Fault signal injection system and method

Abstract

The embodiment of the invention relates to the field of simulation testing, and discloses a fault signal injection system and method. In the invention, a fault signal comprises one or any combination of the following: a voltage signal, a current signal, an open circuit signal, a ground short circuit signal or a mutual short circuit signal, and the system comprises an upper computer used for sending a control instruction to the combination of a plurality of groups of signal board cards and switch board cards; the signal board cards and the switch board cards are in communication connection with the upper computer, the signal board cards are electrically connected with the corresponding switch board cards, and the signal board cards are used for generating the fault signals based on the control instructions. The switch board card is used for sending the fault signals to a plurality of to-be-tested devices based on the control instruction. Therefore, the expandability and the configurability of the system are improved.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of simulation testing, and in particular to a fault signal injection system and method. Background Technology

[0002] A fault signal injection system is a testing device used to simulate and generate various electrical fault states. It is widely used in reliability verification and fault diagnosis in fields such as power electronics, automatic control, and rail transportation. By injecting preset fault signals into the device or system under test, abnormal behaviors that may occur under real operating conditions can be reproduced in a controlled experimental environment, thereby enabling a systematic evaluation of the equipment's fault tolerance, protection strategies, and safety performance.

[0003] Existing fault signal injection systems typically use a main control board with a control chip at its core to control the fault signal output, with key parameters such as signal type, number of channels, and signal amplitude fixed in the main control board. As a result, if it is necessary to add fault types, number of channels, or signal amplitude, the entire main control board must be redesigned or replaced, which reduces the scalability of the signal injection system. Summary of the Invention

[0004] The purpose of this invention is to provide a fault signal injection system and method that solves the problem that increasing the number of fault types, channels, or signal amplitude requires redesigning or replacing the entire main control board, which reduces the scalability of the signal injection system.

[0005] To address the aforementioned technical problems, embodiments of the present invention provide a fault signal injection system. The fault signal includes one or any combination of the following: voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal. The system includes: a host computer for sending control commands to a combination of several sets of signal boards and switch boards; and the combination of the several sets of signal boards and switch boards communicatively connected to the host computer. The signal boards are electrically connected to their corresponding switch boards. The signal boards are used to generate the fault signal based on the control commands, and the switch boards are used to send the fault signal to several devices under test based on the control commands.

[0006] An embodiment of the present invention also provides a fault signal injection method, wherein the fault signal is a voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal, comprising: a host computer sending control commands to a combination of several groups of signal boards and switch boards; the signal boards in the combination of several groups of signal boards and switch boards generating the fault signal based on the control commands; and the switch boards sending the fault signal to several devices under test based on the control commands.

[0007] In this embodiment of the invention, the host computer software replaces the fixed output logic on the main control board, issuing control commands to multiple boards via a bus. Signal types and injection logic can be flexibly configured without a dedicated control chip. Each signal board generates fault signals such as voltage, current, open circuit, short circuit to ground, or mutual short circuit according to the commands, achieving a modular design. When additional output channels are needed, simply add new signal boards in parallel. After being switched by a switching board, the generated fault signals are directed to the corresponding channels and injected into any number of devices under test, thus supporting multi-channel concurrent testing under the unified control of the host computer. In summary, through the decoupling of the "control-generation-distribution" three-layer modules, this invention not only enables arbitrary combinations of various fault signals but also allows for real-time adjustment of the signal type and quantity output at the software level, meeting high-concurrency and diverse testing needs, and achieving the invention objective of a "flexibly expandable and easily configurable fault signal injection system."

[0008] Additionally, the signal board includes a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit. The first voltage signal output unit receives the control command and generates the voltage signal under the control command. The voltage signal amplification unit, electrically connected to the voltage signal output unit, amplifies the amplitude of the voltage signal under the control command and outputs the amplified voltage signal to the corresponding switch board. The current signal output unit receives the control command, generates the current signal under the control command, and outputs the current signal to the corresponding switch board. The short-circuit unit generates the open-circuit signal, the short-circuit signal to ground, or the mutual short-circuit signal. The switch board includes a switch switching unit electrically connected to the corresponding voltage signal amplification unit, the current signal output unit, and the short-circuit unit, and sends the fault signal to the device under test according to the control command. In this embodiment of the invention, the signal board integrates the voltage output unit, the amplification unit, the current output unit, and the short-circuit unit into one unit, and the host computer software drives each unit uniformly through control commands. By generating, amplifying, and short-circuiting fault signals within the signal board and selecting fault signals on the switch board, high precision and high integration of the signal injection architecture are achieved.

[0009] In addition, the signal board includes N signal channels, each of which is equipped with a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit. Each signal channel is used to generate a fault signal; N is an integer greater than or equal to 1. The switch board includes N switch channels corresponding one-to-one with the N signal channels, each of which is equipped with a switch switching unit for outputting the corresponding fault signal. By configuring fault injection units in the signal board and switch board in a one-to-one correspondence at the channel granularity, linear scalability and high-concurrency injection of the system are achieved. Attached Figure Description

[0010] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0011] Figure 1 This is a structural diagram of a fault signal injection system provided according to an embodiment of the present invention;

[0012] Figure 2 This is an interactive page diagram of the host computer in the fault signal injection system provided according to an embodiment of the present invention;

[0013] Figure 3 This is a structural diagram of the voltage signal amplification unit in the fault signal injection system provided according to an embodiment of the present invention;

[0014] Figure 4 This is a structural diagram of a current signal conversion unit in a fault signal injection system provided according to an embodiment of the present invention;

[0015] Figure 5 This is a structural diagram of a switch switching unit in a fault signal injection system provided according to an embodiment of the present invention;

[0016] Figure 6 This is a schematic diagram of the working principle of a fault signal injection system provided according to an embodiment of the present invention. Detailed Implementation

[0017] In the research and testing processes of power electronics, automatic control, and rail transportation, system reliability and safety are paramount. Fault signal injection systems, through various fault states such as voltage, can reproduce abnormal behavior under real-world conditions in a controlled experimental environment, thereby enabling a systematic evaluation of the fault tolerance, protection strategies, and overall safety performance of the device under test. These systems typically generate and inject corresponding fault signals into the simulation system or equipment after receiving a fault injection command, to complete the task of simulating multi-channel, multi-type faults. However, existing solutions are mostly based on a single-chip control unit, which has the following problems:

[0018] (1) First, the main control board has the key parameters such as signal type, number of channels and amplitude range fixed in the hardware design. Once the design is completed, it is difficult to expand or adjust. If a new fault type or channel needs to be added, the main control board can only be redesigned or replaced, which wastes costs and causes the experiment to be down for too long, seriously affecting the testing efficiency and flexibility.

[0019] (2) Secondly, traditional main control boards usually only provide coarse-grained open / short circuit functions, and have not made in-depth optimizations for the amplitude accuracy, dynamic range and switching response speed of voltage and current signals. When it is necessary to simulate electrical faults with high speed or small amplitude changes, the existing system is difficult to meet the test requirements of high precision and high bandwidth, which limits its further application in fields such as power electronics and servo systems.

[0020] (3) Finally, the main control board has a high degree of integration and a large size. Once a fault occurs, the entire board needs to be repaired or replaced, resulting in high maintenance costs and difficulty in rapid on-site replacement.

[0021] Based on the above shortcomings, a fault signal injection system that can flexibly expand the signal types and number of channels, and provide high-precision simulation and fast switching is needed to meet the increasingly diverse and high-reliability testing requirements.

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the various embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details are presented in the various embodiments of the present invention to facilitate a better understanding of this application. However, the technical solutions claimed in this application can be implemented even without these technical details and various variations and modifications based on the following embodiments. The division of the various embodiments below is for ease of description and should not constitute any limitation on the specific implementation of the present invention. The various embodiments can be combined with and referenced by each other without contradiction.

[0023] One embodiment of the present invention relates to a fault signal injection system. The fault signal includes one or any combination of the following: voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal. The system includes: a host computer for sending control commands to a combination of several sets of signal boards and switch boards; and the combination of the several sets of signal boards and switch boards communicatively connected to the host computer. Each signal board is electrically connected to a corresponding switch board. The signal boards generate the fault signal based on the control commands, and the switch boards send the fault signal to several devices under test based on the control commands. In this embodiment, the host computer software replaces the fixed output logic on the main control board, sending control commands to multiple sets of boards via a bus. Signal types and injection logic can be flexibly configured without a dedicated control chip. Each signal board generates fault signals such as voltage, current, open circuit, short circuit to ground, or mutual short circuit according to the commands, achieving a modular design. When an additional output channel is needed, only additional signal boards need to be connected in parallel. The generated fault signals are switched by the switch board and then guided to communication channels and injected into any number of devices under test, thus supporting multi-channel concurrent testing under the unified control of the host computer. In summary, by decoupling the "control-generation-distribution" three-layer modules, this invention can not only realize arbitrary combinations of various fault signals, but also adjust the type and quantity of output signals in real time at the software level, meeting the needs of high concurrency and diverse testing, and achieving the invention objective of "a flexible, expandable and easily configurable fault signal injection system".

[0024] The following is a detailed description of the implementation details of a fault signal injection system according to an embodiment of the present invention. The following content is only for the convenience of understanding the implementation details and is not necessary for implementing this solution.

[0025] This invention relates to a fault signal injection system, wherein the fault signal includes one or any combination of the following: voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal, such as... Figure 1 As shown, the system includes a host computer and a combination of several sets of signal boards and switch boards that are communicatively connected to the host computer, wherein:

[0026] The host computer is used to send control commands to a combination of several signal boards and switch boards.

[0027] like Figure 2The host computer is equipped with a visual interface for technicians to select the required fault signals and signal parameters such as current and voltage. The visual interface supports various interactive methods, including graphical controls, drop-down menus, sliders, and input boxes, and supports real-time display of the currently selected parameters and their changing trends. After receiving the user's settings, the host computer can perform validity checks, range restrictions, and necessary safety prompts on the selected parameters to prevent damage to the equipment under test due to misoperation. The host computer is responsible for sending the selected fault signals and parameters as control commands to the corresponding boards and can dynamically adjust the output signal type, amplitude, duration, and switching sequence according to the test progress. This visual interface can also preset multiple test schemes, allowing technicians to load batch test tasks at once, achieving automated batch injection of multi-channel, multi-type fault signals.

[0028] The combination of several groups of signal boards and switch boards that are communicatively connected to the host computer, wherein the signal boards are electrically connected to the corresponding switch boards, the signal boards are used to generate the fault signal based on the control command, and the switch boards are used to send the fault signal to several devices under test based on the control command.

[0029] In this embodiment of the invention, each group of signal boards and switch boards is connected in parallel to the host computer via a communication bus. The communication bus can be RS485, CAN bus, Ethernet bus, etc., and can be selected based on the wiring distance, anti-interference capability, and bandwidth requirements of the test site. This direct connection between the boards and the host computer overcomes the limitations of the number of interfaces and protocol types of traditional main control boards, enabling the host computer in this embodiment to simultaneously connect to any number of signal boards and switch board combinations. Furthermore, different combinations can be physically isolated and logically independently controlled, thereby achieving the simultaneous output of more fault signals than the main control board method. Further, the system supports issuing instructions and switching signals to different boards within millisecond-level time slices, thus meeting the requirements of high-concurrency, low-latency test scenarios.

[0030] Furthermore, this direct connection between the board and the host computer eliminates the design constraint of the main control board approach, which requires the fault signal output logic to be fixed in the hardware circuit. Instead, the fault signal control logic is implemented by the host computer software, which is compilable and upgradeable. The signal amplitude range and channel allocation strategy can be flexibly adjusted through the software layer without replacing the hardware board, thereby reducing the system maintenance and upgrade costs.

[0031] In addition, this architecture allows for the integration of security verification and diagnostic modules on the host computer, enabling real-time monitoring and fault prediction of the status of lower-level boards, thereby further improving the stability and reliability of system operation.

[0032] In this embodiment of the invention, the signal board includes a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit;

[0033] The first voltage signal output unit in the aforementioned signal board is used to receive the control command and generate the voltage signal under the control command; the voltage signal amplification unit is electrically connected to the voltage signal output unit and is used to amplify the amplitude of the voltage signal under the control command and output the amplified voltage signal to the corresponding switch board.

[0034] Specifically, the aforementioned first voltage signal output unit employs a serial port-controlled analog output module. This module features 12-bit resolution and can output 0–20mA current signals and ±10V voltage signals on each channel. It uses serial communication for control and provides four channels of analog output capability. The module's internal output slope and update rate are programmable to adapt to different response speed requirements, and it supports power-down memory to ensure the continuity and safety of the testing process. Through the host computer control software, users can set any target voltage value within the ±10V range in a visual interface, thereby meeting the diverse needs of simulating different types of faults.

[0035] In the signal link, the voltage signal amplification unit is electrically connected to the first voltage signal output unit, and its specific structure is as follows: Figure 3 As shown, it includes a precision operational amplifier and a precision resistor circuit. The precision operational amplifier is a low-noise, low-drift model to ensure minimal signal distortion and high amplitude accuracy during amplification. The resistance ratio of the precision resistor circuit can be flexibly configured according to the target amplification factor, covering a range from 1x to 10x or even higher, so as to amplify the small voltage signal output from the first voltage signal output unit to the voltage signal range required by the system (such as ±40V, ±60V or even higher).

[0036] In addition, the aforementioned signal board also includes a current signal output unit, which is used to receive the control command, generate the current signal under the control command, and output the current signal to the corresponding switch board.

[0037] Specifically, the aforementioned current signal output unit includes: a second voltage signal output unit, used to output a voltage signal under the control command; and a current signal conversion unit, electrically connected to the second voltage signal output unit, used to convert the voltage signal into the current signal under the control command.

[0038] Specifically, the aforementioned second voltage signal output unit employs a serial port-controlled analog output module. This module features 12-bit resolution and can output 0–20mA current signals and ±10V voltage signals on each channel. It uses serial communication for control and provides four channels of analog output capability. The module's internal output slope and update rate are programmable to adapt to different response speed requirements and support power-down memory to ensure the continuity and safety of the testing process. Through the host computer control software, users can dynamically drive the current output unit via a visual interface. Through software settings, a stable analog voltage signal can be generated within a ±10V range as the drive input for the subsequent current signal output unit.

[0039] The aforementioned current signal conversion unit is electrically connected to the second voltage signal output unit, and its specific structure is as follows: Figure 4 As shown, the unit includes a precision operational amplifier and a precision resistor circuit. The precision operational amplifier is a low-noise, low-temperature-drift model, which, together with the precision resistor network, linearly converts the input voltage signal into a proportionally corresponding current signal. By adjusting the resistance ratio of the resistor network, the voltage-to-current conversion ratio can be flexibly changed to adapt to different current output ranges (such as ±20mA, ±100mA, or even ±200mA). To ensure the stability and accuracy of the output current, this unit can also be configured with a closed-loop feedback control circuit to monitor the output current in real time and automatically compensate for deviations, thus maintaining high-precision output even under load changes or ambient temperature variations.

[0040] In addition, the short-circuit unit is used to generate the open-circuit signal, the short-circuit signal to ground, or the mutual short-circuit signal.

[0041] Among them, such as Figure 5 This short-circuit unit is mainly implemented using a switch switching unit element in a switchboard, which switches the conduction or disconnection state of the channel according to control commands issued by the host computer. In open-circuit mode, the short-circuit unit completely disconnects the signal loop, isolating the signal input terminal of the device under test from the system; in ground short-circuit mode, the signal output terminal is directly connected to the system signal ground, thereby simulating a fault scenario of accidental grounding of the signal terminal; in mutual short-circuit mode, two or more signal channels are shorted together by an internal controllable switch to simulate abnormal situations such as insulation damage between channels or abnormal interconnection of wires.

[0042] Furthermore, it also includes a switch board connected to the aforementioned signal board, including a switch switching unit, which is electrically connected to the corresponding voltage signal amplification unit, current signal output unit, and short-circuit unit, and is used to send the fault signal to the device under test according to the control command.

[0043] It should be noted that the aforementioned switch switching unit is used to connect one of the voltage signal amplification unit, the current signal output unit, and the short-circuit unit to the device under test based on the control command, thereby realizing dynamic switching and single-channel output control of different types of fault signals.

[0044] In other words, the aforementioned switching unit is essentially a dual-channel single-pole double-throw relay, such as... Figure 5 As shown, in fault signal output channel 1, the switch switching unit includes K1, K1-1, K1-2, and K1-3: K1-3 is used to control whether the output channel of the switch board selects between voltage and current signals; K1-1 is used to select between voltage / current signals and open-circuit signals; K1-2 is used to select between short-circuit signals to ground and mutual short-circuit signals; and K1 is used to perform the final output switching between the signals selected by K1-1 and K1-2. The advantage of this multi-level selection structure is that only one signal source can be activated at any given time, avoiding conflicts and interference caused by simultaneous outputs from different signal units, thus improving the safety and reliability of the system. Simultaneously, this structure supports the host computer to complete switching in millisecond-level time slices, making it suitable for test scenarios requiring rapid fault injection and recovery.

[0045] In an optional embodiment, the switching unit of the present invention may also include an electrical isolation module, a surge suppression element and an overcurrent protection circuit to prevent damage to the signal source and the device under test caused by transient impact or abnormal load during the switching process.

[0046] In the above embodiments of the present invention, the signal board integrates the voltage output unit, amplification unit, current output unit, and short-circuit unit on the same hardware platform, forming a highly modular integrated design. Each unit communicates with the host computer via control lines, and the host computer software issues unified control commands to achieve precise driving and coordinated scheduling of each unit. Simultaneously, the switch board undertakes the final signal path selection and output isolation functions, ensuring that only one fault signal is conducted to the device under test at any given time, thereby effectively preventing multi-source signal conflicts.

[0047] In an optional embodiment of the present invention, each board in the fault signal injection system is provided with several independent signal channels. Each channel can independently inject a fault signal into the corresponding device under test or simulation system, and supports synchronous or asynchronous injection modes between different channels. Specifically:

[0048] The signal board includes N signal channels, each signal channel having a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit. Each signal channel is used to generate a fault signal; N is an integer greater than or equal to 1. The switch board includes N switch channels corresponding one-to-one with the N signal channels, each switch channel having a switch switching unit for outputting the corresponding fault signal.

[0049] In the above embodiments, each channel on each signal board integrates the first voltage signal output unit, voltage signal amplification unit, current signal output unit, and short-circuit unit mentioned in the above embodiments. These units are isolated from each other in the hardware circuit design to ensure that a fault or switch in one channel will not interfere with the signal output stability of other channels. Correspondingly, each channel on each switch board is configured with the switch switching unit mentioned in the above embodiments. Each switch switching unit can select the output signal type of the channel according to the host computer instruction within a millisecond time slice, realizing rapid switching of different types of fault signals. Specifically, each channel can independently select to output a voltage signal, current signal, open-circuit signal, short-circuit signal to ground, or mutual short-circuit signal. Furthermore, when needed, parameters such as output amplitude, duration, and switching sequence can be set via software, thereby flexibly simulating various fault scenarios that may occur in a real operating environment.

[0050] In some embodiments, the number of these channels can be 16, 32, 64, or even more, and the number of channels on each signal board and switch board can be customized according to application requirements. Channels can achieve unified clock synchronization through a compliant communication protocol, thereby supporting precise timing control of multiple channels. For example, in some tests, different types of fault signals can be injected simultaneously on different channels to simulate complex scenarios of simultaneous or cascading faults. This independent and concurrent channel design enables the system to cover a wider range of testing needs and significantly improves testing efficiency and the realism of fault injection.

[0051] In this embodiment of the invention, the number of combinations of signal boards and switch boards can be determined based on the number of devices under test. This is one of the key aspects of this embodiment.

[0052] As those skilled in the art will recognize, in this embodiment of the invention, because it overcomes the structural limitations of relying on a central control board for connection and control in the prior art, the signal boards and switch boards communicate directly in parallel with the host computer. Therefore, there is no upper limit to the number of combinations in the hardware architecture. In other words, the fault signal injection system of this embodiment can flexibly expand the number of boards according to test requirements to simultaneously connect any number of simulation models under test or actual systems. Each additional combination of signal boards and switch boards adds a corresponding number of independent fault injection channels to the system, achieving linear expansion without changing the hardware design of existing boards or the host computer.

[0053] Under this architecture, the system can not only inject multiple different types of fault signals simultaneously onto a single device under test, but also execute independent fault injection tasks in parallel on multiple different devices under test. For example, technicians can inject voltage dip faults, mutual short circuit faults, and open circuit faults onto three different devices, respectively, and monitor the status and test results of each channel in real time through a host computer, thereby significantly improving testing efficiency and concurrency capabilities.

[0054] Furthermore, in this embodiment of the invention, the circuit structure and model of each signal board can be a completely identical standardized design, or different circuit structures and model configurations can be adopted according to different testing requirements; similarly, each switch board can also be an identical standardized model, or a version with different functional characteristics. As long as the signal boards and switch boards in each pair are matched in terms of interface protocol, electrical characteristics, and signal processing capabilities, the corresponding fault signal type and quantity can be output.

[0055] In some application scenarios, both signal boards and switch boards adopt a standardized design with the same model number. This not only facilitates mass production and inventory management but also significantly improves the system's replaceability and maintainability in the field. When any signal board or switch board fails, technicians only need to remove the faulty board and replace it with a working board of the same model to restore system operation. There is no need to disassemble the entire chassis or interrupt testing of other channels, thus significantly shortening maintenance time and reducing downtime risk.

[0056] On the other hand, when testing different projects or equipment, different models and performance levels of boards can be mixed within the same system. For example, high-precision, high-bandwidth signal boards can be deployed in some channels to simulate high-speed transient faults, while low-cost, low-speed boards can be deployed in other channels for long-term stability testing. Through this flexible configuration strategy, the system can maintain high interchangeability and ease of maintenance while also considering cost control and test performance optimization, thus adapting to various application needs from scientific research experiments to industrial mass production testing.

[0057] In this embodiment of the invention, the length of both the signal board and the switch board is less than or equal to 220 mm, and the width is less than or equal to 100 mm.

[0058] Specifically, when each signal board and switch board has 16 channels, both boards adopt a "blade board" design, meaning they are elongated strips with standardized guide rail slots and electrical connection interfaces along their edges. This blade board structure not only occupies little space, allowing for high-density integration of multiple boards within a limited chassis space, but also facilitates rapid installation and removal via vertical plug-and-play, supporting plug-and-play and hot-swappable operations. During maintenance, technicians can replace faulty boards individually without interrupting other channels, significantly reducing downtime and improving system availability.

[0059] In this embodiment of the invention, the above-mentioned board combination can be installed in a standard 3U chassis. The chassis can reserve multiple blade mounting positions and ventilation channels, and is equipped with heat dissipation measures such as fans, temperature control modules or air guide plates to ensure long-term stable operation under high channel density.

[0060] Each group of signal and switch boards in the aforementioned "blade board" structure can be configured individually within the chassis. Unlike traditional main control board structures, where all boards are typically fixed to the chassis and mounted to a main control board on the side of the chassis via slots, with signal and control logic centrally processed by this main control board, expansion and maintenance are limited, this approach is different. In this embodiment of the invention, after each board is fixed (either inside the chassis or on a separate mounting bracket), it is connected to the host computer via an independent communication cable, and then connected to the host computer port via a switch or direct connection.

[0061] This design ensures that the boards within the system are completely independent and undependent, with each board capable of being replaced or expanded individually, avoiding the complexities of overall disassembly and reassembly. Furthermore, due to the small size and low manufacturing cost of the modules and boards, the system can achieve flexible channel configurations and functional combinations while maintaining high-density integration. It boasts strong scalability and can adapt to various types and scales of fault signal injection requirements, including laboratory R&D verification, small-batch production testing, and large-scale industrial field testing.

[0062] like Figure 6The working principle of the fault signal injection system described in the above embodiments of the present invention is as follows: When the system needs to output a voltage signal, the host computer software sends a control command to the target channel through the communication bus, driving the voltage signal output unit to generate a small-amplitude analog voltage signal. This signal is amplified to the target amplitude set by the voltage amplification unit, and then conducted to the corresponding output channel through the switch switching unit, ultimately being injected into the device under test. When the system needs to output a current signal, the host computer similarly controls the voltage signal output unit to generate a small-amplitude voltage signal. This signal is converted from voltage to current by the current output unit, amplified to the set current range, and then conducted to the output port by the switch switching unit, thus realizing current-type fault injection into the device under test. When the system needs to output an open-circuit fault signal, the switching unit disconnects the channel from all signal sources to achieve complete isolation, thereby simulating a fault situation of line interruption or poor contact. When the system needs to output a short-circuit fault signal to ground, the switching unit connects the channel directly to the signal ground to simulate the situation of the signal line being accidentally grounded. When the system needs to output a short-circuit fault signal between signal channels, the switching unit establishes a low-impedance connection between the target channel and another designated channel to simulate the short circuit phenomenon caused by line insulation damage or wire entanglement.

[0063] In this embodiment of the invention, the host computer software replaces the fixed output logic on the main control board, issuing control commands to multiple boards via a bus. Signal types and injection logic can be flexibly configured without a dedicated control chip. Each signal board generates fault signals such as voltage, current, open circuit, short circuit to ground, or mutual short circuit according to the commands, achieving a modular design. When additional output channels are needed, simply add new signal boards in parallel. After being switched by a switching board, the generated fault signals are directed to the corresponding channels and injected into any number of devices under test, thus supporting multi-channel concurrent testing under the unified control of the host computer. In summary, through the decoupling of the "control-generation-distribution" three-layer modules, this invention not only enables arbitrary combinations of various fault signals but also allows for real-time adjustment of the signal type and quantity output at the software level, meeting high-concurrency and diverse testing needs, and achieving the invention objective of a "flexibly expandable and easily configurable fault signal injection system."

[0064] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0065] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0066] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0067] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0068] Furthermore, the examples mentioned in the above embodiments can be freely combined, and any combination can be understood as an embodiment. The terms "embodiment" or "example" appearing in various locations in the specification do not necessarily refer to the same embodiment, nor are they independent or alternative embodiments mutually exclusive with other embodiments. Those skilled in the art will understand that the embodiments described herein can be combined with other embodiments.

[0069] Another embodiment of the present invention relates to a fault signal injection method, wherein the fault signal is a voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal, comprising: a host computer sending control commands to a combination of several groups of signal boards and switch boards; the signal boards in the combination of several groups of signal boards and switch boards generating the fault signal based on the control commands; and the switch boards sending the fault signal to several devices under test based on the control commands.

[0070] In some embodiments, the signal board includes a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit; the switch board includes a switch switching unit electrically connected to the corresponding voltage signal amplification unit, current signal output unit, and short-circuit unit; the signal board in the combination of the plurality of signal boards and switch boards generates the fault signal based on the control command; and the switch board sends the fault signal to a plurality of devices under test based on the control command, including: the plurality of signal boards controlling the voltage signal amplification unit, current signal output unit, and short-circuit unit in the signal board to generate the fault signal based on the control command; and the plurality of switch boards corresponding to the signal boards controlling the switch switching unit to send the fault signal generated by the signal board to the device under test based on the control command.

[0071] Those skilled in the art will understand that the above embodiments are specific embodiments for implementing the present invention, and in practical applications, various changes in form and detail may be made without departing from the spirit and scope of the present invention.

Claims

1. A fault signal injection system, characterized in that, The fault signal includes one or any combination of the following: voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal; the system includes: The host computer is used to send control commands to a combination of several signal boards and switch boards. The combination of several groups of signal boards and switch boards that are communicatively connected to the host computer, wherein the signal boards are electrically connected to the corresponding switch boards, the signal boards are used to generate the fault signal based on the control command, and the switch boards are used to send the fault signal to several devices under test based on the control command.

2. The fault signal injection system according to claim 1, characterized in that, The signal board includes a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit; The first voltage signal output unit is used to receive the control command and generate the voltage signal under the control command; the voltage signal amplification unit is electrically connected to the voltage signal output unit and is used to amplify the amplitude of the voltage signal under the control command and output the amplified voltage signal to the corresponding switch board. The current signal output unit is used to receive the control command, generate the current signal under the control command, and output the current signal to the corresponding switch board; the short circuit unit is used to generate the open circuit signal, the short circuit to ground signal, or the mutual short circuit signal. The switch board includes a switch switching unit, which is electrically connected to the corresponding voltage signal amplification unit, current signal output unit, and short-circuit unit, and is used to send the fault signal to the device under test according to the control command.

3. The fault signal injection system according to claim 2, characterized in that, The signal board includes N signal channels. Each signal channel is provided with a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit. Each signal channel is used to generate a fault signal. N is an integer greater than or equal to 1. The switch board includes N switch channels that correspond one-to-one with the N signal channels. Each switch channel is equipped with a switch switching unit for outputting the corresponding fault signal.

4. The fault signal injection system according to claim 2, characterized in that, The switching unit is used to connect one of the voltage signal amplification unit, the current signal output unit, and the short-circuit unit to the device under test based on the control command.

5. The fault signal injection system according to claim 2, characterized in that, The current signal output unit includes: The second voltage signal output unit is used to output a voltage signal under the control command; The current signal conversion unit is electrically connected to the second voltage signal output unit and is used to convert the voltage signal into the current signal under the control command.

6. The fault signal injection system according to claim 1, characterized in that, Based on the number of devices under test, determine the number of combinations of signal boards and switch boards.

7. The fault signal injection system according to claim 1, characterized in that, Each set of signal boards and switch boards is connected in parallel to the host computer via a communication bus.

8. The fault signal injection system according to claim 1, characterized in that, The length of both the signal board and the switch board is less than or equal to 220 mm, and the width is less than or equal to 100 mm.

9. A fault signal injection method, characterized in that, The fault signal is a voltage signal, current signal, open circuit signal, short circuit to ground signal, or mutual short circuit signal, including: The host computer sends control commands to a combination of several signal boards and switch boards; The signal board in the combination of several groups of signal boards and switch boards generates the fault signal based on the control command, and the switch board sends the fault signal to several devices under test based on the control command.

10. The fault signal injection method according to claim 9, characterized in that, The signal board includes a first voltage signal output unit, a voltage signal amplification unit, a current signal output unit, and a short-circuit unit. The switch board includes a switch switching unit, which is electrically connected to the corresponding voltage signal amplification unit, current signal output unit, and short-circuit unit. The signal boards in the combination of the plurality of signal boards and switch boards generate the fault signal based on the control command, and the switch boards send the fault signal to a plurality of devices under test based on the control command, including: Based on the control command, the plurality of signal boards control the voltage signal amplification unit, current signal output unit and short-circuit unit in the signal boards to generate the fault signal; Based on the control command, several switch boards corresponding to the signal board control the switch switching unit to send the fault signal generated by the signal board to the device under test.

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