Electromagnet multi-mode test, control and integrated demagnetization system and method thereof

Abstract

The invention relates to an electromagnet multi-mode test, control and integrated degaussing system and a method thereof, belongs to the technical field of electromagnet test and control, and solves one of the problems in the prior art that electromagnet test operation is tedious, the automation degree is low, the test process configuration is inflexible, the degaussing control precision is insufficient, and data management is inconvenient. Comprising a hardware layer and a software layer. The hardware layer comprises a central processing unit, a programmable power supply module, a data acquisition device and a demagnetization control module; the software layer is a main control software program running in the central processing unit, and the main control software program integrates the following functional architectures: a user identity authentication and authority dynamic management module, a multi-mode integrated operation architecture module, a data acquisition control module, a structured data storage module and a data query and report module; the multi-mode integrated operation framework module comprises a test mode, a control mode and a test mode. According to the system, full-process coverage and cooperation of the electromagnet from research and development, production to maintenance are achieved.

Description

A multi-mode testing, control, and integrated demagnetization system and method for electromagnets. Technical Field

[0001] This invention relates to the field of electromagnet testing and control technology, and in particular to a multi-mode testing, control and integrated demagnetization system and method for electromagnets. Background Technology

[0002] As a crucial electromechanical conversion component, the stability and reliability of electromagnets directly affect the normal operation of related equipment in many fields such as power, machinery, and medicine. Therefore, comprehensive and accurate performance testing and characteristic characterization are essential in the research, development, production, and maintenance of electromagnets.

[0003] Traditional electromagnet testing methods primarily rely on manual operation of multiple independent instruments, which is not only inefficient and lacks repeatability, but also difficult to standardize, posing operational safety hazards and data management challenges. To address the drawbacks of manual testing, some automated testing solutions have emerged. For example, some systems are developed using graphical programming platforms (such as LabVIEW), enabling preliminary program control of the testing process. Demagnetization methods also exist, such as applying reverse current or AC demagnetization via hardware switching.

[0004] However, existing automated testing systems still have significant shortcomings: First, the system functions are often relatively simple, with theoretical simulation, manual fine-tuning, and automated sequence testing being isolated from each other, lacking a unified integrated operation platform; second, the configuration of the test process is usually fixed in the program code, resulting in poor flexibility and difficulty in adapting to different models of electromagnets or rapidly changing test requirements; third, the demagnetization process mostly relies on manual operation or simple hardware triggering, lacking a standard demagnetization procedure that is precisely controlled by software, repeatable, and with clearly defined steps; and fourth, insufficient consideration is given to system security, structured storage of test data, and convenient traceability.

[0005] Therefore, it is necessary to continuously optimize the systems and methods for testing and demagnetizing electromagnets. Summary of the Invention

[0006] Based on the above analysis, the embodiments of the present invention aim to provide a multi-mode testing, control, and integrated demagnetization system and method for electromagnets, at least to solve one of the problems in the prior art such as cumbersome testing operations, low degree of automation, inflexible test process configuration, insufficient demagnetization control accuracy, and inconvenient data management.

[0007] The objective of this invention is mainly achieved through the following technical solutions:

[0008] This invention provides a multi-mode testing, control, and integrated demagnetizing system for electromagnets, including a central processing unit, a programmable power supply module, a data acquisition device, and a demagnetizing control module;

[0009] The central processing unit includes:

[0010] The module includes a user identity authentication and dynamic permission management module, a multi-mode integrated operation architecture module, a data acquisition and control module, a structured data storage module, and a data query and reporting module.

[0011] The multi-mode integrated operation architecture module includes an experimental mode, a control mode, and a test mode.

[0012] The central processing unit is connected to the programmable power supply module via a communication interface, sends control commands to the programmable power supply module, and receives status readback data from the programmable power supply module; the central processing unit is connected to the data acquisition device, and receives the physical state signal of the electromagnet under test acquired by the data acquisition device; the central processing unit controls the data acquisition device to drive the demagnetization control module to switch the polarity of the current applied to the electromagnet by the programmable power supply module.

[0013] Within the central processing unit, the user authentication and dynamic permission management module transmits verified user permission information to the multi-mode integrated operation architecture module to dynamically control the multi-mode integrated operation architecture module's access to the experiment, control, and test modes. When the multi-mode integrated operation architecture module runs in any of the experiment, control, and test modes, it calls the data acquisition control module to collect data in real time and sends the processed data stream to the structured data storage module for archiving. The data query and reporting module responds to user retrieval and report generation requests based on the archived data in the structured data storage module.

[0014] Furthermore, the programmable power supply module is controlled by the central processing unit and operates in constant current mode to provide a precisely adjustable excitation current or voltage to the electromagnet under test.

[0015] Furthermore, the data acquisition device includes a mechanical sensor, a current sensor, a temperature sensor, a state detection sensor, and an input / output (I / O) board;

[0016] The mechanical sensor includes a pressure sensor or a suction sensor, used to accurately measure the attraction force generated by the electromagnet.

[0017] The current sensor is used to monitor the actual operating current flowing through the electromagnet coil to ensure the accuracy of the excitation.

[0018] The temperature sensor is a thermocouple or a resistance temperature sensor, used to monitor the temperature change and temperature-sensitive characteristics of the electromagnet in real time during operation.

[0019] The state detection sensor is used in the suction test to automatically determine whether the adsorbed object has been successfully picked up or accidentally fallen off, and converts the physical state into a switch signal that can be recognized by the software.

[0020] Furthermore, the demagnetization control module consists of a set of relays controlled by an input / output (IO) board;

[0021] By controlling the on / off combinations of relays, the polarity of the current connected to the electromagnet coil can be switched.

[0022] Furthermore, the multi-mode integrated operation architecture module integrates the test mode, control mode, and test mode through a tab control on the human-computer interaction main control interface. The background adopts an event-driven state machine architecture combined with a queue message processor. The main event loop captures user operations and generates commands for queuing, while parallel consumers cyclically dequeue and execute the corresponding states.

[0023] Furthermore, the test mode has a built-in interpolation calculation module that can calculate the expected working current based on the pre-stored multi-dimensional characteristic data table of current-temperature-suction force and the user-set target suction force and temperature parameters through an interpolation algorithm.

[0024] It supports user-configured test procedures that include multiple temperature points, temperature rise and heat preservation time sequences, and can drive hardware to perform simulated or actual high-temperature performance tests, displaying relevant parameters in real time.

[0025] Furthermore, the control mode provides a low-level direct manual control interface for the programmable power supply module and input / output I / O boards, allowing users to set the power output mode, voltage, current, and power parameters, and read the output values ​​in real time.

[0026] The control mode integrates software demagnetization function, where users can set the target value of demagnetization reverse current and the demagnetization duration. The software automatically controls the hardware to complete the demagnetization operation according to a preset logic sequence. The demagnetization operation includes output termination, parameter preset, path reverse switching, reverse excitation application, delay holding, post-processing decision and path recovery steps.

[0027] Furthermore, the test mode provides fully automated test sequence execution functionality;

[0028] A dynamic testing engine based on an external configuration file is adopted, which defines the test items, parameters, pass / fail criteria and execution order.

[0029] The system parses and executes test sequences through a queue message processor state machine architecture, automatically completing hardware control, delay waiting, data acquisition, result judgment, and image capture.

[0030] Furthermore, the test mode provides a debug execution mode, including single-step execution and specified jump execution.

[0031] This invention also provides a multi-mode testing, control, and integrated demagnetization method for electromagnets, implemented using the aforementioned system, comprising the following steps:

[0032] S1: User authentication and operation permission loading;

[0033] S2: Operation mode selection and system initialization;

[0034] S3: Execute the test mode, control mode, or test mode according to the selected mode;

[0035] S4: During mode execution, all system data is synchronously collected and structured and archived.

[0036] S5: Perform historical data queries and generate query reports;

[0037] The control mode integrates a demagnetization method, which includes:

[0038] Receive a demagnetization start command, the command including a demagnetization reverse current setting value and a demagnetization duration;

[0039] Send a command to the programmable power supply module through the communication interface to shut down the power output of the programmable power supply module;

[0040] The output current parameter of the programmable power supply module is set to the received demagnetizing reverse current target value, and the polarity mark of the demagnetizing reverse current target value indicates the current direction.

[0041] Send the first set of control signals to the demagnetization control module to drive the relay to operate, thereby physically switching the current path connected to the electromagnet coil to the reverse conduction state;

[0042] Re-enable the output of the programmable power supply module, so that the preset reverse current flows through the electromagnet coil;

[0043] Maintain the reverse current output for the set demagnetization duration;

[0044] After the delay hold step is completed, a decision is made based on the user-preset post-processing options to either maintain the power output or turn off the power output.

[0045] A second set of control signals is sent to the demagnetization control module to drive the relay to reset, restore the current path to the forward conduction preset state, complete the demagnetization process, and prepare for subsequent operations.

[0046] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0047] 1. This invention integrates hardware control, multi-mode software architecture, and data management to construct an integrated electromagnet testing system. The system integrates experimental modes for theoretical analysis and parameter prediction, control modes for fine debugging and demagnetization, and test modes for automated sequence testing. Through role-based unified permission management and structured data flow, it achieves full-process coverage and collaboration from R&D, production to maintenance, thus changing the problems of cumbersome operation and single function of traditional electromagnet testing systems.

[0048] 2. The system and method of this invention replace traditional manual operation with automated testing driven by state machines and external configuration, realizing fully automatic execution and intelligent judgment of test sequences, improving testing efficiency and consistency of results; the system integrates a precisely set multi-step demagnetization program in control mode, replacing operation that relies on human experience with programmable timing control, ensuring accurate reproduction of demagnetization process parameters and stable and reliable effect.

[0049] 3. This invention uses an external configuration file (such as a CSV file) to define the test process, decoupling the test logic from the main control software program. Users can flexibly customize test items without modifying the source code, enabling the system to quickly adapt to diverse product models and test specifications. At the same time, the system realizes automatic data collection, structured archiving, and visual querying of data throughout the entire test process, building a complete data traceability chain and providing an efficient and reliable data foundation for product quality analysis, process optimization, and decision-making.

[0050] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objects and other advantages of this invention can be realized and obtained from what is particularly pointed out in the description and drawings. Attached Figure Description

[0051] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0052] Figure 1 is a schematic diagram of the user identity authentication and dynamic permission management module interface in the system of an embodiment of the present invention;

[0053] Figure 2 is a diagram showing the system composition and information interaction relationship of an embodiment of the present invention;

[0054] Figure 3 is a logic control diagram of an embodiment of the present invention. Detailed Implementation

[0055] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0056] This invention provides a multi-mode testing, control, and integrated demagnetizing system for electromagnets, including a central processing unit, a programmable power supply module, a data acquisition device, and a demagnetizing control module;

[0057] The central processing unit includes:

[0058] The module includes a user identity authentication and dynamic permission management module, a multi-mode integrated operation architecture module, a data acquisition and control module, a structured data storage module, and a data query and reporting module.

[0059] The central processing unit is connected to the programmable power supply module via a communication interface, sends control commands to the programmable power supply module, and receives status readback data from the programmable power supply module; the central processing unit is connected to the data acquisition device, and receives the physical state signal of the electromagnet under test acquired by the data acquisition device; the central processing unit controls the data acquisition device to drive the demagnetization control module to switch the polarity of the current applied to the electromagnet by the programmable power supply module.

[0060] Within the central processing unit, the user authentication and dynamic permission management module transmits verified user permission information to the multi-mode integrated operation architecture module to dynamically control the multi-mode integrated operation architecture module's access to the experiment, control, and test modes. When the multi-mode integrated operation architecture module runs in any of the experiment, control, and test modes, it calls the data acquisition control module to collect data in real time and sends the processed data stream to the structured data storage module for archiving. The data query and reporting module responds to user retrieval and report generation requests based on the archived data in the structured data storage module.

[0061] Specifically, the central processing unit (CPU) serves as the core of the system, employing an industrial computer (ICC) to run the main control software. Its configuration must meet the operational requirements of the main control software, and it is responsible for the logical control, task scheduling, data processing, human-computer interaction, and communication with various hardware modules of the entire system. For example, the hardware configuration of the CPU is as follows: CPU frequency not less than 1.6GHz, memory not less than 512MB, and hard disk not less than 20GB.

[0062] The programmable power supply module is controlled by the central processing unit and operates in constant current mode to provide a precisely adjustable excitation current or voltage to the electromagnet under test. Specifically, the programmable power supply module is connected to the industrial computer of the central processing unit through an interface such as USB (e.g., VISA protocol), receives remote control commands, sets parameters such as output current, voltage, and power, and can provide feedback on the actual output value. For example, the programmable power supply module is an M3111 type programmable DC power supply.

[0063] The data acquisition device includes a mechanical sensor, a current sensor, a temperature sensor, a state detection sensor, and an input / output (I / O) board. The mechanical sensor includes a pressure sensor or a suction sensor for accurately measuring the attraction force generated by the electromagnet. The current sensor, which can be integrated into the programmable power supply or configured independently as an external sensor, monitors the actual operating current flowing through the electromagnet coil to ensure the accuracy of the excitation. The temperature sensor is a thermocouple or resistance temperature sensor, attached to a designated location on the electromagnet coil or core, for real-time monitoring of temperature changes and temperature-sensitive characteristics during electromagnet operation. The state detection sensor is used for... In the suction test, the system automatically and objectively determines whether the adsorbed object has been successfully picked up or accidentally fallen off, converting the physical state into a switch signal that can be recognized by the software. For example, the state detection sensor is a limit switch or a photoelectric drop sensor. The input / output (IO) board is used to connect and control digital and analog signals, and to collect analog or digital signals from the mechanical sensor, current sensor, temperature sensor, and state detection sensor. It can communicate with the industrial control computer via USB to serial port (such as a driver converter based on the FT232 chip) and use the VISA protocol or a specific serial protocol to convert physical quantities into digital data for processing by the main control software.

[0064] The demagnetizing control module consists of a set of relays controlled by the IO board; by controlling the on / off combination of the relays, the polarity of the current connected to the electromagnet coil can be switched, thereby achieving precise software control of applying positive working current or reverse demagnetizing current without changing the physical wiring of the power supply; the set of relays can be two or more relays.

[0065] The user authentication and permission dynamic management module dynamically manages the operation permissions of users in each mode according to preset user roles (such as operators, engineers, and administrators), which is achieved by enabling and disabling interface controls through software control. Specifically, Figure 1 shows a schematic diagram of the user authentication and permission dynamic management module interface. The user authentication and permission dynamic management module is the security entry point of the system, and its operation process is as follows: First, the system receives the identity identification information (such as username, password, and employee number) provided by the user and verifies it. After successful verification, the system calls the pre-stored role-permission mapping rule library, associates and obtains the operation permission level corresponding to the user's identity. Subsequently, the system main control software dynamically configures the access status of each functional module in the main operation interface based on the permission level during runtime. Specifically, it selectively enables or disables the interactive interfaces associated with each functional module according to the user role. Through this mechanism, the system achieves fine-grained control over the functional access scope of different operators at the software logic level, thereby ensuring the security of system operation and the confidentiality of core data. For example, "workers" are only allowed to execute tests and query results; "engineers" have added user management permissions; and "manufacturers" have the highest permissions, such as device factory settings.

[0066] Specifically, the multi-mode integrated operation architecture module integrates the test mode, control mode and test mode through a tab control on the human-computer interaction main control interface. The background adopts an event-driven state machine architecture combined with a queue message processor (QMH). The main event loop captures user operations and generates commands to be queued, and parallel consumers dequeue and execute the corresponding states in a loop.

[0067] The test mode is used for loading, visualizing, theoretically analyzing, estimating parameters, and designing preliminary experiments for electromagnet characteristic data. It has a built-in interpolation calculation module that can calculate the expected operating current based on the pre-stored multi-dimensional characteristic data table of current-temperature-suction force and user-defined target suction force and temperature parameters through an interpolation algorithm. It supports user-configured test procedures that include multiple temperature points, temperature rise, and heat preservation time sequences, and can drive hardware to perform simulated or actual high-temperature performance tests, displaying relevant parameters in real time.

[0068] Specifically, after the user selects the electromagnet model through the "Select Model" dropdown menu, the system loads the "Current-Temperature-Suction" characteristic data table for that model from the backend database or CSV file and displays it in a multi-column list control. Simultaneously, characteristic curves can be plotted in the XY graph control. The core algorithm is as follows: After the user selects the electromagnet model, the system loads the "Current-Temperature-Suction" characteristic data table for that model. The system receives the target suction force value (N) and target temperature value (°C) set by the user. When the system receives a calculation trigger command from the user, the interpolation calculation module within the system is invoked. This module uses the target suction force value (N) and target temperature value (°C) as input parameters, queries the pre-stored current-temperature-suction characteristic data table, and performs a bilinear interpolation algorithm on the corresponding two-dimensional parameter plane of the data table to calculate the expected operating current value that meets the target parameters. The calculated current value is then fed back by the system in the corresponding display area of ​​the human-machine interface main control interface. The test mode also supports multiple stages. The configuration and execution of the temperature test process can be achieved by the user defining a set of timing control parameters through the interface, including multiple target temperature points and the corresponding temperature rise duration and holding duration for each point. After the user confirms the configuration, the system submits the timing control parameter sequence to the background task queue. When a test start command is received, the system generates a corresponding temperature control command based on the timing control parameter sequence. Depending on the system connection status, this command can be used to drive external temperature control equipment (such as a high and low temperature test chamber) to perform physical temperature cycling, or to perform process simulation when no hardware is connected, i.e., to drive the hardware to perform simulated or actual high temperature performance tests. Throughout the test, the system collects or simulates and calculates the current temperature status in real time and dynamically updates and displays it on the interface.

[0069] Specifically, the control mode provides a low-level direct manual control interface for the programmable power supply module and I / O board. Users can set parameters such as power output mode, voltage, current, and power, and read the output values ​​in real time. Simultaneously, this mode integrates a software demagnetization function. Users can set the target value of the demagnetization reverse current and the demagnetization duration, and the software automatically controls the hardware to complete a multi-step demagnetization operation according to a preset logic sequence. When running the software demagnetization function in control mode, the system first receives the demagnetization parameters set by the user, including the target value of the reverse current and the demagnetization duration. After receiving the demagnetization start command, the system automatically executes a precisely programmed, uninterrupted multi-step control sequence, which is executed in the following logical order:

[0070] Receive a demagnetization start command, the command including a demagnetization reverse current setting value and a demagnetization duration;

[0071] Output termination procedure: Send a command to the programmable power supply module via a communication interface (e.g., following the VISA protocol) to shut down its power output;

[0072] Parameter preset step: Set the output current parameter of the programmable power supply module to the received demagnetizing reverse current target value (the polarity mark of this value indicates the current direction);

[0073] Path reversal switching steps: The first set of control signals is sent to the relay group of the demagnetization control module through the IO board to drive the relay to act, thereby physically switching the current path connected to the electromagnet coil to the reverse conduction state.

[0074] Reverse excitation application step: Re-enable the output of the programmable power supply module to allow a preset reverse current to flow through the electromagnet coil;

[0075] Delay hold step: Maintain the reverse current output for the set demagnetization duration;

[0076] Post-processing decision step: After the delay hold step is completed, a decision is made on whether to maintain power output or turn off power output based on the user-preset post-processing options;

[0077] Path restoration steps: Regardless of the power output status, the second set of control signals is sent to the relay group through the IO board to drive the relay to reset, restore the current path to the forward conduction preset state, complete the demagnetization process and prepare for subsequent operations.

[0078] The entire demagnetization process is controlled in a closed loop by a software program, ensuring strict repeatability of current amplitude, action time, and polarity switching sequence, thereby achieving a stable and consistent demagnetization effect.

[0079] Specifically, the test mode provides fully automated test sequence execution functionality; it employs a dynamic test engine driven by an external configuration file (such as a CSV file), which defines complete test items, parameters, pass / fail criteria, and execution order. The system parses and executes this sequence through a queued message processor (QMH) state machine architecture, automatically completing tasks such as hardware control, delay waiting, data acquisition, result judgment, and image capture. The test mode achieves fully automated testing of electromagnet performance based on externally configurable instruction sequences, and its operation flow includes:

[0080] S1: Test Sequence Loading and Parsing

[0081] After receiving the test model selection instruction, the system automatically locates and loads the corresponding external structured configuration file (such as a CSV file) according to the instruction; this design separates the specific test logic from the main program code, thus decoupling the test logic from the core of the main program.

[0082] The system parses the configuration file and converts its contents into an internally executable queue of test steps. Each element in the queue contains an operation type, parameter set, and judgment criteria. This design allows modifications and expansions to the test process to be made only by updating the external configuration file without changing or recompiling the software source code. The operation types include "Set Current," "Suction Test," "Delay," and "Image Saving."

[0083] S2: Automated Test Execution

[0084] Upon receiving the test start command, the system enters the automated execution phase, processing each element in the test step queue sequentially. The specific process is as follows:

[0085] S21: Read and parse the operation type identifier and related parameters of the current step;

[0086] S22: Based on the parsed operation type, the instructions and parameters are distributed to the corresponding functional modules for execution; specifically, if it is a hardware parameter setting instruction, the programmable power supply module or IO board is driven to perform corresponding control; if it is a data acquisition and judgment instruction, the sensor measurement is triggered, and the real-time measurement value is compared with the preset threshold to generate a judgment result; if it is a timing control instruction, the system timer is called to perform precise delay; if it is a process recording instruction, the peripheral device (such as a camera) is controlled to complete image capture and storage;

[0087] Preferably, the system also provides a debug execution mode, in which the user can intervene and control the execution process, including:

[0088] Single-step execution: In test mode, the control system takes only one test step from the queue and executes it at a time, then pauses and waits for the next instruction, which facilitates observation and verification item by item;

[0089] Specify jump execution: Allows users to specify a target step number. In test mode, the system will start executing subsequent steps from the specified position in the test queue, which facilitates quick location and reproduction of specific problems. This debug execution mode provides a flexible means for the development, verification and fault diagnosis of test sequences, realizes refined manual intervention in the automated test process, and significantly improves the development efficiency of the test program itself and the convenience of reliability verification.

[0090] S23: Update the execution status, measurement data and judgment results of steps S21 and S22 to the system in real time, and simultaneously feed them back to the human-computer interaction interface.

[0091] S3: Process Control and Exception Handling

[0092] Throughout the execution process, the system continuously monitors the execution status of each step. If a step fails to execute or the judgment result does not meet the standard, the system will determine the subsequent process direction according to the preset process control strategy (continue execution or stop immediately).

[0093] S4: Data Archiving

[0094] After the test process is completed, the system automatically archives and stores the complete execution process data (including step sequence, parameters, measurement values, judgment results and timestamps) in a preset structured format.

[0095] Specifically, the data acquisition and control module performs real-time data acquisition and management. During system operation, it concurrently acquires heterogeneous data streams from different hardware interfaces and software modules. These heterogeneous data streams include, but are not limited to: output parameter readback values ​​from the programmable power supply module (such as actual current and voltage); various sensor measurements from hardware-layer data acquisition devices (such as suction, temperature, and status switch values); configuration parameters and commands generated by user operations; and operation event logs and timestamps generated internally by the system. This module ensures that all data is collected synchronously and forms a time-aligned stream, providing complete and consistent data input for subsequent real-time display, process judgment, and structured storage.

[0096] Specifically, the structured data storage module performs automated and standardized archiving management of all information generated throughout the testing cycle. Upon initialization of each test task, a hierarchical directory structure following the format "year / month / day / serial number / " is automatically created based on the current system date and the unique serial number of the current test. This design establishes a strong index relationship between data and the spatiotemporal dimension. All heterogeneous data streams from the data acquisition and control module are integrated, automatically generated, and saved as standardized structured data files (such as .csv or .xls files) in the corresponding serial number directory. Unstructured files such as process images captured during the test are automatically saved in the same directory using naming rules associated with data files and standard formats such as .jgp (e.g., serial number_timestamp.jpg), ensuring a complete association between data and images.

[0097] Specifically, the data query and reporting module retrieves, reviews, and generates reports from historical test data stored in the structured data storage module. The module's operation process is as follows:

[0098] The system responds to the user's step-by-step selection operation based on the "year-month-day" directory structure established by the structured data storage module. When the user selects a specific date directory, the system dynamically loads the data index under that directory and presents a summary of all test tasks within that date in list form, including test sequence number, execution time and final test results.

[0099] When a user selects a specific test sequence number from the summary list, the system automatically locates and reads the structured data file (such as a .xls file) corresponding to that sequence number. The system parses the file content, loads the complete process data of this test, and displays it in the details area of ​​the interface. In the details display area, if the record information of a certain test step is associated with a saved process image file, the system can respond to the user's viewing command. The system automatically locates and loads the corresponding image file according to the preset file naming rules and storage path, and displays it in the designated area of ​​the interface, thereby mutually verifying the data results and the visual process.

[0100] In response to the user's export command, the system automatically generates a well-structured and complete test report document (such as PDF format) based on the detailed test data currently being viewed, formatted according to a preset template. The user can save the report document to a specified local location, thereby completing the portable archiving and distribution of test data.

[0101] It should be noted that in the system, the central processing unit (CPU) sends control commands to the programmable power supply module via a digital communication interface (such as USB or serial port, following the VISA protocol) to set parameters such as output voltage, current, and power. The programmable power supply module then transmits the actual output values ​​(current and voltage) back to the CPU, achieving closed-loop monitoring and status feedback. Various sensors (mechanical, temperature, current, and status sensors) in the data acquisition device sense the physical state of the electromagnet in real time. After signal conditioning and analog-to-digital conversion, the digitized test data is transmitted to the CPU via a data bus. The CPU processes and displays the received data in real time, and then archives it using a structured data storage module. The CPU sends digital control signals to the I / O boards in the data acquisition device. Upon receiving the signals, the I / O boards drive the relay group in the demagnetization control module to operate (engage or disconnect). The relay operation changes the current transmission path, achieving a polarity switch (positive operating current) of the current loaded onto the electromagnet coil by the programmable power supply module. (Reverse demagnetizing current). Inside the central processing unit, after user login verification, the system dynamically configures the access status of each functional module in the main operation interface according to the user's role and permissions, controlling the enabling and disabling of test mode, control mode, and testing mode. In any of the test, control, or testing modes, the system collects heterogeneous data streams from various hardware interfaces and software modules in real time and concurrently through the data acquisition and control module, including: output readback values ​​from the programmable power supply module, measurement values ​​from various sensors, user operation commands and configuration parameters, and internal system event logs and timestamps. After all the collected data is integrated, it is automatically archived by the structured data storage module according to the hierarchical directory structure of "year / month / day / serial number" and saved as structured data files (such as .csv, .xls) and associated image files. The data query and reporting module, based on the directory structure established by the storage module, supports users to browse and retrieve historical test data by time hierarchy and can generate standardized test reports with one click.

[0102] This invention also provides a multi-mode testing, control, and integrated demagnetization method for electromagnets, implemented using the aforementioned system. The method is executed by a main control software program running on the central processing unit, coordinating various hardware modules to achieve fully automated and intelligent control from task triggering to data archiving. The method includes the following steps:

[0103] S1: User authentication and operation permission loading

[0104] The user authentication and dynamic permission management module receives and verifies the user's input identity credentials. After successful verification, it dynamically loads and activates the corresponding user's operation permissions in the human-computer interaction interface module according to predefined role-permission mapping rules, thereby establishing a secure access foundation for subsequent operations.

[0105] S2: Operation Mode Selection and System Initialization

[0106] In response to the user's mode selection command in the human-machine interface module, the system enters the corresponding core operating architecture: test mode, control mode, or test mode; at the same time, the system initializes the corresponding hardware connections (such as programmable power supply module, data acquisition device) and software configuration according to the selected mode, in preparation for the execution of specific tasks.

[0107] S3: Execute the corresponding test mode, control mode or test mode according to the different modes selected in step S2;

[0108] Once the test mode is entered, the characteristic analysis and parameter prediction process is executed: First, the pre-stored characteristic data corresponding to the selected electromagnet model is loaded; then, the target suction force and target temperature parameters set by the user are received, and the expected working current is calculated through the built-in interpolation calculation module; finally, based on the test process of multiple temperature points, temperature rise and heat preservation time sequence configured by the user, the hardware is driven to conduct simulated or actual high temperature performance tests, and the relevant parameters are displayed in real time.

[0109] Upon entering control mode, the system executes a direct hardware control and integrated demagnetization process. Through the manual control interface in the multi-mode integrated operation architecture module, it receives direct setting commands from the user for the output parameters (current, voltage, mode) of the programmable power supply module and controls its output. When a demagnetization start command is received, a precisely programmed demagnetization control sequence is executed: the programmable power supply module stops output and presets a reverse current value → the demagnetization control module switches the current path to reverse → the power supply is turned on to apply reverse current and precisely timed → the demagnetization control module restores the current path to the forward direction.

[0110] Upon entering test mode, a fully automated test process is executed. Based on the selected test model, the test step queue is parsed from an external CSV configuration file and loaded into memory, decoupling the test logic from the main program. Using a queue message processor (QMH) state machine, each step in the queue is executed sequentially: including sending control commands to the programmable power supply module and data acquisition device, acquiring real-time measurement data through the data acquisition control module, and automatically comparing and judging the measurement data against preset pass / fail thresholds in the configuration file. During the execution of the test sequence, an image capture device is automatically triggered to take process photos according to instructions.

[0111] S4: During the execution of any mode of step S3, all data in the system are synchronously collected and structured and archived.

[0112] During the execution of any mode in step S3, the data acquisition control module concurrently acquires all data streams from the programmable power supply module, data acquisition device, user operation, and internal system in real time. After the task is completed, the structured data storage module automatically starts, creates a directory according to the hierarchical rule of "year-month-day-serial number" based on the task trigger time and unique serial number, and classifies and archives the complete structured test data files and unstructured process image files into the corresponding directories.

[0113] S5: Perform historical data queries and generate query reports.

[0114] The data query and reporting module responds to user data retrieval requests by supporting conditional browsing based on the "year-month-day" directory hierarchy to locate target test tasks; loading and displaying complete and detailed data and associated process images of any test; and generating and exporting structured test report documents with one click based on the currently viewed detailed data.

[0115] Preferably, in the test mode, a debug execution sub-process is also provided, which allows users to control the execution of the test sequence by single-step execution or specified jump execution, for the development and verification of the test process.

[0116] The method described in this invention, through the closed-loop execution of the above steps S1 to S5, organically integrates user permission management, multi-mode task scheduling, hardware collaborative control, data acquisition and processing, intelligent archiving and traceability functions, thereby realizing full-cycle, integrated, and high-precision automated management of electromagnet performance testing, control and maintenance.

[0117] Example

[0118] This embodiment takes the factory full performance test and demagnetization maintenance of an electromagnet with model number "EMT-A100" as an example to demonstrate the complete workflow of the system and method of the present invention.

[0119] The system in this embodiment includes a hardware layer and a software layer;

[0120] The hardware layer includes a central processing unit (industrial computer), a programmable power supply module (M3111 programmable DC power supply), a data acquisition device (tension and compression sensors, thermocouples and drop sensors), and a demagnetization control module (a dual-channel relay group controlled by an I / O board).

[0121] The software layer is the main control software program running on the central processing unit. The main control software program adopts a modular design and integrates the following functional architecture:

[0122] The module includes a user identity authentication and dynamic permission management module, a multi-mode integrated operation architecture module, a data acquisition and control module, a structured data storage module, and a data query and reporting module.

[0123] The method includes the following steps:

[0124] S1: User authentication and operation permission loading

[0125] The operator starts the system and completes identity authentication on the login screen. Based on their "engineer" role permissions, the system loads the corresponding operation interface, at which point the main control interface with full functional permissions is loaded.

[0126] S2: Operation Mode Selection and System Initialization

[0127] S21: Before starting the formal test, the operator first enters the test mode to prepare theoretically;

[0128] After selecting the model "EMT-A100" through the interface, the system will load the pre-stored "current-temperature-suction" characteristic data table for that model.

[0129] Operator inputs target operating parameters: target suction force 230N, target temperature 25℃;

[0130] After the calculation function is triggered, the system's built-in interpolation calculation module performs bilinear interpolation based on the characteristic data table, calculates and displays the expected operating current of 0.44A under this condition;

[0131] Operators can further plan a temperature rise and insulation profile from room temperature to 600°C in the “Test Procedure” configuration table for subsequent simulation analysis.

[0132] S22: The operator enters the test mode through the main operation interface and selects the test model as "EMT-A100";

[0133] The system automatically parses the external structured configuration file (CSV format) associated with the model; the file defines a complete test sequence, as shown in the example below: including steps such as "Set current (0.2A)", "Suction test (lower limit 45N, upper limit 55N)", "Delay (60s)", "Hot suction test" and "Process image recording";

[0134] The system generates a unique serial number TEST-20251126-001 for this task and loads the parsed test instruction queue into memory;

[0135] The operator issues a start test command, and the system parses and executes the sequence through the Queued Message Processor (QMH) state machine architecture:

[0136] Execute the current setting command: control the programmable power supply module to output a constant current of 0.2A;

[0137] Execute the suction test command: The data acquisition and control module obtains the actual sensor value (suction force 53.2N, temperature 25℃) and automatically compares it with the preset qualified threshold (45N, 55N) in the configuration file, and determines it as "qualified";

[0138] Execute the delay instruction: The system waits precisely for 60 seconds;

[0139] Execute the hot test command: collect data again (suction force 55.6N, temperature 200℃) and automatically determine "pass";

[0140] Execution process recording instruction: Trigger external image acquisition device to take a picture;

[0141] Once all steps are completed, no manual intervention is required for measurement, timing, or judgment throughout the entire process.

[0142] S23: Integrated software demagnetization operation

[0143] After the test is completed, the operator switches to control mode. In this mode, the operator sets the demagnetization parameters (reverse current 2.0A, duration 200ms) and issues a demagnetization start command. The system then executes a preset software-defined precise demagnetization sequence: control the power supply to stop output and preset the reverse current value to 2.0A → control the demagnetization control module to switch the current path → turn on the power supply to apply the reverse current and precisely time for 200ms → finally restore the system to standby state. The entire process is controlled by a closed-loop program to ensure the accuracy of timing and parameters.

[0144] S3: End-to-end data synchronization and structured archiving

[0145] In the above process, the data acquisition and control module collects all hardware readback data, sensor measurement values ​​and operation events in real time; after the task is completed, the structured data storage module runs automatically, and creates a hierarchical directory of "year-month-day-serial number" in the storage medium according to the task time (November 26, 2025) and serial number, and archives the complete structured test data files and process image files in this directory.

[0146] S4: Historical Data Tracing and Report Generation

[0147] Operators can trace data through the data query and reporting module; the system provides a browsing interface based on time hierarchy (year, month, day), allowing operators to quickly locate the current test task (serial number TEST-20251126-001) and view all its detailed data and related images; the module also provides a report export function, which can generate a standardized test report document containing key data and conclusions with one click.

[0148] Comparative Example

[0149] This comparative example uses the traditional method to complete the same test task (model EMT-A100, same test items):

[0150] Preparation and setup: This requires operating multiple independent devices such as a DC regulated power supply, digital multimeter, pointer-type tensile gauge, and temperature recorder, and manually zeroing and setting parameters for each one;

[0151] Manual testing: The operator manually adjusts the power supply current, visually reads the reading of the tension gauge pointer and records it manually on a paper form, uses a stopwatch to time the test, takes photos with a separate digital camera and manually records the associated information;

[0152] Manual demagnetization: The operator needs to manually turn off the power, change the physical wiring or operate the switch box to reverse the current direction, readjust the current, and rely on personal experience to estimate the time to perform demagnetization. After the operation is completed, the circuit needs to be restored.

[0153] Data management: All data is scattered across paper record sheets, storage units of different instruments, and independent photo files. Later queries require manual cross-referencing, which is inefficient and prone to errors.

[0154] Table 1 Comparison of the effects of the embodiments and comparative examples.

[0155]

[0156] By comparing the specific operation procedures and quantitative data of the above embodiments and comparative examples, it can be seen that the integrated system and method provided by the present invention systematically solves the core problems of low efficiency, large error, poor consistency, insufficient flexibility and difficult data management in traditional testing methods through multi-mode software architecture, external configuration drive, precise software demagnetization control and structured data management, and realizes full-process automation and intelligence of electromagnet testing from operation to management.

[0157] Those skilled in the art will understand that all or part of the processes of the methods described in the above embodiments can be implemented by a computer program instructing related hardware, and the program can be stored in a computer-readable storage medium. The computer-readable storage medium may be a disk, optical disk, read-only memory, or random access memory, etc.

[0158] The above description is only a preferred embodiment of the present invention, but the scope of protection 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 scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A multi-mode testing, control, and integrated demagnetization system for electromagnets, characterized in that, The system includes a central processing unit, a programmable power supply module, a data acquisition device, and a demagnetization control module. The central processing unit comprises: a user authentication and dynamic access control module, a multi-mode integrated operation architecture module, a data acquisition and control module, a structured data storage module, and a data query and reporting module. The multi-mode integrated operation architecture module includes an experimental mode, a control mode, and a test mode. The central processing unit is connected to the programmable power supply module via a communication interface, sending control commands to the programmable power supply module and receiving status readback data from the programmable power supply module. The central processing unit is also connected to the data acquisition device, receiving the physical state signal of the electromagnet under test acquired by the data acquisition device. The central processing unit drives the electromagnet under test by controlling the data acquisition device. The demagnetization control module activates to switch the polarity of the current applied to the electromagnet by the programmable power supply module. Inside the central processing unit, the user authentication and dynamic permission management module transmits verified user permission information to the multi-mode integrated operation architecture module to dynamically control its access to the test, control, and experimental modes. When the multi-mode integrated operation architecture module operates in any of the test, control, or experimental modes, it invokes the data acquisition control module to collect data in real time and sends the processed data stream to the structured data storage module for archiving. The data query and reporting module responds to user retrieval and report generation requests based on the archived data in the structured data storage module.

2. The system according to claim 1, characterized in that, The programmable power supply module is controlled by the central processing unit and operates in constant current mode to provide a precisely adjustable excitation current or voltage to the electromagnet under test.

3. The system according to claim 1, characterized in that, The data acquisition device includes a force sensor, a current sensor, a temperature sensor, a status detection sensor, and an input / output (I / O) board. The force sensor includes a pressure sensor or a suction sensor for accurately measuring the attraction force generated by the electromagnet. The current sensor monitors the actual operating current flowing through the electromagnet coil to ensure the accuracy of the excitation. The temperature sensor is a thermocouple or a resistance temperature sensor for real-time monitoring of temperature changes and temperature-sensitive characteristics during the electromagnet's operation. The status detection sensor automatically determines whether the attracted object has been successfully picked up or accidentally fallen off in the attraction force test, converting the physical state into a switch signal that can be recognized by the software.

4. The system according to claim 1, characterized in that, The demagnetizing control module consists of a set of relays controlled by an input / output (IO) board; by controlling the on / off combinations of the relays, the polarity of the current connected to the electromagnet coil can be switched.

5. The system according to claim 1, characterized in that, The multi-mode integrated operation architecture module integrates the test mode, control mode, and test mode through a tab control on the human-computer interaction main control interface. The background adopts an event-driven state machine architecture combined with a queue message processor. The main event loop captures user operations and generates commands for queuing. Parallel consumers dequeue the commands and execute the corresponding states in a loop.

6. The system according to claim 5, characterized in that, The test mode has a built-in interpolation calculation module, which can calculate the expected working current based on the pre-stored multi-dimensional characteristic data table of current-temperature-suction force and the user-set target suction force and temperature parameters through an interpolation algorithm. It supports user configuration of test procedures including multiple temperature points, temperature rise and heat preservation time sequence, and can drive hardware to perform simulated or actual high-temperature performance tests, and display relevant parameters in real time.

7. The system according to claim 5, characterized in that, The control mode provides a low-level direct manual control interface for the programmable power supply module and input / output I / O boards. Users can set the power output mode, voltage, current, and power parameters, and read the output values ​​in real time. The control mode integrates a software demagnetization function, where users can set the target value of the demagnetization reverse current and the demagnetization duration. The software automatically controls the hardware to complete the demagnetization operation according to a preset logic sequence. The demagnetization operation includes output termination, parameter preset, path reverse switching, reverse excitation application, delay holding, post-processing decision, and path recovery steps.

8. The system according to claim 5, characterized in that, The test mode provides fully automated test sequence execution; it adopts a dynamic test engine driven by an external configuration file, which defines the test items, parameters, pass / fail criteria and execution order; the system parses and executes the test sequence through a queue message processor state machine architecture, automatically completing hardware control, delay waiting, data acquisition, result judgment and image capture.

9. The system according to claim 5, characterized in that, The test mode provides a debug execution mode, including single-step execution and specified jump execution.

10. A multi-mode testing, control, and integrated demagnetization method for electromagnets, characterized in that, The system implementation according to any one of claims 1 to 9 includes the following steps: S1: user authentication and operation permission loading; S2: operation mode selection and system initialization; S3: executing test mode, control mode or test mode according to the selected mode; S4: synchronously collecting and structured archiving all system data during mode execution; S5: performing historical data query and generating a query report; the control mode integrates a demagnetization method, the demagnetization method including: receiving a demagnetization start command, the command including a demagnetization reverse current setting value and a demagnetization duration; sending a command to the programmable power supply module through a communication interface to turn off the power output of the programmable power supply module; setting the output current parameter of the programmable power supply module to the value received. The demagnetizing reverse current target value is set, and the polarity of the demagnetizing reverse current target value indicates the current direction; a first set of control signals is sent to the demagnetizing control module to drive the relay to operate, thereby physically switching the current path connected to the electromagnet coil to the reverse conduction state; the output of the programmable power supply module is restarted, so that the preset reverse current flows through the electromagnet coil; the reverse current output is maintained for the set demagnetizing duration; after the delay holding step is completed, a decision is made on whether to maintain the power output or turn off the power output according to the user's preset post-processing options; a second set of control signals is sent to the demagnetizing control module to drive the relay to reset, restore the current path to the forward conduction preset state, complete the demagnetizing process, and prepare for subsequent operations.

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