Industrial vehicle line fault detector and detection method

Abstract

The invention discloses an industrial vehicle line fault detector and a detection method, and aims to solve the problem that the detection efficiency is low due to the fact that an existing fault error reporting device is lack of line fault recognition capability and depends on manual line detection. The system comprises an external interface and an internal circuit, a source interface supplies energy to connected modules, a control signal group comprises a plurality of control signal interfaces, the control signal interfaces obtain the connection states of the connected modules, a CAN communication interface group comprises a plurality of CAN communication interfaces, and each CAN communication interface communicates with each module. In response to signals fed back by the power supply interface group, the control signal group and the CAN communication interface group, the display screen and the LED array output fault information, the fault positioning capability and speed are improved, the maintenance time is shortened, and the production efficiency is improved through collaborative error code reporting and physical detection.

Description

Technical Field

[0001] The present invention relates to the field of fault detection of industrial vehicles, and more particularly to a method and module for displaying and troubleshooting line faults of industrial vehicles. Background Art

[0002] Industrial vehicles often experience downtime due to wiring faults during operation. Traditional troubleshooting methods rely on maintenance personnel carrying multiple measuring tools (such as multimeters and oscilloscopes) to perform step-by-step inspections, which is inefficient. While existing vehicle instrumentation can display fault codes, these messages are typically sent by the control unit (ECU), which can indicate a wide range of issues and makes it difficult to pinpoint specific wiring problems. Consequently, the lack of rapid diagnostic tools often leads to lengthy repair times in the event of a vehicle failure, causing inconvenience for both operators and the factory.

[0003] Existing fault reporting devices lack the ability to identify line faults, especially the problem of inaccurate electrical levels caused by line aging and failure of key contacts, which further affects the ability to read faults.

[0004] Therefore, this application aims to make improvements by coordinating error reporting codes and physical detection to improve the ability and speed of locating faults, reduce maintenance time, and improve production efficiency. Summary of the Invention

[0005] The present invention overcomes the shortcomings of existing fault reporting devices, which lack the ability to identify line faults and rely on manual line detection, resulting in low detection efficiency. It provides an industrial vehicle line fault detector and detection method, which improves the ability and speed of locating faults by coordinating error reporting codes and physical detection angles, reduces maintenance time, and improves production efficiency.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions: An industrial vehicle line fault detector is used to detect various modules of an industrial vehicle, comprising: External interfaces, including a power interface group, a control signal group, and a CAN communication interface group. The power interface group includes several power interfaces that supply energy to connected modules. The control signal group includes several control signal interfaces that obtain the connection status of connected modules. The CAN communication interface group includes several CAN communication interfaces that communicate with each module. and The internal circuit includes a processing layer, an isolation layer, an input layer, and an output layer. The processing layer includes a controller and a detection circuit. The isolation layer includes an isolation protection circuit. The input layer includes an input circuit connected to an external interface. The output layer includes a display circuit connected to a display screen and an LED array. In response to the signals fed back by the power interface group, the control signal group and the CAN communication interface group, the display screen and the LED array output fault information.

[0007] The Industrial Vehicle Line Fault Detector is a tool that gathers fault information through a combination of physical testing and CAN error information. This coordinated approach allows for accurate fault diagnosis. Compared to CAN testing alone, it can identify issues arising from the line itself, helping maintenance personnel or users quickly locate the cause of a fault.

[0008] In addition to setting up a CAN communication interface group for connecting to the CAN bus, this application also has a power interface group and a control signal group, which are connected to each module respectively, supplying driving energy through the power interface and detecting its physical state through the control signal.

[0009] The internal circuitry's processing, isolation, input, and output layers are arranged on corresponding PCBs. Components are mounted on the top or bottom layers, connected via buried or blind vias. The circuitry on each layer receives control signals and CAN communication signals, which are then displayed via the brightness and color of the display and LED array.

[0010] Preferably, the output isolation protection circuit includes an optocoupler and a TVS diode. Each input circuit connecting the control signal interface and the CAN communication interface is connected to the detection circuit via the optocoupler and TVS diode. The optocoupler isolates the original vehicle system from the detection circuit to reduce noise. The TVS diode is connected in parallel between the line and ground to clamp surge voltages (such as transient high-voltage pulses).

[0011] A method for detecting line faults in industrial vehicles is based on the industrial vehicle line fault detector described above. In response to the on / off status of each line, fluctuations in signal levels, and CAN data, a controller controls the brightness and color status of LEDs corresponding to each module and generates a fault code for display.

[0012] As mentioned earlier, the controller contains a built-in detection program, either hard-coded or running on a general-purpose computer. It receives route connectivity, signal fluctuations, and CAN data as input and outputs them on a display and LED array. Users and maintenance personnel use the display and LED array to determine the cause of the fault. The display displays module error information based on the communication protocol, while the LED array indicates the physical connection status. By combining this physical connection status with the digital error information, the fault location and cause can be accurately determined.

[0013] Preferably, when the industrial vehicle is started, the controller scans the external interface and generates an alarm in response to a signal indicating a circuit break.

[0014] Preferably, the method for determining whether the control signal and the CAN communication interface are disconnected includes injecting a constant current into the target interface, and in response to comparing the voltage drop value at both ends of the detection line with the size of a first preset threshold, the controller outputs a first Boolean value, and determines whether the line is on or off based on the first Boolean value. The constant current is generated by the controller, which is independent of the power supply of the power interface. The constant current source is output to the target line, and the on or off can be determined by detecting the voltage drop of the line. If the line is normal, the voltage drop is small. If it is disconnected or the resistance is too large, the voltage drop is large. Based on the comparison of the voltage drop with the first preset threshold, the data obtained is used as the basis for determining whether the line is on or off. The size of the first preset threshold can be set to 2V.

[0015] Preferably, during operation of the industrial vehicle, the controller reads the signal level, performs fluctuation detection on circuits with abnormal level levels, and controls the LED to output a first preset color or a second preset color in response to the fluctuation detection result. The controller reads the level and, for circuits corresponding to fluctuating levels, continuously detects the fluctuation. If the fluctuation range is normal, the LED displays the first preset color; if it is abnormal, the LED displays the second preset color.

[0016] Preferably, the method for determining that the voltage level is abnormal includes mapping the voltage value of the control signal interface to a controller-readable voltage. In response to comparing the mapped voltage value with a second preset threshold value, the controller outputs a second Boolean value. In response to the second Boolean value, the controller determines whether to detect the fluctuation of the control signal. The levels generated by the control signal include high and low levels. When there is a fault or defect in the connection, the level signal will deviate from the normal range. The information obtained by the change in the level signal makes it difficult to read the information represented by the level. The present application ensures the accuracy and reliability of the information obtained by detecting the level voltage.

[0017] Preferably, the fluctuation detection includes detecting the number of level jumps of the corresponding module, and outputting the fluctuation detection result by counting the number of jumps in a unit time.

[0018] Preferably, the method for mapping the voltage value of the control signal interface to a readable voltage by the controller includes providing a voltage divider circuit, the voltage divider circuit including a voltage divider resistor connected to the control signal interface. The voltage range of the control signal is 0-24V, and after being divided by the voltage divider circuit, the voltage is controlled to be between 0-5V, thereby being within the range of the controller, thereby determining the voltage level of the circuit and further determining whether the voltage level is qualified.

[0019] Preferably, the second preset threshold is input via an external device electrically connected to the industrial vehicle line fault detector.

[0020] Preferably, the industrial vehicle line fault detector also includes an internal or external memory, into which the controller writes a work log. Based on the historical data in the work log and in response to the fault codes fed back by the CAN communication interface, the controller selects and counts the error codes associated with the corresponding modules and displays them on the display screen. In addition to displaying the current error information, historical data can also be used to better reveal the cause of the fault.

[0021] Compared with the prior art, the present invention has the following beneficial effects: (1) Combining the error information of the CAN bus with the physical signals obtained through the power interface and control signals, the fault location can be located more quickly, improving maintenance efficiency; (2) Determine the reliability of the obtained signal by judging the connectivity of the route and the fluctuation of the signal. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of the present invention; Figure 2 is a flow chart of the present invention; Figure 3 It is a flow chart of level fluctuation detection of the present invention; In the picture: External interface 1, power interface group 2, control signal group 3, CAN communication interface group 4, processing layer 5, isolation layer 6, input layer 7, output layer 8, display screen 9, LED array 10. DETAILED DESCRIPTION

[0023] The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

[0024] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present application belongs.

[0025] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0026] In the present disclosure, terms such as "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "side", "bottom", etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. They are merely relational words determined for the convenience of describing the structural relationships of the various parts or elements of the present disclosure, and do not specifically refer to any part or element in the present disclosure, and should not be understood as limitations on the present disclosure.

[0027] In this disclosure, terms such as "fixed connection," "connected," and "connection" should be interpreted broadly to mean a fixed connection, an integral connection, or a detachable connection; a direct connection or an indirect connection through an intermediary. Relevant researchers or technicians in this field may determine the specific meaning of these terms in this disclosure based on specific circumstances, and they should not be construed as limiting this disclosure.

[0028] Example: An industrial vehicle circuit fault detector is used to detect various modules of the industrial vehicle, and comprises an external interface 1 and an internal circuit.

[0029] Ginseng Figure 1 As shown, the external interface 1 includes a power interface group 2, a control signal group 3, and a CAN communication interface group 4. The power interface group 2 includes several power interfaces, which are connected to the power supply line to provide energy to the connected modules. The power interfaces have a strong overcurrent capacity. The control signal group 3 includes several control signal interfaces, which are connected to the vehicle's non-CAN discrete signal lines. Through detection, physical quantities such as switching values ​​and analog values ​​are obtained. These signals are connected through hardware without the need for protocol parsing. The on / off and electrical level of each line are detected in real time. The control signal interface obtains the connection status of the connected modules. The CAN communication interface group 4 includes several CAN communication interfaces, which are connected to the CAN bus. Each CAN communication interface communicates with each module and reads the fault code issued by the controller through the CAN bus protocol. This is digital communication.

[0030] In order to avoid plugging the wrong interface, the power interface group 2, control signal group 3 and CAN communication interface group 4 are set to different colors, and special-shaped interfaces are set.

[0031] The internal circuit includes a processing layer 5, an isolation layer 6, an input layer 7, and an output layer 8. The processing layer 5 includes a controller and a detection circuit. The isolation layer 6 includes an isolation protection circuit. The input layer 7 includes an input circuit connected to the external interface 1. The output layer 8 includes a display circuit connected to the display screen 9 and the LED array 10. In response to the signals fed back by the power interface group 2 , the control signal group 3 and the CAN communication interface group 4 , the display screen 9 and the LED array 10 output fault information.

[0032] The output isolation protection circuit includes optocouplers and TVS diodes. Each input circuit connecting the control signal interface and the CAN communication interface is connected to the detection circuit via optocouplers and TVS diodes. Optocouplers isolate the vehicle system from the detection circuit and filter out noise. TVS diodes, connected in parallel between the line and ground, clamp surge voltages (such as transient high-voltage pulses). Each signal input follows a sequence: optocoupler, TVS diode, detection circuit. The power interface is connected to the overcurrent / overvoltage protection circuit.

[0033] The Industrial Vehicle Line Fault Detector is a tool that gathers fault information through a combination of physical testing and CAN error information. This coordinated approach allows for accurate fault diagnosis. Compared to CAN testing alone, it can identify issues arising from the line itself, helping maintenance personnel or users quickly locate the cause of a fault.

[0034] In addition to setting up a CAN communication interface group 4 for connecting to the CAN bus, this application also has a power interface group 2 and a control signal group 3, which are connected to each module respectively, supplying driving energy through the power interface and detecting its physical state through the control signal.

[0035] The internal circuitry's processing layer 5, isolation layer 6, input layer 7, and output layer 8 are arranged on corresponding PCBs. Components are mounted on the top or bottom layers, connected via buried or blind vias. The circuitry on each layer receives control signals and CAN communication signals, which are displayed via the brightness and color of the display screen 9 and LED array 10.

[0036] Ginseng Figure 2 As shown, a method for detecting line faults in industrial vehicles is based on the aforementioned line fault detector. In response to the on / off status of each line, fluctuations in signal levels, and CAN data, a controller controls the brightness and color of LEDs corresponding to each module and generates a fault code for display screen 9. Specifically, the controller controls the brightness and color of corresponding LEDs in response to line on / off status, controls the color of corresponding LEDs in response to signal level fluctuations, and displays an error message on display screen 9 in response to CAN data.

[0037] When the industrial vehicle is started, the controller scans the external interface 1 and generates an alarm in response to a signal indicating a circuit break.

[0038] The method for determining whether a control signal and a CAN communication interface are disconnected includes injecting a constant current into the target interface. In response to comparing the voltage drop across the detection line with a first preset threshold, the controller outputs a first Boolean value, and the continuity of the line is determined based on the first Boolean value. The constant current is generated by the controller, independent of the power supply of the power interface. The constant current source is output to the target line, and the continuity can be determined by detecting the voltage drop of the line. If the line is normal, the voltage drop is small. If it is disconnected or has excessive resistance, the voltage drop is large. The data obtained by comparing the voltage drop with the first preset threshold is used as the basis for determining whether the line is on or off. The first preset threshold can be set to 2V.

[0039] During the operation of the industrial vehicle, the controller reads the level of the signal, and performs fluctuation detection on the circuit with abnormal level. In response to the result of the fluctuation detection, the controller controls the LED to output the first preset color or the second preset color. The controller reads the level, and for the circuit corresponding to the level with fluctuation, the controller continuously detects the fluctuation. If the fluctuation range is normal, the first preset color is displayed through the LED, and if it is abnormal, the second preset color is displayed. The method for determining that the voltage level is abnormal includes mapping the voltage value of the control signal interface to a controller-readable voltage, and in response to comparing the mapped voltage value with the second preset threshold, the controller outputs a second Boolean value. In response to the second Boolean value, the controller determines whether to perform fluctuation detection on the control signal. The level generated by the control signal includes a high level and a low level. When there is a fault or defect in the connection, the level signal will deviate from the normal range. The information represented by the level is obtained by changing the level signal, which makes it difficult to read. The present application ensures the accuracy and reliability of the information obtained by detecting the level voltage.

[0040] The first preset color indicates that the signal level is normal, and the second preset color indicates that the level is abnormal.

[0041] Ginseng Figure 2 As shown, fluctuation detection includes detecting the number of level jumps of the corresponding module, and outputting the fluctuation detection result by counting the number of jumps in a unit time. The number of jumps is generally set to 5 times per second. The method of mapping the voltage value of the control signal interface to a readable voltage of the controller includes setting a voltage divider circuit, which includes a voltage divider resistor connected to the control signal interface. The voltage range of the control signal is 0-24V. After being divided by the voltage divider circuit, it is controlled to be between 0-5V, so that it is within the range of the controller. This is used to determine the voltage level of the circuit and then determine whether its level is qualified. The second preset threshold is input through an external device electrically connected to the industrial vehicle line fault detector. As an example, the present application provides a set of second preset values ​​(high level > 10V, low level < 2V). When the high level or low level does not meet the second preset threshold, it is recorded as one time, and the corresponding number of deviations is counted.

[0042] The industrial vehicle line fault detector also includes a built-in or external memory. The controller writes a work log into the memory. Based on the historical data in the work log and in response to the fault codes fed back by the CAN communication interface, the controller selects and counts the error codes related to the corresponding modules and displays them on the display screen 9. In addition to displaying the current error information, the historical data can also better reveal the cause of the fault.

[0043] As previously mentioned, the controller contains a built-in detection program, either hard-coded or running on a general-purpose computer. It receives route connectivity, signal fluctuations, and CAN data as input and outputs them on the display screen 9 and LED array 10. Users and maintenance personnel use the display screen 9 and LED array 10 to determine the cause of the fault. The display screen 9 displays module error information based on the communication protocol, while the LED array 10 displays the physical connection status. By combining the determination of the physical connection status with the digital error information, the fault location and cause can be accurately determined.

[0044] Specifically, after the vehicle is powered on, the controller performs a self-test. If a circuit breaker is detected, an alarm is issued, and the circuit breaker is located via the display 9 and LEDs, and the test process ends. The alarm may be triggered by turning off the LED corresponding to the circuit breaker and lighting up other normal LEDs.

[0045] If the self-test passes, the control signal level is checked. If it fails, a separate level fluctuation detection process is initiated, where the number of fluctuations per unit time is counted. If it passes, the first preset color is output and the process returns to the original detection process. If it fails, the second preset color is output and the result is displayed on the LED, ending the detection process.

[0046] In the original detection process, the digital signal of the CAN interface is received, the corresponding error code is generated, the LED displays the error code and related prompt information, the display color of the aforementioned LED is combined, and then the detection process is ended.

[0047] In some embodiments, cross-verification is also performed by displaying the error code and the level result of the control signal through the LED. By checking whether the level signal of the control signal is normal, the cause is actively determined. If the level is abnormal, a "physical line failure" is prompted; if the level is normal, a "sensor or controller failure" is prompted.

[0048] The above-described embodiments are only preferred solutions of the present invention and are not intended to limit the present invention in any form. Other variations and modifications are possible without exceeding the technical solutions described in the claims.

Claims

1. An industrial vehicle line fault detector for detecting various modules of an industrial vehicle, characterized in that: include: External interfaces, including a power interface group, a control signal group, and a CAN communication interface group. The power interface group includes several power interfaces that supply energy to connected modules. The control signal group includes several control signal interfaces that obtain the connection status of connected modules. The CAN communication interface group includes several CAN communication interfaces that communicate with each module. and The internal circuit includes a processing layer, an isolation layer, an input layer, and an output layer. The processing layer includes a controller and a detection circuit. The isolation layer includes an isolation protection circuit. The input layer includes an input circuit connected to an external interface. The output layer includes a display circuit connected to a display screen and an LED array. In response to the signals fed back by the power interface group, the control signal group and the CAN communication interface group, the display screen and the LED array output fault information.

2. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 1, characterized in that: The output isolation protection circuit includes an optocoupler and a TVS diode. The input circuits connecting the control signal interface and the CAN communication interface are connected to the detection circuit via the optocoupler and the TVS diode.

3. A method for detecting line faults in industrial vehicles, characterized in that: Based on the industrial vehicle line fault detector as described in claim 1, in response to the on-off status of each route, the fluctuation of the signal level and the CAN data, the controller controls the brightness and color status of the LED corresponding to each module and generates a fault code displayed on the display screen.

4. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 3, characterized in that: When the industrial vehicle is started, the controller scans the external interface and, in response to a signal indicating that the interface is disconnected, the controller issues an alarm.

5. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 4, characterized in that: The method for determining whether the control signal and the CAN communication interface are open includes injecting a constant current into the target interface, and in response to comparing the voltage drop value at both ends of the detection line with the size of a first preset threshold, the controller outputs a first Boolean value, and determines whether the line is open or closed based on the first Boolean value.

6. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 3, wherein During the operation of the industrial vehicle, the controller reads the level of the signal, performs fluctuation detection on the line with abnormal level, and controls the LED to output the first preset color or the second preset color in response to the result of the fluctuation detection.

7. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 6, characterized in that: The method for determining that the voltage level is abnormal includes mapping the voltage value of the control signal interface into a controller-readable voltage, and in response to comparing the mapped voltage value with a second preset threshold, the controller outputs a second Boolean value, and in response to the second Boolean value, the controller determines whether to detect fluctuations in the control signal.

8. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 7, characterized in that: The method for mapping the voltage value of the control signal interface to a controller-readable voltage includes setting a voltage divider circuit, which includes a voltage divider resistor connected to the control signal interface.

9. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 7, characterized in that: The second preset threshold is input through an external device electrically connected to the industrial vehicle line fault detector.

10. The method and module for displaying and troubleshooting industrial vehicle line faults according to claim 3, characterized in that: The industrial vehicle line fault detector also includes a built-in or external memory. The controller writes a work log into the memory. Based on the historical data in the work log and in response to the fault code fed back by the CAN communication interface, the controller screens and counts the error codes related to the corresponding modules and displays them on the display screen.

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