A multifunctional automated testing method and system for industrial control computer ports

Abstract

This invention discloses a multifunctional automated testing method and system for industrial control computer (ICC) ports, relating to the technical field of ICCs. The method includes: connecting the serial port and network port of the ICC under test to a test fixture; activating the power supply module to provide PoE load; controlling the test fixture to send data frames of a preset format to each serial port, while simultaneously activating the host computer test module to identify and monitor the data content; comparing the data with a preset data template to determine if the serial port reception is correct, performing a consistency check, and obtaining the serial communication test result; and determining if the network communication is normal, obtaining the network port test result. This invention solves the technical problems of low efficiency and poor accuracy in existing manual testing, which makes it difficult to meet the needs of large-scale production, and lacks the ability to collaboratively test serial and network ports under PoE load. It achieves the technical effects of automated testing, improved testing efficiency and accuracy, and enhanced reliability of ICC ports.

Description

Technical Field

[0001] This application relates to the field of industrial control computer technology, specifically to a multifunctional automated testing method and system for industrial control computer ports. Background Technology

[0002] Industrial control computers (ICCs) play a crucial role in industrial automation and intelligent manufacturing, undertaking key tasks such as data processing, equipment control, and information interaction. Their serial and network ports serve as vital interfaces for data transmission and communication between the ICC and external devices and systems. The stability and accuracy of these port functions directly impact the operational efficiency and reliability of the entire industrial control system. Communication failures or abnormal data transmission at these ports can lead to equipment downtime, loss of production data, and even serious safety incidents. However, traditional ICC port testing, which involves manually connecting test equipment, sending test data, recording and comparing results, is not only inefficient and time-consuming, making it difficult to meet the demands of large-scale production and rapid delivery, but also prone to errors, resulting in inconsistent and inaccurate test results. Furthermore, under PoE (Power over Ethernet) load conditions, the coordinated testing of serial and network ports becomes even more complex, and existing testing methods cannot comprehensively and efficiently detect port performance under complex operating conditions.

[0003] Therefore, current technologies suffer from low efficiency and poor accuracy in manual testing, making it difficult to meet the needs of large-scale production, and lack the ability to conduct collaborative testing of serial ports and network ports under PoE load. Summary of the Invention

[0004] This application provides a multifunctional automated testing method and system for industrial control computer ports, which solves the technical problems of low efficiency and poor accuracy of manual testing in the prior art, making it difficult to meet the needs of large-scale production, and lacking the ability to conduct collaborative testing of serial ports and network ports under PoE load. It achieves the technical effects of realizing automated testing, improving testing efficiency and accuracy, and improving the reliability of industrial control computer ports.

[0005] This application provides a multi-functional automated testing method for industrial control computer ports. The method includes: connecting the serial port and network port of the industrial control computer under test to a test fixture, and turning on the power supply module of the test fixture to provide PoE load; under PoE load conditions, controlling the test fixture to send data frames of a preset format to each serial port, and simultaneously activating the host computer test module of the industrial control computer to identify and listen to the data content received by the local serial port; the host computer compares the received data content with a preset data template to determine whether the serial port reception is correct, and simultaneously sends confirmation data back to the test fixture; the test fixture receives the data and performs a consistency judgment to obtain the serial communication test result; the host computer test module automatically identifies the network port with the connection status, configures a fixed IP address, sends test messages to the test fixture and receives its response to determine whether the network communication is normal and obtains the network port test result.

[0006] In a possible implementation, the multi-functional automated testing method for an industrial control computer port further performs the following processing: restoring the IP address configured on the network port to DHCP dynamic mode and saving the test record.

[0007] In a possible implementation, the multi-functional automated testing method for an industrial control computer port further performs the following processing: setting a target power; gradually increasing the load from low power to the target power in stages according to a preset power loading window to simulate an actual power supply scenario; pausing for a preset time based on the power loading reaching the target power condition, monitoring the power absorbed by the load circuit in the test fixture in real time, and sampling voltage and current data; judging whether the fluctuation of power supply parameters meets the target requirements based on the sampled voltage and current data, and obtaining PoE load test results, including current, voltage, power curves and stability evaluation.

[0008] In a possible implementation, the multi-functional automated testing method for an industrial control computer port further performs the following processing: dividing the power into stages according to the target power and configuring the dynamic window step size for each stage; performing phased loading according to the mapping relationship between the dynamic window step size and the power of the stage, and continuously monitoring the fluctuation of power supply parameters, wherein the duration of each stage is not less than 5 seconds; and performing feature aggregation based on the fluctuation of each stage to obtain the PoE load test results.

[0009] In a possible implementation, the multi-functional automated testing method for an industrial control computer port also performs the following processing: comparing the response data length, field structure, and CRC check results; if any judgment result is abnormal, the serial communication is marked as abnormal.

[0010] In a possible implementation, the multi-functional automated testing method for industrial control computer ports further performs the following processing: feeding back the serial communication test results, network port test results, and PoE load test results to the host computer for interface visualization conversion; the test fixture includes multiple parallel test ports, and when multiple serial ports and multiple network ports are tested in parallel, a mapping relationship is established between the multiple parallel test ports and the serial communication test results, network port test results, and PoE load test results, generating a visual integration list, which is then sent to the host computer for interface visualization conversion.

[0011] In a possible implementation, the multifunctional automated testing method for an industrial control computer port further performs the following processing: collecting historical test samples and constructing a communication status sample library; using the status identification features in the communication status sample library as training features, including at least CRC error rate, communication delay, and abnormal fluctuation values, to establish a historical model for identifying bit error rate, response delay, and PoE power supply stability indicators; performing matching analysis between the current test data and the historical model through a boundary identification module to identify whether there are abnormal patterns or potential fault states; and sending the abnormal patterns or potential fault states to the host computer interface for re-inspection reminders.

[0012] In a possible implementation, the multifunctional automated testing method for industrial control computer ports further performs the following processing: Each sample in the communication state sample library includes CRC error rate, response delay, PoE voltage drop, power fluctuation, number of voltage sags, port connection establishment time dimension features, and test result labels. Based on the communication state sample library, a clustering algorithm is used to perform unsupervised clustering of the samples to divide them into multiple communication state clusters. According to the multiple communication state clusters, transitional samples located between two or more communication state clusters are identified as transitional state data. Using the transitional state data as a training set, combined with the boundary features of the communication state clusters, a boundary anomaly detector is trained to identify abnormal communication patterns or boundary anomalies in the current test data, thus constructing the boundary identification module.

[0013] In a possible implementation, the multi-functional automated testing method for an industrial control computer port further performs the following processing: identifying whether the current test data falls into the boundary of multiple communication state clusters or is determined to be an isolated anomaly; when the current test data falls into the boundary of multiple communication state clusters or is determined to be an isolated anomaly, outputting a potential fault status; generating a re-inspection reminder based on the potential fault status and sending it to the host computer interface.

[0014] This application also provides a multifunctional automated testing system for industrial control computer ports. The system includes: a port connection unit, used to connect the serial port and network port of the industrial control computer under test to the test fixture respectively through a test fixture, and to turn on the power supply module of the test fixture to provide PoE load; a data content recognition unit, used to control the test fixture to send data frames of a preset format to each serial port under PoE load conditions, and simultaneously activate the host computer test module of the industrial control computer to identify and listen to the data content received by the local serial port; a data comparison unit, used by the host computer to compare the received data content with a preset data template to determine whether the serial port reception is correct, and simultaneously send the confirmation data back to the test fixture, which performs a consistency judgment after receiving the data to obtain the serial communication test result; and a port test result acquisition unit, used by the host computer test module to automatically identify the network port connection status, configure a fixed IP address, send test messages to the test fixture and receive its response to determine whether the network communication is normal and obtain the network port test result.

[0015] This application proposes a multi-functional automated testing method and system for industrial control computer (ICC) ports. The method involves connecting the serial port and network port of the ICC under test (ICC) to a test fixture, activating the power supply module to provide a PoE load, controlling the test fixture to send preset format data frames to each serial port, and simultaneously activating the host computer test module to identify and monitor the data content. The data is then compared with a preset data template to determine if the serial port reception is correct, performing a consistency check to obtain the serial communication test result, and finally determining if network communication is normal to obtain the network port test result. This method solves the technical problems of low efficiency and poor accuracy in existing manual testing, which is insufficient to meet the needs of large-scale production, and lacks the ability to conduct collaborative testing of serial and network ports under PoE load. It achieves automated testing, improves testing efficiency and accuracy, and enhances the reliability of ICC ports. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments of this disclosure will be briefly described below. Flowcharts are used in this application to illustrate the operations performed by the system according to the embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed precisely in sequence. Instead, various steps can be processed in reverse order or simultaneously as needed. Furthermore, other operations can be added to these processes, or one or more steps can be removed from these processes.

[0017] Figure 1 This is a schematic diagram of a multifunctional automated testing method for an industrial control computer port, provided as an embodiment of this application.

[0018] Figure 2This is a schematic diagram of a multifunctional automated testing system for an industrial control computer port, provided as an embodiment of this application.

[0019] Explanation of reference numerals in the attached figures: Port connection unit 10, data content recognition unit 20, data comparison unit 30, port test result acquisition unit 40. Detailed Implementation

[0020] The above description is merely an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, specific embodiments of this application are given below.

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description of this application will be provided in conjunction with the accompanying drawings. The described embodiments should not be considered as limitations on this application. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] In the following description, references to "some embodiments" describe a subset of all possible embodiments. However, it is understood that "some embodiments" can be the same or different subsets of all possible embodiments and can be combined with each other without conflict. The terms "first" and "second" are used merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or modules not explicitly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only.

[0023] This application provides a multi-functional automated testing method for industrial control computer ports, such as... Figure 1 As shown, the method includes:

[0024] In step S100, the serial port and network port of the industrial control computer under test are connected to the test fixture respectively, and the power supply module of the test fixture is turned on to provide PoE load.

[0025] Preferably, a test fixture is used to connect the serial port (e.g., RS-232 / 485, for serial data transmission) and network port (e.g., RJ45, for Ethernet communication) of the industrial control computer under test (ICC) to establish a physical connection channel. The test fixture acts as an intermediate medium to achieve automated testing and control of the port functions. The test fixture is equipped with interfaces matching the ICC port (e.g., serial cables, network cables), and electrical connections are established through standardized interfaces to ensure data transmission stability. Then, the power supply module of the test fixture is activated to provide a PoE load, simulating the working environment of the port under power in a real industrial scenario. PoE transmits data and power simultaneously via the network cable, allowing network devices to receive power while communicating. ICCs often receive power via PoE (e.g., to power external cameras, sensors, etc.). Providing a PoE load verifies the stability of the port when power transmission and data communication are parallel, the collaborative working capability of the power supply module and data transmission module, and the port's anti-interference and reliability under power conditions.

[0026] Furthermore, step S100 also includes step S110, setting the target power; step S120, gradually increasing the load from low power to the target power in stages according to the preset power loading window to simulate the actual power supply scenario; step S130, stopping for a preset time based on the power loading reaching the target power condition, monitoring the power absorbed by the load circuit in the test fixture in real time, and sampling voltage and current data; step S140, judging whether the power supply parameter fluctuation meets the target requirements based on the sampled voltage and current data, and obtaining the PoE load test results, including current, voltage, power curves and stability evaluation.

[0027] Preferably, a target power, i.e., the rated power supply (such as 15.4W for common PoE standard power), is set according to the industrial control computer port specifications or industry standards. This is used to simulate the power supply requirements of the port under real load, ensuring that the test conditions are consistent with the actual working conditions. Then, according to the preset power loading window (such as increasing the total power by 5% every 100ms), the load is gradually increased from low power to the target power in stages. That is, by increasing the load in a stepwise manner (from low power to target power), the damage to the equipment or test errors caused by instantaneous high power surges are avoided. Among them, the power demand of the PoE load changes dynamically with the working state (such as a sudden increase in power when the camera is started). The staged loading can simulate the gradual change of load and test the dynamic response capability of the port. After loading to the target power, the port stays for a preset time (such as 30 minutes) to ensure that the port operates under stable power and expose potential problems such as heat loss and component aging.

[0028] Preferably, the load circuit in the test fixture is monitored in real time to absorb power and sample voltage and current data. Specifically, the test fixture has a built-in power monitoring module (such as a Hall current sensor or voltage sampling circuit) to obtain the power absorbed by the load circuit, i.e., the actual power consumed, for verifying power supply efficiency. High-precision sensors are used to collect and sample voltage and current data in real time. Then, based on the sampled data, the voltage / current fluctuation range (e.g., allowable voltage fluctuation ≤ ±5% of the rated value) is calculated and compared with the design requirements to determine whether it meets the standard. For example, if the target voltage is 48V, an actual fluctuation range between 45.6V and 50.4V is considered qualified. This yields the PoE load test results, including current, voltage, and power curves, with time on the horizontal axis and parameter values ​​on the vertical axis, visually presenting dynamic changes for analyzing the dynamic characteristics of the port under load (e.g., transient response time, steady-state error); and stability evaluation, such as "power fluctuation ≤ 1%, conforming to IEEE 802.3at standard," which helps assess the reliability of the industrial control computer, such as screening out unqualified power modules.

[0029] Furthermore, step S120 also includes step S121, dividing the power into stages according to the target power and configuring the dynamic window step size for each stage; step S122, loading in stages according to the mapping relationship between the dynamic window step size and the power of the stage, and continuously monitoring the fluctuation of power supply parameters, wherein the duration of each stage is not less than 5 seconds; step S123, performing feature aggregation based on the fluctuation of each stage to obtain the PoE load test results.

[0030] Preferably, the power loading window increases the load once every 100ms, i.e., 10 times per second. This is a high-frequency dynamic test that can capture rapidly fluctuating signals. Each load increases the total power by 5%. Assuming the target power is 30W, each load increases the power by 1.5W (30W × 5%), gradually increasing from 0W to 30W, requiring a total of 20 loads (100% / 5% = 20), with a total loading time of 20 × 100ms = 2 seconds. Furthermore, the measured voltage / current / power values ​​are allowed to deviate from the target values ​​within ±5%, which is more efficient than... For example, if the target power is 30W, the power fluctuation is allowed to be ≤1.5W. Then, the system is divided into stages according to the target power, and the dynamic window step size for each stage is configured. The system is then loaded in stages according to the mapping relationship between the stage dynamic window step size and the stage power. In the low-power stage, a large step size (5% / 4%) is used to quickly cover the basic load; in the high-power stage, a small step size (3% / 2%) is used to avoid triggering the protection circuit due to excessive loading when approaching the rated power. The stage division is shown in Table 1 for a target power of 30W.

[0031] Table 1. Target Power Stage Segmentation and Dynamic Step Size Configuration Data Table

[0032]

[0033] Preferably, the fluctuation of power supply parameters is continuously monitored, and the duration of each stage is not less than 5 seconds. Specifically, the instantaneous fluctuation of voltage / current during each loading stage (such as the voltage drop amplitude during loading) and the steady-state fluctuation of parameters during the holding period (such as whether the voltage remains stable within ±5% within 5 seconds) are monitored. Then, feature aggregation is performed based on the fluctuation of each stage, including analysis of time-domain features and frequency-domain features. The time-domain features include the maximum and minimum values, mean and variance of voltage / current, and the number of times the threshold is exceeded. The frequency-domain features are obtained by analyzing the main frequency and harmonic component ratio of the fluctuation signal through FFT. Finally, the PoE load test results are obtained by integrating the data. The average current, fluctuation amplitude and abnormal frequency of each stage are comprehensively analyzed to determine whether the performance of the industrial control computer meets the standards.

[0034] Step S200: Under PoE load conditions, control the test fixture to send data frames of a preset format to each serial port, and at the same time activate the host computer test module of the industrial control computer to identify and listen to the data content received by the local serial port.

[0035] Preferably, a microcontroller module is embedded in the test fixture, pre-written with a standard command frame format. Under PoE load conditions, fixed-period data frames are sent to the industrial control computer via RS232 / RS485 ports. Specifically, data frames are sent to the serial port at preset time intervals (e.g., 10ms / frame), while simultaneously recording the transmission timestamp and data content, and supporting multi-channel parallel transmission. The data frame includes standard fields such as start bit, device address, function code, data area, checksum (e.g., CRC16), and end bit. The host computer test module of the industrial control computer is activated to identify and monitor the data content received on the local serial port. The host computer software captures the data frames received on the local serial port in real time, extracts key information (such as data area content and checksum results), and performs field-level comparisons, including comparing the byte-level matching degree between received and transmitted data and calculating the bit error rate. Simultaneously, acknowledgment data is sent to the test fixture, which performs secondary reception and comparison, forming a closed-loop bidirectional communication verification mechanism to effectively identify data anomalies, format errors, frame loss, and other problems.

[0036] In step S300, the host computer compares the received data content with the preset data template to determine whether the serial port reception is correct, and sends the confirmation data back to the test fixture. After receiving the data, the test fixture performs a consistency judgment to obtain the serial communication test result.

[0037] Preferably, the preset data template includes a standard data frame structure (such as the address segment, function code segment, data segment, and check segment of a Modbus protocol frame), a legal value range (such as the upper and lower limits of register values), and timing rules (such as a response timeout threshold of 50ms). The template also presets normal data (such as the real-time temperature value of the sensor), abnormal data (such as error values ​​exceeding the measurement range), and boundary data (such as the maximum value of the register) to verify the processing capability of the serial port under different operating conditions. The host computer performs byte-level matching of each received data frame with the preset data template to determine whether the serial port reception is correct, that is, to check whether the data segment content conforms to the preset format (such as temperature data must be a 16-bit signed integer). At the same time, it records the data reception time interval to determine whether there are frame drops (such as two consecutive frames with an interval of more than 20ms being considered abnormal) or out-of-order problems.

[0038] Preferably, the host computer encapsulates the verification result into acknowledgment data (such as including a "received correctly / incorrectly" status code, error type identifier, and original data digest) and sends it back to the test fixture. For example, if the received data fully conforms to the template, an ACK acknowledgment frame is sent; if an error is found (such as CRC check failure), a NAK error frame is sent. The test fixture compares the original transmitted data with the acknowledgment data sent back by the host computer to verify the bidirectional consistency of the communication link. If an inconsistency is found, the test fixture uses the timestamp and frame sequence number to locate the specific link where the error occurred (such as serial port hardware failure or software parsing error), obtains the serial communication test result, and thus achieves end-to-end reliability verification of serial communication under PoE load.

[0039] Furthermore, step S300 also includes performing a consistency judgment after the test fixture receives the data, including comparing the response data length, field structure and CRC check result. If any judgment result is abnormal, the serial communication is marked as abnormal.

[0040] Preferably, the test fixture performs a consistency check after receiving the data, including comparing the response data length, field structure, and CRC check results. Specifically, the response data length comparison check refers to comparing the length of the data frame sent by the test fixture with the length of the acknowledgment frame returned by the host computer to ensure that there is no data loss or redundancy. For example, if the test fixture sends a 10-byte data frame and the host computer returns 9 or 11 bytes, it is determined to be an abnormal length (possibly due to serial port buffer overflow or poor cable contact causing byte loss). The field structure comparison check includes checking whether the acknowledgment frame contains the mandatory fields specified by the protocol (such as start character, address field, function code field), whether the order is correct, and verifying whether the values ​​of each field are within the legal range. The CRC check result comparison check refers to the test fixture calculating the CRC check value of the sent data and comparing it with the check value in the frame returned by the host computer. If the CRC check fails, it indicates that a bit flip has occurred during data transmission, and the position of the erroneous byte can be located by XOR operation. When any judgment result is abnormal, the serial communication is marked as abnormal and written to the test log. The priority of the abnormality is CRC check failure (directly determine that the data is untrustworthy) > field structure error (protocol parsing failure) > data length abnormality (partial data may be valid). If both length abnormality and CRC error exist at the same time, the CRC error is recorded first. In the end, the serial communication fault is quickly located and classified to facilitate the reliability verification of the industrial control computer.

[0041] In step S400, the host computer test module automatically identifies the network port with the connection status, configures a fixed IP address, sends test messages to the test fixture and receives its response, determines whether the network communication is normal, and obtains the network port test result.

[0042] Preferably, the host computer reads the link status register of the industrial control computer's network card to determine whether the network port is physically connected (Link light is on) and the data transmission status (Act light flashes). Then, the host computer's test software automatically scans and identifies available network adapters through the network interface API, assigns a fixed IP address (e.g., configures an address in the 192.168.1.x range), and connects to the test fixture. If the port was originally configured to dynamically obtain an IP address via DHCP, the host computer's test module temporarily overwrites it with a fixed IP address to avoid test failure due to the unavailability of the DHCP server. During the testing phase, test messages are sent and responses are received. These test messages include ICMP protocol (Ping test), TCP protocol test, UDP protocol test, and application layer protocol (such as HTTP) test. The ICMP protocol (Ping test) sends a 32-byte Echo. The Request message, after receiving the EchoReply, calculates the round-trip time (RTT) and packet loss rate (requiring a packet loss rate of 0% and a latency ≤10ms); the TCP protocol test involves initiating a three-way handshake to a specified port (e.g., 8080) on the test fixture to verify the port's listening status; the UDP protocol test involves sending a UDP packet containing random data (e.g., destination port 9999), and the fixture returns the same data to verify no packet loss; the application layer protocol (e.g., HTTP) test involves sending a GET request and parsing the response status code (200 indicates normal) and data content.

[0043] Preferably, the network interface communication capability is determined by verifying the content, response delay, and connection status. For example, a response timeout threshold (e.g., 500ms) is set, and communication is considered interrupted if the timeout occurs. The byte-level consistency between the sent message and the received response is compared (e.g., UDP return data must be exactly the same as the sent data). Example network communication status test evaluation data is shown in Table 2.

[0044] Table 2 Network Communication Status Test and Evaluation Data Table

[0045]

[0046] The final network port test results are obtained, and test report files can be exported, including the test time and network communication status of each port (such as packet loss rate, throughput, and latency jitter value), such as the types of network communication anomalies and possible causes. This enables comprehensive reliability verification of industrial network ports under complex working conditions and ensures test efficiency and accuracy.

[0047] Furthermore, step S400 also includes restoring the IP address configured on the network port to DHCP dynamic mode and saving the test record.

[0048] Preferably, during the testing phase, to ensure stable communication, the host computer configures the network port with a fixed IP address. After the test is completed, the IP address configured on the network port is restored to DHCP dynamic mode. That is, the current fixed IP configuration program is stopped, the DHCP client service is enabled, a Discover message is sent to the DHCP server to request an IP address, the dynamic IP address assigned by the server is received, network parameters such as DNS server are automatically obtained, and test records are saved, including test environment parameters (industrial control computer model, firmware version, test fixture model, test time), port test results, and anomaly records (such as boundary anomaly type, characteristic value, and re-inspection suggestions).

[0049] Furthermore, step S400 also includes feeding back the serial communication test results, network port test results, and PoE load test results to the host computer for interface visualization conversion; the test fixture includes multiple parallel test ports, and when multiple serial ports and multiple network ports are tested in parallel, a mapping relationship is established between the multiple parallel test ports and the serial communication test results, network port test results, and PoE load test results, generating a visualization integration list, which is sent to the host computer for interface visualization conversion.

[0050] Preferably, the test fixture includes multiple parallel test ports, i.e., equipped with multiple independent serial ports and network ports, supporting simultaneous testing of more than 8 ports. The test fixture has a built-in FPGA / MCU chip, and multi-port synchronous testing is achieved through time-division multiplexing or hardware parallel channels to avoid mutual interference. When multiple serial ports and multiple network ports are tested in parallel, a mapping relationship is established between the multiple parallel test ports and the serial communication test results, network port test results, and PoE load test results. This includes assigning a unique ID to each test port and carrying the port ID tag in the results, while aligning the parallel test data through timestamps to ensure that the results are not confused. An example mapping relationship is shown in Table 3.

[0051] Table 3 Mapping Relationship Between Parallel Test Ports and Test Results

[0052] Test port ID Corresponding industrial control computer port Test type Test Results COM1_TP Industrial PC COM1 Serial communication Bit error rate 0.00%, latency 15ms ETH0_TP Industrial PC network port 1 Network port Throughput 980Mbps, packet loss 0 POE1_TP Power supply port 1 PoE load Power fluctuation ±2.7%, stable and meeting standards.

[0053] This generates a visual integration list, which uses green, yellow, and red colors to indicate the status (qualified / critical / failed) for quick location of abnormal ports, as shown in Table 4:

[0054] Table 4 Visualization Integration List

[0055] Port type Test Project Key Indicators state serial port Communication testing <![CDATA[Bit error rate 0.5×10 -6 > qualified network port Throughput test 965Mbps (Target ≥ 950Mbps) qualified PoE load Stability test Voltage fluctuation +4.8% critical

[0056] Finally, the visualized integrated list of serial communication test results, network port test results, and PoE load test results is transmitted to the host computer via USB connection or Ethernet for interface visualization conversion, thereby realizing efficient management of multi-port parallel testing and intuitive display of results, ensuring the digitalization and visualization of industrial control computer quality control.

[0057] Furthermore, the multi-functional automated testing method for industrial control computer ports also includes step S410, collecting historical test samples and constructing a communication status sample library; step S420, using the status identification features in the communication status sample library as training features, including at least CRC error rate, communication delay, and abnormal fluctuation values, to establish a historical model for identifying bit error rate, response delay, and PoE power supply stability indicators; step S430, using a boundary identification module to match and analyze the current test data with the historical model to identify whether there are abnormal patterns or potential fault states; and step S440, sending the abnormal patterns or potential fault states to the host computer interface for re-inspection reminders.

[0058] Preferably, at least 1000 sets of historical test data (including normal, critical, and fault states) are collected to construct a communication state sample library. Each set of data may include serial communication data, such as the number of CRC errors, data frame transmission delay, and bit error rate; network port data, such as throughput, packet loss rate, and latency jitter; and PoE load data, such as voltage / current fluctuation values ​​at each stage and power stability rating. The sample states are labeled as "normal," "potential fault," and "serious fault." The state recognition features in the communication state sample library are used as training features, including at least the CRC error rate (number of CRC errors per unit time / total number of frames), communication delay (e.g., serial port response delay average 5ms, standard deviation 1ms), and fluctuation value anomalies (the main frequency component of PoE voltage fluctuations, the frequency distribution of network latency jitter).

[0059] Preferably, a historical model is established to identify bit error rate, response latency, and PoE power supply stability indicators. This model is based on random forest (suitable for multi-feature classification, such as distinguishing between "cable fault" and "protocol error") or LSTM neural network (capturing latency change trends in time-series data, such as predicting whether the latency will exceed the threshold in the next 5 minutes). A historical model (anomaly identification model) for bit error rate, response latency, and unstable PoE power supply is established by analyzing a large amount of test data. Then, a boundary recognition module matches and analyzes the current test data with the historical model, making intelligent judgments in gray areas where the communication status is not completely abnormal, and probabilistically providing intelligent alerts for potential faults. Specifically, the system calculates features such as CRC error rate and average latency in real time for the current test data, generates feature vectors, and compares these feature vectors with abnormal patterns in the historical model using Euclidean distance or cosine similarity. A matching threshold is set (e.g., similarity > 0.8 is considered an abnormal pattern), identifying the existence of abnormal patterns or potential fault states and issuing warnings. For example, if latency fluctuations exceed the historical average + 20%, a yellow warning (potential fault) is issued, and the host computer interface displays "Communication latency is rising, attention is advised"; if the CRC error rate > 0.1%, a red warning (emergency fault) is issued, the interface flashes, and a voice prompt says "Serious data error detected, this port should be manually re-inspected immediately."

[0060] Furthermore, step S430 also includes step S431, where each sample in the communication state sample library includes CRC error rate, response delay, PoE voltage drop, power fluctuation, number of voltage sags, port connection establishment time dimension features, and test result label. Based on the communication state sample library, a clustering algorithm is used to perform unsupervised clustering of the samples to divide them into multiple communication state clusters. Step S432, based on the multiple communication state clusters, transitional samples located between two or more communication state clusters are identified as transitional state data. Step S433, using the transitional state data as a training set, combined with the boundary features of the communication state clusters, a boundary anomaly detector is trained to identify abnormal communication patterns or boundary anomalies in the current test data, thus constructing the boundary identification module.

[0061] Preferably, each sample in the communication status sample library includes: CRC error rate (the proportion of frames that fail CRC verification per unit time), response delay (round-trip time of communication messages), PoE voltage drop (the magnitude of voltage deviation from the rated value when PoE is powered), power fluctuation (the deviation between the measured power value and the target value under PoE load), voltage drop frequency (the number of times the voltage drops by more than 5% per unit time), port connection establishment time (the time taken to establish a communication link between the network port / serial port), and test result labels (such as stable, unstable, abnormal, potential abnormal, etc.). Then, based on the communication status sample library, a clustering algorithm (such as K-means++ clustering) is used to perform unsupervised clustering on the samples. The initial cluster centers are used to avoid local optima. That is, the Euclidean distance between features is calculated, and the point with the farthest distance is selected as the first center. Subsequent centers are selected according to the principle that the farther away from the center, the higher the probability, until there are K (K=4~6), thereby dividing multiple communication status clusters, such as ideal stable clusters, marginally stable clusters, critically unstable clusters, and fault clusters.

[0062] Preferably, transitional samples located between two or more communication state clusters are identified based on multiple communication state clusters. This involves calculating the distance from the sample to the center of each cluster. If the distance to two communication state clusters is less than the set feature space distance, the sample is considered to be close to the boundary of the two clusters, i.e., belonging to the neighborhood intersection region of the two clusters. This sample is then used as transitional state data. The mean and variance of the transitional samples in each dimension are then calculated. Using the transitional state data as the training set, combined with the boundary features of the communication state clusters (i.e., the transitional state data (normal transitional samples and potential abnormal samples near the boundary) are positive samples, and the standard samples within the stable clusters are negative samples), a boundary anomaly detector is trained based on a single-class support vector machine to obtain a boundary identification module. This module is used to identify abnormal points that deviate from the normal cluster boundary, i.e., to identify abnormal communication patterns or boundary anomalies in the current test data. This enables accurate identification of communication state boundary anomalies, facilitating predictive maintenance of industrial control computers.

[0063] Furthermore, step S433 also includes step a, identifying whether the current test data falls into the boundary of multiple communication state clusters or is determined to be an isolated anomaly; step b, when the current test data falls into the boundary of multiple communication state clusters or is determined to be an isolated anomaly, outputting a potential fault status; step c, generating a re-inspection reminder based on the potential fault status and sending it to the host computer interface.

[0064] Preferably, the distance between the current test data feature vector and the center of each cluster is calculated. If the distance to ≥2 cluster centers is less than 1.5 times the cluster radius, for example, if it is close to both "stable cluster" and "unstable cluster", it is determined that the boundaries of multiple communication state clusters have fallen into the cluster. If the number of samples within a certain distance (e.g., Euclidean distance 0.5) around the data point of the current test data is less than the threshold (e.g., less than 3), it is regarded as an outlier and is identified as an isolated anomaly. Then, the transition states with similar characteristics to the current boundary in the historical sample library are queried, and the corresponding fault types are associated. Alternatively, the most likely fault state when the current test data is an isolated anomaly is found through association rule mining. This is output as a potential fault state, and a re-inspection reminder (e.g., if there is a potential fault risk in this port, please conduct a manual re-inspection) is generated and sent to the host computer interface.

[0065] In the above text, refer to Figure 1 A multi-functional automated testing method for an industrial control computer port according to an embodiment of the present invention is described in detail. Next, reference will be made to... Figure 2 This invention describes a multifunctional automated testing system for an industrial control computer port according to an embodiment of the present invention.

[0066] According to an embodiment of the present invention, a multifunctional automated testing system for industrial control computer ports is provided to address the technical problems in the prior art, such as low efficiency and poor accuracy of manual testing, difficulty in meeting the needs of large-scale production, and lack of collaborative testing capabilities for serial and network ports under PoE loads. This system achieves the technical effects of automated testing, improved testing efficiency and accuracy, and enhanced reliability of industrial control computer ports. Figure 2 As shown, a multi-functional automated testing system for industrial control computer ports includes: a port connection unit 10, a data content recognition unit 20, a data comparison unit 30, and a port test result acquisition unit 40.

[0067] The port connection unit 10 is used to connect the serial port and network port of the industrial control computer under test through the test fixture, and to turn on the power supply module of the test fixture to provide PoE load. The data content recognition unit 20 is used to control the test fixture to send data frames of a preset format to each serial port under PoE load conditions, and at the same time activate the host computer test module of the industrial control computer to identify and listen to the data content received by the local serial port. The data comparison unit 30 is used for the host computer to compare the received data content with a preset data template to determine whether the serial port reception is correct, and at the same time send the confirmation data back to the test fixture. After receiving the data, the test fixture performs a consistency judgment to obtain the serial communication test result. The port test result acquisition unit 40 is used for the host computer test module to automatically identify the network port with the connection status, configure a fixed IP address, send test messages to the test fixture and receive its response to determine whether the network communication is normal and obtain the network port test result.

[0068] The specific configuration of the port test result acquisition unit 40 will be described in detail below. The port test result acquisition unit 40 further includes: restoring the IP address configured on the network port to DHCP dynamic mode and saving the test record.

[0069] The specific configuration of the port connection unit 10 will be described in detail below. The port connection unit 10 further includes: setting a target power; gradually increasing the load from low power to the target power in stages according to a preset power loading window to simulate an actual power supply scenario; pausing for a preset time based on the power loading reaching the target power condition, monitoring the power absorbed by the load circuit in the test fixture in real time, and sampling voltage and current data; judging whether the power supply parameter fluctuation meets the target requirements based on the sampled voltage and current data, and obtaining the PoE load test results, including current, voltage, power curves and stability evaluation.

[0070] The specific configuration of the port connection unit 10 will be described in detail below. The port connection unit 10 further includes: performing stage segmentation according to the target power and configuring the dynamic window step size for each stage; performing staged loading according to the mapping relationship between the stage dynamic window step size and the stage power, and continuously monitoring the fluctuation of power supply parameters, wherein the duration of each stage is not less than 5 seconds; and performing feature aggregation based on the fluctuation of each stage to obtain the PoE load test results.

[0071] The specific configuration of the data comparison unit 30 will be described in detail below. The data comparison unit 30 further includes: comparison response data length, field structure and CRC check result; when any judgment result is abnormal, the serial communication is marked as abnormal.

[0072] The specific configuration of the port test result acquisition unit 40 will be described in detail below. The port test result acquisition unit 40 further includes: feeding back the serial communication test results, network port test results, and PoE load test results to the host computer for interface visualization conversion; the test fixture includes multiple parallel test ports. When multiple serial ports and multiple network ports are tested in parallel, a mapping relationship is established between the multiple parallel test ports and the serial communication test results, network port test results, and PoE load test results, generating a visual integration list, which is then sent to the host computer for interface visualization conversion.

[0073] The following will describe in detail the specific configuration of the multi-functional automated testing system for industrial control computer ports. The multi-functional automated testing system for industrial control computer ports further includes: collecting historical test samples to construct a communication status sample library; using the status identification features in the communication status sample library as training features, including at least CRC error rate, communication delay, and abnormal fluctuation values, to establish a historical model for identifying bit error rate, response delay, and PoE power supply stability indicators; matching and analyzing the current test data with the historical model through a boundary identification module to identify whether there are abnormal patterns or potential fault states; and sending the abnormal patterns or potential fault states to the host computer interface for re-inspection reminders.

[0074] The following section will continue to describe in detail the specific configuration of the multi-functional automated testing system for industrial control computer ports. The multi-functional automated testing system for industrial control computer ports further includes: each sample in the communication state sample library includes CRC error rate, response latency, PoE voltage drop, power fluctuation, number of voltage sags, port connection establishment time dimension features, and test result labels; based on the communication state sample library, unsupervised clustering is performed on the samples using a clustering algorithm to divide them into multiple communication state clusters; according to the multiple communication state clusters, transitional samples located between two or more communication state clusters are identified as transitional state data; using the transitional state data as a training set, combined with the boundary features of the communication state clusters, a boundary anomaly detector is trained to identify abnormal communication patterns or boundary anomalies in the current test data, thus constructing the boundary identification module.

[0075] The following section will continue to describe in detail the specific configuration of the multi-functional automated testing system for the industrial control computer port. The multi-functional automated testing system for the industrial control computer port further includes: identifying whether the current test data falls within the boundaries of multiple communication state clusters or is determined to be an isolated anomaly; when the current test data falls within the boundaries of multiple communication state clusters or is determined to be an isolated anomaly, outputting a potential fault status; generating a re-inspection reminder based on the potential fault status and sending it to the host computer interface.

[0076] The multi-functional automated testing system for industrial control computer ports provided in this embodiment of the invention can execute the multi-functional automated testing method for industrial control computer ports provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the method.

[0077] Although this application makes various references to certain modules in the system according to the embodiments of this application, any number of different modules can be used and run on user terminals and / or servers. The various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of each functional unit are only for easy distinction between each other and are not used to limit the scope of protection of this invention.

[0078] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A multi-functional automated testing method for industrial control computer ports, characterized in that, include: Connect the serial port and network port of the industrial control computer under test to the test fixture respectively, and turn on the power supply module of the test fixture to provide PoE load; Under PoE load conditions, the test fixture is controlled to send data frames of a preset format to each serial port, and the host computer test module of the industrial control computer is activated to identify and listen to the data content received by the local serial port. The host computer compares the received data content with the preset data template to determine whether the serial port reception is correct, and sends the confirmation data back to the test fixture. After receiving the data, the test fixture performs a consistency judgment to obtain the serial port communication test result. The host computer test module automatically identifies the network port with the connection status and configures a fixed IP address. By sending test messages to the test fixture and receiving its response, it determines whether the network communication is normal and obtains the network port test results. The power supply module of the test fixture is turned on to provide the PoE load, and also includes: Set the target power; According to the preset power loading window, the load is gradually increased from low power to the target power in stages to simulate the actual power supply scenario; Based on the power loading reaching the target power condition, the test fixture stays for a preset time, and monitors the power absorbed by the load circuit in the test fixture in real time, sampling voltage and current data. Based on the sampled voltage and current data, determine whether the power supply parameter fluctuations meet the target requirements, and obtain the PoE load test results, including current, voltage, power curves and stability evaluation.

2. The multi-functional automated testing method for industrial control computer ports according to claim 1, characterized in that, After obtaining the network port test results, the following is also included: Restore the IP address configured on the network port to DHCP dynamic mode and save the test record.

3. The multi-functional automated testing method for industrial control computer ports according to claim 1, characterized in that, According to the preset power loading window, the load is gradually increased from low power to the target power in stages, including: The target power is used to divide the power into stages, and the dynamic window step size for each stage is configured. The loading is performed in stages according to the mapping relationship between the dynamic window step size and the stage power, and the fluctuation of power supply parameters is continuously monitored, with each stage lasting for no less than 5 seconds. The PoE load test results are obtained by aggregating features based on the volatility of each stage.

4. The multi-functional automated testing method for industrial control computer ports according to claim 1, characterized in that, After receiving the data, the test fixture performs a consistency check, including comparing the response data length, field structure, and CRC check result. If any check result is abnormal, the serial communication is marked as abnormal.

5. The multi-functional automated testing method for industrial control computer ports according to claim 3, characterized in that, Also includes: The serial communication test results, network port test results, and PoE load test results are fed back to the host computer for interface visualization conversion. The test fixture includes multiple parallel test ports. When multiple serial ports and multiple network ports are tested in parallel, a mapping relationship is established between the multiple parallel test ports and the serial communication test results, network port test results, and PoE load test results. A visual integration list is generated and sent to the host computer for interface visualization conversion.

6. The multi-functional automated testing method for industrial control computer ports according to claim 1, characterized in that, Also includes: Collect historical test samples and build a communication status sample library; Using the state recognition features in the communication state sample library as training features, including at least CRC error rate, communication delay, and abnormal fluctuation values, a historical model is established to identify bit error rate, response delay, and PoE power supply stability indicators. The boundary recognition module matches and analyzes the current test data with historical models to identify whether there are abnormal patterns or potential fault states. The abnormal mode or potential fault status is sent to the host computer interface for re-inspection reminder.

7. The multi-functional automated testing method for industrial control computer ports according to claim 6, characterized in that, The boundary recognition module performs matching analysis between the current test data and historical models, including: Each sample in the communication state sample library includes CRC error rate, response delay, PoE voltage drop, power fluctuation, number of voltage sags, port connection establishment time dimension features, and test result label. Based on the communication state sample library, a clustering algorithm is used to perform unsupervised clustering of the samples to divide them into multiple communication state clusters. Based on the multiple communication state clusters, identify transition samples located between two or more communication state clusters as transition state data; Using the transition state data as a training set, and combining the boundary features of the communication state cluster, a boundary anomaly detector is trained to identify abnormal communication patterns or boundary anomalies in the current test data, thus constructing the boundary recognition module.

8. The multi-functional automated testing method for industrial control computer ports according to claim 7, characterized in that, The boundary recognition module is constructed, and then includes: Identify whether the current test data falls within the boundaries of multiple communication state clusters or is identified as an isolated outlier. When the current test data falls into the boundary of multiple communication state clusters or is determined to be an isolated anomaly, a potential fault status is output. A re-inspection reminder is generated based on the potential fault status and sent to the host computer interface.

9. A multi-functional automated testing system for an industrial control computer port, characterized in that, The system is used to implement a multi-functional automated testing method for industrial control computer ports as described in any one of claims 1 to 8, and the system includes: The port connection unit is used to connect the serial port and network port of the industrial control computer under test through the test fixture, and to turn on the power supply module of the test fixture to provide PoE load. The data content recognition unit is used to control the test fixture to send data frames of a preset format to each serial port under PoE load conditions, and at the same time activate the host computer test module of the industrial control computer to identify and listen to the data content received by the local serial port. The data comparison unit is used by the host computer to compare the received data content with the preset data template to determine whether the serial port reception is correct. At the same time, the confirmation data is sent back to the test fixture. After receiving the data, the test fixture performs a consistency judgment to obtain the serial port communication test result. The port test result acquisition unit is used by the host computer test module to automatically identify the network port with the connection status, configure a fixed IP address, send test messages to the test fixture and receive its response to determine whether the network communication is normal and obtain the network port test result. The port connection unit also includes: Set the target power; according to the preset power loading window, gradually increase the load from low power to the target power in stages to simulate the actual power supply scenario; based on the power loading reaching the target power condition, pause for a preset time, monitor the power absorbed by the load circuit in the test fixture in real time, and sample voltage and current data; based on the sampled voltage and current data, determine whether the power supply parameter fluctuation meets the target requirements, and obtain the PoE load test results, including current, voltage, power curves and stability evaluation.

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