A pump truck testing system and testing method thereof

Abstract

The invention discloses a pump truck test system and a test method thereof. In the test system, a host computer, a boom controller, a transfer controller, a controller under test and a display screen establish communication through a CAN bus, and the transfer controller and each controller under test are connected through an IO port; the transfer controller receives instructions issued by the host computer and converts them into corresponding switch quantity or analog quantity signals, and transmits them to the IO port of the controller under test through the IO port; the port state of the controller under test is fed back and transmitted to the host computer for display; the host computer sends instructions to the transfer controller through the CAN bus, and the transfer controller converts the signal into a switch quantity or analog quantity and transmits it to the controller under test; the controller under test receives the signal, executes the program under test and feeds back the output signal to the transfer controller, and the transfer controller feeds back the signal to the host computer. The invention can reduce the test cost by using a semi-physical simulation test bench to perform program testing.

Description

Technical Field

[0001] The invention relates to the technical field of special mechanical equipment, and in particular to a pump truck testing system and a testing method thereof. Background Art

[0002] Concrete pump truck is a kind of engineering machinery that uses pressure to transport pre-mixed concrete along the arranged pipeline to a certain height and distance. It is widely used in modern construction projects. The controller is the key equipment for the normal operation of the concrete pump truck, which is equivalent to the control center of the concrete pump truck. The control program is the core of the reliable operation of the concrete pump truck.

[0003] The existing control program is not bench tested when it is downloaded to the concrete pump truck. Errors in the control program can only be discovered on the actual vehicle, which will cause a lot of manpower and material losses. In addition, debugging directly on the actual vehicle has a high risk and may damage the vehicle. At the same time, there are many types of concrete pump trucks, and different types of pump trucks require different control programs. Therefore, a simple, fast and safe way to test the control program is urgently needed.

[0004] Control program bench testing has been widely used in the machinery industry, but there is no bench developed for pump trucks (bench testing is a device used to test and evaluate other equipment, products or systems in a laboratory or engineering environment). Therefore, this semi-physical simulation test bench (a semi-physical simulation test bench is a test platform that connects the controller and the controlled object for testing) is studied to solve the current dilemma.

[0005] There are two main methods in the existing technology:

[0006] 1) Use the Codesys online function to connect to the controller to test the pump truck control program;

[0007] 2) Actual vehicle testing, online monitoring of the pump truck status, and testing.

[0008] The pump truck control program was tested using the Codesys online function. The test coverage was insufficient and most functions could not be tested or the test results were unsatisfactory.

[0009] Conducting actual pump truck testing is a high-risk method that can easily cause damage to the pump truck, is costly, and has low efficiency. Summary of the invention

[0010] Purpose of the invention: The purpose of the present invention is to provide a pump truck testing system and testing method, which can avoid the problem of pump truck damage caused by actual vehicle testing and reduce testing costs.

[0011] Technical solution: A pump truck testing system, including:

[0012] The host computer is used as the main control computer to monitor and control the entire test system;

[0013] CAN bus, used to connect different controllers and devices to achieve data communication;

[0014] The boom controller is directly connected to the CAN bus and is responsible for controlling the movement and operation of the boom;

[0015] The transfer controller connects the host computer and the controller under test and is used for signal transfer, conversion and transmission;

[0016] GPS, used to provide location information, connected to the controller under test via wired mode, and connected to the backend server via wireless mode;

[0017] The controller under test executes the program under test and performs corresponding actions according to the IO port status and the received CAN bus instructions;

[0018] Multiple display screens, used to display system status, operation interface or other important information, connected to the controller under test via wired mode;

[0019] Among them, the host computer, arm controller, transfer controller, controller under test and display screen establish communication through CAN bus, and the transfer controller and each controller under test are connected through IO port;

[0020] The transfer controller receives the instructions sent by the host computer and converts them into corresponding switch or analog signals, and transmits them to the IO port of the controller under test through the IO port; it feeds back the port status of the controller under test and transmits it to the host computer for display; the host computer sends instructions to the transfer controller through the CAN bus, and the transfer controller converts the signal into switch or analog and transmits it to the controller under test; the controller under test receives the signal, executes the program under test and feeds back the output signal to the transfer controller, and the transfer controller feeds back the signal to the host computer.

[0021] Furthermore, the host computer interface has the functions of issuing commands and displaying status, wherein the issuing of commands from the host computer interface is realized through the on-board operation box, the off-board operation box, the remote control and the operation buttons.

[0022] Furthermore, the host computer operation interface was written in Visual Studio using C# language, and the transfer controller program was written using Codesys.

[0023] Furthermore, the CAN bus includes a first CAN bus and a second CAN bus. The signals transmitted by the first CAN bus include the first controller CAN bus, display screen, GPS, remote control and recorder; the signals transmitted by the second CAN bus include the second controller CAN bus, bus multi-way valve, encoder and chassis bus.

[0024] The testing method of any of the above pump truck testing systems comprises the following steps:

[0025] S1, the host computer operation switches to the local control mode;

[0026] S2, the host computer communicates with the transfer controller through the CAN card, and the transfer controller receives the proximity control signal sent by the host computer through the CAN address;

[0027] S3, the transfer controller processes the near control signal and outputs it through the output port;

[0028] S4, the proximity control mode input port of the controller under test is powered and receives the proximity control signal;

[0029] S5, the controller under test outputs the near control permission state;

[0030] S6, the host computer receives the local control status, allows and issues the local control positive pump instruction;

[0031] S7, the transfer controller receives the near control positive pump signal through the CAN address;

[0032] S8, the transfer controller outputs a signal through the positive pump output port;

[0033] S9, the positive pump input port of the tested controller is powered;

[0034] S10, the controller under test processes the input signal and outputs a close control permission signal through the positive pump solenoid valve output port;

[0035] S11, the positive pump solenoid valve input port of the transfer controller receives the feedback signal of the positive pump solenoid valve of the controller under test;

[0036] S12, the transfer controller processes the feedback signal of the positive pump solenoid valve and forwards it;

[0037] S13, the host computer receives the feedback signal of the positive pump solenoid valve through the CAN address;

[0038] S14, the host computer displays the positive pump status.

[0039] Further, in step S7, the transfer controller receives the positive pump signal sent by the host computer through the CAN address.

[0040] Further, in step S13, the host computer receives the positive pump feedback signal of the transfer controller through the CAN address.

[0041] Further, in step S14, the "positive pump" status on the host computer interface turns green, indicating that the test has passed.

[0042] Compared with the prior art, the present invention has the following significant effects:

[0043] 1. In the present invention, by using a semi-physical simulation test bench to perform program testing, the problem of possible damage to the pump truck due to actual vehicle testing is avoided, and the testing cost is reduced;

[0044] 2. The semi-physical simulation test bench of the present invention has good scalability. The types of bench tests can be expanded without changing the bench test method to cope with possible new pump trucks in the future. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 It is a control program simulation test flow chart of the present invention;

[0046] Figure 2 This is the hardware architecture diagram of the test system of the present invention

[0047] Figure 3 This is a schematic diagram of the test system of the present invention;

[0048] Figure 4 It is a schematic diagram of the upper computer interface display;

[0049] Figure 5 It is a test flow chart of the present invention. DETAILED DESCRIPTION

[0050] The present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0051] like Figure 1 , Figure 2 As shown, the pump truck test system of the present invention includes a host computer, a CAN bus, a boom controller, a transfer controller, a GPS, a controller under test and multiple display screens. The host computer is connected to the boom controller, the transfer controller and the controller under test through the CAN bus.

[0052] Host computer: As the main control computer of the pump truck test system, it is responsible for overall monitoring and control. It can be connected to the transfer controller through the CAN network or directly, and is responsible for status display, command issuance and test project management.

[0053] CAN (Controller Area Network) bus: used to connect different controllers and devices to achieve data communication.

[0054] Boom controller: responsible for controlling the movement and operation of the boom, directly connected to the CAN bus.

[0055] Transfer controller: connects the host computer and the controller under test, used for signal transfer, conversion and transmission. The main functions are as follows:

[0056] a) Receive the instructions sent by the host computer and convert them into corresponding switch or analog signals, and transmit them to the IO port of the controller under test through the IO port;

[0057] b) Feedback the port status of the controller under test and transmit it to the host computer for display;

[0058] GPS: Global Positioning System, used to provide location information, connected to the controller under test via wired mode, and connected to the background server via wireless mode for positioning, operating condition data transmission, etc.

[0059] Controller under test: executes the program under test and performs corresponding actions according to the IO port status and the received CAN bus instructions.

[0060] Display screen: used to display system status, operation interface or other important information. Connected to the controller under test via wired connection.

[0061] The host computer, arm controller, transfer controller, controller under test and display establish communication through CAN bus, and the transfer controller and each controller under test are connected through IO port. The host computer communicates with the transfer controller through CAN bus, and the transfer controller processes the switch quantity and analog quantity signals of the host computer and the controller under test and transmits them to form a closed-loop test with feedback.

[0062] like Figure 3 The figure shows the schematic diagram of the pump truck test system. The working principle is as follows:

[0063] The host computer sends the command to the transfer controller through the CAN bus. The transfer controller converts the signal into a switch quantity or an analog quantity and transmits it to the controller under test. The controller under test receives the signal, executes the program under test and feeds back the output signal to the transfer controller. The transfer controller feeds back the signal to the host computer, and the host computer interface displays the status. The host computer interface is shown in the figure below. Figure 4 shown.

[0064] In this embodiment, the test system is programmed in C# language based on Visual Studio. The host computer operation interface is established according to the actual operation function requirements and display information of the pump truck, and the host computer program is written. The host computer operation interface has the functions of command issuance and status display. The host computer interface commands are issued through the on-board operation box, the off-board operation box, the remote control, and the operation buttons, so that each button has the function of changing the display state according to the status feedback. The display information is displayed through the status of each label, dial, etc. in the host computer display screen frame.

[0065] Codesys is used to write the transfer controller program, so that the transfer controller can receive the instructions sent by the host computer and process the instructions into switch or analog signals to transmit to the controller under test, and feed back the signals of the controller under test to the host computer; the following are the specific signals transmitted by the two CAN buses:

[0066] The signals transmitted by the first CAN bus include: the first controller CAN bus, display screen, GPS, remote control (120Ω), and recorder;

[0067] The signals transmitted by the second CAN bus include: the second controller CAN bus, bus multi-way valve, encoder, and chassis bus.

[0068] Take the positive pump test as an example, combined with Figure 5 , the implementation process of the test method of the present invention is described in detail, and the technical terms involved are as follows:

[0069] Positive pumping is a working mode of a concrete pump truck, in which concrete is sucked from the hopper of the pump truck and delivered to the required place through the pumping system. In positive pumping mode, the pumping system of the concrete pump truck will deliver concrete to the specified location at a certain pressure and speed.

[0070] Close control means adjusting the pump truck to close control mode;

[0071] Remote control refers to adjusting the pump truck to remote control mode.

[0072] like Figure 5 As shown in the flowchart, the implementation steps of the pump truck testing method of the present invention are as follows:

[0073] Step 1: Switch the host computer operation to the local control mode;

[0074] The host computer needs to switch to the local control mode to prepare for local control operation.

[0075] Step 2, the host computer communicates with the transfer controller through the CAN card, and the transfer controller receives the signal through the address;

[0076] After clicking the near control button on the upper computer interface, a message is sent through the CAN card in the form of CAN communication, and the message ID is 0x460_Byte5.3. At the same time, the transfer controller receives the message through the CAN bus interface of the first controller.

[0077] The main function of the CAN card is to convert the communication protocol to ensure that data can be transmitted between devices without obstacles and that CAN bus data can be received smoothly.

[0078] Step 3, the transfer controller processes the near control signal and outputs it through the output port;

[0079] The relay controller processes the received proximity control signal and outputs the processed signal through the output port of the relay controller (pin number is 62, port number is A02, the port is analog output, 0-5V, 30mA); when the proximity control signal needs to be output, the output voltage of the output port is 0V; if it is not a proximity control signal, the output voltage of the output port is 5V.

[0080] Step 4: The input port of the controller under test is powered and receives the proximity control signal;

[0081] When the input port of the controller under test (pin number is 34, port number is AI11, the port is analog input, 0-10k, 12bit) detects that the port is grounded, that is, the analog value is <100, there is a near control signal input.

[0082] Step 5, the controller under test outputs a close control permission state;

[0083] Proximity control permission is an intermediate state, that is, after the proximity control button is operated, the controller under test executes the logic and returns to the proximity control state, and the display and the host computer display the proximity control state.

[0084] Step 6: The host computer receives the local control status, allows and issues the local control positive pump instruction.

[0085] Step 7, the transfer controller receives the signal through the CAN address;

[0086] Through CAN card communication, the transfer controller receives the positive pump signal sent by the host computer through the CAN address (0X460.BYTE4.3-near control jog positive pump).

[0087] Step 8, the transfer controller outputs a signal through the positive pump output port;

[0088] The relay controller processes the positive pump signal and outputs it through the positive pump output port (pin number 97, port number OUT29 / PWM15, high-side output 2A, or PVM (50-1000HZ) output 2A, with current feedback, 10bit); when the positive pump signal needs to be output, the output voltage of this port is 24V; if the positive pump signal does not need to be output, the output voltage of this port is 0V.

[0089] Step 9, the positive pump input port of the tested controller is powered;

[0090] The positive pump input port (pin number 89, port number DI17, switch input, 0-36V) of the controller under test is energized, indicating that the local control positive pump input signal has been received; when a 24V high-level input is detected at the port, a positive pump signal is input.

[0091] Step 10, the controller under test processes the input signal and outputs a close control permission signal through the positive pump solenoid valve output port;

[0092] Among them, the pin number of the positive pump solenoid valve output port is 9, the port number is OUT4, and the high-side output is 2A. When the positive pump solenoid valve needs to be driven, the port outputs a 24V voltage.

[0093] Step 11, the positive pump solenoid valve input port of the transfer controller receives the positive pump solenoid valve feedback signal of the controller under test.

[0094] The local control permission signal is input into the controller under test through the hard line, and the positive pump solenoid valve input port of the transfer controller (pin number is 33, port number is DI6, switch input, 0-36V) receives the positive pump solenoid valve feedback signal of the controller under test; when the port detects a high-level input, the positive pump solenoid valve is energized.

[0095] Step 12, the transfer controller processes the signal and forwards it;

[0096] The relay controller inputs the processed signal to the controller under test through hard wiring.

[0097] Step 13, the host computer receives the feedback signal through the CAN address;

[0098] The host computer communicates via the CAN card and receives the positive pump feedback signal from the transfer controller via ID 0x560_BYTE2.1.

[0099] Step 14: The host computer displays the positive pump status.

[0100] The host computer displays the current pump status, such as Figure 4 The operator needs to confirm whether the pump status is correct. At the current step, if the "positive pump" status on the host computer interface turns green, the test is passed, and then the next test is performed.

Claims

1. A pump truck testing system, characterized in that: include: The host computer is used as the main control computer to monitor and control the entire test system; CAN bus, used to connect different controllers and devices to achieve data communication; The boom controller is directly connected to the CAN bus and is responsible for controlling the movement and operation of the boom; The transfer controller connects the host computer and the controller under test and is used for signal transfer, conversion and transmission; GPS, used to provide location information, connected to the controller under test via wired mode, and connected to the backend server via wireless mode; The controller under test executes the program under test and performs corresponding actions according to the IO port status and the received CAN bus instructions; Multiple display screens, used to display system status, operation interface or other important information, connected to the controller under test via wired mode; Among them, the host computer, arm controller, transfer controller, controller under test and display screen establish communication through CAN bus, and the transfer controller and each controller under test are connected through IO port; The transfer controller receives the instructions sent by the host computer and converts them into corresponding switch or analog signals, and transmits them to the IO port of the controller under test through the IO port; Feedback the port status of the controller under test and transmit it to the host computer for display; the host computer sends instructions to the transfer controller through the CAN bus, and the transfer controller converts the signal into a switch quantity or an analog quantity and transmits it to the controller under test; the controller under test receives the signal, executes the program under test and feeds back the output signal to the transfer controller, and the transfer controller feeds back the signal to the host computer.

2. The pump truck testing system according to claim 1, characterized in that: The host computer interface has the functions of issuing commands and displaying status, wherein the command issuance of the host computer interface is realized through the on-board operation box, off-board operation box, remote control and operation buttons.

3. The pump truck testing system according to claim 1, characterized in that: The host computer operation interface was written in Visual Studio using C# language, and the transfer controller program was written using Codesys.

4. The pump truck testing system according to claim 1, characterized in that: The CAN bus includes a first CAN bus and a second CAN bus. The signals transmitted by the first CAN bus include the first controller CAN bus, display screen, GPS, remote control and recorder; the signals transmitted by the second CAN bus include the second controller CAN bus, bus multi-way valve, encoder and chassis bus.

5. The testing method of the pump truck testing system according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1, the host computer operation switches to the local control mode; S2, the host computer communicates with the transfer controller through the CAN card, and the transfer controller receives the proximity control signal sent by the host computer through the CAN address; S3, the transfer controller processes the near control signal and outputs it through the output port; S4, the proximity control mode input port of the controller under test is powered and receives the proximity control signal; S5, the controller under test outputs the near control permission state; S6, the host computer receives the local control status, allows and issues the local control positive pump instruction; S7, the transfer controller receives the near control positive pump signal through the CAN address; S8, the transfer controller outputs a signal through the positive pump output port; S9, the positive pump input port of the tested controller is powered; S10, the controller under test processes the input signal and outputs a close control permission signal through the positive pump solenoid valve output port; S11, the positive pump solenoid valve input port of the transfer controller receives the feedback signal of the positive pump solenoid valve of the controller under test; S12, the transfer controller processes the feedback signal of the positive pump solenoid valve and forwards it; S13, the host computer receives the feedback signal of the positive pump solenoid valve through the CAN address; S14, the host computer displays the positive pump status.

6. The testing method according to claim 5, characterized in that: In step S7, the transfer controller receives the positive pump signal sent by the host computer through the CAN address.

7. The testing method according to claim 5, characterized in that: In step S13, the host computer receives the positive pump feedback signal of the transfer controller through the CAN address.

8. The testing method according to claim 5, characterized in that: In step S14, the "positive pump" status on the host computer interface turns green, indicating that the test has passed.

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