A method, system, medium and product for collecting and controlling test data of a heating cable

Abstract

A method, system, medium and product for collecting and controlling test data of heating cables, which relate to the technical field of measuring electrical variables. The method includes: collecting real-time test data, cable image data and real-time ambient temperature when each heating cable is powered on for a test; determining the predicted ambient temperature of each heating cable according to the real-time test data and the preset test ambient temperature; determining the real-time working power of the temperature adjustment device corresponding to each heating cable according to the predicted ambient temperature and the real-time ambient temperature; controlling the temperature adjustment device to work according to the real-time working power; determining the real-time working state of the target heating cable; stopping the target power-on test of the target heating cable when the real-time working state is abnormal; and generating the power-on test result of the target heating cable after detecting the end of the target power-on test. Implementing the above technical solution improves the accuracy of the test results of power-on tests on heating cables used alone under extreme temperature conditions.

Description

Technical Field

[0001] This application relates to the technical field of measuring electrical variables, and particularly to a method, system, medium, and product for collecting and controlling test data of heating cables. Background Art

[0002] During the research and development and quality inspection of heating cables, the power-on test is a crucial link. By powering on the heating cable, its working state in the actual use scenario can be simulated, so as to obtain key performance data and provide a strong basis for product optimization and improvement. Especially the power-on test under extreme conditions plays a decisive role in evaluating the reliability of heating cables in harsh environments.

[0003] Currently, in the field of heating cable tests, the common practice is to place multiple heating cables together in the same test area and conduct power-on tests simultaneously. During the test, the test data of the preset heating cables are collected through sensors, and the performance of the heating cables is evaluated based on the collected test data.

[0004] However, since some heating cables are used alone, when multiple heating cables are powered on simultaneously in the same area, each cable will release heat during the test. As a result, when conducting power-on tests on these heating cables under extreme temperatures, the heat released by other heating cables will interfere with the test temperature around these heating cables, causing a deviation between the actual test temperature around these heating cables and the preset test temperature. At this time, the data collected based on the actual test temperature will have errors and cannot truly reflect the performance of these heating cables used alone at the preset test temperature, affecting the accuracy of the test results and further affecting the accuracy of the evaluation results of the performance of these heating cables used alone. Summary of the Invention

[0005] This application provides a method, system, medium, and product for collecting and controlling test data of heating cables, which can improve the accuracy of test results for power-on tests of heating cables used alone under extreme temperature conditions.

[0006] In a first aspect, the present application provides a method for collecting and controlling test data of heating cables. The method includes: collecting real-time test data, cable image data, and real-time ambient temperature during the power-on test of each heating cable in a target test area, where the test data includes the surface temperature, voltage, and current of the heating cable; determining the predicted ambient temperature of each heating cable according to the real-time test data and a preset test ambient temperature, where the predicted ambient temperature is the ambient temperature around the temperature sensor corresponding to the heating cable when only one heating cable is powered on in the target test area and the test ambient temperature is the preset test ambient temperature; determining the real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature and the real-time ambient temperature, where the sub-test area is obtained by dividing the target test area, each sub-test area corresponds to a temperature adjustment device, and the temperature adjustment device includes a refrigeration device and a heating device, and the real-time working power is the working power that the temperature adjustment device needs to adjust to keep the real-time ambient temperature and the predicted ambient temperature within a certain error range; controlling the temperature adjustment device to work according to the real-time working power to keep the actual test ambient temperature of each heating cable within a certain error range from the preset test ambient temperature; determining the real-time working state of the target heating cable according to the target real-time test data and target cable image data corresponding to the target heating cable, where the real-time working state includes normal and abnormal; stopping the target power-on test of the target heating cable when the real-time working state is abnormal; and generating a power-on test result of the target heating cable after detecting the end of the target power-on test.

[0007] By adopting the above technical solution, when it is detected that the error between the actual test temperature of a separately used heating cable and the preset test temperature is large, the actual test temperature of the heating cable is adjusted by the temperature control device to keep the actual test temperature and the preset test temperature of the heating cable within a certain error range, so that the data collected based on the actual test temperature can truly reflect the performance of the separately used heating cable at the preset test temperature, reducing the influence of the inconsistency between the actual test temperature and the preset test temperature on the accuracy of the test result, and improving the accuracy of the test result of the power-on test of the separately used heating cable under extreme temperature conditions. At the same time, the automatically processes and analyzes the collected real-time test data and cable image data, and generates a power-on test result of the heating cable, reducing the time for manual data processing and analysis, and improving the efficiency and accuracy of test data processing.

[0008] In combination with some embodiments of the first aspect, in some embodiments, determining the predicted ambient temperature of each heating cable based on the real-time test data and the preset test ambient temperature specifically includes: substituting the real-time test data, the preset test ambient temperature, the energization test duration of each heating cable, and the distance between the heating cable and the corresponding temperature sensor into the ambient temperature estimation formula to obtain the predicted ambient temperature of each heating cable;

[0009] Among them, the ambient temperature estimation formula is:

[0010] ; where is the predicted ambient temperature of the heating cable when the energization test duration is , is the preset test ambient temperature, is the energization test duration, is the voltage of the heating cable when the energization test duration is , is the current of the heating cable when the energization test duration is , is the material density of the heating cable, is the specific heat capacity of the material of the heating cable, is the cross-sectional area of the heating cable, is the distance between the sensor for collecting the ambient temperature and the heating cable, is the standard deviation of the temperature distribution, is the temperature correction constant.

[0011] By adopting the above technical solution, by comprehensively considering multiple key factors such as real-time test data, preset test ambient temperature, energization test duration, and the distance between the heating cable and the temperature sensor, and substituting them into the ambient temperature estimation formula to determine the predicted ambient temperature, it is possible to more accurately simulate the ambient temperature situation when only one heating cable is energized for testing, fully considering various influencing factors of the heating cable in actual operation. Compared with simple temperature speculation, the calculated predicted ambient temperature is more in line with the actual situation, improving the accuracy and reliability of the predicted ambient temperature.

[0012] In some embodiments in combination with some embodiments of the first aspect, based on the predicted ambient temperature and the real-time ambient temperature, determining the real-time operating power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located specifically includes: respectively calculating the first real-time operating power, the second real-time operating power, and the third real-time operating power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature, the real-time ambient temperature, and the preset temperature adjustment duration. The first real-time operating power includes the first heating power of the heating device and the first cooling power of the cooling device when only the heating device is adjusted. The second real-time operating power includes the second heating power of the heating device and the second cooling power of the cooling device when only the cooling device is adjusted. The third real-time operating power includes the third heating power of the heating device and the third cooling power of the cooling device when both the heating device and the cooling device are adjusted simultaneously; respectively calculating the first energy consumption corresponding to the first real-time operating power, the second energy consumption corresponding to the second real-time operating power, and the third energy consumption corresponding to the third real-time operating power according to the preset temperature adjustment duration, the first real-time operating power, the second real-time operating power, and the third real-time operating power; selecting the fourth real-time operating power corresponding to the minimum energy consumption as the real-time operating power of the temperature adjustment device according to the first energy consumption, the second energy consumption, and the third energy consumption.

[0013] Adopting the above technical solution, by respectively calculating the real-time operating power of the temperature adjustment device and its corresponding energy consumption under different temperature adjustment schemes, and selecting the real-time operating power corresponding to the minimum energy consumption as the operating power of the temperature adjustment device, it can not only effectively reduce the energy consumption during the entire test process, reduce unnecessary energy waste, but also reduce the test cost and improve the energy utilization efficiency during long-term operation.

[0014] In some embodiments in combination with some embodiments of the first aspect, after the step of generating the power-on test result of the target heating cable after detecting the end of the target power-on test, the method further includes: when the power-on test result is qualified, identifying the outer sheath damage area, the outer sheath aging degree, and the insulation layer aging degree of the target heating cable according to the target cable image data of the target heating cable; determining the test risk value of each test area in the remaining test area set according to the outer sheath damage area, the outer sheath aging degree, the insulation layer aging degree, and the remaining test area set of the target heating cable. The remaining test area set is the set of test areas that have not been subjected to the power-on test among all the test areas in the preset test plan of the target heating cable; when there is one or more test risk values in the test risk values that do not exceed the preset risk threshold, selecting the test area corresponding to the minimum test risk value as the next test area of the target heating cable.

[0015] With the above technical solution, when the power-on test result is qualified, the damaged area of the outer sheath, the aging degree of the outer sheath, and the aging degree of the insulating layer of the target heating cable are identified, and based on these data and the remaining test area set of the heating cable, the test risk value of the heating cable continuing to conduct power-on tests in each test area of the remaining test area set is calculated. When one or more test risk values in the test risk value do not exceed the preset risk threshold, the test area corresponding to the smallest test risk value is selected as the next test area of the target heating cable, which can effectively reduce the possibility of safety accidents caused by problems such as cable aging or damage during the test and improve the safety of the test process.

[0016] Combined with some embodiments of the first aspect, in some embodiments, after the step of selecting the test area corresponding to the smallest test risk value as the next test area of the target heating cable when one or more test risk values in the test risk value do not exceed the preset risk threshold, the method further includes: determining the first color of the test indicator light, the second color of the abnormal indicator light, and the third color of the area indicator light corresponding to the target heating cable according to the power-on test result, the abnormal situation of the sensor, and the next test area, where the test indicator light is used to display the power-on test result of the target heating cable, the abnormal indicator light is used to display the abnormal situation of the sensor corresponding to the target heating cable, and the area indicator light is used to display the next test area of the target heating cable; sending corresponding control instructions to the test indicator light, the abnormal indicator light, and the area indicator light in sequence according to the first color, the second color, and the third color.

[0017] With the above technical solution, the key information in the test, namely the power-on test result, the abnormal situation of the sensor, and the next test area, is intuitively displayed to the staff through different indicator lights. The staff can directly perform subsequent operations according to the guidance of the indicator lights, saving the time for the staff to obtain work information and improving the efficiency of the entire power-on test process of the heating cable.

[0018] In some embodiments in combination with some embodiments of the first aspect, after the steps of collecting real-time test data, cable image data, and real-time ambient temperature during the power-on test of each heating cable in the target test area, the method further includes: collecting a temperature image of a preset thermometer in a target test sub-area corresponding to the target heating cable in the target test area; identifying the actual temperature of the preset thermometer according to the temperature image; obtaining the real-time temperature collected by a temperature sensor corresponding to the preset thermometer; when the temperature difference between the actual temperature and the real-time temperature exceeds a preset error range, calibrating the surface temperature data in the target real-time test data corresponding to the target heating cable according to the temperature difference to obtain calibrated temperature data, and setting the working state of the temperature sensor corresponding to the target heating cable to an abnormal state; updating the surface temperature data in the target real-time test data according to the calibrated temperature data.

[0019] By adopting the above technical solution, by comparing the actual temperature measured by the thermometer and the real-time temperature collected by the temperature sensor, when it is found that the temperature difference exceeds the preset error range, that is, the temperature sensor fails and the collected data is inaccurate, the data collected by the temperature sensor can be calibrated in time, which can improve the accuracy of test data collection and then improve the accuracy of the power-on test result. At the same time, marking the working state of the temperature sensor as abnormal enables the staff to process the faulty temperature sensor in time.

[0020] In some embodiments in combination with some embodiments of the first aspect, after the step of generating the power-on test result of the target heating cable after detecting the end of the target power-on test, the method further includes: when the power-on test result is unqualified, determining the unqualified reason of the target heating cable according to the abnormal data during the power-on test of the target heating cable; obtaining the historical test records of other heating cables with the same cable model as the target heating cable in the historical test total record; determining the total frequency of the occurrence of the unqualified reason in the historical test record according to the historical test record and the unqualified reason; when the total frequency exceeds a preset frequency threshold, sending a command to stop production to the heating cable production machine corresponding to the cable model.

[0021] By adopting the above technical solution, when the power-on test result of the heating cable is unqualified, by analyzing the abnormal data during the test of the target heating cable, the specific unqualified reason can be determined quickly and accurately, avoiding the blindness of the traditional troubleshooting method. When it is detected that the occurrence frequency of the unqualified reason exceeds the preset threshold, stopping the production of the heating cable can avoid waste of resources and cost increase caused by continuing to produce unqualified products.

[0022] In a second aspect, an embodiment of the present application provides a test data acquisition and control system, including a temperature adjustment device, a sensor, and a server. Among them, the server includes: one or more processors and a memory; the memory is coupled to the one or more processors, and the memory is used to store computer program code, and the computer program code includes computer instructions. The one or more processors call the computer instructions to enable the test data acquisition and control system to execute the method described in the first aspect and any possible implementation manner in the first aspect.

[0023] In a third aspect, an embodiment of the present application provides a computer-readable storage medium, including instructions. When the above instructions run on the test data acquisition and control system, the test data acquisition and control system is enabled to execute the method described in the first aspect and any possible implementation manner in the first aspect.

[0024] In a fourth aspect, the present application provides a computer program product. When the computer program product runs on the test data acquisition and control system, the test data acquisition and control system is enabled to execute the method described in the first aspect and any possible implementation manner in the first aspect.

[0025] It can be understood that the test data acquisition and control system provided in the second aspect above, the storage medium provided in the third aspect, and the computer program product provided in the fourth aspect are all used to execute the method provided by the present application. Therefore, the beneficial effects that can be achieved can refer to the beneficial effects in the corresponding method, which will not be elaborated here.

[0026] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:

[0027] 1. When the present application detects that the error between the actual test temperature of the heating cable used alone and the preset test temperature is large, the actual test temperature of the heating cable is adjusted through the temperature control device, so that the actual test temperature of the heating cable and the preset test temperature are kept within a certain error range, so that the data collected based on the actual test temperature can truly reflect the performance of the heating cable used alone at the preset test temperature, reduce the influence of the inconsistency between the actual test temperature and the preset test temperature on the accuracy of the test results, and improve the accuracy of the test results of the power-on test of the heating cable used alone under extreme temperature conditions.

[0028] 2. The present application identifies the damaged area of the outer sheath of the target heating cable, the degree of aging of the outer sheath, and the degree of aging of the insulating layer, and calculates the test risk value of the heating cable for continued power-on testing in each test area of the remaining test area set based on this data and the remaining test area set of the heating cable. When one or more test risk values in the test risk value do not exceed the preset risk threshold, the test area corresponding to the smallest test risk value is selected as the next test area of the target heating cable, effectively reducing the possibility of safety accidents caused by cable aging or damage during the test process and improving the safety of the test process.

[0029] 3. The present application compares the actual temperature measured by the thermometer and the real-time temperature collected by the temperature sensor. When it is detected that the temperature difference exceeds the preset error range, that is, the temperature sensor fails and the collected data is inaccurate, the data collected by the temperature sensor is calibrated in a timely manner, which can improve the accuracy of test data collection and thus improve the accuracy of the power-on test result. Description of the Drawings

[0030] Figure 1 is a structural schematic diagram of a system architecture to which the heating cable test data acquisition control method in the embodiment of the present application can be applied;

[0031] Figure 2 is a flowchart of the heating cable test data acquisition control method in the embodiment of the present application;

[0032] Figure 3 is another flowchart of the heating cable test data acquisition control method in the embodiment of the present application;

[0033] Figure 4 is an exemplary hardware structural schematic diagram of the test data acquisition control system in the embodiment of the present application. Detailed Embodiments

[0034] The terms used in the following embodiments of the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and claims of the present application, the singular forms "a", "an", "the", "above", "said", "this" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used in the present application refers to any or all possible combinations including one or more of the listed items.

[0035] Hereinafter, the terms "first" and "second" are only used for descriptive purposes and should not be construed as implying or suggesting relative importance or implicitly indicating the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the embodiments of the present application, unless otherwise specified, the meaning of "a plurality" is two or more.

[0036] A heating cable is a device that efficiently converts electrical energy into heat energy. It is usually composed of a heating core wire, an insulating layer, and an outer sheath. Its working principle is based on Joule's law, and heat is generated when an electric current passes through the heating core wire with a certain resistance. According to the heating characteristics, heating cables can be divided into two categories: constant power and self-limiting temperature. The former outputs stable heat, and the latter can automatically adjust the power according to the ambient temperature change. The working ambient temperature of heating cables is generally between -20°C and 50°C. In some special industrial application scenarios, heating cables with special designs and protections can adapt to higher or lower temperature environments. For example, the high temperature can reach about 200°C, and the low temperature can reach -60°C. During the process of the heating cable being powered on and working, for the heating cable with constant power heating, the temperature it emits itself can be 120°C, 205°C, 250°C, etc.; for the self-limiting temperature heating cable, the temperature it emits itself is generally between 65°C and 105°C.

[0037] Figure 1 It is a schematic structural diagram of a system architecture to which the method for collecting and controlling test data of a heating cable in an embodiment of the present application can be applied.

[0038] Please refer to Figure 1 , the test data acquisition and control system includes sensors, image acquisition devices, temperature control devices, and servers.

[0039] As the core component of the system, the server is used to analyze and process the data collected by the sensors and image acquisition devices and send control instructions to the temperature control devices. The sensors are used to collect the test data during the power-on test of the heating cable and transmit the collected test data to the server. The image acquisition devices are used to collect the image data during the power-on test of the heating cable and transmit the collected image data to the server. The temperature control devices are used to receive the control instructions transmitted by the server and adjust the operating power of the devices according to the control instructions.

[0040] Among them, the sensors include voltage sensors, current sensors, temperature sensors, etc. The temperature control devices include refrigeration devices, heating devices, etc.

[0041] Through the above system architecture, the test data acquisition and control system can adjust the actual test temperature of the heating cable through the temperature control device, so that the actual test temperature of the heating cable and the preset test temperature are kept within a certain error range, and reduce the interference of the heat released by other heating cables in the same test area on the actual test temperature of the heating cable.

[0042] In related technologies, the common practice of the energization test of heating cables is to centrally place multiple heating cables in the same test area and conduct the energization test simultaneously. During the test process, the test data of the preset heating cable is collected through sensors, and the performance of the heating cable is evaluated based on the collected test data. However, since some heating cables are used alone, when multiple heating cables are simultaneously energized in the same area during the test, each cable will release heat during the test, resulting in the heat released by other heating cables interfering with the test temperature around these heating cables during the energization test at extreme temperatures, causing a deviation between the actual test temperature around these heating cables and the preset test temperature. At this time, the data collected based on the actual test temperature will have errors, which cannot truly reflect the performance of these heating cables used alone at the preset test temperature, affecting the accuracy of the test results, and further affecting the accuracy of the evaluation results of the performance of these heating cables used alone.

[0043] Generally, in order to ensure the accuracy of the evaluation results of the performance of these heating cables used alone, physical isolation is used through isolation boards to isolate each heating cable, avoiding the interference of the heat released by other heating cables on the test temperature around these heating cables. However, there will still be heat conduction between isolation boards of different materials, and some heat will still be transferred to the surroundings of the isolated heating cables, causing a deviation between the actual test temperature and the preset test temperature. If the interference of the heat released by other heating cables on the test temperature around these heating cables is to be reduced to an extremely low level, multiple insulation boards with excellent heat insulation performance or energization tests are required for each heating cable separately. However, insulation boards with excellent heat insulation performance are generally expensive, which will greatly increase the cost of the energization test of the heating cable. At the same time, conducting energization tests for each heating cable separately will greatly reduce the efficiency of the energization test of the heating cable. To improve the efficiency of the energization test of the heating cable when conducting energization tests for each heating cable separately, multiple energization test devices are required, which will also greatly increase the cost of the energization test of the heating cable.

[0044] When the heating cable test data acquisition and control method in the embodiment of the present application is adopted, when it is detected that the error between the actual test temperature of the heating cable used alone and the preset test temperature is large, the actual test temperature of the heating cable is adjusted through the temperature control device, so that the actual test temperature of the heating cable and the preset test temperature are kept within a certain error range, so that the data collected based on the actual test temperature can truly reflect the performance of the heating cable used alone at the preset test temperature, reduce the influence of the inconsistency between the actual test temperature and the preset test temperature on the accuracy of the test result, and improve the accuracy of the test result of the energized test of the heating cable used alone under extreme temperature conditions on the premise of saving the test cost and ensuring the energized test efficiency.

[0045] The following will describe the method of the embodiment of the present application in conjunction with Figure 2 to illustrate.

[0046] Please refer to Figure 2 , which is a schematic flowchart of the heating cable test data acquisition and control method in the embodiment of the present application.

[0047] S201. Collect real-time test data, cable image data, and real-time ambient temperature when each heating cable in the target test area is energized.

[0048] Collect the voltage, current, surface temperature, and real-time ambient temperature of each heating cable in the target test area when it is energized through sensors, and collect the cable image data of each heating cable through an image acquisition device.

[0049] Among them, the test data includes the surface temperature, voltage, and current of the heating cable.

[0050] S202. Determine the predicted ambient temperature of each heating cable according to the real-time test data and the preset test ambient temperature.

[0051] Among them, the predicted ambient temperature is the ambient temperature around the heating cable collected by the temperature sensor corresponding to the heating cable when there is only one heating cable energized in the target test area and the test ambient temperature is the preset test ambient temperature.

[0052] Specifically, a pre-trained heat transfer model is used to determine the predicted ambient temperature of each heating cable. The heat transfer model is constructed based on heat transfer principles such as heat conduction described by Fourier's law, heat convection reflected by Newton's law of cooling, and heat radiation presented by the Stefan-Boltzmann law. Voltage, current, the preset test ambient temperature, and the relative position relationship between the temperature sensor and the heating cable (such as the distance between the temperature sensor and the heating cable, etc.) are used as input parameters. By collecting a large amount of actual data under different working conditions (covering various combinations of voltage and current, different preset test ambient temperatures, and actual measured ambient temperature data corresponding to diverse relative positions of the temperature sensor and the heating cable), these actual data are compared with the model simulation results and optimized. The parameters of the model are continuously adjusted to improve the accuracy of the model in simulating the heat transfer process, making the predicted ambient temperature output by the model approach the actual measured value and achieving accurate and reliable ambient temperature prediction.

[0053] The voltage, current, and the relative position relationship between the temperature sensor and the heating cable in the real-time test data are input into the heat transfer model. First, based on the voltage and current, the heat generation amount of the heating cable is determined using Joule's law (or calculated by the power formula). Combining the preset test ambient temperature as the starting condition, the heat conduction process is calculated according to Fourier's law, the heat convection situation is determined based on Newton's law of cooling, the heat radiation amount is calculated according to the Stefan-Boltzmann law, and at the same time, considering the influence of the relative position relationship between the temperature sensor and the heating cable on the heat weight received by the three heat transfer methods, these heat transfer processes and their interactions are comprehensively simulated and calculated. Finally, the predicted ambient temperature is output, that is, the ambient temperature collected by the temperature sensor when only one heating cable is energized in the target test area and the test ambient temperature is the preset value.

[0054] S203. Determine the real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature and the real-time ambient temperature.

[0055] Among them, the sub-test area is obtained by dividing the target test area. Each sub-test area corresponds to a temperature adjustment device. The temperature adjustment device includes a refrigeration device and a heating device. The real-time working power is the working power that the temperature adjustment device needs to adjust to make the real-time ambient temperature and the predicted ambient temperature within a certain error range.

[0056] Specifically, calculate the difference between the predicted ambient temperature and the real-time ambient temperature. If the difference is within the preset error range, determine the real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located as the current working power of the temperature adjustment device.

[0057] If the difference is not within the preset error range and is positive, it indicates that the real-time ambient temperature is lower than the predicted ambient temperature, and the error between the real-time ambient temperature and the predicted ambient temperature is large. In this case, a heating device is needed to increase the temperature. Obtain the pre-established mapping relationship between temperature difference and heating power change, which is constructed based on a large amount of pre-collected experimental data. During the experiment, for different sub-experiment areas, considering factors such as their heat capacity, the heating efficiency of the heating device used, and environmental heat loss, record the change in heating power required to make the temperature of the sub-experiment area reach stability within the preset adjustment duration at different temperature differences. Through the analysis and fitting of these experimental data, obtain a mapping table, mapping function, or mathematical model that can reflect the corresponding relationship between temperature difference and heating power change, and store it in the system. Look up the corresponding change in the working power of the heating device in the mapping relationship according to the difference, and calculate the heating power of the heating device that can raise the real-time ambient temperature to the predicted ambient temperature within the preset adjustment duration based on the change in power and the current working power of the heating device. The cooling power of the cooling device is the current working power of the cooling device.

[0058] If the difference is not within the preset error range and is negative, it indicates that the real-time ambient temperature is higher than the predicted ambient temperature, and the error between the real-time ambient temperature and the predicted ambient temperature is large. In this case, a cooling device is needed to lower the temperature. Obtain the pre-established mapping relationship between temperature difference and cooling power. The establishment method of this relationship is the same as that of the mapping relationship between temperature difference and heating power change, considering factors such as the heat capacity of the sub-experiment area, the cooling efficiency of the cooling device, and environmental heat loss. Look up the corresponding change in the working power of the cooling device in the mapping relationship according to the difference, and calculate the cooling power of the cooling device that can lower the real-time ambient temperature to the predicted ambient temperature within the preset adjustment duration based on the change in power and the current working power of the cooling device. The heating power of the heating device is the current working power of the heating device.

[0059] S204. Control the temperature adjustment device to work according to the real-time working power, so that the actual test environment temperature of each heating cable is within a certain error range of the preset test environment temperature.

[0060] Determine the corresponding control command according to the real-time working power of the temperature adjustment device, and send this control command to the temperature adjustment device. After receiving this control command, the temperature adjustment device works according to this real-time working power, so that the actual test environment temperature of each heating cable is within a certain error range of the preset test environment temperature.

[0061] S205. Determine the real-time working state of the target heating cable according to the target real-time test data and target cable image data corresponding to the target heating cable.

[0062] Among them, the real-time working status includes normal and abnormal.

[0063] Specifically, obtain the normal reference range of test data under the normal working status of the heating cable corresponding to the cable model of the target heating cable. Compare the values of voltage, current, surface temperature, etc. in the target real-time test data corresponding to the target heating cable with the corresponding normal reference range. If there is test data exceeding the normal reference range, determine that the first working status of the target heating cable is abnormal; otherwise, determine that the first working status of the target heating cable is normal.

[0064] At the same time, based on the target cable image data, identify the aging condition, outer sheath damage condition, and insulation layer damage condition (the outer sheath is outside the insulation layer to protect the insulation layer) of the heating cable through image recognition technologies (such as convolutional neural network models based on deep learning, edge detection algorithms, template matching methods, etc.). Taking the convolutional neural network model as an example, the model is trained based on a large number of heating cable images with different aging, outer sheath damage, and insulation layer damage conditions. These images are marked with data such as the aging area and aging degree, outer sheath damage area and damage area, and insulation layer damage area. During the training process, the convolutional neural network learns the appearance features of normal heating cables by learning these marked images, including the smooth surface and uniform color of the outer sheath, and the relatively uniform appearance of the insulation layer through the outer sheath. At the same time, the model also learns the characteristic changes during aging, such as the cracks and fading of the outer sheath during aging, and the color change and transparency change of the insulation layer during aging; as well as the characteristics during damage, such as the irregular edges and fracture marks of the damaged outer sheath, and the internal structure that may be exposed when the insulation layer is damaged.

[0065] Input the target cable image data into the model, and the model will perform comprehensive feature extraction and analysis on the image. The model first identifies the outer sheath based on the features learned during training, judges its aging condition through features such as texture and color, calculates the proportion of the aging area in the total area of the outer sheath to quantify the aging degree, and at the same time performs damage detection on the outer sheath to identify whether there are damage features such as irregular edges and fracture marks. When damage is detected, determine the damage area of the damaged area through pixel calculation, etc.; since the outer sheath is outside the insulation layer, the model will then identify the insulation layer condition at the damaged area, judge the aging degree of the insulation layer from changes in color, transparency, etc. For insulation layer damage, if the internal structure change of the insulation layer can be observed at the damaged area of the outer sheath, or there are abnormal color and texture changes in the insulation layer, it is determined that the insulation layer is damaged.

[0066] Compare the aging degree of the outer sheath and the insulation layer, the damaged area of the outer sheath with the corresponding thresholds. If any abnormal threshold condition is met or the insulation layer is damaged, determine that the second working state is abnormal and record the cause of the abnormality; otherwise, it is normal. The causes of the abnormality include insulation layer damage, severe aging of the insulation layer, severe damage to the outer sheath, and severe aging of the outer sheath, etc.

[0067] Finally, comprehensively consider the first working state determined based on the test data and the second working state determined based on image recognition. If both are normal, determine that the real-time working state of the target heating cable is normal; if any one of the working states is abnormal, determine that the real-time working state is abnormal.

[0068] S206. When the real-time working state is abnormal, stop the target power-on test of the target heating cable.

[0069] When the real-time working state is abnormal, send a stop operation command to the temperature regulation device and the power supply device of the target heating cable. After receiving the command, the power supply device stops supplying power to the target heating cable to stop the target power-on test.

[0070] S207. After detecting the end of the target power-on test, generate the power-on test result of the target heating cable.

[0071] Specifically, when detecting that the power supply device of the target heating cable stops running, determine the power-on test result of the target heating cable according to the real-time working state of the target heating cable. If the real-time working state is abnormal, determine that the power-on test result is unqualified and record the reason for the unqualified; otherwise, determine that the power-on test result is qualified.

[0072] Among them, the reasons for unqualified include abnormal test data, insulation layer damage, severe aging of the insulation layer, severe damage to the outer sheath, and severe aging of the outer sheath, etc. If the first working state is abnormal and the second working state is normal, determine that the reason for unqualified is abnormal test data; if the first working state is normal and the second working state is abnormal, use the cause of the abnormality corresponding to the second working state as the reason for unqualified; if both the first working state and the second working state are abnormal, determine that the reasons for unqualified are abnormal test data and the cause of the abnormality corresponding to the second working state.

[0073] In the embodiments of the present application, when the error between the actual test temperature of the heating cable used alone and the preset test temperature is detected to be large, the actual test temperature of the heating cable is adjusted through the temperature control device, so that the actual test temperature of the heating cable and the preset test temperature are kept within a certain error range, so that the data collected based on the actual test temperature can truly reflect the performance of the heating cable used alone at the preset test temperature, reduce the influence of the inconsistency between the actual test temperature and the preset test temperature on the accuracy of the test results, and improve the accuracy of the test results of the power-on test of the heating cable used alone under extreme temperature conditions. At the same time, the collected real-time test data and cable image data are automatically processed and analyzed, and the power-on test results of the heating cable are generated, reducing the time for manual data processing and analysis, and improving the efficiency and accuracy of test data processing.

[0074] The following will further illustrate the method of the embodiments of the present application in conjunction with Figure 3 to further illustrate the method of the embodiments of the present application.

[0075] Please refer to Figure 3 , which is another flowchart of the method for collecting and controlling test data of the heating cable in the embodiments of the present application.

[0076] S301. Collect real-time test data, cable image data, and real-time ambient temperature when each heating cable in the target test area is powered on for testing.

[0077] Step S301 is similar to step S201 in the embodiment shown in Figure 2 , and reference can be made to the description in step S201, which will not be elaborated here.

[0078] S302. Collect the temperature image of the preset thermometer in the target test sub-area corresponding to the target heating cable in the target test area.

[0079] Collect the temperature image of the preset thermometer in the target test sub-area corresponding to the target heating cable in the target test area through the image acquisition device.

[0080] S303. Identify the actual temperature of the preset thermometer according to the temperature image.

[0081] Specifically, first preprocess the image, and then use an edge detection algorithm (such as the Canny algorithm) to extract the edge information of the thermometer in the temperature image, accurately locate the contour of the thermometer and the edges of the scale lines and readings. Based on these edge information, through morphological operations, such as dilation and erosion, the edge features are further enhanced.

[0082] Then, a character recognition model in template matching or deep learning is used to recognize the temperature reading. If template matching is adopted, a template library containing various possible temperature reading characters needs to be prepared in advance. The digital characters segmented from the image are compared with the templates in the template library one by one, the similarity is calculated, and the most matching template is found to determine the reading. If a deep learning model such as a convolutional neural network (CNN) is used, a large number of thermometer images with temperature reading annotations need to be used to train the model in advance. The trained model can directly and accurately recognize the reading in the temperature image.

[0083] Finally, combining the scale characteristics of the thermometer and the recognized reading, the actual temperature of the preset thermometer is determined.

[0084] S304. Obtain the real-time temperature collected by the temperature sensor corresponding to the preset thermometer.

[0085] According to the unique identifier of the temperature sensor corresponding to the preset thermometer, obtain the real-time temperature collected by the corresponding temperature sensor. Among them, the relative relationship between the preset thermometer and its corresponding temperature sensor is adjacent.

[0086] S305. When the temperature difference between the actual temperature and the real-time temperature exceeds the preset error range, calibrate the surface temperature data in the target real-time test data corresponding to the target heating cable according to the temperature difference to obtain calibrated temperature data.

[0087] When the temperature difference between the actual temperature and the real-time temperature exceeds the preset error range, calibrate the surface temperature data in the target real-time test data corresponding to the target heating cable according to the temperature difference to obtain calibrated temperature data, and set the working state of the temperature sensor corresponding to the target heating cable to an abnormal state.

[0088] Specifically, when the temperature difference between the actual temperature and the real-time temperature exceeds the preset error range, calibrate the surface temperature data in the target real-time test data corresponding to the target heating cable according to the preset calibration rule. Among them, the calibration rule can be calibrated temperature data = surface temperature data + temperature difference, or it can be calibrated based on a compensation function. A compensation function based on the temperature difference is established, and this function can be obtained by fitting a large amount of experimental data. This method can more precisely reflect the complex relationship between the temperature difference and the calibration value, especially applicable to the situation where the relationship between the temperature difference and the calibration value is not simply linear or piecewise linear, and is not limited here.

[0089] After completing the calibration of the surface temperature data, set the working state of the temperature sensor corresponding to the target heating cable to an abnormal state.

[0090] S306. Update the surface temperature data in the target real-time test data according to the calibrated temperature data.

[0091] Replace the surface temperature data in the target real-time test data with the corresponding calibrated temperature data according to the calibrated temperature data.

[0092] S307. Calculate the predicted ambient temperature of each heating cable through the ambient temperature estimation formula.

[0093] Substitute the real-time test data, the preset test ambient temperature, the energization test duration of each heating cable, and the distance between the heating cable and the corresponding temperature sensor into the ambient temperature estimation formula to obtain the predicted ambient temperature of each heating cable.

[0094] Among them, the ambient temperature estimation formula is:

[0095] ; where is the predicted ambient temperature of the heating cable when the energization test duration is , is the preset test ambient temperature, is the energization test duration, is the voltage of the heating cable when the energization test duration is , is the current of the heating cable when the energization test duration is , is the material density of the heating cable, is the specific heat capacity of the material of the heating cable, is the cross-sectional area of the heating cable, is the distance between the sensor for collecting the ambient temperature and the heating cable, is the standard deviation of the temperature distribution, is the temperature correction constant.

[0096] In the ambient temperature estimation formula, is the preset test ambient temperature, which is the starting reference value for the entire temperature estimation. It represents the ambient temperature condition set or measured in the target test area before the energization test of the heating cable starts.

[0097] In the formula The part is the calculation of the change in ambient temperature caused by factors such as the heating of the heating cable itself and the heat transfer process from the start of energization to the energization test duration of .

[0098] Among them, reflects the correlation between the heating characteristics of the heating cable and its own physical properties. represents the heating cable when the energization duration is The instantaneous electric power at that time. The larger its value, the more heat is generated by the cable per unit time. And Comprehensively reflects the physical properties of the heating cable, such as material density, specific heat capacity, and cross-sectional area. The material density affects the mass per unit volume of the cable. The specific heat capacity determines the amount of heat required to raise the temperature of the cable per unit mass by one unit. The cross-sectional area is related to the heat dissipation and heat distribution of the cable. The larger the product of these three physical quantities, the stronger the ability of the cable to absorb and store heat. Under the same heating power, its temperature change is relatively small, and the impact on the surrounding environmental temperature will also be different. This part of the ratio reflects the relative relationship between the heat generated by the cable per unit time and its own heat storage capacity, directly affecting the heating effect of the heating cable on the surrounding environment.

[0099] Shows the role of the distance between the sensor collecting the ambient temperature and the heating cable and the standard deviation of the temperature distribution in the estimation of the ambient temperature. The distance between the sensor and the heating cable determines the degree of heat loss during the transfer of heat from the heating cable to the sensor. Generally speaking, the farther the distance, the more heat is dissipated due to heat exchange with the surrounding medium during the transfer, and the smaller the temperature change measured by the sensor affected by the heating cable. The standard deviation of the temperature distribution describes the degree of temperature dispersion in space. The larger the standard deviation, the more uneven the temperature distribution in the test area, which makes the relationship between the temperature value collected by the sensor and the actual temperature around the heating cable more complex, thus affecting the accurate estimation of the ambient temperature.

[0100] As the temperature correction constant, it is a coefficient determined after comprehensively considering many actual working conditions factors. These factors include but are not limited to the air flow condition in the test area, the heat conduction performance of the environment, and whether there are other heat sources or cold source interferences, etc.

[0101] is the duration of the power-on test. As time increases, the heating cable continuously generates heat, and the heat generated accumulates and affects the surrounding environmental temperature. The duration of the power-on test, as a time variable, reflects this dynamic process of heat accumulation and temperature change over time.

[0102] Generally speaking, the entire ambient temperature estimation formula comprehensively and meticulously considers various factors such as the heat generation and physical properties of the heating cable itself, the distance between the temperature sensor and the cable, the temperature distribution characteristics, and the actual working conditions. Through the synergistic effect of each parameter, it can more scientifically and accurately estimate the predicted ambient temperature of each heating cable under different power-on test durations.

[0103] S308. Calculate the first real-time operating power, the second real-time operating power, and the third real-time operating power of the temperature adjustment device corresponding to the sub-test area where each heating cable is located.

[0104] According to the predicted ambient temperature, the real-time ambient temperature, and the preset temperature adjustment duration, calculate the first real-time operating power, the second real-time operating power, and the third real-time operating power of the temperature adjustment device corresponding to the sub-test area where each heating cable is located, respectively.

[0105] Among them, the first real-time operating power includes the first heating power of the heating device and the first cooling power of the cooling device when only the heating device is adjusted; the second real-time operating power includes the second heating power of the heating device and the second cooling power of the cooling device when only the cooling device is adjusted; the third real-time operating power includes the third heating power of the heating device and the third cooling power of the cooling device when both the heating device and the cooling device are adjusted simultaneously.

[0106] Specifically, calculate the difference between the predicted ambient temperature and the real-time ambient temperature. If the difference is within the preset error range, determine the first real-time operating power, the second real-time operating power, and the third real-time operating power of the temperature adjustment device corresponding to the sub-test area where each heating cable is located as the current operating power of the temperature adjustment device.

[0107] If the difference is not within the preset error range, according to the pre-established temperature difference - heating power change mapping relationship, find the corresponding heating device operating power change amount in the mapping relationship based on the absolute value of the difference. Calculate the first heating power of the heating device according to the operating power change amount, the positive or negative situation of the difference, and the current operating power of the heating device. The first cooling power of the cooling device is the current operating power of the cooling device.

[0108] According to the pre-established temperature difference - cooling power change mapping relationship, find the corresponding cooling device operating power change amount in the mapping relationship based on the absolute value of the difference. Calculate the second cooling power of the cooling device according to the operating power change amount, the positive or negative situation of the difference, and the current operating power of the cooling device. The second heating power of the heating device is the current operating power of the heating device.

[0109] According to the absolute value of the difference, divide the absolute value by two to obtain the heating temperature difference and the cooling temperature difference. If the predicted ambient temperature is greater than the real-time ambient temperature, the heating temperature difference is positive and the cooling temperature difference is negative; otherwise, the heating temperature difference is negative and the cooling temperature difference is positive. Respectively, find the change in the working power of the heating device and the change in the working power of the cooling device corresponding to the heating temperature difference and the cooling temperature difference in the corresponding preset mapping relationship. According to the change in the working power of the heating device, the positive or negative situation of the heating temperature difference, and the current working power of the heating device, calculate the third heating power of the heating device. According to the change in the working power of the cooling device, the positive or negative situation of the cooling temperature difference, and the current working power of the cooling device, calculate the third cooling power of the cooling device.

[0110] Among them, when the difference is positive, the working power of the corresponding device increases by the corresponding change; when the difference is negative, the working power of the corresponding device decreases by the corresponding change.

[0111] S309. Calculate the first energy consumption, the second energy consumption, and the third energy consumption.

[0112] According to the preset temperature adjustment duration, the first real-time working power, the second real-time working power, and the third real-time working power, calculate the first energy consumption corresponding to the first real-time working power, the second energy consumption corresponding to the second real-time working power, and the third energy consumption corresponding to the third real-time working power respectively.

[0113] Specifically, according to the heating power of the heating device and the cooling power of the cooling device, calculate the first energy consumption, the second energy consumption, and the third energy consumption through a preset energy consumption calculation formula. Among them, the energy consumption calculation formula can be the heating power multiplied by the preset temperature adjustment duration plus the cooling power multiplied by the preset temperature adjustment duration.

[0114] S310. Select the fourth real-time working power corresponding to the minimum energy consumption as the real-time working power of the temperature adjustment device according to the first energy consumption, the second energy consumption, and the third energy consumption.

[0115] Compare the first energy consumption, the second energy consumption, and the third energy consumption, and select the fourth real-time working power corresponding to the minimum energy consumption as the real-time working power of the temperature adjustment device. Among them, the fourth real-time working power is one of the first, second, and third real-time working powers.

[0116] S311. Control the temperature adjustment device to work according to the real-time working power.

[0117] S312. Determine the real-time working state of the target heating cable.

[0118] S313. When the real-time working state is abnormal, stop the target power-on test of the target heating cable.

[0119] S314. After detecting the end of the target power-on test, generate the power-on test result of the target heating cable.

[0120] Steps S311 - S314 are similar to Figure 2 Steps S204 - S207 in the illustrated embodiment. Refer to the descriptions in Steps S204 - S207, and details are not repeated here.

[0121] S315. When the power-on test result is qualified, determine the outer sheath breakage area, the degree of outer sheath aging, and the degree of insulation layer aging of the target heating cable.

[0122] When the power-on test result is qualified, based on the target cable image data of the target heating cable, identify the outer sheath breakage area, the degree of outer sheath aging, and the degree of insulation layer aging of the target heating cable.

[0123] Steps S315 is similar to Figure 2 Step S205 in the illustrated embodiment. Refer to the description in Step S205, and details are not repeated here.

[0124] S316. Determine the test risk values of each test area in the remaining test area set.

[0125] Based on the outer sheath breakage area, the degree of outer sheath aging, the degree of insulation layer aging, and the remaining test area set of the target heating cable, determine the test risk values of each test area in the remaining test area set.

[0126] Among them, the remaining test area set is the set of test areas that have not undergone power-on tests among all the test areas in the preset test plan of the target heating cable.

[0127] Specifically, based on the preset test plan and test records of the target heating cable, determine the remaining test area set of the target heating cable. Obtain the preset weights of the outer sheath breakage area, the preset weights of the degree of outer sheath aging, and the preset weights of the degree of insulation layer aging corresponding to each test area in the remaining test area set. Based on the preset weights of the outer sheath breakage area, the preset weights of the degree of outer sheath aging, the preset weights of the degree of insulation layer aging, the outer sheath breakage area, the degree of outer sheath aging, and the degree of insulation layer aging, calculate the test risk values of each test area in each remaining test area set through weighted calculation.

[0128] S317. When there is one or more test risk values in the test risk values that do not exceed the preset risk threshold, select the test area corresponding to the smallest test risk value as the next test area of the target heating cable.

[0129] When one or more test hazard values in the test hazard values do not exceed the preset hazard threshold, select the test area corresponding to the smallest test hazard value as the next test area for the target heating cable. When there is no one or more test hazard values in the test hazard values that do not exceed the preset hazard threshold, send information to stop the test plan of the target heating cable to the corresponding staff.

[0130] S318. Determine the first color of the test indicator light, the second color of the abnormal indicator light, and the third color of the area indicator light corresponding to the target heating cable.

[0131] Based on the power-on test result, the abnormal situation of the sensor, and the next test area, determine the first color of the test indicator light, the second color of the abnormal indicator light, and the third color of the area indicator light corresponding to the target heating cable.

[0132] Among them, the test indicator light is used to display the power-on test result of the target heating cable, the abnormal indicator light is used to display the abnormal situation of the sensor corresponding to the target heating cable, and the area indicator light is used to display the next test area of the target heating cable.

[0133] Specifically, according to the first color correspondence table of the test indicator light, the second color correspondence table of the abnormal indicator light, and the third color correspondence table of the area indicator light, respectively obtain the first color corresponding to the power-on test result, the second color corresponding to the abnormal situation of the sensor, and the third color corresponding to the next test area.

[0134] S319. Send corresponding control instructions to the test indicator light, the abnormal indicator light, and the area indicator light.

[0135] Based on the first color, the second color, and the third color, determine the corresponding first control instruction, second control instruction, and third control instruction, send the first control instruction to the test indicator light, send the second control instruction to the abnormal indicator light, and send the third control instruction to the area indicator light.

[0136] S320. When the power-on test result is unqualified, determine the unqualified reason of the target heating cable.

[0137] When the power-on test result is unqualified, obtain the unqualified reason recorded when the power-on test result was determined to be unqualified in step S314. Among them, the unqualified reason is determined based on the abnormal data of the target heating cable during the power-on test.

[0138] S321. Obtain the historical test records of other heating cables with the same cable model as the target heating cable in the historical total test records.

[0139] According to the cable model of the target heating cable, search for the historical test records of other heating cables with the same cable model in the total historical test records stored in the memory.

[0140] S322. Determine the total frequency of the reasons for non-conformity in the historical test records.

[0141] According to the historical test records and the reasons for non-conformity, determine the total frequency of the reasons for non-conformity in the historical test records.

[0142] Specifically, extract the non-conforming test records with the test result of non-conformity in the historical test records. Traverse the reasons for non-conformity in the non-conforming test records. When there is only one reason for non-conformity of the target heating cable, compare this reason for non-conformity with the reason for non-conformity of the target heating cable. When there is a certain reason for non-conformity that is consistent with the reason for non-conformity of the target heating cable, increment the frequency of the reason for non-conformity of the target heating cable in the historical test records by one; when there are multiple reasons for non-conformity of the target heating cable, when there is a certain reason for non-conformity that is consistent with a certain reason for non-conformity of the target heating cable, increment the frequency of a certain reason for non-conformity of the target heating cable in the historical test records by one. After traversing all non-conforming test records, obtain the total frequency of each reason for non-conformity of the target heating cable in the historical test records.

[0143] S323. When the total frequency exceeds the preset frequency threshold, send a command to stop production to the heating cable production machine corresponding to the cable model.

[0144] Specifically, when there is one or more total frequencies that exceed the preset frequency threshold in the total frequency, determine the heating cable production machine for producing the heating cable of this cable model, and send a command to stop production to the heating cable production machine. After receiving the command, the heating cable production machine stops running. At the same time, when there is one or more total frequencies that are the same as the number of records in the historical test records in the total frequency, send a message to the designer of the heating cable of this cable model to remind the designer that there are design problems with the heating cable of this cable model.

[0145] In the embodiments of the present application, when it is detected that the error between the actual test temperature of the heating cable used alone and the preset test temperature is large, the temperature control device is used to adjust the actual test temperature of the heating cable, so that the actual test temperature of the heating cable and the preset test temperature are kept within a certain error range, so that the data collected based on the actual test temperature can truly reflect the performance of the heating cable used alone at the preset test temperature, reduce the influence of the inconsistency between the actual test temperature and the preset test temperature on the accuracy of the test results, and improve the accuracy of the test results of the power-on test of the heating cable used alone under extreme temperature conditions. When the power-on test result is qualified, by calculating the test risk values of the heating cable continuing to conduct power-on tests in each test area in the remaining test area set, and selecting the test area corresponding to the smallest test risk value as the next test area of the target heating cable, the possibility of causing safety accidents during the test due to problems such as cable aging or damage can be effectively reduced, and the safety of the test process can be improved. By using different indicator lights to visually display the key information in the test to the staff for viewing, the time for the staff to obtain work information is saved, and the efficiency of the entire power-on test process of the heating cable is improved. By comparing the actual temperature measured by the thermometer and the real-time temperature collected by the temperature sensor, when it is detected that the temperature difference exceeds the preset error range, that is, the temperature sensor fails and the collected data is inaccurate, the data collected by the temperature sensor can be calibrated in time, the accuracy of the test data collection is improved, and further the accuracy of the power-on test result is improved. When the power-on test result of the heating cable is unqualified, by analyzing the abnormal data of the target heating cable during the test, the specific reason for the unqualified can be quickly and accurately determined, avoiding the blindness of the traditional troubleshooting method. When it is detected that the occurrence frequency of the unqualified reason exceeds the preset threshold, the production of the heating cable is stopped, which can avoid waste of resources and increase in costs caused by continuing to produce unqualified products.

[0146] The method for collecting and controlling test data of the heating cable in the embodiments of the present application is described above. Next, in combination with the above method for collecting and controlling test data of the heating cable, the test data collection and control system in the embodiments of the present application will be described in detail.

[0147] Please refer to Figure 4 , which is an exemplary hardware structure diagram of the test data collection and control system in the embodiments of the present application.

[0148] In some embodiments, the test data acquisition and control system 400 includes a computer device, which may be a terminal device. The computer device includes a processor 401, a memory 402, a sensor module 403, a communication module 404, an input device 405, and an output device 406 connected via a system bus. Among them, the processor 401 of the computer device is used to provide computing and control capabilities. The memory 402 of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system, a computer program, and a database. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The database is used to store data. The sensor module 403 of the computer device is used to collect test data, ambient temperature data, etc. during the energization test of the heating cable. The communication module 404 of the computer device is used to transmit the collected test data, ambient temperature data, and image data to the server and send control instructions to the temperature control device, the indicator light, etc. The input device 405 of the computer device is used to receive the collected test data, ambient temperature data, and image data, etc. The output device 406 of the computer device is used to display the test data, test results, etc. The computer program, when executed by the processor 401, implements the heating cable test data acquisition and control method in the embodiments of the present application.

[0149] Those skilled in the art can understand that Figure 4 the structure shown in is only a block diagram of some structures related to the solution of the present application, and does not constitute a limitation on the computer device to which the solution of the present application is applied. The specific computer device may include more or fewer components than those shown in the figure, or combine some components, or have a different component layout.

[0150] In some embodiments of the present application, a computer-readable storage medium is provided, including instructions, which, when running on the test data acquisition and control system 400, can cause the test data acquisition and control system 400 to execute the heating cable test data acquisition and control method in the embodiments of the present application.

[0151] As described above, the above embodiments are only used to illustrate the technical solutions of the present application, and are not intended to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present application.

[0152] As used in the foregoing embodiments, depending on the context, the term "when" may be construed to mean "if", or "after", or "in response to determining", or "in response to detecting". Similarly, depending on the context, the phrase "when determining" or "if (the stated condition or event) is detected" may be construed to mean "if determined", or "in response to determining", or "when (the stated condition or event) is detected", or "in response to detecting (the stated condition or event)".

[0153] In the foregoing embodiments, it may be implemented in whole or in part by software, hardware, firmware, or any combination thereof. When implemented using software, it may be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, the processes or functions described in the embodiments of the present application are generated in whole or in part. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center by wire (such as coaxial cable, optical fiber, digital subscriber line) or wirelessly (such as infrared, wireless, microwave, etc.). The computer-readable storage medium may be any available medium that can be accessed by a computer or a data storage device such as a server or data center that includes one or more integrated available media. The available medium may be a magnetic medium (such as a floppy disk, hard disk, magnetic tape), an optical medium (such as a DVD), or a semiconductor medium (such as a solid-state drive), etc.

[0154] Those of ordinary skill in the art can understand that all or part of the processes in the methods of the foregoing embodiments can be completed by hardware instructed by a computer program. The program can be stored in a computer-readable storage medium. When the program is executed, it may include the processes of the foregoing method embodiments. The foregoing storage medium includes various media that can store program codes, such as ROM or random access memory RAM, magnetic disks, or optical discs.

Claims

1. A method for collecting and controlling test data of a heating cable, characterized in that, Including: Collecting real-time test data, cable image data, and real-time ambient temperature during the power-on test of each heating cable in the target test area, where the real-time test data includes the surface temperature, voltage, and current of the heating cable; Determining the predicted ambient temperature of each heating cable according to the real-time test data and the preset test ambient temperature, where the predicted ambient temperature is the ambient temperature around the heating cable collected by the corresponding temperature sensor when only one heating cable is powered on for testing in the target test area and the test ambient temperature is the preset test ambient temperature; Determining the real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature and the real-time ambient temperature. The sub-test area is obtained by dividing the target test area, and each sub-test area corresponds to a temperature adjustment device. The temperature adjustment device includes a refrigeration device and a heating device, and the real-time working power is the working power that the temperature adjustment device needs to adjust to keep the real-time ambient temperature and the predicted ambient temperature within a certain error range; Controlling the temperature adjustment device to work according to the real-time working power to keep the actual test ambient temperature of each heating cable within a certain error range from the preset test ambient temperature; Determining the real-time working state of the target heating cable according to the target real-time test data and target cable image data corresponding to the target heating cable, where the real-time working state includes normal and abnormal; When the real-time working state is abnormal, stopping the target power-on test of the target heating cable; After detecting the end of the target power-on test, generating the power-on test result of the target heating cable; The step of determining the predicted ambient temperature of each heating cable according to the real-time test data and the preset test ambient temperature specifically includes: Substituting the real-time test data, the preset test ambient temperature, the power-on test duration of each heating cable, and the distance between the heating cable and the corresponding temperature sensor into the ambient temperature estimation formula to obtain the predicted ambient temperature of each heating cable; Wherein, the ambient temperature estimation formula is: Among them, T(t) is the predicted ambient temperature of the heating cable at the energization test duration of t, T env is the preset test ambient temperature, t is the energization test duration, V(t) is the voltage of the heating cable at the energization test duration of t, I(t) is the current of the heating cable at the energization test duration of t, ρ is the material density of the heating cable, C is the specific heat capacity of the material of the heating cable, A is the cross-sectional area of the heating cable, d is the distance between the sensor for collecting the ambient temperature and the heating cable, σ is the standard deviation of the temperature distribution, and k is the temperature correction constant.

2. The method according to claim 1, wherein The step of determining the real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature and the real-time ambient temperature specifically includes: Calculating the first real-time working power, the second real-time working power, and the third real-time working power of the temperature adjustment device corresponding to each sub-test area where the heating cable is located according to the predicted ambient temperature, the real-time ambient temperature, and the preset temperature adjustment duration. The first real-time working power includes the first heating power of the heating device and the first refrigeration power of the refrigeration device when only the heating device is adjusted. The second real-time working power includes the second heating power of the heating device and the second refrigeration power of the refrigeration device when only the refrigeration device is adjusted. The third real-time working power includes the third heating power of the heating device and the third refrigeration power of the refrigeration device when both the heating device and the refrigeration device are adjusted; According to the preset temperature regulation duration, the first real-time working power, the second real-time working power, and the third real-time working power, calculate the first energy consumption corresponding to the first real-time working power, the second energy consumption corresponding to the second real-time working power, and the third energy consumption corresponding to the third real-time working power respectively; according to the first energy consumption, the second energy consumption, and the third energy consumption, select the fourth real-time working power corresponding to the minimum energy consumption as the real-time working power of the temperature regulation device.

3. The method according to claim 1, wherein After the step of generating the power-on test result of the target heating cable after detecting the end of the target power-on test, the method further includes: When the power-on test result is qualified, identify the outer sheath damage area, the outer sheath aging degree, and the insulation layer aging degree of the target heating cable according to the target cable image data of the target heating cable; According to the outer sheath damage area, the outer sheath aging degree, the insulation layer aging degree, and the remaining test area set of the target heating cable, determine the test risk value of each test area in the remaining test area set, where the remaining test area set is the set of test areas that have not been subjected to a power-on test among all the test areas in the preset test plan of the target heating cable; When there is one or more test risk values in the test risk values that do not exceed the preset risk threshold, select the test area corresponding to the smallest test risk value as the next test area of the target heating cable.

4. The method according to claim 3, wherein After the step of selecting the test area corresponding to the smallest test risk value as the next test area of the target heating cable when there is one or more test risk values in the test risk values that do not exceed the preset risk threshold, the method further includes: determining the first color of the test indicator light, the second color of the abnormal indicator light, and the third color of the area indicator light corresponding to the target heating cable according to the power-on test result, the abnormal situation of the sensor, and the next test area, where the test indicator light is used to display the power-on test result of the target heating cable, the abnormal indicator light is used to display the abnormal situation of the sensor corresponding to the target heating cable, and the area indicator light is used to display the next test area of the target heating cable; According to the first color, the second color, and the third color, sequentially send corresponding control commands to the test indicator light, the abnormal indicator light, and the area indicator light.

5. The method according to claim 1, wherein After the step of collecting the real-time test data, cable image data, and real-time ambient temperature when each heating cable in the target test area is subjected to a power-on test, the method further includes: Collect the temperature image of the preset thermometer in the target test sub-area corresponding to the target heating cable in the target test area; Identify the actual temperature of the preset thermometer according to the temperature image; Obtain the real-time temperature collected by the temperature sensor corresponding to the preset thermometer; When the temperature difference between the actual temperature and the real-time temperature exceeds a preset error range, calibrate the surface temperature data in the target real-time test data corresponding to the target heating cable according to the temperature difference to obtain calibrated temperature data, and set the working state of the temperature sensor corresponding to the target heating cable to an abnormal state; Update the surface temperature data in the target real-time test data according to the calibrated temperature data.

6. The method according to claim 1, wherein After the step of generating the power-on test result of the target heating cable after detecting the end of the target power-on test, the method further includes: When the power-on test result is unqualified, determine the unqualified reason of the target heating cable according to the abnormal data during the power-on test of the target heating cable; Obtain the historical test records of other heating cables with the same cable model as the target heating cable in the total historical test records; Determine the total frequency of the occurrence of the unqualified reason in the historical test records according to the historical test records and the unqualified reason; When the total frequency exceeds a preset frequency threshold, send a command to stop production to the heating cable production machine corresponding to the cable model.

7. A test data acquisition and control system, characterized in that, Including a temperature regulation device, a sensor, and a server, wherein the server includes: one or more processors and a memory; The memory is coupled to the one or more processors, and the memory is used to store computer program code, the computer program code includes computer instructions, and the one or more processors call the computer instructions to enable the test data acquisition control system to execute the method according to any one of claims 1-6.

8. A computer-readable storage medium storing computer instructions, characterized in that, When the computer instructions run on the test data acquisition control system, enable the test data acquisition control system to execute the method according to any one of claims 1-6.

9. A computer program product, characterized in that, When the computer program product runs on the test data acquisition control system, enable the test data acquisition control system to execute the method according to any one of claims 1-6.

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