Hardware interface function testing device of train-mounted controller

Abstract

The invention relates to a hardware interface function testing device for a train-mounted controller, and the device is characterized in that a housing of the testing device is provided with testing interfaces which comprise a speed sensor interface, an acceleration sensor interface, an analog quantity input / output interface, a digital quantity input / output interface, and a power interface; a network test module, a communication function test module, a speed sensor test module, an analog quantity test module, a digital quantity test module and an accelerometer are arranged in the test device; the speed sensor test module is used for simulating the test of a train speed sensor, the motor is fixed on the mounting bracket, the coupling is firstly fixed with the motor, the gear is sleeved on the coupling for fixation, the motor drives the gear to rotate through the coupling, and the speed sensor reads the speed information of the gear rotation and transmits the speed information to the vehicle-mounted controller. Compared with the prior art, the vehicle-mounted controller hardware interface function testing device provided by the invention can perform comprehensive and efficient testing.

Description

Technical Field

[0001] This invention relates, and in particular, to a hardware interface function testing device for a train onboard controller. Background Technology

[0002] As the safety brain of train operation, the functionality and effectiveness of the hardware interfaces of the onboard controller directly determine the safety of train operation. The onboard controller consists of numerous functional modules and boards, with a large number of input and output interfaces, including power input and output interfaces, analog input and output interfaces, digital input and output interfaces, speed sensor interfaces, acceleration sensor interfaces, MVB interfaces, and network interfaces.

[0003] The current vehicle controller hardware interface testing has the following deficiencies: 1. The tests are scattered and lack integration; existing tests mostly adopt the "single module independent test" mode, and each interface test is temporarily connected to external simulation equipment. The test scenarios are fragmented and cannot simulate the "multi-interface collaboration" state when the vehicle controller is actually working.

[0004] 2. Poor test stability and high error rate: Because the test environment is set up temporarily on demand, there are problems such as poor contact and signal interference, resulting in a high test error rate and making it impossible to accurately locate potential faults in the hardware interface.

[0005] 3. Lack of dual-system redundancy testing capability; To meet railway safety requirements, on-board controllers generally adopt a "dual-system redundancy" design, but existing testing devices only support single-system interface testing and cannot verify the synchronization and consistency of dual-system interfaces. This leads to the exposure of dual-system coordination defects during later system commissioning, delaying the development cycle.

[0006] 4. Inefficient and lack of standardized processes: Full interface testing of a single vehicle controller requires manual setup of different test scenarios, and there is no fixed test equipment. The test process depends on the experience of the operators, and the test results of different personnel are inconsistent, making it difficult to meet the needs of efficient testing. Summary of the Invention

[0007] The purpose of this invention is to address the deficiencies of the existing technology by providing a hardware interface function testing device for a train onboard controller.

[0008] The objective of this invention can be achieved through the following technical solutions: A hardware interface function testing device for a train onboard controller, wherein the housing of the testing device is provided with testing interfaces, including a speed sensor interface, an acceleration sensor interface, an analog input / output interface, a digital input / output interface, and a power interface; The testing device is internally equipped with a network testing module, a communication function testing module, a speed sensor testing module, an analog quantity testing module, a digital quantity testing module, and an accelerometer; The speed sensor test module is used to simulate the testing of train speed sensors and includes gears, couplings, motors, multiple speed sensors, and mounting brackets. The mounting bracket is fixedly mounted on the machine housing. A motor is fixedly mounted on one side of the mounting bracket, and the output end of the motor drives a coupling. The coupling passes through the mounting bracket, and a gear is sleeved and fixed on the coupling on the other side of the mounting bracket. Multiple speed sensors are arranged along the circumference of the gear and are fixedly mounted on the mounting bracket by speed sensor mounting brackets. The speed sensors are connected to a speed sensor interface to read the speed information of the gear rotation and transmit it to the vehicle controller.

[0009] As a preferred technical solution, the test interface of the test device includes test channels for dual or multiple systems.

[0010] As a preferred technical solution, the analog quantity test module includes a set of analog resistors, which are used to simulate the analog input and output of the vehicle controller.

[0011] As a preferred technical solution, the test device is also equipped with a branch terminal block; one side of the branch terminal block is connected to the speed sensor, accelerometer and analog resistor, and branches the speed sensor, accelerometer and analog signal lines, and the other side of the branch terminal block is connected to the speed sensor interface, accelerometer interface and analog input / output interface respectively, so as to realize multi-system testing.

[0012] As a preferred technical solution, the network test module includes a switch installed inside the test device, and the switch provides a network test channel for the vehicle controller through a network interface.

[0013] As a preferred technical solution, the communication function test module includes an MVB converter, which is connected to a first USB interface via a USB cable and powered through the first USB interface; the vehicle controller is connected to the MVB converter via a DB9 interface to perform communication function testing.

[0014] As a preferred technical solution, the digital quantity test module includes a set of relays and a digital quantity interface parallel module; The relay provides two independent switching contacts, which are connected to the digital input / output interface via a digital interface parallel module for testing digital input / output. The output interface of the vehicle controller drives the relay coil, and the input interface of the vehicle controller acquires data through the relay switch contacts. The input interface of the vehicle controller acquires the contact signals of the dual system to verify the consistency of the digital input / output dual system.

[0015] As a preferred technical solution, the speed sensor test module also includes a power switch and a second USB interface. The power switch is used to control the start and stop of the motor; the second USB interface can be connected bidirectionally. Inside the test device, the second USB interface is connected to the motor via a cable. Outside the test device, the second USB interface is connected to the host computer via a cable, where the speed of the motor is set to simulate different speed scenarios of the train.

[0016] As a preferred technical solution, the speed sensor is a Hall speed sensor, and each speed sensor outputs two speed signals.

[0017] As a preferred technical solution, the gear is made of magnetically conductive low-carbon steel.

[0018] As a preferred technical solution, the power interface includes a 220V AC power interface and a 110V DC power interface; the test device is equipped with a power conversion module, a 220V AC power distribution terminal block and a 110V DC power distribution terminal block. The input power supply voltage of the test device is 220V AC, which is connected through the 220V AC power interface, and the power is distributed to the power converter and switch through the 220VAC power distribution terminal block. The power conversion module converts 220V AC to 110V DC, and the output of the power conversion module is connected to the 110V DC power distribution terminal block; the 110V DC power distribution terminal block distributes power to the vehicle controller and provides a total of 110V DC power output to the outside.

[0019] As a preferred technical solution, one or more fans are installed on each side of the testing device, with one fan drawing air inward and the other fan exhausting air outward; the testing device is equipped with a 24V DC power supply interface, and the vehicle controller supplies power to each fan through the 24V DC power supply interface.

[0020] Compared with the prior art, the present invention has the following beneficial effects: The train onboard controller hardware interface function testing device proposed in this invention integrates the testing functions of the core hardware interface of the onboard controller into a single device, solving the pain points and difficulties of existing testing, and providing comprehensive interface testing coverage. In accordance with railway safety standards, all key interfaces are designed with dual-system test channels, which can simultaneously verify the consistency of dual-system signals, improve test stability and efficiency, and realize plug-and-play standardized testing. Attached Figure Description

[0021] Figure 1 This is a first perspective view of the hardware interface function testing device for the train on-board controller of the present invention.

[0022] Figure 2 This is a second perspective view of the hardware interface function testing device for the train on-board controller of the present invention.

[0023] Figure 3 This is an installation diagram of the upper-level equipment inside the testing device of the present invention.

[0024] Figure 4 This is an installation diagram of the speed sensor testing device inside the testing apparatus of the present invention.

[0025] Figure 5 This is an installation diagram of the middle and lower layer equipment inside the testing device of the present invention.

[0026] Figure 6 This is a block diagram of the main interface of the testing device of the present invention.

[0027] Figure 7 This is a typical test procedure for the hardware interface function test device of the train on-board controller used in this invention.

[0028] The following components are labeled in the diagram: 1. Chassis; 2. Switch; 3. Speed ​​sensor interface; 4. Accelerometer interface; 5. Analog input / output interface; 6. 110V DC power interface; 7. MVB converter; 8. First USB interface; 9. Digital input / output interface; 10. 24V DC power interface; 11. 220V AC power interface; 12. Motor power switch; 13. Second USB interface; 21. Fan; 22. Analog resistor; 23. Branch terminal block; 24. Accelerometer; 25. Gear; 26. Coupling; 27. Motor; 28. Speed ​​sensor; 29. ​​Speed ​​sensor mounting bracket; 30. Mounting bracket; 31. Power converter; 32. 220V AC power distribution terminal block; 33. 110V DC power distribution terminal block; 34. Relay; 35. Relay base; 36. Parallel module base; 37. Parallel module. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0030] Example 1 This invention proposes a hardware interface function testing device for train onboard controllers, which realizes integrated testing of the core hardware interfaces of the onboard controller, covering the power supply (110V DC / 24V DC), analog signals (input / output), digital signals (input / output), speed signals, acceleration signals, multi-function vehicle bus (MVB) interface, and network interface of the onboard controller. It does not require external multiple devices, supports dual-system redundant synchronous testing, and is adapted to the dual-system architecture of the onboard controller.

[0031] like Figure 1 As shown, the interfaces and devices installed on the front and right sides of the test device are as follows. The test device housing 1 serves as the carrier for all interfaces and devices. A 24-port switch 2 is installed at the bottom of the test device. The interfaces required for testing are installed on the front of the test device, including two speed sensor interfaces 3, two accelerometer interfaces 4, two analog input / output interfaces 5, four 110V DC power interfaces 6, one MVB converter 7, one first USB interface 8, eight digital input / output interfaces 9, and four 24V DC power interfaces 10. Two fans 21 are installed on the right side of the test device.

[0032] like Figure 2 As shown, the interfaces and devices installed on the back and left side of the test device are described. The devices installed on the back include a 220V AC power interface 11, a motor power switch 12 and a second USB interface 13. Two fans 21 are also installed on the left side of the test device.

[0033] Specifically, the testing device has two fans 21 installed on the left and right sides respectively. The left fan draws air inward, and the right fan exhausts air outward. The fans are powered by 24V DC, and the vehicle controller supplies power to these four fans through the power interface 10. This serves two purposes: firstly, to test the 24V DC power output function of the vehicle controller, and secondly, to control the internal temperature of the device through the fans, preventing overheating of components from affecting the test accuracy.

[0034] Furthermore, this device is based on "layered integration and modular design," comprising a casing 1 and three internal functional modules (bottom, middle, and top layers), along with external interfaces and a heat dissipation system. The specific structure is as follows: like Figure 3 As shown, the equipment installed on the upper layer of the test device includes: a speed sensor test module, an accelerometer 24, an analog resistor 22, and a branch terminal block 23.

[0035] like Figure 4 As shown, the speed sensor test module is used to simulate the testing of train speed sensors. It includes mounting brackets 30 for each test device, three speed sensor mounting brackets 29, three speed sensors 28, one gear 25, one coupling 26, and one motor 27. The motor 27 is fixed to the mounting bracket 30. The coupling 26 is first fixed to the motor 27, and the gear 25 is fitted onto the coupling 26 for fixation. The motor 27 drives the gear 25 to rotate through the coupling 26, and the speed sensor 28 reads the speed information of the gear rotation and transmits it to the on-board controller.

[0036] Specifically, the equipment is equipped with three Hall effect speed sensors, each speed sensor 28 outputting two speed signals, providing a total of six speed signal tests. A gear 25 is installed within the testing device as the test object for the speed sensors. The test gear has a module m=2, number of teeth z=80, and is made of magnetic low-carbon steel. The gear 25 is fixedly connected to a motor 27 via a coupling 26, and the motor 27 drives the gear 25 to rotate. The motor 27 is mounted on a mounting bracket 30. The speed sensor 28 is mounted on a speed sensor mounting bracket 29. The mounting position of the speed sensor 28 mounting bracket 29 on the mounting bracket 30 is adjustable. By adjusting the mounting position, the distance between the speed sensor 28 and the gear 25 can be adjusted. The required mounting clearance between the speed sensor 28 and the gear tooth surface is controlled between 0.3 and 1.8 mm. mm; a motor power switch 12 is located on the back of the testing device to control the start and stop of the motor 27; a second USB interface 13 is also located on the back of the testing device. This USB interface is bidirectional and can be connected to the motor 27 via a cable inside the testing device; outside the testing device, the second USB interface 13 can be connected to a host computer via a cable to set the speed of the motor 27 and simulate different train speed scenarios. The testing device supports synchronous speed acquisition from both the on-board controller and the dual system.

[0037] The test device is equipped with an accelerometer 24, and the accelerometer signal can be tested from three channels in each of the two systems via the branch terminal block 23.

[0038] The test device is equipped with an analog resistor 22 to simulate the analog input (such as current signal) and output (such as voltage signal) of the vehicle controller; it provides a total of 10 signal tests for each of the two systems.

[0039] Branch terminal block 23 is mainly used for branching the speed sensor 28, accelerometer 24 and analog signals to meet the testing requirements of dual systems.

[0040] like Figure 6As shown, the equipment installed in the middle and bottom layers of the test device includes a power converter 31 for converting 220VAC to 110V DC power, a 220V AC power distribution terminal block 32 for supplying power to the power conversion module and the switch 2 respectively, a 110V DC power distribution terminal block 33 for outputting power to the vehicle controller, a relay 34, with each relay mounted on a relay base 35, and a parallel module 37, which is mounted on a parallel module base 36.

[0041] Specifically, the bottom layer of the test device is equipped with a switch 2, a power conversion module 31, a 220V AC power distribution terminal block 32, and a 110V DC power distribution terminal block 33.

[0042] The test device uses a 220V AC input power supply, connected via a 220V AC power interface 11 on the back of the device. This interface includes a switch for easy control of the device's power supply. The 220V AC power distribution terminal block 32 distributes power to the power converter 31 and the switch 2. The power conversion module 31 converts 220V AC to 110V DC and outputs the power to the 110V DC power distribution terminal block 33. The 110V DC power distribution terminal block 33 distributes power to the vehicle controller, providing a total of four 110V DC power outputs. Switch 2 is a 24-port switch, powered by 220V AC, providing a network testing channel to the vehicle controller via a network interface.

[0043] The middle layer of the test device is equipped with relay 34, relay base 35, MVB converter 7, digital interface parallel module 37 and parallel module base 36.

[0044] The test device is equipped with an MVB converter 7, which is powered by a USB interface. The MVB converter 7 is connected to the first USB interface 8 via a USB cable and is powered externally. The vehicle controller is connected to the MVB converter 7 via a DB9 interface for communication function testing.

[0045] The test setup uses relay 34 to test digital input / output signals. The output interface of the vehicle controller drives the relay coil, while the input interface of the vehicle controller acquires data via relay switch contacts. The relay coil employs a "dual-system parallel drive" (dual-system outputs of the vehicle controller drive the signal together). Relay 34 provides two independent switch contacts. The input interface of the vehicle controller acquires the dual-system contact signals to verify the consistency of the digital input / output signals across the two systems. The relay is connected to the digital input / output interface 9 via a digital interface parallel module 37. Relay 34 must be mounted on relay base 35, and digital interface parallel module 37 is mounted on module base 36.

[0046] like Figure 6 The diagram shown is a test wiring diagram of the train onboard controller hardware interface function test device proposed in this invention. This invention integrates the test function of the core hardware interface of the onboard controller into a single device, solving the pain points and difficulties of existing tests, and providing comprehensive interface test coverage. In accordance with railway safety standards, all key interfaces (speed, acceleration, analog quantity, and digital quantity) are designed with dual-system test channels, which can simultaneously verify the consistency of dual-system signals, improve test stability and efficiency, and realize plug-and-play standardized testing.

[0047] Example 2 As another embodiment of the present invention, such as Figure 7 As shown, this embodiment also provides a typical process for testing using the device described in Embodiment 1 above, and the specific steps are as follows: S1. Test preparation: Burn the function test software into the vehicle controller and install the vehicle controller signal transmission and acquisition software on the host computer (to observe whether the interface function is normal in real time). S2. Connect the power cord of the test device, connect the interface cable of the vehicle controller to the interface cable of the test device, connect the host computer to the second USB interface 13 for motor control, connect the host computer to the first USB interface 8 for power input of the MVB converter 7, and connect the host computer to the network of the switch 2. S3. Turn on the power input switch of the test device and turn on the motor control switch; S4. Set the motor speed via the host computer; S5. Turn on the power switch of the vehicle controller; S6, Test begins; S7. Collect vehicle controller function test information in real time on the host computer; S8. Test complete. Turn off the power.

[0048] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0049] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A hardware interface function testing device for a train onboard controller, characterized in that, The test device has a test interface on its housing (1), including a speed sensor interface (3), an acceleration sensor interface (4), an analog input / output interface (5), a digital input / output interface (9), and a power interface; The testing device is equipped with a network testing module, a communication function testing module, a speed sensor testing module, an analog quantity testing module, a digital quantity testing module, and an accelerometer (24). The speed sensor test module is used to simulate the test of train speed sensors and includes gears (25), couplings (26), motors (27), multiple speed sensors (28) and mounting brackets (30). The mounting bracket (30) is fixedly mounted on the housing (1). A motor (27) is fixedly mounted on one side of the mounting bracket (30). The output end of the motor (27) is connected to a coupling (26). The coupling (26) passes through the mounting bracket (30), and a gear (25) is sleeved and fixed on the coupling (26) on the other side of the mounting bracket (30). Multiple speed sensors (28) are arranged circumferentially along the gear (25) and fixedly mounted on the mounting bracket (30) by a speed sensor mounting bracket (29). The speed sensors (28) are connected to the speed sensor interface (3) to read the speed information of the gear (25) and transmit it to the vehicle controller.

2. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The test interfaces of the test equipment all include test channels for dual or multiple systems.

3. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The analog quantity test module includes a set of analog resistors (22), which are used to simulate the analog input and output of the vehicle controller.

4. The hardware interface function testing device for a train onboard controller according to claim 3, characterized in that, The test device is also equipped with a branch terminal block (23); one side of the branch terminal block (23) is connected to the speed sensor (28), the accelerometer (24) and the analog resistor (22), and the branch lines of the speed sensor (28), the accelerometer (24) and the analog signal are connected. The other side of the branch terminal block (23) is connected to the speed sensor interface (3), the accelerometer interface (4) and the analog input / output interface (5) respectively, so as to realize multi-system testing.

5. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The network test module includes a switch (2) installed inside the test device, which provides a network test channel for the vehicle controller through a network interface.

6. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The communication function test module includes an MVB converter (7), which is connected to a first USB interface (8) via a USB cable and is powered by the first USB interface (8). The vehicle controller is connected to the MVB converter (7) via a DB9 interface to perform communication function testing.

7. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The digital quantity test module includes a set of relays (34) and a digital quantity interface parallel module (37). The relay (34) provides two independent switching contacts, which are connected to the digital input / output interface (9) through the digital interface parallel module (37) for testing digital input / output. The output interface of the vehicle controller drives the relay coil, and the input interface of the vehicle controller acquires data through the relay switch contacts. The input interface of the vehicle controller acquires the contact signals of the dual system to verify the consistency of the digital input / output dual system.

8. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The speed sensor test module also includes a power switch (12) and a second USB interface (13). The power switch (12) is used to control the start and stop of the motor; the second USB interface (13) can be connected bidirectionally. Inside the test device, the second USB interface (13) is connected to the motor (27) via a cable. Outside the test device, the second USB interface (13) is connected to the host computer via a cable. The speed of the motor (27) is set on the host computer to simulate different speed scenarios of the train.

9. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The speed sensor (28) is a Hall speed sensor, and each speed sensor (28) outputs two speed signals.

10. A hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The gear (25) is made of magnetic low-carbon steel.

11. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, The power interface includes a 220V AC power interface (11) and a 110V DC power interface (6); the test device is equipped with a power conversion module (31), a 220V AC power distribution terminal block (32) and a 110V DC power distribution terminal block (33). The input power supply voltage of the test device is 220V AC, which is connected through the 220V AC power interface (11) and the power is distributed to the power converter (31) and the switch (2) through the 220VAC power distribution terminal block (32); The power conversion module (31) converts 220V AC to 110V DC. The output of the power conversion module (31) is connected to the 110V DC power distribution terminal block (33). The 110V DC power distribution terminal block (33) distributes power to the vehicle controller and provides a total of 110V DC power output to the outside.

12. The hardware interface function testing device for a train onboard controller according to claim 1, characterized in that, One or more fans (21) are installed on each side of the test device. One fan (21) draws air inward and the other fan (21) exhausts air outward. The test device is equipped with a 24V DC power supply interface (10), and the vehicle controller supplies power to each fan (21) through the 24V DC power supply interface (10).

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