Batch automatic detection method and system for electric energy meter keyboards

Abstract

The invention relates to the technical field of electric energy meters, in particular to a batch automatic detection method and system for electric energy meter keyboards, and the method comprises the steps: connecting keys to the same AD detection port through resistors with different resistance values, pulling up the keys to a 3.3 V power supply to construct a voltage division circuit, and enabling the voltage of the AD port to be 3.3 V when no key is pressed down; the keys are pressed down, theoretical voltage of the corresponding AD port is calculated, and a standard detection library is built in the single-chip microcomputer to store theoretical values of the keys; during detection, the actual voltage of the AD port is acquired and compared with a theoretical value, and the key fault is judged if the deviation exceeds a preset range. And in the overall connectivity verification, calculating a theoretical parallel voltage value of the voltage division of the equivalent resistor and the pull-up resistor, comparing the theoretical parallel voltage value with an actual value, and judging that the global connection is abnormal if the deviation exceeds a threshold value. The tool air cylinder presses down the keyboard cover plate to automatically trigger batch detection, abnormal information is read through the communication interface, and abnormal electric energy meters are processed. Therefore, the problems of low manual detection efficiency, high cost, missed detection and misjudgment risks and the like in the prior art are solved.

Description

Technical Field

[0001] This application relates to the technical field of electric energy meters, and particularly to a batch automatic detection method and system for an electric energy meter keyboard. Background Art

[0002] In the African power market, at present, most countries widely use prepaid meters based on the STS protocol, and the forms of keyboard meters and rail meters with user interface units are relatively common. The user interface unit is installed in the customer's home and undertakes the important responsibility of communicating with the electric meter. The silicone keyboard integrated in it allows users to input the electricity sales TOKEN sold by the power authority to recharge the electric meter, so as to ensure the normal use of the user's electricity. This mode meets the specific needs in the development of the African power grid and plays an important role in the local power supply system.

[0003] However, with the rapid development of the national power grids in African countries in recent decades, the demand for electric energy meters has been increasing day by day, and many domestic electric energy meter manufacturers have exported a large number of electric energy meters to Africa. However, in this production process, the detection link of the silicone keyboard has become a major problem. At present, there is no effective method for batch and rapid detection of the silicone keyboards of electric energy meters. Most manufacturers still use the method of pressing each key manually and observing the liquid crystal display to judge whether the key is normal. This traditional manual detection method not only consumes a large amount of manpower, but also has extremely low efficiency, which has become a bottleneck in the production process of electric energy meters and seriously restricts the improvement of the manufacturer's production capacity. More importantly, there is a possibility of missed detection and misjudgment in manual testing, which brings serious loopholes to the quality control of electric energy meters. Since the silicone keyboard is a key component of the keyboard meter, once a problem occurs, it will directly cause the customer to be unable to recharge and the power to be cut off at the user's home, and the consequences will be unimaginable. Summary of the Invention

[0004] This application provides a batch automatic detection method and system for an electric energy meter keyboard to solve the problems in the prior art, such as the lack of a method for batch and rapid detection of the silicone keyboards of electric energy meters, the low efficiency, high cost and the risk of missed detection and misjudgment relying on manual detection, which affect the production capacity and quality.

[0005] The first aspect of the embodiments of the present application provides a method for batch automatic detection of an electric energy meter keyboard, including the following steps: Connect each key to the same AD detection port through resistors with different resistance values and pull it up to the 3.3V power supply to construct a voltage division circuit, so that the voltage of the AD port is 3.3V when no key is pressed; When any key is pressed, calculate the theoretical voltage of the corresponding AD port based on the principle of series voltage division to form a mapping relationship between the key and the voltage; Define a table in the single-chip microcomputer to store the theoretical voltage values when each key is not pressed, and establish a standard detection library; Real-time collect the actual sampled voltage of the AD port and compare it with the theoretical voltage value. If it is detected that the deviation between the actual sampled voltage and the theoretical voltage value exceeds the preset range, it is determined that there is a hardware failure in the corresponding key, and the specific abnormal key information is recorded and stored in the storage space of the electric energy meter itself; When performing the overall connectivity verification, calculate the voltage division of the parallel equivalent resistance of all key resistors and the pull-up resistor to obtain the theoretical parallel voltage value, and compare it with the actual sampled voltage. If the deviation exceeds the preset threshold, it is determined that there is a global connection abnormality; When the tooling cylinder presses down the keyboard cover plate, automatically trigger the batch detection process of voltage acquisition, single-chip microcomputer theoretical value comparison, single-key fault detection and overall connectivity verification of the voltage division detection circuit, and read the stored abnormal key information through the communication interface, and perform marking, isolation or alarm processing on the abnormal electric energy meter according to the preset rules.

[0006] Optionally, the design of the voltage division circuit includes: Divide the 12 keys of the 3×4 keyboard into two groups, with 6 keys in each group connected to two independent AD detection ports respectively; Each group of keys is connected in series with a common pull-up resistor R7 through a resistor with a unique resistance value to form a dual AD detection architecture, where the first AD port is connected to keys 1 to 6, and the second AD port is connected to keys 7 to 12; When the detection voltage of any AD port deviates from the preset theoretical value, locate the abnormal key group by looking up the table, and narrow down the repair range to the 6 keys controlled by the corresponding AD port.

[0007] Optionally, the voltage division circuit further includes a filter capacitor, and the filter capacitor is connected in parallel between the AD detection port and the ground for filtering high-frequency noise interference in the sampled voltage.

[0008] Optionally, the theoretical voltage calculation of the voltage division circuit includes: For the voltage calculation when a single key is pressed, the formula is: ; Where is the resistance value of the current key, is the resistance value of the common pull-up resistor; For the calculation of the parallel equivalent voltage when all keys are pressed, the formula is: [[ID=2Y]] ; Where It is the number of buttons connected to the current AD port.

[0009] Optionally, the tooling is a six-position test tooling, and the duration for the tooling cylinder to press down the keyboard cover plate is 3 seconds.

[0010] Optionally, the implementation method for the communication interface to read abnormal information includes: communicating with the upper computer of the tooling using the RS-485 bus protocol, with the baud rate set to 115200 bps; after the power meter completes the detection, it actively uploads a JSON data packet containing the meter number, fault code, and voltage sampling value; after the upper computer parses the data packet, if a fault flag is detected, it controls the robotic arm to transfer the abnormal power meter to the repair pipeline and synchronously records the fault type in the MES system.

[0011] Optionally, perform marking, isolation, or alarm processing on the abnormal power meter according to preset rules, including: if the single-button fault quantity ≤ 2, mark it as a secondary abnormality and allow it to enter the secondary re-inspection process; if the single-button fault quantity > 2 or there is a global connection abnormality, mark it as a primary abnormality and directly isolate it to the scrap area; the two-dimensional code information of all abnormal power meters is automatically synchronized to the cloud database for quality traceability analysis.

[0012] Optionally, the abnormal button information includes the button number, theoretical voltage value, actual sampled voltage value, and deviation percentage.

[0013] Optionally, it is determined that there is a global connection abnormality, including: triggering each button separately in sequence, recalculating the theoretical parallel voltage value and comparing it with the actual value to locate the specific faulty button group; if the deviation of a certain button group exceeds 50% of the global threshold, it is determined that there is an open or short circuit fault in this group.

[0014] The second aspect of the embodiments of this application provides a batch automatic detection system for an electric energy meter keyboard, including: a voltage division detection module, used to construct a button voltage division circuit through resistors with different resistances and connect it to the AD detection port; a theoretical value storage module, used to define a table of theoretical voltage values for each button in the single-chip microcomputer; a voltage acquisition module, used to sample the voltage of the AD port in real time and perform filtering processing; a fault determination module, used to compare the actual voltage with the theoretical value, locate abnormal buttons, and generate fault codes; a tooling control module, used to trigger batch detection by pressing with a cylinder and coordinate the communication interface to upload data; an abnormal processing module, used to perform marking, isolation, or alarm operations according to the fault code level.

[0015] Thus, this application has at least the following beneficial effects: In the embodiments of the present application, an efficient and intelligent detection of the silicone keyboard of the electric energy meter is realized by constructing a voltage dividing circuit and an AD detection architecture and combining with a tooling automatic triggering mechanism. Each key is connected to the same AD detection port through resistors with different resistance values and pulled up to the 3.3V power supply, and a mapping relationship between the key and the voltage is formed based on the principle of series voltage division. A standard detection library is established in the single-chip microcomputer. When the tooling cylinder presses down the keyboard cover plate, the entire process of voltage acquisition, theoretical value comparison, single-key fault detection, and overall connectivity verification is automatically triggered. By accurately comparing the real-time sampled voltage with the theoretical value (with an accuracy of ±0.05V), single-key faults and global connection anomalies (parallel resistance change of ±5%) can be quickly located. With a six-meter position test tooling, the single-meter detection time is shortened from 5 seconds manually to 0.5 seconds, and the production capacity is increased by more than 100 times. Combined with a grading processing mechanism (re-inspection is allowed when the single-key fault is ≤2, and it is directly scrapped when it is >2 or there is a global anomaly) and MES system data traceability, the missed detection rate is controlled below 0.1%, significantly reducing the labor cost and after-sales risk. Thus, the problems in the prior art that there is a lack of a method for batch and rapid detection of the silicone keyboard of the electric energy meter, relying on manual detection with low efficiency, high cost, and the risk of missed detection and misjudgment, affecting production capacity and quality, are solved.

[0016] Additional aspects and advantages of the present application will be given in part in the following description, become apparent in part from the following description, or be understood through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and / or additional aspects and advantages of the present application will become apparent and be readily understood from the following description of the embodiments in conjunction with the accompanying drawings, where: Figure 1 is a flowchart of a method for batch automatic detection of an electric energy meter keyboard according to an embodiment of the present application; Figure 2 is a schematic diagram of the hardware design circuit of an electric energy meter keyboard according to an embodiment of the present application; Figure 3 is a schematic diagram of the appearance of a supporting tooling according to an embodiment of the present application; Figure 4 is a structural diagram of a system for batch automatic detection of an electric energy meter keyboard according to an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] The embodiments of the present application will be described in detail below. The examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions from beginning to end. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to explain the present application, but should not be construed as limiting the present application.

[0019] The following describes a method and system for batch automatic detection of an electric energy meter keyboard according to an embodiment of the present application. Aiming at the problem of low efficiency of manual detection mentioned in the above background technology, the present application provides a method for batch automatic detection of an electric energy meter keyboard. In this method, by constructing a voltage dividing circuit and an AD detection architecture, combined with a tooling automation trigger mechanism, efficient and intelligent detection of the silicone keyboard of the electric energy meter is realized. Each key is connected to the same AD detection port through resistors with different resistance values and pulled up to a 3.3V power supply. Based on the principle of series voltage division, a mapping relationship between the key and the voltage is formed, and a standard detection library is established in the single-chip microcomputer. When the tooling cylinder presses down the keyboard cover plate, the entire process of voltage acquisition, theoretical value comparison, single-key fault detection, and overall connectivity verification is automatically triggered. By accurately comparing the real-time sampled voltage with the theoretical value (with an accuracy of ±0.05V), single-key faults and global connection anomalies (±5% change in parallel resistance) can be quickly located. Using a six-meter position test tooling, the single-meter detection time is shortened from 5 seconds manually to 0.5 seconds, and the production capacity is increased by more than 100 times. With the grading processing mechanism (≤2 single-key faults allow re-inspection, >2 or global anomalies are directly scrapped) and MES system data traceability, the missed detection rate is controlled below 0.1%, significantly reducing labor costs and after-sales risks. Thus, the problems in the prior art, such as the lack of a method for batch rapid detection of the silicone keyboard of the electric energy meter, relying on manual detection with low efficiency, high cost, and the risks of missed detection and misjudgment, affecting production capacity and quality, are solved.

[0020] The following describes a method and system for batch automatic detection of an electric energy meter keyboard according to an embodiment of the present application.

[0021] Specifically, Figure 1 is a schematic flow chart of a method for batch automatic detection of an electric energy meter keyboard provided by an embodiment of the present application.

[0022] As Figure 1 shown, the method for batch automatic detection of the electric energy meter keyboard includes the following steps: In step S101, each key is connected to the same AD detection port through resistors with different resistance values and pulled up to a 3.3V power supply to construct a voltage dividing circuit, so that the voltage of the AD port is 3.3V when no key is pressed.

[0023] It can be understood that the embodiment of the present application realizes the quantitative detection of the key state through the voltage dividing circuit, makes each key correspond to a unique theoretical voltage value, and constructs a digital detection basis at the hardware layer. When no key is pressed, the AD port is fixed at 3.3V, providing a stable reference point for the system and ensuring the reliability of the detection reference.

[0024] In an embodiment of the present application, the design of the voltage divider circuit includes: dividing the 12 keys of the 3×4 keyboard into two groups, with each group of 6 keys connected to two independent AD detection ports respectively; each group of keys is connected in series with a common pull-up resistor R7 through a resistor of a unique resistance value to form a dual AD detection architecture, wherein the first AD port is connected to keys 1 to 6, and the second AD port is connected to keys 7 to 12; when the detection voltage of any AD port deviates from the preset theoretical value, the abnormal key group is located by looking up the table, and the maintenance scope is narrowed to the 6 keys controlled by the corresponding AD port.

[0025] It can be understood that the embodiment of the present application constructs an efficient fault diagnosis system of "group detection-precise positioning" by dividing the 12 keys into two groups and connecting them to independent AD ports. Each group is equipped with a unique resistance resistor in series with a common pull-up resistor. When the voltage of a certain AD port deviates from the theoretical value, the abnormal key group (6-key range) can be quickly locked, which reduces the fault location range by 50% compared with the traditional single AD full-key detection solution, greatly improving the maintenance efficiency; at the same time, the dual-port parallel detection mechanism supports synchronous sampling of two groups of keys, and cooperates with the subsequent overall connectivity verification to achieve hierarchical diagnosis of hardware faults (single-key fault / intra-group abnormality). Without adding complex hardware, the detection accuracy and cost are balanced through circuit topology optimization. It is especially suitable for batch detection scenarios of medium-sized key matrices such as 3×4 keyboards, providing a hardware foundation for rapid fault detection in the mass production stage.

[0026] In the embodiment of the present application, the theoretical voltage calculation of the voltage divider circuit includes: For calculating the voltage when a single button is pressed, the formula is: ; in, is the resistance value of the current button, is the common pull-up resistor value; For the calculation of the parallel equivalent voltage when all keys are pressed, the formula is: ; in, The number of buttons connected to the current AD port.

[0027] Specifically, assuming that when button 1 is pressed, resistors R7 and R1 form a series circuit. The voltage of the AD port at this time is the divided voltage on resistor R1. According to the voltage division principle of the series circuit, the divided voltage on resistor R1 is 3.3×51 / (51+15)=2.55V. Similarly, the voltage when each button is pressed is shown in Table 1 below.

[0028] Table 1 Voltage table corresponding to buttons

[0029] When all the buttons are pressed, it is equivalent to the resistance of all the buttons being connected in parallel and then in series with R7. According to the principle of parallel circuit, the equivalent resistance of R1, R2, R3, R4, R5, and R6 in parallel is 2.22KΩ. At this time, the voltage of the AD port is 3.3×2.22 / (2.22+15)=0.42V. On the contrary, if there is a problem with the hardware of one of the buttons, such as the resistor of button 2 is poorly soldered or the circuit is broken for some reason, then only the equivalent resistance of R1, R3, R4, R5, and R6 in parallel is calculated to be 2.35KΩ. The voltage of the AD port is calculated to be 3.3×2.35 / (2.35+15)=0.45V, which is not equal to the theoretical voltage of 0.42V. Therefore, the program can determine that button 2 is not pressed, or there is a problem with the hardware circuit of button 2 and it cannot be recognized normally.

[0030] In an embodiment of the present application, the voltage divider circuit further includes a filter capacitor, which is connected in parallel between the AD detection port and the ground to filter out high-frequency noise interference in the sampled voltage.

[0031] It can be understood that the embodiment of the present application improves the voltage sampling accuracy by filtering out high-frequency noise, thereby ensuring the reliability of the detection results.

[0032] Specifically, the capacitor uses the characteristic of "passing high frequencies and blocking low frequencies" to short-circuit high-frequency noise (such as power frequency interference and circuit switching noise) mixed in the voltage signal of the AD detection port to ground, thereby avoiding sampling voltage fluctuations caused by noise. This design can reduce the fluctuation range of the actual sampling voltage from ±0.2V to within ±0.05V, ensuring accurate deviation judgment when compared with the theoretical voltage value, and preventing misjudgments caused by noise interference (such as normal buttons being mistakenly judged as faults) or missed detections (such as minor poor contact faults being masked by noise). At the same time, the introduction of filter capacitors does not increase the cost of complex hardware (the cost of a single meter only increases by US$0.1), but significantly improves the anti-interference ability of the detection system. It is especially suitable for scenarios with strong electromagnetic interference in industrial production environments, providing hardware-level noise suppression guarantees for stable operation during batch testing.

[0033] In step S102, when any key is pressed, the corresponding AD port theoretical voltage is calculated based on the series voltage division principle to form a mapping relationship between the key and the voltage.

[0034] The mapping relationship uniquely corresponds to the voltage value generated when each button is pressed. For example: Pressing button 1 (R1 = 1kΩ) → V_AD ≈ 0.47V; pressing button 2 (R2 = 2kΩ) → V_AD ≈ 0.83V.

[0035] It can be understood that the embodiments of the present application construct the mapping relationship between the keys and voltages based on the series voltage division principle, and convert the physical actions of the keys into quantifiable electrical signal characteristics. When any key is pressed, its corresponding resistance value and the common pull-up resistor form a voltage division circuit, causing a unique theoretical voltage value to be generated at the AD detection port, realizing the precise mapping of "one key, one voltage". This mechanism provides a quantitative basis for the single-chip microcomputer to establish a standard detection library, making it possible to compare the subsequent actual sampled voltage with the theoretical value, thereby converting the manual visual judgment of key failures into digital detection of electrical signal deviations.

[0036] In step S103, a table is defined in the single-chip microcomputer to store the theoretical voltage values when each key is not pressed, and a standard detection library is established.

[0037] It can be understood that the embodiments of the present application establish a standard detection library by defining a table in the single-chip microcomputer to store the theoretical voltage values when each key is not pressed, providing a quantitative comparison benchmark for key failure detection. This library pre-calculates and stores the theoretical voltage values corresponding to each key based on the series voltage division principle. During detection, the single-chip microcomputer compares the real-time sampled voltage with the theoretical values in the library, and determines whether the key is abnormal through a preset deviation threshold, upgrading the detection from manual observation to digital quantification, significantly improving the efficiency to 0.5 seconds per single table, and being able to accurately record deviation data, providing support for fault analysis and process optimization. This mechanism makes the detection process replicable, adapts to different models of electric energy meters, supports software upgrades to adjust the threshold, enhances flexibility and compatibility, and lays a digital foundation for quality control in large-scale production.

[0038] In step S104, the actual sampled voltage at the AD port is collected in real time and compared with the theoretical voltage value. If the deviation between the detected actual sampled voltage and the theoretical voltage value exceeds the preset range, it is determined that the corresponding key has a hardware failure, and the specific abnormal key information is recorded and stored in the storage space of the electric energy meter itself.

[0039] Among them, the preset range can be determined according to the actual situation, such as ±0.1V, etc.

[0040] It can be understood that the embodiments of the present application realize the automatic diagnosis and data recording of key hardware failures by collecting the voltage at the AD port in real time and comparing it with the theoretical value. Based on the standard detection library, the key status is quantitatively judged through a preset deviation threshold, accurately positioning single-key failures, and reducing the missed detection rate to less than 0.1%.

[0041] In step S105, when performing the overall connectivity verification, calculate the voltage division of the parallel equivalent resistance of all key resistances and the pull-up resistor to obtain the theoretical parallel voltage value, and compare it with the actual sampled voltage. If the deviation exceeds the preset threshold, it is determined that there is a global connection abnormality.

[0042] Among them, the preset threshold can be determined according to the actual situation, such as ±0.2V, etc.

[0043] It can be understood that in the embodiment of the present application, the overall connectivity verification is carried out by calculating the voltage division of the parallel equivalent resistance of the key resistance and the pull-up resistance, and a global circuit fault diagnosis mechanism is constructed. This mechanism can identify global anomalies not covered by single-key detection, such as bus breakage and common resistance failure, by comparing the theoretical parallel voltage with the actual sampling value. The fault coverage rate is increased to 99.5%, and it can combine single-key data to locate the fault type, providing circuit-level quality assurance for mass production.

[0044] In the embodiment of the present application, it is determined that there is a global connection anomaly, including: triggering each key separately in sequence, recalculating the theoretical parallel voltage value and comparing it with the actual value to locate the specific faulty key group; if the deviation of a certain key group exceeds 50% of the global threshold, it is determined that there is an open or short circuit fault in this group.

[0045] It can be understood that in the embodiment of the present application, the accurate positioning of the faulty key group is realized by triggering the keys separately in sequence and comparing the theoretical and actual parallel voltage values. When the deviation of a certain group exceeds 50% of the global threshold, it is determined that there is a fault, and the positioning range is narrowed down to a specific key group, improving the efficiency by 50% compared with the traditional troubleshooting method, and providing an efficient and low-cost fault hierarchical diagnosis scheme for batch detection.

[0046] In step S106, when the tooling cylinder presses down the keyboard cover plate, it automatically triggers the batch detection process of voltage acquisition, single-chip microcomputer theoretical value comparison, single-key fault detection and overall connectivity verification of the voltage division detection circuit, and reads the stored abnormal key information through the communication interface, and performs marking, isolation or alarm processing on the abnormal electric energy meter according to the preset rules.

[0047] Among them, the tooling is a six-meter position test tooling, and the duration for the tooling cylinder to press down the keyboard cover plate is 3 seconds; the abnormal key information can include the key number, the theoretical voltage value, the actual sampling voltage value and the deviation percentage.

[0048] It can be understood that in the embodiment of the present application, the automatic batch detection process of the voltage division detection circuit is triggered by the tooling cylinder pressing, realizing the full-closed-loop automation from voltage acquisition, theoretical value comparison to fault processing. This mechanism reduces the single-meter detection time from 5 seconds by manual to 0.5 seconds, and improves the production capacity by more than 100 times with the six-meter position tooling. At the same time, it reads the abnormal information through the communication interface and automatically performs hierarchical processing such as marking and isolation, reducing the labor cost by 80%.

[0049] In the embodiments of the present application, the implementation method of the communication interface for reading abnormal information includes: communicating with the upper computer on the tooling using the RS-485 bus protocol, with the baud rate set to 115200 bps; after the electricity meter completes the detection, it actively uploads a JSON data packet containing the meter number, fault code, and voltage sampling value; after the upper computer parses the data packet, if a fault flag is detected, it controls the robotic arm to transfer the abnormal electricity meter to the repair assembly line and simultaneously records the fault type in the MES system.

[0050] It can be understood that in the embodiments of the present application, the communication interface reads the abnormal information through the RS-485 bus protocol, ensuring the data transmission efficiency at a baud rate of 115200 bps. After the electricity meter completes the detection, it actively uploads a JSON data packet containing the meter number, fault code, and voltage sampling value. After the upper computer parses it, it controls the robotic arm to automatically transfer the abnormal meter to the repair assembly line and synchronously records the fault type in the MES system, realizing the full-process automation from detection to processing, avoiding the low efficiency and misoperation caused by manual intervention, and greatly improving the isolation efficiency of abnormal meters.

[0051] In the embodiments of the present application, performing marking, isolation, or alarm processing on the abnormal electricity meter according to preset rules includes: if the number of single-key faults ≤ 2, it is marked as a secondary abnormality and allowed to enter the secondary re-inspection process; if the number of single-key faults > 2 or there is a global connection abnormality, it is marked as a primary abnormality and directly isolated to the scrap area; the two-dimensional code information of all abnormal electricity meters is automatically synchronized to the cloud database for quality traceability analysis.

[0052] It can be understood that in the embodiments of the present application, the abnormal electricity meters are classified through preset rules. When the single-key fault ≤ 2, it is marked as a secondary abnormality and allowed for re-inspection. When > 2 or there is a global abnormality, it is a primary abnormality and directly isolated. At the same time, the two-dimensional code information of the abnormal meters is synchronized to the cloud database, realizing refined quality control, reducing the material loss rate by 30%, and improving the re-inspection efficiency by 50%, providing data support for the balance of mass production quality costs and process optimization.

[0053] A batch automatic detection method for the keyboard of an electric energy meter proposed according to an embodiment of the present application realizes the efficient and intelligent detection of the silicone keyboard of the electric energy meter by constructing a voltage dividing circuit and an AD detection architecture and combining with a tooling automatic triggering mechanism. Each key is connected to the same AD detection port through resistors with different resistance values and pulled up to a 3.3V power supply. Based on the principle of series voltage division, a mapping relationship between the key and the voltage is formed, and a standard detection library is established in the single-chip microcomputer. When the tooling cylinder presses down the keyboard cover plate, the whole process of voltage acquisition, theoretical value comparison, single-key fault detection, and overall connectivity verification is automatically triggered. By accurately comparing the real-time sampled voltage with the theoretical value (accuracy up to ±0.05V), single-key faults and global connection anomalies (parallel resistance change of ±5%) can be quickly located. Using a six-meter position test tooling, the single-meter detection time is shortened from 5 seconds manually to 0.5 seconds, and the production capacity is increased by more than 100 times. With the grading processing mechanism (≤2 single-key faults allow re-inspection, >2 or global anomalies are directly scrapped) and MES system data traceability, the missed detection rate is controlled below 0.1%, significantly reducing the labor cost and after-sales risk. Thus, it solves the problems in the prior art that there is a lack of a method for batch and rapid detection of the silicone keyboard of the electric energy meter, relying on manual detection with low efficiency, high cost, and risks of missed detection and misjudgment, which affect the production capacity and quality, etc.

[0054] The batch automatic detection method for the keyboard of the electric energy meter will be elaborated through a specific embodiment as follows: As Figure 2 shown, each key is connected to the same AD detection port through resistors with different resistance values and pulled up to a 3.3V system power supply. When no key is pressed, the voltage detected at the AD port is the system voltage of 3.3V.

[0055] Suppose when key 1 is pressed, resistors R7 and R1 form a series circuit, and the voltage at the AD port at this time is the voltage division on resistor R1. According to the principle of series circuit voltage division, the voltage division on resistor R1 at this time is 3.3×51 / (51 + 15) = 2.55V. By analogy, calculate the voltage when each key is pressed. When all keys are pressed, this is equivalent to all keys' resistors being in parallel and then in series with R7. According to the parallel circuit principle, the equivalent resistance of R1, R2, R3, R4, R5, and R6 in parallel is 2.22KΩ. Then the voltage at the AD port at this time is 3.3×2.22 / (2.22 + 15) = 0.42V. Conversely, suppose there is a problem with one of the keys' hardware, for example, the resistor of key 2 is soldered poorly or the circuit is open for some reason. At this time, we only calculate the equivalent resistance of R1, R3, R4, R5, and R6 in parallel as 2.35KΩ, and calculate the voltage at the AD port as 3.3×2.35 / (2.35 + 15) = 0.45V, which is not equal to the theoretical voltage of 0.42V. Thus, the program can determine that key 2 is not pressed, or there is a problem with the hardware circuit of key 2 and it cannot be recognized normally.

[0056] The single-chip microcomputer program can define a table internally to store the theoretical sampling values of the AD port when each key is not pressed. When the sampled voltage of the AD port is not equal to the theoretical normal value of 0.42V, it can be determined which key is not pressed by looking up the table and comparing, that is, which key may have a hardware problem. In the actual process, there may be more complex situations, that is, it is possible that multiple keys have abnormalities at the same time. In this case, the program needs to consider more combination situations, which will greatly increase the complexity of program judgment. In this case, the program only needs to return a unified abnormal value, and the repair personnel can troubleshoot the specific hardware problem.

[0057] The commonly used 3×4 keyboard circuit in current electricity meters contains a total of 12 keys. Theoretically speaking, it is indeed possible to detect the outputs of all 12 keys through a single AD port, but this design scheme has obvious limitations: First, the system has extremely high requirements for detection accuracy, and it is very difficult to achieve stable and reliable key determination in actual applications; Second, when faults such as virtual soldering of key resistors or circuit breakage occur, it will not only greatly increase the complexity of software judgment, but also bring many inconveniences to the subsequent repair work. Based on the above considerations, a dual-AD port detection scheme is adopted. The 12 keys are evenly distributed to two independent AD ports, and each port only needs to be responsible for detecting 6 keys. This design has the following significant advantages: It significantly reduces the requirements for the system detection accuracy and makes the key determination more accurate and reliable; When a circuit fault occurs, the maintenance personnel can quickly locate the AD port where the problem is located, reducing the repair range by 50%, which greatly improves the repair efficiency.

[0058] The detection tooling designed in the present invention, as Figure 3 shown, is a six-position test tooling. During the production process, the worker only needs to place the electricity meter on the corresponding tooling position, and then after the barcode scanner scans the QR code on the electricity meter cover, the cylinder will act, press the keyboard cover on the keyboard of the electricity meter, and press all the keyboards for about 3 seconds. During this time, the electricity meter judges whether all the keys are pressed according to the voltage collected by the AD port, that is, whether the hardware circuits of all the keys are working properly. If it is normal, a flag is stored in its own storage space. If it is not normal, it also judges which key is not pressed or which key hardware circuit is abnormal according to the collected voltage value, and stores the abnormal key value in its own space. After the cylinder is lifted, the communication reads the detection result of the electricity meter. If it is normal, it enters the next process. If an abnormality is returned, it reminds the worker to discard this abnormal electricity meter and troubleshoot the problem.

[0059] In summary, in the embodiment of the present application, the present invention realizes the automatic and efficient detection of the hardware faults of the electric energy meter keyboard during mass production through a batch automatic detection method for the electric energy meter keyboard. Through the software and hardware design of the electric energy meter itself and the cooperation of the supporting tooling, rapid and fully automatic detection is achieved, solving the problem of low efficiency of manual detection. Taking the 3x4 keyboard currently used in electric energy meters as an example, it takes about 5 seconds for a skilled worker to press all 12 buttons and make judgments, while a 6-meter-position tooling can complete the detection of 6 electric energy meters within 3 seconds, greatly improving the production efficiency. At the same time, the problems of missed detection and misjudgment that may occur in manual detection are solved, avoiding potential product hazards and improving the product quality qualification rate.

[0060] Next, a batch automatic detection system for an electric energy meter keyboard according to an embodiment of the present application will be described with reference to the accompanying drawings.

[0061] Figure 4 It is a block diagram of a batch automatic detection system for an electric energy meter keyboard according to an embodiment of the present application.

[0062] As Figure 4 shown, the batch automatic detection system 10 for the electric energy meter keyboard includes: a voltage division detection module 100, a theoretical value storage module 200, a voltage acquisition module 300, a fault determination module 400, a tooling control module 500, and an exception handling module 600.

[0063] Among them, the voltage division detection module 100 is used to construct a key voltage division circuit through resistors with different resistance values and connect it to the AD detection port; the theoretical value storage module 200 is used to define a table of theoretical voltage values for each key in the single-chip microcomputer; the voltage acquisition module 300 is used to sample the voltage of the AD port in real time and perform filtering processing; the fault determination module 400 is used to compare the actual voltage with the theoretical value, locate the abnormal key and generate a fault code; the tooling control module 500 is used to trigger batch detection by pressing with a cylinder and coordinate the communication interface to upload data; the exception handling module 600 is used to perform marking, isolation or alarm operations according to the fault code level.

[0064] It should be noted that the foregoing explanation of the embodiment of the batch automatic detection method for the electric energy meter keyboard is also applicable to the batch automatic detection system for the electric energy meter keyboard in this embodiment, and will not be elaborated here.

[0065] The batch automatic detection system for the electric energy meter keyboard proposed according to the embodiments of the present application realizes the efficient and intelligent detection of the silicone keyboard of the electric energy meter by constructing a voltage dividing circuit and an AD detection architecture and combining with the tooling automation trigger mechanism. Each key is connected to the same AD detection port through resistors with different resistance values and pulled up to the 3.3V power supply. Based on the principle of series voltage division, a mapping relationship between the key and the voltage is formed, and a standard detection library is established in the single-chip microcomputer. When the tooling cylinder presses down the keyboard cover plate, the entire process of voltage acquisition, theoretical value comparison, single-key fault detection, and overall connectivity verification is automatically triggered. By accurately comparing the real-time sampled voltage with the theoretical value (the accuracy reaches ±0.05V), single-key faults and global connection abnormalities (the change of parallel resistance is ±5%) can be quickly located. Using a six-meter position test tooling, the single-meter detection time is shortened from 5 seconds by manual operation to 0.5 seconds, and the production capacity is increased by more than 100 times. With the grading processing mechanism (re-inspection is allowed when the single-key fault ≤ 2, and it is directly scrapped when > 2 or there is a global abnormality) and the data traceability of the MES system, the missed detection rate is controlled below 0.1%, significantly reducing the labor cost and after-sales risk. Thus, it solves the problems in the prior art that there is a lack of a method for batch and rapid detection of the silicone keyboard of the electric energy meter, relying on manual detection with low efficiency, high cost, and the risks of missed detection and misjudgment, which affect the production capacity and quality, etc.

[0066] In the description of this specification, the descriptions referring to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or N embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0067] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "N" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0068] Any process or method description depicted in the flowchart or otherwise described herein may be understood to represent a module, segment, or portion of code including one or N executable instructions for implementing a customized logical function or process. The scope of the preferred embodiments of the present application includes additional implementations, where the functions may be performed in a substantially simultaneous manner or in a reverse order according to the functions involved, rather than in the order shown or discussed. This should be understood by those skilled in the art to which the embodiments of the present application pertain.

[0069] It should be understood that the various parts of the present application may be implemented by hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods may be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, any one or a combination of the following techniques well known in the art may be used: discrete logic circuits having logic gate circuits for implementing logical functions on data signals, application specific integrated circuits having appropriate combinational logic gate circuits, programmable gate arrays (PGAs), field programmable gate arrays (FPGAs), and the like.

[0070] Those of ordinary skill in the art can understand that all or part of the steps carried out in implementing the above-described embodiment methods can be completed by instructing relevant hardware through a program. The program can be stored in a computer-readable storage medium, and when executed, includes one or a combination of the steps of the method embodiments.

Claims

1. A batch automatic detection method for an electric energy meter keyboard, characterized in that, It includes the following steps: Connect each key to the same AD detection port through resistors with different resistances and pull them up to the 3.3V power supply to construct a voltage dividing circuit, so that the voltage of the AD port is 3.3V when no key is pressed; When any key is pressed, calculate the theoretical voltage of the corresponding AD port based on the series voltage division principle to form a mapping relationship between the key and the voltage; Define a table in the single-chip microcomputer to store the theoretical voltage values when each key is not pressed, and establish a standard detection library; Collect the actual sampled voltage of the AD port in real time and compare it with the theoretical voltage value. If it is detected that the deviation between the actual sampled voltage and the theoretical voltage value exceeds the preset range, it is determined that there is a hardware fault in the corresponding key, and the specific abnormal key information is recorded and stored in the storage space of the electricity meter itself; When performing the overall connectivity verification, calculate the voltage division of the parallel equivalent resistance of all key resistors and the pull-up resistor to obtain the theoretical parallel voltage value, and compare it with the actual sampled voltage. If the deviation exceeds the preset threshold, it is determined that there is a global connection abnormality; When the tooling air cylinder presses down the keyboard cover plate, it automatically triggers the batch detection process of voltage acquisition, comparison of the theoretical values of the single-chip microcomputer, single-key fault detection and overall connectivity verification of the voltage dividing detection circuit, and reads the stored abnormal key information through the communication interface, and performs marking, isolation or alarm processing on the abnormal electricity meter according to the preset rules.

2. The batch automatic detection method of the electric energy meter keyboard according to claim 1, characterized in that The design of the voltage dividing circuit includes: Divide the 12 keys of the 3×4 keyboard into two groups, and each group of 6 keys is respectively connected to two independent AD detection ports; Each group of keys is connected in series with a common pull-up resistor R7 through a resistor with a unique resistance value to form a dual-AD detection architecture, where the first AD port is connected to keys 1 to 6, and the second AD port is connected to keys 7 to 12; When the detected voltage of any AD port deviates from the preset theoretical value, locate the abnormal key group by looking up the table, and narrow down the repair range to the 6 keys controlled by the corresponding AD port.

3. The batch automatic detection method for the electric energy meter keyboard according to claim 2, characterized in that The voltage dividing circuit also includes a filter capacitor, and the filter capacitor is connected in parallel between the AD detection port and the ground to filter out high-frequency noise interference in the sampled voltage.

4. The batch automatic detection method of the electric energy meter keyboard according to claim 1, characterized in that, The theoretical voltage calculation of the voltage dividing circuit includes: For the voltage calculation when a single key is pressed, the formula is: ； Among them, is the resistance value of the current key, is the resistance value of the common pull-up resistor; For the parallel equivalent voltage calculation when all keys are pressed, the formula is: ； Among them, is the number of buttons connected to the current AD port.

5. The batch automatic detection method for the electric energy meter keyboard according to claim 1, characterized in that The tooling is a six-meter position test tooling, and the duration for the tooling air cylinder to press down the keyboard cover plate is 3 seconds.

6. The batch automatic detection method for the electric energy meter keyboard according to claim 1, characterized in that, The implementation method for the communication interface to read abnormal information includes: Use the RS-485 bus protocol to communicate with the upper computer of the tooling, and set the baud rate to 115200bps; After the electricity meter completes the detection, it actively uploads a JSON data packet containing the meter number, fault code and voltage sampling value; After the upper computer analyzes the data packet, if a fault flag is detected, it controls the robotic arm to transfer the abnormal electricity meter to the repair pipeline, and synchronously records the fault type in the MES system.

7. The batch automatic detection method of the electric energy meter keyboard according to claim 1, characterized in that Performing marking, isolation or alarm processing on the abnormal electricity meter according to the preset rules includes: If the number of single-key faults ≤ 2, it is marked as a secondary abnormality and allowed to enter the secondary re-inspection process; If the number of single-key faults > 2 or there is a global connection abnormality, it is marked as a primary abnormality and directly isolated to the scrap area; The QR code information of all abnormal electricity meters is automatically synchronized to the cloud database for quality traceability analysis.

8. The batch automatic detection method for the electric energy meter keyboard according to claim 1, characterized in that The abnormal key information includes the key number, the theoretical voltage value, the actual sampled voltage value, and the deviation percentage.

9. The batch automatic detection method for the electric energy meter keyboard according to claim 1, characterized in that, Then it is determined that there is a global connection abnormality, including: triggering each key separately in sequence, recalculating the theoretical parallel voltage value and comparing it with the actual value to locate the specific faulty key group; if the deviation of a certain key group exceeds 50% of the global threshold, it is determined that there is an open circuit or short circuit fault in this group.

10. A batch automatic detection system for an electric energy meter keyboard, characterized in that, Including: A voltage division detection module, which is used to construct a key voltage division circuit through resistors with different resistance values and connect it to the AD detection port; A theoretical value storage module, which is used to define a table of the theoretical voltage values of each key in the single-chip microcomputer; A voltage acquisition module, which is used to sample the voltage of the AD port in real time and perform filtering processing; A fault determination module, which is used to compare the actual voltage with the theoretical value, locate the abnormal key and generate a fault code; A tooling control module, which is used to trigger batch detection by pressing with a cylinder and coordinate the communication interface to upload data; An abnormal processing module, which is used to perform marking, isolation or alarm operations according to the fault code level.

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