Train control on-board device debugging test system and method

Abstract

The application discloses a kind of column control vehicle equipment hacking test system and method.The system includes industrial computer, PLC intelligent control equipment, relay, data recording unit DRU and server;Industrial computer is connected with PLC intelligent control equipment communication;PLC intelligent control equipment is electrically connected with relay;Industrial computer is connected with server communication;DRU is connected with server communication, and it includes: industrial computer is based on pre-configured hacking strategy configuration parameter generation PLC control instruction and is issued to PLC intelligent control equipment with PLC control instruction;PLC intelligent control equipment controls relay to test signal control to the vehicle equipment to be tested, so that the vehicle equipment to be tested is based on test signal execution equipment hacking test;DRU obtains the abnormal event log of the vehicle equipment to be tested in equipment hacking process and sends the abnormal event log to server;Server carries out log analysis to abnormal event log, generates the fault diagnosis result of the vehicle equipment to be tested and feeds back the fault diagnosis result to industrial computer.

Description

Technical Field

[0001] This invention relates to the field of rail transit technology, and in particular to a system and method for burning out train control onboard equipment. Background Technology

[0002] All 300T vehicle-mounted equipment cabinets undergo burn-in testing before leaving the factory. For some intermittent and difficult-to-locate startup failures, it is necessary to start the vehicle-mounted equipment multiple times to reproduce or confirm the fault. In their daily management of the vehicle-mounted equipment, electrical personnel also conduct burn-in tests on spare parts or faulty repair parts for each unit.

[0003] Currently, the burn-in testing fixtures for 300T vehicle-mounted equipment rely heavily on manual operation and diagnostics. This is especially true for occasional start-up failures, which require multiple restarts of the vehicle-mounted equipment to reproduce or confirm the fault. This involves a large amount of repetitive work, consumes manpower, and is prone to errors or overlooking potential faults. Therefore, how to automate the burn-in testing of vehicle-mounted equipment, reducing the inefficiency and probability of errors caused by manual operation, has become an urgent problem to be solved. Summary of the Invention

[0004] This invention provides a system and method for automating the burn-in testing of train control onboard equipment, thereby reducing the inefficiency and probability of errors caused by manual operation.

[0005] According to one aspect of the present invention, a train control on-board equipment burn-in test system is provided, comprising an industrial control computer, a PLC intelligent control device, relays, a data recording unit (DRU), and a server; the industrial control computer is communicatively connected to the PLC intelligent control device; the PLC intelligent control device is electrically connected to the relays; the industrial control computer is communicatively connected to the server; and the DRU is communicatively connected to the server, comprising: An industrial control computer is used to generate PLC control instructions based on pre-configured burn-in strategy configuration parameters, and to send the PLC control instructions to PLC intelligent control devices. The PLC intelligent control device is used to control the relay to perform test signal control on the on-board equipment under test, so that the on-board equipment under test can perform equipment burn-in test based on the test signal. DRU is used to obtain the abnormal event logs of the vehicle-mounted device under test during the device burn-in process, and send the abnormal event logs to the server; The server is used to perform log analysis on the abnormal event log, generate fault diagnosis results for the vehicle-mounted equipment under test, and feed back the fault diagnosis results to the industrial control computer.

[0006] According to another aspect of the present invention, a method for burn-in testing of train control onboard equipment is provided, characterized in that it is applied to a burn-in testing system for train control onboard equipment, the system comprising an industrial control computer, a PLC intelligent control device, relays, a data recording unit (DRU), and a server; the industrial control computer is communicatively connected to the PLC intelligent control device; the PLC intelligent control device is electrically connected to the relays; the industrial control computer is communicatively connected to the server; the DRU is communicatively connected to the server, and the method comprises: The industrial control computer generates PLC control instructions based on pre-configured burn-in strategy parameters and sends the PLC control instructions to the PLC intelligent control device. The PLC intelligent control device controls the relay to control the test signal of the on-board equipment under test, so that the on-board equipment under test can perform a device burn-in test based on the test signal; The abnormal event logs of the on-board device under test during the device burn-in process are obtained through the data recording unit (DRU), and the abnormal event logs are sent to the server. The server performs log analysis on the abnormal event logs, generates fault diagnosis results for the vehicle-mounted equipment under test, and feeds back the fault diagnosis results to the industrial control computer.

[0007] The technical solution of this invention uses an industrial control computer to generate PLC control commands based on pre-configured burn-in strategy parameters, and then sends these commands to a PLC intelligent control device. The PLC intelligent control device controls relays to provide test signal control for the on-board equipment under test, allowing the equipment to perform burn-in testing based on these signals. Anomaly logs of the on-board equipment during the burn-in process are acquired via a DRU and sent to a server. The server analyzes the anomaly logs, generates fault diagnosis results for the on-board equipment under test, and feeds these results back to the industrial control computer. This technical solution automates burn-in testing of on-board equipment, reducing the inefficiency and error rate caused by manual operation. It solves the inefficiency problem of traditional burn-in methods, achieving significant optimization in multiple dimensions such as labor costs, testing efficiency, fault diagnosis, and equipment management. This greatly saves labor costs, reduces the risk of human error, improves burn-in testing efficiency, shortens the fault diagnosis cycle, enhances the stability of the testing process, and can adapt to the needs of large-scale equipment testing.

[0008] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 This is a schematic diagram of a train control onboard equipment burn-in test system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of a train control onboard equipment burn-in test system provided in an embodiment of the present invention; Figure 3 This is a flowchart of a burn-in test method for train control onboard equipment according to an embodiment of the present invention; Figure 4 This is a flowchart of a burn-in test method for train control onboard equipment provided in an embodiment of the present invention. Detailed Implementation

[0011] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0012] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0013] Example 1 Figure 1This is a schematic diagram of a train control on-board equipment burn-in test system provided in an embodiment of the present invention. This embodiment is applicable to the automated burn-in test of the CTCS3-300T train control on-board equipment cabinet. The train control on-board equipment burn-in test system 10 includes an industrial computer 11, a PLC (Programmable Logic Controller) intelligent control device 12, a relay 13, a data recording unit (DRU) (14), and a server 15. The industrial computer 11 is communicatively connected to the PLC intelligent control device 12; the PLC intelligent control device 12 is electrically connected to the relay 13; the industrial computer 11 is communicatively connected to the server 15; and the DRU (14) is communicatively connected to the server 15. The specific execution process is as follows: The industrial computer 11 is used to generate PLC control instructions based on the pre-configured burn-in strategy configuration parameters, and send the PLC control instructions to the PLC intelligent control device 12; The PLC intelligent control device 12 is used to control the relay 13 to perform test signal control on the on-board equipment under test, so that the on-board equipment under test can perform equipment burn-in test based on the test signal. DRU (14) is used to obtain the abnormal event logs of the on-board device under test during the device burn-in process and send the abnormal event logs to the server 15; Server 15 performs log analysis on abnormal events, generates fault diagnosis results for the vehicle-mounted equipment under test, and feeds back the fault diagnosis results to the industrial control computer 11.

[0014] The burn-in strategy configuration parameters can be predetermined by relevant technical personnel based on actual needs. Specifically, the burn-in strategy configuration parameters may include burn-in mode, total burn-in duration, single startup runtime, power-off interval duration, number of startups, and device unit number. The vehicle-mounted device to be tested can be the vehicle-mounted device to be subjected to the burn-in test.

[0015] The stress test mode can include a dual-system alternating stress test mode and a single-system stress test mode. The dual-system alternating stress test mode cycles through testing the A-system first, then the B-system; the single stress test mode can be either the A-system or the B-system. The single start-up runtime is the device runtime for any test cycle within the cyclical test process; the power-off interval is the interval between power-down and the previous power-on. The number of starts is the number of times the device is powered on and tested cyclically within the total stress test duration. The device unit number can be the pre-entered device identifier or device number of the on-board device under test.

[0016] For example, if the burn-in mode is a dual-system alternating burn-in mode, the corresponding PLC control instruction can be an A / B system power supply circuit switching instruction, triggered by the completion of each on-board equipment power-off process. If the total burn-in time is set to 2 hours, the corresponding PLC control instruction can be a burn-in process termination instruction, triggered by the system's cumulative running time reaching 2 hours. If the single start-up running time is set to 12 minutes, the corresponding PLC control instruction can be a device power-off instruction, triggered by a single system single-run time reaching 12 minutes. If the power-off interval is 5 minutes, the corresponding PLC control instruction can be a next-round system power-on instruction, triggered by a device power-off time reaching 5 minutes. If the number of starts is set to 10, the corresponding PLC control instruction can be a start-stop cyclic execution instruction, triggered by satisfying the single-run time and power-off interval, and the number of cycles not reaching 10. If the equipment unit number is set to scan and enter 5 on-board devices to be tested, the corresponding PLC control instruction is the equipment data association instruction. The instruction trigger condition can be that the scan and enter number is completed and then bound to the subsequent burn-in data.

[0017] The PLC intelligent control equipment controls relays to provide test signal control for the on-board equipment under test, enabling the on-board equipment to perform a burn-in test based on the test signal. Specifically, the PLC intelligent control equipment controls the test signal of the on-board equipment under test through relay control, so that the on-board equipment under test performs a burn-in test after receiving the test signal.

[0018] In an optional embodiment, the system further includes a DC power supply and an interactive terminal; a relay is electrically connected to the DC power supply and the interactive terminal respectively; correspondingly, the control relay performs test signal control on the on-board equipment under test, so that the on-board equipment under test can perform a device burn-in test based on the test signal, including: receiving a PLC control command; if the PLC control command is a power-on command, the PLC intelligent control device controls the relay to close the power circuit of the DC power supply to supply power to the on-board equipment under test; at the same time, the control interactive terminal starts the pre-deployed on-board equipment test software, generates a test signal and sends it to the on-board equipment under test for device testing, so that the on-board equipment under test can perform a device burn-in test based on the test signal.

[0019] The interactive terminal can be a DMI (Driver Machine Interface).

[0020] Specifically, the PLC intelligent control device receives PLC control commands from the industrial control computer. If the PLC control command is a power-on command, the PLC intelligent control device controls the relay to close the DC power supply circuit, simultaneously supplying power to the on-board device under test and the interactive terminal. Simultaneously, it controls the interactive terminal DMI to launch the pre-deployed on-board device test software. This on-board device test software can be dedicated software for performing burn-in tests on the on-board device. Within this on-board device test software, data can be automatically input and braking tests can be performed without manual operation.

[0021] The on-board equipment testing software, executed within the interactive terminal, generates a series of test signals and sends them to the on-board equipment under test for burn-in testing. Specifically, after the equipment under test and the DMI are powered on, the dedicated testing software deployed within the DMI automatically starts and automatically inputs test data such as driver number, vehicle number, and vehicle group number according to a preset script. The DMI automatically triggers the braking test process to generate test signals, which are then executed by the on-board equipment under test to generate test results.

[0022] In an optional embodiment, the system further includes an input / output IO driver module; accordingly, after the on-board device under test is powered on, the IO driver module outputs a cab activation signal, a forward feedback signal, an emergency braking feedback signal, and a normal braking feedback signal to the on-board device under test to ensure that the on-board device under test enters a normal operating state.

[0023] The role of the IO driver module in the vehicle-mounted equipment burn-in testing process is to ensure the normal startup and functional testing of the equipment. The IO driver module continuously outputs four types of signals to the cabinet of the vehicle-mounted equipment under test: cab activation, forward feedback signal, emergency braking feedback signal, and common braking feedback signal. These signals are necessary conditions for the vehicle-mounted equipment under test to enter normal operation after power-on; the absence of any one of them will lead to startup failure or functional abnormalities. During the automatic braking test performed by the DMI, the braking feedback signal from the IO driver module is transmitted to the vehicle-mounted equipment under test in real time, ensuring that the equipment recognizes and completes the braking test process. The IO driver module automatically outputs stable signals throughout the entire process, requiring no manual intervention.

[0024] In an optional embodiment, the system further includes a Balise Transmission Module (BTM) host and an antenna; the BTM host is electrically connected to a relay; the system further includes: after the on-board device under test is powered on, the BTM host and the antenna work together to provide a transponder signal to the on-board device under test, so as to ensure the integrity of functional testing during the burn-in test of the on-board device under test.

[0025] The BTM (Balise Transmission Module) host and antenna are peripheral devices for rack startup and burn-in testing of the vehicle-mounted equipment under test. The BTM host is responsible for processing transponder-related data, and the antenna is used to receive external transponder signals. Through the collaboration of the BTM host and antenna, the vehicle-mounted equipment under test is provided with the signal support required for normal operation, ensuring the integrity of equipment functions during the burn-in test.

[0026] Once the industrial control computer determines that the single-run duration meets the conditions based on the burn-in strategy configuration parameters, it sends a power-off command to the PLC intelligent control device. The PLC intelligent control device then controls the relay to disconnect the power circuit. The industrial control computer sends a data download trigger command to the server. Upon receiving the command, the server forwards it to the DRU (Data Recording Unit), which retrieves the abnormal event logs of the vehicle-mounted device under test during the burn-in process and sends them to the server. It should be noted that the abnormal event log download must be completed before the vehicle-mounted device under test is shut down.

[0027] In one optional embodiment, acquiring the abnormal event logs of the on-board device under test during the device burn-in process and sending the abnormal event logs to the server includes: after the industrial control computer sends a power-off command to the PLC intelligent control device, the PLC intelligent control device controls the relay to disconnect the power supply circuit of the DC power supply, and the industrial control computer sends a data download trigger command to the server; when the server receives the data download trigger command, it forwards the data download trigger command to the DRU; the DRU retrieves the abnormal event logs from the storage unit of the on-board device under test and sends the abnormal event logs to the server.

[0028] Among them, the abnormal event log is AE-log (Application Event Log), which is used to record log files of various abnormal events during the operation of the vehicle equipment, such as communication interruption, module response timeout and MVB (Multifunction Vehicle Bus) bus error; during the stress test, abnormal data generated by the vehicle equipment will be written to AE-log in real time. The subsequent diagnostic system can quickly locate the time, type and cause of the fault by parsing AE-log.

[0029] The server analyzes the abnormal event logs, generates fault diagnosis results for the vehicle-mounted equipment under test, and feeds these results back to the industrial control computer. For example, based on the abnormal data characteristics obtained from analyzing the abnormal event logs, the server automatically locates the specific unit where the fault occurred and feeds back the diagnosis results and fault location information to the industrial control computer.

[0030] The industrial control computer receives the diagnostic results from the server and, combined with the previously entered device number of the vehicle-mounted equipment under test, automatically generates a complete burn-in test report. The report may include core information such as burn-in parameters, equipment operating data, and fault location results. Relevant technical personnel can remotely access the server data through a query terminal. Queryable content may include historical burn-in reports, raw AE-log data, and equipment burn-in statistics, thereby enabling data traceability and full lifecycle management of the equipment.

[0031] Optionally, the system also includes a control device; the control device is used to log in to the policy management software of the industrial control computer; the burn-in policy configuration parameters are configured based on the policy management software. The control device can be a KVM (Keyboard, Video, Mouse) switcher. In the scenarios of automatic burn-in, diagnosis, and daily maintenance of train control onboard equipment, the KVM switcher can serve as a testing auxiliary device, enabling remote control and signal switching of multiple onboard industrial control computers and test terminals through a single keyboard, monitor, and mouse. This eliminates the need to configure peripherals for each device individually, significantly simplifying the test environment setup, saving operating space, and improving the efficiency of parallel burn-in of multiple onboard devices.

[0032] During the stress test phase, relevant technicians can log into the industrial control computer's policy management software via a KVM switch and configure the stress test policy parameters based on the test management software. During the fault diagnosis phase, the local fault log interface of each onboard device under test can be accessed via KVM. The alarm information displayed on the device screen can be linked and analyzed with data from the DRU and AE-log (abnormal event log) to accurately locate hardware and software faults.

[0033] Optionally, the system also includes a switch; the switch is used to build a local area network (LAN) to enable data transmission between the industrial control computer, server, and DRU. The core function of the switch is to build a LAN, thereby enabling bidirectional data transmission and command forwarding between devices such as the industrial control computer, server, DRU, and query terminal, to ensure the normal operation of functions such as data download, diagnostic result feedback, and remote query.

[0034] In a preferred embodiment, such as Figure 2 The diagram shows a structural schematic of a train control onboard equipment burn-in test system. This system includes an industrial computer, server, PLC intelligent control equipment, switch, DC power supply, data recording unit (DRU), relays, interactive terminal (DMI), IO driver module, BTM host and antenna, and KVM driver. The specific execution process is as follows: Relevant technicians log into the industrial control computer via KVM and configure the burn-in strategy management software. Assuming the burn-in strategy configuration parameters are set as follows: dual-system alternating mode, total duration 2 hours, single run 12 minutes, power outage interval 5 minutes, and 10 start-ups, while simultaneously scanning and recording the unit numbers of 5 devices undergoing repair. The industrial control computer generates a PLC control instruction set and data acquisition trigger rules, and synchronizes the device numbers to the server via Ethernet. The IO drive module continuously outputs cab activation, forward, and braking feedback signals to the vehicle-mounted equipment cabinet, activating the BTM host and antenna, and receiving transponder signals, providing peripheral support for equipment startup.

[0035] The industrial control computer can send the first power-on command for the A-series equipment to the PLC intelligent control device via an RS485 (Recommended Standard 485, a serial differential communication standard) interface. Upon receiving the command, the PLC intelligent control device controls the relay to close the DC power supply circuit, supplying power to the A-series equipment on the vehicle. After the on-board equipment is powered on, the DMI automatically starts the dedicated test software, inputs test data such as train number and section, and automatically performs braking tests. The test status is fed back to the industrial control computer in real time. The BTM host and antenna work together to provide transponder signal support for the A-series equipment, ensuring the integrity of functional testing.

[0036] When a single operation has lasted 12 minutes, the industrial control computer sends an A-series power-off command to the PLC intelligent control device, which then controls the relay to disconnect the power circuit. The industrial control computer then sends the first data download trigger command to the server according to preset rules. Upon receiving the command, the server immediately forwards it to the DRU, which reads the AE-log operation log from the onboard device's A-series storage unit. The DRU uploads the log data to the server, which then activates an intelligent analysis algorithm to parse data such as voltage and communication status. If no anomalies are found, a fault-free diagnostic result is generated and fed back to the industrial control computer.

[0037] After the equipment is powered off, the system enters a 5-minute interval. The IO driver module maintains signal output, waiting for the next start command. After the 5-minute interval, the industrial control computer sends the first power-on command (B-series) to the PLC intelligent control device. The PLC intelligent control device switches its power supply circuit to B-series power, repeating the above test procedure. The server completes the B-series log analysis and feeds back the diagnostic results to the industrial control computer. The system then enters another 5-minute power-off interval. The system repeats the above command interaction and data acquisition process according to the alternating test logic of A-series and B-series until a total of 10 starts are completed.

[0038] For example, during the third A-series test, when the server analyzes the AE-log data and identifies an abnormal voltage below the threshold, it determines that the A-series power module is faulty and feeds back information such as the fault time and the faulty unit to the industrial control computer. The diagnostic results of each startup are synchronized from the server to the industrial control computer in real time, and the industrial control computer stores the data according to the device number. When the system completes 10 startups, or the cumulative runtime reaches 2 hours, the industrial control computer immediately sends a burn-in process termination command to the PLC intelligent control device, and all onboard equipment is powered off. If 10 startups are completed but the total duration is less than 2 hours, the system terminates the burn-in process based on the completion of the startup count.

[0039] The industrial control computer aggregates all data from 10 startups and, combined with server diagnostic results, automatically generates a single-device stress test report by device number. The report includes start / stop records, test results, and fault location conclusions. The industrial control computer uploads all reports to the server for data archiving. Electrical personnel can remotely log in to the server via a query terminal, enter the device number, and retrieve the corresponding device's stress test report, raw AE-log data, and fault statistics, providing a basis for maintenance.

[0040] The technical solution of this invention uses an industrial control computer to generate PLC control commands based on pre-configured burn-in strategy parameters, and then sends these commands to a PLC intelligent control device. The PLC intelligent control device controls relays to provide test signal control for the on-board equipment under test, allowing the equipment to perform burn-in testing based on these signals. Anomaly logs of the on-board equipment during the burn-in process are acquired via a DRU and sent to a server. The server analyzes the anomaly logs, generates fault diagnosis results for the on-board equipment under test, and feeds these results back to the industrial control computer. This technical solution automates burn-in testing of on-board equipment, reducing the inefficiency and error rate caused by manual operation. It solves the inefficiency problem of traditional burn-in methods, achieving significant optimization in multiple dimensions such as labor costs, testing efficiency, fault diagnosis, and equipment management. This greatly saves labor costs, reduces the risk of human error, improves burn-in testing efficiency, shortens the fault diagnosis cycle, enhances the stability of the testing process, and can adapt to the needs of large-scale equipment testing.

[0041] Figure 3This is a flowchart illustrating a burn-in test method for train control onboard equipment provided in an embodiment of the present invention. This embodiment is applicable to the automated burn-in test of a CTCS3-300T train control onboard equipment cabinet. The method can be applied to a train control onboard equipment burn-in test system. The system includes an industrial control computer, a PLC intelligent control device, relays, a data recording unit (DRU), and a server; the industrial control computer is communicatively connected to the PLC intelligent control device; the PLC intelligent control device is electrically connected to the relays; the industrial control computer is communicatively connected to the server; and the DRU is communicatively connected to the server. The method includes: S31. The industrial control computer generates PLC control instructions based on the pre-configured burn-in strategy configuration parameters and sends the PLC control instructions to the PLC intelligent control device.

[0042] S32. The PLC intelligent control device controls the relay to control the test signal of the on-board equipment under test, so that the on-board equipment under test can perform equipment burn-in test based on the test signal.

[0043] S33. Obtain the abnormal event logs of the on-board device under test during the device burn-in process through the data recording unit (DRU), and send the abnormal event logs to the server.

[0044] S34. Analyze the abnormal event logs through the server, generate fault diagnosis results for the vehicle-mounted equipment under test, and feed the fault diagnosis results back to the industrial control computer.

[0045] Furthermore, the system also includes a DC power supply and an interactive terminal; relays are electrically connected to the DC power supply and the interactive terminal respectively; correspondingly, the control relays control the on-board equipment under test with test signals so that the on-board equipment under test can perform equipment burn-in tests based on the test signals, including: receiving PLC control commands; if the PLC control command is a power-on command, the PLC intelligent control device controls the relays to close the power circuit of the DC power supply to supply power to the on-board equipment under test; at the same time, the control interactive terminal starts the pre-deployed on-board equipment test software, generates test signals and sends them to the on-board equipment under test for equipment testing, so that the on-board equipment under test can perform equipment burn-in tests based on the test signals.

[0046] Furthermore, the system also includes an input / output IO driver module; the system also includes: after the on-board equipment under test is powered on, the IO driver module outputs a cab activation signal, a forward feedback signal, an emergency braking feedback signal, and a normal braking feedback signal to the on-board equipment under test to ensure that the on-board equipment under test enters a normal operating state.

[0047] Furthermore, the system also includes a transponder transmission module (BTM) host and an antenna; the BTM host is electrically connected to a relay; the system also includes: after the on-board device under test is powered on, the BTM host and the antenna work together to provide a transponder signal to the on-board device under test, so as to ensure the integrity of functional testing during the burn-in test of the on-board device under test.

[0048] Furthermore, the abnormal event logs of the on-board device under test during the device burn-in process are obtained and sent to the server. This includes: after the industrial control computer sends a power-off command to the PLC intelligent control device, the PLC intelligent control device controls the relay to disconnect the DC power supply circuit, and the industrial control computer sends a data download trigger command to the server; when the server receives the data download trigger command, it forwards the data download trigger command to the DRU; the DRU retrieves the abnormal event logs from the storage unit of the on-board device under test and sends the abnormal event logs to the server.

[0049] Furthermore, the system also includes a control device; the control device is used to log in to the policy management software of the industrial control computer; the burn-in policy configuration parameters are configured based on the policy management software.

[0050] Furthermore, the system also includes switches; the switches are used to build a local area network to enable data transmission between industrial control computers, servers, and DRUs.

[0051] Furthermore, the burn-in strategy configuration parameters include burn-in mode, total burn-in duration, single startup runtime, power outage interval duration, number of startups, and device unit number.

[0052] In one optional embodiment, log analysis is performed on the abnormal event log to generate a fault diagnosis result for the vehicle-mounted device under test, including: inputting the abnormal event log into a pre-trained fault prediction model to obtain the fault diagnosis result of the vehicle-mounted device under test output by the model.

[0053] Fault prediction models are used for fault diagnosis or prediction of in-vehicle equipment, and can be pre-trained by relevant technicians. The training method for fault prediction models is as follows: Obtain historical abnormal event logs within a historical time period and label the historical abnormal event logs with fault labels to obtain the true fault label values; input the historical abnormal event logs and the true fault label values ​​into a pre-selected network model to obtain the model output predicted fault results; train the network model based on the true fault label values ​​and predicted fault results until the preset model training termination condition is met to obtain the fault prediction model.

[0054] The actual fault label values ​​can be pre-labeled by relevant technical personnel, based on manual or semi-automatic data labeling. The labeling content includes fault type, fault occurrence time, fault unit, and fault triggering conditions. Historical anomaly event logs can extract massive amounts of AE-log data from the server's historical database, covering full-state data such as normal equipment operation, intermittent faults, and definite faults.

[0055] Historical anomaly logs and actual fault label values ​​are input into a pre-selected network model to obtain the model's predicted fault results. The network model can be a convolutional neural network or a random forest, among others. Based on the actual fault label values ​​and the predicted fault results, a current loss value is determined using a pre-selected loss function. The network model is then trained based on this current loss value until a preset model training termination condition is met, resulting in a fault prediction model. The model training termination condition can be that the current loss value reaches a set loss threshold, the current loss value stabilizes, or the current iteration count reaches a set iteration count threshold; this embodiment does not impose any restrictions on these conditions.

[0056] The above-mentioned method of using fault prediction models for fault diagnosis or fault prediction of vehicle-mounted equipment improves the accuracy of fault prediction or diagnosis of vehicle-mounted equipment.

[0057] In one specific embodiment, the train control on-board equipment burn-in test system includes an industrial computer, a server, a PLC intelligent control device, a switch, a DC power supply, a data recording unit (DRU), relays, an interactive terminal (DMI), an I / O driver module, a BTM host and antenna, and a KVM driver. The specific execution process is as follows: Relevant technicians log into the industrial control computer via KVM and configure the burn-in strategy management software. Assuming the burn-in strategy configuration parameters are set as follows: dual-system alternating mode, total duration 2 hours, single run 12 minutes, power outage interval 5 minutes, and 10 start-ups, while simultaneously scanning and recording the unit numbers of 5 devices undergoing repair. The industrial control computer generates a PLC control instruction set and data acquisition trigger rules, and synchronizes the device numbers to the server via Ethernet. The IO drive module continuously outputs cab activation, forward, and braking feedback signals to the vehicle-mounted equipment cabinet, activating the BTM host and antenna, and receiving transponder signals, providing peripheral support for equipment startup.

[0058] The industrial control computer can send the first power-on command for the A-series equipment to the PLC intelligent control device via an RS485 (Recommended Standard 485, a serial differential communication standard) interface. Upon receiving the command, the PLC intelligent control device controls the relay to close the DC power supply circuit, supplying power to the A-series equipment on the vehicle. After the on-board equipment is powered on, the DMI automatically starts the dedicated test software, inputs test data such as train number and section, and automatically performs braking tests. The test status is fed back to the industrial control computer in real time. The BTM host and antenna work together to provide transponder signal support for the A-series equipment, ensuring the integrity of functional testing.

[0059] When a single operation has lasted 12 minutes, the industrial control computer sends an A-series power-off command to the PLC intelligent control device, which then controls the relay to disconnect the power circuit. The industrial control computer then sends the first data download trigger command to the server according to preset rules. Upon receiving the command, the server immediately forwards it to the DRU, which reads the AE-log operation log from the onboard device's A-series storage unit. The DRU uploads the log data to the server, which then activates an intelligent analysis algorithm to parse data such as voltage and communication status. If no anomalies are found, a fault-free diagnostic result is generated and fed back to the industrial control computer.

[0060] After the equipment is powered off, the system enters a 5-minute interval. The IO driver module maintains signal output, waiting for the next start command. After the 5-minute interval, the industrial control computer sends the first power-on command (B-series) to the PLC intelligent control device. The PLC intelligent control device switches its power supply circuit to B-series power, repeating the above test procedure. The server completes the B-series log analysis and feeds back the diagnostic results to the industrial control computer. The system then enters another 5-minute power-off interval. The system repeats the above command interaction and data acquisition process according to the alternating test logic of A-series and B-series until a total of 10 starts are completed.

[0061] For example, during the third A-series test, when the server analyzes the AE-log data and identifies an abnormal voltage below the threshold, it determines that the A-series power module is faulty and feeds back information such as the fault time and the faulty unit to the industrial control computer. The diagnostic results of each startup are synchronized from the server to the industrial control computer in real time, and the industrial control computer stores the data according to the device number. When the system completes 10 startups, or the cumulative runtime reaches 2 hours, the industrial control computer immediately sends a burn-in process termination command to the PLC intelligent control device, and all onboard equipment is powered off. If 10 startups are completed but the total duration is less than 2 hours, the system terminates the burn-in process based on the completion of the startup count.

[0062] like Figure 4The flowchart illustrates a burn-in test method for train control onboard equipment. After the train control onboard equipment burn-in test system starts up, the onboard equipment information is entered and transmitted to the server. The industrial control computer sends PLC control commands to the PLC intelligent control device. Based on these commands, the PLC intelligent control device controls the relays to close the power supply, powering on the onboard equipment cabinet, DMI, and BTM. The train control onboard equipment starts up. If startup is successful, the DMI automatically inputs information to perform a braking test. Before the equipment stops, an AE-log download command is sent to the industrial control computer, which forwards it to the DRU via the server. The DRU retrieves the AE-log from the onboard equipment and transmits it to the server. The server performs intelligent data diagnostics, obtains the burn-in test results, and generates a report. The process ends when the required number of startups is reached; otherwise, the above process repeats.

[0063] The industrial control computer aggregates all data from 10 startups and, combined with server diagnostic results, automatically generates a single-device stress test report by device number. The report includes start / stop records, test results, and fault location conclusions. The industrial control computer uploads all reports to the server for data archiving. Electrical personnel can remotely log in to the server via a query terminal, enter the device number, and retrieve the corresponding device's stress test report, raw AE-log data, and fault statistics, providing a basis for maintenance.

[0064] Existing vehicle-mounted equipment burn-in systems rely heavily on manual operation and diagnostics, requiring manual control of the equipment's power-on and power-off processes, as well as manual analysis and fault location. Especially for intermittent start-up faults requiring multiple restarts for reproduction or confirmation, dedicated personnel are essential, resulting in low burn-in efficiency and low fault location accuracy. This invention, however, automates burn-in and diagnostics for 300T vehicle-mounted equipment based on user-defined burn-in strategies. This includes automatic power-on and power-off control, automatic DMI data input, automatic braking tests, automatic AE-log download for intelligent analysis and fault location, automatic burn-in report generation, and remote querying of historical burn-in records. This invention supports simultaneous burn-in and intelligent diagnostics for multiple vehicle-mounted equipment cabinets. Compared to existing solutions, this invention effectively saves manpower, improves burn-in efficiency and fault location accuracy, and supports historical data traceability, which is significant for equipment management.

[0065] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0066] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A burn-in test system for train control onboard equipment, characterized in that, The system includes an industrial computer, a PLC intelligent control device, relays, a data recording unit (DRU), and a server; the industrial computer is communicatively connected to the PLC intelligent control device. The PLC intelligent control device is electrically connected to the relay; The industrial control computer is communicatively connected to the server; The DRU communicates with the server, including: An industrial control computer is used to generate PLC control instructions based on pre-configured burn-in strategy configuration parameters, and to send the PLC control instructions to PLC intelligent control devices. The PLC intelligent control device is used to control the relay to perform test signal control on the on-board equipment under test, so that the on-board equipment under test can perform equipment burn-in test based on the test signal. DRU is used to obtain the abnormal event logs of the vehicle-mounted device under test during the device burn-in process, and send the abnormal event logs to the server; The server is used to perform log analysis on the abnormal event log, generate fault diagnosis results for the vehicle-mounted equipment under test, and feed back the fault diagnosis results to the industrial control computer.

2. The system according to claim 1, characterized in that, The system also includes a DC power supply and an interactive terminal; the relay is electrically connected to the DC power supply and the interactive terminal respectively; correspondingly, controlling the relay to perform test signal control on the on-board device under test, so that the on-board device under test can perform device burn-in testing based on the test signal, includes: Upon receiving a PLC control command, if the PLC control command is a power-on command, the PLC intelligent control device controls the relay to close the power circuit of the DC power supply to provide power to the vehicle-mounted device under test. At the same time, the control interactive terminal starts the pre-deployed vehicle-mounted device test software, generates test signals and sends them to the vehicle-mounted device under test for device testing, so that the vehicle-mounted device under test can perform device burn-in testing based on the test signals.

3. The system according to claim 2, characterized in that, The system also includes an input / output IO driver module; the system further includes: after the vehicle-mounted device under test is powered on, the IO driver module outputs a cab activation signal, a forward feedback signal, an emergency braking feedback signal, and a normal braking feedback signal to the vehicle-mounted device under test to ensure that the vehicle-mounted device under test enters a normal operating state.

4. The system according to claim 2, characterized in that, The system also includes a transponder transmission module (BTM) host and an antenna; the BTM host is electrically connected to the relay; the system further includes: after the on-board device under test is powered on, the BTM host and the antenna work together to provide a transponder signal to the on-board device under test, so as to ensure the integrity of the functional test during the burn-in test of the on-board device under test.

5. The system according to claim 1, characterized in that, The step of obtaining the abnormal event logs of the vehicle-mounted device under test during the device burn-in process and sending the abnormal event logs to the server includes: After the industrial control computer sends a power-off command to the PLC intelligent control device, the PLC intelligent control device controls the relay to disconnect the DC power supply circuit, and the industrial control computer sends a data download trigger command to the server. When the server receives the data download trigger instruction, it forwards the data download trigger instruction to the DRU. The DRU retrieves abnormal event logs from the storage unit of the on-board device under test and sends the abnormal event logs to the server.

6. The system according to claim 1, characterized in that, The system also includes a control device; the control device is used to log in to the policy management software of the industrial control computer; the burn-in policy configuration parameters are configured based on the policy management software.

7. The system according to claim 1, characterized in that, The system also includes a switch; the switch is used to build a local area network to enable data transmission between the industrial control computer, the server and the DRU.

8. The system according to claim 1, characterized in that, The burn-in strategy configuration parameters include burn-in mode, total burn-in duration, single startup duration, power outage interval duration, number of startups, and device unit number.

9. A method for stress testing of train control onboard equipment, characterized in that, A system for burning out train control onboard equipment is provided, comprising an industrial computer, a PLC intelligent control device, relays, a data recording unit (DRU), and a server; the industrial computer is communicatively connected to the PLC intelligent control device. The PLC intelligent control device is electrically connected to the relay; The industrial control computer is communicatively connected to the server; The DRU communicates with the server, and the method includes: The industrial control computer generates PLC control instructions based on pre-configured burn-in strategy parameters and sends the PLC control instructions to the PLC intelligent control device. The PLC intelligent control device controls the relay to control the test signal of the on-board equipment under test, so that the on-board equipment under test can perform a device burn-in test based on the test signal; The abnormal event logs of the on-board device under test during the device burn-in process are obtained through the data recording unit (DRU), and the abnormal event logs are sent to the server. The server performs log analysis on the abnormal event logs, generates fault diagnosis results for the vehicle-mounted equipment under test, and feeds back the fault diagnosis results to the industrial control computer.

10. The method according to claim 9, characterized in that, The step of performing log analysis on the abnormal event log to generate fault diagnosis results for the vehicle-mounted equipment under test includes: The abnormal event logs are input into the pre-trained fault prediction model to obtain the fault diagnosis results of the on-board equipment under test output by the model. The training method for the fault prediction model is as follows: Obtain historical abnormal event logs within a historical time period, and label the historical abnormal event logs with fault tags to obtain the actual fault tag values; The historical abnormal event logs and the actual fault label values ​​are input into a pre-selected network model to obtain the predicted fault results output by the model. Based on the actual fault label values ​​and the predicted fault results, the network model is trained until the preset model training termination condition is met, thus obtaining the fault prediction model.

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