Electronic control intelligent detection method, system and device for sewing machine

Abstract

The application relates to a sewing machine electric control intelligent detection method, system and device, wherein the method comprises the following steps: based on a preset time sequence, difference control instructions are sequentially sent to a sewing machine electric control, each difference control instruction comprises a motor identifier and an action parameter of the sewing machine electric control; in response to the difference control instruction, a driving circuit corresponding to the motor identifier in the sewing machine electric control drives a load motor to execute a test action corresponding to the action parameter; when each load motor executes the corresponding test action, the running feedback signal of the corresponding load motor is synchronously acquired, and the electric parameter of the driving circuit driving the load motor is synchronously collected; based on the running feedback signal and the electric parameter, the load motor and the driving circuit are associated analyzed to obtain a fault detection result. The application can solve the problem that in the related art, the fault identification effect of the sewing machine electric control driving circuit and the motor is poor based on an automatic detection process.

Description

Technical Field

[0001] This application relates to the field of intelligent detection technology for sewing machine electronic control systems, and in particular to an intelligent detection method, system, and device for sewing machine electronic control systems. Background Technology

[0002] In the production and quality inspection process of sewing machines, efficient and reliable testing of their electronic control systems is a crucial step in ensuring overall machine performance and improving production efficiency. With the widespread adoption of automation technology, automated testing of electronic control systems has become a clear industry requirement.

[0003] In existing technologies, automated testing of sewing machine electrical controls can be achieved by sequentially driving each motor to perform basic actions such as zeroing. However, its core logic lies in sequentially verifying whether each predetermined function can be executed, which is a functional verification. This testing method fails to capture the deep connection between the real-time operational feedback of the motors and the electrical parameters of the drive circuit within the electrical control system. Therefore, it cannot effectively identify electrical faults in the drive circuit and motors, making it impossible to accurately locate the corresponding faults.

[0004] There is currently no effective solution to the technical problem of how to effectively identify faults in the electronic control drive circuit and motor of sewing machines based on automated detection processes. Summary of the Invention

[0005] This application provides a method, system, and device for intelligent detection of sewing machine electronic control systems to solve the problem that the identification of faults in the electronic control drive circuit and motor of sewing machines based on automated detection processes is not effective in related technologies.

[0006] In a first aspect, this application provides a sewing machine electronic control intelligent detection method, applicable to sewing machine electronic control intelligent detection devices; the method includes:

[0007] Based on a preset timing sequence, differentiated control commands are sent sequentially to the sewing machine electronic control unit. Each differentiated control command includes the motor identifier and action parameters of the sewing machine electronic control unit.

[0008] In response to the differentiated control command, the drive circuit in the sewing machine electronic control system corresponding to the motor identifier drives its load motor to perform a test action corresponding to the action parameters;

[0009] When each load motor performs the corresponding test action, the corresponding load motor's operation feedback signal is acquired synchronously, and the electrical parameters of the drive circuit driving the load motor are collected synchronously.

[0010] Based on the operational feedback signal and the electrical parameters, a correlation analysis is performed on the load motor and its drive circuit to obtain fault detection results.

[0011] In some embodiments, before sequentially sending differentiated control commands to the sewing machine electronic control unit, the method further includes:

[0012] Based on a preset communication protocol, a communication detection command is sent to the sewing machine's electronic control system through a pre-established communication link;

[0013] Receive response data returned by the sewing machine electronic control based on the communication detection command; the response data includes the model information of the sewing machine electronic control.

[0014] The response data is parsed to automatically identify the model information of the sewing machine's electronic control system and verify the operation of the communication link.

[0015] In some embodiments, the step of performing correlation analysis on the load motor and its drive circuit based on the operating feedback signal and the electrical parameters to obtain fault detection results includes:

[0016] Based on the operation feedback signal, the actual operating state of the corresponding load motor is analyzed, and the actual operating state is compared with the expected state of the test action executed by the load motor to obtain the first state determination result.

[0017] The electrical parameters of the drive circuit corresponding to the load motor are compared with the preset circuit parameter threshold range to obtain the second state determination result.

[0018] By combining the first state determination result and the second state determination result, the fault detection result of the load motor and the corresponding drive circuit is obtained.

[0019] In some further embodiments, the method further includes:

[0020] The operation feedback signal is a pulse sequence signal generated by an encoder coaxially connected to the corresponding load motor; the electrical parameters include the phase current and phase voltage of the drive circuit;

[0021] Based on the pulse sequence signal, at least one parameter among the speed, direction and position of the load motor is analyzed to obtain the first state determination result.

[0022] The real-time sampled phase current and phase voltage data are compared with the preset phase current threshold range and phase voltage threshold range, respectively, to obtain the second state determination result.

[0023] In some embodiments, prior to performing correlation analysis on the load motor and its drive circuit, the method further includes:

[0024] Each circuit component associated with a drive circuit in the sewing machine's electronic control system is pre-assigned a unique component identification identifier; wherein, the circuit component is a component that constitutes or is connected to the corresponding drive circuit.

[0025] In some further embodiments, after performing correlation analysis on the load motor and its drive circuit to obtain fault detection results, the method further includes:

[0026] Based on the motor identifier or component identification identifier corresponding to the faulty drive circuit, a preset test excitation signal is sequentially applied to each circuit component corresponding to the drive circuit.

[0027] Collect the response signals of each circuit component to the test excitation signal;

[0028] Analyze the degree of conformity between the response signal and the expected response, and locate the specific faulty component based on the degree of conformity.

[0029] In some embodiments, the method further includes:

[0030] Assign a unique interface identifier to all the function interfaces under test of the sewing machine's electronic control system;

[0031] Test commands are sent to the sewing machine's electronic control system via serial communication. The test commands include the interface identifier of the function interface under test and the expected logic level that the function interface under test is required to respond to.

[0032] Receive the actual logic level fed back from the corresponding function interface under test;

[0033] The actual logic level is compared with the expected logic level. When the actual logic level is consistent with the expected logic level, the corresponding function interface under test is determined to be qualified.

[0034] In some embodiments, the sewing machine electronic control includes multiple independent drive circuits, each drive circuit driving a load motor; the motor identifier is used to select the corresponding drive circuit and the corresponding load motor.

[0035] Secondly, this application provides a sewing machine electronic control intelligent detection system, applicable to sewing machine electronic control intelligent detection devices; the system includes a detection control module; the detection control module includes an instruction control unit, a drive response unit, a synchronization acquisition unit, and a fault analysis unit;

[0036] The instruction control unit is used to send differentiated control instructions to the sewing machine electronic control unit sequentially based on a preset timing sequence. Each differentiated control instruction includes the motor identifier and action parameters of the sewing machine electronic control unit.

[0037] The drive response unit is used to respond to the differentiated control command and control the drive circuit in the sewing machine electronic control that corresponds to the motor identifier, so as to drive its load motor to perform the test action corresponding to the action parameters.

[0038] The synchronous acquisition unit is used to synchronously acquire the running feedback signal of the corresponding load motor when each load motor performs the corresponding test action, and synchronously acquire the electrical parameters of the drive circuit driving the load motor.

[0039] The fault analysis unit is used to perform correlation analysis on the load motor and its drive circuit based on the operation feedback signal and the electrical parameters to obtain fault detection results.

[0040] Thirdly, this application provides a sewing machine electronic control intelligent detection device, including a machine housing;

[0041] The internal structure of the machine housing integrates the sewing machine electronic control intelligent detection system as described in Part Three;

[0042] The bottom of the chassis is equipped with an anti-slip pad, and the outer wall has an anti-static layer.

[0043] The chassis is equipped with a display screen and an interface module.

[0044] Compared with the prior art, the embodiments of this application have the following beneficial effects:

[0045] This application embodiment automates the testing process by driving a load motor to perform test actions using a sewing machine electronic control drive circuit. By simultaneously acquiring the load motor's operational feedback signal and the drive circuit's electrical parameters during test actions, it overcomes the shortcomings of isolated and asynchronous signal detection in existing technologies, enabling real-time monitoring of multi-dimensional signals under dynamic operating conditions. Through correlation analysis of the operational feedback signal and electrical parameters, it effectively identifies latent faults that are difficult to diagnose using a single signal dimension, such as phase loss or micro-short circuits. Based on the diagnostic results, targeted testing of related circuit components allows for precise fault localization to specific circuit components. This application embodiment can effectively identify and locate latent faults in the sewing machine's electronic control drive circuit based on an automated testing process.

[0046] Details of one or more embodiments of this application are set forth in the following drawings and description to make other features, objects and advantages of this application more readily apparent. Attached Figure Description

[0047] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0048] Figure 1 This is a flowchart of a sewing machine electronic control intelligent detection method provided in an embodiment of this application;

[0049] Figure 2 This is a flowchart of a communication detection process provided in an embodiment of this application;

[0050] Figure 3 This is a flowchart of an association analysis process provided in an embodiment of this application;

[0051] Figure 4 This is a flowchart of a fault location process provided in an embodiment of this application;

[0052] Figure 5 This is a block diagram of a sewing machine electronic control intelligent detection system provided in one embodiment of this application;

[0053] Figure 6 This is an overall block diagram of a sewing machine electronic control intelligent detection system provided in one embodiment of this application.

[0054] In the diagram: 510, Detection and control module; 511, Command and control unit; 512, Drive response unit; 513, Synchronous acquisition unit; 514, Fault analysis unit. Detailed Implementation

[0055] To better understand the purpose, technical solution, and advantages of this application, the application is described and illustrated below in conjunction with the accompanying drawings and embodiments.

[0056] Unless otherwise defined, the technical or scientific terms used in this application shall have the general meaning understood by one of ordinary skill in the art to which this application pertains. Words such as “a,” “an,” “an,” “the,” “the,” and “these” used in this application do not indicate quantitative limitation and may be singular or plural. The terms “comprising,” “including,” “having,” and any variations thereof used in this application are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or device that comprises a series of steps or modules (units) is not limited to the listed steps or modules (units) but may include steps or modules (units) not listed, or may include other steps or modules (units) inherent to these processes, methods, products, or devices. Words such as “connected,” “linked,” and “coupled” used in this application are not limited to physical or mechanical connections but may include electrical connections, whether direct or indirect. “Multiple” used in this application refers to two or more. “And / or” describes the relationship between related objects, indicating that three relationships may exist; for example, “A and / or B” can represent: A alone, A and B simultaneously, and B alone. Normally, the character " / " indicates that the objects before and after it are in an "or" relationship. The terms "first," "second," "third," etc., used in this application are merely to distinguish similar objects and do not represent a specific order.

[0057] This embodiment provides a method for intelligent detection of the electronic control system of a sewing machine, applicable to intelligent detection devices for the electronic control system of sewing machines. Figure 1 This is a flowchart of the intelligent electronic detection method for sewing machines in this embodiment, as shown below. Figure 1 As shown, the process includes the following steps:

[0058] Step S110: Based on a preset timing sequence, send differentiated control instructions to the sewing machine electronic control in sequence. Each differentiated control instruction includes the motor identifier and action parameters of the sewing machine electronic control.

[0059] The preset timing mentioned in this step refers to a pre-arranged sequence of instructions that executes each detection subtask according to a fixed time interval or logical order, ensuring the orderliness and repeatability of the detection process. Differential control instructions refer to command data packets designed for different functional motors within the sewing machine's electronic control system, such as the spindle motor, presser foot motor, and feed motor. These command data packets carry specific control content and parameters. Motor identifiers are unique identification codes assigned to each independently controllable motor in the sewing machine's electronic control system, used to accurately locate the control target during communication. Action parameters refer to the values ​​in the control instructions used to define the specific motion characteristics of the motor, such as the motor's rotation direction, target speed, runtime, and acceleration. This step, through programmed and time-sequential instruction scheduling, replaces the traditional manual setting and triggering of test items, achieving an automated starting point for the detection process and fundamentally avoiding sequence errors or omissions that may result from manual operation.

[0060] In step S120, in response to the differentiated control command, the drive circuit in the sewing machine electronic control system corresponding to the motor identifier drives its load motor to perform the test action corresponding to the action parameters.

[0061] The motor identifiers mentioned in this step correspond to the load motors. A single drive circuit can correspond to multiple load motors, or it can correspond to only a single load motor. Here, the load motors are pre-determined based on the motor identifiers, and then the drive motor that should be driven is determined based on the correspondence between the load motors and the drive circuits. This step achieves precise matching between instructions, drive circuits, and physical motors through motor identifiers, ensuring that test actions are accurately applied to the target object. Controlling the load motor to perform standardized test actions, such as forward rotation, reverse rotation, acceleration, and deceleration, through the drive circuit is the core link in achieving automated and standardized testing.

[0062] In step S130, when each load motor performs the corresponding test action, the corresponding load motor's operation feedback signal is acquired synchronously, and the electrical parameters of the drive circuit driving the load motor are collected synchronously.

[0063] The operational feedback signals mentioned in this step refer to the physical signals that reflect the real-time operating status of the load motor during operation; the electrical parameters of the drive circuit refer to the electrical quantities that characterize the circuit's operating status in the power circuit that provides drive energy to the load motor. This step uses a high-precision data acquisition circuit to simultaneously capture feedback signals from the mechanical side and operating parameters from the electrical side within the same time window of the motor's dynamic operation. This synchronous acquisition mechanism breaks through the limitations of traditional time-sharing and item-by-item detection, obtaining coupled data of the load and drive system under actual operating conditions, which is crucial for discovering hidden faults.

[0064] Step S140: Based on the operation feedback signal and electrical parameters, perform correlation analysis on the load motor and its drive circuit to obtain fault detection results.

[0065] The correlation analysis mentioned in this step refers to the process of cross-comparing, logically calculating, and jointly determining the operating feedback signals and electrical parameters from the same load motor system. The fault detection result here refers to the comprehensive status judgment conclusion made for the subsystem composed of the corresponding load motor and its corresponding drive circuit after correlation analysis, such as "qualified," "phase loss fault," "micro-short circuit fault," "encoder abnormality," or "insufficient drive capability." This step is the core of this invention for achieving high-precision fault diagnosis. For example, when there is a latent electrical fault such as a micro-short circuit in the drive circuit, the electrical parameters may show some abnormalities, but the feedback signal may not be abnormal; when the load motor has mechanical jamming, the feedback signal is abnormal, but the electrical parameters are normal. Traditional single-signal detection is prone to missing these faults. In this step, correlation analysis can identify latent electrical faults with inconsistent signal performance, thus improving the detection rate of latent electrical faults.

[0066] Through steps S110 to S140, this embodiment constructs an automated detection closed loop from instruction-driven operation, action execution, synchronous signal acquisition to data correlation analysis. Compared with related technologies, traditional manual inspection relies on operators visually, aurally, or using multimeters to perform point-by-point measurements under static or simple operating conditions. The detection signals are isolated and heavily dependent on personal experience. For example, an inspector might test the motor resistance separately and then test the motor rotation under no-load conditions, but cannot simultaneously monitor the matching relationship between current and speed under complex dynamic conditions such as motor loading and speed changes. Therefore, it is powerless to address faults such as dynamic imbalance and intermittent phase loss. This embodiment, however, simulates a real working scenario through automated timing control, acquires high-dimensional spatiotemporal correlation data through synchronous acquisition, and finally achieves model-based intelligent diagnosis through correlation analysis.

[0067] In summary, the method provided in this embodiment can effectively solve the problem in the prior art that the identification effect of faults in the electronic control drive circuit and motor of sewing machines based on automated detection processes is not good.

[0068] In some of these embodiments, please refer to Figure 2 Before sequentially sending differentiated control commands to the sewing machine's electronic control unit, the method also includes the following steps:

[0069] Based on a preset communication protocol, communication detection commands are sent to the sewing machine's electronic control system via a pre-established communication link.

[0070] The preset communication protocol mentioned in this step typically refers to a complete set of communication protocols agreed upon in advance between the intelligent detection device running the method of this embodiment and the electronic control of the sewing machine under test for exchanging data, including data format, transmission rate, and verification rules. The pre-established communication link refers to a communication channel that is physically connected by connectors and cables and logically initialized by the system, such as a UART serial port link. The communication detection command refers to a specific command data frame that conforms to the communication protocol format and is used to detect the presence of the sewing machine electronic control and enable basic interaction.

[0071] This step automates the most basic connectivity testing. Before deploying complex motor drives and signal detection, it first verifies that the physical connections and underlying communication are functioning correctly. This effectively prevents the entire testing process from failing due to basic issues such as loose connectors, broken cables, or the control unit not being powered on, thus avoiding wasted testing time.

[0072] Receive response data returned by the sewing machine electronic control based on the communication detection command; the response data includes the model information of the sewing machine electronic control.

[0073] The response data mentioned in this step refers to the response data packet organized and returned by the electronic control unit of the sewing machine under test after correctly receiving the communication test command, according to the same communication protocol format. In this step, receiving the response data not only confirms the smooth bidirectional communication link, but more importantly, it obtains the identification information of the electronic control unit. This transforms the machine model information, which traditionally required manual verification or input, into information automatically reported by the equipment, providing accurate identification data for subsequent processes.

[0074] If a response is received, the response data is parsed to automatically identify the model information of the sewing machine's electronic control system and verify the operation of the communication link. If the communication link is normal, the main detection process begins.

[0075] The parsing mentioned in this step refers to the process by which the intelligent detection system, according to known communication protocols, disassembles, verifies, and extracts valid information fields from the received raw response data byte stream. This step is the core of information processing and judgment. Through parsing, on the one hand, the electronic control unit model is accurately extracted, enabling automatic identification of the detection object and automatically calling the matching detection program library and parameter thresholds to prevent errors that may occur due to manual model selection; on the other hand, based on whether a response is received and whether the format and content of the response data are correct, the hardware circuitry and basic communication software functions of the communication link can be comprehensively judged to be qualified, completing the first step in diagnosing the core interactive capabilities of the electronic control unit.

[0076] If no response is received, the communication link is determined to be faulty, and the communication process ends due to failure.

[0077] The communication pre-inspection and model identification process described in this embodiment serves as a preliminary step in the entire automated testing process. By verifying the communication foundation beforehand, it avoids performing subsequent complex tests on invalid connections, thereby improving the reliability of the entire system. Furthermore, this method can replace the error-prone manual model selection or parameter setting, achieving plug-and-play identification and laying an accurate data foundation for full-process automation.

[0078] In some embodiments, the method further includes a power-on initialization step before sending differentiated control commands to the sewing machine electronic control system sequentially based on a preset timing sequence:

[0079] The general input / output ports of the intelligent detection device running the method of this embodiment are set to a preset initial closed state. The initial voltage data of the intelligent detection device itself is collected synchronously, and zero-point calibration is performed on the motor in the intelligent detection device. Subsequently, a communication handshake verification is performed with the interaction module of the intelligent detection device to confirm that the intelligent detection device is ready.

[0080] In some of these embodiments, please refer to Figure 3 Step S140 involves performing a correlation analysis on the load motor and its drive circuit based on the operating feedback signal and electrical parameters to obtain fault detection results, including the following steps:

[0081] Step S141: Based on the operation feedback signal, analyze the actual operating state of the corresponding load motor, compare the actual operating state with the expected state of the test action executed by the load motor, and obtain the first state determination result.

[0082] The analysis mentioned in this step refers to the process of decoding and calculating the operational feedback signal to extract specific physical quantities that directly characterize the motor's motion state. Actual operating state refers to the actual motion parameters of the load motor during the test, obtained through analyzing the operational feedback signal. Expected state refers to the theoretical motion state that the motor should achieve under normal response conditions, preset based on the motion parameters of the currently executed test action. The first state determination result refers to a preliminary judgment on whether the mechanical actuator of the load motor is functioning normally, derived by comparing the degree of conformity between the actual operating state and the expected state.

[0083] This step independently verifies the accuracy of the final execution of the command and action chain. Directly detecting whether the load motor correctly executes the control commands can effectively identify mechanical or sensor-related faults that cause the actual motion to deviate from the command requirements, such as motor stall, encoder damage, and transmission mechanism jamming.

[0084] Step S142: collect electrical parameters of the driving circuit corresponding to the load motor, compare the electrical parameters of the driving circuit corresponding to the load motor with a preset circuit parameter threshold range, and obtain a second state determination result. It should be understood that this step and step S141 can be executed in parallel simultaneously or sequentially, and neither execution order affects the final result.

[0085] The preset circuit parameter threshold range mentioned in this step refers to the safety and qualified value intervals of key electrical parameters preset according to the normal working characteristics of driving circuits for different types of motors. The second state determination result refers to the preliminary determination conclusion on whether the electrical performance of the driving circuit itself is normal, which is obtained by judging whether all the real-time collected electrical parameters of the driving circuit fall within their corresponding threshold ranges.

[0086] This step independently evaluates the electrical health status of the driving circuit. By monitoring whether the power supply and power output are stable and compliant, it can directly detect pure electrical faults such as overcurrent, undervoltage and output unbalance of the driving circuit.

[0087] Step S143: integrate the first state determination result and the second state determination result to obtain a fault detection result of the load motor and the corresponding driving circuit. In practical scenarios, if both or either of the two state determination results is unqualified, it is determined that a fault exists, and an unqualified result is output; if both state determination results are qualified, a qualified result is output, and the determination is ended. After a fault is determined, refined fault location can be optionally performed.

[0088] This step is the decision-making core of double verification. It is not a simple listing of two results, but a logical integration. For example, only when both the conditions of normal mechanical operation and normal electrical performance are satisfied, the overall motor system is determined to be qualified. This mechanism greatly improves the reliability and depth of diagnosis, and can identify hidden faults that are difficult to be detected by single-dimensional detection, such as slight phase loss or intermittent faults caused by poor contact.

[0089] In this embodiment, through dual-path independent verification and comprehensive decision-making of mechanical operation and electrical performance, a high-reliability fault diagnosis logic is constructed, which significantly improves the ability to identify complex hidden faults.

[0090] In some further embodiments, the method further comprises the following steps:[+

[0091] the operation feedback signal is a pulse sequence signal generated by an encoder coaxially connected to the corresponding load motor; the electrical parameters include phase current and phase voltage of the driving circuit.

[0092] The pulse sequence signal mentioned in this embodiment refers to a digital pulse signal with a fixed number and phase relationship, which is periodically generated by the rotary encoder as it rotates with the motor shaft. Its frequency is proportional to the motor speed, and its phase relationship can reflect the direction of rotation. Phase current and phase voltage specifically refer to the operating current flowing through each phase winding and the driving voltage applied to each phase winding in a multi-phase motor drive circuit. They are the core electrical parameters for evaluating the balance and load status of the drive circuit.

[0093] Based on the pulse sequence signal analysis, at least one parameter among the load motor's speed, direction of rotation, and position is used as the actual operating state to obtain the first state determination result.

[0094] This step transforms raw pulses into quantified motion information. Through the analysis process, the abstract pulse sequence is converted into specific physical quantities such as rotational speed and direction, which can be precisely mathematically compared with command values, significantly improving the accuracy and sensitivity of state assessment.

[0095] The real-time sampled phase current and phase voltage data are compared with the preset phase current threshold range and phase voltage threshold range, respectively, to obtain the second state determination result.

[0096] This step establishes clear acceptance criteria for electrical parameters. By comparing real-time data with preset threshold ranges set for different models and operating modes, a standardized and objective determination of the electrical state of the drive circuit is achieved. This replaces the fuzzy judgment method of relying on maintenance personnel's experience to observe oscilloscope waveforms or estimate current values ​​in traditional testing, making the second state determination results consistent and repeatable.

[0097] In some further embodiments, before synchronously acquiring the electrical parameters of the drive circuit driving the load motor, the method further includes:

[0098] Based on the initial voltage data collected during the power-on initialization process by the intelligent detection device equipped with the method of this embodiment, and the ambient temperature fed back by the temperature sensor, the analog-to-digital converter circuit is self-calibrated to eliminate zero-point drift and gain error, and to ensure the accuracy of voltage and current sampling.

[0099] In some embodiments, the method further includes the following steps before performing correlation analysis on the load motor and its drive circuit:

[0100] Each circuit component associated with a drive circuit in the sewing machine's electronic control system is pre-assigned a unique component identification identifier; wherein, a circuit component is a component that constitutes or is connected to the corresponding drive circuit.

[0101] The circuit components mentioned in this embodiment refer to the basic electronic components or modules that constitute the functional unit of the motor drive circuit or are directly electrically connected to it, such as specific power switching transistors, current sampling resistors, gate driver chips, fuses, connectors, etc. Component identification refers to a unique numerical or symbolic code assigned to each circuit component within the system, used to represent that specific physical component in software logic and diagnostic information.

[0102] This embodiment establishes a precise mapping relationship from physical hardware to digital information. By assigning a unique ID to each key component, a clear structural network is established at the logical level. This allows any detection result or fault phenomenon to be associated with a specific physical location, laying an indispensable data foundation for subsequent in-depth analysis from system-level fault alarms to component-level fault location, and is a prerequisite for achieving accurate maintenance.

[0103] In some further embodiments, please refer to Figure 4 After performing correlation analysis on the load motor and its drive circuit to obtain fault detection results, the method also includes the following steps:

[0104] The system receives fault detection results and determines whether they indicate a fault. If a fault exists, it sequentially applies preset test excitation signals to each circuit component corresponding to the faulty drive circuit, based on the motor identifier or component identification mark. In a real-world scenario, it can determine whether the fault is stably reproducible. If it is stably reproducible, the process continues; if the fault is not stably reproducible, it is determined to be a transient interference or a false alarm, and the process ends. If the fault detection results indicate that no fault exists, the process ends.

[0105] In this step, the test excitation signal refers to a specially designed electrical signal applied to diagnose the function of a specific circuit component, such as a voltage pulse of a specific amplitude, a square wave of a specific frequency, or a simulated load current signal.

[0106] This step initiates a proactive diagnostic process. Once an anomaly is detected in a drive circuit, this step automatically and systematically applies targeted test signals to each component within the circuit under diagnosis, based on established identifiers. This mimics the logic of experienced repair technicians using signal generators, multimeters, and other tools to troubleshoot point by point, but achieves automation and standardization.

[0107] When the fault is stably reproduced, the response signals of each circuit component to the test excitation signal are collected.

[0108] The response signal mentioned in this step refers to the electrical response, such as voltage and current, generated at the output terminal or relevant test point of the circuit component under test after receiving the test excitation signal.

[0109] This step acquires component-level diagnostic data. High-precision acquisition circuitry captures the actual response of each component under specific stimuli, providing direct evidence for judging its individual performance and replacing the manual touching of measurement points required in traditional maintenance.

[0110] Analyze the degree of conformity between the response signal and the expected response, locate the specific faulty component based on the degree of conformity, and the process ends.

[0111] The expected response mentioned in this step refers to the characteristics of the correct response signal that should theoretically be produced when a test stimulus signal is applied to a circuit component while it is functioning properly. The conformity refers to the degree of matching between the actual acquired response signal and the expected response signal in key features, which is usually quantitatively evaluated using algorithms.

[0112] This step uses an algorithm to automatically compare the actual response of each component with the expected response. When the response of a component deviates significantly from the standard, it can be identified as a faulty component. This achieves precise location of the fault point from a circuit module to a specific component.

[0113] This embodiment uses automated closed-loop testing, which can automatically and accurately locate the specific failed component after the system detects an anomaly, greatly shortening the repair and diagnosis time and reducing the requirements for the experience of repair personnel.

[0114] In some further embodiments, after obtaining the fault detection result, if the fault detection result indicates that a fault exists, the method further includes:

[0115] Based on the motor identifier or component identification mark that indicates the fault, the corresponding detection process is automatically repeated at least once to verify the stable reproducibility of the fault and avoid false alarms caused by momentary interference or poor contact.

[0116] In some embodiments, the method further includes the following steps:

[0117] Assign a unique interface identifier to all the interfaces of the sewing machine's electrical control system that are to be tested.

[0118] The interface under test (DUT) mentioned in this step refers to the digital input / output pins or ports on the sewing machine's electronic control system used to connect to external sensors, actuators, or other peripheral devices. The interface identifier is a unique identification code assigned to each DUT interface within the testing system, used to accurately locate the DUT in communication commands.

[0119] This step establishes a digital index of all I / O interfaces, enabling the software to precisely control and query each specific physical interface through identifiers, laying a structured management foundation for automated testing.

[0120] Test commands are sent to the sewing machine's electronic control system via serial communication. The test commands include the interface identifier of the function under test and the expected logic level that the function under test is required to respond to.

[0121] The expected logic level mentioned in this step refers to the level state that the target interface is expected to present, as specified in the test command, such as a high level like +24V or a low level like 0V.

[0122] This step enables remote, targeted control of a specific interface. The system sends structured commands via serial port, instructing the internal logic of the electronic control unit to drive the target interface or set internal pull-up / pull-down switches to the desired state, thereby initiating a specific test.

[0123] Receive the actual logic level fed back from the corresponding function interface under test.

[0124] This step obtains the actual response of the interface under test. For output interfaces, this could be the actual output level; for input interfaces, it could be the external test level applied by the detection system and read by the electronic control unit. This is the direct basis for judgment.

[0125] The actual logic level is compared with the expected logic level. If the actual logic level is consistent with the expected logic level, the corresponding function interface under test is deemed qualified.

[0126] This step automates the judgment. Through simple logical comparison, it objectively determines whether the interface circuit is functioning correctly. It completely replaces the traditional method of manually using a multimeter to test continuity or observing LEDs, offering high efficiency and unambiguity.

[0127] It should be understood that the overall process of this embodiment, as a comprehensive test of the electronic control I / O interface, can be arranged after the motor drive test process or as an independent test thread running in parallel with it in the complete test procedure. The logical premise is that the main communication link has been established. This sequential arrangement ensures that both the motor drive and the functional interface are systematically verified, together forming a complete electronic control automation test solution.

[0128] This embodiment integrates the traditionally cumbersome and scattered manual inspection of I / O interfaces into an automated, standardized testing process based on identifier addressing and logic comparison, which significantly improves the testing efficiency and reliability of the electronic control signal interface group.

[0129] In some further embodiments, after obtaining the fault detection result, the method further includes:

[0130] All test results, corresponding identifiers, timestamps, and equipment serial numbers are packaged according to a preset data format and uploaded to the server via a wired network or wireless communication module for quality analysis, production traceability, and progress monitoring.

[0131] In some embodiments, the sewing machine electronic control includes multiple independent drive circuits, each drive circuit driving a load motor; a motor identifier is used to select the corresponding drive circuit and the corresponding load motor.

[0132] The independent drive circuit mentioned in this embodiment refers to a power electronic circuit unit that is physically separated from the electronic control hardware and is dedicated to controlling and driving a motor with a specific function. "Selected" here means that, through a motor identifier, control commands, data acquisition, and status queries are accurately associated with the target drive circuit and its connected load motor in the software logic and communication protocol.

[0133] This embodiment clearly defines the topological relationship of the object under inspection: the electronic control system is a collection of multiple drive circuits and load motor pairs. It also clarifies that the core function of the motor identifier is to serve as a key index for accurately addressing and controlling the load motor and its corresponding drive circuit in the detection system. This ensures the accurate delivery of detection commands and the correct attribution of status data.

[0134] This embodiment also provides a sewing machine electronic control intelligent detection system, which is applicable to the above-described method embodiments and preferred embodiments, and will not be repeated as already described. The terms "module," "unit," "subunit," etc., used below refer to combinations of software and / or hardware that implement a predetermined function. Although the apparatus described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0135] Please refer to Figure 5 The system includes a detection and control module 510, which is the core control component of the system. Through the collaboration of hardware circuits and software, it realizes automated and intelligent detection of the sewing machine's electronic control. Specifically, the detection and control module 510 includes an instruction control unit 511, a drive response unit 512, a synchronous acquisition unit 513, and a fault analysis unit 514.

[0136] The instruction control unit 511 is used to send differentiated control instructions sequentially based on a preset timing sequence. Each differentiated control instruction includes the motor identifier and motion parameters of the sewing machine's electronic control.

[0137] The drive response unit 512 is used to respond to differentiated control commands and control the drive circuit in the sewing machine's electronic control system corresponding to the motor identifier, so as to drive its load motor to perform test actions corresponding to the action parameters.

[0138] The synchronous acquisition unit 513 is used to synchronously acquire the running feedback signal of the corresponding load motor when each load motor performs the corresponding test action, and synchronously acquire the electrical parameters of the drive circuit that drives the load motor.

[0139] The fault analysis unit 514 is used to perform correlation analysis on the load motor and its drive circuit based on the operation feedback signal and electrical parameters to obtain fault detection results.

[0140] It should be noted that the aforementioned instruction control unit, drive response unit, synchronization acquisition unit, and fault analysis unit can be either functional modules or program modules, and can be implemented in either software or hardware. For modules implemented in hardware, these modules can reside in the same processor; or they can be located in different processors in any combination.

[0141] In some of these embodiments, please refer to Figure 6 The system also includes:

[0142] The data management module is used to package all test results, identifiers, timestamps, and device information in a preset format after the testing process is completed, and upload them to the server or cloud via a communication interface.

[0143] The human-machine interface display module uses an industrial-grade touch LCD screen to display the detection status and results to the operator and to receive operation commands.

[0144] The interface connection module, including the interface adapter board and test cables, is used to establish a physical connection and signal path between the detection control module and the electrical control of the sewing machine under test.

[0145] The auxiliary detection module includes a motor of the same model as the original sewing machine's electronic control unit. Its operation is controlled by the detection control module to simulate real load during detection.

[0146] The power supply module, including a power socket, power switch, fuse and switching power supply, is used to provide a suitable and stable DC power supply for the entire system and the electrical control under test.

[0147] In some embodiments, the instruction control unit in the detection control module further includes:

[0148] The communication pre-inspection subunit is used to send communication detection commands to the sewing machine electronic control unit through a pre-established communication link based on a preset communication protocol before sending differentiated control commands. It also receives and parses the response data returned by the sewing machine electronic control unit to automatically identify the model information of the sewing machine electronic control unit and verify the operation of the communication link.

[0149] In some embodiments, the fault analysis unit in the detection control module includes:

[0150] The first determination subunit is used to analyze the actual operating state of the corresponding load motor based on the operation feedback signal, and compare the actual operating state with the expected state to obtain the first state determination result;

[0151] The second determination subunit is used to compare the electrical parameters of the driving circuit with the preset circuit parameter threshold range to obtain the second state determination result.

[0152] The comprehensive judgment subunit is used to combine the first state judgment result and the second state judgment result to generate the fault detection result of the load motor and the corresponding drive circuit.

[0153] In some further embodiments, the synchronous acquisition unit in the detection control module is specifically configured as follows:

[0154] The pulse sequence signal generated by the encoder coaxially connected to the load motor is used as the operation feedback signal, and the phase current and phase voltage of the drive circuit are collected as electrical parameters.

[0155] Furthermore, the detection control module also includes:

[0156] The signal analysis subunit is used to analyze the pulse sequence signal to obtain at least one parameter among the speed, direction and position of the load motor, and provide the parameter to the first judgment subunit of the fault analysis unit as the actual operating state.

[0157] The second judgment subunit of the fault analysis unit is specifically configured to compare the real-time sampled phase current and phase voltage data with the preset phase current threshold range and phase voltage threshold range, respectively.

[0158] In some embodiments, the detection control module further includes:

[0159] The identification management unit is used to pre-assign and store unique component identification identifiers for the circuit components associated with each drive circuit in the sewing machine's electronic control system; wherein, the circuit component is a component that constitutes or is connected to the corresponding drive circuit.

[0160] In some further embodiments, the fault analysis unit in the detection control module further includes:

[0161] The refined fault location subunit is used to, after obtaining the detection result indicating the fault, apply preset test excitation signals to each circuit component corresponding to the drive circuit in sequence based on the motor identifier or component identification mark corresponding to the drive circuit that has failed; collect the response signals of each circuit component to the test excitation signals; and analyze the degree of conformity between the response signals and the expected responses in order to locate the specific faulty component.

[0162] In some embodiments, the detection control module further includes:

[0163] The functional interface testing unit is used to assign a unique interface identifier to all the functional interfaces under test of the sewing machine electronic control; send test commands containing the interface identifier and expected logic level to the sewing machine electronic control via serial communication; receive the actual logic level fed back by the corresponding functional interface under test; and compare the actual logic level with the expected logic level to determine the interface qualification.

[0164] In some embodiments, the drive response unit in the detection control module is specifically configured to: select the corresponding drive circuit in the sewing machine electronic control system, which contains multiple independent drive circuits, based on the motor identifier, to drive its load motor to perform test actions.

[0165] In some further embodiments, the detection control module further includes:

[0166] Initialization and self-calibration unit, wherein:

[0167] The system initialization subunit is used to perform general input / output port status initialization, system voltage reference acquisition, motor zero-point calibration, and internal communication handshake after the system is powered on.

[0168] The ADC self-calibration subunit is used to perform self-calibration on the analog-to-digital converter circuit based on an initial reference and temperature feedback before the synchronous acquisition unit acquires electrical parameters.

[0169] In some embodiments, the fault analysis unit in the detection control module further includes:

[0170] The fault re-verification subunit is used to automatically control relevant units to repeat the corresponding detection process based on the fault identifier after generating the detection result indicating the fault, in order to verify the stable reproducibility of the fault.

[0171] This embodiment also provides a sewing machine electronic control intelligent detection device, including a machine housing;

[0172] The machine casing integrates any of the aforementioned intelligent electronic control detection systems for sewing machines;

[0173] The bottom of the chassis is equipped with anti-slip pads, and the outer wall has an anti-static layer;

[0174] The chassis is equipped with a display screen and interface modules.

[0175] In some embodiments, the internal layout of the chassis is partitioned, integrating a power supply module, a detection and control module, a human-machine interface module, and an auxiliary detection module. The power supply module includes a power socket, power switch, fuse, and switching power supply, providing a stable DC power supply for the entire device and the electrical control under test. The core of the detection and control module is an intelligent detection and control board integrating a microprocessor, motor drive circuit, voltage and current detection circuit, and communication interface circuit. The human-machine interface module is the display screen, using an industrial-grade touchscreen LCD. The auxiliary detection module includes a motor of the same model as the original sewing machine electrical control, driven by the detection and control module, used to simulate a real load during testing.

[0176] In some embodiments, the interface module includes an interface adapter board and test cables. The interface adapter board is fixed inside the chassis, with one side connected to the detection and control module via an internal wiring harness, and the other side providing a standardized external interface; the test cables are used to connect the external interface to the corresponding interface of the electrical control of the sewing machine under test, achieving precise docking.

[0177] In some further embodiments, the interface module is a bed-of-needle connector module. This module includes a probe matrix that uses pneumatic or mechanical pressing to bring the probes into direct contact with test points on the control board of the sewing machine under test, replacing the pluggable cable connection method and offering higher connection life and testing speed.

[0178] In some embodiments, the device also integrates a data communication module. This module can be a wired network interface based on a network cable, or it can integrate a wireless local area network and a wireless communication chip, used to package the detection data generated by the sewing machine's electronic control intelligent detection system and upload it to a remote server or cloud platform in real time.

[0179] In some further embodiments, the chassis is made of high-strength cold-rolled steel plate and has a cuboid structure. Internally, it features guide rails and mounting plates. The power supply module, detection and control module, etc., all adopt a modular design and are fixed via guide rails and mounting plates for easy maintenance and upgrades. The chassis surface is treated with anti-static spraying, and the bottom is fitted with rubber anti-slip pads to ensure the stability and safety of the equipment during detection operations.

[0180] This embodiment also provides a computer device, including a memory and a processor, wherein the memory stores a computer program and the processor is configured to run the computer program to perform the steps in any of the above method embodiments.

[0181] Optionally, the computer device may further include a transmission device and an input / output device, wherein the transmission device is connected to the processor and the input / output device is connected to the processor.

[0182] It should be noted that the specific examples in this embodiment can refer to the examples described in the above embodiments and optional implementations, and will not be repeated in this embodiment.

[0183] Furthermore, in conjunction with the sewing machine electronic control intelligent detection method provided in the above embodiments, this embodiment can also provide a storage medium for implementation. This storage medium stores a computer program; when executed by a processor, the computer program implements any of the sewing machine electronic control intelligent detection methods described in the above embodiments.

[0184] It should be noted that all information and data involved in this application are authorized by the user or fully authorized by all parties and will be used legally.

[0185] It should be understood that the specific embodiments described herein are merely illustrative of the application and not intended to limit it. All other embodiments derived by those skilled in the art based on the embodiments provided in this application without inventive effort are within the scope of protection of this application.

[0186] Obviously, the accompanying drawings are merely some examples or embodiments of this application. Those skilled in the art can apply this application to other similar situations based on these drawings without any creative effort. Furthermore, it is understood that although the work done in this development process may be complex and lengthy, for those skilled in the art, certain design, manufacturing, or production modifications made based on the technical content disclosed in this application are merely conventional technical means and should not be considered as insufficient disclosure of this application.

[0187] The term "embodiment" in this application refers to a specific feature, structure, or characteristic described in connection with an embodiment that may be included in at least one embodiment of this application. The appearance of this phrase in various places in the specification does not necessarily imply the same embodiment, nor does it imply that it is mutually exclusive with or independent of other embodiments. It will be clearly or implicitly understood by those skilled in the art that the embodiments described in this application may be combined with other embodiments without conflict.

[0188] The above embodiments merely illustrate several implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of patent protection. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application.

Claims

1. A sewing machine electronic control intelligent detection method, characterized in that, Applicable to intelligent electronic detection devices for sewing machines; the method includes: Based on a preset timing sequence, differentiated control commands are sent sequentially to the sewing machine electronic control unit. Each differentiated control command includes the motor identifier and action parameters of the sewing machine electronic control unit. The differentiated control command refers to a command data packet designed for different functional motors inside the sewing machine electronic control unit, and the command data packet carries targeted control content and parameters. In response to the differentiated control command, the drive circuit in the sewing machine electronic control system corresponding to the motor identifier drives its load motor to perform a test action corresponding to the action parameters; When each load motor performs the corresponding test action, the corresponding load motor's operation feedback signal is acquired synchronously, and the electrical parameters of the drive circuit driving the load motor are collected synchronously. Each circuit component associated with a drive circuit in the sewing machine's electronic control system is pre-assigned a unique component identification identifier; wherein, the circuit component is a component that constitutes or is connected to the corresponding drive circuit. Based on the operational feedback signal and the electrical parameters, a correlation analysis is performed on the load motor and its drive circuit to obtain a fault detection result. This includes: analyzing the actual operating state of the corresponding load motor based on the operational feedback signal; comparing the actual operating state with the expected state of the test action performed by the load motor to obtain a first state determination result; comparing the electrical parameters of the drive circuit corresponding to the load motor with a preset circuit parameter threshold range to obtain a second state determination result; and combining the first state determination result and the second state determination result to obtain a fault detection result for the load motor and its corresponding drive circuit. The operation feedback signal is a pulse sequence signal generated by an encoder coaxially connected to the corresponding load motor; the electrical parameters include the phase current and phase voltage of the drive circuit; based on the pulse sequence signal, at least one parameter of the load motor's speed, direction of rotation, and position is analyzed to obtain the actual operating state and thus the first state determination result is obtained; the real-time sampled phase current and phase voltage data are compared with preset phase current threshold ranges and phase voltage threshold ranges respectively to obtain the second state determination result; Based on the motor identifier or component identification mark corresponding to the faulty drive circuit, a preset test excitation signal is sequentially applied to each circuit component corresponding to the drive circuit; the response signal of each circuit component to the test excitation signal is collected; the degree of conformity between the response signal and the expected response is analyzed, and the specific faulty component is located based on the degree of conformity.

2. The intelligent electronic detection method for sewing machines according to claim 1, characterized in that, Before sequentially sending differentiated control commands to the sewing machine electronic control unit, the method further includes: Based on a preset communication protocol, a communication detection command is sent to the sewing machine's electronic control system through a pre-established communication link; Receive response data returned by the sewing machine electronic control based on the communication detection command; the response data includes the model information of the sewing machine electronic control. The response data is parsed to automatically identify the model information of the sewing machine's electronic control system and verify the operation of the communication link.

3. The intelligent electronic detection method for sewing machines according to claim 1, characterized in that, The method further includes: Assign a unique interface identifier to all the function interfaces under test of the sewing machine's electronic control system; Test commands are sent to the sewing machine's electronic control system via serial communication. The test commands include the interface identifier of the function interface under test and the expected logic level that the function interface under test is required to respond to. Receive the actual logic level fed back from the corresponding function interface under test; The actual logic level is compared with the expected logic level. When the actual logic level is consistent with the expected logic level, the corresponding function interface under test is determined to be qualified.

4. The intelligent electronic detection method for sewing machines according to claim 1, characterized in that, The sewing machine electronic control includes multiple independent drive circuits, each drive circuit drives a load motor; the motor identifier is used to select the corresponding drive circuit and the corresponding load motor.

5. A sewing machine electronic control intelligent detection system, characterized in that, This invention relates to an intelligent electronic detection device for sewing machines; the system includes a detection control module; the detection control module includes an instruction control unit, a drive response unit, a synchronization acquisition unit, and a fault analysis unit. The instruction control unit is used to send differentiated control instructions to the sewing machine electronic control unit sequentially based on a preset timing sequence. Each differentiated control instruction includes the motor identifier and action parameters of the sewing machine electronic control unit. The differentiated control instruction refers to a command data package designed for different functional motors inside the sewing machine electronic control unit, and the command data package carries targeted control content and parameters. The drive response unit is used to respond to the differentiated control command and control the drive circuit in the sewing machine electronic control that corresponds to the motor identifier, so as to drive its load motor to perform the test action corresponding to the action parameters. The synchronous acquisition unit is used to synchronously acquire the running feedback signal of the corresponding load motor when each load motor performs the corresponding test action, and synchronously acquire the electrical parameters of the drive circuit driving the load motor. The identification management unit is used to pre-assign a unique component identification identifier to each circuit component associated with each drive circuit in the sewing machine's electronic control system; wherein, the circuit component is a component that constitutes or is connected to the corresponding drive circuit. The fault analysis unit is used to perform correlation analysis on the load motor and its drive circuit based on the operation feedback signal and the electrical parameters to obtain fault detection results; The fault analysis unit includes: The first determination subunit is used to analyze the actual operating state of the corresponding load motor based on the operation feedback signal, compare the actual operating state with the expected state of the test action executed by the load motor, and obtain the first state determination result. The second determination subunit is used to compare the electrical parameters of the drive circuit corresponding to the load motor with a preset circuit parameter threshold range to obtain a second state determination result. The comprehensive judgment subunit is used to combine the first state judgment result and the second state judgment result to generate the fault detection result of the load motor and the corresponding drive circuit; The operation feedback signal is a pulse sequence signal generated by an encoder coaxially connected to the corresponding load motor; the electrical parameters include the phase current and phase voltage of the drive circuit; The signal analysis subunit is used to analyze the pulse sequence signal to obtain at least one parameter among the speed, direction and position of the load motor, and provide the parameter to the first judgment subunit of the fault analysis unit as the actual operating state. The second determination subunit is further configured to compare the real-time sampled phase current and phase voltage data with preset phase current threshold ranges and phase voltage threshold ranges, respectively, so as to obtain the second state determination result. The refined fault location subunit is used to sequentially apply preset test excitation signals to each circuit component corresponding to the drive circuit based on the motor identifier or component identification identifier corresponding to the faulty drive circuit; collect the response signals of each circuit component to the test excitation signals; analyze the degree of conformity between the response signals and the expected responses; and locate the specific faulty component based on the degree of conformity.

6. A sewing machine electronic control intelligent detection device, characterized in that, Including the chassis; The internal casing integrates the intelligent electronic control detection system for sewing machines as described in claim 5; The bottom of the chassis is equipped with an anti-slip pad, and the outer wall has an anti-static layer. The chassis is equipped with a display screen and an interface module.

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