An industrial signal detection system and method integrating multi-signal generation and intelligent analysis

Abstract

This application provides an industrial signal detection system and method integrating multi-signal generation and intelligent analysis, relating to the field of automatic control technology. The system includes a PLC testing platform, an intelligent signal testing device, and a flexible wiring device. The method includes: determining the wiring method based on the electrical signal type; connecting the hardware module under test (DUT) to the intelligent signal testing device via the flexible wiring device; establishing a data flow direction based on the test type; acquiring test signals and collected signals through the intelligent signal testing device and performing communication time synchronization calibration to achieve timing alignment; calling evaluation criteria from an expert rule base to perform real-time comparative analysis of the collected and test signals; and finally generating and outputting a test report. This application achieves fully automated testing of industrial signals, replacing manual experience-based judgment with intelligent analysis, significantly improving testing efficiency and accuracy.

Description

Technical Field

[0001] This application relates to the field of automatic control technology, and in particular to an industrial signal detection system and method that integrates multi-signal generation and intelligent analysis. Background Technology

[0002] With the rapid development of industrial automation and intelligence, automatic control technologies and products such as PLCs (Programmable Logic Controllers) have been widely used. However, this has also created higher demands on the convenience, real-time performance, reliability, and intelligent analysis capabilities of PLC products for signal detection. Existing industrial signal detection systems suffer from the following technical bottlenecks: Signal processing is fragmented: the detection of digital and analog signals is usually done manually, the test wiring is complex, and the test power supply or wiring needs to be reconfigured for different types of signals.

[0003] Limited communication protocols: Most data analysis software only supports a single industrial protocol, making it difficult to adapt to multiple brands of PLCs and smart devices, resulting in high interconnection costs and poor compatibility.

[0004] Fragmented signal processing: Test data relies on manual offline analysis, lacks real-time intelligent diagnosis and energy efficiency assessment functions, and has a lag in response; The evaluation criteria are not scientific enough: they rely on traditional manual offline analysis and lack scientific evaluation criteria.

[0005] Therefore, there is an urgent need to design an industrial signal detection system that is compatible with multiple protocols, efficiently processes multiple signals, and integrates intelligent analysis. Summary of the Invention

[0006] In view of the above problems, this application is made to provide an industrial signal detection system and method integrating multi-signal generation and intelligent analysis that overcomes or at least partially solves the above problems. The technical solution is as follows: In a first aspect, an industrial signal detection system integrating multi-signal generation and intelligent analysis is provided, the system comprising: PLC test platform, intelligent signal test device and flexible wiring device; The PLC test platform includes a PLC controller, a PLC communication module, and a hardware module under test. The PLC controller is used to configure the channel parameters of the hardware module under test, receive control commands and control the output module to send test signals, and realize data interaction; the PLC communication module is used for data communication between the PLC test system and the intelligent signal test device; the hardware module under test is used to simulate the hardware architecture and firmware logic of the test target, including digital input / output modules and analog input / output modules; The intelligent signal testing device includes a network communication unit, a data analysis unit, a signal detection and generation unit, a digital-to-analog converter, a control power supply, digital quantity terminals, analog quantity terminals, an expert rule base, a report generation unit, and a display screen. The network communication unit is used for bidirectional data communication and signal synchronization; the data analysis unit is equipped with a real-time operating system for reading evaluation criteria, controlling signal output parameters, performing communication time synchronization calibration, and pushing evaluation results; the signal detection and generation unit is used to send and acquire electrical signals, including digital and analog signals; the digital-to-analog converter is used for format conversion of analog signals; the control power supply is used for system power supply and test signal source; digital and analog terminal blocks are used to connect flexible wiring devices; the expert rule base stores test rules built based on a relational database, including evaluation criteria and test configuration templates; the report generation unit is used to generate test reports; and the display screen is used to display the test status and evaluation results of the test cards.

[0007] Secondly, an industrial signal detection method integrating multi-signal generation and intelligent analysis is provided, the method comprising: The wiring method is determined according to the type of electrical signal being tested. The hardware module under test and the intelligent signal testing device are connected through a flexible wiring device. The types of electrical signals include analog and digital signals. According to the test type, a test data flow path is established. The test signal, which serves as the comparison benchmark, is acquired through the intelligent signal testing device, and the electrical signal is collected through the signal detection and generation unit. Through communication time synchronization calibration, the collected signal and the test signal are aligned in time. Obtain the evaluation criteria from the expert rule base, compare and analyze the collected signals and test signals in real time according to the evaluation criteria, generate and output test reports containing the evaluation results and / or display test curves and evaluation results in real time.

[0008] In one possible implementation, the flexible wiring device includes a wiring arm and a control cable. The wiring arm has an insulated plastic shell and copper alloy contacts, supports independent plugging and unplugging, and has a built-in elastic buckle at the head. The control cable has an electromagnetic shielding design, and its two ends are respectively connected to the wiring arm and the terminal of the signal intelligent test device.

[0009] In one possible implementation, if the electrical signal type is analog, the wiring method includes: When testing the -10-10V analog input module, the intelligent signal testing device outputs a test signal with a voltage variation range of -10-10V to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog input module, the intelligent signal testing device outputs a current test signal with a voltage variation range of 0 to 20mA to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the -10-10V analog output module, the intelligent signal testing device collects the voltage test signal with a variation range of -10-10V output by the output module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog output module, the intelligent signal testing device acquires the current test signal with a range of 0-20mA output from the module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal.

[0010] In one possible implementation, if the electrical signal type is a switching signal, the wiring method includes: When testing a 220V AC current-sinking switch input module, the signal intelligent test device outputs an AC test signal with a voltage variation range of 0 to 220V to the test card. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal. When testing a 24V DC current-source switch input module, the intelligent signal testing device outputs a DC test signal with a voltage variation range of 0 to 24V to the test card. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing a 220V AC current-sinking switch output module, the intelligent signal testing device collects an AC test signal with a voltage variation range of 0 to 220V output by the module. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing the 24V DC switch output module, the intelligent signal testing device collects the DC test signal with a voltage variation range of 0 to 24V output by the output module. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal.

[0011] In one possible implementation, the test types include input module tests and output module tests. Based on the test type, a test data flow path is established, including: For input module testing, the intelligent signal testing device sends a test signal, which is transmitted to the input module under test via a flexible wiring device. The input module under test then transmits the acquired signal to the intelligent testing device via a PLC. For output module testing, the intelligent signal testing device sends control commands to the PLC via a communication link. After receiving the control commands, the PLC controls the test card to send pulse signals or sine waves, which are transmitted to the intelligent signal testing device via a flexible wiring device. At the same time, the PLC transmits the test signals to the intelligent testing device via communication.

[0012] In one possible implementation, communication time synchronization calibration includes: The intelligent signal testing device sends a heartbeat pulse to the PLC testing system and records the sending time; the intelligent signal testing device receives the response pulse from the PLC testing system and records the receiving time. Calculate the communication delay compensation value for a single sample based on the transmission and reception times; The timestamp of the acquired electrical signal is subtracted from the corresponding communication delay compensation value to achieve timing alignment with the test signal.

[0013] In one possible implementation, the evaluation criteria from an expert rule base are obtained, and the collected signals and test signals are compared and analyzed in real time according to the evaluation criteria, including: When the electrical signal type is analog, the test signal adopts a periodically continuously changing curve, and at least one sampling point is obtained within the preset period. The first coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a first sampling curve and a first test curve based on at least one sampling point; the coordinates of the acquired signal corresponding to the i-th sampling point are... The corresponding test signal coordinates are ; Calculate the curve similarity between the acquired signal and the test signal. and mean absolute error rate ; like Similarity greater than the preset tolerance curve ,or Greater than the preset tolerance absolute error rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to Wset1 and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

[0014] In one possible implementation, the evaluation criteria are obtained from an expert rule base, and the collected signals and test signals are compared and analyzed in real time according to the evaluation criteria. The implementation also includes: When the electrical signal type is a switch quantity, the test signal adopts a square wave signal, and at least one sampling point is obtained within a preset period. A second coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a second sampling curve and a second test curve based on at least one sampling point; the coordinate of the rising edge of the corresponding acquisition signal at the i-th sampling point is... The coordinates of the falling edge are The coordinates of the rising edge of the corresponding test signal are The coordinates of the falling edge are ; Calculate the time deviation rate between the acquired signal and the test signal. and signal deviation rate ;like Greater than the preset tolerance time deviation rate ,or Greater than the preset tolerance signal deviation rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

[0015] In one possible implementation, curve similarity The calculation formula is: (1) Mean Absolute Error Rate The calculation formula is: (2) in, Let be the ordinate value of the i-th sampling point of the test signal. is the ordinate value of the i-th sampling point of the acquired signal, and n is the total number of sampling points.

[0016] In one possible implementation, the time deviation rate The calculation formula is: (3) Signal deviation rate The calculation formula is: (4) Where n is the total number of sampling points.

[0017] By utilizing the above technical solutions, the industrial signal detection system and method integrating multi-signal generation and intelligent analysis provided in this application includes a PLC testing platform, a signal intelligent testing device, and a flexible wiring device. The method includes: determining the wiring method based on the electrical signal type; connecting the hardware module under test (DUT) to the signal intelligent testing device via the flexible wiring device; establishing a data flow direction based on the test type; acquiring test signals and collected signals through the signal intelligent testing device and performing communication time synchronization calibration to achieve timing alignment; calling the evaluation criteria in the expert rule base to perform real-time comparative analysis of the collected signals and test signals; and finally generating and outputting a test report. This application achieves fully automated testing of industrial signals, replacing manual experience-based judgment with intelligent analysis, significantly improving testing efficiency and accuracy. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the description of the embodiments of this application will be briefly introduced below.

[0019] Figure 1 This paper shows an architecture diagram of an industrial signal detection system integrating multi-signal generation and intelligent analysis provided in an embodiment of this application. Figure 2 This illustration shows a schematic diagram of the flexible wiring device structure in an industrial signal detection system integrating multi-signal generation and intelligent analysis provided in an embodiment of this application. Figure 3 A flowchart of an industrial signal detection method integrating multi-signal generation and intelligent analysis provided in an embodiment of this application is shown; Figure 4 This illustration shows a schematic diagram of the first sampling curve and the first test curve plotted in the industrial signal detection method integrating multi-signal generation and intelligent analysis provided in the embodiments of this application. Figure 5 This illustration shows a schematic diagram of the second sampling curve and the second test curve drawn in the industrial signal detection method integrating multi-signal generation and intelligent analysis provided in the embodiments of this application; Figure 6 This illustration shows a schematic diagram of the input module signal test data flow provided in a specific embodiment of this application; Figure 7 This diagram illustrates the signal test data flow of the output module provided in a specific embodiment of this application. Detailed Implementation

[0020] Exemplary embodiments of the present application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present application are shown in the drawings, it should be understood that the present application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this application will be thorough and complete, and will fully convey the scope of the present application to those skilled in the art.

[0021] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such use can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the term "comprising" and its variations should be interpreted as open-ended terms meaning "including but not limited to."

[0022] The inventors discovered through analysis that existing industrial signal detection technologies suffer from systemic fragmentation and lag: in signal processing, testing of switch and analog signals relies on manual configuration and complex wiring, resulting in low efficiency; in system compatibility, the single communication protocol makes it difficult to adapt to multiple brands of equipment, leading to high interconnection costs; in data analysis, it relies on manual offline processing and lacks real-time intelligent diagnostic capabilities; and in evaluation criteria, it is largely based on subjective experience, lacking scientific and unified quantitative standards. These factors collectively result in cumbersome, inefficient, and unreliable industrial signal detection processes.

[0023] To address the aforementioned technical problems, embodiments of this application provide an industrial signal detection system integrating multi-signal generation and intelligent analysis, such as... Figure 1 As shown, the industrial signal detection system integrating multi-signal generation and intelligent analysis includes a PLC test platform, a signal intelligent test device, and a flexible wiring device. The PLC test platform includes a PLC controller, a PLC communication module, and a hardware module under test. The PLC controller is used to configure the channel parameters of the hardware module under test, receive control commands and control the output module to send test signals, and realize data interaction; the PLC communication module is used for data communication between the PLC test system and the intelligent signal test device; the hardware module under test is used to simulate the hardware architecture and firmware logic of the test target, including digital input / output modules and analog input / output modules.

[0024] The PLC controller can adopt a modular multi-core processor and support configuration in multiple programming languages ​​such as ladder diagrams and structured text. The channel parameters of the hardware module under test can include electrical signal type, range, and sampling frequency. During the test, the PLC controller receives control instructions from the intelligent signal testing device, controls the output module to send test signals of pulses or specific curves, and converts the input / output signals of the hardware module under test into communication protocol data through the internal data bus to complete the data interaction with the intelligent signal testing device. Among them, the PLC communication module can control the data communication delay between the PLC test platform and the intelligent signal test device through the integration of physical interfaces such as Ethernet or PROFIBUS (Process Field Bus); It is worth noting that the hardware module under test also has a channel fault self-detection function, which can provide real-time feedback on abnormal information such as module power supply status and channel short circuit / open circuit to the PLC controller.

[0025] The intelligent signal testing device includes a network communication unit, a data analysis unit, a signal detection and generation unit, a digital-to-analog converter, a control power supply, digital quantity terminals, analog quantity terminals, an expert rule base, a report generation unit, and a display screen. The network communication unit is used for bidirectional data communication and signal synchronization; the data analysis unit is equipped with a real-time operating system for reading evaluation criteria, controlling signal output parameters, performing communication time synchronization calibration, and pushing evaluation results; the signal detection and generation unit is used to send and acquire electrical signals, including digital and analog signals; the digital-to-analog converter is used for format conversion of analog signals; the control power supply is used for system power supply and test signal source; digital and analog terminal blocks are used to connect flexible wiring devices; the expert rule base stores test rules built based on a relational database, including evaluation criteria and test configuration templates; the report generation unit is used to generate test reports; and the display screen is used to display the test status and evaluation results of the test cards.

[0026] Among them, the network communication unit integrates multiple physical interfaces such as Ethernet and PROFIBUS, and supports mainstream industrial communication protocols such as Modbus (a serial communication protocol), Profinet (Process Field Network), and EtherNet / IP (Ethernet Industrial Protocol) to realize bidirectional data communication and test signal synchronization between the PLC test platform and the intelligent signal test device. The data analysis unit can use an industrial-grade embedded CPU (Central Processing Unit). During testing, it can read the evaluation criteria in the expert rule base, perform real-time calculation and analysis on the acquired and test signals, control the signal output parameters (such as amplitude, frequency, and waveform type) of the signal detection and generation unit, push the evaluation results to the display screen and report generation unit in real time, and synchronize and calibrate the communication time of the test signal and the acquired signal to achieve timing alignment between the transmission of the test signal and the acquisition signal, and eliminate interference from network communication. The signal detection and generation unit includes two independent processing channels for digital and analog signals, which can simultaneously emit signals within a specific range. The channels support two voltage levels: 24V DC and 220V AC. The acquisition response time and acquisition accuracy are higher than the performance of the test card. It supports the generation of sine waves, square waves, triangle waves and custom waveforms. Among them, the digital-to-analog converter can adopt a differential input design to convert the analog signal and the digital signal into a different format, and the conversion error meets the test requirements; The control power supply also has overvoltage, overcurrent, and short-circuit protection functions to ensure the stability of the output signal; The expert rule base stores information that may include: digital test rules derived from human experience of different PLC modules; and evaluation parameters corresponding to electrical signal types (such as tolerance curve similarity W). set1 Tolerance for absolute error rate W set2、 Tolerance signal deviation rate and tolerance signal deviation rate Test configuration templates for PLC modules from different brands (such as wiring methods and signal ranges); a historical fault case library. Maintenance personnel can drive system iteration by editing and modifying the test rule library; The report generation unit can integrate a printer interface and a network transmission module. The report content includes information such as test time, module model, channel number, test curve, evaluation results and anomaly analysis. It can be pushed to maintenance personnel through three methods: local printing, email push or cloud platform upload. It is worth noting that the display screen can adopt a touch screen design, support multi-window display, and can display signal input and output curves (including coordinate zoom and data point query functions), card test status (qualified / failed / under test) and system operating parameters (such as communication rate and power supply voltage) in real time.

[0027] This embodiment constructs a closed-loop system integrating a PLC testing platform, a signal intelligent testing device, and a flexible wiring device. This system integrates the dispersed hardware connection, signal generation, data acquisition, and analysis and evaluation functions into a unified, fully automated testing solution. The multi-protocol compatible network communication and flexible wiring device solve the problems of complex device interconnection and wiring. The signal detection and generation unit, combined with an expert rule base, enables scientific, real-time, and intelligent analysis and unified evaluation of digital and analog signals. This system transforms the traditional testing process, which relies on human experience and manual operation, into a standardized testing process that is configurable, traceable, and automatically outputs results.

[0028] This application provides one possible implementation method, such as... Figure 2 As shown, the flexible wiring device in the above system includes a wiring arm and a control cable. The wiring arm uses an insulated plastic shell and copper alloy contacts, supports independent plugging and unplugging, and has a built-in elastic buckle at the head. The control cable adopts an electromagnetic shielding design, and its two ends are respectively connected to the wiring arm and the terminal of the signal intelligent test device.

[0029] In this embodiment, each wiring arm corresponds to a signal channel or common terminal of the PLC card, and the tail is connected to the control cable. The elastic buckle built into the head of the wiring arm can tightly engage with the signal terminal of the hardware module under test. The two ends of the control cable can use anti-drop connectors. By using physical connection components with independent plug-in and electromagnetic shielding design, the complex and interference-prone manual wiring process in traditional testing is transformed into a standard, reliable and easy-to-deploy signal path, thereby providing a stable and efficient physical layer connection foundation for hardware modules of different types and specifications.

[0030] Based on the industrial signal detection system integrating multi-signal generation and intelligent analysis provided in the above embodiments, and based on the same inventive concept, this application also provides an industrial signal detection method integrating multi-signal generation and intelligent analysis, such as... Figure 3 As shown, the method may specifically include the following steps S101-S103: Step S101: Determine the wiring method according to the type of electrical signal being tested, and connect the hardware module under test and the intelligent signal testing device through a flexible wiring device. The electrical signal types include analog signals and digital signals. Step S102: According to the test type, establish a test data flow path, acquire the test signal as a comparison benchmark through the intelligent signal testing device, and collect electrical signals through the signal detection and generation unit; through communication time synchronization calibration, make the collected signal and the test signal time-aligned. This step includes tests for input modules and tests for output modules.

[0031] Step S103: Obtain the evaluation criteria from the expert rule base, perform real-time comparison and analysis of the collected signals and test signals according to the evaluation criteria, generate and output a test report containing the evaluation results and / or display the test curve and evaluation results in real time.

[0032] This embodiment transforms the traditional, fragmented testing steps that rely on manual experience into a closed-loop, automated, and intelligent full-process testing method through standardized wiring configuration, time-synchronized test signal acquisition, and real-time analysis based on expert rules. This enables efficient processing of different electrical signal types and test tasks.

[0033] This application embodiment provides a possible implementation method. In step S101 above, the wiring method is determined according to the type of the tested electrical signal. If the electrical signal type is an analog quantity, the wiring method includes: When testing the -10-10V analog input module, the intelligent signal testing device outputs a test signal with a voltage variation range of -10-10V to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog input module, the intelligent signal testing device outputs a current test signal with a voltage variation range of 0 to 20mA to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the -10-10V analog output module, the intelligent signal testing device collects the voltage test signal with a variation range of -10-10V output by the output module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog output module, the intelligent signal testing device acquires the current test signal with a range of 0-20mA output from the module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal.

[0034] This embodiment summarizes the testing of analog signals with different voltage and current specifications into standardized positive and negative electrode connection rules, thereby transforming the complex wiring process that traditionally relied on manual experience and operation into clear and repeatable standardized operating steps.

[0035] This application embodiment provides a possible implementation method. In step S101 above, the wiring method is determined according to the type of the tested electrical signal. If the electrical signal type is a switch signal, the wiring method includes: When testing a 220V AC current-sinking switch input module, the signal intelligent test device outputs an AC test signal with a voltage variation range of 0 to 220V to the test card. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal. When testing a 24V DC current-source switch input module, the intelligent signal testing device outputs a DC test signal with a voltage variation range of 0 to 24V to the test card. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing a 220V AC current-sinking switch output module, the intelligent signal testing device collects an AC test signal with a voltage variation range of 0 to 220V output by the module. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing the 24V DC switch output module, the intelligent signal testing device collects the DC test signal with a voltage variation range of 0 to 24V output by the output module. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal.

[0036] In this embodiment, the intelligent signal testing device can output an AC test signal with a voltage variation range that is appropriately beyond the range of 0 to 220V to the test card according to the rated parameters of the test card. For example, when the rated signal acquisition parameter of the test card is 250V AC, it can output an AC test signal with a voltage variation range of 220V to 250V to the test card. The intelligent signal testing device can output a DC test signal with a voltage variation range appropriately exceeding 0 to 24V to the test card according to the rated parameters of the test card. For example, when the rated signal acquisition parameter of the test card is 30V AC, it can output a DC test signal with a voltage variation range of 24V to 30V to the test card. This embodiment does not limit the output voltage variation range of AC test signals or DC test signals.

[0037] This embodiment summarizes the testing of switching signals with different voltage and current specifications into standardized positive and negative electrode connection rules, thereby transforming the complex wiring process that traditionally relied on manual experience and operation into clear and repeatable standardized operating steps.

[0038] This application embodiment provides a possible implementation method. In step S102 above, a test data flow path is established according to the test type, which specifically includes the following steps: For input module testing, the intelligent signal testing device sends a test signal, which is transmitted to the input module under test via a flexible wiring device. The input module under test then transmits the acquired signal to the intelligent testing device via a PLC. For output module testing, the intelligent signal testing device sends control commands to the PLC via a communication link. After receiving the control commands, the PLC controls the test card to send pulse signals or sine waves, which are transmitted to the intelligent signal testing device via a flexible wiring device. At the same time, the PLC transmits the test signals to the intelligent testing device via communication.

[0039] This embodiment defines clear data generation, transmission, and feedback paths for both input and output test scenarios, unifying the scattered and easily confused signal flows in traditional testing into a clear and standardized bidirectional data path, thereby achieving standardization and automation of the test process.

[0040] This application embodiment provides a possible implementation method. The communication time synchronization calibration in step S102 above specifically includes the following steps: The intelligent signal testing device sends a heartbeat pulse to the PLC testing system and records the sending time; the intelligent signal testing device receives the response pulse from the PLC testing system and records the receiving time. Calculate the communication delay compensation value for a single sample based on the transmission and reception times; The timestamp of the acquired electrical signal is subtracted from the corresponding communication delay compensation value to achieve timing alignment with the test signal.

[0041] In this embodiment, if the time interval between the sending time and the receiving time is T n The communication delay compensation value is The formula for calculating the communication delay compensation value is: By using heartbeat pulse interaction and precise time delay calculation, the network communication delay that is difficult to observe directly is quantified into a correctable compensation value, thereby automatically eliminating timing deviations before signal comparison and achieving high-precision time synchronization between test signals and acquired signals.

[0042] This application embodiment provides a possible implementation method. In step S103 above, the evaluation criteria in the expert rule base are obtained, and the collected signal and the test signal are compared and analyzed in real time according to the evaluation criteria. Specifically, the steps include: When the electrical signal type is analog, the test signal adopts a periodically continuously changing curve, and at least one sampling point is obtained within the preset period. The first coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a first sampling curve and a first test curve based on at least one sampling point; the coordinates of the acquired signal corresponding to the i-th sampling point are... The corresponding test signal coordinates are ; Calculate the curve similarity between the acquired signal and the test signal. and mean absolute error rate ; like Similarity greater than the preset tolerance curve ,or Greater than the preset tolerance absolute error rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to Wset1 and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

[0043] Among them, curve similarity The calculation formula is: (1) Mean Absolute Error Rate The calculation formula is: (2) Let be the ordinate value of the i-th sampling point of the test signal. is the ordinate value of the i-th sampling point of the acquired signal, and n is the total number of sampling points.

[0044] The first coordinate system, first sampling curve, and first test curve established in this embodiment are as follows: Figure 4 As shown, by converting continuous analog signals into discrete sampling point sequences that can be quantified and analyzed, and automatically comparing them based on curve similarity and mean absolute error rate, the traditional curve analysis process that relies on manual and subjective experience can be transformed into an objective, unified, and repeatable automated quantitative evaluation process.

[0045] This application embodiment provides a possible implementation method. In step S103 above, the evaluation criteria in the expert rule base are obtained, and the collected signal and the test signal are compared and analyzed in real time according to the evaluation criteria. Specifically, the steps include: When the electrical signal type is a switch quantity, the test signal adopts a square wave signal, and at least one sampling point is obtained within a preset period. A second coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a second sampling curve and a second test curve based on at least one sampling point; the coordinate of the rising edge of the corresponding acquisition signal at the i-th sampling point is... The coordinates of the falling edge are The coordinates of the rising edge of the corresponding test signal are The coordinates of the falling edge are ; Calculate the time deviation rate between the acquired signal and the test signal. and signal deviation rate ;like Greater than the preset tolerance time deviation rate ,or Greater than the preset tolerance signal deviation rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

[0046] Among them, time deviation rate The calculation formula is: (3) Signal deviation rate The calculation formula is: (4) n is the total number of sampling points.

[0047] The second coordinate system, second sampling curve, and second test curve established in this embodiment are as follows: Figure 5 As shown, the rising and falling edge characteristics of the switch signal are quantified into calculable time deviation rate and signal deviation rate, transforming the traditional switch state test that relies on manual observation and experience into a digital evaluation process that is automatically executed based on clear mathematical thresholds.

[0048] The above introduces Figure 2 The embodiments shown have various implementation methods for each step. The following will further explain the industrial signal detection method integrating multi-signal generation and intelligent analysis of the present application through specific embodiments.

[0049] This specific embodiment mainly addresses the problems of cumbersome manual wiring, fragmented testing processes, reliance on human experience for evaluation, and lack of high-precision time synchronization in industrial signal detection.

[0050] I. Input Module Testing like Figure 6 As shown, this section uses the intelligent signal testing device as the signal source to demonstrate the complete data flow of the hardware module (input card) under test, covering both analog and digital signals.

[0051] Analog input module test (-10-10V voltage input module) 1. Connection and Configuration: Connect the analog terminals of the signal intelligent test device to the channel terminals of the hardware module under test (a -10-10V analog input module) using a flexible wiring device. Configure the module in the PLC controller, setting the range and sampling rate.

[0052] 2. Establish test data flow: (1) Signal generation and transmission: The intelligent signal testing device generates a sine wave test signal with an amplitude of ±10V and a frequency of 1Hz by its signal detection and generation unit according to the test command, and applies it to the input card under test through a flexible wiring device.

[0053] (2) Signal acquisition and feedback: The input card under test samples and converts the input voltage to analog-to-digital. The PLC controller reads this digital value and transmits it back to the intelligent test device through the PLC communication module and network communication unit. This data is the acquired signal.

[0054] (3) Synchronization and Analysis: The data analysis unit performs communication time synchronization calibration to align the timing of the test signal and the acquired signal. Then, it calls the analog quantity evaluation criteria from the expert rule base to calculate the curve similarity. With mean absolute error rate The evaluation result is automatically generated after being compared with the preset threshold.

[0055] Test of digital input module (24V DC current-source digital input module) 1. Connection and Configuration: Connect the switch input terminals of the intelligent signal testing device to the hardware module under test using a flexible wiring device according to specific polarities (the signal terminal of the card is connected to the negative electrode, and the common terminal is connected to the positive electrode). Configure the switch input module in the PLC controller.

[0056] 2. Establish test data flow: (1) Signal generation and transmission: The signal detection and generation unit of the intelligent signal testing device generates a 0-24VDC square wave test signal, which is applied to the module under test through a flexible wiring device.

[0057] (2) Signal acquisition and feedback: The module under test detects the input level status, the PLC controller reads the status value and transmits it back to the intelligent test device through the communication link, which becomes the acquired signal.

[0058] (3) Synchronization and Analysis: After time synchronization calibration, the data analysis unit calls the switch quantity evaluation criteria in the expert rule base, compares the rise / fall time and level of the test signal and the acquired signal, and calculates the time deviation rate. and signal deviation rate It will automatically generate evaluation results.

[0059] II. Output Module Test Implementation Examples like Figure 7As shown, this section demonstrates the complete data flow of the PLC test platform driving the hardware module under test (output card) to generate signals according to instructions, which are then collected and analyzed by the intelligent signal testing device, covering both analog and digital signals.

[0060] Analog output module test (0-20mA current output module) 1. Connection and Configuration: Connect the analog terminals of the signal intelligent test device to the output terminals of the hardware module under test (a 0-20mA analog output module) using a flexible wiring device. Complete the module configuration in the PLC controller.

[0061] 2. Establish test data flow: (1) Command issuance and signal reference synchronization: The intelligent signal testing device sends a control command to the PLC controller through the communication link, instructing it to control the module under test to output a current test signal with a ramp change of, for example, 0-20mA. The signal parameters defined by this command are simultaneously synchronized to the intelligent signal testing device as an analysis reference.

[0062] (2) Physical signal output and acquisition: The module under test generates a corresponding physical current signal at its output terminal according to the instruction. This signal is directly acquired by the signal detection and generation unit of the intelligent signal testing device through a flexible wiring device. This data is the acquired signal.

[0063] (3) Synchronization and Analysis: The data analysis unit performs time synchronization calibration on the benchmark test signal and the physically acquired signal. Then, it calls the analog quantity evaluation criteria to calculate... and Parameters such as these enable automatic evaluation.

[0064] Test of digital output module (220V AC current sinking digital output module) 1. Connection and Configuration: Connect the switch terminals of the intelligent signal testing device to the hardware module under test using a flexible wiring device according to specific polarities (the card signal terminal is connected to the negative electrode, and the common terminal is connected to the positive electrode). Configure the output module in the PLC controller.

[0065] 2. Establish test data flow: (1) Command issuance and signal reference synchronization: The intelligent signal testing device sends a command to the PLC controller, requesting the module under test to output a 0-220V AC square wave test signal. The waveform parameters defined by this command are synchronized to the intelligent signal testing device as a reference.

[0066] (2) Physical signal output and acquisition: The module under test outputs an AC voltage signal, which is directly acquired by the signal detection and generation unit of the intelligent signal testing device through a flexible wiring device to obtain the acquired signal.

[0067] (3) Synchronization and Analysis: After timing alignment, the data analysis unit calls the switch quantity evaluation criteria, compares the edge characteristics of the reference square wave and the acquired waveform, and calculates... and Automatic evaluation is completed.

[0068] III. Results Summary and Output For any of the above test procedures, the final evaluation result, signal curve (comparison graph of test signal and acquired signal), and key parameters (such as...) The report generation unit automatically generates standardized test reports, including test configuration information, and displays them in real time on the screen. Reports can be printed locally, sent via email, or uploaded to the cloud platform.

[0069] This embodiment realizes fully automated testing of industrial signals, significantly improving testing efficiency and accuracy by replacing manual experience-based judgment with intelligent analysis.

[0070] It should be noted that the sequence numbers of the steps in the above embodiments do not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application. In practical applications, all the above possible implementation methods can be arbitrarily combined in a combined manner to form possible embodiments of this application, which will not be described in detail here.

[0071] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that within the spirit and principles of this application, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the corresponding technical solutions to leave the protection scope of this application.

Claims

1. An industrial signal detection system integrating multi-signal generation and intelligent analysis, characterized in that, The system includes: PLC test platform, intelligent signal test device and flexible wiring device; The PLC test platform includes a PLC controller, a PLC communication module, and a hardware module under test. The PLC controller is used to configure the channel parameters of the hardware module under test, receive control commands and control the output module to send test signals, and realize data interaction; the PLC communication module is used for data communication between the PLC test system and the intelligent signal test device; the hardware module under test is used to simulate the hardware architecture and firmware logic of the test target, including digital input / output modules and analog input / output modules; The intelligent signal testing device includes a network communication unit, a data analysis unit, a signal detection and generation unit, a digital-to-analog converter, a control power supply, digital quantity terminals, analog quantity terminals, an expert rule base, a report generation unit, and a display screen. The network communication unit is used for bidirectional data communication and signal synchronization; the data analysis unit is equipped with a real-time operating system for reading evaluation criteria, controlling signal output parameters, performing communication time synchronization calibration, and pushing evaluation results; the signal detection and generation unit is used to send and acquire electrical signals, including digital and analog signals; the digital-to-analog converter is used for format conversion of analog signals; the control power supply is used for system power supply and test signal source; digital and analog terminal blocks are used to connect flexible wiring devices; the expert rule base stores test rules built based on a relational database, including evaluation criteria and test configuration templates; the report generation unit is used to generate test reports; and the display screen is used to display the test status and evaluation results of the test cards.

2. The system according to claim 1, characterized in that, The flexible wiring device includes a wiring arm and a control cable. The wiring arm has an insulated plastic shell and copper alloy contacts, supports independent plugging and unplugging, and has a built-in elastic buckle at the head. The control cable adopts an electromagnetic shielding design, and its two ends are connected to the wiring arm and the terminal of the intelligent signal testing device, respectively.

3. A method for industrial signal detection integrating multi-signal generation and intelligent analysis, applied to the system described in claim 1 or 2, characterized in that, The method includes: The wiring method is determined according to the type of electrical signal being tested. The hardware module under test and the intelligent signal testing device are connected through a flexible wiring device. The types of electrical signals include analog and digital signals. According to the test type, a test data flow path is established. The test signal, which serves as the comparison benchmark, is acquired through the intelligent signal testing device, and the electrical signal is collected through the signal detection and generation unit. Through communication time synchronization calibration, the collected signal and the test signal are aligned in time. Obtain the evaluation criteria from the expert rule base, compare and analyze the collected signals and test signals in real time according to the evaluation criteria, generate and output test reports containing the evaluation results and / or display test curves and evaluation results in real time.

4. The method according to claim 3, characterized in that, If the electrical signal type is analog, the wiring methods include: When testing the -10-10V analog input module, the intelligent signal testing device outputs a test signal with a voltage variation range of -10-10V to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog input module, the intelligent signal testing device outputs a current test signal with a voltage variation range of 0 to 20mA to the test card. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the -10-10V analog output module, the intelligent signal testing device collects the voltage test signal with a variation range of -10-10V output by the output module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal. When testing the 0-20mA analog output module, the intelligent signal testing device acquires the current test signal with a range of 0-20mA output from the module. The positive signal terminal of the test card is connected to the positive electrode of the test signal, and the negative signal terminal of the test card is connected to the negative electrode of the test signal.

5. The method according to claim 3, characterized in that, If the electrical signal type is a switch signal, the wiring methods include: When testing a 220V AC current-sinking switch input module, the signal intelligent test device outputs an AC test signal with a voltage variation range of 0 to 220V to the test card. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal. When testing a 24V DC current-source switch input module, the intelligent signal testing device outputs a DC test signal with a voltage variation range of 0 to 24V to the test card. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing a 220V AC current-sinking switch output module, the intelligent signal testing device collects an AC test signal with a voltage variation range of 0 to 220V output by the module. The signal terminal of the test card is connected to the negative electrode of the test signal, and the common terminal of the test card is connected to the positive electrode of the test signal. When testing the 24V DC switch output module, the intelligent signal testing device collects the DC test signal with a voltage variation range of 0 to 24V output by the output module. The signal terminal of the test card is connected to the positive electrode of the test signal, and the common terminal of the test card is connected to the negative electrode of the test signal.

6. The method according to any one of claims 3-5, characterized in that, The test types include input module testing and output module testing. Based on the test type, a test data flow path is established, including: For input module testing, the intelligent signal testing device sends a test signal, which is transmitted to the input module under test via a flexible wiring device. The input module under test then transmits the acquired signal to the intelligent testing device via a PLC. For output module testing, the intelligent signal testing device sends control commands to the PLC via a communication link. After receiving the control commands, the PLC controls the test card to send pulse signals or sine waves, which are transmitted to the intelligent signal testing device via a flexible wiring device. At the same time, the PLC transmits the test signals to the intelligent testing device via communication.

7. The method according to any one of claims 3-5, characterized in that, Communication time synchronization calibration includes: The intelligent signal testing device sends a heartbeat pulse to the PLC testing system and records the sending time; the intelligent signal testing device receives the response pulse from the PLC testing system and records the receiving time. Calculate the communication delay compensation value for a single sample based on the transmission and reception times; The timestamp of the acquired electrical signal is subtracted from the corresponding communication delay compensation value to achieve timing alignment with the test signal.

8. The method according to any one of claims 3-5, characterized in that, Obtain the evaluation criteria from the expert rule base, and perform real-time comparative analysis of the collected signals and test signals based on the evaluation criteria, including: When the electrical signal type is analog, the test signal adopts a periodically continuously changing curve, and at least one sampling point is obtained within the preset period. The first coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a first sampling curve and a first test curve based on at least one sampling point; the coordinates of the acquired signal corresponding to the i-th sampling point are... The corresponding test signal coordinates are ; Calculate the curve similarity between the acquired signal and the test signal. and mean absolute error rate ; like Similarity greater than the preset tolerance curve ,or Greater than the preset tolerance absolute error rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to Wset1 and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

9. The method according to any one of claims 3-5, characterized in that, The system retrieves evaluation criteria from the expert rule base, performs real-time comparative analysis of the acquired and test signals based on these criteria, and also includes: When the electrical signal type is a switch quantity, the test signal adopts a square wave signal, and at least one sampling point is obtained within a preset period. A second coordinate system is established with the test time as the horizontal axis and the test voltage or current as the vertical axis. The data analysis unit plots a second sampling curve and a second test curve based on at least one sampling point; the coordinate of the rising edge of the corresponding acquisition signal at the i-th sampling point is... The coordinates of the falling edge are The coordinates of the rising edge of the corresponding test signal are The coordinates of the falling edge are ; Calculate the time deviation rate between the acquired signal and the test signal. and signal deviation rate ;like greater than the preset tolerance time deviation rate ,or Greater than the preset tolerance signal deviation rate If the result is unfavorable, then the evaluation result is poor; if Less than or equal to and Less than or equal to If the result is satisfactory, the evaluation is considered qualified.

10. The method according to claim 8, characterized in that, Curve similarity The calculation formula is: （1） Mean Absolute Error Rate The calculation formula is: （2） in, Let be the ordinate value of the i-th sampling point of the test signal. is the ordinate value of the i-th sampling point of the acquired signal, and n is the total number of sampling points.

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