Automatic test system for electromagnetic flow converter

Abstract

The invention relates to the technical field of electromagnetic flow converters, in particular to an electromagnetic flow converter automatic test system, which comprises a large screen display module, a data server module, a workstation module, a serial port converter module and a semi-finished product test cabinet module, and is characterized in that the large screen display module is used for displaying production line data statistical information in real time; the data server module deploys a database, is in communication connection with the large screen display module and is used for storing operation management data, test cases, test results and analysis data; the work station module deploys test system software and is in communication connection with the data server module to serve as a system operation platform. According to the invention, an efficient data management and visual data server module is adopted to support local or cloud deployment, and a data storage, backup and authority management system is configured, so that full-life-cycle management of test data and operation logs is realized, and data security and traceability are guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electromagnetic flow transducer, in particular to an automatic test system for electromagnetic flow transducer. BACKGROUND

[0002] As a core equipment in the field of industrial measurement and control, electromagnetic flow transducer is widely used in key industries such as petroleum chemical industry, water conservancy, food and medicine, environmental protection monitoring, etc. The accuracy of its performance parameters directly affects the stability of industrial process and the reliability of measurement data. The device measures the flow of conductive liquid through electromagnetic induction principle, and needs to accurately calibrate and test key parameters such as signal amplification multiple, zero drift coefficient, range linearity and anti-interference ability in the production process. With the improvement of industrial automation level, the demand for electromagnetic flow transducer is increasing year by year, and the annual compound growth rate of such equipment in the past five years is 18.7%, which puts higher requirements on the efficiency and quality control of production and manufacturing links. Currently, the industry generally adopts manual operation mode for transducer parameter calibration test, and the specific process includes: connecting oscilloscope, signal generator, power meter and other discrete instruments manually, applying standard excitation signal to each transducer to be tested one by one, manually reading the display panel data and recording, and then calculating the calibration coefficient according to the empirical formula. This traditional testing method has multiple technical bottlenecks: Low efficiency: the complete test cycle of a single device is as long as 45-60 minutes, and if calculated according to an 8-hour work system, a single technician can test only 8-10 devices per day, which is difficult to meet the demand of large-scale production. The actual test data of a certain medium-sized instrument enterprise shows that in a production line with a monthly capacity of 5000 units, the test link becomes the key bottleneck restricting the capacity expansion, resulting in a delivery cycle extension of 15-20 days. Measurement accuracy depends on manual operation: operators need to frequently adjust knobs, operate keys and read data, and visual fatigue and differences in operation habits will introduce human errors. According to the comparison test by the measurement institution, the repeatability error of zero drift parameter in manual test is ±0.3%FS, which is far beyond the industry standard requirement of ±0.1%FS, seriously affecting product consistency. Data management is missing: paper records and Excel table information input method make it difficult to associate test data with production batch, component number and other information in real time, and it is difficult to realize whole life cycle quality traceability. A recall case shows that the missing test data caused the failure to locate the fault batch, and the enterprise suffered a direct economic loss of more than 2 million yuan. Safety risk is high: the test process involves 220V AC power supply, high frequency signal source and other dangerous energy, and manual wiring operation has the risk of electric shock and instrument damage. According to the industry statistics in the past three years, the equipment damage rate caused by misoperation is 5.2%, and the annual average number of personnel minor injury accidents is 3.7 per ten thousand working hours.

[0003] In view of the above problems, an electromagnetic flow converter automatic test system is provided. SUMMARY

[0004] The electromagnetic flow converter automatic test system is provided to solve the problems in the background art.

[0005] To achieve the above object, the electromagnetic flow converter automatic test system comprises the following technical solutions. The electromagnetic flow converter automatic test system comprises: A large-screen display module is configured to display production line test data, statistical reports and abnormal early warning information in real time. A data server module is configured to deploy a database and connect the large-screen display module through network communication, configure a data storage unit, a data interaction interface unit and a data backup unit, and store test case libraries, historical test results and statistical analysis data. A workstation module is configured to deploy a test system software and connect the data server module through communication, serve as an operation platform for test process control and data analysis, and comprise a test case management unit, a test parameter configuration unit and a test result determination unit. A serial converter module is independent of the workstation module and a semi-finished product test cabinet module, is connected to the network port of the workstation module and the serial / 485 interface of the semi-finished product test cabinet module through communication, supports Modbus RTU / ASCII protocol conversion and multi-thread concurrent data processing. The semi-finished product test cabinet module comprises at least one set of test mechanisms, each set of test mechanisms comprises a semi-finished product testing machine and a measured device connected thereto, and the semi-finished product testing machine is connected to the workstation module through the serial converter module to realize bidirectional data transmission.

[0006] Preferably, the semi-finished product testing machine comprises: A multifunctional processing module is integrated with a controllable signal source, an excitation output module, a signal input module and a communication module, the controllable signal source is configured with a high-precision DAC digital-analog converter to generate a standard flow simulation signal. A detection module comprises an analog AI current detection module, a digital DI switch detection module and a digital DI frequency detection module, which are respectively configured to monitor current signals, switch states and frequency signals in real time. A control unit MCU is electrically connected to the multifunctional processing module and the detection module, is configured with a signal processing algorithm, is used to synchronously collect, calibrate and identify abnormal signals, and is connected to the serial converter module through a serial communication module to realize data interaction. The output module includes a transmission output module, an alarm output module and a frequency output module, and is configured to output test instructions according to detection results. The power module is configured with a surge protection circuit and a backup battery, and provides stable working power for the multifunctional processing module, the detection module and the control unit.

[0007] Preferably, the data server module is a local PC server or a cloud server, the data interaction interface unit supports the workstation module to call or write data through a RESTful API or a message queue protocol, and the data backup unit supports automatic backup of test data and operation logs at a fixed time.

[0008] Preferably, the serial converter module has an adaptive baud rate identification function and at least four independent serial / 485 channels, each channel is configured with an optoelectronic isolation circuit, and electrical isolation and concurrent communication between the workstation module and multiple semi-finished product testing machines are realized.

[0009] Preferably, the semi-finished product testing cabinet module is internally provided with physically isolated test stations, each station is configured with an independent power switch, a magnetic type conductive connector and an anti-reverse connection signal interface, the magnetic type conductive connector supports quick plugging of the device under test, the plugging force is ≤5N and the contact resistance is ≤10mΩ.

[0010] Preferably, the signal processing algorithm executed by the control unit MCU includes: Kallman filtering is performed on the 4-20mA signal collected by the analog quantity AI current detection module to eliminate electromagnetic interference noise; Based on the state signal of the digital quantity input DI switch detection module, the excitation output parameters of the multifunctional processing module are dynamically adjusted; The pulse signal collected by the digital quantity input DI frequency detection module is compared with a preset frequency range to realize linear calibration of the flow sensor.

[0011] Preferably, the communication module supports Modbus RTU, HART and Profibus-DP protocols, the serial communication module uses an RS-485 interface, the communication rate is adaptively in the range of 2400bps-115200bps, and has a data frame check and retransmission mechanism.

[0012] Preferably, the workstation module includes: The test instruction automatic generation unit is configured to calculate test parameters and generate a test instruction sequence according to a preset test case; The test instruction automatic generation unit includes: The test parameter calculation module is configured to use the formula a range of expected values is calculated; wherein, is a sensitivity coefficient, is a bias coefficient, is a tolerance coefficient; an instruction sequence generation module configured to generate an instruction sequence containing a voltage test command and an expected range according to the calculated test parameters; a data receiving and parsing unit configured to receive and parse multi-channel detection data fed back by the semi-finished product testing machine in real time; a threshold comparison and determination unit configured to analyze the parsed data based on a threshold comparison algorithm to generate a test result determination; the threshold comparison and determination unit comprises: a signal processing module configured to perform filtering and down-sampling processing on the original detection data; and a Z-score calculation module configured to use the formula to calculate the standard score of the processed data; wherein, X is an observation value, μ is a sample mean, and σ is a sample standard deviation; an abnormality determination module configured to determine that the data is abnormal when the absolute value of the standard score exceeds a preset threshold; an abnormality processing unit configured to trigger an alarm output module of the semi-finished product testing machine when the detection data is abnormal; the abnormality processing unit comprises: a risk assessment module configured to use the formula Risk = Deviation × Duration × Impact Factor to calculate an abnormality risk score, wherein Deviation is a deviation rate, Duration is an abnormality duration, and Impact Factor is a test item impact factor; an alarm triggering module configured to trigger an alarm output of a corresponding level according to the risk score level; a data storage unit configured to store abnormal data markers to a data server module; the data storage unit comprises: a test identifier and a testing machine identifier; an abnormality occurrence timestamp; processed detection data and corresponding Z-score values; a risk score and a deviation rate index; test parameter metadata.

[0013] Preferably, the large-screen display module comprises: a real-time data visualization unit that uses the ECharts chart library to generate a test data trend chart, a qualified rate column chart, and an abnormality distribution heat map; Test progress monitoring unit dynamically displays the real-time status, test completion rate and estimated remaining time of each test station; The abnormal warning unit triggers an audible and visual alarm based on the preset threshold, and sends SMS / email notifications to designated management personnel.

[0014] Preferably, the detection module of the semi-finished product testing machine adopts time-sharing multiplexing sampling technology, and the synchronous acquisition period of current, switch status and frequency signal is less than 10ms, so that the measurement accuracy of multi-parameter mixed detection is improved by more than 20% compared with single current detection.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The efficient data management and visualization data server module supports local / cloud deployment, configures data storage, backup and permission management systems, and implements full lifecycle management of test data and operation logs, ensuring data security and traceability. The large-screen display module dynamically presents production line data in real time, using visual charts to help managers quickly grasp test progress and equipment status, improving decision-making efficiency.

[0016] The semi-finished product tester with multi-dimensional automated testing capabilities integrates modules such as controllable signal source, AI current detection, and DI switch / frequency detection. It can simultaneously monitor multiple types of signals such as current, switch status, and frequency. Combined with relay switches, it realizes automatic control of circuit on-off, covering the core functional test scenarios of electromagnetic flow converters, ensuring test accuracy and comprehensiveness.

[0017] Highly compatible and stable communication, the serial port converter module supports Modbus RTU / ASCII and RS-232 / RS-485 mixed protocols. It features adaptive baud rate and multi-threaded concurrent processing capabilities, and can stably convert at least four groups of serial port / 485 signals. It is compatible with the communication requirements of different devices under test, resolving signal conflicts during parallel testing of multiple devices and improving system versatility.

[0018] The semi-finished test cabinet with convenient hardware design adopts an isolated workstation design, equipped with an independent power switch, magnetic conductive connector and signal interface, which supports fast plugging and unplugging of the device under test and electrical isolation, significantly shortens the power-on and power-off time of the equipment and the complexity of wiring, reduces the error rate of manual operation, and adapts to the efficient testing needs in mass production environments.

[0019] The high-reliability and stability power module integrates a surge protection circuit and backup battery to resist grid fluctuations and provide battery life during power outages, ensuring that the test process is not affected by external power supply anomalies. The system processes test data in real time through the MCU and communicates with the workstation to achieve closed-loop control of the test process, reducing errors caused by manual intervention and improving the credibility of test results. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Schematic diagram of the system architecture of the present invention; Figure 2 This is a schematic diagram of the semi-finished product testing machine architecture of the present invention; Figure 3 This is a schematic diagram of the workstation architecture of the present invention; Figure 4 This is a schematic diagram of the communication module of the present invention; Figure 5 This is a schematic diagram of the excitation current detection module of the present invention; Figure 6 This is a schematic diagram of the reference power supply circuit of the present invention; Figure 7 Schematic diagram of two types of wiring terminals for analog output of Huahai flowmeter of the present invention; Figure 8 Schematic diagram of the current signal sampling circuit of the present invention; Figure 9 This is a wiring diagram of the active output relay of the present invention; Figure 10 This is a wiring diagram of the wire-system passive output relay of the present invention; Figure 11 Schematic diagram of the AD sampling circuit of the present invention; Figure 12 This is a schematic diagram of the isolation circuit of the present invention; Figure 13 This is a schematic diagram of the serial communication circuit of the present invention; Figure 14 This is a schematic diagram of the flow meter alarm output circuit of the present invention; Figure 15 This is a schematic diagram of a high alarm active output detection circuit of the present invention; Figure 16 This is a schematic diagram of the power switching circuit of the present invention; Figure 17 Schematic diagram of a local low alarm detection circuit 1 of the present invention; Figure 18 This is a schematic diagram of a local low alarm detection circuit 2 of the present invention; Figure 19 This is a schematic diagram of the alarm detection power supply circuit of the present invention; Figure 20 Schematic diagram of the sampling and comparison circuit 1 of the present invention; Figure 21 Schematic diagram of sampling and comparison circuit 2 of the present invention; Figure 22 This is a schematic diagram of the amplifier circuit of the present invention; Figure 23 This is a schematic diagram of the power switching circuit when the frequency is passively outputted according to the present invention. DETAILED DESCRIPTION

[0021] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0022] Example 1: See also Figures 1-23 , electromagnetic flow converter automatic testing system, including:.

[0023] Electromagnetic flow converter automatic testing system, including: Large screen display module, used to display production line data statistics in real time; The data server module deploys the database and communicates with the large-screen display module to store operation management data, test cases, test results, and analysis data; The data server module is a local PC server or cloud server. The data interaction interface unit supports the workstation module to retrieve or write data through RESTful API or message queue protocol. The data backup unit supports scheduled automatic backup of test data and operation logs.

[0024] The workstation module deploys the test system software and communicates with the data server module, serving as the system operating platform.

[0025] Serial port converter module, which connects the workstation module and the semi-finished test cabinet module to realize signal conversion from network port to multiple serial ports or 485 communication ports; The serial port converter module has adaptive baud rate recognition function and at least 4 independent serial port / 485 channels. Each channel is equipped with optoelectronic isolation circuit to achieve electrical isolation and concurrent communication between the workstation module and multiple semi-finished product testers. A semi-finished test cabinet module includes at least one set of test mechanisms, each set of test mechanisms correspondingly connected to at least one device under test; Physically isolated test stations are set inside the cabinet of the semi-finished test cabinet module. Each station is equipped with an independent power switch, a magnetic conductive connector and an anti-reverse signal interface. The magnetic conductive connector supports quick plugging and unplugging of the device under test.

[0026] a test instruction automatic generation unit configured to calculate test parameters according to preset test cases and generate a test instruction sequence; Test instruction automatic generation unit, including: The test parameter calculation module is configured based on the basic parameters in the preset test case, using the formula Calculate the expected value range; wherein, is a sensitivity coefficient, is a bias coefficient, is a tolerance coefficient; an instruction sequence generation module configured to generate an instruction sequence containing a voltage test command and an expected range according to the calculated test parameters; a data receiving and analyzing unit configured to receive and analyze multi-channel detection data fed back by the semi-finished product testing machine in real time; a threshold comparison and determination unit configured to analyze the analyzed data based on a threshold comparison algorithm to generate a test result determination; the threshold comparison and determination unit comprises: a signal processing module configured to filter and down-sample the original detection data; and a Z-score calculation module configured to calculate the standard score of the processed data using the formula ; wherein X is an observation value, μ is a sample mean, and σ is a sample standard deviation; an abnormality determination module configured to determine that the data is abnormal when the absolute value of the standard score exceeds a preset threshold; an abnormality processing unit configured to trigger an alarm output module of the semi-finished product testing machine when the detection data is abnormal; the abnormality processing unit comprises: a risk assessment module configured to calculate an abnormality risk score using the formula Risk = Deviation × Duration × Impact Factor, wherein Deviation is a deviation rate, Duration is an abnormality duration, and Impact Factor is a test item impact factor; an alarm triggering module configured to trigger an alarm output of a corresponding level according to a risk score level; a data storage unit configured to store abnormal data markers to a data server module; the data storage unit comprises: a test identifier and a testing machine identifier; an abnormality occurrence timestamp; processed detection data and corresponding Z-score values; a risk score and a deviation rate index; test parameter metadata.

[0027] Embodiment 2: As shown in Figure 2 each group of test mechanisms of the semi-finished product testing cabinet module comprises: a multifunctional processing module integrated with a controllable signal source, an excitation output module, a signal input module, and a communication module, the controllable signal source being configured with a high-precision DAC digital-to-analog converter for generating a standard flow simulation signal; The communication module supports Modbus RTU, HART and Profibus-DP protocols, the serial communication module uses RS-485 interface, the communication rate is adaptively in the range of 2400bps-115200bps, and has data frame checking and retransmission mechanism; The detection module includes analog AI current detection module, digital input DI switch detection module and digital input DI frequency detection module, which are respectively used for real-time monitoring of current signal, switch state and frequency signal; The detection module of the semi-finished product testing machine adopts time-sharing multiplexing sampling technology for synchronous collection of current, switch state and frequency signal; The control unit MCU is electrically connected with the multifunctional processing module and the detection module, is configured with a signal processing algorithm, is used for synchronous collection, calibration and abnormality discrimination of multiple detection signals, and realizes data interaction through the serial communication module and the serial converter module; The signal processing algorithm executed by the control unit MCU includes: Kallman filtering is performed on the 4-20mA signal collected by the analog AI current detection module to eliminate electromagnetic interference noise; Based on the state signal of the digital input DI switch detection module, the excitation output parameter of the multifunctional processing module is dynamically adjusted; The pulse signal collected by the digital input DI frequency detection module is compared with the preset frequency range to realize the linearity calibration of the flow sensor; The output module includes a transmitting output module, an alarm output module and a frequency output module, which are used for outputting test instructions according to detection results; The power module is configured with a surge protection circuit and a backup battery to provide stable working power supply for the multifunctional processing module, the detection module and the control unit.

[0028] The electromagnetic flow converter automatic testing system includes a large screen display module: The real-time data visualization unit generates test data trend chart, qualified rate column chart and abnormal distribution heat map by using ECharts chart library; The test progress monitoring unit dynamically displays the real-time state, test completion rate and expected remaining time of each test station; The abnormal early warning unit triggers sound and light alarm based on preset threshold and pushes short message / email notification to designated manager.

[0029] The controllable signal generator adopts a method of dividing the excitation signal to obtain it, and due to the high voltage and high frequency characteristics of the dual-frequency electromagnetic flowmeter, the excitation steady current is a switching power supply scheme, so the excitation coil must be connected in series in the excitation circuit.

[0030] The signal change gear adjustment method uses a magnetic latching relay to select the resistor (temperature drift selects 5PPM) network mode to switch the change.

[0031] Controllable signal generator circuit interface part: Interface Power supply Communication Input Output Characteristic 5V / 9V 485 Excitation signal Flow signal Pin number 2-pin 2-pin 2-pin 3-pin This part can be designed independently and controlled by the workstation, or it can be integrated into the test machine and deployed by the test machine. Considering the system structure of the whole machine test, it is more appropriate to integrate it into the test machine.

[0032] Air traffic control function test: This function only requires turning off the signal output of the controllable signal generator and reading the empty pipe status flag of the flowmeter under test. To consider dynamic verification, a simulation test with or without signal switching can be added to verify the empty pipe stability.

[0033] Read the air traffic control value and the PC makes a secondary judgment.

[0034] Excitation signal detection: This function is mainly to confirm whether the excitation circuit is normal, whether there is an excitation signal after the excitation coil is connected, and whether the current is stable.

[0035] For dual-frequency electromagnetic flowmeter products, an excitation current detection function is designed. After the excitation circuit is connected, the corresponding status of the flowmeter being measured can be read.

[0036] For instruments without this function, indirect detection can be considered. Since the controllable signal generator is obtained by dividing the excitation signal voltage, the excitation signal size can be calculated based on the signal acquisition results and the current gear position.

[0037] Signal sampling detection: This function is the core of the tester's inspection. First, the test recipe communication is used to set the required parameters for the instrument under test. Then, the controllable signal generator is controlled to sequentially generate six sets of signals. The instantaneous flow rate value of the flowmeter under test is read via communication. The maximum and minimum values ​​are taken from multiple readings to calculate repeatability deviation. The average value of each of the six signal sets is used to calculate linearity, accuracy, and calibration coefficients.

[0038] For efficiency reasons, we recommend using instantaneous values ​​for testing. For cumulative verification, pulse output counting can be combined with cumulative confirmation over a fixed time period. The cumulative raw value is calculated by converting the flow rate at the gear indicated by the signal to time.

[0039] All data during the test are packaged and uploaded to the workstation and saved to the data server for future reference.

[0040] Set flow switch to 10 m / s, check if the flow rate display is 10.000 m / s. If the error display is beyond ±0.003 m / s, the "factory calibration coefficient" value in the converter menu needs to be modified. And the value of "factory calibration coefficient" = 10.000 ± 0.003 m / s.

[0041] Set the flow switch to each flow rate stop of the flow switch, respectively, and check the linearity.

[0042] Transmitter output detection: This function includes calibration and testing. The detection tool involved is a high-precision ammeter, which is self-made on the test machine. The high-precision current acquisition circuit can use LU-14017 (8-channel acquisition) or use high-precision ADC devices combined with high-precision input resistors for acquisition. The acquisition accuracy meets the 0.05% level requirement.

[0043] Calibration is performed first. The flowmeter to be tested needs to be opened in communication manual mode. The high and low transmitter code values can be specified. Through high-precision current acquisition, the accurate current value is returned to the flowmeter output at this time. After 2 points are completed, the flowmeter can calculate the calibration slope and zero point deviation to complete the calibration.

[0044] Testing process, can be carried out independently, through the communication manual mode, to 5 transmitter output points, test the accuracy of the transmitter output. It can also be run as a whole, combined with the signal sampling detection process of 4.2.2.4, and the transmitter accuracy test is carried out at the same time.

[0045] Alarm output detection: This function is mainly to test whether the switch output is damaged and whether the alarm parameters meet the logic requirements. The detection tool involved is the switch state detection. Since a flowmeter has at most 2 DO outputs, each test machine realizes 2 DI acquisition, requiring the use of optocoupler isolation, adjusting the current limiting parameters of the optocoupler to meet the high and low level requirements.

[0046] Testing process, can be carried out independently, through the communication manual mode, to 5 transmitter output points, test the accuracy of the transmitter output. It can also be run as a whole, combined with the signal sampling detection process of 4.2.2.4, and the transmitter accuracy test is carried out at the same time.

[0047] Frequency output detection: This function is mainly to test whether the frequency output is damaged and whether the frequency signal characteristics are qualified. The detection tool involved is the frequency meter and amplitude detection. Since a flowmeter has at most 1 frequency output, each test machine realizes 1 frequency acquisition. The frequency value is obtained using the capture method, and the signal amplitude can be extracted using the peak detection circuit.

[0048] For signal amplitude does not need to collect accurate value, only need to confirm whether to exceed the required amplitude can be considered using the upper limit comparator to confirm the peak amplitude, the lower limit comparator to confirm the valley amplitude. Peak valley change frequency and signal frequency synchronization can be reliable operation.

[0049] Frequency capture method, this function uses 3 way capture for detection. Can calculate the frequency, peak valley pulse width time.

[0050] Test process, can be independent, through the communication manual mode, designated frequency output test. Can also be integrated operation, combined with 4.2.2.4 signal sampling detection process, frequency output test at the same time.

[0051] Communication function detection: The function is all the measured flow meter must be measured, also must be normal can be carried out project, measured flow meter must ensure that the communication parameters consistent agreement. Each test begins, first have test machine to the measured instrument to send hand (arbitrary one communication message), confirm the communication link is normal, can carry out other test. Communication link is not normal, 3 times can not communicate, prompt communication function is abnormal. At this time the detection parameters and hardware.

[0052] The whole test process will frequently communicate operation, so will statistics communication error rate as the communication function index.

[0053] Storage function detection: The function is to the measured instrument parameter change, cumulative result storage, read detection.

[0054] In the test process will design parameter change situation, or according to the test recipe to modify the specified parameters. After the test, to the measured flow meter power off, power on to read the corresponding parameters, confirm whether the power down before save value.

[0055] To the cumulative result in power off, power on, confirm whether consistent with the power down before.

[0056] Power management: The function is to the measured instrument power, on / off control, using relay control. Test process according to the selected test scheme example control, test end, automatic power off.

[0057] Example 3: The main core of the workstation is the test system software deployed on the workstation PC. Software contains test, data query, signal source maintenance, system settings, a total of 4 sub functions.

[0058] (1) system settings System settings include communication port management, user rights, tester management.

[0059] Communication port management is to set the correspondence of multiple communication serial ports of the system, and inform the system software of the system communication wiring for command operation according to the allocation.

[0060] User authority is to manage the software login account. The function use authority of the administrator, operator and viewer is set.

[0061] Test machine management is to set the corresponding number, address and operation instruction set of each test machine, so as to save PC operation by using tools such as code scanning gun.

[0062] (2) Signal source maintenance This part has two functions. One is manual signal output, which can specify the test machine to give the required signal, which is used for manual test signal source or product targeted test research. The other is maintenance and detection, which uses the confirmed product to access the system and go through the test process to verify whether the system has functional defects.

[0063] (3) Data query Test result query is to query the semi-finished product test result data of a certain product according to order, time period and product serial number. The test result of each product and the process test data can be queried.

[0064] Pass rate statistics is a query and statistics function. Report export is to export the file of the queried data or the test report of single test result.

[0065] (4) Test Since the test machine completes the test process of the smallest functional module unit, and the complete semi-finished product test is tested according to the specific test requirements considering the completeness, efficiency and other comprehensive factors. Therefore, the formula test scheme is adopted. Before testing, the test formula is selected, which includes test items and test parameters of each item. The software supports saving multiple formula schemes, and each set formula can be named and stored for next use, which can be directly selected and called.

[0066] Test start is the process that the system software automatically instructs the test machine to complete the test formula according to the operation before testing through communication instruction, reads the test result and saves it into the data server.

[0067] Test start process steps: A. Scan the bar code of the measured instrument with the scanning gun, and then manually connect the test machine. Multiple measured instruments are connected to the idle machine position in turn.

[0068] B. Scan the test group bar code with the scanning gun after connecting the group. Inform the system which group of test machines is used. The system defaults to perform communication handshake to confirm the online status of the test machine. The preparation is ready for testing.

[0069] C, select test formula. Can scan gun scan formula bar code.

[0070] D, scan start bar code, or click software start test button, start test.

[0071] E, during the test, the state area gives real-time progress prompt, and the problem site will give color prompt. The test process is calibrated first, then tested, and selected according to the formula.

[0072] F, with special parameter customization, the parameter table can be set first, and the default configuration parameter after the test is completed.

[0073] G, after the test is completed, the machine is automatically stopped, and according to the site prompt, the qualified condition can be directly observed, and the detailed information of each station can be queried by clicking.

[0074] Note: This part of the function can be customized according to production habits. For example, add order information, which can realize digital assistance of order progress.

[0075] (5) Data server The data server is mainly to install a database for the test system to design a database form. This database can be installed on the local workstation, or a separate server PC (to avoid accidental deletion on site), or deployed on a cloud server for remote business data support, such as sales personnel can check if the production plan has completed the required order test, and when the customer requires to provide product test report, directly export remotely.

[0076] All historical data on the workstation, statistical analysis, are all based on this data.

[0077] (6) Large screen display scheme Large screen display is a kind of data display platform for product production process management in production site or exhibition hall.

[0078] The content that can be displayed is, for example, monthly test amount, one-time pass rate, production test efficiency and test capacity change trend curve; current product state large graph under test; This part can be designed independently as software or WEB form and displayed on a large liquid crystal screen. The display effect is mainly in the form of graphics, such as curve, column chart, pie chart, flip plate data, etc.

[0079] Example 4: As shown in Figures 4-23 , the electromagnetic flow converter automatic test system further comprises: As shown in Figure 4 , the communication module comprises: Communication design two groups of 485 communication, using 2 ADM2483, to achieve isolation with the front, a group of host communication, a group of standard signal source and test machine communication, two groups of 485 power supply sharing a group of isolation power supply, through the IF0505S-W75 isolation module to achieve. Communication terminal design 2 groups, considering the system cascade and wiring is convenient, with the host communication terminal leaves 2 terminal. At the same time in order to facilitate debugging, two groups of communication control line increase communication indicator.

[0080] As Figure 5 shown, the excitation current detection module: Normal excitation current is positive and negative 250MA rectangular wave, in order to facilitate detection, let the excitation current through 1R resistance sampling, voltage becomes ±250mv, for easy identification, through the differential amplifier 10 times, to ±2.5V bidirectional rectangular wave, through 4 comparators, the first two comparison voltage lower limit threshold value is about ±2.3, to 2 half cycle positive rectangular wave, in the or gate, output a complete positive rectangular wave, for CPU capture, can identify the frequency of excitation signal, the latter 2 comparators for detecting excitation signal whether super limit, the upper limit threshold value is ±2.7V, if pulse output, signal limit, can be detected through IO port interrupt. Because of the small power consumption, -5V power supply using module ICL7660 to achieve.

[0081] As Figure 6 , Figure 7 , Figure 8 shown, 4~20MA analog input detection: According to the flowmeter analog output 4~20mA actual data, the accuracy is high, in full scale 20mA output, the error is within ±5μA, the accuracy is equivalent to 0.025%, considering to calibrate the actual input signal, the sampling accuracy is improved 1 times, to 0.01%, the effective bit of AD should be 13 bit, considering 16 bit above AD, at the same time considering the cost, select the 20 bit AD of single chip SH79F085 to realize analog input acquisition.

[0082] 4~20mA current input detection, active and passive signal access through relay switching, passive input needs to provide 24V power supply, because there are 2 kinds of wiring terminal when Huahai flowmeter analog passive output, 24V power supply also needs to be switched through the relay.

[0083] Considering the maximum current 22mA, sampling resistance is 1 ohm (low temperature drift), sampling voltage 22*1=22mV, using chip internal PGA amplification 50 times, 22mV*50=1.1V, in the reference voltage range.

[0084] Active and passive signal and power supply switching as follows: AsFigure 9 、 Figure 10 、 Figure 11 For the convenience of control, the control IO of the relay is controlled by the main CPU, and no communication with the slave CPU is needed when the relay needs to be switched each time.

[0085] SH79F085 is used as the slave CPU, which is equivalent to an ADC chip, and exchanges data with the main CPU through analog SPI communication. A pilot lamp is reserved to observe whether the CPU is running normally.

[0086] Considering isolation, a set of independent 24V power supply is provided for the AO module. The slave CPU is powered by 5V, and 24V is stepped down to 5V by 78M05 to power the CPU, as shown in Figure 12 .

[0087] As shown in Figure 13 , serial communication: The main system and AD acquisition communication adopt serial communication, and are isolated from the main system by optocoupler PC817.

[0088] As shown in Figure 14 、 Figure 15 , alarm output detection: The alarm output of the flowmeter is open-drain output, which is divided into high alarm and low alarm two-way output. Considering isolation from the main system, optocoupler PC817 is used to realize it.

[0089] When the high alarm output is on, U12 is on, the optocoupler conduction voltage is about 1.4V, the loop current I=(24-1.4) / (2.4K+1K)=6.6(mA), which meets the optocoupler conduction condition, and the power consumption of R50 is P=0.0066*0.0066*1K=0.04(W).

[0090] As shown in Figure 16 , passive detection of high alarm output: When passive, the detection circuit needs to be powered. When U11 is on, the bias voltage on R60 is 5.8V, the transistor Q15 is on, and Q14 is also on, and the 12V power supply powers the detection circuit.

[0091] When the high alarm output is on, U12 is on, the conduction voltage is 1.4V, D12 voltage drop is 0.7V, Q14 saturation voltage drop is 0.3V, loop current I=(12-1.4-0.7-0.3) / (100+470+470+1K)=4.7(mA), which meets the requirements.

[0092] When the high alarm output is off, the loop current I=(12-0.3-0.7-0.3) / (470+470+100)=10.2(mA), the power consumption of R57 / R59 is P=0.048(W), which meets the requirements.

[0093] When active output, control light coupling U11 is closed, triode Q15 is in the off state due to R60 grounding, Q14 base is also in the off state due to R53 pull-up, and +12V output is closed.

[0094] As shown in Figure 17 Alarm detection power supply: Alarm detection is isolated from the main system, and the isolation power supply is DC module IF0512S, which converts 5V to 12V. Alarm detection and frequency detection can share a set of power supplies.

[0095] Frequency / pulse output detection: Sampling comparison circuit: The frequency output contains active and passive. When active output, in order to detect the high level (+24V) amplitude, two resistors 500K and 100K are connected in parallel at the output end, sampling voltage is about 4V, when passive output, sampling voltage is about 2V, at this time the high level amplitude is about 11V. In order to ensure the detection of low level 1V, LM339 uses dual power supply, and the low level sampling is 0.16V.

[0096] Set the voltage value of VCMP. If the required frequency is captured on the CAP2 pin, it means that the amplitude output is normal, and the frequency and pulse width can be calculated. If it is pulse output, the number of pulses can be counted.

[0097] The high and low level amplitudes are detected by setting the VCMP value. Change the high and low threshold of VCMP. If the frequency can be captured, it means that the high and low level amplitudes are normal.

[0098] +12V power supply is reduced to +5V by 78L05, and +5V is converted to-5V by ICL7660 to provide positive and negative power supply for LM339.

[0099] PWM-DA circuit: The voltage value of VCMP can be set. Through PWM control of light coupling on-off, a certain duty cycle pulse is obtained. After double RC integration, a stable DC voltage is formed. The voltage range of VCMP is 0-5V, and the amplification circuit is reserved here.

[0100] Power supply control: The flowmeter power supply is divided into 220V and 24V, and HF140FF / 005 / 2Z relay is selected for switching. The 24V connects the normally closed contact, and the 220V connects the normally open contact to avoid simultaneous connection. J1 and J6 are 24V and 220V access terminals, and J5 is the power supply terminal output to the flowmeter.

[0101] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. The electromagnetic flow converter automatic testing system is characterized by: include: Large-screen display module, used for real-time visualization of production line test data, statistical reports and abnormal warning information; The data server module deploys a database and is connected to the large-screen display module via network communication. It is configured with a data storage unit, a data interaction interface unit, and a data backup unit for storing a test case library, historical test results, and statistical analysis data; The workstation module deploys the test system software and communicates with the data server module, serving as an operating platform for test process control and data analysis, including a test case management unit, a test parameter configuration unit, and a test result determination unit; A serial port converter module, independent of the workstation module and the semi-finished product test cabinet module, communicatively connects the network port of the workstation module and the serial port / 485 interface of the semi-finished product test cabinet module, and supports Modbus RTU / ASCII protocol conversion and multi-threaded concurrent data processing; The semi-finished product test cabinet module includes at least one group of test mechanisms, each group of test mechanisms includes a semi-finished product test machine and a corresponding tested device connected thereto; the semi-finished product test machine realizes bidirectional data transmission with the workstation module through the serial port converter module.

2. The automatic testing system for electromagnetic flow converter according to claim 1, characterized in that: The semi-finished product testing machine includes: A multifunctional processing module, integrating a controllable signal source, an excitation output module, a signal input module and a communication module. The controllable signal source is equipped with a high-precision DAC digital-to-analog converter to generate a standard flow analog signal; Detection module, including analog AI current detection module, digital input DI switch detection module and digital input DI frequency detection module, which are used to monitor current signal, switch status and frequency signal in real time respectively; A control unit MCU is electrically connected to the multi-functional processing module and the detection module, and is configured with a signal processing algorithm for synchronously collecting, calibrating, and distinguishing abnormalities of multiple detection signals, and realizing data exchange with the serial port converter module through the serial port communication module; Output module, including transmission output module, alarm output module and frequency output module, used to output test instructions according to the test results; The power supply module is equipped with a surge protection circuit and a backup battery to provide stable working power for the multi-functional processing module, the detection module and the control unit.

3. The automatic testing system for electromagnetic flow converter according to claim 2, characterized in that: The data server module is a local PC server or a cloud server. The data interaction interface unit supports the workstation module to retrieve or write data through RESTful API or message queue protocol. The data backup unit supports regular automatic backup of test data and operation logs.

4. The automatic testing system for electromagnetic flow converter according to claim 3, characterized in that: The serial port converter module has an adaptive baud rate recognition function and at least 4 groups of independent serial port / 485 channels. Each group of channels is equipped with a photoelectric isolation circuit to achieve electrical isolation and concurrent communication between the workstation module and multiple semi-finished product test machines.

5. The automatic testing system for electromagnetic flow converter according to claim 4, characterized in that: The semi-finished test cabinet module has physically isolated test stations inside the cabinet. Each station is equipped with an independent power switch, a magnetic conductive connector and an anti-reverse connection signal interface. The magnetic conductive connector supports quick plugging and unplugging of the device under test.

6. The electromagnetic flow converter automatic testing system according to claim 2, characterized in that: The signal processing algorithm executed by the control unit MCU includes: Perform Kalman filtering on the 4-20mA signal collected by the analog AI current detection module to eliminate electromagnetic interference noise; Dynamically adjust the excitation output parameters of the multifunctional processing module based on the status signal of the digital input DI switch detection module; The pulse signal collected by the digital input DI frequency detection module is compared with the preset frequency range to achieve linearity calibration of the flow sensor.

7. The automatic testing system for electromagnetic flow converter according to claim 6, characterized in that: The communication module supports ModbusRTU, HART and Profibus-DP protocols. The serial communication module adopts RS-485 interface, the communication rate adaptive range is 2400bps-115200bps, and it has data frame check and retransmission mechanism.

8. The automatic testing system for electromagnetic flow converter according to claim 7, characterized in that: The workstation module includes: a test instruction automatic generation unit configured to calculate test parameters according to preset test cases and generate a test instruction sequence; Test instruction automatic generation unit, including: The test parameter calculation module is configured based on the basic parameters in the preset test case, using the formula Calculate the expected value range; in, is the sensitivity coefficient, is the bias coefficient, is the tolerance factor; an instruction sequence generation module configured to generate an instruction sequence including a voltage test command and an expected range according to the calculated test parameters; A data receiving and analyzing unit configured to receive and analyze multi-channel detection data fed back by a semi-finished product testing machine in real time; a threshold comparison and determination unit configured to analyze the parsed data based on a threshold comparison algorithm and generate a test result determination; The threshold comparison and judgment unit includes: The signal processing module is configured to filter and downsample the original detection data; the Z-score calculation module is configured to use the formula Calculate standard scores for processed data; Where X is the observed value, μ is the sample mean, and σ is the sample standard deviation; an anomaly determination module, configured to determine that the data is abnormal when the absolute value of the standard score exceeds a preset threshold; an exception handling unit configured to trigger an alarm output module of the semi-finished product testing machine when the detection data is abnormal; Exception handling unit, including: The risk assessment module is configured to calculate the anomaly risk score using the formula Risk = Deviation × Duration × Impact Factor, where Deviation is the deviation rate, Duration is the anomaly duration, and Impact Factor is the test item impact factor; An alarm trigger module is configured to trigger an alarm output of a corresponding level according to the risk score level; a data storage unit configured to store abnormal data marks in a data server module; A data storage unit comprising: Test identification and test machine identification; The timestamp of the exception occurrence; Processed test data and corresponding Z-score value; risk scoring and deviation rate indicators; Test parameter metadata.

9. The automatic testing system for electromagnetic flow converter according to claim 8, characterized in that: The large-screen display module includes: Real-time data visualization unit, using ECharts chart library to generate test data trend charts, pass rate histograms and abnormal distribution heat maps; Test progress monitoring unit dynamically displays the real-time status, test completion rate and estimated remaining time of each test station; The abnormal warning unit triggers an audible and visual alarm based on the preset threshold, and sends SMS / email notifications to designated management personnel.

10. The automatic testing system for electromagnetic flow converter according to claim 9, characterized in that: The detection module of the semi-finished product testing machine adopts time-division multiplexing sampling technology to synchronously collect current, switch status and frequency signals.

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