Unmanned environment test system and method

Abstract

The invention provides an unmanned environment test system and method, and belongs to the technical field of environment test and automatic control, and the system comprises a superior management system, a centralized control subsystem as a control center, and a test condition subsystem, an intelligent operation subsystem and a safety monitoring subsystem as an execution and monitoring layer. The centralized control subsystem receives a task issued by the superior management system and then decomposes an instruction to the subsystem of the execution and monitoring layer; the intelligent operation subsystem drives the test condition subsystem to execute standardized operation through the PLC control system; the test condition subsystem adjusts environmental parameters according to instructions of the intelligent operation subsystem; and the safety monitoring subsystem monitors equipment and environment states in real time and triggers alarm and emergency measures, so that through organic combination of centralized control, environment condition simulation, standardized operation and the safety monitoring subsystem, unmanned transfer and automatic test of test products are realized, and the test efficiency, data accuracy and safety are improved.

Description

Technical Field

[0001] This application belongs to the field of environmental testing and automation control technology, specifically, it relates to an unmanned environmental testing system and method. Background Technology

[0002] Environmental testing is an indispensable and crucial step in product development, production, and quality certification. Its purpose is to simulate single or combined environmental stresses to accelerate the exposure of potential product defects and process weaknesses, thereby assessing its reliability, durability, and environmental adaptability, and providing a scientific basis for design improvements and quality judgments.

[0003] At present, most of the environmental testing systems widely used in the market are traditional manual operation modes, which have a series of defects and are difficult to adapt to the development needs of modern industrial intelligence, high efficiency and high reliability. (1) High labor costs: Environmental testing cycle is long and requires technicians to be on duty and inspect continuously. In particular, the labor costs are huge in continuous testing with three shifts. (2) Safety issues: In high-risk tests such as temperature and humidity, temperature shock, vibration and impact, the test products need to rely on personnel to handle, install and operate, which can easily generate safety hazards; some environmental test conditions are extremely harsh (such as extreme high and low temperatures, harmful gas environment), manual inspection has safety hazards, which may threaten the health of operators, and some test sites have high requirements for explosion-proof and anti-static, and traditional laboratories are insufficient in terms of safety protection. (3) Risks introduced by human error: Manual operation is difficult to guarantee the standardization and repeatability of the test process, and the accuracy and credibility of the test results are easily seriously affected. (4) Data fragmentation and risk lag: Test data is scattered in different equipment and different personnel, making it difficult to achieve real-time collection, storage and fusion processing analysis. The correlation between the occurrence of failures and specific environmental stresses is often delayed, making it impossible to achieve real-time and intelligent early warning during the experiment.

[0004] To address some of the aforementioned issues, some automated equipment has emerged on the market, such as robotic arms for sample handling or automatic control of individual test chambers. However, these improvements are partial and non-systematic, failing to fundamentally achieve unmanned and intelligent operation of the entire environmental testing process. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide an unmanned environmental testing system and method that can realize unmanned operation and automated control of the entire testing process, thereby improving testing efficiency, data accuracy and safety.

[0006] Firstly, this application provides an unmanned environmental testing system, which adopts a three-level system architecture, including: an upper-level management system, a centralized control subsystem as the control center, and a test condition subsystem, an intelligent operation subsystem, and a safety monitoring subsystem as the execution and monitoring layer; the subsystems are connected to each other using a hybrid communication architecture that combines industrial Ethernet, bus, and hardwired connections; The centralized control subsystem is used to receive tasks issued by the upper management system, decompose instructions to the execution and monitoring layer subsystems, summarize data, and analyze and process it. The intelligent operation subsystem is used to drive the test condition subsystem to perform standardized operations through the PLC control system. The test condition subsystem is used to adjust environmental parameters according to the instructions of the intelligent operation subsystem; The safety monitoring subsystem is used to monitor the status of equipment and the environment in real time, and to trigger alarms and emergency measures.

[0007] In some embodiments, the centralized control subsystem interacts with the upper-level management system via the OPC UA protocol; the centralized control subsystem is connected to the test condition subsystem, the intelligent operation subsystem, and the safety monitoring subsystem via Profinet industrial Ethernet; the intelligent operation subsystem is connected to the test condition subsystem via Modbus-RTU bus; the safety monitoring subsystem uses a dual link of hardwired connection and industrial Ethernet to connect with other subsystems, wherein emergency stop signals are transmitted via hardwired connection and status data is transmitted via industrial Ethernet.

[0008] In some embodiments, the command frames issued by the host computer include read / write register, read / write SRAM, software reset, and program boot.

[0009] In some embodiments, under program loading boot mode: The centralized control subsystem includes a hardware system and a software system; the hardware system includes a main control computer, a data server, terminal computers, a centralized display screen, and a network switch; the software system includes: The equipment management module is used to manage equipment ledger information, combine functions, and generate system configuration files; The test management module is used for the full lifecycle control of test projects, displaying test progress in real time and performing statistical analysis on test data; The status display and control module is used for real-time acquisition and control of equipment data, construction and display of laboratory digital twin models based on a 3D engine, and monitoring and storage of field environmental parameters. The exception management module is used to define and monitor the handling of system exception events; The data application service module is used for data interaction with external systems and specialized data analysis; The system management module is used for managing permissions and operations.

[0010] In some embodiments, the test condition subsystem includes multiple independent test chambers; each test chamber is equipped with a test chamber for generating environmental stress, the test chamber including at least one of a temperature and humidity chamber, a temperature shock chamber, a vibration table, and an impact table, and the test chamber is equipped with an explosion-proof door; The test chamber's controller is connected to the intelligent operation subsystem via a Modbus-RTU bus to receive control commands; the sensors built into the test chamber feed back real-time data to the intelligent operation subsystem via an analog input module; the explosion-proof door is equipped with an electromagnetic lock controlled by the intelligent operation subsystem and a position sensor for feedback on the door's status.

[0011] In some embodiments, the intelligent operation subsystem includes: Composite robot, integrating articulated robot and AGV; A ground rail device is used to provide a fixed movement path for the composite robot; A trolley used to carry and transport test samples; A positioning device is installed on the turnover trolley and is used to perform positioning in conjunction with the ground rail; A gripper, installed at the end of the articulated robot, is used to grasp and place test samples; The electrical control device includes a PLC control system and sensors; the PLC control system is used to receive instructions from the centralized control subsystem and drive the composite robot, the ground rail device, and the gripper to work together to complete the transfer and installation of the sample.

[0012] In some embodiments, the security monitoring subsystem includes: The test environment safety monitoring module is used to monitor the environmental conditions of the test room through temperature and humidity sensors and cameras. The test chamber data safety monitoring module is used to monitor the test chamber's operating parameters and sample characteristic parameters through data acquisition equipment; The intelligent operation safety monitoring module is used to monitor the operating status of the composite robot through displacement sensors; The data display and storage module is used to centrally display and record secure data; The security monitoring and management platform module is used for unified control and access authentication of security monitoring functions; The safety monitoring subsystem adopts a graded alarm mechanism, which is divided into at least two alarm levels according to the severity of the situation, and triggers different audible and visual prompts and handling measures.

[0013] In some embodiments, the three-dimensional digital twin model constructed in the status display and control module updates its device status synchronously with the physical device status, with a delay of ≤1 second.

[0014] In some embodiments, the PLC control system employs structured programming; wherein, the emergency stop interrupt procedure has the highest priority.

[0015] In some embodiments, the tiered alarm mechanism includes: Level 1 alarm, in response to test chamber overheating, combustible gas leakage or robot collision, triggers emergency stop, high-decibel audible and visual alarm and pushes information to the mobile terminal of management personnel; Level 2 alarm: In response to excessive fluctuations in test chamber parameters or robot positioning deviations, an intermittent audible and visual alarm is triggered, and the system's automatic correction program is initiated.

[0016] Secondly, this application also provides an unmanned environmental testing method, implemented using the unmanned environmental testing system described in any one of the first aspects, comprising the following steps: The centralized control subsystem generates a test plan, including information on the target test chamber and samples, based on the test tasks issued by the superior management system, and sends execution instructions to the intelligent operation subsystem. The intelligent operation subsystem drives the composite robot to grab the sample and transport it to the target laboratory. After positioning by the positioning device, the sample is installed in the test chamber and the explosion-proof door is closed. The test conditions subsystem initiates the environmental test according to preset parameters, and the safety monitoring subsystem monitors the test status and uploads it to the centralized control subsystem in real time. After the test is completed, the test condition subsystem returns to a safe state, the intelligent operation subsystem drives the composite robot to transfer the sample back to the temporary storage area or the next test location, and the centralized control subsystem automatically analyzes the test data, generates a test report and stores it.

[0017] The unmanned environmental testing system and method described in this application achieves unmanned transportation and automated testing of test products through the organic combination of centralized control, environmental condition simulation, standardized operation and safety monitoring subsystems, which greatly improves testing efficiency, and significantly enhances test safety, operational standardization and data management capabilities. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This paper shows a general structural block diagram of the unmanned environmental testing system described in an embodiment of this application; Figure 2 The software architecture diagram of the unmanned environment testing system described in the embodiment of this application is shown; Figure 3 A flowchart of the unmanned environment testing method described in the embodiments of this application is shown. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the accompanying drawings in this application are for illustrative and descriptive purposes only and are not intended to limit the scope of protection of this application. Furthermore, it should be understood that the schematic drawings are not drawn to scale. The flowcharts used in this application illustrate operations implemented according to some embodiments of this application. It should be understood that the operations in the flowcharts may not be implemented in sequence, and steps without logical contextual relationships may be reversed or implemented simultaneously. In addition, those skilled in the art, guided by the content of this application, may add one or more other operations to the flowcharts, or remove one or more operations from the flowcharts.

[0021] Furthermore, the described embodiments are merely some, not all, of the embodiments of this application. The components of the embodiments of this application described and illustrated herein can typically be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0022] It should be noted that the term "comprising" will be used in the embodiments of this application to indicate the presence of the features declared thereafter, but does not exclude the addition of other features.

[0023] In view of the technical problems raised in the background art, this application provides an unmanned environmental testing system and method, which can realize unmanned operation and automated control of the entire testing process and improve testing efficiency.

[0024] See the instruction manual appendix Figure 1This application provides an unmanned environmental testing system, which includes four core subsystems: a centralized control subsystem, a test condition subsystem, an intelligent operation subsystem, and a safety monitoring subsystem. Each subsystem works collaboratively through data interaction. The centralized control subsystem is the middle layer (control hub), while the intelligent operation subsystem, test condition subsystem, and safety monitoring subsystem are the bottom layer (execution and monitoring layer). At the same time, the centralized control subsystem interfaces with the enterprise's MES / PLM and other upper-level management systems to form a three-level architecture of "upper-level system - middle control layer - bottom execution and monitoring layer".

[0025] The centralized control subsystem is responsible for task scheduling, data storage, and visualization management. It is the "brain" of the system, receiving tasks from higher levels and decomposing instructions to lower-level subsystems. At the same time, it aggregates and analyzes data from the entire system. The intelligent operation subsystem, as the control core, drives the test conditions subsystem to perform standardized operations through a PLC control system. It is the "hands and feet" of the system, automating physical operations such as sample transfer and installation. The test conditions subsystem provides the environmental stresses required for the test (such as high and low temperatures, vibration, and shock). It is the "test field" of the system, adjusting environmental parameters according to the instructions of the intelligent operation subsystem to meet the test standard requirements. The safety monitoring subsystem monitors the status of equipment and the environment in real time, triggering alarms and emergency measures. It is the "safety shield" of the system, providing safety protection throughout the entire test process and ensuring the safety of personnel, equipment, and test samples.

[0026] The centralized control subsystem, testing condition subsystem, intelligent operation subsystem, and safety monitoring subsystem are connected using a hybrid communication architecture combining industrial Ethernet, bus, and hardwired connections to ensure real-time, reliable, and secure data transmission. The specific connection scheme is as follows: The centralized control subsystem interacts with the upper-level management system via the OPC UA protocol to transmit non-real-time data such as test task instructions and test results. The protocol supports data encryption and authentication to ensure data transmission security. The centralized control subsystem connects with the underlying subsystems via Profinet industrial Ethernet to transmit real-time control instructions (such as robot motion instructions and test chamber parameter adjustment instructions), with a communication rate ≥100Mbps and latency ≤10ms, meeting the real-time control requirements during testing. The intelligent operation subsystem connects with the test condition subsystem via a Modbus-RTU bus to a PLC controller, enabling precise control of test chamber door opening and closing, test parameter triggering, etc., with a sampling period ≤500ms, ensuring the timeliness and accuracy of test condition adjustments. The safety monitoring subsystem uses a dual link combining hard-wired connection (emergency stop signal) and industrial Ethernet (status data) to connect with other subsystems. The emergency stop signal is transmitted via hard-wired connection with a response time ≤100ms, prioritizing safety. Status data is uploaded via industrial Ethernet, enabling visualization of the entire system's safety status.

[0027] Additionally, see the instruction manual appendix. Figure 2 This demonstrates the software architecture of the unmanned environmental testing system, which is also the specific software functional implementation structure of the centralized control subsystem. Specifically, the centralized control subsystem is the control and data hub of the unmanned environmental testing system, composed of a software system (the core of functional implementation) and a hardware system (the physical carrier). The hardware system includes a main control computer, a data server, terminal computers, a centralized display screen, and a network switch. The software system runs on the terminal between the data server and the equipment, and includes six main modules: The equipment management module supports batch import from Excel and is used to manage the ledger information (name, number, parameters) of all test equipment (test chambers, robots, etc.). It can also combine functions to form a system configuration file in XML format. When the configuration changes, it automatically records the version log (including the person making the change, the time of the change, and the content of the change). It supports configuration file rollback to ensure the traceability of system configuration.

[0028] The test management module has full lifecycle control over test projects, such as functions for creating, editing, starting, stopping, pausing, and resuming; it displays the test progress in real time; and it performs statistical analysis on test process data and results.

[0029] The status display and control module provides real-time monitoring: It collects equipment data in real time via Socket communication (sampling period 1s). When equipment malfunctions, the icon turns red and flashes. Clicking the icon allows you to view malfunction details (such as malfunction type, occurrence time, and associated equipment). 3D display: It constructs a 1:1 laboratory model based on Unity3D, including laboratory buildings, equipment, robots, and other modeling elements. It supports mouse drag-and-drop scaling (0.1~10x scaling), 360° rotation, translation, and roaming operations. The equipment status in the model (such as test chamber door opening / closing, robot position) is updated synchronously with the actual equipment (delay ≤1s). Environmental monitoring: It connects to temperature and humidity sensors via RS485 bus to collect temperature and humidity data from various areas of the laboratory (accuracy ±0.5℃ / ±3% RH), establishing a routine test station temperature and humidity database. It supports querying historical curves by hour / day / month to assist in analyzing the impact of the environment on test results.

[0030] The anomaly management module defines and monitors various anomalies, triggering audible and visual alarms and recording them when they occur; it supports automated processing according to preset procedures or manual intervention.

[0031] Data Application Service Module: Responsible for data transmission and reception with external systems; building a database to store all equipment and test data, providing multi-dimensional (by sample, project, time) query interfaces; supporting data export in Word / Excel format; providing specialized data analysis functions to support data mining and pattern summarization.

[0032] System management module: Covers the management of personnel, roles, accounts, menus and operation logs to ensure the safe and orderly operation of the system.

[0033] The test conditions subsystem is the environmental stress providing unit, responsible for providing and precisely controlling various environmental stresses required for the test. This includes, but is not limited to, multiple specialized test chambers such as impact test chambers, vibration test chambers, temperature and humidity test chambers, and temperature shock test chambers. Each test chamber is equipped with corresponding environmental test chambers (such as temperature and humidity chambers, vibration tables, and impact tables), and is equipped with explosion-proof doors to meet special safety requirements. Each test chamber controller (such as a temperature controller or vibration controller) is connected to the PLC of the intelligent operation subsystem via a Modbus-RTU bus, receiving test parameter commands (such as target temperature and vibration frequency) from the PLC to automatically adjust test conditions. Built-in sensors in the test chambers (temperature, humidity, and acceleration sensors) transmit real-time data to the PLC via analog input modules (4~20mA signals), which then uploads the data to the centralized control subsystem, forming a closed-loop control of "command issuance - data feedback." Furthermore, the explosion-proof doors are equipped with electromagnetic locks and NPN proximity switches (position sensors). The electromagnetic locks are controlled by the PLC, and the proximity switches provide feedback on the door status (open / closed) to the safety monitoring subsystem, ensuring that the explosion-proof doors are only opened under safe test conditions.

[0034] The intelligent operation subsystem is the automated execution unit of the system, realizing unmanned sample transfer, installation, and testing operations. Its core components are as follows: The composite robot, with an AGV and a six-axis robotic arm and a dedicated controller, is responsible for grasping, transporting and installing test samples.

[0035] Ground rail devices provide robots with fixed movement paths, expanding their working range.

[0036] Turnover trolley, a customized heavy-duty trolley, is used to carry and transport test samples, and is equipped with heavy-duty dual directional wheels and dual omnidirectional brake wheels.

[0037] The positioning device is installed on both sides of the turnover trolley and works with the ground rail to ensure that the trolley runs without deviation or derailment.

[0038] Specially designed grippers that support unlimited rotation are used for precise gripping and placement of test samples.

[0039] Explosion-proof distribution cabinets prevent sparks, arcs, or high temperatures generated during the operation of electrical equipment from triggering explosions of surrounding explosive gases or dust.

[0040] The electrical control device includes a PLC control system (including a CPU module, I / O modules, etc.) and proximity switch sensors. The PLC control system receives instructions from the centralized control subsystem and drives the robot and actuators to complete the entire process of "transporting the sample from the temporary storage area to the laboratory door → the indoor robot dragging the sample into the room → the gripper installing the sample into the test chamber".

[0041] The control logic is as follows: The sample transfer process involves the centralized control subsystem issuing transfer commands to the PLC. The PLC drives the AGV to move along the ground rail to the temporary storage area (positioning accuracy ±5mm). A laser positioning sensor detects the position of the transfer trolley, and the PLC controls a mechanical positioning pin to insert into the trolley's positioning hole, locking the trolley (positioning error ≤0.1mm). A six-axis robotic arm grips the sample with a gripper, adjusting the gripping force (100~500N) according to the sample weight, and moves it to the AGV platform. A proximity switch sensor confirms the sample's position. The AGV moves along the ground rail to the entrance of the target laboratory. The PLC controls the laboratory's indoor robot (a small AGV) to drag the transfer trolley to the designated position inside. The indoor robot locks the trolley using a positioning device, and the robotic arm delivers the sample into the test chamber. A proximity switch inside the test chamber confirms the sample is installed in place (deviation ≤0.5mm), completing the transfer.

[0042] The PLC control logic adopts structured programming. The program architecture includes a main program (OB1), interrupt programs (such as emergency stop interrupt OB100), and function blocks (such as sample positioning FB1 and test chamber control FB2). Among them, the emergency stop interrupt program has the highest priority and immediately cuts off the robot power source and test chamber power supply after being triggered. The program supports online modification and monitoring, and automatically records fault codes (such as E01 - AGV positioning failure, E02 - insufficient gripper force) when a fault occurs, which facilitates fault diagnosis and maintenance.

[0043] The safety monitoring subsystem provides comprehensive, multi-level safety protection throughout the entire process. It includes a test environment safety monitoring module, a test chamber data safety monitoring module, a smart operation safety monitoring module, a data display and storage module, and a safety monitoring management platform module.

[0044] The experimental environment safety monitoring module monitors the overall environmental status of the laboratory through temperature and humidity sensors, cameras, and other means.

[0045] The test chamber data safety monitoring module monitors changes in test chamber operating parameters and sample characteristic parameters in real time through data acquisition equipment.

[0046] The intelligent operation safety monitoring module monitors the robot's position and posture during operation using displacement sensors and other means to prevent collisions and misoperations.

[0047] The data display and storage module integrates a server, a display screen, and a buzzer to centrally display all security data and alarm information, and to record them.

[0048] The security monitoring and management platform module achieves unified control and access authentication for all security monitoring functions through terminal controllers, identity recognition devices, etc.

[0049] The safety monitoring subsystem employs a tiered alarm mechanism, dividing alarms into at least two levels based on severity and triggering different audible and visual alerts and response measures. In one embodiment, the system is divided into three levels based on the severity of the anomaly, enabling differentiated responses: Level 1 alarm (emergency): such as test chamber overheating (exceeding the set value by 10°C), combustible gas leakage (concentration ≥ 20% of the lower explosive limit), robot collision; triggers emergency stop (cuts off the power supply to the test chamber and the robot's power source), buzzer sounds continuously (85dB), the central display screen flashes red, and alarm information (including abnormal location and type) is pushed to the management personnel's mobile APP to ensure rapid response to emergencies.

[0050] Level 2 alarm (early warning): such as excessive temperature and humidity fluctuations in the test chamber (±1℃ / ±5% RH), robot positioning deviation (±3mm); the buzzer sounds intermittently (1 second on, 2 seconds off), the screen displays a yellow warning, the system automatically attempts to correct (such as adjusting the temperature controller parameters, repositioning the robot), and if the correction fails, it is upgraded to Level 1 alarm.

[0051] Level 3 Alarm (Notification): This occurs when equipment calibration is due or the sample is about to complete testing; a blue notification appears on the screen, but no buzzer sounds, only informing the operator to proceed with preparations. All alarm information (including alarm time, location, cause, and handling result) is stored in the data server in real time and retained for ≥3 years. It supports querying and exporting by alarm level, time range, and equipment number, facilitating traceability and safety analysis of the testing process.

[0052] This application provides an unmanned environmental testing system that, through the organic integration of centralized control, environmental condition simulation, standardized operation, and safety monitoring subsystems, achieves unmanned transportation and automated testing of test products, significantly improving test safety, operational standardization, and data management capabilities. Specifically, through the collaborative control of various subsystems, it achieves fully unmanned operation from task assignment, sample transportation, environmental testing to data archiving, significantly saving labor costs and eliminating human error. Employing a unified central control platform and a hybrid communication network, it achieves deep integration of information flow and control flow, supporting 3D-visualized digital twin monitoring and data-driven intelligent decision-making. The intelligent operation subsystem replaces manual high-risk operations, and combined with multi-level safety monitoring and hard-wired emergency stop mechanisms, greatly enhances the safety of personnel and equipment during the testing process. Furthermore, it achieves automatic data acquisition, centralized storage, in-depth analysis, and traceable management of test data, providing a solid data foundation for product reliability improvement. The modular subsystem design facilitates functional expansion and adjustment according to testing needs. It is suitable for environmental testing in fields such as military, aerospace, and electronic equipment, and has considerable application value and promising prospects for widespread adoption.

[0053] Based on the same inventive concept, see appendix to the specification. Figure 3 This application also provides an unmanned environment testing method, implemented using the aforementioned unmanned environment testing system, comprising the following steps: S1. The centralized control subsystem generates a test plan including information on the target test chamber and samples based on the test tasks issued by the superior management system, and sends execution instructions to the intelligent operation subsystem. S2. The intelligent operation subsystem drives the composite robot to grab the sample and transport it to the target laboratory. After positioning by the positioning device, the sample is installed in the test chamber and the explosion-proof door is closed. S3. The test conditions subsystem starts the environmental test according to the preset parameters, and the safety monitoring subsystem monitors the test status and uploads it to the centralized control subsystem in real time. S4. After the test is completed, the test condition subsystem returns to a safe state, the intelligent operation subsystem drives the composite robot to transfer the sample back to the temporary storage area or the next test location, and the centralized control subsystem automatically analyzes the test data, generates a test report and stores it.

[0054] The following explanation uses a temperature shock test as an example to illustrate the process. Specifically: Task assignment and solution generation: Users issue a temperature shock test task through a higher-level management system integrated with the enterprise's MES / PLM. Upon receiving the task, the centralized control subsystem automatically calls pre-set test specifications to generate a detailed test plan, including the test profile (high and low temperature range, residence time, transition time), target test chamber (temperature shock chamber 1), and sample information. Operators place the sample to be tested in the designated temporary storage area. Image recognition is performed by the safety monitoring subsystem's camera, or RFID technology is used to confirm the sample information matches the task. Subsequently, the centralized control subsystem sends instructions to the intelligent operation subsystem.

[0055] The automated sample transfer and installation intelligent operation subsystem's PLC control system is activated, driving the composite robot to move along the ground track to the temporary storage area. The robot uses a special gripper to pick up the sample and place it on a transfer cart. The robot then pulls the transfer cart to the entrance of the "Temperature Shock Chamber 1". A proximity switch sensor detects the arrival signal; the centralized control subsystem sends a command to the test conditions subsystem to open the explosion-proof door of the temperature shock test chamber. The robot (or a dedicated indoor robot) drags the transfer cart into the chamber and precisely aligns it with the test chamber using a positioning device. The robot's gripper transfers the sample from the transfer cart and precisely installs it in the designated position inside the temperature shock test chamber. The robot then exits, and the explosion-proof door closes.

[0056] Environmental testing execution and monitoring: The centralized control subsystem sends a start command and test profile parameters to the "Temperature Shock Chamber 1" of the test conditions subsystem; the temperature shock chamber begins operation, cycling through high and low temperatures according to the preset profile; throughout this process, all modules of the safety monitoring subsystem operate continuously: the test chamber data safety monitoring module collects real-time temperature and sample response data; the test environment safety monitoring module monitors indoor environmental parameters; and the intelligent operation safety monitoring module ensures that no personnel or foreign objects enter the hazardous area. All data is uploaded in real-time to the database of the centralized control subsystem via Profinet and Modbus-RTU networks.

[0057] After the experiment concludes and resets, and data is archived and a report is generated, the temperature shock chamber automatically returns to a safe state. The system then reverses step 3, driving a robot to remove the sample from the chamber and transport it back to the temporary storage area or the next testing location. The data application service module of the centralized control subsystem automatically analyzes and processes the collected data throughout the process to determine if the test results meet the standards. The system automatically generates a test report containing the test curves, key data, and conclusions, storing it in a Word / Excel format in the database. Users can query and download the report via their terminals to complete the testing process.

[0058] This application provides an unmanned environmental testing method that enables fully unmanned and intelligent operation of the entire process, including automatic handling of test samples, application of environmental stress, standardized control throughout the entire process, full lifecycle management of data, and final generation of test reports. This significantly improves testing efficiency, data accuracy, and overall reliability engineering capabilities, ensures test safety, and meets the testing requirements of high-reliability products.

[0059] Finally, it should be noted that the above embodiments are merely specific implementations of this application, used to illustrate the technical solutions of this application, and not to limit them. The protection scope of this application is not limited thereto. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features, within the scope of the technology disclosed in this application; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application. All should be covered within the protection scope of this application. Therefore, the protection scope of this application should be determined by the protection scope of the claims.

Claims

1. An unmanned environmental testing system, characterized in that, The system adopts a three-tier architecture, including: an upper-level management system, a centralized control subsystem as the control center, and a test condition subsystem, an intelligent operation subsystem, and a safety monitoring subsystem as the execution and monitoring layer; the subsystems are connected by a hybrid communication architecture that combines industrial Ethernet, bus, and hardwired connections. The centralized control subsystem is used to receive tasks issued by the upper management system, decompose instructions to the execution and monitoring layer subsystems, summarize data, and analyze and process it. The intelligent operation subsystem is used to drive the test condition subsystem to perform standardized operations through the PLC control system. The test condition subsystem is used to adjust environmental parameters according to the instructions of the intelligent operation subsystem; The safety monitoring subsystem is used to monitor the status of equipment and the environment in real time, and to trigger alarms and emergency measures.

2. The unmanned environmental testing system according to claim 1, characterized in that, The centralized control subsystem interacts with the upper-level management system via the OPC UA protocol; the centralized control subsystem is connected to the test condition subsystem, intelligent operation subsystem, and safety monitoring subsystem via Profinet industrial Ethernet; the intelligent operation subsystem is connected to the test condition subsystem via Modbus-RTU bus; the safety monitoring subsystem uses a dual link of hardwired connection and industrial Ethernet to connect with other subsystems, wherein emergency stop signals are transmitted via hardwired connection and status data is transmitted via industrial Ethernet.

3. The unmanned environmental testing system according to claim 1, characterized in that, The centralized control subsystem includes a hardware system and a software system; the hardware system includes a main control computer, a data server, terminal computers, a centralized display screen, and a network switch; The software system includes: The equipment management module is used to manage equipment ledger information, combine functions, and generate system configuration files; The test management module is used for the full lifecycle control of test projects, displaying test progress in real time and performing statistical analysis on test data; The status display and control module is used for real-time acquisition and control of equipment data, construction and display of laboratory digital twin models based on a 3D engine, and monitoring and storage of field environmental parameters. The exception management module is used to define and monitor the handling of system exception events; The data application service module is used for data interaction with external systems and specialized data analysis; The system management module is used for managing permissions and operations.

4. The unmanned environmental testing system according to claim 1, characterized in that, The test conditions subsystem includes multiple independent test chambers; each test chamber is equipped with a test chamber for generating environmental stress, the test chamber including at least one of a temperature and humidity chamber, a temperature shock chamber, a vibration table, and an impact table, and the test chamber is equipped with an explosion-proof door; The test chamber's controller is connected to the intelligent operation subsystem via a Modbus-RTU bus to receive control commands; the sensors built into the test chamber feed back real-time data to the intelligent operation subsystem via an analog input module; the explosion-proof door is equipped with an electromagnetic lock controlled by the intelligent operation subsystem and a position sensor for feedback on the door's status.

5. The unmanned environmental testing system according to claim 4, characterized in that, The intelligent operation subsystem includes: Composite robot, integrating articulated robot and AGV; A ground rail device is used to provide a fixed movement path for the composite robot; A trolley used to carry and transport test samples; A positioning device is installed on the turnover trolley and is used to perform positioning in conjunction with the ground rail; A gripper, installed at the end of the articulated robot, is used to grasp and place test samples; The electrical control device includes a PLC control system and sensors; the PLC control system is used to receive instructions from the centralized control subsystem and drive the composite robot, the ground rail device, and the gripper to work together to complete the transfer and installation of the sample.

6. The unmanned environmental testing system according to claim 5, characterized in that, The safety monitoring subsystem includes: The test environment safety monitoring module is used to monitor the environmental conditions of the test room through temperature and humidity sensors and cameras. The test chamber data safety monitoring module is used to monitor the test chamber's operating parameters and sample characteristic parameters through data acquisition equipment; The intelligent operation safety monitoring module is used to monitor the operating status of the composite robot through displacement sensors; The data display and storage module is used to centrally display and record secure data; The security monitoring and management platform module is used for unified control and access authentication of security monitoring functions; The safety monitoring subsystem adopts a graded alarm mechanism, which is divided into at least two alarm levels according to the severity of the situation, and triggers different audible and visual prompts and handling measures.

7. The unmanned environmental testing system according to claim 3, characterized in that, The three-dimensional digital twin model constructed in the status display and control module updates its device status synchronously with the physical device status, with a delay of ≤1 second.

8. The unmanned environmental testing system according to claim 1, characterized in that, The PLC control system uses structured programming; among which, the emergency stop interrupt program has the highest priority.

9. The unmanned environmental testing system according to claim 6, characterized in that, The tiered alarm mechanism includes: Level 1 alarm, in response to test chamber overheating, combustible gas leakage or robot collision, triggers emergency stop, high-decibel audible and visual alarm and pushes information to the mobile terminal of management personnel; Level 2 alarm: In response to excessive fluctuations in test chamber parameters or robot positioning deviations, an intermittent audible and visual alarm is triggered, and the system's automatic correction program is initiated.

10. A method for unmanned environmental testing, characterized in that, The unmanned environmental testing system described in claim 6 is used to achieve this, comprising the following steps: The centralized control subsystem generates a test plan, including information on the target test chamber and samples, based on the test tasks issued by the superior management system, and sends execution instructions to the intelligent operation subsystem. The intelligent operation subsystem drives the composite robot to grab the sample and transport it to the target laboratory. After positioning by the positioning device, the sample is installed in the test chamber and the explosion-proof door is closed. The test conditions subsystem initiates the environmental test according to preset parameters, and the safety monitoring subsystem monitors the test status and uploads it to the centralized control subsystem in real time. After the test is completed, the test condition subsystem returns to a safe state, the intelligent operation subsystem drives the composite robot to transfer the sample back to the temporary storage area or the next test location, and the centralized control subsystem automatically analyzes the test data, generates a test report and stores it.

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