Vacuum pump system testing method and system, computer equipment and readable storage medium

Abstract

The invention discloses a vacuum pump system testing method and system, computer equipment and a readable storage medium, and the method comprises the steps: selecting a target fault from a fault mode library, the fault mode library being a fault mode set pre-established for a layered architecture of a tested vacuum pump system; and controlling a fault injection agent through a fault injection controller, injecting the target fault into the tested vacuum pump system, and generating a test result based on the response of the tested vacuum pump system after the target fault is injected. According to the method and the device, active, systematic and reproducible evaluation of the reliability of the vacuum pump system is realized, and the defects of limited fault scene coverage, difficulty in active triggering of a specific fault and lack of systematic evaluation basis in a traditional test method are effectively overcome.

Description

Technical Field

[0001] This application relates to the field of industrial equipment reliability testing technology, specifically to a vacuum pump system testing method, system, computer equipment, and readable storage medium. Background Technology

[0002] Existing testing methods for vacuum pump systems primarily focus on the pump's inherent performance indicators, such as factory performance testing (ultimate vacuum, pumping speed, etc.) and routine maintenance and diagnostics performed by listening for abnormal noises and monitoring vibration signals. However, a modern vacuum pump system is a complex mechatronic system comprising the pump body, motor controller, controller, sensors, and monitoring software. Current testing methods, which mainly target the pump's inherent performance, cannot effectively assess the reliability of its control system.

[0003] Furthermore, relying on naturally occurring faults or faults preset by limited experience for testing presents problems such as difficulty in fault reproduction and low test coverage. It is difficult to systematically cover various extreme, rare, or concurrent fault scenarios, and it is also impossible to proactively and controllably simulate abnormal operating conditions of the system at different levels (such as the physical execution layer, signal sensing layer, control drive layer, and information interaction layer).

[0004] Therefore, existing technologies lack a method that can systematically construct failure scenarios and conduct comprehensive reliability testing of vacuum pump systems based on these scenarios. Summary of the Invention

[0005] This application provides a vacuum pump system testing method, system, computer equipment, and readable storage medium, which can actively and controllably apply various preset faults to the vacuum pump system and systematically evaluate its response behavior and reliability, so as to at least partially solve the above-mentioned technical problems.

[0006] According to a first aspect of this application, a method for testing a vacuum pump system is provided, comprising: The target fault is selected from the fault mode library, which is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test. The target fault is injected into the vacuum pump system under test by controlling the fault injection agent through the fault injection controller. Test results are generated based on the response of the tested vacuum pump system after the target fault is injected.

[0007] Optionally, the method further includes: Test cases are created based on the fault mode library; wherein the configuration information of the test cases includes at least one of the fault mode to be injected, fault triggering conditions, fault duration, and expected response behavior, and the expected response behavior is the response behavior expected from the vacuum pump system under test when the fault is injected.

[0008] Optionally, the step of controlling the fault injection agent through the fault injection controller to inject the target fault into the vacuum pump system under test includes: Based on the test cases, control instructions are generated and sent to the fault injection agent at a predetermined time according to the fault triggering conditions. The fault injection agent receives and responds to the control instructions to inject the target fault into the vacuum pump system under test through hardware interruption or software simulation.

[0009] Optionally, the method further includes: Obtain the response data of the vacuum pump system under test when the test case is executed; The reliability assessment results of the tested vacuum pump system are generated based on the response data.

[0010] Optionally, obtaining the response data of the vacuum pump system under test when the test case is executed includes: During fault injection, fault persistence, and fault recovery, the fault injection controller continuously monitors the tested vacuum pump system through the fault injection agent and records the corresponding response data. When the fault duration in the test case ends, the fault injection controller controls the fault injection agent to perform a fault cancellation operation, and continues to monitor and record the response data corresponding to the recovery process of the vacuum pump system under test.

[0011] Optionally, generating the reliability assessment result of the tested vacuum pump system based on the response data includes: The response data is compared with the expected response behavior in the test case; The test case is determined to pass or fail based on the comparison results. Based on the results of multiple test cases, the reliability quantification index of the tested vacuum pump system is calculated.

[0012] Optionally, comparing the response data with the expected response behavior in the test case includes: Based on a predefined reliability evaluation index system that includes multiple evaluation indicators, the response data is analyzed to obtain the actual quantitative values ​​of the tested vacuum pump system for each evaluation index. Each of the actual quantitative values ​​is compared with the judgment threshold set for the corresponding evaluation index in the expected response behavior; Based on the comparison results, the pass or fail status of the test case is automatically determined; The evaluation index is used to quantify at least one aspect of the function, safety, or performance of the vacuum pump system.

[0013] According to a second aspect of this application, a testing system is also provided for performing a test method for a vacuum pump system designed in any of the above aspects, comprising: A fault injection controller is configured to select a target fault from a fault mode library and generate control commands; wherein the fault mode library is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test. The fault injection agent establishes a communication connection with the fault injection controller and the vacuum pump system under test, and is configured to receive and execute the control command, inject the target fault into the vacuum pump system under test, and generate test results based on the response of the vacuum pump system under test after the target fault is injected.

[0014] According to a third aspect of this application, a computer device is also provided, comprising: One or more processors; Memory, which stores computer program instructions; When the computer program instructions are executed by the one or more processors, the computer device performs the method of any of the above-described aspects.

[0015] According to a fourth aspect of this application, a computer-readable storage medium is also provided, on which a computer program is stored, wherein the computer program, when executed by a processor, implements the steps of the method of any of the above-described aspects.

[0016] The embodiments of this application achieve proactive, systematic and reproducible assessment of the reliability of vacuum pump systems by constructing a structured fault mode library and implementing fault injection and response monitoring based on the library. This effectively overcomes the shortcomings of traditional testing methods, such as limited coverage of fault scenarios, difficulty in actively triggering specific faults, and lack of systematic assessment basis. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart illustrating a vacuum pump system testing method provided by an exemplary embodiment of this disclosure; Figure 2This is another flowchart illustrating the vacuum pump system testing method provided by an exemplary embodiment of this disclosure; Figure 3 This is a schematic diagram of the structure of the test system provided in an exemplary embodiment of this disclosure. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0021] "A and / or B" includes the following three combinations: A only, B only, and a combination of A and B.

[0022] The use of "applies to" or "configured to" in this application implies open and inclusive language, which does not exclude the applicability to or configuration to devices performing additional tasks or steps. Additionally, the use of "based on" implies openness and inclusivity, because processes, steps, calculations, or other actions "based on" one or more of the stated conditions or values ​​may in practice be based on additional conditions or values ​​beyond those stated.

[0023] In this application, the term "exemplary" is used to mean "used as an example, illustration, or description." Any embodiment described as "exemplary" in this application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use this application. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that this application can be made without using these specific details. In other instances, well-known structures and processes are not described in detail to avoid obscuring the description of this application with unnecessary detail. Therefore, this application is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed in this application.

[0024] In existing technologies, testing of vacuum pump systems mainly focuses on performance verification and routine maintenance, such as testing performance indicators like ultimate vacuum and pumping speed, or performing post-event diagnosis by monitoring signals like vibration and current. However, these methods have significant limitations: First, the test object is primarily the pump body itself, making it difficult to effectively assess the overall reliability of the entire mechatronic system, including the controller, sensors, and drive unit. Second, relying on naturally occurring faults or limited experience for testing is extremely inefficient, and many extreme, rare, or concurrent faults are almost impossible to occur naturally in a laboratory environment. This results in incomplete test case coverage, numerous unknown risks, and an inability to systematically verify the system's fault tolerance and boundary conditions. Furthermore, the lack of systematic and proactively controllable simulation methods for abnormal operating conditions (such as sensor signal drift, motor overcurrent, and communication interruptions) makes it difficult to assess the behavior, self-diagnostic capabilities, and fault recovery capabilities of the entire vacuum pump system under abnormal conditions. The testing process lacks hierarchy and automation, failing to comprehensively cover all system components from the physical layer to the information layer.

[0025] To address the aforementioned technical challenges, this application proposes a testing method, system, and computer-readable storage medium for a vacuum pump system. By constructing a fault mode library for different levels of the vacuum pump system, and based on this library, actively and precisely applying faults through a fault injection agent while monitoring the system response to assess its reliability, a full-link, systematic reliability verification of the vacuum pump system, from physical execution to information interaction, is achieved. This method can proactively, flexibly, and repeatedly simulate various fault scenarios, significantly improving test coverage and fault reproducibility, thereby accurately identifying potential system defects and providing data support for the reliability design and optimization of the vacuum pump system.

[0026] On the one hand, this embodiment provides a test method for a vacuum pump system, such as... Figure 1 As shown, it includes the following steps: Step S101: Select the target fault from the fault mode library, wherein the fault mode library is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test.

[0027] Step S102: Control the fault injection agent through the fault injection controller to inject the target fault into the vacuum pump system under test.

[0028] Step S103: Generate test results based on the response of the tested vacuum pump system after the injection of the target fault.

[0029] The embodiments of this application construct a structured fault mode library for the vacuum pump system under test, and implement fault injection and response monitoring based on the fault mode library, thereby realizing an active, systematic and reproducible assessment of the reliability of the vacuum pump system. This effectively overcomes the technical problems of limited fault scenario coverage, difficulty in actively triggering specific faults and lack of systematic assessment basis in traditional testing methods.

[0030] In some embodiments, the layered architecture of the vacuum pump under test includes a physical execution layer, a signal sensing layer, a control drive layer, and an information interaction layer, wherein the failure modes are defined for one or more layers in the layered architecture.

[0031] Among them, physical execution layer faults are used to simulate abnormalities in the actuators of the vacuum pump system; signal sensing layer faults are used to simulate abnormalities in the sensor signals of the vacuum pump system; control drive layer faults are used to simulate abnormalities in the controller interface and logic of the vacuum pump system; and information interaction layer faults are used to simulate communication abnormalities inside or outside the vacuum pump system.

[0032] A structured fault mode library is built into the fault injection controller. This fault mode library is defined based on the system architecture hierarchy of the vacuum pump system, and specifically includes: This is designed to address faults defined at the physical execution layer, simulating abnormal operating states of actuators in a vacuum pump system. For example, it can simulate faults such as decreased motor torque or insufficient output by controlling the motor drive current.

[0033] This is designed to simulate abnormal signal characteristics of various sensors connected to a vacuum pump system, addressing faults defined in the signal sensing layer. For example, it can simulate pressure sensor readings drifting, getting stuck at a fixed value, or exceeding their range; it can also simulate circuit faults such as short circuits or open circuits in temperature sensors.

[0034] This is designed to address faults defined in the control drive layer, simulating anomalies in the hardware interface and internal control logic of the controller (such as a microcontroller or PLC) of a vacuum pump system. For example, it can simulate abnormalities in the controller's digital input / output (I / O) points, such as being set to normally open or normally closed states; or it can simulate control logic errors by tampering with specific variable values ​​or register values ​​in the controller's memory.

[0035] This system addresses faults defined in the information interaction layer, simulating anomalies in communication links between internal components of a vacuum pump system or with external devices. Examples include simulating communication network latency, packet loss, message content tampering, duplicate message reception, or communication interruption. The industrial communication protocols involved may include, but are not limited to, Modbus, PROFIBUS, and Ethernet / IP.

[0036] This embodiment uses a layered and precise modeling approach to categorize and manage faults according to the architectural hierarchy of the vacuum pump system. It establishes precise mathematical models or numerical descriptions for each fault mode, making test case design more systematic and achieving higher test coverage. Furthermore, by constructing a layered fault mode library, the testing approach shifts from passive waiting to active verification, solving the technical problems of difficult fault reproduction and low test coverage. Specifically, the layered approach systematically identifies potential fault types at each layer, from physical hardware to information interaction, by dividing the vacuum pump system into top-down or bottom-up hierarchical levels, forming a comprehensive "fault map." This significantly improves test coverage and avoids test blind spots. For example, the layered approach encourages testing to focus not only on obvious physical layer faults such as motor failure but also on hidden faults such as control command loss due to network packet delays (information interaction layer), microcontroller I / O point jamming (control drive layer), or pressure sensor reading drift (signal sensing layer). Meanwhile, various fault modes are clearly defined and stored in a structured fault mode library, transforming abstract fault concepts into configurable and callable specific test items, ensuring that each fault can be accurately and repeatably reproduced. For example, the "pressure sensor stuck" fault is precisely defined as "sending a fixed analog voltage signal to the controller." During testing, simply calling this fault mode from the library and setting the parameters allows for accurate and repeatable reproduction of the fault.

[0037] It should be noted that the fault injection controller, as the central processing unit of the system, is responsible for storing and managing the fault mode library and test case library, and issuing specific fault injection instructions to the fault injection agents based on the test cases. The fault injection agent, as the instruction execution unit, is responsible for receiving instructions from the fault injection controller and executing the specific fault injection operations. As an independent test device, the fault injection agent does not store the fault mode library itself, thus allowing it to focus on high-precision, high-real-time signal injection tasks. The fault injection controller centrally manages and maintains test standards and test cases uniformly, and the same fault mode library can be issued instructions to different fault injection agents for testing different vacuum pump systems.

[0038] In some embodiments, the method further includes: Test cases are created and managed based on a fault mode library. The configuration information for each test case includes at least one of the following: the fault mode to be injected, the fault triggering condition, the fault duration, and the expected response behavior. The expected response behavior is the expected response behavior of the vacuum pump system under test when the fault is injected.

[0039] The test case is stored in the fault injection controller in XML format or database form. The configuration of the test case includes the fault mode to be injected, indicating what type of fault is being injected; the trigger time or condition for fault injection, indicating when the fault is injected; the duration of the fault; and the expected correct response of the system during fault injection, representing the expected behavior of the vacuum pump under test.

[0040] In some embodiments, a fault injection agent is controlled by a fault injection controller to inject the target fault into the vacuum pump system under test, including: Control commands are generated based on test cases and sent to the fault injection agent at a predetermined time according to the fault triggering conditions. The fault injection agent receives and executes the control commands to inject the target fault into the vacuum pump system under test through hardware interruption or software simulation.

[0041] In some embodiments, before generating control instructions based on test cases, the method further includes: The fault injection agent is serially connected to the communication link inside the vacuum pump system under test.

[0042] In one specific implementation, injecting faults into the vacuum pump system via a fault injection agent responding to commands from the fault injection controller is achieved by building a dedicated fault injection test platform. This platform comprises three main parts: a fault injection controller, a fault injection agent, and the vacuum pump system under test. The fault injection controller, running as host software on a separate computer device (such as a personal computer), is responsible for storing and managing the fault mode library and test case library, and integrates an automated testing engine for scheduling, executing, monitoring, recording, and analyzing fault injection commands. The fault injection agent is implemented as a dedicated hardware device (e.g., an FPGA-based board) or software gateway, containing at least one of an analog injection module, a digital injection module, and a network packet injection module, used to receive and execute specific fault injection commands from the fault injection controller. The vacuum pump system under test includes its own controller, sensors, motor drivers, and vacuum pump motor.

[0043] When establishing a system connection, a fault injection agent is removably connected to the communication link within the vacuum pump system under test in a man-in-the-middle manner. Specifically, the fault injection agent is serially connected to the communication link between the sensor and the pump controller, or between the pump controller and the driver, thereby enabling the fault injection agent to intercept and tamper with physical signals or communication messages.

[0044] During test execution, control commands are first generated based on test cases selected from the fault mode library; then, the control commands are sent to the fault injection agent through the fault injection controller; finally, the fault injection agent executes the control commands and completes the fault injection into the vacuum pump system under test through its hardware interrupt capability or software simulation function, thereby realizing the reliability test of the vacuum pump system.

[0045] In some embodiments, the method further includes: Obtain the response data of the vacuum pump system under test when the test case is executed; The reliability assessment results of the tested vacuum pump system are generated based on the response data.

[0046] The response data is used to characterize the dynamic response of the tested vacuum pump system, including at least one of the following: whether its controller triggers an alarm, whether the actuator makes an adjustment, or whether the system operating state changes.

[0047] In some embodiments, obtaining response data of the vacuum pump system under test during test case execution includes: During fault injection, fault persistence, and fault recovery, the fault injection controller continuously monitors the tested vacuum pump system through the fault injection agent and records the corresponding response data. When the fault duration in the test case ends, the fault injection agent is controlled by the fault injection controller to perform the fault cancellation operation, and the response data corresponding to the recovery process of the vacuum pump system under test continues to be monitored and recorded.

[0048] In some specific embodiments, the method further includes: When the duration of the fault in the test case ends, the fault injection agent is controlled by the automated test engine of the fault injection controller to perform a fault cancellation operation, restoring the signal of the disturbed vacuum pump system to normal.

[0049] In some specific embodiments, after the fault injection agent is controlled by the automated test engine of the fault injection controller to perform a fault reversal operation and restore the signal of the disturbed vacuum pump system to a normal state, the method further includes: The automated test engine of the fault injection controller monitors the process of the vacuum pump system signal recovering to the normal state, and records the behavioral data and time of recovery from the fault state to the normal operating state.

[0050] Specifically, the automated test engine in the fault injection controller leads the process of monitoring the vacuum pump system response and generating a reliability assessment report, forming a fully automated test cycle.

[0051] The testing process begins with the test initialization and baseline recording phase. During this phase, the fault injection controller, through the fault injection agent, first collects data on the vacuum pump system operating under normal conditions for a period of time before injecting any fault. This establishes baseline data for various key performance parameters of the vacuum pump system, serving as a comparison benchmark for subsequent fault response analysis.

[0052] The process then proceeds to the fault triggering and execution phase. After the user selects or configures specific test cases through the fault injection controller, the automated test engine sends instructions to the fault injection agent at predetermined times within the fault triggering conditions, based on the test case definition. For example, a test case could be defined as "fixing the reading of pressure sensor P1 to 100 Pa for 10 seconds at the 30th second of vacuum pump system operation." Upon receiving the instructions, the fault injection agent executes corresponding hardware or software operations, such as switching the analog signal line to the vacuum pump system controller to a programmable resistor via its analog injection module, outputting a precise voltage signal corresponding to the 100 Pa pressure.

[0053] During the post-fault injection and fault recovery phases, the fault injection controller enters a comprehensive response monitoring and data acquisition process. The fault injection controller continuously monitors and records various dynamic responses of the vacuum pump system through the fault injection agent, including but not limited to: whether the vacuum pump system controller correctly detects abnormal sensor signals and triggers the expected alarm signals; whether the human-machine interface accurately displays the fault status; whether actuators such as motor speeds make adjustments consistent with the control logic; and whether the overall operating status of the vacuum pump system has changed.

[0054] When the preset fault duration ends, the fault injection agent automatically performs a fault cancellation operation, restoring the interfered vacuum pump system signal to normal. Afterward, the fault injection controller continues to monitor the vacuum pump system's recovery process, recording its behavior and time of returning from the fault state to normal operation.

[0055] Based on all response data collected throughout the fault injection, persistence, and recovery process, the analysis engine within the fault injection controller automatically analyzes the reliability performance of the vacuum pump system using its built-in rule base and evaluation algorithms, and generates a structured reliability assessment report.

[0056] In this embodiment, by calling test cases, the triggering time and duration of fault injection can be controlled with high precision, effectively verifying the response logic of the vacuum pump system controller when facing rapidly changing abnormal operating conditions.

[0057] In some embodiments, a reliability assessment result for the tested vacuum pump system is generated based on the response data, including: Compare the response data with the expected response behavior in the test cases; The test case is determined based on the comparison results; Based on the results of multiple test cases, the reliability quantification index of the tested vacuum pump system is calculated.

[0058] In some embodiments, before injecting the target fault into the tested vacuum pump system by controlling a fault injection agent via a fault injection controller: Data is collected from the vacuum pump system under test during normal operation to establish baseline data for the performance parameters of the vacuum pump system under test.

[0059] The baseline data includes a comprehensive benchmark dataset of performance metric baselines, status metric baselines, and alarm log baselines, providing a comparison standard for subsequent reliability assessments.

[0060] Performance baselines include the slope of the normal pumping curve of the vacuum pump, the range of vacuum fluctuation after stabilization, the normal range of motor current / speed, and the time required for the vacuum pump system to reach stability.

[0061] The baseline status indicators include the reasonable range of various sensor data and the normal status of key variables inside the controller when the vacuum pump system is operating normally.

[0062] Alarm log baseline, including confirmation that the vacuum pump system has no abnormal alarms during fault-free injection.

[0063] In some embodiments, comparing response data with expected response behavior in test cases includes: Based on a predefined reliability evaluation index system that includes multiple evaluation indicators, the response data is analyzed to obtain the actual quantitative values ​​of the tested vacuum pump system in each of the evaluation indicators. Each of the actual quantitative values ​​is compared with the judgment threshold set for the corresponding evaluation index in the expected response behavior; Based on the comparison results, the pass or fail status of the test case is automatically determined; The evaluation index is used to quantify at least one aspect of the function, safety, or performance of the vacuum pump system.

[0064] This reliability assessment index system constitutes the systematic framework for the assessment, and the preset response data specifically reflects the expected response behavior defined for each test case within this framework.

[0065] Specifically, the analysis engine within the fault injection controller first establishes a multi-dimensional reliability evaluation index system. This system defines multiple evaluation dimensions and specific evaluation indicators for each dimension. The evaluation dimensions include functional, security, and performance dimensions.

[0066] Thus, the process of generating a reliability assessment report for the vacuum pump system based on response data is completed through the data analysis and assessment module integrated within the fault injection controller, achieving automation from data acquisition to intelligent assessment.

[0067] Specific evaluation metrics under the functional dimension include the vacuum pump system's fault detection capability, fault tolerance, and functional recovery capability. Specifically, fault detection capability is assessed by whether the vacuum pump system correctly triggers the expected alarms or fault codes within a preset time threshold. Fault tolerance is assessed by whether deviations in the vacuum pump system's performance (such as vacuum level) are within safety tolerances and whether basic functionality is maintained. Functional recovery capability is assessed by whether the vacuum pump system can automatically or manually return to normal operation after fault clearance, and the recovery time.

[0068] Specific evaluation indicators under the safety dimension include the vacuum pump system's ability to transition to a safe state and its performance in performing no dangerous actions. Specifically, whether the vacuum pump system has entered the expected safe state (such as smooth shutdown or degraded operation) according to safety design specifications is used to evaluate its ability to transition to a safe state. Whether the vacuum pump system has performed any unexpected or dangerous actions (such as motor overspeed or valve malfunction) is used to evaluate its performance in performing no dangerous actions.

[0069] Specific evaluation metrics within the performance dimension include the response time and performance degradation of the vacuum pump system. Specifically, response time is assessed by the time from fault injection to the vacuum pump system making its first correct response (e.g., alarm, status change). Performance degradation is assessed by the degree of decline in key performance indicators (e.g., pumping speed, energy consumption) during the duration of the fault.

[0070] In some embodiments, the reliability assessment results include at least one of the following: an execution summary, a detailed test results table, a reliability quantification score, a problem and defect analysis, and a key data curve.

[0071] The execution summary provides an overview of the overall test pass rate and key issues.

[0072] The test results table is used to list the fault injection description, expected behavior, actual observed behavior, response time, and test results (pass / fail) for each test case in tabular form.

[0073] The reliability quantification score includes core indicators such as fault detection rate, number of safety violations, and mean recovery time. Specifically, the fault detection rate is calculated using the formula (number of successfully detected faults / total number of injected faults) × 100%. The number of safety violations represents the number of times the vacuum pump system enters a dangerous state. The mean recovery time represents the average time from clearing all recoverable faults to normal functioning.

[0074] Problem and defect analysis is used to automatically identify test cases that fail and analyze potential causes (such as logical defects, incorrect parameter configuration, and improper hardware selection).

[0075] Data curves are used to represent changes in system vacuum and current at key event points (such as the time of fault injection or alarm trigger) as supporting evidence to ensure that the evaluation conclusions have a sufficient data basis.

[0076] The embodiments of this application establish a system performance baseline, construct a multi-dimensional reliability evaluation index system, and realize automated comparison and judgment based on a rule engine, ultimately generating structured evaluation results. This transforms fault testing from traditional subjective and qualitative judgment to objective and quantitative scientific evaluation, significantly improving the accuracy and consistency of test results.

[0077] Please see Figure 2 This is another flowchart illustrating the vacuum pump system testing method provided by an exemplary embodiment of this disclosure.

[0078] In one specific implementation, combined with Figure 3 The fault injection test procedure shown below, and the test method for the vacuum pump system, are implemented through the following detailed steps: In step S201, the fault injection controller, through the fault injection agent, collects multiple data points of the vacuum pump system under test running under normal conditions for a predetermined period of time before injecting the fault, and establishes a system performance baseline.

[0079] Step S202: On the fault injection controller, respond to the user's operation to select or configure specific test cases.

[0080] In step S203, the automated test engine within the fault injection controller sends instructions to the fault injection agent at a predetermined time according to the definition of the selected test cases, so that the fault injection agent receives and responds to the instructions to perform fault injection.

[0081] The test cases explicitly specify the fault mode to be injected (selected from the fault mode library), the trigger time or condition for fault injection, the duration of the fault, and the expected correct system response. After receiving the instruction, the fault injection agent performs specific operations through its analog injection module, digital injection module, or network packet injection module. For example, it physically switches the analog signal line to the vacuum pump system controller to a programmable resistor and outputs a precise voltage signal representing a specific fault state (such as a pressure sensor reading fixed at 100 Pa).

[0082] In step S204, during fault injection, fault persistence, and subsequent fault recovery, the fault injection controller continuously and comprehensively monitors and records various dynamic response data of the vacuum pump system through the fault injection agent.

[0083] Specifically, the monitoring content may include: whether the controller of the vacuum pump system correctly detects the fault and triggers the expected alarm or fault code within a preset time threshold; whether the human-machine interface correctly displays the corresponding fault status; whether the speed of the actuator, such as the motor, is adjusted accordingly according to the control logic; and whether the operating status of the entire system changes in accordance with or deviates from the expected changes.

[0084] Step S205: When the preset fault duration in the test case ends, the fault injection agent automatically performs a fault cancellation operation to restore the interfered vacuum pump system signal to normal.

[0085] The fault injection controller continues to monitor the recovery process of the vacuum pump system through an agent, recording its specific behavior and the time required to return from the fault state to the normal operating state.

[0086] In step S206, the fault injection controller stores the recorded response data into the database.

[0087] In step S207, the analysis engine within the fault injection controller automatically compares the actual response behavior of the vacuum pump system with the expected response behavior in the test cases using a predefined rule engine, and determines the pass or fail status of each test case based on the comparison results. If the actual response behavior matches or is better than the expected response behavior, proceed to step S208. Otherwise, proceed to step S209.

[0088] Step S208: Mark the test case as "passed".

[0089] Step S209: Mark the test case as "failed" and perform preliminary root cause analysis based on a predefined fault tree to identify potential problem areas.

[0090] Specifically, firstly, the injected fault events are precisely correlated and aligned with the collected system response data on the timeline. Then, using a predefined rule engine, the actual response behavior of the vacuum pump system is automatically compared with the expected response behavior in the test cases, and various quantitative indicators in the reliability assessment index system (such as fault detection rate, number of safety violations, and mean recovery time) are automatically calculated. Based on the comparison and calculation results, the pass or fail status of each test case is automatically determined.

[0091] Step S210: Integrate the judgment results of all test cases, the calculated quantitative indicators, and the root cause analysis conclusions to automatically generate a structured reliability assessment result.

[0092] The reliability assessment results include an execution summary, a detailed test results table, a reliability quantification score, a problem and defect analysis, and related key data curves as evidence.

[0093] Through the above steps, fully automated and systematic testing and quantitative evaluation of the reliability of the vacuum pump system were achieved.

[0094] On the other hand, this embodiment provides a testing system for performing the steps of the method in any of the above embodiments. For example... Figure 3 As shown, the test system 30 includes: The fault injection controller 301 is configured to select a target fault from the fault mode library 3011 and generate control commands; wherein the fault mode library 3011 is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test. The fault injection agent 302 establishes a communication connection with the fault injection controller 301 and the vacuum pump system 31 under test, and is configured to receive and execute the control command to inject the target fault into the vacuum pump system 31 under test, and generate test results based on the response of the vacuum pump system 31 under test after the injection of the target fault.

[0095] It should be noted that the test system 30 adopts a non-intrusive design architecture. Specifically, the fault injection controller 301, as the central control unit, is responsible for centrally storing and managing the fault mode library 3011 and the test case library 3012, and issuing fault injection commands. The fault injection agent 302, as the command execution unit, receives commands from the fault injection controller 301 and executes specific fault injection operations. As an independent test device, the fault injection agent 302 does not store the fault mode library 3011 itself, thus focusing on high-precision, high-real-time signal injection tasks. Furthermore, the fault injection agent 302 temporarily connects to the communication link of the vacuum pump system 31 under test in a man-in-the-middle manner. The fault injection agent 302 is not a component of the vacuum pump system 31 under test; it only intervenes in the operation of the vacuum pump system 31 under test during the testing phase and is removed after the test is completed, thereby ensuring the integrity and independence of the vacuum pump system 31 as the final product. This ensures that the reliability verification process of the vacuum pump system does not depend on or change the hardware or software configuration of the final product. The fault injection controller 301 centrally manages and maintains test standards and test cases in a unified manner, and the same set of fault mode libraries can be issued to different fault injection agents 302 through commands to be applied to test different vacuum pump systems.

[0096] The vacuum pump system 31 under test includes a pump controller 311, a sensor 312, a motor driver 313, and a vacuum pump motor 314.

[0097] In some embodiments, the fault injection controller 301 further includes an automated test engine 3013.

[0098] The fault injection controller 301 runs as host computer software on an independent computer device (such as a personal computer). It is responsible for storing and managing the fault mode library 3011 and the test case library 3012, and integrates an automated test engine 3013 to complete the scheduling, execution, monitoring, recording and analysis of fault injection instructions.

[0099] In some embodiments, the fault injection agent 302 can be removably serially (man-in-the-middle) connected to the communication link of the vacuum pump system 31 under test.

[0100] The fault injection agent 302 is not a component of the vacuum pump system 31 under test. It only intervenes in the operation of the vacuum pump system 31 under test during the testing phase and is removed after the test is completed, thereby ensuring the integrity and independence of the vacuum pump system 31 under test as a final product. Therefore, the fault injection agent 302 is connected to the communication link of the vacuum pump system 31 under test through a removable man-in-the-middle connection.

[0101] In some embodiments, the fault injection agent 302 includes at least one of an analog injection module 3021, a digital injection module 3022, and a network packet injection module 3023.

[0102] The fault injection agent 302 is a dedicated hardware device (e.g., an FPGA-based board) or software gateway used to receive and execute specific fault injection commands from the fault injection controller 301. During system connection establishment, the fault injection agent 302 is connected to the communication link of the vacuum pump system 31 under test in a removable man-in-the-middle manner. Specifically, the fault injection agent 302 is serially connected to the communication link between the pump controller 311 and the sensor 312, or between the pump controller 311 and the motor driver 313, thereby enabling the fault injection agent 302 to intercept and tamper with physical signals or communication messages.

[0103] In some embodiments, the fault injection controller 301 is further configured to create and manage test cases. The test case configuration includes at least one of the following: a fault mode to be injected, fault triggering conditions, fault duration, and expected response behavior, wherein the expected response behavior is the response behavior expected from the vacuum pump system under test upon fault injection.

[0104] In some embodiments, the automated test engine 3013 is configured to generate control instructions based on the test case library 3012 and send the control instructions to the fault injection agent 302 at a predetermined time according to the fault triggering conditions. The fault injection agent 302 is configured to receive and respond to the control instructions to inject the fault into the vacuum pump system 31 under test through hardware interruption or software simulation to test the vacuum pump system 31 under test.

[0105] In some embodiments, the automated testing engine 3013 is further configured to: Obtain the response data of the vacuum pump system 31 under test when the test cases are executed; Based on the response data, a reliability assessment result for the tested vacuum pump system 31 is generated.

[0106] In some embodiments, the automated testing engine 3013 is further configured to: During fault injection, fault persistence, and fault recovery, the fault injection agent 302 continuously monitors the vacuum pump system 31 under test and records the corresponding response data. When the duration of the fault in the test case ends, the fault injection agent 302 controls the fault cancellation operation and continues to monitor and record the response data corresponding to the recovery process of the vacuum pump system 31 under test.

[0107] In some embodiments, the automated testing engine 3013 is further configured to: Compare the response data with the expected response behavior in the test cases; The test case is determined based on the comparison results; Based on the judgment results of multiple test cases, the reliability quantification index of the tested vacuum pump system 31 is calculated.

[0108] In some embodiments, the automated testing engine 3013 is further configured to: Based on a predefined reliability assessment index system, the actual response behavior is compared with the expected response behavior to obtain the quantitative assessment results of the tested vacuum pump system 31 on each assessment index, and the pass or failure status of the test case is automatically determined.

[0109] In some embodiments, the automated test engine 3013 is also configured to collect data from the vacuum pump system 31 under test during normal operation to establish baseline data for performance parameters.

[0110] The test system 30 of this embodiment executes the method of any of the above embodiments. By constructing a structured fault mode library for the vacuum pump system under test, and performing fault injection and response monitoring based on the fault mode library, it achieves an active, systematic, and reproducible assessment of the reliability of the vacuum pump system. This effectively overcomes the technical problems of limited fault scenario coverage, difficulty in actively triggering specific faults, and lack of systematic assessment basis in traditional test methods. The test system 30 has all the beneficial effects of the above-described vacuum pump system test methods, which will not be elaborated further in this disclosure.

[0111] This application also provides a fault injection controller for executing the vacuum pump system testing method described in any of the above embodiments. The controller is configured to store a fault mode library including faults in the vacuum pump system under test, and to generate and issue control commands based on faults selected from the fault mode library. The fault injection agent receives and responds to the control commands to inject the fault into the vacuum pump system under test, thereby testing the vacuum pump system. This fault injection controller possesses all the beneficial effects of the above-described vacuum pump system testing method, which will not be elaborated further here.

[0112] This application also provides a fault injection agent for executing the vacuum pump system testing method described in any of the above embodiments. The agent is configured to receive and respond to control commands from a fault injection controller, injecting a fault into the vacuum pump system under test to perform the test. The control commands are generated and issued by the fault injection controller based on a fault selected from a pre-stored fault mode library. This fault injection agent possesses all the beneficial effects of the aforementioned vacuum pump system testing method, which will not be elaborated upon further herein.

[0113] This application also provides a computer device, including: One or more processors; Memory, which stores computer program instructions; When the computer program instructions are executed by the one or more processors, the computer device performs the method as described in any of the above embodiments.

[0114] The computer device has all the beneficial effects of the above-described vacuum pump system test method, which will not be repeated here.

[0115] This application also provides a computer-readable storage medium storing a computer program thereon, which is loaded by a processor to perform the method described in any of the above embodiments.

[0116] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0117] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0118] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0119] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0120] In a typical configuration, a computer device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0121] Memory may include non-persistent memory in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0122] Computer-readable media include both permanent and non-permanent, removable and non-removable media, which can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by computer devices. As defined herein, computer-readable media does not include transient media, such as modulated communication signals and carrier waves.

[0123] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0124] The above provides a detailed description of a vacuum pump system testing method, system, controller, computer equipment, and readable storage medium provided in the embodiments of this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A method for testing a vacuum pump system, characterized in that, include: The target fault is selected from the fault mode library, which is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test. The target fault is injected into the vacuum pump system under test by controlling the fault injection agent through the fault injection controller. Test results are generated based on the response of the tested vacuum pump system after the target fault is injected.

2. The method according to claim 1, characterized in that, The method further includes: Test cases are created based on the fault mode library; wherein the configuration information of the test cases includes at least one of the fault mode to be injected, fault triggering conditions, fault duration, and expected response behavior, and the expected response behavior is the response behavior expected from the vacuum pump system under test when the fault is injected.

3. The method according to claim 2, characterized in that, The step of injecting the target fault into the tested vacuum pump system by controlling the fault injection agent through the fault injection controller includes: Based on the test cases, control instructions are generated and sent to the fault injection agent at a predetermined time according to the fault triggering conditions. The fault injection agent receives and responds to the control instructions to inject the target fault into the vacuum pump system under test through hardware interruption or software simulation.

4. The method according to claim 2, characterized in that, The method further includes: Obtain the response data of the vacuum pump system under test when the test case is executed; The reliability assessment results of the tested vacuum pump system are generated based on the response data.

5. The method according to claim 4, characterized in that, The step of obtaining the response data of the vacuum pump system under test when the test case is executed includes: During fault injection, fault persistence, and fault recovery, the fault injection controller continuously monitors the tested vacuum pump system through the fault injection agent and records the corresponding response data. When the fault duration in the test case ends, the fault injection controller controls the fault injection agent to perform a fault cancellation operation, and continues to monitor and record the response data corresponding to the recovery process of the vacuum pump system under test.

6. The method according to claim 5, characterized in that, The process of generating a reliability assessment result for the tested vacuum pump system based on the response data includes: The response data is compared with the expected response behavior in the test case; The test case is determined to pass or fail based on the comparison results. Based on the results of multiple test cases, the reliability quantification index of the tested vacuum pump system is calculated.

7. The method according to claim 6, characterized in that, The step of comparing the response data with the expected response behavior in the test case includes: Based on a predefined reliability evaluation index system that includes multiple evaluation indicators, the response data is analyzed to obtain the actual quantitative values ​​of the tested vacuum pump system for each evaluation index. Each of the actual quantitative values ​​is compared with the judgment threshold set for the corresponding evaluation index in the expected response behavior; Based on the comparison results, the pass or fail status of the test case is automatically determined; The evaluation metrics are used to quantify at least one aspect of the functionality, safety, or performance of the vacuum pump system.

8. A testing system for performing the vacuum pump system testing method as described in any one of claims 1 to 7, characterized in that, include: A fault injection controller is configured to select a target fault from a fault mode library and generate control commands; wherein the fault mode library is a set of fault modes pre-established for the hierarchical architecture of the vacuum pump system under test. The fault injection agent establishes a communication connection with the fault injection controller and the vacuum pump system under test, and is configured to receive and execute the control command, inject the target fault into the vacuum pump system under test, and generate test results based on the response of the vacuum pump system under test after the target fault is injected.

9. A computer device, characterized in that, include: One or more processors; Memory, which stores computer program instructions; When the computer program instructions are executed by the one or more processors, the computer device performs the method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, It stores a computer program thereon, which, when executed by a processor, implements the method as described in any one of claims 1 to 7.

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