A test platform and test method for scalable circuit control components

Abstract

This invention relates to the field of aerospace technology, specifically to a scalable circuit control component testing platform and testing method. It includes a control cabinet (1) and testing fixtures (2). In terms of testing functions, the platform can test I / O circuits, communication circuits, analog commands, PWM circuits, storage functions, drive circuits, conditioning circuits, sensor signal acquisition, power supply, and secondary power supplies, providing comprehensive functionality and complete testing items. Regarding product status, the platform can test the control components of mass-produced electric drive controllers, and can also gradually detect and locate faults in the control components of reworked products, greatly improving the work efficiency of testing personnel. In terms of product adaptability and scalability, users can adapt to the control components of more products by adjusting the hardware bed of needles and selecting test items in the software to create the required test sequence, thereby achieving batch testing of multiple products, which is more convenient and faster, greatly reducing the workload of researchers.

Description

Technical Field

[0001] This invention relates to the field of aerospace technology, and more specifically to a scalable circuit control component test platform and test method. Background Technology

[0002] More-electric and all-electric aircraft technologies are increasingly becoming the mainstream methods of aircraft propulsion, and more and more motor control systems are being applied in the aviation field. With the increasing variety and quantity of electric drive controller products being delivered, and the shortening delivery cycle, manufacturers are facing a sharp rise in labor costs and increasingly tight time pressures. The traditional testing method, where testers meticulously follow test procedures using various test equipment to test control components step by step, is becoming increasingly inadequate. Traditional testing methods involve complex steps and require highly skilled testers, necessitating the preparation of various measuring instruments and test equipment such as oscilloscopes, multimeters, power supplies, signal generators, and resistance boxes. Testing the various functions of the circuit board often requires soldering temporary power and signal lines, or damaging existing cables, potentially causing damage to circuit board solder joints or cables. Furthermore, as the operating time of electric drive controller products continues to increase, the number of products requiring rework and testing is also gradually increasing. The causes of failure in reworked products are complex and diverse, including component damage or aging, circuit abnormalities, pin desoldering or poor contact, and significant changes in component performance at high and low temperatures. Locating and repairing faulty products not only consumes a significant amount of time and energy for researchers and testers, but also poses a considerable challenge to the skill levels of personnel in aircraft repair shops due to the complexity and diversity of product designs, severely impacting the delivery of mass-produced electric drive controllers. Modern aircraft product production lines and aircraft repair shops increasingly require an automated, non-destructive board-level testing method. Summary of the Invention

[0003] To address the challenges posed by the complexity and repetitiveness of circuit board testing procedures during mass production deliveries by aerospace electric drive product manufacturers, and the difficulty in fault localization for returned products in aircraft repair shops, this invention designs a scalable circuit control component testing platform and method. This platform can be used for testing board-level products such as CPU boards, conditioning boards, and drive boards (hereinafter collectively referred to as control components) of airborne electric drive controllers. It can test various circuits and functions related to I / O circuits, communication circuits (including 422, 429, and CAN communication), analog commands, PWM circuits, storage functions, drive circuits, conditioning circuits, sensor signal acquisition, power supply, and secondary power supplies. For different products, only different test items need to be selected in the software; no specially designed test programs are required. The testing platform is used to test the hardware circuits and software logic of the circuit board and has both manual and automatic control modes. In manual mode, the board-level testing unit provides the external power supply and various excitation signals required by the control board, facilitating manual testing by designers and testers. In automatic mode, the board-level testing unit automatically determines the normality of the hardware circuits and software logic through excitation injection and signal acquisition.

[0004] Invention Technical Solution

[0005] The present invention provides an scalable circuit control component testing platform and testing method, which mainly determines whether the various functions of the control component are normal by inputting external excitation signals and collecting board-level signals, thereby achieving the purpose of mass production of circuit boards and automatic fault location.

[0006] A scalable circuit control component test platform includes a test and control cabinet (1) and a test fixture (2);

[0007] The measurement and control cabinet (1) includes: cabinet (3), AC power distribution box (4), programmable power supply (5), oscilloscope (6), data acquisition instrument (7), switch (8), signal distribution and conditioning box (9), multi-computer switch (KVM) (10), and main control computer (11). The AC power distribution box (4), programmable power supply (5), oscilloscope (6), data acquisition instrument (7), switch (8), signal distribution and conditioning box (9), multi-computer switch (KVM) (10), and main control computer (11) are placed in the slots of the cabinet (3) from top to bottom. The AC power distribution box (4) is connected to the programmable power supply (5), oscilloscope (6), data acquisition instrument (7), switch (8), signal distribution and conditioning box (9), KVM (10), and main control computer (11) respectively to realize the power supply of the internal equipment of the measurement and control cabinet (1). The switch (8) is connected to the programmable power supply (5), oscilloscope (6), data acquisition instrument (7), signal distribution and conditioning box (9), and main control computer (11) via network ports to realize software control of the equipment. The signal distribution and conditioning box (9) is connected to the programmable power supply (5), oscilloscope (6), data acquisition instrument (7), and main control computer (11) to realize the distribution, switching, conditioning, and acquisition of power supply and input / output signals of the control components. The KVM (10) is connected to the main control computer (11) and is used as the screen, mouse, and keyboard of the main control computer (11).

[0008] The test fixture (2) includes: a housing (12), a quick clamp (13), a guide rail (14), and a needle plate (15). The housing (12) includes a three-dimensional support part and a main body part. The needle plate (15) includes: a pressure plate, a needle plate guide rail, a PCB base, a needle bed, and a positioning pin. The quick clamp (13) is connected to the three-dimensional support part on the housing (12), and is connected to the pressure plate on the needle plate (15) through the guide rail (14). The PCB base of the needle plate (15) is fixed to the main body part on the housing (12). The needle plate guide rail connects the pressure plate and the PCB base. The needle bed is fixed on the PCB base, and the positioning pin is fixed below the pressure plate. By manually pressing the quick clamp, the quick clamp drives the guide rail and the pressure plate to move downward along the needle plate guide rail, so that the positioning pin fixes the control component on the PCB substrate below. The test point on the control component can contact the needle bed, thereby introducing the excitation signal into the control component through the probe on the needle bed, and introducing the signal to be tested from the control component into the test platform. The test fixture is a fixture that holds the control components in place and presses against the probe bed, leading each test point to the test interface via spring probes. The test probe plate design provides expansion for the test equipment, meeting the requirements for debugging different new products and locating faults in reworked products.

[0009] The electrical interface of the signal distribution and conditioning box (9) on the control cabinet (1) is connected to the electrical interface of the housing (12) on the test fixture (2) via a quick-connect, anti-misfit aviation circular connector. Six types of cables are provided according to the signal type used: power supply cable, communication cable, discrete quantity cable, digital quantity cable, analog input cable, and analog output cable. The power supply cable provides two 0-28V power supply lines and one 24V power supply line. The communication cable provides one communication line for receiving and sending RS422, CAN, and 429 communication data. The discrete quantity cable provides two signal lines for the excitation and measurement of discrete quantities. The digital quantity cable provides two signal lines for the excitation and measurement of digital quantities. The analog output cable provides two signal lines for providing voltage, current, resolver, LVDT, and resistance signals to the control components. The analog input cable provides two signal lines for the input and measurement of analog quantities.

[0010] Furthermore, the AC distribution box (4) includes: a voltmeter, an ammeter, a fuse, a start switch, a shutdown switch, an emergency stop switch, a leakage protection switch, an AC contactor, an AC power strip, and an AC input socket. The AC power supply is supplied to the AC distribution box (4) via the power cord and the AC input socket. The AC power strip supplies power to the programmable power supply (5), oscilloscope (6), switch (8), signal distribution and conditioning box (9), KVM (10), main control computer (11), and test fixture (2). The voltmeter and ammeter are mainly used to display the power supply voltage and current of the control cabinet. The start switch, shutdown switch, emergency stop switch, leakage protection switch, fuse, and AC contactor are used to implement power supply control, overcurrent protection, and other functions, effectively protecting the personal safety of test personnel and the safety of equipment.

[0011] The programmable power supply (5) includes: four DC power supplies with a voltage output range of 0-20V and a current output range of 0-10A, and one DC power supply with a voltage output range of 0-40V and a current output range of 0-19A. The programmable power supply with a voltage output range of 0-20V provides 3.3V, ±5.0V, and ±15V DC power to the control board assembly, and the programmable power supply with a voltage output range of 0-40V provides 28V DC power. All five programmable power supplies are connected to the switch (8) via network ports, thereby enabling software control of the output voltage and current using the main control computer (11).

[0012] Among them, the oscilloscope (6) is a four-channel oscilloscope equipped with LAN connectivity, used for the control and monitoring of the waveform characteristics of the signal.

[0013] The data acquisition unit (7) includes: one data acquisition unit equipped with USB and LAN interfaces and built-in signal conditioning function, one 40-channel single-ended multiplexer, and one 20-channel multiplexer. The input of the data acquisition unit is connected to the two multiplexers. The data acquisition unit is used to measure signals such as voltage, resistance, frequency, and pulse width, and can be switched to any measurement point for testing via a self-test switchboard. The single-ended multiplexer is used to measure two-wire inputs other than current. The 20-channel multiplexer enables AC and DC current measurement without the use of an external shunt resistor.

[0014] Among them, the switch (8) is used to realize the communication and high-speed data transmission between the main control computer (11) and the programmable power supply (5), oscilloscope (6), data acquisition instrument (7), and signal distribution and conditioning box (9).

[0015] The signal distribution and conditioning box (9) includes: a transmitter, a self-test switching board, a signal conditioning circuit, a disconnection board, an electrical interface, and a module power supply. The electrical interface is connected to the disconnection board, the disconnection board is connected to the transmitter, the transmitter is connected to the self-test switching board, and the self-test switching board is connected to the signal conditioning circuit. The electrical interface is implemented using a quick-connect anti-misinsertion aviation circular connector, which is used to connect the control cabinet and the test fixture. The transmitter is used to achieve power, input, and output isolation, filter and attenuate the field signal, isolate different potentials, and suppress external magnetic cabin interference. Different transmitter output types are selected according to different excitation requirements to achieve the excitation output requirements. The disconnection board is used to realize the signal disconnection function. When the control cabinet hardware resources are disconnected, external signals can be manually injected or tested on the control components. The self-test switching board includes: a 2-pole 5A general-purpose power relay with a rated voltage of 24V, a solid-state relay with a control voltage of 3-32VDC and a load voltage of 5-220VDC, and a control circuit. The self-test switching board is used to connect hardware resources and the device under test. Each board provides 64-line switching capability and provides test resource switching capability for two buses. When the external cable connection is disconnected, the test platform can realize open-loop self-test function and give the operating status of key signals (voltage output, I / O level) and key devices (sensors). The function of the signal conditioning circuit is to condition the excitation signal. The excitation signal is output by the board in the main control computer (11). After conditioning, the excitation signal is conditioned to the signal type required by the control components (voltage type excitation, current type excitation, resolver signal). The module power supply is a 24V power supply with short circuit, overload and overvoltage protection, used for powering the relays and transmitters.

[0016] Among them, KVM(10) uses a pull-out LCD control terminal module.

[0017] The main control computer (11) includes: a chassis, a controller, an analog output card (AO card), a high-speed digital signal card, a resolver signal card (RVDT signal card), a linear transform sensor signal card (LVDT card), a discrete output card (DO card), a discrete input card (DI card), a resistor card, a CAN bus communication card, an ARINC429 card, a MIL-STD-1553B bus communication card, and an RS422 bus communication card. The signal terminals of the analog output card, resolver signal card, linear transform sensor signal card, discrete output card, resistor card, and high-speed digital signal card are connected to the conditioning circuit of the signal distribution and conditioning box (9) to realize the excitation and acquisition of IO signals and sensor signals; the control terminal is connected to the controller to realize the control of communication, input, output functions and modes. The CAN bus communication card, ARINC429 card, MIL-STD-1553B bus communication card, and RS422 bus communication card are connected to the disconnect board of the signal distribution and conditioning box (9) to realize communication testing between the control components on the test fixture (2) and the main control computer (11). The chassis uses a chassis with 4GB / s bandwidth, 17 mixing slots and 1 system slot. Analog output card is used to output voltage or current excitation signals (external isolation module). High-speed digital card is used to output high-speed digital signals. Resolver signal is implemented using digital-to-linear resolver converter. LVDT card uses LVDT simulation card for LVDT sensor signal simulation. Discrete input card and discrete output card use discrete input / output card for external DI type signal acquisition and DO type excitation output. Resistor card uses 4-channel resistor switching board for PT1000 / PT100 temperature sensor simulation. RS422 bus communication card is used to communicate with the onboard DSP chip via RS422 bus. The CAN bus communication card is used for CAN bus communication with the onboard DSP chip. The ARINC429 communication card is used for ARINC429 bus communication with the onboard DSP chip. The MIL-STD-1553B bus communication card is used for 1553B bus communication with the onboard DSP chip.

[0018] In the test fixture (2), the bottom probe in the pin board (15) is designed to bring out the electrical interface connector of the control component, and the concave test probe is used to connect to the electrical interface pad. Considering the characteristics of the pads of the control components (through, surface mount and via) of the electric drive controller, as well as the high-density pin spacing of DSP and CPLD, and the characteristics of the maximum power supply of 3A, a 50mil test probe is selected. The front side uses a long needle with a working stroke of 4.3mm and a maximum stroke of 6.35mm. The bottom side uses a short needle with a working stroke of 2.5mm and a maximum stroke of 4.2mm. The needle is selected according to different test purposes: a 30° conical head is selected for clean surfaces such as chip pads, a 4-claw crown-type needle is selected for protruding pads and upright component pads, and a 9-pin triceps (serrated) needle is selected for upright components and connector leg pads. The PCB base is arranged to avoid the component openings to ensure that the board body is evenly stressed and the components on the board do not come into contact with each other.

[0019] The entire device has a convenient and reliable assembly structure, and is easy to maintain due to the convenient connection of its various internal functional modules.

[0020] A method for testing scalable circuit control components includes the following steps:

[0021] Step 1: Press the start switch on the AC distribution box (4). The main control computer (11) will turn on simultaneously and open the host computer software. The software will open and connect to the database, and enter the system self-test. The system self-test will automatically check whether the power supply, equipment, function boards, etc. are working properly and display the self-test results. At the same time, it will output 24VDC to ensure that the signal distribution conditioning box, resistor card and resolver card work properly.

[0022] Step 2: Enter the main program (the interface is now the test interface). The software initializes the test interface, power supply, devices, and function boards. Subsequent operations can only be performed after initialization is complete.

[0023] Step 3: Align the positioning holes at the four corners of the control component with the positioning bolts and insert them into the slots; move the quick clamp to press down the pressure plate, and use the pressure pin to press down the control component to lower it until it reaches the needle plate. The lower test probe will then contact the test point and draw out the signal.

[0024] Step 4: Power Supply Test. The power supply test includes a 28V power supply test and a power conversion module test.

[0025] a. 28V Power Supply Test. Select the control component test sequence and check the "28V Power Supply" test item. Enter the serial number of the board under test and click the "OK" button to start the test and complete the power supply test for the control component. Observe the power supply status and check the software records for any abnormal states. The control and implementation logic is as follows: Before powering the control component, the internal excitation connection is disconnected by programmable control, and the interface resistance is checked using a data acquisition instrument; switch to an oscilloscope for online excitation voltage waveform monitoring (single channel); power is supplied to the control component, and the system switches to the data acquisition instrument for online excitation voltage monitoring. The control and implementation logic function block diagram is as follows: Figure 3 As shown. b. Power Conversion Module Test. Check the "Conversion Module Test" test item. The test items are 5V and ±15V output tests. Enter the serial number of the board under test and click the "OK" button to start the test and complete the power conversion module test. The control component is a 28V to 5V and ±15V power supply module. The 5V is the VCC power supply, which powers the communication circuit, the isolation optocoupler in the IO circuit, the operational amplifier, the driver circuit, the CPU and CPLD, and other circuits and chips. The ±15V is the power supply for the operational amplifier. The control and implementation logic is as follows: Before testing the control component, the external excitation connection is disconnected by programmable control, and the interface resistance is checked using a data acquisition instrument; when testing the control component, switch to the data acquisition instrument for online voltage monitoring.

[0026] Step 5: Communication test.

[0027] a. Host Computer 422 Communication. Select the "28V, 5V, and 3.3V Power Supply" and "Host Computer 422 Communication Test" test items, enter the serial number of the board under test, and click "OK" to complete the host computer 422 communication test for the control component. During testing, if the control board component does not have a CPU component installed, a serial port loopback test can be achieved by shorting the serial port receive port and transmit port on the interface between the control board component and the CPU component. Perform the following tests in sequence: communication test, CPU to serial port positive terminal high-level transmission test, CPU to serial port positive terminal low-level transmission test, serial port to CPU high-level transmission test, and serial port to CPU low-level transmission test. 3.3V is used for power supply to the communication circuit. An RS422 bus communication card is used to complete the test for the RS422 communication interface. The control and implementation logic is as follows: The RS422 serial port communication interface, after passing through a self-test switching board and a disconnection board, is directly connected to the control board's communication interface via an electrical interface; when the RS422 communication signal passes through the self-test switching board, it can be switched to an oscilloscope or data acquisition instrument for online excitation testing; before the control components are powered on, the acquisition channel is programmed to switch to the resistance range to complete the interface resistance check; the spare serial port is selected to perform cross-communication self-test within the measurement and control cabinet; the RS422 communication interface is directly connected to the control board's communication interface via an electrical interface to complete protocol communication verification; and the system switches to an oscilloscope for online bus waveform monitoring (single channel).

[0028] b. Redundancy interval 422 communication test. Same as step 5a.

[0029] c. CAN Communication Test. Select the "28V, 5V, and 3.3V Power Supply" and "CAN Communication Test" items, enter the serial number of the board under test, and click "OK" to complete the CAN communication test of the control component. Perform the communication test, the CAN card to CPU high-level transmission test, and the CAN card to CPU low-level transmission test in sequence. The logic is the same as in step 5a.

[0030] Step 6: Sampling circuit testing. This step includes:

[0031] a. Phase Current Test. Select the "28V, 5V, and 3.3V Power Supply" and "Phase Current Test" test items, and click "OK" to complete the A and B phase current test of the control component. This test item checks whether the output of the phase current sampling and conditioning circuit meets the requirements. The 3.3V supply is for the limiting circuit. The specific method is: given an input level and a specified output range, determine whether the output of the conditioning circuit meets the requirements. The control and implementation logic is as follows: before the control component is powered on, after the programmable controller disconnects from the internal excitation connection, the interface resistance can be checked using a data acquisition instrument; the excitation is output after conditioning through the voltage output card, and monitored by the current acquisition module; switch to the oscilloscope for online excitation voltage waveform monitoring (single channel); switch to the data acquisition instrument for online excitation current monitoring.

[0032] The conditioning process employs isolated modules, offering advantages such as no signal interference and convenient single-channel maintenance. Different types of voltage / current modules are selected for each channel. The signal excitation function (including voltage and current type excitation, resistive excitation, resolver type excitation, LVDT type excitation, IO type excitation, and DO type excitation) is designed for simultaneous output across all channels. This reduces overall test completion time during automated testing and allows for complete, continuous, and reliable simulation of external excitation states during later application debugging, improving debugging and troubleshooting efficiency and fault location accuracy.

[0033] The current-type excitation method is as follows: The analog output card outputs a ±10V voltage signal to the power isolation module. After conversion by the power isolation module (response time 10ms transient), it outputs the current excitation signal (-150mA to +150mA) required by the control board. The excitation signal passes through the self-test switching board and the disconnection board, and is then introduced to the target control board through the electrical interface. When the excitation signal passes through the self-test switching board, the self-test load resistor is enabled. Switching to an oscilloscope or data acquisition instrument allows for online excitation detection.

[0034] b. Bus current test. Same as step 6a.

[0035] c. Front-end and rear-end bus voltage testing. Same as step 6a, except that voltage sampling uses voltage-type excitation, load resistance is not used during self-test, and online excitation voltage monitoring is used during monitoring.

[0036] d. Temperature Sampling Test. The temperature sampling test includes IGBT temperature sampling test and motor temperature sampling test, both of which are resistive excitation tests. During the test, select the "28V and 5V, 3.3V power supply" and "Temperature Sampling Test" test items, enter the serial number of the board under test, and click "OK" to complete the control component temperature sampling test. This test item checks whether the voltage output of the temperature sampling circuit meets the requirements. The control and implementation logic is as follows: Use a resistor output card to output a resistive excitation signal, adjust the resistance signal according to the 8421 encoding method, and output it directly. After passing through the self-test switching board and the disconnection board, it is introduced to the target control board through the electrical interface. When the excitation signal passes through the self-test switching board, it switches to the data acquisition instrument for online excitation detection. Before the control component is powered on, the programmable controller disconnects the internal excitation connection, and then the data acquisition instrument checks the interface resistance.

[0037] Step 7: IO Module Level Test. Select the "28V and 5V, 3.3V Power Supply" and "IO Level Test" test items, enter the serial number of the board under test, and click "OK" to complete the control component level test. The test automatically provides and switches the input and output test points of the control component's IO ports, completing the test of the isolation optocoupler output level involved in the control component IO level test. The IO module level test method and implementation logic are basically the same as steps a and c in Step 6.

[0038] Step 8: Resolver Decoding Module Test. Select the "28V, 5V, and 3.3V Power Supply" and "Resolver Excitation Test" items, enter the serial number of the board under test, and click "OK" to complete the resolver excitation test of the conditioning board. This test includes:

[0039] a. Resolver SPI Communication Test. The core of the resolver SPI test involves software-controlled resolver board outputting 12 angle values ​​with an initial value of 10 degrees and a gradient of 30 degrees. Simultaneously, the 16-bit register value output by the resolver decoder chip is measured, and the first 12 bits are taken. The difference between the output value of each subsequent angle and the output value of the previous angle should be approximately 341. The absolute error of this difference from 341 should be controlled between 0 and 50.

[0040] b. Resolver Excitation Test. This test mainly determines whether the test results meet the requirements by measuring the excitation voltage and excitation frequency range output by the resolver decoding module. The signal transmission process is as follows: the control board outputs resolver excitation, which is transmitted through the electrical interface, the disconnection board, and the self-test switching board to the resolver simulation card; the resolver simulation card receives the resolver excitation and outputs the resolver signal (sine and cosine) according to the settings, which is transmitted through the self-test switching board and the disconnection board to the target control board via the electrical interface. The control and implementation logic is as follows: before the control component is powered on, the programmable disconnection is performed, and the interface resistance is checked using a data acquisition instrument; after the control component is powered on, the system switches to the data acquisition instrument for online excitation voltage monitoring; the resolver excitation is input to the digital-to-linear resolver converter, and after conditioning, the resolver signal is output according to the set angle value; the system switches to an oscilloscope for online waveform monitoring (single channel), frequency measurement, and phase difference measurement; the oscilloscope's three channels are used to acquire the excitation and signal ends of the resolver signal for waveform analysis.

[0041] Step 9: APWM Waveform Test. This test uses a digital output board to output a set of APWM waveforms. The waveform amplitude is 3.3V, the frequency is 10kHz, the duty cycle of the positive pulses of APWM1, APWM3, and APWM5 is 40%, and the duty cycle of the positive pulses of APWM2, APWM4, and APWM6 is 58%. Therefore, the dead time is 1 / 10000*0.02=0.000002S=2uS. Check the "28V and 5V, 3.3V power supply", "CPLDFault set high", and "APWM test" test items, enter the serial number of the board under test, and click "OK" to complete the APWM waveform test of the control component. The test output waveform frequency error should not exceed 500Hz, the amplitude should be 5±0.2V, and the duty cycle error should not exceed 5% to be considered qualified. The control and implementation logic is as follows: Before the control component is powered on, the acquisition channel is programmed to switch to the resistance range to complete the interface resistance check; the PWM signal is input to the data acquisition instrument for acquisition through the electrical interface, the disconnection board, and the self-test switching board; the PWM signal value is directly acquired by the data acquisition instrument and oscilloscope, and the measurement range is configured according to the signal type.

[0042] Step 10: Onboard Chip Circuit Testing. This test includes two types of tests: control port testing and functional testing. The control port test logic is as follows: The DSP's built-in test program outputs static chip select and enable signals, and a data acquisition unit collects data from the corresponding chip ports to verify the correctness of the control ports. The signals tested in the control port test include: FLASH chip, SDRAM, NVRAM, I2C, SPI, watchdog timer, and CPLD. The functional test verifies the read / write functions of each chip using the DSP's built-in test program.

[0043] In steps 4-10 above, without connecting the external electrical interface cable, the output devices in the measurement and control cabinet can be self-tested and self-calibrated by the data acquisition instrument; the hardware resources of the measurement and control cabinet can be disconnected by the disconnecting board to manually inject external signals or test the product.

[0044] For single or multiple tests of control components, you can select steps 4-10 above for automatic or manual testing as needed. For automatic testing of control components for batch production products, during testing, select the required test items in steps 4-10, enter the serial number of the board under test, and click "OK" to complete the full functional performance test of the control component.

[0045] The beneficial effects of this invention are as follows: This invention develops a scalable circuit control component testing platform. The testing platform assists users in performing performance testing and functional verification of electric drive controller components, greatly improving user testing efficiency and allowing ample time for users to identify and resolve problems. The testing platform enables manual and automatic operations for board-level testing and features high production efficiency, low labor intensity, safety and reliability, and good demonstrability. In terms of control component types, the testing platform can test various control components, including control boards, conditioning boards, and drive boards, demonstrating strong adaptability. Regarding testing functions, the platform can test I / O circuits, communication circuits (including multiple communication methods such as 422, 429, and CAN communication), analog commands, PWM circuits, storage functions, drive circuits, conditioning circuits, sensor signal acquisition, power supply, and secondary power supplies, offering comprehensive functionality and complete test items. In terms of product status, the platform can test the control components of mass-produced electric drive controllers and gradually detect and locate faults in the control components of returned products, greatly improving the efficiency of testing personnel. Regarding product adaptability and scalability, users can adapt to the control components of more products by adjusting the hardware bed of needles and selecting test items in the software to create the required test sequence in the test step tree structure, thereby achieving batch testing of multiple products, which is more convenient and faster, greatly reducing the workload of researchers. Signal measurement is achieved through contact between the needle bed and the control components, reducing tedious wiring work and avoiding additional soldering or cable damage. This makes the control components and their cables neater, reduces damage to control components caused by soldering errors, and makes it easier for assembly personnel to assemble the product. The monitoring controls in the test software installed on the industrial control computer can monitor the voltage and current changes of each power supply in real time. When the voltage and current changes exceed the set threshold values, the power supply is promptly cut off, preventing damage to the product due to prolonged overvoltage, undervoltage, or overcurrent, making it safer and more reliable. The test software uses database technology. On the one hand, the test platform provides data playback functionality during the test process, enabling it to pinpoint which test failed and why, thus providing diagnostic and repair suggestions for testers. On the other hand, the test software provides a fault tree configuration function, allowing users to set the fault tree hierarchy and the relationship between faulty modules, thereby providing maintenance personnel with the cause of the fault and solution suggestions during fault localization. Attached Figure Description

[0046] Figure 1 This is a structural diagram of a test platform for scalable circuit control components.

[0047] Among them, 1-housing assembly, 2-high voltage DC contactor assembly, 3-busbar assembly, 4-fuse, 5-lightning protection filter and reverse charging module, 6-external aviation connector. 1-measurement and control cabinet, 2-test fixture, 3-cabinet, 4-AC distribution box, 5-programmable power supply, 6-oscilloscope, 7-data acquisition instrument, 8-switch, 9-signal distribution and conditioning box, 10-KVM switch, 11-main control computer.

[0048] Figure 2 This is a functional block diagram of a test platform for scalable circuit control components;

[0049] Figure 3 It is a block diagram of the control and implementation logic functions for signal input and output. Detailed Implementation

[0050] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be described in more detail below. In the examples, the same or similar reference numerals denote the same or similar components or elements having the same or similar functions throughout. The described embodiments are some, but not all, embodiments of this invention. The embodiments described below with reference to reference are exemplary and intended to explain this invention, and should not be construed as limiting the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. The embodiments of this invention will be described in detail below.

[0051] Example 1

[0052] The test and control cabinet (1) is the main component of the electric drive controller board-level test unit. It provides the signal excitation required for testing the electric drive controller circuit board and collects the output signals of the circuit board for testing. Among them, the 220V power supply box (3) provides power to the test platform and has functions such as power-on switch, power-off switch, emergency stop switch, power supply voltage and current display, and overcurrent protection. The programmable power supply (4) provides power to the electric drive controller circuit board. The oscilloscope (5) is equipped with a function generator for signal waveform testing. The data acquisition instrument (6) has a built-in digital multimeter for signal testing. The signal distribution and conditioning box (7) has a built-in switching board to realize functions such as fault injection of the electric drive controller circuit board. It also provides breakpoints for easy testing and external interfaces for easy connection. The KVM (8) can access and control the computer by directly connecting the keyboard, monitor and mouse. The main control computer (9) provides the test resources, platform and software development environment required for the electric drive controller circuit board. In addition, secondary power supplies and on-board chip interface signals are added to meet future board-level test requirements. Implementable test items are designed in the test platform software. It has a certain degree of interface scalability to meet the debugging needs of new products.

[0053] The test fixture (2) mainly includes a bed of needles (11) and test cables (12). The bed of needles (11) is used to fix the electric drive controller circuit board and to lead the test signals from the board and the test cabinet (1) to the connector, assisting the test cabinet (1) in completing the test of the electric drive controller circuit board. The bed of needles (11) can switch the test state according to the status of the circuit board (depending on whether the DSP daughter board is installed). When the electric drive controller board is not equipped with the DSP daughter board, pressing the switch will illuminate the indicator light. The test circuit is led to the designated connector through the probe. Pressing the quick clamp by hand will press down the pressure plate, and the TP point on the circuit board will be connected to the test circuit, which is reliable and convenient. There are 6 types of test cables (12) used to connect the test cabinet and the bed of needles. The connection relationship between the 6 types of test cabinet and bed of needles achieved by the test cables is shown in Table 1.

[0054] Table 1. Connection relationship between the test cabinet and the needle bed

[0055]

[0056]

[0057] When testing the input signal of the target circuit board, the main control computer software controls the excitation source board to output the excitation signal, which is led to the test probe bed through the test cable, introduced into the target control board through the electrical interface of the test target, and after being conditioned by the internal circuitry of the board, fed back to the cable under test through the test probes pressed against the test holes of the target control board, and transmitted to the data acquisition instrument in the test and control cabinet. After being converted into data by the data acquisition instrument according to the configured signal type, the test and control software reads the data, interprets and displays it, and reports and records the test results according to the preset criteria program.

[0058] When testing the output signal of the target circuit board, the main control computer software sends the product output command to the onboard chip through the product communication bus. The onboard chip outputs the corresponding signal to the conditioning circuit. By pressing the test probes at the front and rear stages of the conditioning circuit on the board, the product output signal is fed back to the cable on the side and transmitted to the data acquisition instrument in the test and control cabinet. After the data acquisition instrument converts the signal into data according to the configured signal type, the test and control software reads the data, interprets and displays it, and reports and records the test results according to the preset judgment program.

[0059] When testing the onboard chips of the target circuit board, the main control computer software sends chip self-test instructions through the product communication bus. The chip completes the FLASH circuit test, SDRAM circuit test, NVRAM circuit test, external I2C circuit test, gate circuit test, SPI circuit test, CPLD circuit test, RS422 bus circuit test, CAN bus circuit test, ARINC429 bus circuit test, and MIL-STD-1553B bus circuit test in sequence according to the written test instructions.

[0060] Both the self-test switching board and the data acquisition instrument use the concept of a multiplexer, which allows high-precision, high-performance instruments to be switched to each node that needs to be tested, saving costs.

[0061] It implements electrical interface testing as specified in the technical requirements, and also designs board-level interface tests for various test types. By designing a test bed, it also brings out secondary signals from some signal interfaces on the PCB board for testing. The summary and analysis of chip interface and board-level interface test results can provide faster, more accurate, and more complete fault location. It completes all computer tests required for the technical specifications.

[0062] The testing platform uses a control system centered on an industrial control computer. Operators can control the output of excitation signals through a human-machine interface, thereby testing the operating status of the board's I / O circuits, communication circuits, PWM circuits, and key components (such as sensors).

[0063] The signal excitation mainly consists of the following 6 parts:

[0064] DC signal excitation: voltage-type excitation and current-type excitation. The DC signal excitation design uses an industrial control computer board to output a standard voltage signal, which is then converted to the corresponding signal range output by an external conditioning module. Current excitation output functions: The excitation is output after conditioning via a voltage output card, and monitored by a current acquisition module; before powering on the product, after disconnecting the internal excitation connection via programmable control, the interface resistance can be checked using a data acquisition instrument; switch to an oscilloscope for online excitation voltage waveform monitoring (single channel); switch to a data acquisition instrument for online excitation current monitoring; when no external electrical interface cable is connected, after enabling the self-test load resistor, the data acquisition instrument can be used for internal self-test and self-calibration within the control cabinet; the control cabinet hardware resources can be disconnected via a disconnect board to manually inject external signals or perform tests on the product.

[0065] The analog output card NIPXIe-6738 outputs a ±10V voltage signal to the power isolation module. After conversion by the power isolation module (response time 10ms transient), it outputs the voltage excitation signal required by the control board (±15V, differential 0~10V or differential 0~2V). The excitation signal is introduced to the target control board through the electrical interface after passing through the self-test switching board and disconnection board.

[0066] When the excitation signal passes through the self-test switching board, it can be switched to an oscilloscope or data acquisition instrument for online excitation testing.

[0067] The NIPXIe-6738 analog output card outputs a ±10V voltage signal to the power isolation module. After conversion by the power isolation module (response time 10ms transient), it outputs the current excitation signal (-150mA to +150mA) required by the control board. The excitation signal is introduced to the target control board through the electrical interface after passing through the self-test switching board and the disconnection board.

[0068] When the excitation signal passes through the self-test switching board, the load resistor for self-test is enabled. Switching to an oscilloscope or data acquisition instrument allows for online excitation testing.

[0069] Resolver-type excitation. The resolver-type excitation is designed to use a digital-to-linear resolver converter to directly output the excitation voltage, signal voltage, and frequency range.

[0070] The test is divided into two parts: the resolver signal end and the excitation end. The resolver excitation is input to the digital-to-linear resolver converter, and after conditioning, the resolver signal is output according to the set angle value. Before powering on the product, after disconnecting the internal excitation connection via programmable control, the interface resistance can be checked using a data acquisition instrument. Switch to an oscilloscope for online waveform monitoring (single channel), frequency measurement, and phase difference measurement; switch to a data acquisition instrument for online excitation voltage monitoring; when no external power interface cable is connected, the data acquisition instrument can be used for self-testing and self-calibration within the control cabinet; the control cabinet hardware resources can be disconnected via a disconnect board to manually inject external signals or perform tests on the product; the excitation and signal ends of the resolver signal are acquired using a three-channel oscilloscope, and waveform analysis can be performed.

[0071] The control board outputs resolver excitation, which is transmitted via an electrical interface, a disconnection board, and a self-test switching board to the resolver simulation card. Upon receiving the resolver excitation, the resolver simulation card outputs resolver signals (sine and cosine) according to its settings. These signals are then transmitted via a self-test switching board and a disconnection board to the target control board via the electrical interface.

[0072] When the resolver excitation and resolver signal pass through the self-test switching board, it can be switched to a data acquisition instrument or oscilloscope for online excitation testing.

[0073] LVDT type excitation. The excitation voltage, signal voltage, and frequency range are set and output directly. Testing is divided into two parts: the LVDT signal terminal and the excitation terminal. The LVDT excitation is input to the LVDT card, and after conditioning, the LVDT signal is output according to the set values. Before powering on the product, after disconnecting the programmable controller from the internal excitation connection, an interface resistance check can be performed using a data acquisition instrument. Switching to an oscilloscope allows for online waveform monitoring (single channel), frequency measurement, and phase difference measurement. Switching to a data acquisition instrument allows for online excitation voltage monitoring. Without connecting the external electrical interface cable, self-testing and self-calibration within the control cabinet can be performed using a data acquisition instrument. The control cabinet hardware resources can be disconnected via a disconnect board to manually inject or test external signals. Using a three-channel oscilloscope to acquire the excitation and signal terminals of the resolver signal allows for waveform analysis.

[0074] The control board outputs LVDT excitation, which is transmitted via the electrical interface, disconnection board, and self-test switching board to the LVDT simulation card. Upon receiving the LVDT excitation, the LVDT simulation card outputs an LVDT signal according to its settings, which is then transmitted via the self-test switching board and disconnection board to the target control board via the electrical interface.

[0075] When the LVDT excitation and LVDT signal pass through the self-test switching board, it can be switched to a data acquisition instrument or oscilloscope for online excitation testing.

[0076] High-speed digital I / O excitation: The high-speed digital I / O excitation is designed to use a high-speed digital meter card to output high-speed digital I / O signals, which are then converted into corresponding signal outputs by an external conditioning circuit. High-speed digital I / O excitation outputs include Hall effect signals (5V level, 15V level), chopper-driven excitation (TTL, 5V, 10kHz), and control excitation (TTL, 5V). Functions include: outputting excitation signals after conditioning via a high-speed digital meter card; before powering on the product, disconnecting the internal excitation connection via a programmable controller allows for interface resistance checks using a data acquisition instrument; online excitation voltage waveform monitoring (single channel) can be performed using an oscilloscope; online excitation voltage monitoring can also be performed using a data acquisition instrument; when no external power interface cable is connected, self-testing and self-calibration within the control cabinet can be performed using a data acquisition instrument; and external signal injection or testing can be manually performed on the product by disconnecting the control cabinet hardware resources via a disconnector.

[0077] The high-speed digital I / O card NIPXIe-6612 outputs high-speed digital I / O signals to the conditioning circuit. After conditioning, the circuit outputs the high-speed digital I / O excitation signal required by the control board. The excitation signal passes through the self-test switchboard and disconnection board, and is then introduced to the target control board via the electrical interface. When the excitation signal passes through the self-test switchboard, it can be switched to an oscilloscope or data acquisition instrument for online excitation testing.

[0078] External DO type excitation. A discrete output card (cPCI-1101A) is used to output aviation 28V / 0V / on discrete signals. Functions of the external DO type excitation output: Direct excitation output via the discrete output card; Before powering on the product, after disconnecting the programmable circuit from the internal excitation connection, an interface resistance check can be performed using a data acquisition instrument; Switching to an oscilloscope for online excitation voltage waveform monitoring (single channel); Switching to a data acquisition instrument for online excitation voltage monitoring; When no external electrical interface cable is connected, self-testing and self-calibration within the control cabinet can be performed using a data acquisition instrument; External signal injection or testing can be manually performed on the product by disconnecting the control cabinet hardware resources via a disconnector.

[0079] The discrete output card outputs a 28V discrete excitation signal. The excitation signal is introduced to the target control board through the electrical interface after passing through the self-test switching board and the disconnection board.

[0080] When the excitation signal passes through the self-test switching board, it can be switched to an oscilloscope or data acquisition instrument for online excitation testing.

[0081] The signal excitation function is designed to output all channels simultaneously, which can reduce the overall test completion time during automatic testing; it can also completely, continuously and reliably simulate the external excitation state during later application debugging, thereby improving debugging and troubleshooting efficiency and improving fault location accuracy.

[0082] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein. The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Within the spirit and principles of the present invention, any person skilled in the art may use the disclosed technical content to make changes or modifications to create equivalent embodiments applicable to other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention, any modifications, equivalent substitutions, improvements, etc., should be included within the protection scope of the present invention.

Claims

1. A scalable circuit control component test platform, characterized in that, Includes measurement and control cabinets and testing fixtures; The measurement and control cabinet includes: a cabinet, an AC power distribution box, a programmable power supply, an oscilloscope, a data acquisition instrument, a switch, a signal distribution and conditioning box, a multi-computer switcher (KVM), and a main control computer. These components are arranged sequentially from top to bottom in the cabinet's slots. The AC power distribution box is connected to the programmable power supply, oscilloscope, data acquisition instrument, switch, signal distribution and conditioning box, KVM, and main control computer to power the equipment inside the cabinet. The switch is connected to the programmable power supply, oscilloscope, data acquisition instrument, signal distribution and conditioning box, and main control computer via network ports to enable software control of the equipment. The signal distribution and conditioning box is connected to the programmable power supply, oscilloscope, data acquisition instrument, signal distribution and conditioning box, and main control computer to distribute, switch, condition, and acquire power and input / output signals for the control components. The KVM is connected to the main control computer and serves as its screen, mouse, and keyboard. The test fixture includes: a housing, quick clamps, guide rails, and a needle plate; the housing includes a three-dimensional support section and a main body; the needle plate includes: a pressure plate, a needle plate guide rail, a PCB base, a needle bed, and positioning pins; the quick clamps are connected to the three-dimensional support section on the housing, and are connected to the pressure plate on the needle plate via the guide rails; the PCB base of the needle plate is fixed to the main body on the housing; the needle plate guide rails connect the pressure plate and the PCB base; the needle bed is fixed on the PCB base; and the positioning pins are fixed below the pressure plate; by manually pressing the quick clamps, the quick clamps drive the guide rails and pressure plates to move downwards along the needle plate guide rails, so that the positioning pins fix the control components on the PCB substrate below, allowing the test points on the control components to contact the needle bed, thereby introducing the excitation signal into the control components through the probes on the needle bed, and introducing the signal to be tested from the control components into the test platform; The electrical interface of the signal distribution and conditioning box on the control cabinet is connected to the electrical interface of the test fixture via a quick-connect, anti-misfit aviation circular connector. Six types of cables are provided according to the signal type used: power supply cable, communication cable, discrete quantity cable, digital quantity cable, analog input cable, and analog output cable. The power supply cable provides two 0-28V power lines and one 24V power line. The communication cable provides one communication line for receiving and transmitting RS422, CAN, and 429 communication data. The discrete quantity cable provides two signal lines for discrete quantity excitation and measurement. The digital quantity cable provides two signal lines for digital quantity excitation and measurement. The analog output cable provides two signal lines for providing voltage, current, resolver, LVDT, and resistance signals to the control components. The analog input cable provides two signal lines for analog quantity input and measurement.

2. The testing platform as described in claim 1, characterized in that, The AC distribution box includes: voltmeters, ammeters, fuses, start switches, shutdown switches, emergency stop switches, leakage protection switches, AC contactors, AC power strips, and AC input sockets. It supplies AC power to the distribution box via power lines and AC input sockets, and supplies power to the programmable power supply, oscilloscope, switch, signal distribution and conditioning box, KVM, main control computer, and testing fixtures via AC power strips. The voltmeters and ammeters are used to display the power supply voltage and current of the control cabinet. The start switches, shutdown switches, emergency stop switches, leakage protection switches, fuses, and AC contactors are used for power supply control and overcurrent protection.

3. The testing platform as described in claim 2, characterized in that, The programmable power supply includes: four DC power supplies with a voltage output range of 0-20V and a current output range of 0-10A, and one DC power supply with a voltage output range of 0-40V and a current output range of 0-19A. The programmable power supply with a voltage output range of 0-20V provides 3.3V, ±5.0V, and ±15V DC power to the control board components, and the programmable power supply with a voltage output range of 0-40V provides 28V DC power. All five programmable power supplies are connected to the switch via network ports, thereby enabling software control of the output voltage and current using the main control computer.

4. The testing platform as described in claim 1, characterized in that, The oscilloscope used is a four-channel oscilloscope with LAN connectivity for controlling and monitoring the waveform characteristics of the signal.

5. The testing platform as described in claim 4, characterized in that, The data acquisition system includes: one data acquisition unit with USB and LAN interfaces and built-in signal conditioning function; one 40-channel single-ended multiplexer; and one 20-channel multiplexer. The inputs of the data acquisition unit are connected to the two multiplexers. The data acquisition unit is used to measure voltage, resistance, frequency, and pulse width signals, and can be switched to any measurement point for testing via a self-test switchboard. The single-ended multiplexer is used to measure two-wire inputs other than current. The 20-channel multiplexer enables AC and DC current measurements without the use of external shunt resistors.

6. The testing platform as described in claim 5, characterized in that, Switches are used to enable high-speed communication and data transmission between the main control computer and programmable power supplies, oscilloscopes, data acquisition instruments, and signal distribution and conditioning boxes.

7. The testing platform as described in claim 6, characterized in that, The signal distribution and conditioning box includes: a transmitter, a self-test switching board, a signal conditioning circuit, a disconnect board, an electrical interface, and a module power supply. The electrical interface connects to the disconnect board, which in turn connects to the transmitter, the transmitter to the self-test switching board, and the self-test switching board to the signal conditioning circuit. The electrical interface uses a quick-connect, anti-misfit aviation circular connector for connecting the control cabinet and the test fixture. The transmitter provides power, input, and output isolation, filters and attenuates field signals, isolates different potentials, and suppresses external magnetic interference. Different transmitter output types can be selected according to different excitation requirements to meet the excitation output requirements. The disconnect board enables signal disconnection; when the control cabinet hardware resources are disconnected, external signals can be manually injected or tested into the control components. The self-test... The switching board includes: a 2-pole 5A general-purpose power relay with a rated voltage of 24V, a solid-state relay with a control voltage of 3-32VDC and a load voltage of 5-220VDC, and control circuitry; a self-test switching board is used to connect hardware resources and the device under test (DUT), each board provides 64-line switching selection capability and the ability to switch between two bus test resources; when the external cable connection is disconnected, the test platform can realize open-loop self-test function, providing the operating status of key signals and key components; the signal conditioning circuit functions to condition the excitation signal; the excitation signal output by the board in the main control computer is conditioned to the signal type required by the control components; the module power supply uses a 24V power supply with short-circuit, overload, and overvoltage protection for powering the relays and transmitters.

8. The testing platform as described in claim 1, characterized in that, in, KVM uses a pull-out LCD control module; The main control computer includes: a chassis, a controller, analog output cards, high-speed digital signal cards, resolver signal cards, linear transform sensor signal cards, discrete output cards, discrete input cards, resistor cards, CAN bus communication cards, ARINC429 cards, MIL-STD-1553B bus communication cards, and RS422 bus communication cards. The signal terminals of the analog output cards, resolver signal cards, linear transform sensor signal cards, discrete output cards, resistor cards, and high-speed digital signal cards are connected to the conditioning circuit of the signal distribution and conditioning box to realize the excitation and acquisition of I / O signals and sensor signals. The control terminals are connected to the controller to realize the control of communication, input, output functions, and modes. The CAN bus communication cards, ARINC429 cards, MIL-STD-1553B bus communication cards, and RS422 bus communication cards are connected to the disconnect board of the signal distribution and conditioning box to enable communication testing between the control components on the test fixture and the main control computer. The chassis uses a 4GB / s bandwidth and has 1 The system includes a chassis with 7 mixing slots and 1 system slot; analog output cards for outputting voltage or current excitation signals; high-speed digital cards for outputting high-speed digital signals; resolver signals implemented using a digital-to-linear resolver converter; LVDT cards using LVDT emulation cards for LVDT sensor signal simulation; discrete input and output cards using discrete input / output cards for acquiring external DI-type signals and outputting DO-type excitations; a resistor card using a 4-channel resistor switching board for PT1000 / PT100 temperature sensor simulation; an RS422 bus communication card for RS422 bus communication with the onboard DSP chip; a CAN bus communication card for CAN bus communication with the onboard DSP chip; an ARINC429 communication card for ARINC429 bus communication with the onboard DSP chip; and a MIL-STD-1553B bus communication card for 1553B bus communication with the onboard DSP chip.

9. The testing platform as described in claim 8, characterized in that, In the test fixture, the bottom probes in the pin plate are designed to control the lead-out of the component's electrical interface connector, and the concave test probes are used to mate with the electrical interface pads.

10. The testing method for the testing platform as described in claim 9, characterized in that, Includes the following steps: Step 1: Press the start switch on the AC distribution box. The main control computer will turn on simultaneously and open the host computer software. The software will open and connect to the database, and enter the system self-test. The system self-test will automatically check whether the power supply, equipment, and function boards are working properly and display the self-test results. At the same time, it will output 24VDC to ensure that the signal distribution conditioning box, resistor card, and resolver card work properly. Step 2: Enter the main program. The software initializes the test interface, power supply, devices and function boards. Subsequent operations can only be performed after initialization is complete. Step 3: Align the positioning holes at the four corners of the control component with the positioning bolts and insert them into the slots; move the quick clamp to press down the pressure plate, and the pressure pin will press against the control component to make it descend, pressing down to the needle plate, and the lower test probe will contact the test point to lead out the signal; Step 4: Power supply test; The power supply test includes 28V power supply test and power conversion module test; a. 28V power supply test; Select the control component test sequence and check the "28V power supply" test item; Enter the serial number of the board under test and click the "OK" button to start the test, which will complete the power supply of the control component; Observe the power supply status and whether there are any abnormal states in the software records; The control and implementation logic is as follows: Before powering the control component, the internal excitation connection is disconnected by programmable control, and the interface resistance is checked using a data acquisition instrument; Switch to an oscilloscope to monitor the online excitation voltage waveform; Power the control components and switch to the data acquisition unit for online excitation voltage monitoring; b. Power Conversion Module Test; Select the "Conversion Module Test" test item, the test items are 5V and ±15V output test; Enter the serial number of the board under test and click the "OK" button to start the test, and the power conversion module test will be completed; The control component is a 28V to 5V and ±15V power supply module. The 5V is the VCC power supply, which powers the isolation optocouplers, operational amplifiers, driver circuits, CPU and CPLD circuits and chips in the communication circuit and IO circuit. The ±15V is the power supply for the operational amplifier; The control and implementation logic is as follows: Before testing the control component, the external excitation connection is disconnected by programmable control, and the interface resistance is checked using a data acquisition instrument; When testing the control component, switch to the data acquisition instrument for online voltage monitoring; Step 5: Communication test; a. Host computer 422 communication; Select the "28V and 5V, 3.3V power supply" and "Host computer 422 communication test" test items, enter the serial number of the board under test, and click "OK" to complete the host computer 422 communication test of the control component; During the test, if the control board component does not have a CPU component installed, a serial port loopback test can be achieved by shorting the serial port receive port and transmit port on the interface between the control board component and the CPU component; Perform the following tests in sequence: communication test, CPU to serial port positive terminal high level test, CPU to serial port positive terminal low level test, serial port to CPU high level test, and serial port to CPU low level test; 3.3V is the power supply for the communication circuit; The RS422 communication interface is tested using an RS422 bus communication card. The control and implementation logic is as follows: the RS422 serial port communication interface, after passing through a self-test switching board and a disconnection board, is directly connected to the control board's communication interface via an electrical interface. When the RS422 communication signal passes through the self-test switching board, it can be switched to an oscilloscope or data acquisition instrument for online excitation testing. Before powering on the control components, the acquisition channel is programmed to switch to the resistance setting to complete the interface resistance check. A spare serial port is selected for cross-communication self-test within the control cabinet. The RS422 communication interface is directly connected to the control board's communication interface via an electrical interface to complete protocol communication verification. Finally, the system switches to an oscilloscope for online bus waveform monitoring. b. Redundancy interval 422 communication test; same as step 5a; c. CAN communication test; Select the "28V and 5V, 3.3V power supply" and "CAN communication test" test items, enter the serial number of the board under test and click "OK" to complete the CAN communication test of the control component; Perform the communication test, CAN card to CPU high level transmission test, and CAN card to CPU low level transmission test in sequence; Implement the same logic as in step 5a; Step 6: Sampling circuit testing; this step includes: a. Phase current test; Select the "28V, 5V and 3.3V power supply" and "phase current test" test items, and click "OK" to complete the A and B phase current test of the control component; among which, 3.3V is the power supply for the limiting circuit; the control and implementation logic is as follows: before the control component is powered on, after the programmable disconnection from the internal excitation connection, the interface resistance can be checked using a data acquisition instrument; the excitation is output through the voltage output card after conditioning, and monitored by the current acquisition module; switch to the oscilloscope for online excitation voltage waveform monitoring; switch to the data acquisition instrument for online excitation current monitoring; The conditioning is implemented using isolation modules, with different types of voltage / current modules selected for each channel; the signal excitation function is designed to allow simultaneous output across all channels. The current-type excitation implementation method is as follows: the analog output card outputs a ±10V voltage signal to the power isolation module. After conversion by the power isolation module, the current excitation signal required by the control board is output. The excitation signal is introduced to the target control board through the self-test switching board and the disconnection board via the electrical interface. When the excitation signal passes through the self-test switching board, the load resistor for self-test is enabled, and the oscilloscope or data acquisition instrument can be switched to perform online excitation detection. b. Bus current test; same as step 6a; c. Front-end and rear-end bus voltage test; same as step 6a, except that: voltage sampling uses voltage-type excitation, load resistor is not used during self-test, and online excitation voltage monitoring is used during monitoring; d. Temperature Sampling Test; The temperature sampling test includes IGBT temperature sampling test and motor temperature sampling test. Both tests are resistive excitation. During the test, select the "28V and 5V, 3.3V power supply" and "temperature sampling test" test items, enter the serial number of the board under test, and click "OK" to complete the temperature sampling test of the control component. The control and implementation logic is as follows: Use the resistor output card to output the resistor excitation signal, adjust the resistor signal according to the 8421 encoding method and output it directly. After passing through the self-test switching board and the disconnection board, it is introduced to the target control board through the electrical interface. When the excitation signal passes through the self-test switching board, switch to the data acquisition instrument for online excitation detection. Before the control component is powered on, disconnect the internal excitation connection by the programmable controller and use the data acquisition instrument to check the interface resistance. Step 7, IO module level test; Select the "28V and 5V, 3.3V power supply" and "IO level test" test items, enter the serial number of the board under test and click "OK" to complete the control component level test; the test automatically provides and switches the input and output test points of the control component IO port to complete the test of the isolation optocoupler output level involved in the control component IO level test; the IO module level test method and implementation logic are the same as a and c in step 6; Step 8: Resolver Decoding Module Test; Select the "28V, 5V and 3.3V Power Supply" and "Resolver Excitation Test" test items, enter the serial number of the board under test, and click "OK" to complete the resolver excitation test of the conditioning board; this test step includes: a. Resolver SPI communication test; The core of the resolver SPI test is that the software controls the resolver board to output 12 angle values ​​with an initial value of 10 degrees and a gradient of 30 degrees to the resolver board. At the same time, the 16-bit register value output by the resolver decoding chip is measured, and the first 12 bits of the value are taken. b. Resolver excitation test: The signal transmission process is as follows: The control board outputs resolver excitation, which is transmitted via the electrical interface, disconnection board, and self-test switching board to the resolver simulation card. Upon receiving the resolver excitation, the resolver simulation card outputs a resolver signal according to the settings. This signal is then transmitted via the self-test switching board and disconnection board to the target control board via the electrical interface. The control and implementation logic is as follows: Before powering on the control component, the programmable disconnection from the internal excitation connection is performed, and the interface resistance is checked using a data acquisition instrument. After powering on the control component, the system switches to the data acquisition instrument for online excitation voltage monitoring. The resolver excitation is input to the digital-to-linear resolver converter, and after conditioning, the resolver signal is output according to the set angle value. The system switches to an oscilloscope for online waveform monitoring, frequency measurement, and phase difference measurement. The oscilloscope's three channels are used to acquire the excitation and signal ends of the resolver signal for waveform analysis. Step 9, APWM waveform test; This test uses a digital output board to output a set of APWM waveforms; the waveform amplitude is 3.3V, the frequency is 10kHz, the duty cycle of the positive pulses of APWM1, APWM3, and APWM5 is 40%, and the duty cycle of the positive pulses of APWM2, APWM4, and APWM6 is 58%; therefore, the dead time is 1 / 10000*0.02=0.000002S=2uS; Select the test items "28V and 5V, 3.3V power supply", "CPLDFault set high" and "APWM test", enter the serial number of the board under test and click "OK" to complete the APWM waveform test of the control component; the frequency error of the test output waveform should not exceed 500Hz, the amplitude should be 5±0.2V, and the duty cycle error should not exceed 5% to be considered qualified; the control and implementation logic is as follows: before the control component is powered on, the acquisition channel is programmed to switch to the resistance range to complete the interface resistance check; The PWM signal is input to the data acquisition instrument via the electrical interface, disconnection board, and self-test switching board. The PWM signal value is directly acquired by the data acquisition instrument and oscilloscope, and the measurement range is configured according to the signal type. Step 10, Onboard Chip Circuit Testing; This test is designed with two types of test items, namely control port testing and functional testing; The control port test control and implementation logic is as follows: output static chip select and enable through the test program built into the DSP, collect the corresponding port of the chip through the data acquisition instrument, and verify whether the control port is correct.

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