Automatic test system and automatic test method for mine wind speed sensor

Abstract

The invention discloses an automatic test system and an automatic test method for a mine wind speed sensor, and the system comprises an initial detection station which is used for detecting a circuit board of the mine wind speed sensor; the assembly station is used for assembling the circuit board and the electronic element to form the mine wind speed sensor; the function detection station is used for carrying out function detection on the assembled mine wind speed sensor; the wind tunnel detection station is used for performing wind tunnel detection on the mine wind speed sensor with qualified function detection; the aging test station is used for carrying out aging test on the mine wind speed sensor which is qualified in performance detection; the final inspection station is used for performing final inspection on the mine wind speed sensor qualified in the aging test, and packaging and storing the mine wind speed sensor qualified in the final inspection; wherein the initial detection station, the assembly station, the function detection station, the wind tunnel detection station and the aging test station form an annular moving line. The test efficiency and the test precision can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of mine wind speed sensors, and in particular to an automated testing system and an automated testing method for mine wind speed sensors. Background Art

[0002] The mine wind speed sensor can continuously monitor the wind speed and air volume (air volume = wind speed x cross-sectional area) at the above-mentioned locations, and can display the wind speed and air volume of the tunnel in real time. It is an important instrument for measuring mine ventilation safety parameters. It is mainly suitable for the total return air lanes, air vents, main underground wind measuring stations, fan shafts, tunneling working faces, coal mining working faces, etc. in coal mines with gas explosion hazards, as well as corresponding mining enterprises.

[0003] Before a mine wind speed sensor leaves the factory, it needs to be tested to ensure its measurement accuracy. Currently, the testing methods for mine wind speed sensors have the following main shortcomings:

[0004] (1) High manual dependence and low testing efficiency

[0005] The traditional testing process relies on manual labor, requiring 19 test items and taking 15 to 22 minutes to test a single device, making it difficult to meet the needs of large-scale production. This repetitive manual work leads to low testing efficiency, limited production capacity, and easily leads to missed tests or misjudgments due to operator fatigue. Test coverage is less than 70%.

[0006] (2) Insufficient data management and traceability capabilities

[0007] Test data relies on manual recording, which is prone to omissions and errors. It is also not integrated with the MES system, leading to data silos, making quality traceability difficult and leading to long improvement cycles. The lack of real-time data collection and analysis capabilities makes it impossible to provide data support for process optimization and hinders the implementation of full-process digital management.

[0008] (3) Low level of automation and intelligence

[0009] Traditional production lines lack automated testing equipment, making unmanned operation of key processes like withstand voltage testing and performance calibration impossible. These processes require two people working together, resulting in high labor costs. LED digital tube inspection relies on manual visual inspection, which suffers from low accuracy, slow speed, and poor stability.

[0010] (4) Poor system integration and coordination

[0011] Testing equipment operated independently, lacking deep integration with the host computer and MES system. This resulted in low collaboration efficiency and mismatched workstation timing. Logistics relied on manual handling, resulting in low material flow efficiency and the inability to achieve intelligent scheduling and seamless integration.

[0012] (5) Insufficient test accuracy and consistency

[0013] Traditional methods are limited by human error and struggle to guarantee repeatable test results, especially in complex scenarios (such as boundary conditions and abnormal processes), where the risk of defect escape is high. The lack of real-time monitoring and closed-loop control mechanisms prevents dynamic adjustment of test parameters, leading to significant fluctuations in product quality and a defect rate as high as 2%.

[0014] (6) Scalability and compatibility limitations

[0015] Traditional testing equipment has poor adaptability, supporting only a single sensor model and unable to quickly switch to multi-product production, making it difficult to meet the diverse market demands. Semi-automated solutions (such as outsourced general-purpose equipment) are costly and lack flexibility, making them incompatible with customized testing requirements (such as wind tunnel calibration and infrared remote control simulation). Summary of the Invention

[0016] The present invention aims to solve at least one of the problems existing in the prior art.

[0017] To this end, the present invention provides an automated testing system and an automated testing method for a mine-used wind speed sensor.

[0018] The technical solution adopted by the present invention to solve its technical problem is:

[0019] An automated testing system for a mine wind speed sensor, comprising:

[0020] The initial inspection station is used to test the circuit boards of the mining wind speed sensors. The qualified circuit boards are transported by AGV logistics vehicles to the three-dimensional warehouse for storage;

[0021] Assembly station, used to assemble circuit boards and electronic components to form a mine wind speed sensor;

[0022] Functional testing station, used to perform functional testing on the assembled mining wind speed sensor;

[0023] Wind tunnel testing station, used to conduct wind tunnel testing on mining wind speed sensors that have passed functional testing;

[0024] Aging test station, used to perform aging test on mining wind speed sensors that have passed performance testing;

[0025] The final inspection station is used to conduct final inspection on the mining wind speed sensors that have passed the aging test, and the mining wind speed sensors that have passed the final inspection are packaged and stored;

[0026] Among them, the initial inspection station, assembly station, function inspection station, wind tunnel inspection station, and aging test station form a circular moving line.

[0027] Furthermore, the functional detection station includes: a host computer, a voltage test module and a performance test module. The voltage test module and the performance test module are both communicatively connected to the host computer. The voltage test module is used to perform a voltage test on the mine wind speed sensor and transmit the test data to the host computer. The performance test module is used to perform a performance test on the mine wind speed sensor and transmit the test data to the host computer.

[0028] Furthermore, the wind tunnel detection station includes: a PLC controller, an annular wind tunnel, a variable frequency speed regulation fan, a wind speed feedback sensor and a temperature and humidity control module. The variable frequency speed regulation fan, the wind speed feedback sensor and the temperature and humidity control module are all communicatively connected to the PLC controller. The variable frequency speed regulation fan is used to blow air into the annular wind tunnel, the wind speed feedback sensor is used to feedback the real-time wind speed in the annular wind tunnel, and the temperature and humidity control module is used to control the temperature and humidity in the annular wind tunnel.

[0029] Furthermore, the voltage test module includes: a voltage tester and a fixing fixture, the fixing fixture is used to fix the mining wind speed sensor, the voltage tester is connected to the mining wind speed sensor through a five-core aviation plug connector, and the voltage tester is connected to the host computer.

[0030] Furthermore, the performance test module includes: a programmable power supply, a programmable oscilloscope, a protocol conversion board and a terminal board. The programmable power supply and the programmable oscilloscope are both connected to the terminal board, the protocol conversion board is connected to the terminal board, and the terminal board is connected to the mining wind speed sensor through a five-core aviation plug connector.

[0031] The present invention also provides an automated testing method for a mine wind speed sensor, comprising the following steps:

[0032] S1. Place the circuit board of the mining wind speed sensor in the initial inspection station for testing. The qualified circuit boards are transported to the three-dimensional warehouse for storage by the AGV logistics vehicle;

[0033] S2. The AGV logistics vehicle transports the qualified circuit board to the assembly station, and the staff assembles the mining wind speed sensor as a whole. The assembled mining wind speed sensor is then sent to the function testing station;

[0034] S3. Performing a withstand voltage test and a performance test on the mining wind speed sensor in the functional testing station, and transporting the qualified mining wind speed sensor to the wind tunnel testing station;

[0035] S4. Performing a wind tunnel test on the mining wind speed sensor in the wind tunnel testing station. The mining wind speed sensor that has passed the test is transported to the aging test station by the AGV logistics vehicle.

[0036] S5. Perform an aging test on the mining wind speed sensor in the aging test station. The mining wind speed sensor that passes the test is transported to the final inspection station by the AGV logistics vehicle;

[0037] S6. In the final inspection station, the mining wind speed sensor is subjected to final quality inspection, and the mining wind speed sensor that has passed the final inspection is packaged and stored.

[0038] Furthermore, in step S3, a withstand voltage test is performed on the mine wind speed sensor, including:

[0039] Place the mining wind speed sensor in the voltage test position, clamp and fix the mining wind speed sensor with a fixing fixture, insert the five-core aviation plug connector into the connection port of the mining wind speed sensor by the pushing mechanism to realize electrical connection with the voltage tester, and the host computer sends a voltage test signal to the voltage tester. The voltage tester performs a voltage test on the mining wind speed sensor, and the voltage test data is sent to the host computer for storage.

[0040] Furthermore, in step S3, a performance test is performed on the mine wind speed sensor, including:

[0041] The mining wind speed sensor is placed in the performance test position, clamped and fixed by a fixing fixture, and the five-core aviation plug connector is inserted into the connection port of the mining wind speed sensor by a pushing mechanism to realize electrical connection with the terminal block. The terminal block communicates with the host computer through the protocol conversion board. The host computer retrieves the test program and sends it to the programmable power supply and programmable oscilloscope. The programmable power supply tests the power supply of the mining wind speed sensor, and the programmable oscilloscope tests the RS485 peak value, frequency, and switch output of the mining wind speed sensor; the performance test data is sent to the host computer for storage.

[0042] Furthermore, in step S4, a wind tunnel test is performed on the mine wind speed sensor, including:

[0043] The PLC controller sends a signal to the variable frequency speed regulating fan to shut down, starts the environmental stabilization program, and performs zero point calibration on the mine wind speed sensor;

[0044] The PLC controller sends a signal to the variable frequency speed regulation fan, controls the variable frequency speed regulation fan to run at 9 m / s, and starts the environmental stabilization program; the wind tunnel feedback sensor detects the wind speed in the annular wind tunnel in real time; the PLC controller reads the output value of the mining wind speed sensor in real time, continuously collects n groups of data and calculates the average value to perform linear calibration on the mining wind speed sensor.

[0045] Furthermore, the wind tunnel test of the mine wind speed sensor also includes:

[0046] Set the target wind speed to 0m / s, 0.4m / s, 1.0m / s, 3.0m / s, 6.0m / s, 9.0m / s, 12.0m / s, and 15.0m / s;

[0047] The PLC controller sends the target wind speed value to the wind tunnel controller and uses the PID algorithm to dynamically adjust the speed of the variable frequency speed regulating fan; the wind tunnel feedback sensor detects the wind speed in the annular wind tunnel in real time. After the wind speed stabilizes, the PLC controller reads the output value of the mine wind speed sensor;

[0048] Compare the output value of the mine wind speed sensor with the target wind speed value and calculate the linear error. If the linear error is greater than 1%, the mine wind speed sensor needs to be calibrated.

[0049] The beneficial effects of the present invention are:

[0050] (1) Improved efficiency

[0051] Shortened testing cycles: The automated testing system significantly reduced the testing time for a single mining wind speed sensor from 18.5 minutes to 9 minutes, a 51% improvement in efficiency. The cycle time for testing one-way wind speed sensors during full-unit testing was reduced from 15 minutes to 8 minutes, a 53% improvement in efficiency; the cycle time for testing two-way wind speed sensors was reduced from 22 minutes to 11 minutes, also a 53% improvement in efficiency. This significantly increased production capacity, increasing annual production capacity from 5,000 units to 9,000 units, an increase of over 80%.

[0052] Reduced staff requirements: The number of test process operators was reduced from 2 to 1, a 50% reduction in staff requirements and lowered labor costs.

[0053] (2) Quality Assurance

[0054] Improved test coverage: The automated testing system achieved 100% test coverage, a qualitative leap compared to the 70% coverage of previous manual testing, effectively reducing the risk of defect escape and ensuring more reliable product quality.

[0055] Reduced defective rate: After implementing the automated testing system, product quality has been significantly improved, with the defective rate reduced from 2% to 0. This has effectively reduced the production of defective products caused by human operational errors and insufficient equipment accuracy, and improved the market competitiveness of products.

[0056] (3) Production process optimization

[0057] Production line layout optimization: By analyzing process flows, we re-arranged production lines and automated equipment. This created a continuous process flow, reduced unnecessary movement of personnel and materials, and improved production efficiency.

[0058] Logistics route optimization: Functional testing and performance calibration work together to increase the beat matching rate to 95%. A circular logistics route was designed based on the production line layout. By linking the WCS with the MES, dynamic task allocation for AGVs and efficient material flow were achieved, avoiding route conflicts and improving logistics efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The present invention will be further described below with reference to the accompanying drawings and examples.

[0060] Figure 1 It is a schematic diagram of the automated testing system of the mine wind speed sensor of the present invention.

[0061] Figure 2 It is a schematic diagram of the test process of the automatic test system of the present invention.

[0062] Figure 3 Schematic diagram of the withstand voltage test of the present invention.

[0063] Figure 4 It is a schematic diagram of some performance tests of the present invention.

[0064] Figure 5 The present invention is a flow chart of an automated testing method for a mine wind speed sensor.

[0065] In the picture: 1. Initial inspection station; 2. AGV logistics vehicle; 3. Assembly station; 4. Functional inspection station; 5. Wind tunnel inspection station; 6. Aging test station. DETAILED DESCRIPTION

[0066] The present invention will now be described in further detail with reference to the accompanying drawings, which are simplified schematic diagrams that illustrate the basic structure of the present invention in a schematic manner.

[0067] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, features defined as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0068] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0069] Example 1

[0070] like Figures 1 to 4 As shown, the automated testing system for a mining wind speed sensor of this embodiment includes: an initial inspection station 1 for inspecting the circuit board of the mining wind speed sensor. Passing inspection circuit boards are transported to a three-dimensional warehouse for storage by an AGV logistics vehicle 2; an assembly station 3 for assembling the circuit board and electronic components to form a mining wind speed sensor; a functional inspection station 4 for performing functional inspection on the assembled mining wind speed sensor; a wind tunnel inspection station 5 for performing wind tunnel inspection on mining wind speed sensors that have passed the functional inspection; an aging test station 6 for performing aging inspection on mining wind speed sensors that have passed the performance inspection; and a final inspection station for performing final inspection on mining wind speed sensors that have passed the aging test. Passing final inspection mining wind speed sensors are packaged and stored. The initial inspection station 1, assembly station 3, functional inspection station 4, wind tunnel inspection station 5, and aging test station 6 form a circular motion path.

[0071] It should be noted that, in terms of workstation layout, this embodiment forms a circular movement line with the initial inspection station 1, assembly station 3, functional inspection station 4, wind tunnel inspection station 5, and aging test station 6, which can make the transportation route of the AGV logistics vehicle 2 more reasonable and streamlined, realize the efficient circulation of products, avoid path conflicts, and improve product circulation efficiency.

[0072] There are significant differences between mine-used wind speed sensors and ordinary wind speed sensors in terms of test requirements, standards, and environmental adaptability, mainly due to the special safety requirements of the mine environment (such as explosion-proof, anti-interference, long-term reliability, etc.). The differences in testing are: (1) Different test standards. Mine-used wind speed sensors must comply with mining-specific standards such as MT 448-2008 and local verification procedures such as JJG (Jin) 14-2014. The test items have more special requirements than ordinary wind speed sensors, such as explosion-proof performance and intrinsic safety performance. (2) Different accuracy and range requirements. Low wind speed accuracy: Mine-used sensors must maintain an error of ≤±0.1m / s at ultra-low wind speeds of 0.1-0.4m / s (ordinary sensors usually start from 0.5m / s); High wind speed range: The upper limit of the range must reach 15m / s (the upper limit of mine ventilation), and the measurement distortion caused by turbulence in the roadway must be resolved; Stability requirements: After 30 days of continuous operation, the error drift must be ≤±2.5%, which is much stricter than ordinary sensors. (3) Mine wind speed sensors must be tested for 2km long-distance signal transmission performance, which is not required for ordinary wind speed sensor testing. (4) The testing equipment uses an explosion-proof annular wind tunnel that complies with QXT 323-2016 and MT448 standards; it must be equipped with an intrinsically safe power supply and associated equipment to simulate an underground monitoring system. (5) Mine wind speed sensors must undergo bidirectional testing, which means the sensor can distinguish between positive and negative airflow (output positive / negative values).

[0073] Therefore, the testing requirements for mine wind speed sensors are much stricter than those for ordinary wind speed sensors, and there are more test items.

[0074] Specifically, functional test station 4 includes a host computer, a withstand voltage test module, and a performance test module. Both modules are communicatively connected to the host computer. The withstand voltage test module is used to perform withstand voltage tests on the mining wind speed sensor and transmit test data to the host computer. The performance test module is used to perform performance tests on the mining wind speed sensor and transmit test data to the host computer. The test instruments at functional test station 4 include a withstand voltage tester, a programmable power supply, a programmable oscilloscope, a shielded darkroom, and a barcode scanning chamber. The withstand voltage tester, programmable power supply, and programmable oscilloscope use RS232 communication interfaces to improve interference resistance. When communicating with the host computer, RS232 is converted to RS485 for data exchange. The host computer and the mining wind speed sensor communicate via CARIBUS. Within the shielded darkroom are machine vision inspection equipment and a sound level meter. The machine vision inspection equipment communicates with the host computer via Modbus TCP, while the sound level meter's communication interface uses RS232 to RS485. Machine vision inspection equipment is used to inspect the appearance of LED digital tubes used in mining wind speed sensors. Compared to the human eye, machine vision inspection equipment offers advantages such as high speed, accuracy, repeatability, and long-term stability. Applying machine vision technology to defect detection in LED digital tube production can significantly improve the accuracy and speed of product quality control. Machine vision inspection equipment uses a high-resolution industrial camera, coupled with a megapixel industrial lens and machine vision image processing software, to inspect the characters on the surface of LED digital tubes. If a defect is detected, the machine vision inspection equipment sends the test results to a host computer.

[0075] The interfaces of the mine wind speed sensor in this embodiment all use five-core aviation sockets, and the connection method adopts PLT-165-R-ZJ. The interface description of the mine wind speed sensor is shown in Table 1.

[0076] Table 1

[0077]

[0078] The withstand voltage test module includes a withstand voltage tester and a fixture. The fixture is used to secure the mining wind speed sensor. The withstand voltage tester is connected to the mining wind speed sensor via a five-core aviation plug connector, which is then connected to a host computer. Before the test, a barcode scanner is used to scan the QR code on the mining wind speed sensor to facilitate the subsequent storage of test data. The mining wind speed sensor to be tested is placed in the withstand voltage test position and clamped with the fixture. After clamping, a push mechanism inserts the five-core aviation plug connector into the mining wind speed sensor's interface to establish an electrical connection with the withstand voltage tester. The host computer then sends a signal to the withstand voltage tester to initiate the withstand voltage test. The withstand voltage test data is stored in the host computer.

[0079] The performance test module includes a programmable power supply, a programmable oscilloscope, a protocol converter board, and a terminal block. The programmable power supply and programmable oscilloscope are connected to the terminal block, which in turn is connected to the terminal block. The terminal block is connected to the mine wind speed sensor via a five-core aviation connector. Because different test instruments use different communication signal types, the protocol converter board converts these signals, enabling smooth communication between the test instrument and the host computer. The mine wind speed sensor is placed in the performance test position and secured with a fixture. A push mechanism inserts the five-core aviation connector into the sensor's connector, establishing an electrical connection with the terminal block. The terminal block communicates with the host computer via the protocol converter board. The host computer retrieves the test program and sends it to the programmable power supply and programmable oscilloscope. The programmable power supply tests the mine wind speed sensor's power supply, while the programmable oscilloscope tests the mine wind speed sensor's RS485 peak value, frequency, and switching output. Performance test data is then transmitted to the host computer for storage.

[0080] The specific items of functional testing are shown in Table 2.

[0081] Table 2

[0082]

[0083]

[0084] The voltage resistance test and performance test are integrated in one station, which can improve the test efficiency. After the functional test is completed, the ACV logistics vehicle 2 transports the mining wind speed sensor to the wind tunnel test station 5 for wind tunnel testing. The wind tunnel test station 5 includes: a PLC controller, an annular wind tunnel, a variable frequency speed regulating fan, a wind speed feedback sensor and a temperature and humidity control module. The variable frequency speed regulating fan, the wind speed feedback sensor and the temperature and humidity control module are all connected to the PLC controller for communication. The variable frequency speed regulating fan is used to blow air into the annular wind tunnel, the wind speed feedback sensor is used to feedback the real-time wind speed in the annular wind tunnel, and the temperature and humidity control module is used to control the temperature and humidity in the annular wind tunnel. At the wind tunnel test station 5, the mining wind speed sensor is mainly subjected to zero point calibration, linear calibration and verification of eight linear calibration points, as shown in Table 3.

[0085] Table 3

[0086]

[0087] Specifically, the PLC controller can run the Codesys system. The wind speed feedback sensor has an accuracy of ±0.1 m / s. The mine wind speed sensor supports the CARIBUS protocol and has an output signal range of 0-15 m / s. During zero-point calibration, the PLC controller shuts down the variable-frequency speed-regulating fan and initiates the environmental stabilization procedure (allowing the environment to stand for 30 seconds). At this point, the wind speed in the annular wind tunnel should be 0 m / s. The wind speed feedback sensor monitors wind speed in real time. If the wind speed feedback sensor value fluctuates by ±0.05 m / s, the fan is fine-tuned. After the environment stabilizes, the mine wind speed sensor measures speed, continuously outputting 10 sets of data at 1-second intervals and sending the monitored values ​​to the host computer. The host computer calculates the average value. If the average value deviates from 0 m / s by more than ±0.1 m / s, the PLC controller automatically sends a zero-point correction command to the mine wind speed sensor. After correction, the test process is repeated until the deviation is ≤ ±0.05 m / s.

[0088] During linear calibration, the PLC controller controls the variable-frequency speed-adjustable fan at 9 m / s. It initiates an environmental stabilization program to stabilize the wind speed within the annular wind tunnel at 9 m / s. If the wind speed feedback sensor's value fluctuates by ±0.05 m / s, the fan is fine-tuned. Once the environment stabilizes, the mining wind speed sensor measures speed, continuously outputting 10 sets of data every one second and sending the monitored values ​​to the host computer. The host computer calculates the average value. If the average value deviates from 9 m / s by more than ±0.1 m / s, the PLC controller automatically sends a correction command to the mining wind speed sensor. After correction, the test process is repeated until the deviation is ≤ ±0.05 m / s.

[0089] During linearity verification, Xi'an presets eight target wind speed values: 0m / s, 0.4m / s, 1.0m / s, 3.0m / s, 6.0m / s, 9.0m / s, 12.0m / s, and 15.0m / s. A PLC controller controls the variable-frequency speed-regulating fan to operate at each of the eight target wind speed values. The wind speed feedback sensor monitors the wind speed in real time. Once the wind speed stabilizes (less than ±0.1m / s), the system begins collecting data from the mine wind speed sensor. The output value of the mine wind speed sensor is read and compared with the actual wind speed in the wind tunnel to calculate the linearity error. If the linearity error is greater than 1%, the deviation is recorded and a calibration coefficient is generated, which is then written to the mine wind speed sensor via CARIBUS.

[0090] When conducting reverse wind speed verification, the PLC controller controls the frequency conversion speed regulation fan to rotate in the opposite direction, repeats the linear calibration process, and determines whether the mine wind speed sensor can identify positive and negative airflows. When conducting a dynamic response test, the wind speed in the annular wind tunnel is controlled to step from 0m / s to 10m / s, and the response time of the mine wind speed sensor (the time required to reach 90% of the target value) is recorded. Response time standard: response time ≤ 2 seconds. Environmental adaptability test: The temperature and humidity control module simulates the mine environment (temperature 40°C, humidity 85%), and repeats the zero point and linear calibration. Alarm function verification: Trigger an over-limit wind speed (such as 15.5m / s) and check the sound and light alarm signal of the mine wind speed sensor (sound intensity ≥ 80dB@1m, light signal visible at 20m).

[0091] In this embodiment, the data frame format of the CARIBUS communication protocol is:

[0092]

[0093] Function code example: 0x03: read sensor data (wind speed value); 0x06: write calibration parameters.

[0094] Exception handling mechanism:

[0095] Communication timeout: If there is no response within 3 seconds, the PLC controller will resend the command (up to 3 times). If it fails, the alarm "ERR-485" will be triggered.

[0096] Wind speed deviation: If the deviation between the actual wind speed and the target value is greater than 5% for 10 seconds, the PLC controller will pause the test and prompt "Wind tunnel out of control".

[0097] Sensor failure: If calibration fails three times in a row, the mining wind speed sensor will be marked as "defective" and pushed to the MES system.

[0098] Example 2

[0099] like Figure 5As shown, this embodiment provides an automated testing method for a mine wind speed sensor, comprising the following steps: S1. The circuit board of the mine wind speed sensor is placed in an initial inspection station 1 for inspection. Passing circuit boards are transported by an AGV logistics vehicle 2 to a three-dimensional warehouse for storage. S2. The passing circuit boards are transported by the AGV logistics vehicle 2 to an assembly station 3, where a staff member assembles the mine wind speed sensor. The assembled mine wind speed sensor is then transported to a functional inspection station 4. S3. At the functional inspection station 4, the mine wind speed sensor undergoes a withstand voltage test and a performance test. Passing mine wind speed sensors are transported to a wind tunnel inspection station 5. S4. At the wind tunnel inspection station 5, the mine wind speed sensor undergoes a wind tunnel test. Passing mine wind speed sensors are transported by an AGV logistics vehicle 2 to an aging test station 6. S5. At the aging test station 6, the mine wind speed sensor undergoes an aging test. Passing mine wind speed sensors are transported by an AGV logistics vehicle 2 to a final inspection station. S6. At the final inspection station, the mining wind speed sensor is subjected to final quality inspection, and the mining wind speed sensor that passes the final inspection is packaged and stored.

[0100] In step S3, a voltage test is performed on the mining wind speed sensor, including: placing the mining wind speed sensor in a voltage test position, clamping the mining wind speed sensor with a fixing fixture, inserting the five-core aviation plug connector into the connection port of the mining wind speed sensor by a pushing mechanism to realize electrical connection with the voltage tester, the host computer sends a voltage test signal to the voltage tester, the voltage tester performs a voltage test on the mining wind speed sensor, and the voltage test data is sent to the host computer for storage.

[0101] In step S3, a performance test is performed on the mining wind speed sensor, including: placing the mining wind speed sensor at a performance test position, clamping the mining wind speed sensor with a fixing fixture, inserting a five-core aviation plug connector into the connection port of the mining wind speed sensor by a pushing mechanism to realize electrical connection with the terminal block, the terminal block communicates with the host computer through the protocol conversion board, the host computer retrieves the test program and sends it to the programmable power supply and the programmable oscilloscope, the programmable power supply tests the power supply of the mining wind speed sensor, and the programmable oscilloscope tests the RS485 peak value, frequency, and switch output of the mining wind speed sensor; the performance test data is sent to the host computer for storage.

[0102] In step S4, a wind tunnel test is performed on the mine wind speed sensor, including: the PLC controller sends a signal to the variable frequency speed regulation fan to shut down, starts the environmental stabilization program, and performs zero point calibration on the mine wind speed sensor; the PLC controller sends a signal to the variable frequency speed regulation fan to control the variable frequency speed regulation fan to run at 9m / s and starts the environmental stabilization program; the wind tunnel feedback sensor detects the wind speed in the annular wind tunnel in real time; the PLC controller reads the output value of the mine wind speed sensor in real time, continuously collects n groups of data and calculates the average value to perform linear calibration on the mine wind speed sensor.

[0103] Wind tunnel testing of the mine wind speed sensor also includes: setting the target wind speed value to 0m / s, 0.4m / s, 1.0m / s, 3.0m / s, 6.0m / s, 9.0m / s, 12.0m / s, and 15.0m / s; the PLC controller sends the target wind speed value to the wind tunnel controller and uses the PID algorithm to dynamically adjust the speed of the variable frequency speed control fan; the wind tunnel feedback sensor detects the wind speed in the circular wind tunnel in real time, and after the wind speed stabilizes, the PLC controller reads the output value of the mine wind speed sensor; the output value of the mine wind speed sensor is compared with the target wind speed value, and the linear error is calculated. If the linear error is greater than 1%, the mine wind speed sensor needs to be calibrated.

[0104] For the parts of this embodiment that are the same as those of the first embodiment, please refer to the description of that part of the embodiment, which will not be repeated here.

[0105] In summary, the automated testing system and automated testing method for a mine wind speed sensor of the present invention have the following advantages:

[0106] (1) Improved efficiency

[0107] Shortened testing cycles: The automated testing system significantly reduced the testing time for a single mining wind speed sensor from 18.5 minutes to 9 minutes, a 51% improvement in efficiency. The cycle time for testing one-way wind speed sensors during full-unit testing was reduced from 15 minutes to 8 minutes, a 53% improvement in efficiency; the cycle time for testing two-way wind speed sensors was reduced from 22 minutes to 11 minutes, also a 53% improvement in efficiency. This significantly increased production capacity, increasing annual production capacity from 5,000 units to 9,000 units, an increase of over 80%.

[0108] Reduced staff requirements: The number of test process operators was reduced from 2 to 1, a 50% reduction in staff requirements and lowered labor costs.

[0109] (2) Quality Assurance

[0110] Improved test coverage: The automated testing system achieved 100% test coverage, a qualitative leap compared to the 70% coverage of previous manual testing, effectively reducing the risk of defect escape and ensuring more reliable product quality.

[0111] Reduced defective rate: After implementing the automated testing system, product quality has been significantly improved, with the defective rate reduced from 2% to 0. This has effectively reduced the production of defective products caused by human operational errors and insufficient equipment accuracy, and improved the market competitiveness of products.

[0112] (3) Data management and collaboration

[0113] Automatic Data Collection and Integration: Test data is automatically collected and integrated through the MES system, reducing manual entry errors and ensuring the accuracy of the data source. Test data is tied to the production process, and the MES system can monitor quality parameters at every stage in real time, providing strong data support for production process optimization and quality control.

[0114] Data Sharing and Visualization: Test data is converted into visual charts to help management quickly identify production bottlenecks and quality risks. Furthermore, through system integration, test data is shared across R&D, production, and quality departments, improving overall collaboration efficiency and providing data support for quality traceability, product improvement, and other tasks.

[0115] (4) Production process optimization

[0116] Production line layout optimization: By analyzing process flows, we re-arranged production lines and automated equipment. This created a continuous process flow, reduced unnecessary movement of personnel and materials, and improved production efficiency.

[0117] Logistics route optimization: Functional testing and performance calibration work together to increase the beat matching rate to 95%. A circular logistics route was designed based on the production line layout. By linking the WCS with the MES, dynamic task allocation for AGVs and efficient material flow were achieved, avoiding route conflicts and improving logistics efficiency.

[0118] With the above-described preferred embodiments of the present invention as a guide, and with reference to the above description, relevant personnel are fully capable of making various changes and modifications without departing from the technical spirit of this invention. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. An automated testing system for a mine wind speed sensor, characterized in that: include: The initial inspection station (1) is used to inspect the circuit boards of the mine wind speed sensor, and the qualified circuit boards are transported by the AGV logistics vehicle (2) to the stereoscopic warehouse for storage; An assembly station (3) is used to assemble a circuit board and electronic components to form a mine wind speed sensor; Functional testing station (4), used for performing functional testing on the assembled mining wind speed sensor; A wind tunnel testing station (5) is used to perform wind tunnel testing on the mining wind speed sensor that has passed the functional test; An aging test station (6) is used to perform an aging test on a mining wind speed sensor that has passed the performance test; The final inspection station is used to conduct final inspection on the mining wind speed sensors that have passed the aging test, and the mining wind speed sensors that have passed the final inspection are packaged and stored; The initial inspection station (1), the assembly station (3), the functional inspection station (4), the wind tunnel inspection station (5), and the aging test station (6) form a circular moving line.

2. The automated testing system for a mine wind speed sensor according to claim 1, wherein: The functional detection station (4) includes: a host computer, a voltage test module and a performance test module. The voltage test module and the performance test module are both communicatively connected to the host computer. The voltage test module is used to perform a voltage test on the mine wind speed sensor and transmit the test data to the host computer. The performance test module is used to perform a performance test on the mine wind speed sensor and transmit the test data to the host computer.

3. The automated testing system for a mine wind speed sensor according to claim 2, wherein: The wind tunnel detection station (5) includes: a PLC controller, an annular wind tunnel, a variable frequency speed regulating fan, a wind speed feedback sensor and a temperature and humidity control module. The variable frequency speed regulating fan, the wind speed feedback sensor and the temperature and humidity control module are all connected to the PLC controller for communication. The variable frequency speed regulating fan is used to blow air into the annular wind tunnel. The wind speed feedback sensor is used to feedback the real-time wind speed in the annular wind tunnel. The temperature and humidity control module is used to control the temperature and humidity in the annular wind tunnel.

4. The automated testing system for a mine wind speed sensor according to claim 2, wherein: The withstand voltage test module includes: a withstand voltage tester and a fixing fixture, the fixing fixture is used to fix the mining wind speed sensor, the withstand voltage tester is connected to the mining wind speed sensor through a five-core aviation plug connector, and the withstand voltage tester is connected to the host computer.

5. The automated testing system for a mine wind speed sensor according to claim 2, wherein: The performance test module includes: a programmable power supply, a programmable oscilloscope, a protocol conversion board and a wiring board. The programmable power supply and the programmable oscilloscope are both connected to the wiring board, the protocol conversion board is connected to the wiring board, and the wiring board is connected to the mining wind speed sensor through a five-core aviation plug connector.

6. An automated testing method for a mine wind speed sensor, characterized in that: The following steps are involved: S1. Place the circuit board of the mining wind speed sensor in the initial inspection station (1) for inspection. The qualified circuit boards are transported to the stereoscopic warehouse for storage by the AGV logistics vehicle (2); S2, the AGV logistics vehicle (2) transports the qualified circuit board to the assembly station (3), and the staff assembles the mining wind speed sensor as a whole, and the assembled mining wind speed sensor is sent to the function testing station (4); S3, in the functional testing station (4), the mine wind speed sensor is subjected to a pressure test and a performance test, and the mine wind speed sensor that has passed the test is transported to the wind tunnel testing station (5); S4. Performing a wind tunnel test on the mining wind speed sensor in the wind tunnel testing station (5). The mining wind speed sensor that passes the test is transported to the aging test station (6) by the AGV logistics vehicle (2); S5. In the aging test station (6), the mining wind speed sensor is subjected to an aging test, and the mining wind speed sensor that has passed the test is transported to the final inspection station by the AGV logistics vehicle (2); S6. In the final inspection station, the mining wind speed sensor is subjected to final quality inspection, and the mining wind speed sensor that has passed the final inspection is packaged and stored.

7. The automated testing method for a mine wind speed sensor according to claim 6, wherein: In step S3, a pressure test is performed on the mine wind speed sensor, including: Place the mining wind speed sensor in the voltage test position, clamp and fix the mining wind speed sensor with a fixing fixture, insert the five-core aviation plug connector into the connection port of the mining wind speed sensor by the pushing mechanism to realize electrical connection with the voltage tester, and the host computer sends a voltage test signal to the voltage tester. The voltage tester performs a voltage test on the mining wind speed sensor, and the voltage test data is sent to the host computer for storage.

8. The automated testing method for a mine wind speed sensor according to claim 7, wherein: In step S3, a performance test is performed on the mine wind speed sensor, including: The mining wind speed sensor is placed in the performance test position, clamped and fixed by a fixing fixture, and the five-core aviation plug connector is inserted into the connection port of the mining wind speed sensor by a pushing mechanism to realize electrical connection with the terminal block. The terminal block communicates with the host computer through the protocol conversion board. The host computer retrieves the test program and sends it to the programmable power supply and programmable oscilloscope. The programmable power supply tests the power supply of the mining wind speed sensor, and the programmable oscilloscope tests the RS485 peak value, frequency, and switch output of the mining wind speed sensor; the performance test data is sent to the host computer for storage.

9. The automated testing method for a mine wind speed sensor according to claim 6, wherein: In step S4, a wind tunnel test is performed on the mining wind speed sensor, including: The PLC controller sends a signal to the variable frequency speed regulating fan to shut down, starts the environmental stabilization program, and performs zero point calibration on the mine wind speed sensor; The PLC controller sends a signal to the variable frequency speed regulation fan, controls the variable frequency speed regulation fan to run at 9 m / s, and starts the environmental stabilization program; the wind tunnel feedback sensor detects the wind speed in the annular wind tunnel in real time; the PLC controller reads the output value of the mining wind speed sensor in real time, continuously collects n groups of data and calculates the average value to perform linear calibration on the mining wind speed sensor.

10. The automated testing method for a mine wind speed sensor according to claim 9, wherein: Wind tunnel testing of mining wind speed sensors also includes: Set the target wind speed to 0m / s, 0.4m / s, 1.0m / s, 3.0m / s, 6.0m / s, 9.0m / s, 12.0m / s, and 15.0m / s; The PLC controller sends the target wind speed value to the wind tunnel controller and uses the PID algorithm to dynamically adjust the speed of the variable frequency speed regulating fan; the wind tunnel feedback sensor detects the wind speed in the annular wind tunnel in real time. After the wind speed stabilizes, the PLC controller reads the output value of the mine wind speed sensor; Compare the output value of the mine wind speed sensor with the target wind speed value and calculate the linear error. If the linear error is greater than 1%, the mine wind speed sensor needs to be calibrated.

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