Portable controller parameter detection system and detection method thereof

Abstract

The invention discloses a portable controller parameter detection system, which comprises a power supply conversion control circuit used for carrying out conversion and voltage stabilization processing on an external input power supply and providing stable and adaptive working voltage for a numerical control power supply board control circuit, a signal acquisition circuit, an RS232 communication circuit, an AD sampling board, an industrial control board and a display. According to the invention, accurate testing and automatic determination of the controller are realized. The equipment not only has the advantages of high test precision, simple and convenient operation, convenient carrying and the like, but also greatly improves the working efficiency and precision of controller detection through the functions of database management, automatic report generation and the like.

Description

Technical Field

[0001] This invention relates to a portable controller parameter detection system. Background Technology

[0002] With the rapid development of industrial automation and intelligence, controllers, as crucial components in electrical control systems, are widely used in various electrical equipment. To ensure the reliability and safety of controllers during operation, rigorous performance testing is essential. Traditional controller testing methods often rely on manual operation and scattered testing tools, resulting in low testing efficiency, insufficient accuracy, and inconsistent results. Therefore, developing a high-precision, portable controller comprehensive tester capable of completing comprehensive controller testing in a short time has become a crucial requirement in the industrial testing field. For example, the driver power unit UV fault detection circuit and device disclosed in CN213023368U includes a contactor signal acquisition module for collecting contactor contact signals and a contactor status display module connected to the contactor signal acquisition module to display the current engagement state of each contactor based on the collected contactor contact signals. By setting connectors and relays matching the number of driver power unit groups, real-time monitoring of each power unit is achieved. The contactor status display module enables real-time display of the contactor engagement state of the power unit, but it can only display the contactor engagement state. Summary of the Invention

[0003] The purpose of this invention is to provide a portable controller parameter testing system that is highly accurate, easy to operate, and convenient to carry, addressing the problems of low testing efficiency, insufficient accuracy, and inconsistent results in existing controller performance testing systems.

[0004] The technical solution of this invention: A portable controller parameter detection system, comprising: The power conversion control circuit is used to convert and regulate the external input power supply, providing a stable and compatible working voltage for CNC power supply board control circuits, signal acquisition circuits, RS232 communication circuits, AD sampling boards, industrial control boards and displays; The CNC power supply board control circuit is connected to the industrial control board and controlled by its commands. It outputs a 28VDC coil input voltage and a 6V5mADC controller contact detection voltage, which directly powers the coil and contacts of the controller under test. The signal acquisition circuit includes a coil signal acquisition circuit, a conversion contact signal detection circuit, and a single contact signal detection circuit; The RS232 communication circuit is built using the SP3232EEY-L / TR chip and is equipped with an SMBJ15CA transient suppression diode and a filter capacitor. It is used to realize serial communication between the device and external devices, and to complete the uploading of detection data, the reception of control commands and the interaction of device status. The AD sampling board is a 16-channel differential analog signal acquisition board. It is connected to the signal acquisition circuit and the industrial control board respectively. It converts the analog signals acquired by the signal acquisition circuit into digital signals and transmits them to the industrial control board.

[0005] The coil signal acquisition circuit is connected to the AD sampling board and is used to acquire the voltage and current signals of the coil of the controller under test, and transmit the acquired analog signals to the AD sampling board.

[0006] The switching contact signal detection circuit is adapted to the detection requirements of 10 switching contacts and is used to capture the voltage transformation signal during the contact operation process, providing the raw signal for the calculation of the action time and return time.

[0007] The CNC power supply control circuit includes a Buck module, which is connected to the industrial computer. The Buck module is connected to a 48VDC power supply and outputs a 28VDC power supply.

[0008] The single-contact signal detection circuit is used to collect the voltage transformation signal during the operation of a single contact.

[0009] A detection method for a portable controller parameter detection system, the specific process of which is as follows: (1) Initialization: The device is powered on, the power conversion control circuit starts and supplies power to each circuit module, AD sampling board, industrial control board and display. The industrial control board, CNC power supply board control circuit and AD sampling board complete self-test. The display initializes and displays test-related information. The device enters standby mode. (2) During the parameter configuration stage, the user sends a configuration command to the industrial control board. The configuration command includes a one-click full-function test mode and a single-step test mode, the type of the controller under test and the preset parameter threshold. The industrial control board receives and stores the configuration command. (3) Inspection ends.

[0010] The testing process for the one-click full-function feature is as follows: (201) The industrial control board sends power supply parameter instructions to the CNC power supply board control circuit according to the configuration instructions. After the CNC power supply board control circuit completes the voltage reduction, voltage regulation and current limiting settings, it sends a ready signal back to the industrial control board. (202) The control and detection interface of the industrial control board connects the coil and contact of the controller under test, and the control circuit of the CNC power board outputs the preset voltage and current to the coil and contact; (203) Signal acquisition circuits start synchronously. The coil signal acquisition circuit acquires coil voltage and current signals, and the conversion contact signal detection circuit or single contact signal detection circuit captures contact voltage change signals. All acquired analog signals are converted into digital signals by the AD sampling board and then transmitted to the industrial control board in real time. (204) The industrial control board performs comprehensive processing on the received digital signals: calculates the pull-in voltage, release voltage, suppression voltage, starting current, and holding current, compares them with the preset error range, and determines whether the parameters are qualified; - through the timing analysis of the contact voltage conversion signal, calculates the pull-in time, release time, and bounce time, compares them with the preset error range, and determines whether the time parameters are qualified; (205) The industrial control board stores the original test data, calculation results and pass / fail judgment conclusions to the memory card and displays the test information on the monitor; (206) After the test is completed, the device can upload the test data to an external device via RS232 communication circuit, or automatically generate a test report, and then cut off the power supply and wait for the next test instruction.

[0011] The single-step testing mode includes the following process: (211) Pull-in voltage detection process: The industrial control board controls the CNC power supply board control circuit to gradually increase the coil power supply voltage from 0VDC. The coil signal acquisition circuit continuously monitors the coil voltage, and the contact signal detection circuit monitors the contact status. When the contact is stably pulled in for the first time, the industrial control board records the coil voltage at this time as the pull-in voltage, compares it with the 0-28VDC measurement range and ±1% error requirement, determines whether it is qualified, and stores the result. (212) Release voltage detection process: The CNC power supply board control circuit first provides a stable pull-in voltage to the coil to ensure stable contact pull-in. Then, the power supply voltage is gradually reduced. The coil signal acquisition circuit continuously monitors the voltage change. When the contact is released stably for the first time, the industrial control board records the coil voltage at this time as the release voltage, compares it with the preset error range, determines whether it is qualified, and stores the result. (213) Detection process of pull-in: The CNC power board control circuit outputs the voltage required for pull-in to the coil. The industrial control board starts timing synchronously. The contact signal detection circuit captures the voltage change of the contact from disconnection to stable pull-in, records the pull-in start time and stable pull-in time, calculates the pull-in time and the rebound time during the pull-in process, compares it with the preset error range, determines whether it is qualified and stores the result. (214) Release process detection procedure: The CNC power board control circuit stops supplying power to the coil, the industrial control board starts timing synchronously, the contact signal detection circuit captures the voltage change of the contact from closing to stable release, records the release start time and stable release time, calculates the release time and the rebound time during the release process, compares it with the preset error range, determines whether it is qualified and stores the result.

[0012] The action time measurement range is 0-100ms, and the bounce time measurement range is 0-20ms. When calculating the time parameters, the timing accuracy of the industrial control board is adapted to the measurement range and error requirements.

[0013] The beneficial effects of this invention are: it enables accurate testing and automated judgment of controllers. This equipment not only boasts advantages such as high testing accuracy, ease of operation, and portability, but also significantly improves the efficiency and accuracy of controller testing through database management and automatic report generation functions. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the power conversion control structure of the present invention.

[0015] Figure 2 This is a schematic diagram of the numerical control power supply structure of the present invention.

[0016] Figure 3 This is a schematic diagram of the coil signal acquisition circuit structure of the present invention.

[0017] Figure 4 This is a schematic diagram of the switching contact signal detection circuit of the present invention.

[0018] Figure 5 This is a schematic diagram of the single-contact signal detection circuit of the present invention.

[0019] Figure 6 This is a schematic diagram of the RS232 communication circuit of the present invention.

[0020] Figure 7 This is a flowchart of the one-click full-function detection process of the present invention.

[0021] Figure 8 This is a flowchart of the pull-in voltage detection process of the present invention.

[0022] Figure 9 This is a flowchart of the release voltage detection process of the present invention.

[0023] Figure 10 This is a flowchart of the adsorption process detection of the present invention.

[0024] Figure 11 This is a flowchart of the release process detection of the present invention. Detailed Implementation

[0025] The portable controller system provided by this invention combines modern electronic technology and information technology to achieve accurate testing and automated judgment of controllers. This device not only boasts advantages such as high testing accuracy, ease of operation, and portability, but also significantly improves the efficiency and accuracy of controller testing through database management and automatic report generation functions.

[0026] Power conversion control circuit: Used to receive external input power (such as 220V AC mains power or 48V DC power), and after rectification, filtering and voltage regulation, output a stable and suitable working voltage to the CNC power supply board control circuit, signal acquisition circuit, RS232 communication circuit, AD sampling board, industrial control board, display and detection interface to eliminate the interference of voltage fluctuation on detection accuracy. The CNC power supply board control circuit establishes a signal electrical connection with the industrial control board and is controlled by its commands. It has a built-in Buck module. After the Buck module is connected to a 48V DC power supply, it can output a 28V DC coil input voltage. It also has the functions of step-down conversion, precise voltage regulation and current limiting control. It can output a 6V 5mA DC (voltage accuracy 0.1V) contact detection voltage. Its current limiting range is adapted to the coil current measurement requirements of 0-20A, and directly provides a stable power supply to the coil and contacts of the controller under test. The signal acquisition circuit includes a coil signal acquisition circuit, a conversion-type contact signal detection circuit, and a single-contact signal detection circuit. The coil signal acquisition circuit is electrically connected to the AD sampling board and is used to acquire voltage signals such as the pull-in voltage, release voltage, and suppression voltage of the coil of the controller under test, as well as current signals such as the starting current and holding current, and transmits the acquired analog signals to the AD sampling board. The conversion-type contact signal detection circuit is adapted to detection scenarios with 10 conversion-type contacts (a total of 20 contacts) and is used to capture voltage transformation signals during contact pull-in, release, and bounce processes, providing raw signals for calculating action time and bounce time. The single-contact signal detection circuit is used to acquire voltage transformation signals during the action of a single contact, enabling independent detection of single-contact action parameters. RS232 communication circuit: Based on the SP3232EEY-L / TR chip, it is equipped with transient suppression diodes (D12, D13, D14, D15, all of model SMBJ15CA) and filter capacitors (C27, C28, C29, C30, C33, all of capacitance value 104). The current limiting resistors in the circuit (R25, R26, R27, R28, all of resistance value 10R) are used to establish a serial communication link between the device and external devices (such as computers, host computers) to realize the uploading of detection data, the reception of control commands and the interaction of device working status. 16-channel differential analog signal AD sampling board: It is electrically connected to the signal acquisition circuit and the industrial control board respectively. It is used to convert the analog signal output by the signal acquisition circuit into a digital signal and transmit it to the industrial control board in real time. The sampling rate and accuracy are adapted to the measurement error requirements of the detection parameters. Industrial control board: As the core control unit of the system, it establishes signal electrical connections with the CNC power supply board control circuit, AD sampling board, memory card, display and detection interface respectively. It is used to coordinate the running sequence of each module, analyze and process the digital signals transmitted by AD sampling board, store the processed detection data to the memory card, and output test information and detection results through the display. Testing interface: It adopts a standardized pluggable interface, which is electrically connected to the CNC power board control circuit, signal acquisition circuit and the controller under test respectively, to realize power transmission and signal communication between the equipment and the controller under test, ensuring reliable connection and convenient operation; Storage card: Used to store raw test data, calculation results, pass / fail judgment conclusions and test reports, supporting long-term data retention and traceability; Display: A touch-screen LCD display is used to show the test operation interface, test parameter configuration options, test progress, test results and fault prompts. Users can directly issue configuration commands through the display.

[0027] The specific process for portable controller parameter detection is as follows: Equipment initialization phase: After the equipment is powered on, the power conversion control circuit starts and supplies power to each module. The industrial control board, CNC power supply board control circuit, and AD sampling board complete self-tests in sequence (including module communication status, power supply voltage stability, and signal acquisition channel validity detection). After initialization, the display shows the test operation interface, the detection interface is in a ready-to-connect state, and the entire equipment enters a standby ready state. If an abnormality is found during the self-test, the display will show the corresponding fault prompt (such as "AD sampling board communication failure" or "unstable power supply voltage"). Parameter configuration stage: The user sends configuration instructions to the industrial control board through the touch screen or external device via RS232 communication circuit. The configuration instructions include the detection mode selection (single-step test / one-click full-function test), the model parameters of the controller under test (such as coil rated voltage, contact type) and the preset parameter qualification thresholds (such as voltage measurement error ±1%, current measurement error ±2%). After receiving the instructions, the industrial control board stores them and completes the initialization of the detection parameters. Detection execution phase: 1. One-click full-featured testing process: The industrial control board sends power supply parameter instructions to the CNC power supply board control circuit according to the configuration instructions. After the CNC power supply board control circuit completes the step-down, voltage regulation and current limiting parameter settings through the Buck module (such as outputting 28V DC coil voltage and 6V 5mA DC contact detection voltage), it sends a power supply ready signal back to the industrial control board. The industrial control board's control and testing interface establishes a reliable electrical connection with the coils and contacts of the controller under test, and the CNC power supply board's control circuit outputs corresponding voltages and currents to the coils and contacts according to preset parameters; The signal acquisition circuit starts working synchronously: the coil signal acquisition circuit acquires the coil voltage and current signals, the conversion type contact signal detection circuit or the single contact signal detection circuit captures the contact voltage change signal, and all the acquired analog signals are converted into digital signals by the AD sampling board and then transmitted to the industrial control board in real time. The industrial control board performs comprehensive processing on the received digital signals to achieve automatic judgment functions: calculating parameters such as pull-in voltage, release voltage, suppression voltage (measurement range -70V~70V, error ±2%), starting current, and holding current (measurement range 0-20A, error ±2%), comparing them with preset error ranges to determine whether the parameters are qualified; and through timing analysis of the contact voltage transformation signal, calculating time parameters such as pull-in time, release time (action time measurement range 0-100ms, error ±1%), and bounce time (measurement range 0-20ms, error ±1%), comparing them with preset error ranges to determine whether the time parameters are qualified. Single-step testing process: Pull-in voltage detection: The industrial control board controls the CNC power supply board control circuit to gradually increase the coil supply voltage from 0V DC at a rate of 0.1V / step. The coil signal acquisition circuit continuously monitors the coil voltage, and the contact signal detection circuit monitors the contact status in real time. When the contact voltage change signal is stable and maintained for a preset time (e.g., 50ms) without bouncing, it is determined to be the first stable pull-in. The industrial control board records the coil voltage at this time as the pull-in voltage, compares this voltage value with the 0-28VDC measurement range and ±1% error requirement, determines whether it is qualified, and stores the test result. Release voltage detection: The CNC power supply board control circuit first outputs a stable pull-in voltage (e.g., 28V DC) to the coil and maintains it for 500ms to ensure stable contact pull-in. Then, the supply voltage is gradually reduced at a rate of 0.1V / step. The coil signal acquisition circuit continuously monitors the voltage change. When the contact voltage change signal is stable and maintained for a preset time (e.g., 50ms), it is determined to be the first stable release. The industrial control board records the coil voltage at this time as the release voltage, compares it with the preset error range, determines whether it is qualified, and stores the detection result. Pull-in process detection: The CNC power board control circuit outputs the voltage required for coil pull-in, the industrial control board starts timing synchronously, and the contact signal detection circuit captures the voltage change process of the contact from the open state to the stable pull-in state. It records the pull-in start time (voltage change start point) and the stable pull-in time (voltage stabilization point), calculates the pull-in time and the bounce time during the pull-in process, compares it with the measurement range of 0-100ms (action time) and 0-20ms (bounce time) and the ±1% error requirement, determines whether it is qualified and stores the test results; Release process detection: The CNC power board control circuit stops supplying power to the coil, and the industrial control board synchronously starts timing. The contact signal detection circuit captures the voltage change process of the contact from the closed state to the stable release state, records the release start time (power supply stop point) and the stable release time (voltage stabilization point), calculates the release time and the bounce time during the release process, compares it with the measurement range of 0-100ms (action time) and 0-20ms (bounce time) and the ±1% error requirement, determines whether it is qualified and stores the test results; Result Output Stage: The industrial control board stores the raw test data, calculation results, and pass / fail judgment conclusions to the memory card, and displays the test progress, test values ​​of each parameter, and final pass / fail conclusion in real time on the monitor. After the test is completed, the equipment can upload the test data to an external device via RS232 communication circuit according to preset instructions, or automatically generate a standardized test report (including test time, model of the controller under test, test values ​​of each parameter, and pass / fail judgment results). Subsequently, the CNC power board control circuit stops supplying power to the controller under test, the test interface is disconnected, and the equipment returns to standby mode to wait for the next test instruction.

[0028] This invention adopts an integrated structure, which is small in size and lightweight, and can meet the needs of mobile testing scenarios such as on-site maintenance and outdoor operations, thus solving the limitations of traditional fixed testing equipment. High detection accuracy: Through precise voltage and current regulation by the CNC power supply board, high-precision signal acquisition by the 16-channel differential analog AD sampling board, and digital processing by the industrial control board, accurate measurement of parameters such as voltage, current, and time is achieved. The measurement error of each parameter is controlled within ±2%, which is far superior to the accuracy of traditional manual detection. High degree of automation: Supports both one-click full-function testing and single-step testing modes. No manual intervention is required in the testing process. It automatically completes parameter collection, calculation, judgment, data storage and report generation, which greatly improves testing efficiency and reduces manual operation costs. Data traceability: Equipped with a dedicated memory card to store test data, and supports uploading to external devices via RS232 communication circuit, facilitating data backup, statistical analysis, and quality traceability; High versatility: It can adapt to the detection requirements of 10-channel changeover contacts (20 contacts in total), and is compatible with different models and specifications of contactors, relays and other controller products, with a wide range of applications; Easy to operate: Equipped with a touch-screen LCD display, the interface is intuitive and easy to operate, allowing testing operations to be completed without professional technicians, thus lowering the barrier to entry.

[0029] (I) System Hardware Selection and Setup 1. Selection of core components: Industrial control board: The STM32H7 series microcontroller is selected. This chip has a high-performance ARM Cortex-M7 core with a main frequency of up to 480MHz. It supports multi-channel high-speed data transmission and complex algorithm processing, which can meet the system's requirements for real-time performance and computing power. The CNC power supply board control circuit uses TI's TPS5430DDAR step-down chip to build a Buck module. The input voltage range is 40-50V DC, and the output voltage can be continuously adjusted within the range of 0-32V DC. The maximum output current can reach 20A. With the help of current sampling resistor and feedback regulation circuit, it can achieve a voltage regulation accuracy of 0.1V and a current limiting accuracy of 0.1A. AD sampling board: It adopts ADS1256 analog-to-digital converter chip, which is a 16-bit differential analog signal acquisition chip with a sampling rate of up to 30kSPS. It has high input impedance and low temperature drift. Combined with INA128 instrumentation amplifier, it can achieve accurate acquisition of weak signals and ensure the acquisition accuracy of voltage and current signals. RS232 communication circuit: The core chip is SP3232EEY-L / TR, which has a built-in charge pump and can achieve RS232 level conversion without an external high-voltage power supply. The communication rate can reach up to 1Mbps. It uses an SMBJ15CA transient suppression diode for electrostatic discharge protection, and filter capacitors C27-C29, C30, and C33 (104 ohms capacitance) to filter out high-frequency noise in the communication line, ensuring communication stability. Display: A 5-inch TFT touch LCD screen with a resolution of 800×480 is selected. It supports multi-touch operation, has a fast response speed, and a clear display interface, making it easy for users to configure parameters and view results. Storage card: Micro SD card with a storage capacity of no less than 16GB, supporting high-speed data read and write, used to store test data and reports; Testing interface: It adopts aviation plug, which has waterproof, dustproof and vibration-resistant characteristics, low contact resistance and reliable connection, and is suitable for harsh industrial environments; Power conversion control circuit: AC-DC power module (input 220V AC, output 48V DC) and DC-DC voltage regulator module (input 48V DC, output 3.3V DC, 5V DC) are selected to provide the appropriate operating voltage for each module. The power module has overvoltage, overcurrent and short circuit protection functions to ensure the safety of system power supply.

[0030] 2. Hardware circuit setup Power conversion control circuit: The AC-DC power module converts 220V AC mains power into 48V DC power. One path directly supplies the Buck module of the CNC power board, and the other path is converted into 3.3V DC (supplying the industrial control board, AD sampling board, RS232 communication circuit) and 5V DC (supplying the display and detection interface) through the DC-DC voltage regulator module. A fuse (rated current 5A) and a TVS transient suppression diode are connected in series in the circuit for overcurrent and overvoltage protection. The CNC power supply board control circuit uses the TPS5430DDAR as its core. It takes in a 48V DC power supply and controls the duty cycle of the chip through the PWM signal output from the industrial control board to achieve accurate output of 28V DC coil voltage and 6V 5mA DC contact detection voltage. A current sampling resistor (0.01Ω / 5W) is connected in series in the output circuit to collect the output current signal and feed it back to the industrial control board to achieve current limiting control. Signal acquisition circuit: The coil voltage of the coil signal acquisition circuit is acquired through a voltage divider resistor (ratio 10:1) to ensure that the voltage input to the AD sampling board is within the range; the coil current is acquired through a series current sampling resistor (0.01Ω), amplified by an INA128 instrumentation amplifier, and then transmitted to the AD sampling board; The conversion contact signal detection circuit uses a 5V DC constant voltage source in series with a 500Ω current-limiting resistor, connected to both ends of the conversion contact. When the contact operates, the output voltage undergoes a sudden high-low level change. This sudden signal is shaped by a Schmitt trigger 74HC14 and then transmitted to the AD sampling board to ensure signal stability and reliability; The structure of the single contact signal detection circuit is the same as that of the conversion contact signal detection circuit, with a separate acquisition channel designed for each single contact to ensure the independence of single contact parameter detection; RS232 communication circuit: The VCC pin of the SP3232EEY-L / TR chip is connected to a 3.3V power supply. The C1+, C1-, C2+, and C2- pins are connected to filter capacitors C27, C28, C29, and C30 (capacitance 104) respectively. The communication pins TX and RX are connected to the USART interface of the industrial control board through current-limiting resistors R25-R28 (10R). Transient suppression diodes D12-D15 are connected in parallel between the communication pins and ground for electrostatic discharge protection. Industrial control board connection: The industrial control board controls the enable and voltage regulation signals of the CNC power supply board through the GPIO interface, transmits data with the AD sampling board through the SPI interface, connects to the RS232 communication circuit through the USART interface, communicates with the memory card through the SDIO interface, and drives the touch screen display through the LCD interface. Shielded wires are used to connect the modules to reduce electromagnetic interference.

[0031] (II) System Software Design 1. Software Architecture The system software is developed based on the FreeRTOS real-time operating system and adopts a modular design. It mainly includes an initialization module, a parameter configuration module, a detection and control module, a data acquisition and processing module, a communication module, a storage module, and a display module. Each module works collaboratively through a task scheduling mechanism.

[0032] 2. Implementation of core module functions Initialization module: After the device is powered on, it completes the initialization configuration of peripherals such as GPIO, SPI, USART, and SDIO on the industrial control board, and performs self-tests on modules such as the CNC power supply board, AD sampling board, memory card, and display. If the self-test passes, it enters the standby state. If an abnormality is detected, it displays fault information on the display and alarms. Parameter configuration module: Provides a touch interface for users to select the detection mode (one-click full function / single step test), input the model of the controller under test, and set the parameter qualification threshold (such as voltage error ±1%). After the parameter configuration is completed, it is stored in the internal Flash of the industrial control board and will not be lost when power is off. The detection control module controls the CNC power supply board to output corresponding voltage and current according to the configuration instructions, controls the connection between the detection interface and the controller under test, coordinates the working timing of the signal acquisition circuit and the AD sampling board, and realizes the automated control of the detection process. Data acquisition and processing module: Receives digital signals transmitted from the AD sampling board, filters out noise interference through a moving average filtering algorithm, calculates parameters such as pull-in voltage, release voltage, and coil current based on the acquired voltage and current signals, calculates pull-in time, release time, and bounce time through a timing analysis algorithm, and compares the calculation results with preset thresholds to determine whether the parameters are qualified. Communication module: Enables RS232 serial communication between the industrial control board and external devices, supports data uploading (detection data, reports) and command reception (remote configuration, control). The communication protocol adopts Modbus-RTU to ensure the reliability and universality of data transmission. Storage module: Stores raw test data, calculation results, and pass / fail judgment conclusions to the memory card according to the naming rule of "test time-controller model", and supports the generation and storage of test reports (in TXT or CSV format); - Display module: Displays the test progress (e.g., "pull-in voltage test in progress"), the test values ​​of each parameter (e.g., "pull-in voltage: 24.5V"), the pass / fail judgment results ("pass" / "fail") and fault prompts in real time. The interface adopts a graphical design, which is intuitive and easy to understand.

[0033] (III) System debugging and performance testing 1. Hardware debugging Power supply debugging: Connect the system to 220V AC mains power and measure the 48V DC, 3.3V DC, and 5V DC output voltages of the power conversion control circuit to ensure that the voltage is stable within the allowable range (fluctuation ±0.05V). Test the overvoltage and overcurrent protection functions. When the input voltage is abnormal, the power module should be able to quickly cut off the output. Communication debugging: Connect the system to the computer via RS232 to USB module, send control commands using a serial port debugging assistant, the system should respond correctly and return status information, upload test data to the computer, and verify communication stability; Signal acquisition and debugging: Connect a standard signal source (voltage 0-32V DC, current 0-20A DC) to test the acquisition accuracy of the signal acquisition circuit, ensuring that the voltage measurement error is ≤±1% and the current measurement error is ≤±2%. CNC power supply debugging: Control the CNC power supply board to output 28V DC and 6V DC voltage, measure the output voltage accuracy, and ensure that the voltage regulation accuracy is ≤0.1V and the current limiting accuracy is ≤0.1A.

[0034] 2. Software debugging Single module debugging: Test the functions of modules such as initialization, parameter configuration, and detection control to ensure that each module works normally according to the design logic; Process debugging: Simulate one-click full-function test and single-step test processes to verify the integrity and automation of the testing process, and ensure that there are no abnormalities in parameter acquisition, calculation, judgment, storage and display. Accuracy debugging: Connect to a standard controller (known pull-in voltage 24V, pull-in time 50ms) for testing, compare the system test results with the standard values, adjust the data processing algorithm, and ensure that the test accuracy meets the design requirements.

[0035] 3. Performance Testing Accuracy test: Ten controllers (contactors and relays) of different models were selected and tested using this system and traditional manual testing methods respectively. The test results of the two methods were compared. The voltage detection error of this system is ≤±1%, the current detection error is ≤±2%, and the time detection error is ≤±1%, which is far better than traditional manual testing (error ±5%). Efficiency test: One-click full-function test was conducted on 20 controllers in the same batch. The average test time of this system was 30 seconds per unit, while the average test time of traditional manual test was 5 minutes per unit, which improved the test efficiency by 10 times. Stability test: The system was continuously powered on for 24 hours, and the same controller was tested cyclically. The test results were recorded. The system did not crash or lose data. The test results were consistent (deviation ≤ 0.5%). Portability test: The overall weight of the system is ≤5kg, and the size is ≤400mm×300mm×200mm. It is equipped with a carrying case and can be easily carried to the field for operation, adapting to different usage environments.

[0036] (iv) Practical application operation steps 1. Equipment Preparation Connect the system to a 220V AC mains power supply or a 48V DC power supply, turn on the power switch, and the system will automatically complete the initialization self-test. The display will show the "Standby Ready" interface.

[0037] 2. Connect the controller under test. Connect the coil pins and contact pins of the controller under test to the corresponding interface of the system through the test interface, ensuring that the connection is firm and the polarity is correct (the positive and negative poles of the coil must not be reversed).

[0038] 3. Parameter Configuration On the touchscreen interface, select the test mode (e.g., "One-click full-function test"), enter the model of the controller under test (e.g., "CJX2-1210 contactor"), confirm the qualified threshold parameters (default voltage error ±1%, time error ±1%), and click "Start Test".

[0039] 4. Detection and execution The system automatically controls the CNC power supply board to output the corresponding voltage and current, starts signal acquisition and data processing, and displays the test progress (such as "Detecting the pull-in time...") and real-time parameter values ​​on the display.

[0040] 5. Viewing Results and Exporting Data After the test is completed, the monitor will display the final test results (such as "Pull-in voltage: 23.8V (pass), Pull-in time: 48.5ms (pass)"). Click "View Report" to view detailed test data. If you need to export the data, connect the RS232 to USB module to the computer and click "Upload Data" to export the test data and report to the computer.

[0041] 6. Equipment shutdown After the test is completed, disconnect the controller under test from the system, turn off the power switch, and store the device in the carrying case to complete the test operation. Through the above specific implementation method, the present invention achieves high-precision, automated, and portable testing of controller parameters, effectively solving many defects of traditional testing methods. It can be widely used in industrial production, equipment maintenance, quality inspection, and other fields, and has significant practical value and promotion prospects.

Claims

1. A portable controller parameter detection system, characterized in that... ,include: The power conversion control circuit is used to convert and regulate the external input power supply, providing a stable and compatible working voltage for CNC power supply board control circuits, signal acquisition circuits, RS232 communication circuits, AD sampling boards, industrial control boards and displays; The CNC power supply board control circuit is connected to the industrial control board and controlled by its commands. It outputs a 28VDC coil input voltage and a 6V5mADC controller contact detection voltage, which directly powers the coil and contacts of the controller under test. The signal acquisition circuit includes a coil signal acquisition circuit, a conversion contact signal detection circuit, and a single contact signal detection circuit; The RS232 communication circuit is built using the SP3232EEY-L / TR chip and is equipped with an SMBJ15CA transient suppression diode and a filter capacitor. It is used to realize serial communication between the device and external devices, and to complete the uploading of detection data, the reception of control commands and the interaction of device status. The AD sampling board is a 16-channel differential analog signal acquisition board. It is connected to the signal acquisition circuit and the industrial control board respectively. It converts the analog signals acquired by the signal acquisition circuit into digital signals and transmits them to the industrial control board.

2. The portable controller parameter detection system according to claim 1, characterized in that: The coil signal acquisition circuit is connected to the AD sampling board and is used to acquire the voltage and current signals of the coil of the controller under test, and transmit the acquired analog signals to the AD sampling board.

3. The portable controller parameter detection system according to claim 1, characterized in that: The switching contact signal detection circuit is adapted to the detection requirements of 10 switching contacts and is used to capture the voltage transformation signal during the contact operation process, providing the raw signal for the calculation of the action time and return time.

4. The circuit structure of the portable controller product parameter detection device according to claim 1, characterized in that: The CNC power supply control circuit includes a Buck module, which is connected to the industrial computer. The Buck module is connected to a 48VDC power supply and outputs a 28VDC power supply.

5. The portable controller parameter detection system as described in claim 1, characterized in that: The single-contact signal detection circuit is used to collect the voltage transformation signal during the operation of a single contact.

6. A detection method based on the portable controller parameter detection system according to any one of claims 1 to 5, the specific process of which is as follows: (1) Initialization: The device is powered on, the power conversion control circuit starts and supplies power to each circuit module, AD sampling board, industrial control board and display. The industrial control board, CNC power supply board control circuit and AD sampling board complete self-test. The display initializes and displays test-related information. The device enters standby mode. (2) During the parameter configuration stage, the user sends a configuration command to the industrial control board. The configuration command includes a one-click full-function test mode and a single-step test mode, the type of the controller under test and the preset parameter threshold. The industrial control board receives and stores the configuration command. (3) Inspection ends.

7. The detection method of the portable controller parameter detection system according to claim 1, characterized in that, The testing process for the one-click full-function feature is as follows: (201) The industrial control board sends power supply parameter instructions to the CNC power supply board control circuit according to the configuration instructions. After the CNC power supply board control circuit completes the voltage reduction, voltage regulation and current limiting settings, it sends a ready signal back to the industrial control board. (202) The control and detection interface of the industrial control board connects the coil and contact of the controller under test, and the control circuit of the CNC power board outputs the preset voltage and current to the coil and contact; (203) Signal acquisition circuits start synchronously. The coil signal acquisition circuit acquires coil voltage and current signals, and the conversion contact signal detection circuit or single contact signal detection circuit captures contact voltage change signals. All acquired analog signals are converted into digital signals by the AD sampling board and then transmitted to the industrial control board in real time. (204) The industrial control board performs comprehensive processing on the received digital signals: calculates the pull-in voltage, release voltage, suppression voltage, starting current, and holding current, compares them with the preset error range, and determines whether the parameters are qualified; - through the timing analysis of the contact voltage conversion signal, calculates the pull-in time, release time, and bounce time, compares them with the preset error range, and determines whether the time parameters are qualified; (205) The industrial control board stores the original test data, calculation results and pass / fail judgment conclusions to the memory card and displays the test information on the monitor; (206) After the test is completed, the device can upload the test data to an external device via RS232 communication circuit, or automatically generate a test report, and then cut off the power supply and wait for the next test command.

8. The detection method of the portable controller parameter detection system according to claim 6, characterized in that, The single-step testing mode includes the following process: (211) Pull-in voltage detection process: The industrial control board controls the CNC power supply board control circuit to gradually increase the coil power supply voltage from 0VDC. The coil signal acquisition circuit continuously monitors the coil voltage, and the contact signal detection circuit monitors the contact status. When the contact is stably pulled in for the first time, the industrial control board records the coil voltage at this time as the pull-in voltage, compares it with the 0-28VDC measurement range and ±1% error requirement, determines whether it is qualified, and stores the result. (212) Release voltage detection process: The CNC power supply board control circuit first provides a stable pull-in voltage to the coil to ensure stable contact pull-in. Then, the power supply voltage is gradually reduced. The coil signal acquisition circuit continuously monitors the voltage change. When the contact is released stably for the first time, the industrial control board records the coil voltage at this time as the release voltage, compares it with the preset error range, determines whether it is qualified, and stores the result. (213) Detection process of pull-in: The CNC power board control circuit outputs the voltage required for pull-in to the coil. The industrial control board starts timing synchronously. The contact signal detection circuit captures the voltage change of the contact from disconnection to stable pull-in, records the pull-in start time and stable pull-in time, calculates the pull-in time and the rebound time during the pull-in process, compares it with the preset error range, determines whether it is qualified and stores the result. (214) Release process detection procedure: The CNC power board control circuit stops supplying power to the coil, the industrial control board starts timing synchronously, the contact signal detection circuit captures the voltage change of the contact from closing to stable release, records the release start time and stable release time, calculates the release time and the rebound time during the release process, compares it with the preset error range, determines whether it is qualified and stores the result.

9. The detection method of the portable controller parameter detection system according to claim 6, characterized in that: The action time measurement range is 0-100ms, and the bounce time measurement range is 0-20ms. When calculating the time parameters, the timing accuracy of the industrial control board is adapted to the measurement range and error requirements.

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