Component testing system for ultraviolet curing control system

Abstract

The invention relates to the field of ultraviolet curing equipment, in particular to a component testing system for an ultraviolet curing control system. The system comprises a UV control unit which is used for selecting a communication port to carry out a transmission test; the light detection unit is used for receiving a test signal transmitted by the communication port of the UV control unit; the PLC control unit receives a response signal from the light control module and is used for calculating the communication success rate of the communication module within a given response time threshold based on a combined judgment algorithm; the display control unit is used for man-machine interaction of the whole test system; by integrating various communication ports and communication modules, the system realizes unified testing of different components, and avoids the tedious process that each component needs to be tested independently; and test commands are sent through different communication ports, so that the accuracy and the reliability of the test are ensured.

Description

Technical Field

[0001] The invention relates to the field of ultraviolet curing equipment, in particular to a component testing system for an ultraviolet curing control system. Background Art

[0002] At present, the test of UV system is mainly component subsystem test. Each component corresponds to a unique system test, which is cumbersome and inefficient. The present invention provides a system solution for testing the quality of each component of a UV system, which mainly solves the quality detection of each component of the UV system when it is incoming, and brings together various component testing methods and testing systems into the same system for testing. The operation is simple and convenient, and the quality of each component of the UV system can be effectively guaranteed. Therefore, a component testing system for a UV curing control system is designed. Summary of the invention

[0003] The purpose of the present invention is to provide a component testing system for a UV curing control system to solve the problem in the above background technology that the current UV system test is mainly component subsystem testing, each component corresponds to a unique system test, the operation is cumbersome and the efficiency is low.

[0004] To achieve the above object, the present invention provides a component testing system for a UV curing control system, comprising: A UV control unit, the UV control unit is used to select a communication port for transmission testing, the UV control unit is provided with a plurality of communication ports, and the communication ports are used to install a communication module for testing; A light detection unit, the light detection unit includes a light control module, a collection monitoring module and a controller module, and the light detection unit is used to receive a test signal transmitted by a communication port of the UV control unit; A PLC control unit, the PLC control unit receives a response signal from the lighting control module and is used to calculate a communication success rate of the communication module within a given response time threshold based on a combined judgment algorithm; The display control unit is used for human-computer interaction of the entire test system, test mode selection, control system start, stop, parameter display and processing system abnormal alarm items.

[0005] As a further improvement of the technical solution, the UV control unit is used to transmit and receive the test signal of the PLC control unit, and the communication port includes a remote IO control port, a DeviceNet communication port, a ProfiNet communication port and an EntherNet communication port; The communication modules used for the test include remote IO control module, DeviceNet communication module, ProfiNet communication module and EntherNet communication module.

[0006] As a further improvement of the present technical solution, the lighting control module responds according to the test signal; the acquisition monitoring module includes a temperature sensor, a photosensor and a wind pressure sensor, which are used to detect the temperature value, light intensity value and wind pressure value inside the lamp head, and transmit the relevant parameters to the UV control unit in real time; the controller module includes a temperature controller, a photosensor and a wind pressure controller, which sends a signal through the PLC control unit to adjust the temperature value, light intensity value and wind pressure value of the test environment.

[0007] As a further improvement of the present technical solution, the PLC control unit establishes communication with the UV control unit. After receiving the test command, the PLC control unit initializes the test system and sends a test start command. The specific test content is divided into a communication module test and a light detection unit test.

[0008] As a further improvement of the technical solution, the specific steps involved in the communication module test are: S1.1, the PLC control unit parses the received data packet, sends the test command in the form of a data frame through the communication port selected by the UV control unit, and controls the standby, light on, and light off of the UV control unit; S1.2, based on the communication of the above different communication ports, the task with the highest response ratio is selected for execution through the highest response ratio priority scheduling algorithm; S1.3, PLC determines whether the UV control unit responds to the command in time through a combination judgment algorithm based on the parameter information fed back.

[0009] As a further improvement of the technical solution, in S1.2, the highest response ratio priority scheduling algorithm is used to ensure that each task has a chance to be executed. By selecting the task with the highest response ratio, the throughput of the system can be maximized. The formula involved in the highest response ratio priority scheduling algorithm is: ; In the formula, Indicates the time the task waits in the ready queue. Indicates the processor time required for the task; Represents the response ratio.

[0010] As a further improvement of the technical solution, in S1.3, the PLC control unit records the time difference between issuing a command and receiving feedback, sets a response time threshold through a response time detection algorithm, and combines it with a communication stability detection algorithm to monitor the reliability of data transmission. A combined judgment algorithm is used for all transmitted data packets, and the percentage of data packets whose response time is less than or equal to the preset threshold is used to obtain a communication success rate within the delay requirement. The specific steps of the combined judgment algorithm are: The response time detection algorithm is used to calculate the response time: ; In the formula, Indicates the sending timestamp; Indicates the receiving timestamp; Indicates the response time; Communication stability detection algorithm, used to calculate the reception rate of sent data packets: ; In the formula, Indicates the number of packets successfully transmitted; Indicates the total number of packets transmitted; Indicates the communication success rate; By setting The response time threshold is used to calculate the communication success rate based on the data received and the total number of transmitted packets within the threshold time: ; In the formula, Indicates the sending timestamp of the i-th data packet; Indicates the receiving timestamp of the i-th data packet; Indicates the preset response time threshold; Represents an indicator function; i represents the starting index.

[0011] As a further improvement of the technical solution, the specific steps involved in the light detection unit test are: S2.1. First, adjust the temperature, light intensity and wind pressure of the temperature controller, light source controller and wind pressure controller to constant values; S2.2. Compare the calibrated deviations using a constant stability comparison algorithm; S2.3. If the deviations between the temperature, light intensity and wind pressure values ​​detected by the sensor and the temperature, light intensity and wind pressure of the controller are within the qualified range, it means that the sensor of the light detection unit is qualified. Otherwise, the test stops and an alarm is sounded.

[0012] As a further improvement of the technical solution, in S2.2, the steps involved in the constant stability comparison algorithm are: The PLC control unit reads the temperature, light intensity and wind pressure of the light detection unit and compares them with the temperature, light intensity and wind pressure in the controller through a threshold comparison algorithm. The threshold comparison algorithm is specifically: ; In the formula, Indicates the value detected by the sensor; Indicates the value set by the controller; Indicates the deviation value; Taking into account the error caused by the detection unit, a linear calibration algorithm is used for verification: ; In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; represents the deviation after calibration; Combining the above two algorithms, the error generated during detection by the detection unit is brought into the threshold comparison algorithm as a parameter to obtain a constant stability comparison algorithm, which is specifically: ; In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; Indicates the value set by the controller; Indicates the deviation after calibration.

[0013] As a further improvement of the present technical solution, the display control unit is used to provide a human-computer interaction interface, and the display control unit also displays the overall status of the system, wherein the overall status includes: system status, transfer parameters, test progress and alarm display.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. A component testing system for a UV curing control system provides a component testing system for a UV curing control system, which significantly improves the test efficiency and ease of operation. By integrating multiple communication ports and communication modules, this system realizes unified testing of different components, avoiding the tedious process of testing each component separately; the PLC control unit can parse the received data packets and send test commands through different communication ports to ensure the accuracy and reliability of the test. In addition, the application of the highest response ratio priority scheduling algorithm and the combined judgment algorithm optimizes the calculation of task scheduling and communication success rate, further improving the overall performance of the system.

[0015] 2. In this component test system for UV curing control systems, the combination of linear calibration and threshold comparison ensures accurate measurement and calibration of parameters such as temperature, light intensity and wind pressure of the light detection unit. The display control unit provides a friendly human-computer interaction interface, which displays the overall status of the system, transfer parameters, test progress and alarm information in real time, making it convenient for operators to monitor and manage the test process. These improvements not only simplify the test process and improve test accuracy, but also significantly improve the reliability of the system and user experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a flowchart of the overall process of the present invention.

[0017] Figure 2 It is a working principle diagram of the present invention.

[0018] Figure 3 It is the work flow chart of the present invention.

[0019] The meaning of each number in the figure is: 1. UV control unit; 2. Light detection unit; 3. PLC control unit; 4. Display control unit. DETAILED DESCRIPTION

[0020] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Example

[0021] See also Figure 1-3 As shown, a component testing system for a UV curing control system is provided, comprising: A UV control unit 1, the UV control unit 1 is used to select a communication port for transmission testing, the UV control unit 1 is provided with a plurality of communication ports, and the communication ports are used to install a communication module for testing; A light detection unit 2, the light detection unit 2 includes a light control module, a collection monitoring module and a controller module, and the light detection unit 2 is used to receive a test signal transmitted by a communication port of the UV control unit 1; A PLC control unit 3, which receives a response signal from the lighting control module and is used to calculate a communication success rate of the communication module within a given response time threshold based on a combined judgment algorithm; The display control unit 4 is used for human-computer interaction of the entire test system, test mode selection, control system start, stop, parameter display and processing system abnormality alarm matters.

[0022] The UV control unit 1 is used to transmit and receive the test signal of the PLC control unit 3, and the communication port includes a remote IO control port, a DeviceNet communication port, a ProfiNet communication port and an EntherNet communication port; The communication modules used for testing include remote IO control module, DeviceNet communication module, ProfiNet communication module and EntherNet communication module; The remote IO control module is based on the local input and output I / O interface protocol, which is a simple and direct electrical signal transmission protocol used to transmit basic digital signals within the device or between short-range devices. By connecting the switch sensor of the UV lamp or the relay that controls the power supply of the UV lamp, the basic signal interaction between the UV control unit and these devices is realized; The DeviceNet communication module is based on the DeviceNet protocol, which is an open and low-cost industrial network standard based on CAN technology. It can be used to connect different UV curing equipment components, realize communication and control between devices, allow real-time data exchange between devices, and support configuration, diagnosis and monitoring of devices. The ProfiNet communication module is based on the ProfiNet protocol, which is a real-time industrial Ethernet standard protocol optimized on the basis of Ethernet to meet the high requirements of industrial automation for real-time performance and reliability. It connects the UV control unit 1 and the PLC control unit 3 to achieve communication between the two, and realizes data sharing and collaborative work; The EntherNet communication module is based on the Ethernet protocol, which is a standard protocol widely used in computer networks. It is used to connect the entire test system to the enterprise's network management system to facilitate remote monitoring of the operating status and test data of UV curing equipment. It provides high-speed data transmission rate and supports a variety of network topologies.

[0023] The acquisition monitoring module includes a temperature sensor, a light sensor and a wind pressure sensor, which are used to detect the temperature value, light intensity value and wind pressure value inside the lamp head, and transmit the relevant parameters to the UV control unit 1 in real time; The controller module includes a temperature controller, a light-sensitive controller and a wind pressure controller, and sends signals through the PLC control unit 3 to adjust the temperature value, light intensity value and wind pressure value of the test environment.

[0024] The PLC control unit 3 establishes communication with the UV control unit 1. The PLC control unit 3 establishes a connection through one of the multiple communication ports provided by the UV control unit 1 (for example, remote IO control port, DeviceNet communication port, ProfiNet communication port or Ethernet communication port) to ensure that the two units can recognize each other in the same network. After receiving the test command, the PLC control unit 3 initializes the test system and sends a test start command. The specific test content is divided into a communication module test and a light detection unit test. The steps involved in the initialization are: After the test content is selected on the display control unit 4, the display control unit 4 sends the data in the form of a data packet to the PLC control unit 3; According to the selected test content, the PLC control unit 3 pre-stores the parameters of the communication module and the controller module for the test; like Figure 3 As shown: the PLC control unit 3 sends a preparation command to the UV control unit 1, so that the UV control unit 1 enters a standby state and is ready to send and receive subsequent control commands.

[0025] The specific steps involved in the communication module test are: S1.1, the PLC control unit 3 parses the received data packet, sends the test command in the form of a data frame through the communication port selected by the UV control unit 1, and controls the standby, light on, and light off of the UV control unit 1; S1.2. Based on the communication of the above different communication ports, the task with the highest response ratio is selected for execution through the highest response ratio priority scheduling algorithm; the highest response ratio priority scheduling algorithm is used to ensure that each task has a chance to be executed. By selecting the task with the highest response ratio, the throughput of the system can be maximized. The formula involved in the highest response ratio priority scheduling algorithm is: ; In the formula, Indicates the time the task waits in the ready queue. Indicates the processor time required for the task; represents the response ratio; S1.3, PLC determines whether the UV control unit responds to the command in time through a combined judgment algorithm based on the parameter information fed back; PLC control unit 3 records the time difference between issuing the command and receiving the feedback, sets the response time threshold through a response time detection algorithm, and combines it with the communication stability detection algorithm to monitor the reliability of data transmission. The combined judgment algorithm is used for all transmitted data packets, and the percentage of data packets with a response time less than or equal to the preset threshold is used to obtain the communication success rate within the delay requirement. The specific steps of the combined judgment algorithm are as follows: The response time detection algorithm is used to calculate the response time: ; In the formula, Indicates the sending timestamp; Indicates the receiving timestamp; Indicates the response time; Communication stability detection algorithm, used to calculate the reception rate of sent data packets: ; In the formula, Indicates the number of packets successfully transmitted; Indicates the total number of packets transmitted; Indicates the communication success rate; By setting The response time threshold is used to calculate the communication success rate based on the data received and the total number of transmitted packets within the threshold time: ; In the formula, Indicates the sending timestamp of the i-th data packet; Indicates the receiving timestamp of the i-th data packet; Indicates the preset response time threshold; represents an indicator function; i represents the starting index; If the UV control unit 1 does not respond to the operation during the test, or responds in a delayed manner, the system will stop the test and issue an alarm. After troubleshooting, the tester can reset the system and retest or determine that the component is unqualified and proceed to the next component test; If the test is successfully completed, it means that the component has passed the test.

[0026] The lighting control module responds according to the test signal, such as Figure 2 As shown: The specific steps involved in the light detection unit test are: S2.1. First, adjust the temperature, light intensity and wind pressure of the temperature controller, light source controller and wind pressure controller to constant values; S2.2. Compare the calibrated deviation using a constant stability comparison algorithm; the steps involved in the constant stability comparison algorithm are: The PLC control unit 3 reads the temperature, light intensity and wind pressure of the light detection unit and compares them with the temperature, light intensity and wind pressure in the controller through a threshold comparison algorithm. The threshold comparison algorithm is specifically: ; In the formula, Indicates the value detected by the sensor; Indicates the value set by the controller; Indicates the deviation value; Taking into account the error generated by the light detection unit 2, a linear calibration algorithm is used for verification: ; In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; represents the deviation after calibration; Combining the above two algorithms, the error generated during detection by the light detection unit 2 is brought into the threshold comparison algorithm as a parameter to obtain a constant stability comparison algorithm, which is specifically: ; In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; Indicates the value set by the controller; represents the deviation after calibration; S2.3. If the values ​​of temperature, light intensity and wind pressure detected by the sensor are within the qualified range with those of the controller, it means that the sensor of the light detection unit is qualified. Otherwise, the test stops and an alarm is sounded. Among them, the optimal operating temperature range of the UV lamp is between 40-60°C. Considering the stability and safety of the system, the acceptable range of temperature deviation may be set to ±5°C, that is, 35-65°C. This is to ensure that within this temperature range, the curing effect, service life of the UV lamp and the safety of the entire system will not be significantly affected; from the performance of the entire UV curing control system, if the temperature deviation is too large, it may affect the accuracy of the light detection unit, and it is deduced that the corresponding acceptable range of temperature deviation may be ±3°C; In the UV curing process, specific materials require specific UV light intensity for curing; the light intensity required by the material is 100mW / cm². Considering that the fluctuation of light intensity may affect the curing effect, according to the tolerance of the curing process, the light intensity deviation qualified range is set to ±10mW / cm²; this is because within this deviation range, the curing degree of the material can still meet the production requirements; the accuracy of the light detection unit itself will also affect the setting of the light intensity deviation qualified range; after considering the stability and repeatability requirements of the system, the light intensity deviation qualified range is set to ±8%; In the UV curing system, wind pressure is very important for the heat dissipation of the UV lamp. The cooling fan of the UV lamp is designed to effectively dissipate heat when the wind pressure is 100Pa. According to the relationship curve between heat dissipation efficiency and wind pressure and the requirements for UV lamp temperature control, the wind pressure deviation qualified range is set to ±10Pa. Too low wind pressure may lead to insufficient heat dissipation and excessive temperature of the UV lamp. Too high wind pressure may increase energy consumption and may cause problems such as vibration of the equipment. It is deduced that the corresponding wind pressure deviation qualified range is set to ±8Pa. The display control unit 4 is used to provide a human-computer interaction interface. The display control unit 4 also displays the overall status of the system, wherein the overall status includes: system status, transfer parameters, test progress and alarm display.

[0027] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments, and the above embodiments and descriptions are only preferred examples of the present invention, and are not intended to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A component testing system for a UV curing control system, characterized in that: include A UV control unit (1), the UV control unit (1) being used to select a communication port for transmission testing, the UV control unit (1) being provided with a plurality of communication ports, the communication ports being used to install a communication module for testing; A light detection unit (2), the light detection unit (2) comprising a light control module, a collection monitoring module and a controller module, the light detection unit (2) being used to receive a test signal transmitted by a communication port of the UV control unit (1); A PLC control unit (3), the PLC control unit (3) receiving a response signal from the lighting control module and being used to calculate a communication success rate of the communication module within a given response time threshold based on a combined judgment algorithm; A display control unit (4), the display control unit (4) is used for human-machine interaction of the entire test system, test mode selection, control of the start and stop of the system, display of parameters, and processing of system abnormality alarms.

2. The component testing system for the UV curing control system according to claim 1, characterized in that: The UV control unit (1) is used to transmit and receive test signals from the PLC control unit (3), and the communication port includes a remote IO control port, a DeviceNet communication port, a ProfiNet communication port, and an EntherNet communication port; The communication modules used for the test include remote IO control module, DeviceNet communication module, ProfiNet communication module and EntherNet communication module.

3. The component testing system for the UV curing control system according to claim 1, characterized in that: The lighting control module responds according to the test signal; The acquisition and monitoring module includes a temperature sensor, a light sensor and a wind pressure sensor, which are used to detect the temperature value, light intensity value and wind pressure value inside the lamp head, and transmit the relevant parameters to the UV control unit (1) in real time; The controller module comprises a temperature controller, a light-sensitive controller and a wind pressure controller, and sends signals through a PLC control unit (3) to adjust the temperature value, light intensity value and wind pressure value of the test environment.

4. The component testing system for the UV curing control system according to claim 1, characterized in that: The PLC control unit (3) establishes communication with the UV control unit (1). After receiving the test command, the PLC control unit (3) initializes the test system and sends a test start command. The specific test content of the test system is divided into a communication module test and a light detection unit test.

5. The component testing system for the UV curing control system according to claim 4, characterized in that: The specific steps involved in the communication module test are: S1.1, the PLC control unit (3) parses the received data packet, sends a test command in the form of a data frame through the communication port selected by the UV control unit (1), and controls the UV control unit (1) to standby, turn on the light, and turn off the light; S1.2, based on the communication of the above different communication ports, the task with the highest response ratio is selected for execution through the highest response ratio priority scheduling algorithm; S1.3, the PLC determines whether the UV control unit (1) responds to the command in time based on the parameter information fed back through a combination judgment algorithm.

6. The component testing system for the UV curing control system according to claim 5, characterized in that: In S1.2, the highest response ratio priority scheduling algorithm is used to ensure that each task has a chance to be executed. The formula involved in the highest response ratio priority scheduling algorithm is: ； In the formula, Indicates the time the task waits in the ready queue. Indicates the processor time required for the task; Represents the response ratio.

7. The component testing system for the UV curing control system according to claim 5, characterized in that: In S1.3, the PLC control unit (3) records the time difference between issuing a command and receiving feedback, sets a response time threshold through a response time detection algorithm, and combines it with a communication stability detection algorithm to monitor the reliability of data transmission. A combined judgment algorithm is used to determine the percentage of data packets whose response time is less than or equal to a preset threshold among all transmitted data packets, thereby obtaining a communication success rate within the delay requirement. The specific steps of the combined judgment algorithm are as follows: The response time detection algorithm is used to calculate the response time: ； In the formula, Indicates the sending timestamp; Indicates the receiving timestamp; Indicates the response time; Communication stability detection algorithm, used to calculate the reception rate of sent data packets: ； In the formula, Indicates the number of packets successfully transmitted; Indicates the total number of packets transmitted; Indicates the communication success rate; By setting The response time threshold is used to calculate the communication success rate based on the data received and the total number of transmitted packets within the threshold time: ； In the formula, Indicates the sending timestamp of the i-th data packet; Indicates the receiving timestamp of the i-th data packet; Indicates the preset response time threshold; Represents an indicator function; i represents the starting index.

8. The component testing system for the UV curing control system according to claim 4, characterized in that: The specific steps involved in testing the light detection unit (2) are: S2.

1. First, adjust the temperature, light intensity and wind pressure of the temperature controller, light source controller and wind pressure controller to constant values; S2.

2. Compare the calibrated deviations using a constant stability comparison algorithm; S2.

3. If the deviations between the temperature, light intensity and wind pressure values ​​detected by the sensor and the temperature, light intensity and wind pressure of the controller are within the qualified range, it means that the sensor of the light detection unit is qualified. Otherwise, the test stops and an alarm is sounded.

9. The component testing system for the UV curing control system according to claim 8, characterized in that: In S2.2, the steps involved in the constant stability comparison algorithm are: The PLC control unit (3) reads the temperature, light intensity and wind pressure of the light detection unit and compares them with the temperature, light intensity and wind pressure in the controller through a threshold comparison algorithm. The threshold comparison algorithm is specifically: ； In the formula, Indicates the value detected by the sensor; Indicates the value set by the controller; Indicates the deviation value; Taking into account the error generated by the light detection unit (2) during detection, a linear calibration algorithm is used for calibration: ； In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; represents the deviation after calibration; Combining the above two algorithms, the error generated during detection by the light detection unit (2) is used as a parameter to introduce into the threshold comparison algorithm to obtain a constant stability comparison algorithm. The constant stability comparison algorithm is specifically: ； In the formula, Indicates the value detected by the sensor; represents the calibration factor; Indicates the calibration offset; Indicates the value set by the controller; Indicates the deviation after calibration.

10. The component testing system for the UV curing control system according to claim 1, characterized in that: The display control unit (4) is used to provide a human-machine interactive interface, and the display control unit (4) also displays the overall state of the system, wherein the overall state includes: system state, transfer parameters, test progress and alarm display.

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