Automatic test system and method based on PCDU test

Abstract

The invention relates to an automatic test system and method based on PCDU test, belongs to the technical field of aerospace power supplies, and designs an automatic test production line and a data analysis system for a satellite power supply controller by taking a desktop control unit as a control core. Various testing devices in an automatic production line are used for simulating on-satellite working conditions of the PCDU, the PCDU and the testing devices needed on the testing production line are connected through a desktop control unit, a needed testing scene is set up according to testing logic to achieve automatic testing, and an industrial personal computer is responsible for sending remote control instructions needed by testing and receiving corresponding telemetering data. And the server accesses the data and uploads the data to the terminal for analysis and processing. The method has the advantages of being easy to use, high in compatibility and capable of achieving correlation analysis of test data of a single PCDU or multiple PCDUs.

Description

Technical Field

[0001] This invention belongs to the field of aerospace power technology, specifically relating to an automated testing system and method based on PCDU testing. Background Technology

[0002] Modern satellites are generally characterized by short launch cycles, low development costs, and large launch numbers. In particular, the rise of commercial satellites in recent years has brought about the concept of satellite constellation design, which has led to a rapid increase in the number of satellites built. This requires continuous reduction in satellite development costs and further compression of development cycles, and mass production of satellites has become a routine practice.

[0003] Throughout the satellite development process, in order to ensure product quality, a large number of tests are conducted at different stages of the development of each unit, and data analysis is performed on the corresponding test results, which takes up a significant amount of time in the entire development cycle.

[0004] Currently, the testing and data analysis of PCDU (Power Distribution Unit) units in satellite power systems are mostly conducted manually. This method is inefficient, time-consuming, and prone to human error. Summary of the Invention

[0005] The purpose of this invention is to provide an automated testing system and method based on PCDU testing. It is simple to apply, highly versatile, greatly improves testing efficiency, effectively shortens the development cycle, and is very suitable for testing a large number of satellite power system control units.

[0006] The above-mentioned objectives of the present invention are mainly achieved through the following technical solutions: An automated testing system based on PCDU testing includes a solar cell array simulation unit, a battery on-orbit simulation unit, a data acquisition and control unit, and a desktop control unit. The desktop control unit is used to receive and process test result data sent by the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition control unit, generate control signals and send them to the solar cell array simulation unit and the battery on-orbit simulation unit, and also to store test data and output it to external devices. The data acquisition and control unit is used to acquire telemetry signals sent by the PCDU, bus ripple signals and dynamic response status during PCDU testing, as well as telemetry changes during automated testing, and to send the test results data to the desktop control unit. The solar array simulation unit is used to receive control signals sent by the desktop control unit, simulate the power supply status of the on-board solar array, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit. The battery on-orbit simulation unit is used to receive control signals sent by the desktop control unit, simulate the actual needs of the on-board payload, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit.

[0007] The desktop control unit includes a visualization display module, a data management module, a telemetry and remote control management module, and an automated testing module, wherein... The visualization module is used to receive test data sent by the data management module and display PCDU parameters and device operating status in real time. The data management module is used to receive test result data sent by the automated testing module, process the received test result data, and send it to the visualization display module and external devices. The telemetry and remote control management module is used to manage communication protocols and configurations, perform telemetry parsing and uploading forwarding, and send configuration information to the automated testing module; The automated testing module receives and processes configuration information sent by the telemetry and remote control management module, sends control signals to external testing equipment to control the PCDU testing process, and receives test result data from the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition and control unit and sends it to the data management module.

[0008] The solar array simulation unit includes a solar array simulation power supply and a switch. The solar array simulation power supply is used to simulate the power supply status of the on-board solar array and verify the external power input and shunt function of the PCDU. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

[0009] The battery on-orbit simulation unit includes a DC electronic load, a multi-channel electronic load, a battery pack simulator, a battery cell simulator, and a switch. The DC electronic load, multi-channel electronic load, battery pack simulator, and battery cell simulator are used to simulate the actual needs of the on-board payload. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

[0010] The acquisition and control unit is also used to realize CAN communication between the external industrial control computer and the PCDU.

[0011] The acquisition and control unit includes an analog signal acquisition board, a relay board, a CAN communication board, a data acquisition instrument, and an oscilloscope. The analog signal acquisition board is used to acquire telemetry signals sent by the PCDU, the relay board is used to send pulse signals to the desktop control unit, the CAN communication board is used to realize CAN communication between the external industrial control computer and the PCDU, the data acquisition instrument is used to acquire and monitor the bus ripple signal and dynamic response status in real time during the PCDU test process, and the oscilloscope is used to acquire electrical signals sent by the PCDU.

[0012] An automated testing method based on PCDU testing, using the aforementioned testing system, specifically includes the following steps: (1) Configure telemetry parameters, remote control commands and telemetry and remote control information of the required equipment according to the PCDU model and the required test equipment, and import them into the desktop control unit; (2) Determine the details of automated testing according to the PCDU testing requirements and import them into the desktop control unit; (3) Configure the required test equipment in the solar cell array simulation unit, the battery on-orbit simulation unit, and the data acquisition and control unit into the corresponding test software, and assign the corresponding IP address in the local area network; (4) Configure the external industrial control computer according to the communication protocol of the PCDU; (5) Configure the external server software, start the server software, and confirm the communication between the desktop control unit and the server software; (6) Conduct tests according to the automated test details obtained in step (2), monitor the changes in telemetry in real time, record the test results and upload them to the server software until the test is completed.

[0013] Upload the automated test details obtained in step (2) to the satellite management platform, generate a test confirmation form, configure the test confirmation form according to the test items, select the corresponding test time interval, and generate the corresponding test item data after the test items are completed.

[0014] In step (6), command software is configured, which is used to run the automated test details obtained in step (2) item by item.

[0015] The command software can run automatically or execute step by step, skip test steps, and make compliance judgments according to criteria.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: This invention simulates the on-board operating conditions of PCDU using various testing equipment in an automated production line. It connects the PCDU and the required testing equipment on the testing production line through a desktop control unit, and builds the required test scenarios according to the test logic to achieve automated testing. It is simple to use, highly compatible, and can realize the correlation analysis of test data from one or more PCDUs. Attached Figure Description

[0017] Figure 1 This is a basic structural diagram of the automated testing production line of the present invention; Figure 2 This is a flowchart of the automated testing process of the present invention. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments: like Figure 1 As shown, an automated test production line and data analysis system for satellite power controllers uses centralized equipment management software to complete the automated testing of PCDUs. It constructs required test scenarios based on equipment logic, monitors the entire testing process via remote control and telemetry, and manages equipment, buses, test personnel, and models through software. The test system features include: a solar array simulation unit, a battery on-orbit simulation unit, a data acquisition and control unit, and a desktop control unit, wherein: The desktop control unit, as the control core of the PCDU test system, has four functional modules: (1) Visualization display module: Real-time display of important PCDU parameters, real-time display of remote control and telemetry data streams, equipment operating status, and diversified display of relevant data when the power controller interacts with the automated test module; (2) Data management module: interprets telemetry and remote control data, list of participating equipment, test item data, and uploads the data to the visualization display module and cloud test system as needed; (3) Telemetry and remote control management module: manages the communication protocols and configurations of different boards, provides local remote control uploading, and transmits the configuration information to the automated testing module; (4) Automated testing module: manages the PCDU testing process, performs telemetry analysis and uploading through the telemetry and remote control management module, manages and controls the testing equipment, collects the corresponding test data and uploads it to the data management module; The desktop control unit provides testers with a PCDU test platform to manage user positions and test models, centrally manage and control stand-alone devices and communication boards, build test scenarios based on actual needs with solar array simulation units, battery on-orbit simulation units and data acquisition control units, monitor and manage test tasks and test data in real time, and realize automated testing of power controllers.

[0019] The solar array simulation unit consists of multiple solar array simulation power supplies and switches. It simulates the power supply status of the on-board solar array, verifies the external power input and shunt function of the PCDU, and connects to the desktop control unit through the switch to realize the input of commands and the transmission of telemetry data.

[0020] The battery on-orbit simulation unit consists of a DC electronic load, multiple electronic loads, a battery pack simulator, and a battery cell simulator. It is used to simulate the actual needs of the on-board payload. It connects to the desktop control unit via a switch to send and receive commands and telemetry, realize program control, and then verify the battery charging and discharging conditions and the battery cell sampling equalization function.

[0021] The data acquisition and control unit consists of analog acquisition boards, relay boards, CAN communication boards, data acquisition instruments, and oscilloscopes. It can realize CAN communication between the industrial control computer and the PCDU, acquire telemetry signals sent by the power controller to the integrated electronic unit and the ground, send active or passive pulse signals through the relay boards to realize the analog transmission of direct commands, acquire and monitor the bus ripple signal and dynamic response status during the PCDU test process in real time, monitor the telemetry changes throughout the entire automated test process, and transmit relevant test data to the desktop control unit for processing.

[0022] like Figure 2 As shown, the present invention includes the following steps: Step 1: Based on the specific model of the single unit and the required test equipment, the relevant telemetry and remote control table needs to be configured. The telemetry parameters of the single unit, the remote control commands, and the telemetry and remote control information of the required equipment are written into the table and imported into the desktop control unit. Step 2: Based on the single-machine testing requirements, write the corresponding automated testing rules. Taking the Lingxi 04 satellite power controller of the StarNet series as an example, write the static power consumption function test, hardware over-discharge protection function test, satellite-rocket separation self-start function test, current shunting function test, on-board power distribution function test, program control command function test and lower-level software function test into a software-recognizable automated test program and import it into the desktop control unit. Step 3: According to the needs of the test unit, configure the required test equipment in the solar cell array simulation unit, battery on-orbit simulation unit, and data acquisition and control unit into the corresponding test software, assign the corresponding IP addresses in the local area network, and the telemetry and remote control signals to be transmitted and received are all provided by the telemetry and remote control meter mentioned in Step 1. After the equipment is configured, it can be added or deleted at any time as needed. Step 4: Configure the industrial control computer according to the communication protocol of the stand-alone unit. This system supports CAN bus, 1553B bus and RS422 bus communication protocols. Taking Lingxi 04 as an example, the lower-level machine of this PCDU uses CAN bus communication. Therefore, configure the instructions, address and other related parameters according to the CAN bus communication protocol to realize the industrial control computer's sending and receiving of PCDU data. Step 5: Configure the server software for storing and uploading test data, configure the telemetry and remote control table related in Step 1, start the server software, and ensure that other software in the desktop control unit communicates with the server; Step 6: Configure the relevant command software and telemetry monitoring software. You need to configure the correct server IP. The remaining parameters should be consistent with the server configuration file to realize the subsequent automated testing, telemetry data monitoring and data uploading functions. Step 7: After correct wiring, start the command software and run the automated test details written in Step 2 item by item. During the test, monitor the changes in telemetry in real time. This test process can be run automatically or executed step by step. You can start and stop at any time and skip test steps. After execution, it will make a compliance judgment according to the criteria and record the command record, telemetry data, and test results, upload them to the server terminal, and store them in the database in real time. Step 8: The satellite management platform allows for single-satellite telemetry record queries. Users can select the test time interval, telemetry code, and other information in the data management query interface. The system also supports exporting to Excel format and generating telemetry curves. Furthermore, the management platform can compare data from multiple PCDUs produced in a batch. Users can select multi-satellite query in the query interface, add multiple satellites, and query telemetry data. Envelope statistics are performed on all data, including common statistical measures such as maximum, minimum, and average values, to determine the consistency of test data for the same batch of PCDUs. Step 9: Upload the test details written in Step 2 to the template configuration interface of the satellite management platform. The system will automatically parse it into a confirmation form template. You can open the test project and configure the test confirmation form. After the configuration is completed, enter the test confirmation form generation interface, select the corresponding test time range, and after the test project, you can directly generate the corresponding test project data, which supports Excel format output. Step 10: Configure the required data extraction table in the data extraction configuration interface of the satellite management platform. It supports table configuration, curve configuration, and performance index discriminant configuration. Multiple test item tables can be organized into one data extraction table. Related telemetry curves can be configured for important parameters. Data from multiple PCDUs of the same batch of satellites can also be extracted into a table for analysis and comparison.

[0023] An automated testing system based on PCDU testing includes a solar cell array simulation unit, a battery on-orbit simulation unit, a data acquisition and control unit, and a desktop control unit. The desktop control unit is used to receive and process test result data sent by the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition control unit, generate control signals and send them to the solar cell array simulation unit and the battery on-orbit simulation unit, and also to store test data and output it to external devices. The data acquisition and control unit is used to acquire telemetry signals sent by the PCDU, bus ripple signals and dynamic response status during PCDU testing, as well as telemetry changes during automated testing, and to send the test results data to the desktop control unit. The solar array simulation unit is used to receive control signals sent by the desktop control unit, simulate the power supply status of the on-board solar array, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit. The battery on-orbit simulation unit is used to receive control signals sent by the desktop control unit, simulate the actual needs of the on-board payload, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit.

[0024] The desktop control unit includes a visualization display module, a data management module, a telemetry and remote control management module, and an automated testing module, wherein... The visualization module is used to receive test data sent by the data management module and display PCDU parameters and device operating status in real time. The data management module is used to receive test result data sent by the automated testing module, process the received test result data, and send it to the visualization display module and external devices. The telemetry and remote control management module is used to manage communication protocols and configurations, perform telemetry parsing and uploading forwarding, and send configuration information to the automated testing module; The automated testing module receives and processes configuration information sent by the telemetry and remote control management module, sends control signals to external testing equipment to control the PCDU testing process, and receives test result data from the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition and control unit and sends it to the data management module.

[0025] The solar array simulation unit includes a solar array simulation power supply and a switch. The solar array simulation power supply is used to simulate the power supply status of the on-board solar array and verify the external power input and shunt function of the PCDU. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

[0026] The battery on-orbit simulation unit includes a DC electronic load, a multi-channel electronic load, a battery pack simulator, a battery cell simulator, and a switch. The DC electronic load, multi-channel electronic load, battery pack simulator, and battery cell simulator are used to simulate the actual needs of the on-board payload. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

[0027] The acquisition and control unit is also used to realize CAN communication between the external industrial control computer and the PCDU.

[0028] The acquisition and control unit includes an analog signal acquisition board, a relay board, a CAN communication board, a data acquisition instrument, and an oscilloscope. The analog signal acquisition board is used to acquire telemetry signals sent by the PCDU, the relay board is used to send pulse signals to the desktop control unit, the CAN communication board is used to realize CAN communication between the external industrial control computer and the PCDU, the data acquisition instrument is used to acquire and monitor the bus ripple signal and dynamic response status in real time during the PCDU test process, and the oscilloscope is used to acquire electrical signals sent by the PCDU.

[0029] An automated testing method based on PCDU testing, using the aforementioned testing system, specifically includes the following steps: (1) Configure telemetry parameters, remote control commands and telemetry and remote control information of the required equipment according to the PCDU model and the required test equipment, and import them into the desktop control unit; (2) Determine the details of automated testing according to the PCDU testing requirements and import them into the desktop control unit; (3) Configure the required test equipment in the solar cell array simulation unit, the battery on-orbit simulation unit, and the data acquisition and control unit into the corresponding test software, and assign the corresponding IP address in the local area network; (4) Configure the external industrial control computer according to the communication protocol of the PCDU; (5) Configure the external server software, start the server software, and confirm the communication between the desktop control unit and the server software; (6) Conduct tests according to the automated test details obtained in step (2), monitor the changes in telemetry in real time, record the test results and upload them to the server software until the test is completed.

[0030] Upload the automated test details obtained in step (2) to the satellite management platform, generate a test confirmation form, configure the test confirmation form according to the test items, select the corresponding test time interval, and generate the corresponding test item data after the test items are completed.

[0031] In step (6), command software is configured, which is used to run the automated test details obtained in step (2) item by item.

[0032] The command software can run automatically or execute step by step, skip test steps, and make compliance judgments according to criteria.

[0033] The above description is only the best specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the protection scope of the present invention.

[0034] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. An automated testing system based on PCDU testing, characterized in that: It includes a solar cell array simulation unit, a battery on-orbit simulation unit, a data acquisition and control unit, and a desktop control unit, among which, The desktop control unit is used to receive and process test result data sent by the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition control unit, generate control signals and send them to the solar cell array simulation unit and the battery on-orbit simulation unit, and also to store test data and output it to external devices. The data acquisition and control unit is used to acquire telemetry signals sent by the PCDU, bus ripple signals and dynamic response status during PCDU testing, as well as telemetry changes during automated testing, and to send the test results data to the desktop control unit. The solar array simulation unit is used to receive control signals sent by the desktop control unit, simulate the power supply status of the on-board solar array, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit. The battery on-orbit simulation unit is used to receive control signals sent by the desktop control unit, simulate the actual needs of the on-board payload, receive telemetry signals sent by the PCDU, and send the test result data to the desktop control unit.

2. The automated testing system based on PCDU testing according to claim 1, characterized in that: The desktop control unit includes a visualization display module, a data management module, a telemetry and remote control management module, and an automated testing module, wherein... The visualization module is used to receive test data sent by the data management module and display PCDU parameters and device operating status in real time. The data management module is used to receive test result data sent by the automated testing module, process the received test result data, and send it to the visualization display module and external devices. The telemetry and remote control management module is used to manage communication protocols and configurations, perform telemetry parsing and uploading forwarding, and send configuration information to the automated testing module; The automated testing module receives and processes configuration information sent by the telemetry and remote control management module, sends control signals to external testing equipment to control the PCDU testing process, and receives test result data from the solar cell array simulation unit, the battery on-orbit simulation unit, and the acquisition and control unit and sends it to the data management module.

3. The automated testing system based on PCDU testing according to claim 1, characterized in that: The solar array simulation unit includes a solar array simulation power supply and a switch. The solar array simulation power supply is used to simulate the power supply status of the on-board solar array and verify the external power input and shunt function of the PCDU. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

4. The automated testing system based on PCDU testing according to claim 1, characterized in that: The battery on-orbit simulation unit includes a DC electronic load, a multi-channel electronic load, a battery pack simulator, a battery cell simulator, and a switch. The DC electronic load, multi-channel electronic load, battery pack simulator, and battery cell simulator are used to simulate the actual needs of the on-board payload. The switch is connected to the desktop control unit and is used to receive control commands and send test result data.

5. The automated testing system based on PCDU testing according to claim 1, characterized in that: The acquisition and control unit is also used to realize CAN communication between the external industrial control computer and the PCDU.

6. The automated testing system based on PCDU testing according to claim 5, characterized in that: The acquisition and control unit includes an analog signal acquisition board, a relay board, a CAN communication board, a data acquisition instrument, and an oscilloscope. The analog signal acquisition board is used to acquire telemetry signals sent by the PCDU, the relay board is used to send pulse signals to the desktop control unit, the CAN communication board is used to realize CAN communication between the external industrial control computer and the PCDU, the data acquisition instrument is used to acquire and monitor the bus ripple signal and dynamic response status in real time during the PCDU test process, and the oscilloscope is used to acquire electrical signals sent by the PCDU.

7. An automated testing method based on PCDU testing, characterized in that: The testing system described in any one of claims 1 to 6 specifically includes the following steps: (1) Configure telemetry parameters, remote control commands and telemetry and remote control information of the required equipment according to the PCDU model and the required test equipment, and import them into the desktop control unit; (2) Determine the details of automated testing according to the PCDU testing requirements and import them into the desktop control unit; (3) Configure the required test equipment in the solar cell array simulation unit, the battery on-orbit simulation unit, and the data acquisition and control unit into the corresponding test software, and assign the corresponding IP address in the local area network; (4) Configure the external industrial control computer according to the communication protocol of the PCDU; (5) Configure the external server software, start the server software, and confirm the communication between the desktop control unit and the server software; (6) Conduct tests according to the automated test details obtained in step (2), monitor the changes in telemetry in real time, record the test results and upload them to the server software until the test is completed.

8. The automated testing method based on PCDU testing according to claim 7, characterized in that: Upload the automated test details obtained in step (2) to the satellite management platform, generate a test confirmation form, configure the test confirmation form according to the test items, select the corresponding test time interval, and generate the corresponding test item data after the test items are completed.

9. The automated testing method based on PCDU testing according to claim 7, characterized in that: In step (6), command software is configured, which is used to run the automated test details obtained in step (2) item by item.

10. An automated testing method based on PCDU testing according to claim 9, characterized in that: The command software can run automatically or execute step by step, skip test steps, and make compliance judgments according to criteria.

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