A channel fault detection method for mixed analog input and output signals

Abstract

The present invention discloses a channel fault detection method for mixed analog input and output signals, comprising the following steps: constructing a channel fault detection system; configuring the working mode of the UIO port of the controller; the processor U1 controls and configures the integrated chip U2; the controller and the field equipment sensor are debugged normally for the first time and the data is recorded; the fault information is judged by comparing with the collected data and reported to the upper computer; the engineering personnel obtain the fault information and go directly to the fault location for repair, automatically realize the judgment of the channel fault, and report the fault information to the engineering personnel through the upper computer software, thereby reducing the repair time, shortening the fault time, and improving the efficiency of fault detection.

Description

Technical Field

[0001] The present invention relates to the technical field of analog signal detection, and in particular to a channel fault detection method for mixed analog input and output signals. Background Art

[0002] At present, at the engineering site, for the mixed analog input and output signal module, when a channel failure occurs, it is impossible to determine whether it is a failure of the module channel itself, a failure of the intermediate communication line, or a failure of the sensor device. Engineering personnel are required to go to the site to check level by level, from the port configuration of the controller, the measurement of the UIO port signal value, the on-off test of the communication line, and the signal value measurement of the sensor device. The testing of these signals requires a lot of manpower and material resources and is very time-consuming, resulting in a long engineering failure time, affecting the normal operation of the project site, and causing a lot of financial losses.

[0003] Chinese patent document CN117991001A discloses an "analog input signal diagnostic device and method". The device includes: a controller, a signal switching module and a switch module; the controller, the signal switching module and the switch module are connected in sequence, the input end of the switch module is used to access the first analog signal, and the output end of the switch module is used to send the first analog signal to the first input end and the second input end of the controller; the signal switching module is used to control the switch module to disconnect when receiving the first control signal output by the controller to cut off the connection between the first analog signal and the controller, and to generate a second analog signal when receiving the second control signal output by the controller and send the second analog signal to the first input end and the second input end of the controller. The above technical solution cannot realize the automatic judgment of multiple channel faults. Summary of the invention

[0004] The present invention mainly solves the technical problem that the original technical solution cannot realize the automatic judgment of multiple channel faults, and provides a channel fault detection method for mixed analog input and output signals. The voltage value of each point is collected by an ADC chip sampling circuit, and then the channel fault type is judged by voltage value calculation and analysis combined with the configuration of the channel type, so as to realize automatic judgment of channel faults in voltage output, voltage input, current output and current input modes, and report the fault information to engineering personnel through upper computer software, thereby reducing maintenance time, shortening fault time and improving fault detection efficiency.

[0005] The above technical problem of the present invention is mainly solved by the following technical solution: The present invention comprises the following steps: S1. constructing a channel fault detection system; S2. Configure the working mode of the UIO port of the controller; S3. Processor U1 controls and configures integrated chip U2; S4. Debug the controller and field equipment sensors for the first time and record the data; S5 compares the collected data to determine the fault information and reports it to the host computer; S6. The engineering staff obtains the fault information and goes directly to the fault location for repair.

[0006] Preferably, the channel fault detection system of step S1 includes a host computer and an MCU processor U1 connected thereto, the MCU processor U1 is respectively connected to the integrated chip U2 and the ADC chip U3; the integrated chip U2 is connected to the field equipment sensor through the sampling resistor R3 and the sampling resistor R4 in parallel; the V2 end and the V4 end of the ADC chip U3 are respectively connected to the input end of the sampling resistor R3 and the sampling resistor R4, the V3 end and the V5 end of the ADC chip U3 are respectively connected to the output end of the sampling resistor R3 and the sampling resistor R4, the V1 end of the integrated chip U2 is connected to the input end of the sampling resistor R3 through the output loop of the solid-state relay U4, the output end of the sampling resistor R3 is connected to the wiring terminal 1 and the connecting line 1 in sequence, the output end of the sampling resistor R4 is connected to the wiring terminal 2 and the connecting line 2 in sequence, and the MCU processor U1 is connected to the input loop of the solid-state relay U4 through the PA1 level.

[0007] Preferably, the working mode of the UIO port of the controller includes a voltage output mode, a voltage range is configured, and the integrated chip U2 is configured to achieve voltage signal output in the same range. The controller and the field equipment sensor are debugged normally for the first time, and the channel voltage output value between terminal 1 and terminal 2 is recorded as Vout.

[0008] Preferably, the voltage at the output end of the ADC chip U3 is collected, and the voltage difference (V3-V5) between the V3 end and the V5 end is compared with Vout. If they are different, it is judged as a channel output failure and the UIO module is replaced and repaired; if the voltage at the V2 end is equal to the voltage at the V3 end, the connecting line 1 is broken; if the voltage at the V4 end is equal to the voltage at the V5 end, the connecting line 2 is broken.

[0009] Preferably, the working mode of the UIO port of the controller includes a voltage input mode, configuring a voltage range, configuring the integrated chip U2 to implement voltage signal input detection in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel voltage input value between terminal 1 and terminal 2 as Vin.

[0010] Preferably, the voltage at the output end of the ADC chip U3 is collected. If the voltage difference (V3-V5) between the V3 end and the V5 end exceeds the voltage range, it is judged as a channel signal out-of-range fault, and the equipment sensor is replaced and repaired; if the voltage at the V2 end is equal to the voltage at the V3 end, the connecting line 1 is broken; if the voltage at the V4 end is equal to the voltage at the V5 end, the connecting line 2 is broken.

[0011] Preferably, the working mode of the UIO port of the controller includes a current output mode, configuring the current range, configuring the integrated chip U2 to achieve the current signal output in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel current output value on the terminal 1 as Iout.

[0012] Preferably, the voltage at the output end of the ADC chip U3 is collected. If the current value (V2-V3) / R3 is different from the preset value Iout or the current value (V5-V4) / R4 is different from the preset value Iout, it is judged as a channel output failure and the UIO module is replaced and repaired; if the voltage at the V2 end is equal to the voltage at the V3 end, the connecting line 1 is broken; if the voltage at the V4 end is equal to the voltage at the V5 end, the connecting line 2 is broken.

[0013] Preferably, the working mode of the UIO port of the controller includes a current input mode, configuring the current range, configuring the integrated chip U2 to achieve current signal input detection in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel current input value on the terminal 1 as Iin.

[0014] Preferably, the voltage at the output end of the ADC chip U3 is collected. If the current value (V3-V2) / R3 exceeds the current range, it is determined that the channel signal is out of range and the device sensor is replaced and repaired. If the voltage at the V2 end is equal to the voltage at the V3 end, the connecting line 1 is broken; if the voltage at the V4 end is equal to the voltage at the V5 end, the connecting line 2 is broken.

[0015] The beneficial effects of the present invention are as follows: the voltage value of each point is collected by the ADC chip sampling circuit, and then the channel fault type is judged by voltage value calculation and analysis combined with the configuration of the channel type, so as to realize automatic judgment of channel faults in voltage output, voltage input, current output and current input modes, and report the fault information to the engineering personnel through the upper computer software, thereby reducing the maintenance time, shortening the fault time and improving the troubleshooting efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a flow chart of the present invention.

[0017] Figure 2 This is a working principle diagram of a voltage output mode of the present invention.

[0018] Figure 3 This is a working principle diagram of a voltage input mode of the present invention.

[0019] Figure 4 This is a working principle diagram of a voltage output mode of the present invention.

[0020] Figure 5This is a working principle diagram of a voltage output mode of the present invention. DETAILED DESCRIPTION

[0021] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the technical solutions of the present application are further described in detail below through embodiments and in combination with the accompanying drawings. It should be understood that the specific implementation method described here is only an optimal embodiment of the present application, which is only used to explain the present application and does not limit the protection scope of the present application. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0022] At present, the most common method for troubleshooting channel faults of mixed analog input and output signals is manual on-site troubleshooting. After arriving at the site, the engineer first checks whether the port configuration is correct through the controller, whether the UIO port type is configured in current mode or voltage mode, and whether the UIO port direction is configured in input mode or output mode; then, after confirming that the port configuration is correct, use a digital multimeter to measure the value of the channel port to confirm whether the port voltage value and current value are normal; then the engineer needs to go to the sensor device end to test the voltage and current values ​​to confirm whether the input or output of the sensor device is normal; when the measured values ​​of the controller UIO port and the measured values ​​of the sensor device are normal, the engineer needs to perform a continuity test on the communication line to determine whether the communication line is normal; the three parts of the controller UIO port, sensor device, and communication line are checked step by step, and the engineer is in the pure manual troubleshooting stage for channel fault troubleshooting.

[0023] The existing manual troubleshooting methods are complicated, time-consuming, and difficult to verify, making on-site troubleshooting difficult. The engineering site has high technical requirements for engineers, who need to be familiar with on-site sensor equipment, master the current and voltage numerical test methods, record the on-site signal test values, and then analyze the channel fault type. These operations require high technical requirements for engineers, take a long time to troubleshoot, and take a long time for engineering maintenance, resulting in long downtime.

[0024] The present application proposes a channel fault detection method for mixed analog input and output signals, which is used to solve the existing channel fault detection of mixed analog input and output signals, automate signal detection, classify different fault types, automatically determine the fault type and fault information, and then upload the fault type and information to the host computer software for storage. The engineering personnel remotely access the controller register via Ethernet, and then read the channel fault information, and realize the remote fault information reading on the host computer software. In this way, the engineering personnel can obtain the fault information without going to the project site, and then prepare the maintenance plan based on the fault information, and then perform the fault repair on site, reducing the maintenance time and shortening the maintenance period.

[0025] Before discussing the exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flow charts. Although the flow charts describe the operations (or steps) as sequential processes, many of the operations (or steps) therein can be implemented in parallel, concurrently, or simultaneously. In addition, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but can also have additional steps not included in the drawings; the process can correspond to a method, function, procedure, subroutine, subprogram, etc.

[0026] The technical solution of the present invention is further specifically described below through embodiments and in conjunction with the accompanying drawings.

[0027] Embodiment: A channel fault detection method for a mixed analog input and output signal of this embodiment is as follows: Figure 1 As shown, fault detection is performed on the analog channel, including analog input and output circuits, ADC sampling circuits, and MCU processor circuits. The integrated chip U2 circuit is an analog input and output circuit, which realizes the signal type selection of voltage or current, and the signal direction selection of input or output. The MCU processor U1 circuit realizes IO level control, SPI communication, Ethernet communication, data calculation and analysis processing. The ADC sampling circuit realizes data collection and processing of the voltage values ​​at each point. U4 is a solid-state relay, and the PA1 level controls the on and off of the two contacts of the solid-state relay.

[0028] The channel fault detection system includes a host computer and an MCU processor U1 connected thereto, wherein the MCU processor U1 is connected to an integrated chip U2 and an ADC chip U3 respectively; the integrated chip U2 is connected to a field equipment sensor through a sampling resistor R3 and a sampling resistor R4 connected in parallel; the V2 end and the V4 end of the ADC chip U3 are respectively connected to the input end of the sampling resistor R3 and the sampling resistor R4, the V3 end and the V5 end of the ADC chip U3 are respectively connected to the output end of the sampling resistor R3 and the sampling resistor R4, the V1 end of the integrated chip U2 is connected to the input end of the sampling resistor R3 through an output circuit of a solid-state relay U4, the output end of the sampling resistor R3 is connected to a wiring terminal 1 and a connecting line 1 in sequence, the output end of the sampling resistor R4 is connected to a wiring terminal 2 and a connecting line 2 in sequence, and the MCU processor U1 is connected to the input circuit of the solid-state relay U4 through a PA1 level.

[0029] The channel signal can be set to voltage output, voltage input, current output, current input.

[0030] Channel fault types include channel output fault, signal connection line disconnection fault, channel input fault, and signal over-range fault.

[0031] Channel 1 is voltage output mode like Figure 2 As shown, the host computer software configures the UIO port of the controller to voltage output mode through Ethernet, with a voltage range of 0-10V. Processor U1 controls integrated chip U2 through SPI communication, and integrated chip U2 implements 0-10V voltage signal output. ADC chip U3 integrates 4-channel ADC voltage acquisition to realize voltage acquisition at both ends of the sampling resistor. Solid-state relay U4 realizes link on-off control of the channel. In voltage output mode, U4 is turned on, as shown in FIG. Figure 1 shown.

[0032] After the controller and field equipment sensors are debugged and run normally for the first time, the controller records the Vout value of channel 1. When the voltage output value of channel 1 is Vout, Vout = V3 - V5, 0V≤Vout≤10V, (V2-V3) / R3=(V5-V4) / R4, V1-V4>V3-V5, channel 1 has a channel signal output failure, ADC chip U3 collects voltage values ​​V3 and V5, processor U1 calculates (V3-V5) value, (V3-V5) value is different from the preset value Vout, and it is judged as a channel output failure. When a channel output failure occurs, processor U1 reports the channel output failure information to the host computer. Engineering personnel can directly obtain the failure information through the host computer software, and then replace and repair the UIO module.

[0033] A disconnection fault occurs in the channel signal connection line of Channel 1, which is divided into the disconnection of connection line 1 and the disconnection of connection line 2. When a disconnection fault occurs in connection line 1, no current flows through connection line 1, so V2 = V3, and it is determined that connection line 1 is disconnected. When a disconnection fault occurs in connection line 2, no current flows through connection line 2, so V4 = V5, and it is determined that connection line 2 is disconnected. When a disconnection fault occurs, the processor U1 reports the information of the disconnection fault to the host computer, and the engineering personnel can directly obtain the fault information through the host computer software, and then repair the disconnected part of the connection line.

[0034] Channel 1 is in the voltage input mode As Figure 3 shown, the host computer software configures the UIO port of the controller into the voltage input mode through the Ethernet method, and the voltage input range is 0 - 10V. The processor U1 controls and configures the integrated chip U2 through the SPI communication method, and the integrated chip U2 realizes the detection of 0 - 10V voltage signal input. The ADC chip U3 integrates 4-channel ADC voltage acquisition to realize the voltage acquisition across the sampling resistor. The solid-state relay U4 realizes the on / off control of the channel link. In the voltage input mode, U4 conducts, as Figure 2 shown.

[0035] After the first commissioning of the controller and the field device sensor is normal and the operation is normal, the controller records the Vin value of Channel 1. The Vin value is output by the field device sensor, and the output value of the sensor is within the voltage range of 0 - 10V. When the Vin value of the voltage input of Channel 1 is collected, Vin = V3 - V5, 0V ≤ Vin ≤ 10V, (V3 - V2) / R3 = (V4 - V5) / R4, V1 - V4 < V3 - V5, a channel signal overrange fault occurs in Channel 1. The ADC chip U3 collects the voltage values V3 and V5, and the processor U1 calculates the value of (V3 - V5). The value of (V3 - V5) exceeds the range of 0 - 10V, and it is determined as a signal input overrange fault. When a signal input overrange fault occurs, the processor U1 reports the signal overrange fault information to the host computer, and the engineering personnel can directly obtain the fault information through the host computer software, and then start the on-site protection mechanism for processing. The processor U1 will pull down the level of PA1 to control the contact of the solid-state relay U4 to disconnect, disconnect the overrange signal from the internal circuit, and realize the protection of the internal channel circuit. After the engineering personnel obtain the fault information on the host computer, they prepare the device sensor in advance, and then go to the site to replace and repair the device sensor, so as to shorten the engineering maintenance time.

[0036] Channel 1 has a channel signal connection line disconnection fault, which is divided into connection line 1 disconnection and connection line 2 disconnection. When connection line 1 has a disconnection fault, no current flows through connection line 1, and no current flows through resistor R3, then V3 = V2. When connection line 2 has a disconnection fault, no current flows through connection line 2, and no current flows through resistor R4, then V4 = V5. When the channel is configured in voltage input mode, when a disconnection fault occurs, processor U1 reports the disconnection fault information to the host computer, and engineering personnel can directly obtain fault information through the host computer software, and then repair the disconnected part of the connection line.

[0037] Channel 1 is current output mode like Figure 4 As shown, the host computer software configures the UIO port of the controller to current output mode through Ethernet, with a current range of 0-20mA. The processor U1 controls and configures the integrated chip U2 through SPI communication, and the integrated chip U2 realizes 0-20mA current signal output. The ADC chip U3 integrates 4-channel ADC voltage acquisition to realize voltage acquisition at both ends of the sampling resistor. The solid-state relay U4 realizes the link on-off control of the channel. In the current output mode, U4 is turned on, as shown in FIG. Figure 3 shown.

[0038] After the controller and field equipment sensors are debugged and run normally for the first time, the controller records the Iout value of channel 1. When the current output value of channel 1 is Iout, 0mA≤Iout≤20mA, (V2-V3) / R3=(V5-V4) / R4, Iout=(V5-V4) / R4, channel 1 has a channel signal output failure, ADC chip U3 collects voltage values ​​V2, V3, V4, V5, processor U1 calculates (V2-V3) value, (V5-V4) value, (V2-V3) / R3 value is different from the preset value Iout, (V5-V4) / R4 value is different from the preset value Iout, and it is judged as a channel output failure. When a channel output failure occurs, processor U1 reports the channel output failure information to the host computer, and engineers can directly obtain the failure information through the host computer software, and then replace and repair the UIO module.

[0039] Channel 1 has a channel signal connection line disconnection fault, which is divided into connection line 1 disconnection and connection line 2 disconnection. When connection line 1 has a disconnection fault, no current flows through connection line 1, and no current flows through resistor R3, then V3 = V2. When connection line 2 has a disconnection fault, no current flows through connection line 2, and no current flows through resistor R4, then V4 = V5. When the channel is configured in current output mode, when a disconnection fault occurs, processor U1 reports the disconnection fault information to the host computer, and engineering personnel can directly obtain fault information through the host computer software, and then repair the disconnected part of the connection line.

[0040] Channel 1 is current input mode like Figure 5 As shown, the host computer software configures the UIO port of the controller to current input mode through Ethernet, with a current range of 0-20mA. Processor U1 controls integrated chip U2 through SPI communication, and integrated chip U2 implements 0-20mA current signal input detection. ADC chip U3 integrates 4-channel ADC voltage acquisition to realize voltage acquisition at both ends of the sampling resistor. Solid-state relay U4 realizes link on-off control of the channel. In current input mode, U4 is turned on, as shown in FIG. Figure 4 shown.

[0041] After the controller and the field equipment sensor are debugged and run normally for the first time, the controller records the Iin value of channel 1. Iin is the output of the sensor. The output value of the sensor Iin is between the current range of 0-20mA. When the current input value of channel 1 is collected to Iin, Iin*R3=V3-V2, Iin*R4=V4-V5, 0≤Iin≤20mA, channel 1 has a channel signal over-range fault, ADC chip U3 collects voltage values ​​V2 and V3, processor U1 calculates the current value (V3-V2) / R3, the current value exceeds the range of 0-20mA, and it is judged as a signal over-range fault. When a signal over-range fault occurs, processor U1 reports the signal over-range fault information to the host computer. Engineering personnel can directly obtain the fault information through the host computer software, and then start the on-site protection mechanism processing. Processor U1 will pull down the PA1 level, control the solid-state relay U4 contacts to disconnect, disconnect the over-range signal from the internal circuit, and realize the protection of the internal channel circuit. After obtaining the fault information on the host computer, the engineering personnel prepare the equipment sensor in advance, and then go to the site to replace and repair the equipment sensor, so that the engineering maintenance time is shortened.

[0042] Channel 1 has a channel signal connection line disconnection fault, which is divided into connection line 1 disconnection and connection line 2 disconnection. When connection line 1 has a disconnection fault, no current flows through connection line 1, and no current flows through resistor R3, then V3 = V2. When connection line 2 has a disconnection fault, no current flows through connection line 2, and no current flows through resistor R4, then V4 = V5. In the channel current input mode, when a disconnection fault occurs, processor U1 reports the disconnection fault information to the host computer, and engineering personnel can directly obtain fault information through the host computer software, and then repair the disconnected part of the connection line.

[0043] Processing logic flow For the channel fault of analog input and output module, the host computer software configures the channel, the processor processes and sends the data, the channel detection circuit judges the fault, classifies the fault, the processor analyzes and processes the data, the host computer software summarizes the fault information, and after unified processing, the fault is reported to the engineering personnel to realize the automatic detection and reporting of channel faults. The specific process is as follows Figure 1 .

[0044] A mixed analog input and output signal module means that each channel of the module supports two types of input and output signal configurations, including 0-20mA current signal input, 0-20mA current signal output, 0-10V voltage signal input, 0-10V voltage signal output. Each channel can be configured into one signal type, input or output, through software. According to the on-site application, each channel can be flexibly configured to support different types of signal input and output.

[0045] The channel of the UIO module refers to the channel of the mixed analog input and output module, which is an external channel and wiring terminal of the module.

[0046] Example 1 In this implementation case, the field device is a valve actuator that supports 0-10V voltage signal input. The controller UIO module channel is connected to the valve actuator. The host computer software sends the UIO configuration through Ethernet, and configures the UIO module channel to the voltage output mode. The preset value is Vout, so that the controller can output voltage Vout through this channel, and control the valve actuator through this voltage value to achieve the switch size of the valve actuator, such as Figure 2 shown.

[0047] When the system is running normally, the processor U1 records the Vout value, the integrated chip U2 outputs the V1 and V4 voltage values, the ADC chip U3 collects the V2, V3, V4, and V5 voltage values, and transmits the voltage values ​​to the MCU processor U1 via SPI, and U1 calculates and processes the data. Vout=V3-V5,0V≤Vout≤10V, (V2-V3) / R3=(V5-V4) / R4, When U1 data is calculated and it is found that Vout≠(V3-V5), V2≠V3, and V4≠V5, processor U1 determines that the channel output is faulty and reports the channel output fault information to the host computer software. The engineering staff can directly obtain the fault information through the host computer software and then prepare the UIO module for replacement and repair.

[0048] When U1 data is calculated, Vout = (V3-V5), V2 = V3, V4 = V5, the processor U1 determines that the channel is disconnected and reports the channel disconnection fault information to the host computer software. The engineering staff can directly obtain the fault information through the host computer software and then replace and repair the connection line.

[0049] Example 2 In this implementation case, the field device is a pressure transmitter with a 0-10V voltage signal output. The controller UIO module channel is connected to the pressure transmitter. The host computer software sends the UIO configuration through Ethernet, configures the UIO module channel to the voltage input mode, and collects the output voltage signal of the pressure transmitter through this channel. In this way, the controller can collect the channel voltage Vin, such as Figure 3 shown.

[0050] When the system is operating normally, the integrated chip U2 collects the voltage values ​​of V1 and V4, and the ADC chip U3 collects the voltage values ​​of V2, V3, V4, and V5, and transmits the voltage values ​​to the processor U1 through SPI. U1 calculates and processes the data, then Vin=V3-V5, 0V≤Vin≤10V, (V3-V2) / R3=(V4-V5) / R4, When U1 data is calculated and it is found that the (V3-V5) value exceeds the range of 0-10V, V2≠V3, and V4≠V5, the processor U1 determines that the channel has an over-range fault, reports the channel over-range fault information to the host computer software, and then starts the field protection mechanism processing. The processor U1 will pull down the PA1 level, control the solid-state relay U4 contact to disconnect, disconnect the over-range signal from the internal circuit, and realize the protection of the internal channel circuit. Engineers can directly obtain fault information through the host computer software, and then prepare the pressure transmitter for replacement and maintenance.

[0051] When U1 data is calculated and it is found that the (V3-V5) value is within the range of 0-10V, V2=V3, V4=V5, the processor U1 determines that the channel is disconnected and reports the channel disconnection fault information to the host computer software. The engineering personnel can directly obtain the fault information through the host computer software and then prepare the connecting line for replacement and repair.

[0052] Example 3 In this implementation case, the field device is a frequency converter that supports 0-20mA current signal input. The controller UIO module channel is connected to the frequency converter. The host computer software sends the UIO configuration through Ethernet, configures the UIO module channel to current output mode, and the channel outputs the current value Iout, such as Figure 4 shown.

[0053] When the system is operating normally, the integrated chip U2 outputs the current Iout, and the ADC chip U3 collects the voltage values ​​of V2, V3, V4, and V5, and transmits the voltage values ​​to the processor U1 through SPI, and U1 calculates and processes the data. Then Iout=(V5-V4) / R4, 0mA≤Iout≤20mA, (V2-V3) / R3=(V5-V4) / R4, When U1 data is calculated, it is found that Iout≠(V5-V4) / R4, Iout≠(V2-V3) / R3, V2≠V3, V4≠V5, then processor U1 determines that the channel output is faulty and reports the channel output fault information to the host computer software. The engineering staff can directly obtain the fault information through the host computer software and then prepare the UIO module for replacement and repair.

[0054] When U1 data is calculated and it is found that V2=V3, V4=V5, the processor U1 determines that the channel is disconnected and reports the channel disconnection fault information to the host computer software. The engineering staff can directly obtain the fault information through the host computer software and then prepare the connecting line for replacement and repair.

[0055] Example 4 In this implementation case, the field device is a temperature sensor with a 4-20mA current signal output. The controller UIO module channel is connected to the temperature sensor. The host computer software sends the UIO configuration through Ethernet, configures the UIO module channel to the current input mode, and collects the output current signal of the temperature sensor through this channel. In this way, the controller can collect the current Iin of this channel, such as Figure 5 shown.

[0056] When the system is operating normally, the integrated chip U2 collects the channel current Iin, and the ADC chip U3 collects the voltage values ​​of V2, V3, V4, and V5, and transmits the voltage values ​​to the processor U1 through SPI, and U1 calculates and processes the data. Then Iin*R3=V3-V2,4≤Iin≤20mA, Iin*R4=V4-V5, When U1 data is calculated and it is found that the (V3-V2) / R3 value exceeds the 4-20mA range, V2≠V3, and V4≠V5, the processor U1 determines that the channel is out of range, reports the channel over-range fault information to the host computer software, and then starts the field protection mechanism processing. The processor U1 will pull down the PA1 level, control the solid-state relay U4 contact to disconnect, disconnect the over-range signal from the internal circuit, and realize the protection of the internal channel circuit. The engineering staff can directly obtain the fault information through the host computer software, and then prepare the temperature sensor for replacement and repair.

[0057] When U1 data is calculated and it is found that the (V3-V2) / R3 value is within the range of 4-20mA, V2=V3, V4=V5, the processor U1 determines that the channel is disconnected and reports the channel disconnection fault information to the host computer software. The engineering staff can directly obtain the fault information through the host computer software and then prepare the connecting line for replacement and repair.

[0058] The specific embodiments described herein are merely examples of the spirit of the present invention. The above embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be construed as limiting the scope of the present application. It should be noted that a technician in the technical field to which the present application belongs may make various modifications or supplements to the described specific embodiments or replace them in a similar manner, but will not deviate from the spirit of the present application or exceed the scope defined in the attached claims. For a person of ordinary skill in the art, multiple variations and improvements may also be made without departing from the concept of the present application. Therefore, the scope of protection of this patent shall be subject to the attached claims.

Claims

1. A channel fault detection method for mixed analog input and output signals, characterized in that: The following steps are involved: S1. Build a channel fault detection system; S2. Configure the working mode of the UIO port of the controller; S3. Processor U1 controls and configures integrated chip U2; S4. Debug the controller and field equipment sensors for the first time and record the data; S5. Compare the collected data to determine the fault information and report it to the host computer; S6. The engineering staff obtains the fault information and goes directly to the fault site for repair.

2. A channel fault detection method for mixed analog input and output signals according to claim 1, characterized in that: The channel fault detection system in step S1 includes a host computer and an MCU processor U1 connected thereto, wherein the MCU processor U1 is connected to the integrated chip U2 and the ADC chip U3 respectively; the integrated chip U2 is connected to the field equipment sensor through the sampling resistor R3 and the sampling resistor R4 connected in parallel; the V2 end and the V4 end of the ADC chip U3 are respectively connected to the input end of the sampling resistor R3 and the sampling resistor R4, the V3 end and the V5 end of the ADC chip U3 are respectively connected to the output end of the sampling resistor R3 and the sampling resistor R4, the V1 end of the integrated chip U2 is connected to the input end of the sampling resistor R3 through the output loop of the solid-state relay U4, the output end of the sampling resistor R3 is connected to the wiring terminal 1 and the connecting line 1 in sequence, the output end of the sampling resistor R4 is connected to the wiring terminal 2 and the connecting line 2 in sequence, and the MCU processor U1 is connected to the input loop of the solid-state relay U4 through the PA1 level.

3. A channel fault detection method for mixed analog input and output signals according to claim 2, characterized in that: The working mode of the UIO port of the controller includes a voltage output mode, a voltage range is configured, and the integrated chip U2 is configured to achieve voltage signal output in the same range. The controller and the field equipment sensor are debugged normally for the first time, and the channel voltage output value between terminal 1 and terminal 2 is recorded as Vout.

4. A method for detecting channel failure of mixed analog input and output signals according to claim 3, characterized in that: Collect the voltage at the output end of ADC chip U3, and compare the voltage difference between V3 and V5 (V3-V5) with Vout. If they are different, it is judged as a channel output failure, and the UIO module should be replaced and repaired. If the voltage at the V2 terminal is equal to the voltage at the V3 terminal, then the connection line 1 is broken; if the voltage at the V4 terminal is equal to the voltage at the V5 terminal, then the connection line 2 is broken.

5. A method for detecting channel failure of mixed analog input and output signals according to claim 2 or 4, characterized in that: The working mode of the UIO port of the controller includes a voltage input mode, configuring a voltage range, configuring the integrated chip U2 to implement voltage signal input detection in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel voltage input value Vin between terminal 1 and terminal 2.

6. A method for detecting channel failure of mixed analog input and output signals according to claim 5, characterized in that: Collect the voltage at the output end of ADC chip U3. If the voltage difference between V3 and V5 (V3-V5) exceeds the voltage range, it is judged as a channel signal over-range fault, and the device sensor should be replaced and repaired. If the voltage at the V2 terminal is equal to the voltage at the V3 terminal, then the connection line 1 is broken; if the voltage at the V4 terminal is equal to the voltage at the V5 terminal, then the connection line 2 is broken.

7. A method for detecting channel failure of mixed analog input and output signals according to claim 2, characterized in that: The working mode of the UIO port of the controller includes a current output mode, configuring a current range, configuring the integrated chip U2 to achieve current signal output in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel current output value on the terminal 1 as Iout.

8. A method for detecting channel failure of mixed analog input and output signals according to claim 7, characterized in that: Collect the voltage at the output end of ADC chip U3. If the current value (V2-V3) / R3 is different from the preset value Iout or the current value (V5-V4) / R4 is different from the preset value Iout, it is judged as a channel output failure and the UIO module is replaced and repaired. If the voltage at the V2 terminal is equal to the voltage at the V3 terminal, then the connection line 1 is broken; if the voltage at the V4 terminal is equal to the voltage at the V5 terminal, then the connection line 2 is broken.

9. A method for detecting channel failure of mixed analog input and output signals according to claim 2 or 7, characterized in that: The working modes of the UIO port of the controller include current input mode, configuring the current range, configuring the integrated chip U2 to realize the current signal input detection in the same range, debugging the controller and the field equipment sensor normally for the first time, and recording the channel current input value on the terminal 1 as Iin.

10. A mixed analog input and output signal channel fault detection method according to claim 9, characterized in that: Collect the voltage at the output end of ADC chip U3. If the current value (V3-V2) / R3 exceeds the current range, it is judged as a channel signal over-range fault, and the device sensor is replaced and repaired; If the voltage at the V2 terminal is equal to the voltage at the V3 terminal, then the connection line 1 is broken; if the voltage at the V4 terminal is equal to the voltage at the V5 terminal, then the connection line 2 is broken.

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