Train control unit automatic test system and test method

Abstract

The application discloses a train control unit automatic test system and method, the system comprises a line body, a docking unit, an insulation voltage resistance test unit, a function test unit and a central control unit; the line body is used for realizing transmission of the measured unit; the insulation voltage resistance test unit and the function test unit are installed on the line body and are arranged along the transmission method of the line body in sequence, the insulation voltage resistance test unit is used for automatically testing insulation resistance and voltage resistance of the measured unit on the line body; the function test unit is used for testing input and output signal, communication function and process state acquisition of the measured unit on the line body; the docking unit is used for automatically interconnecting external interfaces of each test unit and external interfaces of the measured unit; the central control unit is connected with the docking unit, the insulation voltage resistance test unit and the function test unit, and is used for realizing test information issuing and test process data collecting. The application has the advantages of high automation degree and high test efficiency.

Description

Technical Field

[0001] This invention relates to the field of train control unit testing technology, specifically to an automated testing system and method for train control units. Background Technology

[0002] Train control units, including transmission control units and auxiliary control units, typically employ a chassis-type or stacked-panel structure. They interconnect with external devices via external interfaces to control the entire traction and auxiliary systems. Due to their structural characteristics, test harnesses are required during production. Operators manually connect the external interfaces to the test equipment, manually start the equipment, and disconnect the harnesses after testing. During testing, manual wiring carries risks of missed or incorrect connections, potentially damaging the product. The product's process status also relies on visual inspection, which is prone to omissions and false positives. Furthermore, manual data collection during testing is often incomplete and inconsistent, leading to difficulties in traceability.

[0003] Production testing of train transmission control units is typically performed using discrete workstations, requiring external interface signals to be wired to the testing equipment for testing. The testing process includes wiring harness disconnection and reconnection, manual condition assessment, inter-workstation transfer, and manual information recording. This method is simple in structure and has few requirements for product characteristics, but it involves a high degree of manual intervention, has low testing efficiency, and cannot guarantee product testing consistency. Summary of the Invention

[0004] The technical problem to be solved by this invention is: in view of the problems existing in the prior art, this invention provides an automated testing system and testing method for train control units with high testing efficiency.

[0005] To solve the above-mentioned technical problems, the technical solution proposed by this invention is as follows:

[0006] An automated testing system for train control units includes a test line, a docking unit, an insulation withstand voltage testing unit, a functional testing unit, and a central control unit. The test line is used to transmit data between the tested units and the units under test. The insulation withstand voltage testing unit and the functional testing unit are mounted on the test line and arranged sequentially along the transmission route. The insulation withstand voltage testing unit is used to automatically test the insulation resistance and withstand voltage of the tested units on the test line. The functional testing unit is used to test the input / output signals, communication functions, and process status of the tested units on the test line. The docking unit automatically interconnects the external interfaces of each testing unit with the external interfaces of the tested units. The central control unit is connected to the docking unit, the insulation withstand voltage testing unit, and the functional testing unit, and is used to transmit test information and collect test process data.

[0007] Preferably, the insulation withstand voltage test unit includes an insulation withstand voltage tester.

[0008] This invention also discloses a testing method based on the automated testing system for train control units as described above, comprising the following steps:

[0009] S1. Test system initialization;

[0010] S2. Start the line to transport the unit under test to the insulation withstand voltage test unit. The unit under test and the insulation withstand voltage test unit are connected through the docking unit. Then the insulation withstand voltage test unit performs the insulation withstand voltage test on the unit under test. After the insulation withstand voltage test is completed, the unit under test and the insulation withstand voltage test unit are released and disconnected through the docking unit. The insulation withstand voltage test unit sends the test data to the central control unit.

[0011] S3. Start the line and transport the unit under test (DUT) to the functional test unit. The DUT and the functional test unit are connected through the docking unit. Then, the functional test unit performs functional tests on the DUT. After the functional test is completed, the DUT and the functional test unit are released and disconnected through the docking unit. The functional test unit sends the test data to the central control unit.

[0012] S4. Start the production line and send the unit under test to the discharge platform.

[0013] Preferably, step S1 specifically includes:

[0014] 1) Start: The test begins;

[0015] 2) Automatic program tool invocation: The test equipment program is invoked from the server based on the model of the unit under test;

[0016] 3) Initialization configuration: Initialize the configuration information of each test unit, track status information, and automatic docking unit status information, and confirm the self-test of each test unit;

[0017] 4) Initialization passed: Confirm that the initialization result is correct.

[0018] Preferably, the specific process of step S2 is as follows:

[0019] 5) Line track operation: Start the track conveyor motor;

[0020] 6) Incoming Material Confirmation: The incoming material platform confirms the presence of the unit under test;

[0021] 7) Inbound buffer: Insulation withstand voltage buffer bit before entering the station;

[0022] 8) Confirmation of the unit under test at the post-workstation: Confirm whether there are any products being tested at the insulation withstand voltage test station;

[0023] 9) Insulation withstand voltage test unit entry signal: Insulation withstand voltage test unit entry permission signal;

[0024] 10) Scan the code to obtain information: Obtain information about the current unit under test and the insulation withstand voltage test requirements;

[0025] 11) Automatic docking: Automatically docking the insulation withstand voltage test unit with the external interface of the unit under test;

[0026] 12) Insulation withstand voltage test: Perform the routine insulation withstand voltage test as required;

[0027] 13) Automatic release: After the test is completed, the insulation withstand voltage test unit and the external interface of the unit under test are automatically released and disconnected;

[0028] 14) Insulation withstand voltage output: Insulation withstand voltage test unit output permission signal.

[0029] Preferably, the specific process of step S3 is as follows:

[0030] 15) Confirmation of the unit under test in the subsequent process: Confirm whether there is a product being tested at the functional testing station;

[0031] 16) Functional test entry: Functional test unit entry permission signal;

[0032] 17) Scan the code to obtain information: Obtain information about the currently tested unit and its functional testing requirements;

[0033] 18) Automatic docking: Perform automatic docking of the external interfaces between the functional test unit and the unit under test;

[0034] 19) Functional testing: Perform functional tests as required;

[0035] 20) Automatic release: After the test is completed, the functional test unit and the external interface of the unit under test are automatically released and disconnected;

[0036] 21) Functional test outbound: Functional test unit outbound permission signal.

[0037] Preferably, the specific process of step S4 is as follows:

[0038] 22) Outbound cache: Cache location after functional testing is completed;

[0039] 23) Feeding confirmation: The feeding platform confirms whether the unit under test exists. If not, the unit under test is sent to the feeding platform.

[0040] 24) End: The test is over.

[0041] Preferably, the specific process of steps 1)-4) is as follows: Run step 1), specifically, open the host computer of the insulation withstand voltage test unit and the host computer of the function test unit respectively. Both host computers include a PC host computer and an HMI host computer. After opening, the software background will automatically confirm the network connection status of the device and the startup status of the host computer.

[0042] After the host computer starts successfully, step 2) is executed automatically. Specifically, the central control unit sends a request to the factory MES information system to obtain the production order information for the day. The insulation withstand voltage test unit requests the central control unit to send production information and writes the obtained information into the local cache, while sending it to the functional test unit. The program tool software is automatically called to call the test software from the production program server according to the drawing number and the test software is automatically started.

[0043] After the test software starts, step 3) is executed. Specifically, the host computer of the insulation withstand voltage test unit and the functional test unit automatically reads the configuration information of the current drawing number in the cache; after obtaining the configuration information, it sends it to the servo system to complete the initialization of the line body and the automatic docking unit.

[0044] Step 4) Specifically, the status information read back from the initialization configuration is compared with the standard information in the cache to confirm whether the initialization has passed. If the initialization fails, it will be re-initialized and the operator will be notified by an alarm.

[0045] Preferably, the configuration information in step 3) includes PLC execution information, feeding platform location information, track width and height information, and automatic docking unit height / encoding / engagement status information.

[0046] Preferably, the specific process of steps 5)-14) is as follows: after initialization is successful, step 5) is run. Specifically, the PLC automatically sends start signal and speed signal to the servo that controls the track operation and controls the servo motor to realize the operation of the entire track.

[0047] Step 6) The receiving platform automatically confirms the presence of the unit under test. When the distance between the receiving platform and the unit under test is less than a certain distance, the platform determines that the unit under test has arrived. At this time, the receiving platform transports the unit under test onto the track for circulation. After circulation is completed, the platform rises back to a fixed height and disengages from the track to wait for new arrivals.

[0048] After the incoming material is confirmed to be in good condition, step 7 is executed. Specifically, there is a blocking cylinder on the incoming material section track. The blocking cylinder automatically rises to buffer the tested unit.

[0049] During step 8), the system automatically checks whether there is a product being tested at the insulation withstand voltage station. If the test is in progress, the buffer station blocking cylinder remains in the raised state. After the subsequent process test permission signal is enabled, the blocking cylinder falls, and the tested unit continues to flow and automatically runs step 9). The tested unit automatically passes through the track docking point between the incoming material section and the insulation withstand voltage test section and enters the insulation withstand voltage test unit.

[0050] After the insulation withstand voltage enters the station, the automatic operation step 10) is completed. The barcode scanning section blocking cylinder is raised by default, and the barcode is scanned at intervals. After the scanning is completed, the relevant information is sent to the host computer of the insulation withstand voltage unit for caching, and the blocking cylinder is automatically lowered.

[0051] The unit under test moves along the track and is intercepted by the current blocking cylinder when it reaches the insulation withstand voltage test station. Automatic operation step 11) is then performed for automatic docking.

[0052] After the electrical connection is completed, the host computer automatically runs step 12). The host computer compares the current production program code with the scanned cache information to see if it is correct, records the serial number of the unit under test, runs the production program, and automatically performs group configuration and voltage setting according to the insulation withstand voltage test requirements. It also completes insulation resistance measurement, withstand voltage measurement and leakage current recording. The actual test results are compared with the standard requirements to determine whether the test is qualified. Finally, the test report is backed up locally and uploaded to the central control system.

[0053] After the test is completed, step 13) will be run automatically, which is the reverse of the action flow in step 11), thereby realizing the disconnection of the insulation withstand voltage test from the unit under test; after automatic disconnection, the blocking cylinder will be in the lowering state, and step 14) will be run automatically to complete the insulation withstand voltage test and transfer to the next process.

[0054] Compared with the prior art, the advantages of the present invention are as follows:

[0055] This invention combines a PLC controller, servo system, sensor devices, and track to achieve automatic flow of the UUT (Unified Underlying Unit) between processes. The automatic docking unit integrates a simulator and LED tester to enable online programming of the UUT and process status judgment. The functional testing unit achieves automatic signal routing through matrix cards and switch cards. Combined with host computer software, hardware control enables automatic operation and testing of the equipment, achieving unmanned and fully automated product testing. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the test system of the present invention in an embodiment.

[0057] Figure 2 This is a front view structural diagram of the upper clamp of the present invention in an embodiment.

[0058] Figure 3 This is a side view of the upper clamp of the present invention in an embodiment.

[0059] Figure 4 This is a front view structural diagram of the lower clamp of the present invention in an embodiment.

[0060] Figure 5 This is a side view of the lower clamp of the present invention in an embodiment.

[0061] Figure 6 This is a flowchart of the testing method of the present invention in an embodiment.

[0062] Legend: 1. Line body; 2. Insulation withstand voltage test unit; 3. Functional test unit; 4. Connecting unit; 401. Upper clamp; 402. Lower clamp. Detailed Implementation

[0063] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0064] like Figure 1 As shown, this embodiment of the invention provides an automated testing system for train control units, including a test line 1, a docking unit 4, an insulation withstand voltage test unit 2, a functional test unit 3, and a central control unit. The insulation withstand voltage test unit 2 and the functional test unit 3 are installed on the test line 1 and arranged sequentially along the transmission method of the test line 1. The main function of the test line 1 is to realize the incoming, buffering, and outgoing of UUTs through a PLC controller, servo system, sensor acquisition device, and barcode scanner, and to complete track operation, lifting, and width adjustment control according to the type of the Unit Under Test (UUT). The main function of the docking unit 4 is to automatically interconnect the external interfaces of each test unit with the external interfaces of the UUT through a linear transmission module. The insulation withstand voltage test unit 2 is mainly used to automatically test the insulation resistance and withstand voltage of the UUT through an insulation withstand voltage tester. The functional test unit 3 is mainly used to realize signal routing between the UUT and the test instrument through a matrix card and a switch card, and to perform input and output signal testing, communication function testing, and process status acquisition of the UUT. The central control system is mainly used to send UUT production information to the test units and to collect and upload process data. The docking unit 4 includes an upper clamp 401 and a lower clamp 402, the specific structure of which is as follows: Figures 2-5 As shown.

[0065] This invention enables unmanned and fully automated testing in the process of testing train control unit products. It is an effective method for solving the problems of information technology in product testing and intelligent production. Compared with traditional testing solutions, it eliminates the need for manual wiring and manual intervention in testing steps, which can effectively reduce manpower and improve the consistency of product test results.

[0066] This invention also provides a testing method based on the automated testing system for train control units described above, comprising the following steps:

[0067] S1. Initialization, specifically:

[0068] 1) Start: The test begins;

[0069] 2) Automatic program invocation: Invokes the test device program from the server based on the UUT model;

[0070] 3) Initialization configuration: Initialize PLC configuration information, track status information, automatic docking unit 4 status information, and confirm the self-test of each instrument, sensor, and board;

[0071] 4) Initialization successful: Confirm that the initialization result is correct;

[0072] S2, Insulation withstand voltage test, specifically:

[0073] 5) Track operation: Start the track conveyor motor;

[0074] 6) Incoming Material Confirmation: The incoming material platform confirms whether a UUT exists;

[0075] 7) Inbound buffer: Insulation withstand voltage buffer bit before entering the station;

[0076] 8) Post-workstation UUT confirmation: Confirm whether there are products undergoing testing at the insulation withstand voltage station;

[0077] 9) Insulation withstand voltage test unit 2 entry permission signal;

[0078] 10) Scan the code to obtain information: Obtain information about the current UUT and insulation withstand voltage test requirements;

[0079] 11) Automatic docking: Perform automatic docking between insulation withstand voltage test unit 2 and the external interface of UUT;

[0080] 12) Insulation withstand voltage test: Perform the routine insulation withstand voltage test as required;

[0081] 13) Automatic release: After the test is completed, the insulation withstand voltage test unit 2 will automatically release and disconnect from the external interface of the UUT;

[0082] 14) Insulation withstand voltage test station output: Insulation withstand voltage test unit 2 output permission signal;

[0083] S3, Functional Testing, specifically:

[0084] 15) Post-process UUT confirmation: Confirm whether there are any products being tested at the functional test station;

[0085] 16) Functional test entry: Functional test unit 3 entry permission signal;

[0086] 17) Scan the code to obtain information: Obtain information about the current UUT and its functional testing requirements;

[0087] 18) Automatic docking: Perform automatic docking between functional test unit 3 and the external interface of UUT;

[0088] 19) Functional testing: Perform functional tests as required;

[0089] 20) Automatic release: After the test is completed, the functional test unit 3 is automatically released and disconnected from the external interface of the UUT;

[0090] 21) Functional test outbound: Functional test unit 3 outbound permission signal;

[0091] S4. Discharge, specifically:

[0092] 22) Outbound cache: Cache location after functional testing is completed;

[0093] 23) Feeding Confirmation: The feeding platform confirms whether a UUT exists;

[0094] 24) Data collection and uploading: Collect test data and upload it to the central control system, which then uploads it to the data server;

[0095] 25) End: The test is over.

[0096] Specifically, the entire testing process is analyzed as follows:

[0097] Step 1) Specifically, open the host computer of insulation withstand voltage test unit 2 and the host computer of function test unit 3 respectively. Both host computers include a PC host computer and an HMI host computer. After opening, the software background will automatically confirm the network connection status of the device and the startup status of the host computer.

[0098] After the host computer starts successfully, step 2) is executed automatically. Specifically, the central control system sends a request to the factory's MES information system to obtain the production order information for the day (including lot ID, drawing number, quantity, and routine test outline version number). Insulation withstand voltage test unit 2 requests the central control unit to send production information and writes the obtained information to its local cache, while simultaneously sending it to the functional test unit 3. The program tool software is automatically invoked to call the test software from the production program server according to the drawing number, and the test software is automatically started.

[0099] After the test software starts, step 3) is executed. Specifically, the host computer automatically reads the configuration information of the current drawing number in the cache for the insulation withstand voltage test unit 2 and the functional test unit 3, including PLC execution information, feeding platform position information, track width and height information, and automatic docking unit 4 height / encoding / engagement status information. After obtaining the configuration information, it is sent to the servo system to complete the initialization of line 1 and automatic docking unit 4, and at the same time, the instrument and board self-test is performed and the status information is read back.

[0100] Step 4) Specifically, the status information read back from the initialization configuration is compared with the standard information in the cache to confirm whether the initialization has passed. If the initialization fails, it will be re-initialized and the operator will be notified by an alarm.

[0101] After initialization is successful, step 5 is executed. Specifically, the PLC automatically sends start and speed signals to the servo motor that controls the track, and controls the servo motor to realize the operation of the entire track. The track is divided into the material receiving section, the insulation withstand voltage test section, the functional test section, and the feeding section. The sections are horizontally connected to each other to realize the smooth flow of products.

[0102] Step 6) Specifically, the receiving platform automatically confirms the UUT's position information through the distance sensor. When the distance sensor measures that the distance between the receiving platform plane and the UUT is less than 10mm, it determines that the material has arrived. At this time, the receiving platform will transport the UUT onto the track for circulation. After the circulation is completed, it will rise back to a fixed height and disengage from the track to wait for new material.

[0103] After the incoming material is confirmed to be in place, proceed to step 7). Specifically, there are blocking cylinders on the incoming material section track. The blocking cylinders automatically rise to buffer the UUT. The length of the buffer track and the number of cylinders can be set according to the required number of buffers and the cycle time requirements.

[0104] During step 8), the PLC automatically confirms whether there is a product being tested at the insulation withstand voltage station. If the test is in progress, the buffer station blocking cylinder remains in the raised state. After the subsequent process test enable signal is enabled, the blocking cylinder falls, and the UUT continues to flow and automatically runs step 9). The UUT automatically passes through the track docking point between the incoming material section and the insulation withstand voltage test section and enters the insulation withstand voltage test unit 2.

[0105] After the insulation withstand voltage enters the station, the automatic operation step 10) is completed. The barcode scanning section blocking cylinder is raised by default. The barcode scanner scans once every 0.5 seconds. After the scanning is completed, the relevant information is sent to the upper computer of the insulation withstand voltage station for caching, and the blocking cylinder is automatically lowered.

[0106] The UUT moves along the track and is intercepted by the current blocking cylinder at the insulation withstand voltage test station, automatically proceeding to step 11). The automatic docking process includes the track descending, the UUT positioning hole automatically engaging with the positioning pin of the lower clamp 402, and the lower clamp 402 having two built-in distance sensors for leveling. These sensors are positioned diagonally across the lower clamp 402. When the distance measured by both sensors is less than 10mm, the blocking cylinder descends, and the clamping device closes. The upper clamp 401 integrates the external interface of the test unit. According to the PLC configuration information, the servo actuator docks with the UUT's external interface at the set speed and distance. The docking is performed in stages, and contact stress is collected in real time by pressure sensors. In the first stage, the upper and lower clamps 402 contact each other. In the second stage, the external interface of the upper clamp 401 and the UUT achieve initial connector contact through the DSUB housing positioning guide device (such as a conventional hole-post mating method). In the third stage, continuous downward pressure achieves electrical connection of the connector.

[0107] This invention employs a segmented, step-by-step approach during docking, allowing for the setting of different pressure thresholds to ensure reliability and safety, and prevent damage to testing equipment and the UUT. For example, the first stage of docking uses upper and lower clamps with 402-hole pins for guiding and positioning; the second stage uses a floating contact method with the DSUB shell (the DSUB shell can move forward, backward, left, and right, i.e., movable installation) to achieve coarse positioning of the connector; and the third stage achieves electrical connection through the interference fit between pins and holes. This floating docking enables automatic connection and disconnection of the product, ensuring safety and reliability during the connection and disconnection process.

[0108] When the electrical connection is completed and the pressure sensor has no alarm, step 12) is automatically executed. The host computer compares the current production program code with the scanned cache information to see if it is correct, records the UUT serial number, and runs the production program. The production program can automatically perform group configuration and voltage setting according to the insulation withstand voltage test requirements, and complete insulation resistance measurement, withstand voltage measurement and leakage current recording. The actual test results will be compared with the standard requirements to determine whether the test is qualified. Finally, the test report will be backed up locally and uploaded to the central control system.

[0109] After the test is completed, step 13) is automatically executed, which is the reverse of the action flow in step 11), thereby realizing the separation of the upper and lower clamps 402 from the UUT for insulation withstand voltage testing. After automatic separation, the blocking cylinder will be in the lowering state, and step 14) will be automatically executed to complete the insulation withstand voltage test and exit the station and flow to the next process.

[0110] When the UUT is transferred to the track docking point between the insulation withstand voltage station and the functional test station, in step 15), the UUT will be stopped by the blocking cylinder. At this time, the PLC will automatically determine whether there is a UUT being tested at the functional test station. After the functional test station entry permission signal is enabled, the blocking cylinder will automatically descend. In step 16), the functional test unit 3 enters the station through the docking track between the two stations.

[0111] After the functional test is initiated, step 17 will be executed automatically. The barcode scanning section blocking cylinder will be raised by default, and the barcode scanner will scan the barcode once every 0.5 seconds. After the scanning is completed, the relevant information will be sent to the host computer of the functional test station for caching, and the blocking cylinder will be lowered automatically.

[0112] The product continues to circulate and run until it reaches the functional test station, where it is blocked by the current blocking cylinder. Step 18) is then automatically executed. The automatic docking execution process here is the same as that in step 11).

[0113] After successful automatic docking, step 19) is executed automatically. The host computer compares the production program code called in step 2) with the scanned cache information to verify its correctness, records the UUT serial number, and runs the production program. The production program automatically completes instrument communication, parameter configuration, and signal output enabling. The matrix card and switch card automatically route signals, thus outputting signals to the UUT through the docking unit 4RCV terminal to automatically complete the entire test. Simultaneously, the 401 fixture on the functional test station integrates a simulator and a FEASA LED tester, enabling online programming of the product and indicator light judgment of the process status. The actual test results are compared with the standard requirements to determine whether the test is qualified. The final test report is backed up locally and uploaded to the central control system.

[0114] After the functional test is completed, step 20) is automatically executed, which is the reverse of the action flow in step 18), thereby realizing the disengagement of the upper and lower clamps 402 from the UUT. After automatic disengagement, the blocking cylinder will remain in the descending state, and step 21) will be automatically executed to complete the functional test, exit the station, and pass through the docking point between the functional test section and the feeding section track.

[0115] Upon reaching the feeding section, step 22) is automatically executed. There is a blocking cylinder on the feeding section track. The blocking cylinder automatically rises to buffer the UUT, and the set length is the same as that of the incoming section.

[0116] When the UUT is buffered, step 23) is executed automatically. The PLC determines whether there is material on the feeding platform. The feeding platform is equipped with a distance sensor. When the distance sensor measures that the distance between the feeding platform plane and the UUT is less than 10mm, it is determined that material has arrived. At this time, the feeding platform automatically rises, indicating that the test is completed and material picking is allowed. After material picking, when the test result is no longer less than 10mm, the feeding platform automatically descends onto the track. At this time, the outgoing buffer blocking cylinder falls, and the UUT continues to flow to the feeding platform.

[0117] After the material receiving and feeding process is completed, UUT automatically runs the data collection and uploading subroutine in step 24), which reads all the result data from steps 2)-23) from the cache and uploads them to the test data server.

[0118] After successful upload, proceed to step 25 to complete the test.

[0119] This invention combines a PLC controller, servo system, sensor devices, and track to achieve automatic flow of the UUT between processes. The automatic docking unit 4 integrates a simulator and LED tester to enable online programming of the UUT and process status judgment. The functional testing unit 3 achieves automatic signal routing through matrix cards and switch cards. Combined with host computer software for hardware control, it realizes automatic operation and testing of the equipment, achieving unmanned and fully automated product testing.

[0120] This invention can test the control units of the traction and auxiliary control systems of trains such as locomotives, EMUs and subways. The test items are not limited to insulation withstand voltage tests and functional tests.

[0121] Related instructions:

[0122] MES (Manufacturing Execution System) information system connects the workshop operation site control through the execution system, including PLCs, data acquisition devices, barcodes, various measuring and testing instruments, robotic arms, etc. The MES system is equipped with necessary interfaces to establish cooperative relationships with manufacturers that provide production site control facilities.

[0123] A PLC controller is a digital electronic device specifically designed for industrial applications. It uses a programmable memory to store instructions for performing logical, sequential, timing, counting, and arithmetic operations, and can control various types of machinery or production processes through digital or analog inputs and outputs.

[0124] As shown in this disclosure and the claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. The terms "first," "second," and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms "comprising" or "including" mean that the element or object preceding the word covers the element or object listed after the word and its equivalents, without excluding other elements or objects. The terms "connected" or "linked" are not limited to physical or mechanical connections but may include electrical connections, whether direct or indirect.

[0125] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A test method based on a train control unit automatic test system, characterized by, Includes the following steps: S1. Test system initialization; S2. Start the line (1) to transport the unit under test to the insulation withstand voltage test unit (2). The unit under test and the insulation withstand voltage test unit (2) are connected through the docking unit (4). Then the insulation withstand voltage test unit (2) performs insulation withstand voltage test on the unit under test. After the insulation withstand voltage test is completed, the unit under test and the insulation withstand voltage test unit (2) are released through the docking unit (4). The insulation withstand voltage test unit (2) sends the test data to the central control unit. S3. Start the line (1) and transport the unit under test to the position of the functional test unit (3). The docking unit (4) is used to connect the unit under test and the functional test unit (3). Then the functional test unit (3) performs functional tests on the unit under test. After the functional test is completed, the docking unit (4) is used to release the unit under test from the functional test unit (3). The functional test unit (3) sends the test data to the central control unit. S4. Start the production line (1) and send the unit to be tested to the discharge platform; Step S1 is as follows: 1) Start: The test begins; 2) Automatic program tool invocation: The test equipment program is invoked from the server based on the model of the unit under test; 3) Initialization configuration: Initialize the configuration information of each test unit, track status information, and automatic docking unit (4) status information, and confirm the self-test of each test unit; 4) Initialization successful: Confirm that the initialization result is correct; The specific process of steps 1)-4) is as follows: Run step 1), specifically, open the host computer of the insulation withstand voltage test unit (2) and the host computer of the function test unit (3) respectively. Both host computers include PC host computer and HMI host computer. After opening, the software background will automatically confirm the network connection status of the device and the startup status of the host computer. After the host computer starts successfully, it will automatically run step 2). Specifically, the central control unit sends a request to the factory MES information system to obtain the production order information for the day. The insulation withstand voltage test unit (2) requests the central control unit to send the production information and writes the obtained information into the local cache. At the same time, it sends it to the functional test unit (3). The program tool software is automatically called to call the test software from the production program server according to the drawing number and the test software is automatically started. After the test software starts, step 3 is executed. Specifically, the host computer automatically reads the configuration information of the current drawing number in the cache of the insulation withstand voltage test unit (2) and the functional test unit (3); after obtaining the configuration information, it sends it to the servo system to complete the initialization of the line body (1) and the automatic docking unit (4). Step 4) Specifically, the status information read back from the initialization configuration is compared with the standard information in the cache to confirm whether the initialization has passed. If the initialization fails, it will be re-initialized and the operator will be notified by an alarm.

2. The test method of claim 1, wherein, The specific process of step S2 is as follows: 5) Line (1) Track operation: Start the track conveyor motor; 6) Incoming Material Confirmation: The incoming material platform confirms the presence of the unit under test; 7) Inbound buffer: Insulation withstand voltage buffer bit before entering the station; 8) Confirmation of the unit under test at the post-workstation: Confirm whether there are any products being tested at the insulation withstand voltage test station; 9) Insulation withstand voltage test unit (2) entry permission signal; 10) Scan the code to obtain information: Obtain information about the current unit under test and the insulation withstand voltage test requirements; 11) Automatic docking: Automatic docking of the insulation withstand voltage test unit (2) with the external interface of the unit under test; 12) Insulation withstand voltage test: Perform the routine insulation withstand voltage test as required; 13) Automatic release: After the test is completed, the insulation withstand voltage test unit (2) is automatically released from the external interface of the unit under test; 14) Insulation withstand voltage test unit (2) outgoing signal: Insulation withstand voltage test unit (2) outgoing signal.

3. The test method according to claim 2, characterized in that, The specific process of step S3 is as follows: 15) Confirmation of the unit under test in the subsequent process: Confirm whether there is a product being tested at the functional testing station; 16) Functional test entry: Functional test unit (3) entry permission signal; 17) Scan the code to obtain information: Obtain information about the currently tested unit and its functional test requirements; 18) Automatic docking: Automatic docking of the functional test unit (3) with the external interface of the unit under test; 19) Functional testing: Perform functional tests as required; 20) Automatic release: After the test is completed, the functional test unit (3) is automatically released from the external interface of the unit under test; 21) Functional test outbound: Functional test unit (3) outbound permission signal.

4. The test method according to claim 3, characterized in that, The specific process of step S4 is as follows: 22) Outbound cache: Cache location after functional testing is completed; 23) Feeding confirmation: The feeding platform confirms whether the unit under test exists. If not, the unit under test is sent to the feeding platform. 24) End: The test is over.

5. The test method according to claim 1, characterized in that, The configuration information in step 3) includes PLC execution information, feeding platform location information, track width and height information, and automatic docking unit (4) height / encoding / engagement status information.

6. The test method according to claim 2, characterized in that, The specific process of steps 5)-14) is as follows: After initialization is successful, step 5) is run. Specifically, the PLC automatically sends start signal and speed signal to the servo that controls the track operation and controls the servo motor to realize the operation of the entire track. Step 6) The receiving platform automatically confirms the presence of the unit under test. When the distance between the receiving platform and the unit under test is less than a certain distance, the platform determines that the unit under test has arrived. At this time, the receiving platform transports the unit under test onto the track for circulation. After circulation is completed, the platform rises back to a fixed height and disengages from the track to wait for new arrivals. After the incoming material is confirmed to be in good condition, step 7 is executed. Specifically, there is a blocking cylinder on the incoming material section track. The blocking cylinder automatically rises to buffer the tested unit. During step 8), the system automatically checks whether there is a product being tested at the insulation withstand voltage station. If the test is in progress, the buffer station blocking cylinder remains in the raised state. After the subsequent process test permission signal is enabled, the blocking cylinder falls down, and the tested unit continues to flow and automatically runs step 9). The tested unit automatically passes through the track docking point between the incoming material section and the insulation withstand voltage test section and enters the insulation withstand voltage test unit (2). After the insulation withstand voltage enters the station, the automatic operation step 10) is initiated. The barcode scanning section blocking cylinder is raised by default, and the barcode is scanned at intervals. After the scanning is completed, the relevant information is sent to the host computer of the insulation withstand voltage unit for caching, and the blocking cylinder is automatically lowered. The unit under test moves along the track and is intercepted by the current blocking cylinder when it reaches the insulation withstand voltage test station. Automatic operation step 11) is then performed for automatic docking. After the electrical connection is completed, the automatic operation step 12) is completed. The host computer compares the current production program code with the scanned cache information to see if it is correct, records the serial number of the unit under test, runs the production program, automatically realizes the group configuration and voltage setting according to the insulation withstand voltage test requirements, and completes the insulation resistance measurement, withstand voltage measurement and leakage current recording. The actual test results will be compared with the standard requirements to determine whether the test is qualified. Finally, the test report is backed up locally and uploaded to the central control system. After the test is completed, step 13) will be run automatically, which is the reverse of the action flow in step 11), thereby realizing the disconnection of the insulation withstand voltage test from the unit under test; after automatic disconnection, the blocking cylinder will be in the lowering state, and step 14) will be run automatically to complete the insulation withstand voltage test and transfer to the next process.

7. The test method according to claim 1, characterized in that, The automated testing system for the train control unit includes a line (1), a docking unit (4), an insulation withstand voltage test unit (2), a functional test unit (3), and a central control unit. The line (1) is used to transmit the data of the unit under test. The insulation withstand voltage test unit (2) and the functional test unit (3) are installed on the line (1) and arranged sequentially along the transmission method of the line (1). The insulation withstand voltage test unit (2) is used to perform automatic insulation resistance testing and withstand voltage testing on the unit under test on the line (1). The functional test unit (3) is used to perform input and output signal testing, communication function testing, and process status acquisition on the unit under test on the line (1). The docking unit (4) is used to automatically interconnect the external interfaces of each test unit with the external interfaces of the unit under test. The central control unit is connected to the docking unit (4), the insulation withstand voltage test unit (2), and the functional test unit (3) respectively, and is used to realize the distribution of test information and the collection of test process data.

8. The test method according to claim 7, characterized in that, The insulation withstand voltage test unit (2) includes an insulation withstand voltage tester.

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