control user permissions.

[0049] The first remote management module establishes connections with the main control modules of each test station via Ethernet. The remote management module needs to provide a query interface for the main control module, and the query interface should at least include:

[0050] 1. An access recognition interface, which is used to determine the model of the product under test connected to the test system based on the resistance value of the product under test, so as to match the test engine and test cases;

[0051] 2. An interface for downloading the engine and test cases, which is used to download the matched test engine and test cases.

[0052] At the test station, the second remote management module uses an all-in-one computer. The main control module 2, the general simulation module 3, the general interface module 4, the alarm module 5, and the power supply module 6 are deployed in a cabinet. The second remote management module is connected to the cabinet through a bracket.

[0053] The second remote management module runs a desktop operating system and is connected to the server side through the Ethernet interface of the test station. The second remote management module includes a browser component, which communicates with the management service component on the first remote management module, enabling test management personnel to monitor test tasks and perform device management at the test site.

[0054] The main control module can be a high-performance computer that can be rack-mounted. The hardware interface provides Ethernet and RS232 serial ports. The operating system uses the Linux operating system, which is more compatible with container services. A Docker environment is deployed, and terminal service components such as a health monitoring component, an access recognition component, a signal definition component, a test management component, and a test engine component are run based on Docker containers. The automatic online of Docker applications is realized through the Systemd service, and communication between components is achieved through the Web API.

[0055] The health monitoring component is developed based on the VISA standard protocol and can read the basic information of all simulation boards compatible with the VISA standard. The basic information of the simulation board includes the slot where the simulation board is located, the in-position status, the name, the manufacturer, etc. At the same time, the health monitoring component encapsulates the self-test interfaces of common simulation boards, supports self-test of a single simulation board and one-key self-test of all resources. All resources include hardware such as the CPU, memory, and hard disk in the flexible automated test system. The status information of the hardware of the simulation board and the flexible automated test system will be transmitted to the alarm component through the serial port and reported to the first remote management module.

[0056] The access recognition component is used to measure the characteristics of the product under test connected to the general interface module and report them to the remote management module for matching the model of the product under test;

[0057] The signal definition component generates a configuration table designed based on XML (Extensible Markup Language) technology through a software-defined hardware interface according to the signal definition set in the first remote management module. This configuration table contains the correspondence between the simulation card channels and the data ICD, and can be read by the test engine component.

[0058] The test engine component is responsible for parsing the test keywords in the test case into test instructions. When calling the test keywords, it reads the configuration table and automatically matches the corresponding message channels based on the ICD fields, so as to send the test instructions to the simulation board card. Subsequently, it receives the test data returned by the simulation board card and returns the test results to the test management component according to the pass criteria.

[0059] The test management component is used to receive the test engine and test cases sent by the first remote management module, dynamically execute the test cases, and at the same time summarize the test results of the cases to generate a test report and upload it to the first remote management module.

[0060] The main control module needs to provide a management interface for the first remote management module. The management interface should at least include:

[0061] 1. The self-detection interface of system resources, which is used to perform self-detection on the main hardware included in the system and return the health status information;

[0062] 2. The test status query interface, which is used to remotely view the status of the test task;

[0063] 3. The test record collection interface, which is used to submit the test result data.

[0064] The general simulation module provides slots and driver adaptation for the simulation board cards, and provides a keyword-based test interface for the main control module. The general simulation module uses an 18-slot PXI industrial control computer running the Linux operating system. In addition to the zero-slot controller, it is also equipped with common protocol simulation board cards such as serial ports, discrete quantities, Ethernet, ARINC429, FC, and 1553B. The PXI industrial control computer is connected to the main control module computer through a communication Ethernet port. The general simulation module includes a main simulation resource component and a first hardware virtualization component.

[0065] The main simulation resource component provides PXI / CPCI hybrid slots, which are compatible with the mixed insertion of most off-the-shelf simulation board cards. The main simulation resource component needs to select and install the resource types and quantities that cover most product test requirements according to actual needs. If a single industrial control chassis cannot meet the requirements, the measurement and control chassis can be expanded through a cascade card. After the resources are selected, the general resources will not be changed under normal circumstances to ensure the consistency of the general interface module.

[0066] The first hardware virtualization component is custom-developed using Python's ZeroRPC module, providing an embedded or non-embedded system environment, running simulation board drivers and driver adaptation software. Through the driver adaptation software, the board driver interfaces of different manufacturers and types are unified, and connected to the test engine component of the main control module through the ZeroRPC service, providing a unified driver interface. When the underlying hardware is upgraded or changed, only simple driver adaptation is required, and there is no need to upgrade the test engine. The test engine component of the main control module can make a call similar to local calls to the driver interfaces mounted on the network through the ZeroRPC client.

[0067] The general simulation module has at least one driver call interface for transmitting and responding to test engine test instructions.

[0068] The general interface module is used to connect the product under test, forward simulation test data between the main control module and the product under test, and support resource expansion at the same time. The general interface module includes an identification resistor component, an extended resource component, a second hardware virtualization component, and an interface adaptation component.

[0069] The identification resistor component uses an electronic resistor to provide a serial port for writing the resistor value, and different avionics products are defined by different resistor values.

[0070] The extended resource component provides PXI / CPCI hybrid slots, compatible with the mixed insertion access of most off-the-shelf simulation boards. The extended resource component is a supplement to the main simulation resources. When the number or type of interfaces provided by the main simulation resources cannot meet the needs of new products, the extended slots can be used for resource expansion.

[0071] The second hardware virtualization component is the same as the first hardware virtualization component of the communication simulation module, providing an embedded or non-embedded system environment, running simulation board drivers and driver adaptation software, and also connecting to the test engine component of the main control module through the RPC service. The first hardware virtualization component and the second hardware virtualization component are distinguished by different IP addresses.

[0072] The interface adaptation component provides a matrix-type general array interface, which can be quickly connected to the UUT externally and connected to the main simulation resource component and the extended resource component internally. Among them, the interfaces corresponding to the main simulation resource component are fixedly arranged, and the interfaces corresponding to the extended resource component can be adjusted as needed through the reserved spare interface unit, and the signal definition is set by the signal definition component of the main control module.

[0073] The general interface module needs to provide at least the following interfaces:

[0074] 1. An identification resistor reading interface for reading the product identification resistor to match the product;

[0075] 2. A drive call interface for transmitting and corresponding to test instructions of a test engine;

[0076] 3. A signal access physical interface for transferring test data between the main simulation resource and the UUT.

[0077] The general interface module uses a customized chassis. There is a RS232 serial port on the side of the chassis for writing the resistance value of the identification resistor. The back of the chassis is a matrix connector facing the general simulation resource, which is used to transfer the interface of the general resource component to the interface adaptation component. The interface adaptation component is located on the top of the customized chassis and is used to connect to the product under test. The main component inside the chassis is a miniaturized PXI measurement and control computer, which provides 4 horizontal plug slots to meet the need for resource expansion.

[0078] The alarm module is used to generate an alarm notification when the device self-check reports a fault or the main control system has a hardware fault, so that the maintenance personnel can quickly respond to troubleshoot. The alarm module is located on the top of the test station. The main part is a four-color safety lamp, equipped with a 4-way switch, which is controlled through the serial port of the main control module. When the hardware is normal, the safety lamp is green. When a hardware fault occurs, the alarm lamp will turn on the yellow light. If the fault is not repaired after the yellow light has been on for 5 minutes, the red light will turn on. If the device is in the maintenance mode, the safety lamp is orange.

[0079] The power supply module is used to provide working power input for the main control module, the general simulation module, the general interface module, and the alarm module. The power supply module is located on the top of the test station and includes a power supply, a main power switch, an emergency stop button, and a sequencer. The power supply output supports the common 5V, 12V, and 28V, each providing two paths. The main power switch is used to power on the power supply and the sequencer. The sequencer is used to control the power-on sequence of each module.

[0080] Figure 3 Described is the complete system working process of the flexible automated test system embodiment of the present invention:

[0081] Step S01: Power on the main power supply, start the power supply sequencer, and power on the main control module, the general simulation module, the alarm module, and the second remote management module in sequence;

[0082] Step S02: The main control module performs a system self-check;

[0083] Step S03: The tester views the test task arrangement through the second remote management module;

[0084] Step S04: The tester installs the product under test, docks the general interface module to the general simulation module, and sets the resistance value of the identification resistor;

[0085] Step S05: The main control module recognizes the resistance value, and the first remote management module receives the resistance value and matches the product information;

[0086] Step S06, the first remote management module issues a test engine and test cases to the main control module;

[0087] Step S07, the main control module starts to execute the test task;

[0088] Step S08, the main control module ends the test task and uploads the test report to the first remote management module;

[0089] Step S09, the tester disassembles the general interface module and the product under test;

[0090] In the embodiment of the flexible automated test system of the present invention, the production test process can be greatly simplified. Since after the product is transferred to the production link, the production test manager will transfer the product information and the matching test engine and test cases to the production system, the on-site test personnel only need to focus on the installation of the product.

[0091] It can be understood that for those of ordinary skill in the art, equivalent substitutions or changes can be made according to the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the protection scope of the appended claims of the present invention.

Claims

1. A flexible automated test system for avionics mass production testing, comprising a server side and several test stations. The server side is deployed with a first remote management module, and the test stations are deployed with a main control module, a general simulation module, and a general interface module. It is characterized in that: The first remote management module automatically sends the test engine and test cases of the product under test identified according to the characteristics of the product under test provided by the main control module on each test station to the test station; remotely defines the signals on the test station; Monitors test tasks, collects and manages test data; The main control module includes a signal definition component, a test engine component, a test management component, and an access recognition component; The signal definition component generates a configuration table according to the signal definition set in the first remote management module through a software-defined hardware interface. The configuration table includes the correspondence between the simulation card channels and the data ICD; The test engine component is responsible for parsing the test keywords in the test case into test instructions, automatically matching the corresponding message channels based on the ICD fields after reading the configuration table when calling the test keywords, so as to send the test instructions to the simulation board card, and then receiving the test data returned by the simulation board card and returning the test result to the test management component according to the pass criterion; The test management component is used to receive the test engine and test cases sent by the first remote management module, dynamically execute the test cases, and at the same time summarize the test results of the cases and generate a test report to upload to the first remote management module; The access recognition component is used to measure the characteristics of the product under test connected to the general interface module and report them to the remote management module for matching the product model of the product under test; The general simulation module provides slots and driver adaptation for the simulation board card, and provides a keyword-based test interface for the main control module; The general interface module is used to connect the product under test, forward simulation test data between the main control module and the product under test, and at the same time support resource expansion, including an identification resistor component, an extended resource component, a second hardware virtualization component, and an interface adaptation component; The identification resistor component uses an electronic resistor, provides a serial port for writing the resistor value, and uses the resistance value as the characteristic of the product under test for the first remote management module to identify the product under test; The extended resource component provides PXI / CPCI hybrid difference slots. When the number or type of interfaces provided by the main simulation resources cannot meet the needs of new products, the extended slots are used for resource expansion; The second hardware virtualization component provides an embedded or non-embedded system environment, runs the simulation board card driver and driver adaptation software, and connects to the test engine component of the main control module through an RPC service; The interface adaptation component provides a matrix-type general array interface, connects to the UUT externally and connects to the main simulation resource component and the extended resource component internally. The interfaces corresponding to the main simulation resource component are arranged in a fixed layout, and the interfaces corresponding to the extended resource component are adjusted as needed through reserved spare interface units. The signal definition is set by the signal definition component of the main control module.

2. The flexible automated test system for avionics mass production testing according to claim 1, characterized in that The first remote management module includes a management service component and a permission management component; The management service component provides a Git server application, supports database functions, and stores the information of the product under test, the matching information between the product under test and the test engine and test cases; It also supports the file management function for storing different versions of the test engine, test case scripts, and test data; The permission management component is used to set and control user permissions.

3. The flexible automated test system for avionics mass production testing according to claim 2, wherein The test station also includes a second remote management module, which contains a browser component. The browser component communicates with the management service component on the first remote management module, enabling test managers to monitor test tasks and manage devices at the test site; The management service component provides a server program for the user interface of the browser component on the second remote management module and generates data for display.

4. The flexible automated test system for avionics mass production testing according to claim 1, characterized in that The general simulation module uses a PXI industrial control computer and includes a main simulation resource component and a first hardware virtualization component; The main simulation resource component provides PXI / CPCI hybrid slots, compatible with the mixed insertion of most off-the-shelf simulation board cards. The main simulation resource component needs to select and install resource types and quantities that cover most product test requirements according to actual needs. If a single industrial control chassis cannot meet the requirements, a cascading card is used to expand the measurement and control chassis; The first hardware virtualization component is custom-developed using the ZeroRPC module of Python, providing an embedded or non-embedded system environment to run the simulation board card driver and driver adaptation software. Through the driver adaptation software, the board card driver interfaces of different manufacturers and types are unified, and connected to the test engine component of the main control module through the ZeroRPC service to provide a unified driver interface.

5. The flexible automated test system for avionics mass production testing according to claim 1, characterized in that The test station also includes an alarm module, and the main control module also includes a health monitoring component. The health monitoring component is developed based on the VISA standard protocol to read the basic information of all simulation board cards compatible with the VISA standard; at the same time, the health monitoring component encapsulates the self-check interface of the simulation board card, supporting single simulation board card self-check and one-key self-check of the hardware in the flexible automated test system. The status information of the simulation board card and the hardware of the flexible automated test system is transmitted to the alarm component through the serial port and reported to the first remote management module; The alarm module is used to generate an alarm notification when the device self-check reports a fault or the main control system hardware fails, enabling maintenance personnel to quickly respond and troubleshoot.

6. The flexible automated test system for avionics mass production testing according to claim 1, characterized in that The test station also includes a power supply module, which is used to provide working power input for the main control module, general simulation module, general interface module, and alarm module, including a power supply, main power switch, emergency stop button, and sequencer.

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