Periodic test device for DCS (Distributed Control System) protection system

Abstract

The invention discloses a periodic test device for a DCS (Distributed Control System) protection system, which relates to the technical field of test devices, is small in size and low in cost, is convenient for operators to carry to complete inspection, and is also convenient to use in the production and debugging stage of the DCS protection system (a traditional large-size periodic test device is convenient to use after being used in the production and debugging stage of the DCS protection system). And the IO port design of the device is good in universality for different DCS protection system devices and modules. Meanwhile, the using method of the device is clear and easy to understand by operators, complex manual parameter input is not needed, and processing of subsequent processes of periodic tests such as report generation, electronic signature and report printing is more reasonable and complete. In addition, the hardware model selection of the device is 100% localized, autonomous and controllable.

Description

Technical Field

[0001] The invention relates to the technical field of testing devices, in particular to a periodic testing device for a DCS protection system. Background Art

[0002] Periodic testing refers to testing conducted at scheduled intervals to detect faults and check operability. Distributed control systems, referred to in English as DCS (Distributed Control System), have the characteristics of decentralized layout and centralized control and are used in various process automatic control systems. After a DCS protection system has been running for a long time, its corresponding equipment may experience aging of components, system communication blockage, board function failure, etc., which poses a potential safety hazard and requires regular testing.

[0003] The periodic test of the DCS protection system is usually carried out after the periodic test device is connected to the DCS protection system. Different modules of the DCS protection system complete data exchange with the periodic test device through the communication module. The types of periodic tests usually include channel verification test, response time test, protection logic test and dedicated driver connection test:

[0004] Channel verification test: Verify whether the input and output channels in the DCS protection system can work normally. By inputting known signals into the system, check whether the system output is consistent with expectations.

[0005] Response time test: evaluates the time it takes for the DCS protection system to take corresponding actions after receiving a specific input signal. This parameter is very important for protection systems with emergency shutdown requirements. The system response time is evaluated by measuring the time difference from the input signal change to the system output corresponding action.

[0006] Protection logic test: Verify whether the system can perform corresponding protection actions according to the predetermined logical sequence and conditions under specific fault or abnormal conditions.

[0007] Special drive connection test. Verify whether the connection and communication between the DCS protection system and the special safety facilities are normal. Through specific input, simulate the execution of protection action to check whether the special facilities respond normally.

[0008] Referring to the invention patent CN 118136291A "Periodic test device, method and storage medium for instrument and control system", the invention provides a periodic test device for instrument and control system (without mentioning the device structure and form). The device includes an acquisition module, a signal acquisition module, a signal recognition module, a keyboard and mouse simulator, a mode selection module, an analysis module and an interrupt response module.

[0009] The acquisition module is used to acquire electronic procedures for periodic tests.

[0010] The signal acquisition module is used to take screenshots of the operation screen during the periodic test, and the screenshot of the operation screen includes the display of the test results of the device under test.

[0011] The signal recognition module uses OCR image recognition technology to identify the screenshots obtained by the signal acquisition module, obtain the actual test value, and then compare it with the expected value.

[0012] The mouse and keyboard simulator is used to simulate the mouse / keyboard operations of test personnel at high speed, and simulate the input operations performed on the operation screen in regular tests.

[0013] The mode selection module is used to switch the use mode of the device according to the selection of the tester, including full-automatic and semi-automatic modes.

[0014] The test record generation module is used to automatically generate electronic test records after the test is completed and save screenshots.

[0015] The analysis module is used to compare and analyze historical data of test results, analyze time drift trends, and estimate the remaining life of the tested channels.

[0016] The interrupt response module is used to interrupt the test and execute single / multi-step execution functions.

[0017] However, the conventional industrial computer-based periodic test device has the disadvantages of being bulky, inconvenient to move, and having high hardware material costs. The invention patent CN 118136291A does not mention the specific device form, and assumes that it is consistent with the conventional industrial computer form.

[0018] At the same time, traditional periodic test devices are usually customized products, and the internal IO pins are connected to the DCS protection system equipment hardware in a fixed state. If new modules are added later or used in different types of DCS protection systems, it is difficult to meet the requirements, and the universal expansibility of the IO interface is poor. The invention patent CN 118136291A also does not mention the processing of internal IO pins and external interfaces.

[0019] In addition, traditional periodic test results (reports) are usually entered manually, and there is a lack of sound management methods in the archiving process. It is possible that the generated reports are not claimed or accounted for by anyone. Summary of the invention

[0020] In view of the above problems, the present invention provides a DCS protection system periodic test device for overcoming the above problems or at least partially solving the above problems.

[0021] The present invention provides the following scheme:

[0022] A DCS protection system periodic test device, comprising:

[0023] A portable housing, wherein the portable housing is provided with a display screen, an IO interface in the form of a wiring terminal, a universal serial port, a network port, a USB interface, and a printing interface; an integrated mainboard is provided inside the portable housing; the IO interface is used to be connected to the corresponding IO module of the DCS protection system equipment through different connectors, and the universal serial port is used to lead out debugging signals and RS422 / RS232 communication signals;

[0024] The integrated mainboard is used to output analog current, switch signal and realize switch signal acquisition through a preset application program; so as to send analog signal, switch signal or their combination to certain modules of the DCS protection system according to the technical requirements of each module of the DCS protection system, and receive the switch signal sent back by the target module of the DCS protection system after the test response, so as to realize the protection response time, protection response accuracy and automatic logic test function.

[0025] Preferably: the application program includes a configuration module, a logic test module, a response time test module, a trigger accuracy test module and a test report module;

[0026] The configuration module is used to configure the default signal output, analog quantity, switch quantity input channel mapping and select the items to be tested;

[0027] The logic test module is used to provide a programming interface related to logic test operations, perform corresponding logic test experiments according to the settings of the configuration module, and complete the comparative analysis of the measured results of regular tests and the expected results through code logic;

[0028] The response time test module is used to provide a programming interface related to the response time test operation, perform a corresponding response time test according to the settings of the configuration module, and complete the analysis of whether the measured response time of the regular test is within the expected response time range through code logic;

[0029] The trigger accuracy test module is used to provide a programming interface related to the trigger accuracy test operation, perform a trigger accuracy test experiment of the corresponding item according to the setting of the configuration module, and complete the analysis of whether the trigger accuracy actually measured in the regular test is within the preset accuracy range through code logic;

[0030] The test report module is used to convert the test conclusion into a string description, generate a docx test report file, display the summary in the GUI, and provide electronic signature and printing function options.

[0031] Preferably, the integrated mainboard uses a programmable system on chip as a processor.

[0032] Preferably: the programmable system on chip includes a chip model SM15D325TMAL.

[0033] Preferably: the model SM15D325TMAL chip includes a serial port controller, a USB controller module, an Ethernet controller, a mobile processor interface, an SPI module, a GPIO module and an SDIO module, the SDIO module is used to communicate with an EMMC device, and the EMMC device is used to store systems and applications.

[0034] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0035] The DCS protection system periodic test device provided by the embodiment of the present invention is small in size, low in cost, and convenient for operators to carry and complete inspections. It is also convenient to use in the production and debugging stage of the DCS protection system (the traditional large-volume periodic test device has a large workload for the processes of disconnection, transportation, and redeployment after use in the production and debugging stage of the DCS protection system). The IO interface design of the device has good versatility for different DCS protection system equipment and modules. At the same time, the method of using the device is clear and easy to understand for operators, without the need for complex manual parameter input, and is more reasonable and complete in the processing of subsequent processes of periodic testing such as report generation, electronic signatures, and report printing. In addition, the hardware selection of the device is 100% domestically produced and independently controllable.

[0036] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0038] Figure 1 It is a structural schematic diagram of a periodic test device for a DCS protection system provided by an embodiment of the present invention;

[0039] Figure 2 It is a schematic diagram of the internal hardware architecture of the periodic test device provided by an embodiment of the present invention;

[0040] Figure 3 It is a schematic diagram of the connection between the periodic test device provided by the embodiment of the present invention and each module of the DCS protection system;

[0041] Figure 4 is a schematic diagram of the device interface design provided by an embodiment of the present invention;

[0042] Figure 5It is a flow chart of the operation of the periodic test application software provided by an embodiment of the present invention.

[0043] In the figure: portable housing 1, display screen 2, IO interface 3, universal serial port 4, network port 5, USB interface 6, printing interface 7, power switch 8. DETAILED DESCRIPTION

[0044] The technical scheme in the embodiment of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiment of the present invention. Obviously, the described embodiment is only a part of the embodiment of the present invention, not all of the embodiments. Based on the embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field belong to the scope of protection of the present invention.

[0045] See also Figure 1 , is a DCS protection system periodic test device provided by an embodiment of the present invention, such as Figure 1 As shown, the device may include:

[0046] A portable housing 1, wherein the portable housing 1 is provided with a display screen 2, an IO interface 3 in the form of a wiring terminal, a universal serial port 4, a network port 5, a USB interface 6, and a printing interface 7; an integrated mainboard is provided inside the portable housing; the IO interface 3 is used to be connected to the corresponding DCS protection system equipment IO module through different connectors, and the universal serial port 4 is used to lead out debugging signals and RS422 / RS232 communication signals;

[0047] The integrated mainboard is used to output analog current, switch signal and realize switch signal acquisition through a preset application program; so as to send analog signal, switch signal or their combination to certain modules of the DCS protection system according to the technical requirements of each module of the DCS protection system, and receive the switch signal sent back by the target module of the DCS protection system after the test response, so as to realize the protection response time, protection response accuracy and automatic logic test function.

[0048] Further, the application includes a configuration module, a logic test module, a response time test module, a trigger accuracy test module and a test report module;

[0049] The configuration module is used to configure the default signal output, analog quantity, switch quantity input channel mapping and select the items to be tested;

[0050] The logic test module is used to provide a programming interface related to logic test operations, perform corresponding logic test experiments according to the settings of the configuration module, and complete the comparative analysis of the measured results of regular tests and the expected results through code logic;

[0051] The response time test module is used to provide a programming interface related to the response time test operation, perform a corresponding response time test according to the settings of the configuration module, and complete the analysis of whether the measured response time of the regular test is within the expected response time range through code logic;

[0052] The trigger accuracy test module is used to provide a programming interface related to the trigger accuracy test operation, perform a trigger accuracy test experiment of the corresponding item according to the setting of the configuration module, and complete the analysis of whether the trigger accuracy actually measured in the regular test is within the preset accuracy range through code logic;

[0053] The test report module is used to convert the test conclusion into a string description, generate a docx test report file, display the summary in the GUI, and provide electronic signature and printing function options.

[0054] In order to further realize localization, the embodiment of the present invention can provide that the integrated mainboard adopts a programmable system on chip as a processor. The programmable system on chip includes a model SM15D325TMAL chip.

[0055] The model SM15D325TMAL chip includes a serial port controller, a USB controller module, an Ethernet controller, a mobile processor interface, an SPI module, a GPIO module and an SDIO module. The SDIO module is used to communicate with an EMMC device, and the EMMC device is used to store systems and applications.

[0056] Traditional periodic test devices are usually in the form of industrial computers, which have the disadvantages of being bulky, inconvenient to move, and using more external structures, resulting in high costs. The miniaturized periodic test device provided by the present invention is compact and can be carried by operators to complete inspections. The use of the device is not restricted by the space where the DCS protection system equipment (usually in the form of a cabinet) is located, and the structure of the miniaturized periodic test device uses less material and is relatively cheaper.

[0057] The IO port (Input / Output) of traditional periodic test devices is not expandable enough. Since periodic test devices are mostly customized products, they are usually designed specifically for a certain type of DCS protection system. The hardware connection relationship between the internal IO pins of the periodic test device and the DCS protection system is a fixed value. This design makes it difficult for the periodic test device to adapt to the DCS protection system or other systems after the module expansion. The periodic test device provided by the present invention adopts a full IO interface external method, and is connected to different DCS protection system devices and modules through a connector, and has good expansion versatility;

[0058] The hardware of the periodic test device provided by the present invention is all domestically produced, meeting the requirements of independent control, solving the problem that some non-domestic chips and other hardware cannot meet the application needs of special industries, and solving the problem of unstable supply status due to external factors.

[0059] The method for using the periodic test device provided by the present invention adds electronic signature and report printing functions to the use process. In addition to completing the most basic periodic test tasks for the DCS protection system, the operator can also sign and authenticate the results of the periodic test and output them in paper form, which is beneficial to the convenience and effectiveness of periodic test archiving.

[0060] The DCS protection system periodic test device provided by the present invention is introduced in detail below.

[0061] The miniaturized DCS protection system periodic test device (hereinafter referred to as the "device") provided by the present invention adopts a light and thin flat-panel design, which is easy to carry and handheld operation, and takes the operation experience into consideration to the greatest extent. The overall dimensions of the device (length × width × thickness) are no more than 300mm × 220mm × 30mm, and the weight is ≤5kg. The device integrates a mainboard, LCD display, connector, etc. The top of the device is designed with a power switch and an external IO interface as a highlight design. The IO interface is in the form of a wiring terminal; the right side is designed with a general communication port, network port, USB port and printing port, which are used to communicate with DCS protection system equipment, connect network equipment, connect to auxiliary operation equipment such as keyboard / mouse when necessary, and print paper periodic test result reports. The front view of the device is as follows: Figure 1 shown.

[0062] The device uses SOPC (System on Programmable Chip) as the processor, the specific model is SM15D325TMAL from SMIC. This chip from SMIC has multiple medium and high-speed protocol interfaces such as USB2.0 and Gigabit Ethernet, integrated EMMC (Embedded Multi Media Card) interface, integrated A15 dual-core and R7 dual-core CPUs, which can meet the needs of high-performance computing cores and high-efficiency real-time control cores at the same time.

[0063] The device of the present invention uses SM15D325TMAL SOPC chip with DAC circuit (Digital to Analog Converter), switch input / output circuit, serial communication circuit, USB interface circuit, printing interface circuit, network interface circuit, EMMC circuit, display interface circuit, etc. The necessary hardware architecture diagram of the device is as follows Figure 2 shown.

[0064] exist Figure 2 In the invention, UART is a serial port controller, which realizes the communication of the debugging serial port, RS232 and RS422 serial output protocols, and communicates with the DCS protection system through the universal serial port, corresponding to the serial port communication circuit described above; the USB controller module mainly realizes the USB2.0 protocol communication, and can be connected as a USB interface and a printing interface through a connector, corresponding to the USB interface circuit and the printing interface circuit described above; GMAC is an Ethernet controller, which supports communication with an external PHY and is connected as a network port, corresponding to the network interface circuit described above; MIPI is a mobile processor interface, which is connected to the liquid crystal display LCD through a MIPI to LVDS chip, corresponding to the display interface circuit; SPI is used to drive the DAC device, and converts the digital quantity signal emitted by the test device into the corresponding current value signal through the VI (voltage to current) conversion circuit, and then is connected to the IO interface as the input of the regular test of the DCS protection system; GPIO is used to send and receive digital quantity signals, corresponding to the switch quantity input / output circuit described above; SDIO supports the EMMC4.41 standard, and the device of the present invention stores the system and application program in the EMMC device.

[0065] The device supports analog current output, switch signal output, and switch signal acquisition functions. According to the specific technical requirements of each module of the DCS protection system, the regular test device sends analog signals, switch signals, or a combination of them to certain modules of the DCS protection system, and receives switch signals sent back by certain modules of the protection system after the test response, so as to realize the protection response time, protection response accuracy, and automated logic test functions. The device connection diagram is as follows Figure 3 , This is only a schematic diagram, and the specific connection relationship needs to be combined with the actual technical requirements of the DCS protection system.

[0066] The device interface design provided by the present invention includes a universal serial port, an IO interface, a network interface, a USB interface and a printing interface. The debugging signal and the RS422 / RS232 communication signal can be led out from the universal serial port to communicate with the debugging device and the DCS protection system respectively; the external IO interface is in the form of a wiring terminal, which is connected to the corresponding DCS protection system device IO module through different connectors. The specific analog quantity and switch quantity signal can be led out from the corresponding channel of the IO interface through software configuration. The schematic diagram of the device interface design is shown in FIG. Figure 4 shown.

[0067] like Figure 5 As shown, the present invention provides a periodic test device application.

[0068] The application mainly includes configuration module, logic test module, response time test module, trigger accuracy test module and test report module.

[0069] The configuration module is used to configure the default signal output; configure the analog and switch input channel mapping; and select the items to be tested.

[0070] The logic test module is used to provide programming interfaces related to logic test operations, perform corresponding logic test experiments according to the settings of the configuration module, and complete comparative analysis of regular test results and expected results through code logic.

[0071] The response time test module is used to provide programming interfaces related to response time test operations, perform corresponding response time test experiments according to the settings of the configuration module, and complete the analysis of whether the measured response time of regular tests is within the expected response time range through code logic.

[0072] The trigger accuracy test module is used to provide programming interfaces related to trigger accuracy test operations, perform trigger accuracy test experiments on corresponding items according to the settings of the configuration module, and complete the analysis of whether the measured trigger accuracy in regular tests is within the preset accuracy range through code logic.

[0073] The test report module is used to convert test conclusions into string descriptions, generate docx test report files, display summaries in the GUI, and provide electronic signature and printing options.

[0074] The docx file is manually pre-written as a template including title, header, blank table, signature column, etc. The remaining blank parts are filled in after the program runs to get the results; the GUI summary is displayed in the "Results" interface of the application software.

[0075] The method for using the periodic test device provided by the present invention comprises:

[0076] 1. The operator connects the periodic test device to the DCS protection system equipment and uses the internal battery of the periodic test device for self-power supply according to the actual situation, or chooses to use the external 24V power supply from the protection system equipment.

[0077] 2. The operator presses Figure 1 The power switch 8 above the periodic test device turns on the device. After the periodic test device is turned on, an authorized administrator account or operator account needs to be entered. After logging in, the system automatically opens the periodic test function application software.

[0078] 3. The operator uses the device touch screen or external mouse device to check the test options on the main interface of the application software according to the test items of the connected equipment, and completes the IO interface configuration of the signal input and output of the test items in the application software.

[0079] 4. After configuring the test items, the operator clicks the "Start Test" button on the main interface to conduct regular tests of the configuration items. The interface can display real-time test information.

[0080] 5. After the test, the operator switches to the "Result" interface to see the test items, test content, and test conclusions displayed in a table format; switch to the "Output" interface to sign the electronic report operator through the touch screen or external mouse device, select the electronic report output path, and click the print button to print the paper report according to actual needs.

[0081] It can be seen that the device provided by the present invention has the characteristics of small size and portability, highlighting the advantage that its use is not restricted by the location of the equipment to be tested. It is significantly different from the industrial computer form of traditional periodic test devices. Most of the periodic test device schemes and patents that can be found do not mention the structural form of the periodic test devices they designed. Domestic processors are used, and other chips, hardware, etc. are all domestically selected. Important module architecture design and universal IO interface external design as a highlight are carried out around the selected model processor. The electronic report signing and paper report printing process after the generation of periodic test results are clarified, which is beneficial to the management of test reports.

[0082] In summary, the DCS protection system periodic test device provided by the present invention is small in size, low in cost, and convenient for operators to carry and complete inspections. It is also convenient to use in the production and debugging stage of the DCS protection system (the traditional large-volume periodic test device has a large workload for the processes of disconnection, transportation, and redeployment after use in the production and debugging stage of the DCS protection system). The IO interface design of the device has good versatility for different DCS protection system equipment and modules. At the same time, the method of using the device is clear and easy to understand for operators, without the need for complex manual parameter input, and is more reasonable and complete in the processing of subsequent processes of periodic testing such as report generation, electronic signatures, and report printing. In addition, the hardware selection of the device is 100% domestically produced and independently controllable.

[0083] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0084] It can be seen from the above description of the implementation mode that those skilled in the art can clearly understand that the present invention can be implemented by means of software plus a necessary general hardware platform. Based on such an understanding, the technical solution of the present invention is essentially or the part that contributes to the prior art can be embodied in the form of a software product, and the computer software product can be stored in a storage medium, such as ROM / RAM, a magnetic disk, an optical disk, etc., including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in each embodiment of the present invention or some parts of the embodiments.

[0085] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between the embodiments can refer to each other, and each embodiment focuses on the differences from other embodiments. In particular, for the system or system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can refer to the partial description of the method embodiment. The system and system embodiments described above are merely schematic, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the scheme of this embodiment. Ordinary technicians in this field can understand and implement it without creative work.

[0086] The above description is only a preferred embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.

Claims

1. A DCS protection system periodic test device, characterized in that: include: A portable housing, wherein the portable housing is provided with a display screen, an IO interface in the form of a wiring terminal, a universal serial port, an Ethernet port, a USB interface, and a printing interface; An integrated mainboard is arranged inside the portable housing; the IO interface is used to connect to the corresponding DCS protection system equipment IO module through different connectors, and the universal serial port is used to lead out debugging signals and RS422 / RS232 communication signals; The integrated mainboard is used to output analog current, switch signal and realize switch signal acquisition through a preset application program; so as to send analog signal, switch signal or their combination to certain modules of the DCS protection system according to the technical requirements of each module of the DCS protection system, and receive the switch signal sent back by the target module of the DCS protection system after the test response, so as to realize the protection response time, protection response accuracy and automatic logic test function.

2. The DCS protection system periodic test device according to claim 1 is characterized in that: The application program includes a configuration module, a logic test module, a response time test module, a trigger accuracy test module and a test report module; The configuration module is used to configure the default signal output, analog quantity, switch quantity input channel mapping and select the items to be tested; The logic test module is used to provide a programming interface related to logic test operations, perform corresponding logic test experiments according to the settings of the configuration module, and complete the comparative analysis of the measured results of regular tests and the expected results through code logic; The response time test module is used to provide a programming interface related to the response time test operation, perform a corresponding response time test according to the settings of the configuration module, and complete the analysis of whether the measured response time of the regular test is within the expected response time range through code logic; The trigger accuracy test module is used to provide a programming interface related to the trigger accuracy test operation, perform a trigger accuracy test experiment of the corresponding item according to the setting of the configuration module, and complete the analysis of whether the trigger accuracy actually measured in the regular test is within the preset accuracy range through code logic; The test report module is used to convert the test conclusion into a string description, generate a docx test report file, display the summary in the GUI, and provide electronic signature and printing function options.

3. The DCS protection system periodic test device according to claim 1 is characterized in that: The integrated mainboard adopts a programmable system on chip as a processor.

4. The DCS protection system periodic test device according to claim 3 is characterized in that: The programmable system on chip includes a chip model SM15D325TMAL.

5. The DCS protection system periodic test device according to claim 4 is characterized in that: The model SM15D325TMAL chip includes a serial port controller, a USB controller module, an Ethernet controller, a mobile processor interface, an SPI module, a GPIO module and an SDIO module. The SDIO module is used to communicate with an EMMC device, and the EMMC device is used to store systems and applications.

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