Comprehensive detection and fault diagnosis device for electrical system
By designing an integrated testing and fault diagnosis device for electrical systems, simulating the communication commands and signals of individual artillery electrical systems, and combining it with a fault detection tree, efficient and accurate diagnosis of artillery electrical system faults is achieved, solving the problem of difficult fault diagnosis in artillery electrical systems. This device is applicable to multiple artillery models.
Patent Information
- Application Number
- CN202511236542.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-01
- Publication Date
- 2025-11-25
AI Technical Summary
Faults in artillery electrical systems are difficult to diagnose and locate due to numerous influencing factors, making fault diagnosis challenging.
Design an electrical system integrated testing and fault diagnosis device. By simulating the communication commands, analog signals and/or digital signals input by other units connected to the unit under test, the device under test is made to run, its output signal is detected, and fault diagnosis is achieved by combining fault detection and diagnostic tree.
It enables efficient and accurate location and diagnosis of faults in artillery electrical systems, supports operators in solving practical problems, is applicable to multiple artillery models, and possesses practicality, advanced technology, applicability, and safety.
Smart Images
Figure CN121008564A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a comprehensive testing and fault diagnosis method for electrical systems. Background Technology
[0002] With the development of automation and intelligent technologies in equipment, artillery electrical systems are becoming increasingly sophisticated and complex. Common individual devices in artillery electrical systems include integrated protection controllers, control computers, display consoles, servo control boxes, inertial navigation equipment, loading displays, and aiming displays. During use and maintenance, faults are not easily identified and located. Furthermore, numerous factors contribute to the difficulty in diagnosing and troubleshooting individual devices. Therefore, a comprehensive electrical system testing and fault diagnosis device is needed to efficiently and comprehensively perform electrical system performance testing and to identify and diagnose electrical system faults. Summary of the Invention
[0003] The technical problem to be solved by this invention is how to accurately locate faults in the electrical system of artillery and efficiently diagnose them.
[0004] One objective of this invention is to provide an intelligent device that can efficiently perform fault detection and diagnosis of the electrical system by communicating with the artillery electrical system or detecting the output signals of individual devices.
[0005] According to one aspect of the embodiments, an electrical system integrated testing and fault diagnosis device is proposed, which simulates communication commands, analog signals and / or digital signals input by other units connected to the unit under test to make the unit under test run, detects the output signal of the unit under test, and thus determines the operating status of the unit under test.
[0006] The device includes: an industrial control motherboard with host computer software configured on it. The host computer software presents the type of the unit, the detection items, and the fault items of the unit through a graphical user interface. The host computer software is configured to accept instructions from the operator to select the type, detection items, and fault items of the unit under test; and a hardware system configured to connect the industrial control motherboard and the unit under test, and to simulate other units connected to the unit under test according to the operator's instructions, send communication instructions, analog signals, and / or digital signals to the unit under test to make the unit under test run, detect the output signal of the unit under test, and send it to the host computer software so that the host computer software can determine the operating status and / or fault type of the unit under test based on the output signal.
[0007] In some examples, the detection logic and fault criteria for the detection items are described using XML files.
[0008] In some examples, the fault item includes a fault diagnosis tree, which guides the determination of the fault type through a combination of fault detection and troubleshooting. The fault item, fault tree structure, and composition can be described using an XML file.
[0009] In some examples, the hardware system includes: a power supply module; a relay module configured to provide multiple power supplies to the unit, each power supply including a relay controlling its output; a voltage acquisition module configured to measure the voltage of the unit; a DA output module configured to output analog signals to the unit; and a control module with lower-level software configured to send communication commands, analog signals, and / or digital signals to the unit under test based on the type, detection items, and fault items selected by the operator on the upper-level software, to enable the unit under test to operate, detect the output signal of the unit under test, and send it to the upper-level software, so that the upper-level software can determine the operating status and / or fault type of the unit under test based on the output signal.
[0010] In some examples, when the unit under test is the display and control console of an artillery piece, the hardware system collects the instructions output from each communication port of the display and control console and sends them to the host computer software. The host computer software judges whether each byte of data in the instruction is correct, thereby verifying whether the transmission of each communication port of the display and control console is working properly. At the same time, after receiving the instructions output from each communication port of the display and control console, the hardware system returns specific data to each communication port of the display and control console within a specified time, which can change the display interface. If the display interface of the display and control console changes based on the specific data, the reception of each communication port of the display and control console is normal; otherwise, it is abnormal.
[0011] In some examples, when the unit under test is the control computer of an artillery piece, the hardware system simulates an inertial navigation system to provide the control computer with various position and attitude information of the artillery piece, simulates a display and control console to issue control commands to the control computer, and simulates a servo control box to provide the control computer with the correct status signals, so that the control computer can complete the calculation of parameters and output the master command signal. The hardware system collects the master command signal and sends it to the host computer software. The host computer software verifies whether the control computer is working properly by verifying the correctness of the master command signal.
[0012] In some examples, when the unit under test is the servo control box of an artillery piece, the hardware system first provides the servo control box with status signals of the simulated hatch, interlock / disengagement switch, and angle limiter, as well as the master command signal of the simulated control computer. Then, it collects the azimuth / elevation power supply, azimuth / elevation enable, and azimuth / elevation command output by the servo control box and sends them to the host computer software. The host computer software verifies whether the servo control box is working properly by checking the correctness of the azimuth / elevation power supply, azimuth / elevation enable, and azimuth / elevation command.
[0013] In some examples, when the unit under test is the integrated protection controller of an artillery piece, the hardware system detects its multiple voltage output signals and simulated fire extinguishing and explosion suppression function signals, and sends them to the host computer software. The host computer software verifies whether the integrated protection controller is working properly by judging the correctness of the multiple voltage output signals and simulated fire extinguishing and explosion suppression function signals.
[0014] In some examples, when the unit under test is the loading display and aiming display of an artillery piece, the host computer software sends specific communication commands to the loading display and aiming display through the hardware system. The normal operation of the aiming display and loading display is verified by whether they can display normally based on the specific communication commands.
[0015] The device proposed in this invention has the following advantages: (1) Practicality: It can detect the working status of the artillery electrical system and diagnose common faults, and assist operators in solving problems in the actual use of artillery; (2) Advanced technology: It can simulate the communication command signals, input status / status signals and working logic required for the operation of a single artillery electrical system, and realize offline detection of the single unit; (3) Applicability: It can comprehensively detect the single units of commonly used electrical systems in artillery through one device; (4) Safety: Safety design is carried out in the circuit design to ensure the normal use of the device, and dedicated cable communication ensures communication security; (5) Expandability: For different models of artillery, comprehensive detection and fault diagnosis of new models of artillery can be quickly realized by expanding the communication interface. Attached Figure Description
[0016] Figure 1 This is a block diagram of an electrical system integrated testing and fault diagnosis device according to an embodiment of the present invention.
[0017] Figure 2 This is a schematic diagram of a host computer software system according to an embodiment of the present invention.
[0018] Figure 3 This is a schematic diagram of a hardware system according to an embodiment of the present invention.
[0019] Figure 4 This is a connection diagram of a hardware system and a detection object according to an embodiment of the present invention.
[0020] Figure 5 This is a typical fault detection flowchart according to an embodiment of the present invention.
[0021] Figure 6 This is a schematic diagram of the signal interaction between the device and the servo control box according to an embodiment of the present invention.
[0022] Figure 7 This is a typical fault diagnosis flowchart according to an embodiment of the present invention. Detailed Implementation
[0023] Figure 1 This is a schematic diagram of a comprehensive electrical system testing and fault diagnosis device (hereinafter referred to as the "device"). This device is an offline testing device that can perform independent, integrated testing of the main components (hereinafter referred to as "units") of an artillery electrical system through external interfaces without disassembly. Figure 1 As shown, the device includes an industrial control motherboard and a hardware system. The hardware system connects to the industrial control motherboard via an interface. The industrial control motherboard is equipped with a software system. The software system includes an operating system and host computer software. The host computer software is application software developed based on the operating system. The operating system can be Windows, Linux, etc.
[0024] like Figure 2 As shown, the host computer software is configured to receive operator commands through the human-machine interface module, send operation commands to the individual units through the interface with the hardware system, and finally present the command results. The device can interact with the operator using peripherals such as a mouse, keyboard, and display screen. The host computer software includes a comprehensive detection module and a fault diagnosis module. The comprehensive detection module realizes the status detection of the individual units of the artillery electrical system; the fault diagnosis module realizes the fault diagnosis of the individual units of the artillery electrical system through an expert system.
[0025] The integrated testing and fault diagnosis modules are configured to present common artillery electrical system unit types through a graphical user interface, including integrated protection controllers, control computers, display consoles, servo control boxes, inertial navigation equipment, loading displays, and aiming displays. The artillery electrical system unit types included in the integrated testing and fault diagnosis modules can be manually added and deleted via XML files.
[0026] The comprehensive testing module presents detectable items for operators to select from for each individual unit. These items can be manually added and deleted via XML files. For each unit, the testing logic and fault criteria for each detectable item are described using XML files.
[0027] The fault diagnosis module presents possible fault items for operators to select from for each individual unit. It uses an expert system to store common fault information and employs a fault diagnosis tree to guide operators through the fault diagnosis process. Fault items, fault tree structure, and components can be described and edited using XML files.
[0028] like Figure 3 , Figure 4 As shown, the hardware system includes: a control module, a power supply module, a voltage acquisition module, a relay module, and a DA output module.
[0029] The control module can use an ARM chip as the main control unit. ARM chips provide a bus interface, facilitating the connection of other external modules.
[0030] The power module is responsible for supplying power to all hardware circuits. The power input is designed to prevent reverse connection. In one implementation, the internal circuitry of the power module converts the input power to 5V and 3.3V voltages. Furthermore, the power module has a power-down detection function and is connected in series with a fuse to prevent malfunction due to a short circuit in the power supply circuit.
[0031] A voltage acquisition module with multiple acquisition channels is designed using a multiplexer. In one embodiment, the voltage acquisition module has 32 acquisition channels, with a maximum measurable voltage of 40V. A 16-bit high-precision converter chip can be used for the AD sampling.
[0032] The relay module provides multiple power supplies to individual units of the artillery electrical system. In one implementation, 16 single-channel relays are designed based on the RS485 interface and Modbus protocol, with each relay controlling one power output.
[0033] The DA output module outputs a 0-20V voltage signal. In one implementation, the DA output module outputs four signals, and the DAC chip uses a 12-bit voltage output 4-wire variable serial interface digital-to-analog converter.
[0034] The hardware system's control module is equipped with lower-level software. The hardware system / control module / lower-level software converts the instructions from the industrial control computer / host computer software into instructions that are sent to the individual unit of the artillery's electrical system, specifically through an interface (such as a serial port) to the unit under test; and it receives the return instructions from the unit under test, judges them, and then sends them to the host computer software.
[0035] The hardware system connects to the artillery electrical system unit via an aviation connector, and enables the detection of multiple units by reusing hardware resources such as communication interfaces and analog or digital detection channels.
[0036] The hardware system can simulate the communication command signals, input status / voltage signals, and working logic required for the operation of a single artillery electrical system, meeting the offline testing requirements of the single unit.
[0037] The device has the ability to simulate the operating conditions of each unit and can provide various signals, including analog signals, digital signals, long and short pulses, and communication messages. The generation of each signal follows a specific timing logic.
[0038] The fault detection principle of the device is as follows: Communication commands, analog signals, and / or digital signals are sent to each component of the artillery's electrical system to activate the individual units. The output signals of each unit are then detected to determine its operational status, thus achieving relatively accurate fault location. Fault diagnosis of the device combines fault detection and troubleshooting, effectively improving the automation and efficiency of the fault diagnosis process. The fault detection principle will be explained in detail below.
[0039] The electrical system of an artillery piece is a unified whole. During operation, each unit coordinates and cooperates to complete tasks such as data acquisition, parameter calculation, and gun adjustment. No single unit can operate independently. Therefore, in order to achieve unit-specific testing, the device must simulate the communication commands, analog signals, and / or digital signals input from other units connected to the unit under test.
[0040] The communication commands, analog signals, and / or digital signals provided by the device to the unit under test must meet the operating logic and timing conditions of the unit under test. For example, for a control computer, it first simulates the position and attitude information provided by the inertial navigation system, then simulates the target position information provided by the display and control console, and only then can the control computer complete the parameter calculations and issue the master command and start signal.
[0041] Since each unit under test has a different function, the device must provide a specific test plan based on the functional characteristics and external interfaces of the specific unit.
[0042] The display and control console serves as the human-machine interface for the entire artillery electrical system. It features a display screen and multiple communication interfaces, enabling real-time communication with inertial navigation equipment, the control computer, the loading display, and the aiming display. It also provides power supply, management, and self-testing functions for other test units. Therefore, the testing of the display and control console employs a combination of automated and manual methods to simulate the interaction between the console and other units of the artillery electrical system. First, the device is connected to each communication port of the display and control console. Then, the operator inputs specific data via the keyboard, and the display and control console sends specific commands to each communication port. The device receives the commands and verifies the correctness of each byte of data, thus verifying the normal operation of the transmission function of each communication port. Simultaneously, after receiving commands from the display and control console, the device returns specific data to each communication port within a specified time. The changes in the display and control console's interface are observed, thus verifying the normal operation of the reception function of each communication port.
[0043] The control computer is the calculation center of the artillery's electrical system. Therefore, testing the control computer requires verifying its gun-setting and calculation functions. The testing steps are as follows: The device simulates the inertial navigation system to provide the current data of the artillery through a communication interface, simulates the display and control console to issue control commands, and simulates the servo control box to provide correct status signals. Only then can the control computer complete the parameter calculation and output the master command signal. The device mainly verifies whether the control computer is working properly by detecting this signal.
[0044] The servo control box primarily receives master commands and, based on the current status of the artillery, issues voltage commands to drive the servo motors. Therefore, testing the servo control box mainly requires simulating the states provided by the hatch, interlock / release switches, angle limiters, etc., as well as the master commands provided by the control computer. Finally, the device verifies its proper functioning by detecting the azimuth and elevation power supply and azimuth and elevation drive signals output by the servo control box.
[0045] For the integrated protection controller, since it mainly provides power to each unit and functions such as fire extinguishing and explosion suppression, the device verifies whether it is working properly by detecting its multi-channel voltage output signals and simulated fire extinguishing and explosion suppression function signals.
[0046] For the loading display and aiming display, the device mainly verifies whether they are working properly by simulating specific serial communication commands and observing whether the display screens of the loading display and aiming display can display normally.
[0047] Figure 5 This demonstrates a typical fault detection process for an artillery electrical system. Step 1: The host computer software on the industrial control computer sends a power-on command to the hardware system. Step 2: Upon receiving the power-on command, the hardware system controls the relay output voltage to supply power to the unit under test. Step 3: The host computer software obtains the test items selected by the operator. Step 4: The host computer software sends test instructions for the test items to the hardware system. Step 5: After receiving the test instructions, the hardware system outputs digital or analog signals to the unit under test, causing it to operate. Step 6: The hardware system obtains the operating status signal output by the unit under test and sends it to the host computer. Step 7: The host computer determines whether the operating status signal of the unit under test is normal based on the set criteria.
[0048] The following describes the fault detection process for the "servo control box" unit. The signal interaction between the servo control box and the device is as follows: Figure 6As shown. Before testing, the operator needs to perform the following operations: (1) Turn on the device switch and wait for the device to complete the self-test and start up; (2) Connect the external interfaces of the "servo control box" unit to the angle limiter, control computer, control console, azimuth / elevation servo driver and other units to the specific interface of the device through cables. (3) After the cables are connected, select "Unit Test" in the device software interface, select "Servo Control Box" as the unit type to be tested, and then start the test. The procedure for detecting servo control box faults using the device is as follows: Step 1, the device outputs operating power to the servo control box, energizing it; Step 2, the device simulates the "disengaged" state of the interlock / disengagement switch and outputs the simulated "disengaged" state signal to the servo control box; Step 3, the device simulates the angle limiter sending a "gun firing angle limitation" signal to the servo control box; Step 4, the device simulates the control computer sending a "azimuth or elevation command" signal to the servo control box via its internal D / A module; Step 5, the device sends a "start" signal to the servo control box; Step 6, the device detects the "azimuth / elevation enable," "azimuth / elevation power output," and "azimuth / elevation command output" signals output by the servo control box; Step 7, the device compares the detected signal values with reference values preset via an XML file and provides a "normal" or "fault" test result. The operator can choose to export and save the test results. Figure 7 The typical fault diagnosis process of the artillery electrical system is demonstrated. Before diagnosis, the operator needs to do the following: (1) turn on the switch of the device and wait for the device to complete the self-test and start up; (2) connect the external interface of the unit to be diagnosed to the specific interface of the device through a cable; (3) after the cable is connected, select "System Diagnosis" in the software interface of the device, and then select the corresponding unit type to be diagnosed to start the diagnosis. The specific diagnostic steps are as follows: Step 1, the device first supplies operating power to the individual unit, powering it on; Step 2, the diagnostic software performs fault matching based on the typical fault selected by the operator or the fault keywords entered; Step 3, the device automatically starts selecting associated signals to begin detection based on the type of the individual unit to be diagnosed and the specific fault type; Step 4, if the detection result is "abnormal", the host computer provides possible faulty component prompts based on the specific fault signal type; Step 5, the operator manually isolates the fault (e.g., replaces components), and then the device detects the associated signals again. If the detection result is still "abnormal", it jumps to Step 4 to continue diagnosis; Step 6, repeat the above steps until the detection result is "normal". At this point, the operator can determine whether the fault has been eliminated. If the fault has been eliminated, select "Yes" to indicate that the diagnosis is complete.
Claims
1. A comprehensive electrical system testing and fault diagnosis device, characterized in that, By simulating communication commands, analog signals, and / or digital signals input from other units connected to the unit under test, the unit under test is made to run, and the output signal of the unit under test is detected, thereby determining the running status of the unit under test.
2. The electrical system integrated testing and fault diagnosis device according to claim 1, characterized in that, The device includes: The industrial control motherboard is equipped with host computer software. The host computer software presents the type of unit, the test items and fault items of the unit through a graphical user interface. The host computer software is configured to accept the operator's instructions to select the type of unit to be tested, the test items and the fault items. The hardware system is configured to connect the industrial control motherboard and the unit under test (DUT), and can simulate other units connected to the DUT according to the operator's instructions, send communication commands, analog signals and / or digital signals to the DUT to make the DUT run, detect the output signal of the DUT, and send it to the host computer software, so that the host computer software can determine the operating status and / or fault type of the DUT based on the output signal.
3. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, The detection logic and fault criteria for each detection item are described in an XML file.
4. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, The fault item includes a fault diagnosis tree. Guided by the fault diagnosis tree, the fault type is determined by a combination of fault detection and troubleshooting. The fault item, fault tree structure and composition can be described by an XML file.
5. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, The hardware system includes: Power module; The relay module is configured to provide multiple power supplies to a single unit, each power supply containing a relay that controls its output; A voltage acquisition module, configured to measure the voltage of a single cell; The DA output module is configured to output analog signals to the unit. The control module is equipped with lower-level software. The lower-level software is configured to send communication commands, analog signals, and / or digital signals to the unit under test (DUT) based on the type, detection items, and fault items selected by the operator on the upper-level software, so as to make the DUT run, detect the output signal of the DUT, and send it to the upper-level software, so that the upper-level software can determine the operating status and / or fault type of the DUT based on the output signal.
6. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, When the unit under test is the display and control console of an artillery piece, the hardware system collects the instructions output from each communication port of the display and control console and sends them to the host computer software. The host computer software judges whether each byte of data in the instruction is correct, thereby verifying whether the transmission of each communication port of the display and control console is working properly. At the same time, after receiving the instructions output from each communication port of the display and control console, the hardware system returns specific data to each communication port of the display and control console within a specified time, which can change the display interface. If the display interface of the display and control console changes based on the specific data, then the reception of each communication port of the display and control console is working properly; otherwise, it is not working properly.
7. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, When the unit under test is the control computer of an artillery piece, the hardware system simulates an inertial navigation system to provide the control computer with various position and attitude information of the artillery piece, simulates a display and control console to issue control commands to the control computer, and simulates a servo control box to provide the control computer with the correct status signals, so that the control computer can complete the calculation of parameters and output the master command signal. The hardware system collects the master command signal and sends it to the host computer software. The host computer software verifies whether the control computer is working properly by verifying the correctness of the master command signal.
8. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, When the unit under test is the servo control box of an artillery piece, the hardware system first provides the servo control box with status signals of the simulated hatch, interlock / disengagement switch, and angle limiter, as well as the master command signal of the simulated control computer. Then, it collects the azimuth / elevation power supply, azimuth / elevation enable, and azimuth / elevation command output by the servo control box and sends them to the host computer software. The host computer software verifies whether the servo control box is working properly by checking the correctness of the azimuth / elevation power supply, azimuth / elevation enable, and azimuth / elevation command.
9. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, When the unit under test is the integrated protection controller of the artillery, the hardware system detects its multi-channel voltage output signals and simulated fire extinguishing and explosion suppression function signals, and sends them to the host computer software. The host computer software verifies whether the integrated protection controller is working properly by judging the correctness of the multi-channel voltage output signals and simulated fire extinguishing and explosion suppression function signals.
10. The electrical system integrated testing and fault diagnosis device according to claim 2, characterized in that, When the unit under test is the loading display and aiming display of an artillery piece, the host computer software sends specific communication commands to the loading display and aiming display through the hardware system. The normal operation of the aiming display and loading display is verified by whether they can display normally based on the specific communication commands.