Packaging machine electric cabinet and junction box testing device and method

Abstract

The invention discloses a packaging machine electric control box and junction box testing device and method, and belongs to the technical field of packaging machine testing. The device comprises a short circuit testing module, an external power supply module, a signal testing module and a man-machine interface industrial personal computer module; substation hot plugging, independent testing and multi-specification equipment compatibility are realized. The test method comprises the following steps: sequentially executing short-circuit test, signal test preparation, system initialization and to-be-tested specification selection, and then completing automatic self-diagnosis, parallel test and manual auxiliary test of digital quantity and analog quantity; the human-computer interface integrates the functions of progress marking, remote control screen switching and one-key testing. In order to solve the problems that a tested object is complex and multiple test points exist, high test efficiency is achieved through multiple means and functions such as signal self-diagnosis, test progress marking, multi-path parallel test and one-key test.

Description

Technical Field

[0001] This invention belongs to the field of packaging machine testing technology, specifically relating to a testing device and method for the electrical control box and junction box of a packaging machine. Background Technology

[0002] Large packaging machines typically have numerous control boxes and junction boxes. Taking a cigarette packaging machine as an example, it consists of a small-packet main unit, a small-packet transparent paper packaging machine, a carton packaging machine, and a carton transparent paper packaging machine. Each unit has its own control box and junction box. These control boxes do not contain controllers and cannot operate independently. Furthermore, the control boxes contain numerous sensor signal lines and power supply lines, resulting in complex wiring. The control boxes and junction boxes also connect to a variety of external devices, including encoders, push-button switches, proximity switches, photoelectric switches, thermocouple temperature sensors, indicator lights, solenoid valves, and valve islands. During the packaging machine's production and assembly process, it is necessary to test the wiring correctness of the control boxes and junction boxes to check for short circuits, open circuits, and incorrect or reversed signal wire connections. The ability to quickly check wiring correctness and identify external equipment faults is crucial for improving production efficiency.

[0003] CN117784750A discloses an automatic testing device and method for aviation control box products. The automatic testing device includes a signal and test simulation subsystem, a signal conditioning box, a programmable power supply, a robotic arm control subsystem, a power distribution system, a test adapter, a human-machine interface, and a mounting platform for the product under test. It improves testing efficiency and the accuracy of light detection judgment, ensures the completeness of product test result recording, improves the visualization of product test results, and solves the problem of requiring a large amount of manpower and time for product testing. However, this device, used for automatic testing of aviation control box products, lacks parallel testing and test progress marking functions.

[0004] CN211061896U discloses a multi-channel cold storage electrical control box testing device, including a printed circuit board and a main control circuit, a multi-channel signal indication circuit, a multi-channel branch control circuit, and a multi-channel branch test circuit respectively disposed on the printed circuit board. The number of signal indication circuits, the number of branch control circuits, and the number of branch test circuits are all the same. Each branch test circuit is electrically connected to the main control circuit in sequence through a corresponding branch control circuit and a corresponding signal indication circuit, and each branch test circuit is also directly electrically connected to the main control circuit. This device enables simultaneous testing of multi-channel signal acquisition and multi-channel output control, facilitating the analysis of the control output timing of each cold storage electrical control box, real-time analysis of data differences, more systematic and centralized testing, convenient debugging, and significantly improved efficiency, which helps ensure the stability, control accuracy, continuity, and safety of the electrical control box. However, this device is for testing multi-channel cold storage electrical control boxes and is not compatible with testing electrical control boxes of different specifications. Summary of the Invention

[0005] To address the current situation where most packaging machine manufacturers rely on manual inspection and testing of signals without a visual interface or predefined test logic, resulting in low efficiency, this invention proposes a testing device and method for packaging machine electrical control boxes and junction boxes to improve testing efficiency.

[0006] To achieve the above objective 1, the present invention adopts the following technical solution: A testing device for an electrical control box and junction box of a packaging machine includes a short-circuit testing module, an external power supply module, a signal testing module, and a human-machine interface industrial control computer; The short-circuit test module consists of a test power supply circuit, a current detection circuit, test probes and a buzzer, and is used to perform short-circuit tests on the high-voltage circuits of the electrical control box and junction box. The external power supply module consists of a switching power supply, a DC circuit breaker with auxiliary contacts, and a power cable, and is used to provide working power to the electrical control box, junction box, and its associated sensors. The signal testing module consists of a PLC controller, a safety controller, an industrial bus switch, a test signal generation circuit, a feedback signal receiving circuit, a communication cable, and a test cable. The human-machine interface industrial control computer is an integrated industrial control computer that runs the human-machine interface software of the testing device, which serves as the human-machine interaction interface for starting the test and displaying and recording the test results. The industrial bus switch connects each electrical control box and distribution box station to the test device in a star topology. The test device uses a synchronous unit data grouping function to independently group the data of each electrical control box station, dividing the main data frame of the industrial bus into sub-data frames corresponding to each synchronous unit, thereby enabling hot-swapping and individual testing of each electrical control box and distribution box station.

[0007] Furthermore, the human-machine interface software has a test progress marking function and a remote screen switching function; The test progress marking function is achieved by real-time detection of changes in the level signals of each input sensor. When the sensor signal level changes twice, the signal is marked as measured. The ratio of the number of measured signals to the total number of signals is the test progress. In the interface software, unmeasured signals are represented by red indicator lights, and measured signals are represented by green indicator lights. Among them, low-level unmeasured signals are dark red, high-level unmeasured signals are bright red, low-level measured signals are dark green, and high-level measured signals are bright green. The remote screen switching function uses the PLC controller to determine the changing sensor signals and automatically switches to the interface where the current sensor signal is located.

[0008] Furthermore, the PLC controller has a built-in test program, which formulates test logic based on the specific wiring diagram of the electrical control box and junction box under test. The PLC controller controls the test signal generation circuit to generate test signals, and at the same time, the feedback signal receiving circuit detects whether the module signals of the electrical control box and junction box meet the expectations. Matrix scanning technology is used to quickly locate fault points, and a multi-channel signal parallel testing method is used to shorten the test time.

[0009] Furthermore, the testing device has an output signal self-diagnostic function; The output signals of the electrical control box and junction box are sequentially set to high level through industrial bus communication, and the sampling resistor in the feedback signal receiving circuit collects the current in the output circuit. If the current is lower than the lower current threshold, it is determined that there is an open circuit in the output circuit; If the current exceeds the upper current threshold, the output will be immediately set to a low level, indicating a short circuit in the output circuit and prompting the user to perform a manual inspection.

[0010] Furthermore, the testing device has the function of parallel testing of multiple signals; Different digital output signal channels are set with different output frequencies, and different analog output signal channels are set with different output amplitudes, which are then output externally through the test signal generation circuit. The feedback signal receiving circuit acquires the response signals from the modules in the electrical control box and junction box, judges the wiring correctness of the multi-channel test circuit by the frequency and amplitude of the response signals, and generates a test report.

[0011] Furthermore, the testing device adopts a portable carrying structure, the front of the test platform has a concave shape, and is divided into three sections: a short-circuit test area, a communication test area, and a power supply test area. The testing device is equipped with handles on the left and right sides and top, and a testing trolley is also provided. The top surface of the test cart uses a 10mm aluminum plate as the test platform for placement and fixation, and a storage cabinet for storing test tools and cables is set under the cart.

[0012] To achieve the above objective 2, the present invention adopts the following technical solution: A testing method for the electrical control box and junction box of a packaging machine, using the testing device for the electrical control box and junction box of a packaging machine as described above, includes the following steps: Step 1: First, use the short-circuit test probes of the special testing device for the electrical control box and junction box of the packaging machine to test the high-voltage interface and 24V power supply interface in the electrical control box and junction box to be tested. If a short circuit fault is detected, the buzzer will sound an alarm to prompt manual troubleshooting. After the fault is eliminated, the test will be repeated. If there is no short circuit in the high-voltage interface and the 24V power supply interface, proceed to Step 2. Step 2: Disconnect the power supply to the high-voltage interface of the electrical control box and junction box under test, stop the air supply to the packaging machine's sub-unit, and connect the test device to the electrical control box and junction box under test using a power cable and a communication cable. Step 3: Power on the packaging machine electrical control box and junction box testing device. On the human-machine interface software, select the specifications and models that match the electrical control box and junction box to be tested. After selection, the testing device completes initialization and enters the testing interface. Step 4: First, the testing device automatically performs open-circuit and short-circuit tests on the digital output circuit in sequence, and generates a digital output signal test and diagnostic report. Step 5: The tester uses a metal sheet to cover each sensor on the packaging machine body in turn, observes the changes in the indicator lights on the human-machine interface, and verifies the correctness of the signal wiring. Step 6: Set different switching frequencies for different digital output signals to achieve parallel testing of digital output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of digital output signals. Step 7: The tester moves the swing arms of each analog actuator to change the analog input of the sensor, observes the analog dial and the changes in the values ​​on the human-machine interface, and verifies the correctness of the signal wiring. Step 8: Set different amplitude values ​​for different analog output signals to achieve parallel testing of analog output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of analog outputs.

[0013] The beneficial technical effects of this invention are as follows: 1. This invention uses an industrial bus star topology connection combined with the data grouping function of the synchronization unit to realize the function of a single test device that can test electrical control boxes and junction boxes of different specifications, thereby reducing the size and cost of the test device.

[0014] 2. The packaging machine's electrical control box and junction box testing device has a signal diagnostic function, which can automatically determine the signal line leakage and short circuit faults in the electrical control box and junction box.

[0015] 3. The packaging machine electrical control box and junction box testing device sets different output signal frequencies for different digital output channels and different signal amplitudes for different analog output channels, thereby enabling parallel testing of multiple output signals and generating test reports.

[0016] 4. The human-computer interaction interface is user-friendly and has remote screen switching and test progress marking functions, which reduces manual screen switching, avoids signal retesting and missed tests, and improves test efficiency.

[0017] 5. The packaging machine's electrical control box and junction box testing device have an ingenious structural design, adopting a portable carrying structure and a matching test trolley, which facilitates mobile testing in different application scenarios. Attached Figure Description

[0018] Figure 1 This is a block diagram of the packaging machine electrical control box and junction box testing device in this invention; Figure 2 This is a structural appearance diagram of the packaging machine electrical control box and junction box testing device in this invention; Figure 3 This is a flowchart of the testing procedure for the packaging machine electrical control box and junction box testing device in this invention; Detailed Implementation

[0019] The specific embodiments of the present invention will be further described below with reference to specific examples: A testing device for the electrical control box and junction box of a packaging machine, such as Figure 1 As shown, it includes a short-circuit test module, an external power supply module, a signal test module, and a human-machine interface industrial control computer; The short-circuit test module consists of a test power supply circuit, a current detection circuit, test probes, and a buzzer, and is used to perform short-circuit tests on the high-voltage circuits of the electrical control box and junction box. The external power supply module consists of a switching power supply, a DC circuit breaker with auxiliary contacts, and a power cable, and is used to provide working power to the electrical control box, junction box, and its associated sensors. The signal testing module consists of a PLC controller, a safety controller, an industrial bus switch, a test signal generation circuit, a feedback signal receiving circuit, communication cables, and test cables. The PLC controller implements the test logic and performs feedback signal judgment. The safety controller tests and judges the safety modules and safety signals of the electrical control box and junction box. The industrial bus switch acts as a bridge for communication between the PLC controller and the packaging machine's electrical control box and junction box, establishing a communication connection via communication cables. The test signal generation circuit receives PLC instructions to provide digital and analog test signals, and the feedback signal receiving circuit receives signals from the electrical control box's output modules and sends them to the PLC controller of the testing device. The human-machine interface industrial control computer is an all-in-one industrial control computer that runs the human-machine interface software of the test device, which serves as the human-machine interaction interface for starting the test and displaying and recording the test results. The industrial bus switch connects each electrical control box and junction box station to the testing device in a star topology. The testing device uses a synchronous unit data grouping function to independently group the data of each electrical control box station. The main data frame of the industrial bus is divided into sub-data frames corresponding to each synchronous unit, ensuring that the communication between each electrical control box station and the testing device does not interfere with each other. This enables hot-swapping and individual testing of each electrical control box and junction box station, thus realizing the function of a single electrical control box testing device that is compatible with testing electrical control boxes and junction boxes of different specifications.

[0020] Specifically, the human-computer interface software has test progress marking function, remote screen switching function and one-click test function; The test progress marking function is achieved by real-time detection of changes in the level signals of each input sensor. When the sensor signal level changes twice, the signal is marked as measured. The ratio of the number of measured signals to the total number of signals is the test progress. In the interface software, unmeasured signals are represented by red indicator lights, and measured signals are represented by green indicator lights. Low-level unmeasured signals are dark red, high-level unmeasured signals are bright red, low-level measured signals are dark green, and high-level measured signals are bright green. This helps to avoid repeated testing and missed testing, and improves testing efficiency. The remote screen switching function uses the PLC controller to detect changing sensor signals and automatically switches to the interface where the current sensor signal is located, avoiding frequent manual interface switching.

[0021] Furthermore, the one-click testing function of the human-machine interface software enables efficient centralized testing of specific components: for multi-input sensors such as absolute encoders and cigarette detectors in the cigarette storage area, and for relatively compact and centralized output mechanisms such as valve islands, one-click testing improves testing efficiency. First, the sensors, encoders, valve islands, and other actuators in the input / output modules of the electrical control box are identified and classified. The absolute encoder has approximately 12 digital inputs, the cigarette detector in the cigarette storage area has 20 signal inputs, and the valve island also has approximately 20 digital outputs. For these relatively concentrated multi-input / output sensors, the tested object is treated as a whole for testing. Each valve plate in the valve island is sequentially set to a high level, and a sequential indicator light is used for judgment. The 20 signals of the cigarette detector in the cigarette storage area are centrally tested. The phase of the absolute encoder is calculated by measuring the input states, and the phase changes are manually observed to ensure they are normal, thus completing the overall test of the encoder signals.

[0022] Specifically, the PLC controller has a built-in test program, which formulates test logic based on the specific wiring diagram of the electrical control box and junction box under test. The PLC controller controls the test signal generation circuit to generate test signals. At the same time, the feedback signal receiving circuit detects whether the module signals of the electrical control box and junction box meet the expectations. Matrix scanning technology is used to quickly locate fault points, and a multi-channel parallel testing method is used to shorten the test time and improve test efficiency.

[0023] Specifically, the testing device has an output signal self-diagnosis function, which can automatically determine whether there are open circuit or short circuit faults in the relevant modules of the electrical control box and junction box; The output signals of the electrical control box and junction box are sequentially set to high level through industrial bus communication, and the sampling resistor in the feedback signal receiving circuit collects the current in the output circuit. If the current is lower than the lower current threshold, it is determined that there is an open circuit in the output circuit and there may be a missing connection in the output signal line. If the current exceeds the upper current threshold, the output will be immediately set to a low level, indicating a short circuit in the output circuit and prompting the user to perform a manual inspection.

[0024] Specifically, the testing device has the function of parallel testing of multiple signals; Different digital output signal channels are set with different output frequencies, and different analog output signal channels are set with different output amplitudes, which are then output externally through the test signal generation circuit. The feedback signal receiving circuit acquires the response signals from the modules in the electrical control box and junction box, judges the wiring correctness of the multi-channel test circuit by the frequency and amplitude of the response signals, and generates a test report.

[0025] Specifically, such as Figure 2 As shown, the testing device adopts a portable carrying structure. The front of the test platform has a concave shape and is divided into three zones: a short-circuit test area, a communication test area, and a power supply test area. The zones are clearly defined, the operation is simple, and it is convenient to insert and remove connectors stably. The test device is equipped with handles on the left, right, and top sides, and a test cart is provided to facilitate moving and testing in different application scenarios. The top surface of the test cart uses a 10mm aluminum plate as the placement and fixing plane for the test platform, and a storage cabinet for storing test tools and cables is set under the cart.

[0026] A testing method for the electrical control box and junction box of a packaging machine, such as Figure 3 As shown, the testing device for the electrical control box and junction box of a packaging machine, as described above, includes the following steps: Step 1: Short circuit test: First, use the short circuit test probes of the special test device for the packaging machine's electrical control box and junction box to test the high-voltage interface and 24V power supply interface inside the electrical control box and junction box under test. If a short circuit fault is detected, the buzzer will sound an alarm to prompt manual troubleshooting. After the fault is resolved, the test will be repeated. If there is no short circuit in the high-voltage interface and the 24V power supply interface, proceed to Step 2. Step 2: Signal test preparation: Disconnect the power supply to the high-voltage interface of the control box and junction box under test, stop the air supply to the packaging machine's sub-unit, and connect the test device to the control box and junction box under test using power cables and communication cables. Step 3: Power on the packaging machine electrical control box and junction box testing device. On the human-machine interface software, select the specifications and models that match the electrical control box and junction box to be tested. After selection, the testing device completes initialization and enters the testing interface. Step 4: First, the testing device automatically performs open-circuit and short-circuit tests on the digital output circuit in sequence, and generates a digital output signal test and diagnostic report. Step 5: Digital input signal test: The tester uses a metal sheet to cover each sensor on the packaging machine body in turn, observes the changes in the indicator lights on the human-machine interface, and verifies the correctness of the signal wiring. Step 6: Digital output signal test: Different switching frequencies are set for different digital output signals to achieve parallel testing of digital output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of digital output signals. Step 7: Analog Input Test: The tester moves the swing arms of each analog actuator to change the analog input of the sensor, observes the analog dial and the changes in the values ​​on the human-machine interface, and verifies the correctness of the signal wiring. Step 8: Analog Output Signal Test: Different amplitude values ​​are set for different analog output signals to achieve parallel testing of analog output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of analog output.

[0027] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A testing device for an electrical control box and junction box of a packaging machine, characterized in that, It includes a short-circuit test module, an external power supply module, a signal test module, and a human-machine interface industrial control computer; The short-circuit test module consists of a test power supply circuit, a current detection circuit, test probes and a buzzer, and is used to perform short-circuit tests on the high-voltage circuits of the electrical control box and junction box. The external power supply module consists of a switching power supply, a DC circuit breaker with auxiliary contacts, and a power cable, and is used to provide working power to the electrical control box, junction box, and its associated sensors. The signal testing module consists of a PLC controller, a safety controller, an industrial bus switch, a test signal generation circuit, a feedback signal receiving circuit, a communication cable, and a test cable. The human-machine interface industrial control computer is an integrated industrial control computer that runs the human-machine interface software of the testing device, which serves as the human-machine interaction interface for starting the test and displaying and recording the test results. The industrial bus switch connects each electrical control box and distribution box station to the test device in a star topology. The test device uses a synchronous unit data grouping function to independently group the data of each electrical control box station, dividing the main data frame of the industrial bus into sub-data frames corresponding to each synchronous unit, thereby enabling hot-swapping and individual testing of each electrical control box and distribution box station.

2. The packaging machine electrical control box and junction box testing device according to claim 1, characterized in that, The human-machine interface software has a test progress marking function and a remote screen switching function; The test progress marking function is achieved by real-time detection of changes in the level signals of each input sensor. When the sensor signal level changes twice, the signal is marked as measured. The ratio of the number of measured signals to the total number of signals is the test progress. In the interface software, unmeasured signals are represented by red indicator lights, and measured signals are represented by green indicator lights. Among them, low-level unmeasured signals are dark red, high-level unmeasured signals are bright red, low-level measured signals are dark green, and high-level measured signals are bright green. The remote screen switching function uses the PLC controller to determine the changing sensor signals and automatically switches to the interface where the current sensor signal is located.

3. The packaging machine electrical control box and junction box testing device according to claim 1, characterized in that, The PLC controller has a built-in test program, which formulates test logic based on the specific wiring diagram of the electrical control box and junction box under test. The PLC controller controls the test signal generation circuit to generate test signals, and at the same time, the feedback signal receiving circuit detects whether the module signals of the electrical control box and junction box meet the expectations. Matrix scanning technology is used to quickly locate fault points, and a multi-channel signal parallel testing method is used to shorten the test time.

4. The packaging machine electrical control box and junction box testing device according to claim 1, characterized in that, The testing device has a self-diagnostic function for the output signal; The output signals of the electrical control box and junction box are sequentially set to high level through industrial bus communication, and the sampling resistor in the feedback signal receiving circuit collects the current in the output circuit. If the current is lower than the lower current threshold, it is determined that there is an open circuit in the output circuit; If the current exceeds the upper current threshold, the output will be immediately set to a low level, indicating a short circuit in the output circuit and prompting the user to perform a manual inspection.

5. The packaging machine electrical control box and junction box testing device according to claim 1, characterized in that, The testing device has the function of parallel testing of multiple signals; Different digital output signal channels are set with different output frequencies, and different analog output signal channels are set with different output amplitudes, which are then output externally through the test signal generation circuit. The feedback signal receiving circuit acquires the response signals from the modules in the electrical control box and junction box, judges the wiring correctness of the multi-channel test circuit by the frequency and amplitude of the response signals, and generates a test report.

6. The packaging machine electrical control box and junction box testing device according to claim 1, characterized in that, The testing device adopts a portable carrying structure, the front of the test platform is concave, and it is divided into three areas: short circuit test area, communication test area and power supply test area. The testing device is equipped with handles on the left and right sides and top, and a testing trolley is also provided. The top surface of the test cart uses a 10mm aluminum plate as the test platform for placement and fixation, and a storage cabinet for storing test tools and cables is set under the cart.

7. A testing method for the electrical control box and junction box of a packaging machine, using the testing device for the electrical control box and junction box of a packaging machine as described in any one of claims 1-6, comprising the following steps: Step 1: First, use the short-circuit test probes of the special testing device for the electrical control box and junction box of the packaging machine to test the high-voltage interface and 24V power supply interface in the electrical control box and junction box to be tested. If a short circuit fault is detected, the buzzer will sound an alarm to prompt manual troubleshooting. After the fault is eliminated, the test will be repeated. If there is no short circuit in the high-voltage interface and the 24V power supply interface, proceed to Step 2. Step 2: Disconnect the power supply to the high-voltage interface of the electrical control box and junction box under test, stop the air supply to the packaging machine's sub-unit, and connect the test device to the electrical control box and junction box under test using a power cable and a communication cable. Step 3: Power on the packaging machine electrical control box and junction box testing device. On the human-machine interface software, select the specifications and models that match the electrical control box and junction box to be tested. After selection, the testing device completes initialization and enters the testing interface. Step 4: First, the testing device automatically performs open-circuit and short-circuit tests on the digital output circuit in sequence, and generates a digital output signal test and diagnostic report. Step 5: The tester uses a metal sheet to cover each sensor on the packaging machine body in turn, observes the changes in the indicator lights on the human-machine interface, and verifies the correctness of the signal wiring. Step 6: Set different switching frequencies for different digital output signals to achieve parallel testing of digital output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of digital output signals. Step 7: The tester moves the swing arms of each analog actuator to change the analog input of the sensor, observes the analog dial and the changes in the values ​​on the human-machine interface, and verifies the correctness of the signal wiring. Step 8: Set different amplitude values ​​for different analog output signals to achieve parallel testing of analog output signals. Click the test button on the human-machine interface to achieve one-click automatic testing of analog outputs.

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