A steering wheel test system and method

Abstract

This invention relates to the field of fault detection technology, specifically to a control panel testing system and method, including a signal triggering module, an oscillation acquisition module, a resistance measurement module, a degradation assessment module, and a lifespan estimation module. In this invention, by constructing a correlation between the sequence of actions and the time difference, and linking the waveform trend at the moment of disconnection with the state evolution during the closing phase, the originally scattered test information is transformed into a continuous changing process for comprehensive identification. This distinguishes between occasional disturbances and continuous degradation, highlights hidden unstable sections and change boundaries, and makes the degradation development path continuously traceable. Simultaneously, it enhances the ability to capture early, weak anomalies, iteratively deepens the characterization of contact state changes, and can extract change patterns from the changing sections to support trend analysis. Lifespan estimation is more consistent with actual consumption processes, maintenance arrangements are more forward-looking and targeted, and the overall state assessment conclusions are more stable and valuable for reference.

Description

Technical Field

[0001] This invention relates to the field of fault detection technology, and in particular to a control panel testing system and method. Background Technology

[0002] The field of fault detection technology mainly involves the status monitoring and anomaly identification of electrical equipment, circuit systems, and their control components during operation. It further integrates fault prediction and health management to analyze the performance degradation trends of equipment over long-term operation. Core aspects include acquiring operational data through voltage and current acquisition, signal continuity detection, response time measurement, and multi-condition loading. Based on comparisons of historical test results with the current state, it identifies and judges trends related to open circuits, short circuits, poor contact, and performance degradation. This field is widely used in the testing of automated control panels and various human-machine interface electrical units in industrial control equipment, forming a comprehensive testing system. This is a systematic technical system based on the process of data acquisition, execution, and status assessment of the test device. Among them, a traditional control panel test system refers to a device that detects and assesses the status of the internal button indicator lights and circuit connections of the control panel. It usually connects the control panel to an external power supply by setting up a test bench. During the test, trigger signals are sequentially input to each button and the circuit channels are switched through relays. At the same time, the voltage, current, and response time of the corresponding port are recorded by the sampling circuit. The measurement results are compared according to a pre-set multiple test sequence to obtain the change data of each functional circuit under different operating conditions and to judge its operating status and change trend.

[0003] Existing technologies rely primarily on channel rotation measurements and result comparisons for judgment. During operation, they focus more on whether the circuit is conductive and whether the results deviate from the predetermined range. They do not adequately reflect the connection between continuous changes before and after an action. When encountering scenarios with frequent short-term rebounds or gradual wear of the contact surface, abnormal signs are often scattered across different test nodes, making it difficult to connect them into a complete evolutionary clue. For example, when local instability only manifests as stage fluctuations, the test conclusion may still appear normal on the surface. This results in slow identification of hidden dangers, coarse determination of degradation locations, and a tendency for delays in determining maintenance timing. Summary of the Invention

[0004] To address the technical problems existing in the prior art, embodiments of the present invention provide a control panel testing system and method, the system comprising: The signal triggering module acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, compares the button triggering sequence with the relay contact switching time, and obtains the button action sequence record based on the switching time difference corresponding to the triggering time point. The oscillation acquisition module records the sequence of button actions, monitors the voltage change at the moment the control panel button contacts are disconnected, compares the voltage changes in segments, determines the voltage amplitude of the corresponding time segments, judges the direction of adjacent segments, and obtains the voltage waveform change when the contacts are disconnected. The resistance measurement module records the voltage waveform changes when the contact is disconnected based on the sequence of button actions, collects the voltage and current during the button closing phase, compares the voltage and current changes, and obtains the result of the contact state change of the contact point. The degradation assessment module, based on the voltage waveform change when the contact is disconnected and the contact state change result, determines the oscillation change direction and contact state change segment according to the trigger sequence, extracts the time period when the abnormality occurs simultaneously, and obtains the abnormal change stage of the contact. The lifespan estimation module extracts the trigger sequence range based on the abnormal change stage of the contact and the change in the contact state of the contact, analyzes the segment location and trigger sequence, and obtains the distribution result of the contact degradation segment.

[0005] As a further aspect of the present invention, the button action sequence record includes a button number sequence, a trigger timestamp sequence, a contact switching delay value, and a trigger order sorting label; the voltage waveform change when the contact is disconnected includes a voltage fluctuation segment sequence, a direction determination identifier, oscillation peak and valley points, and segment duration; the contact contact state change result includes a contact resistance value, a closed current curve, a closed voltage curve, and contact stability parameters; the contact abnormal change stage includes a degradation initiation segment, a degradation duration segment, a degradation interval segment, and a segment association index; and the contact degradation segment distribution result includes a segment distribution location sequence, an interval classification label, a degradation trend type, and a lifespan stage division.

[0006] As a further aspect of the present invention, the corresponding switching time difference refers to the time interval when two adjacent states and segments switch; Determining the direction of adjacent segments refers to judging the directional relationship between movement and change based on the changing trend of adjacent data segments.

[0007] As a further aspect of the present invention, the oscillation change direction refers to the current trend direction of the signal change during the oscillation process; The contact state change segment refers to the time and data interval corresponding to the transition from one contact state to another.

[0008] As a further aspect of the present invention, the signal triggering module includes: The time acquisition submodule acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, acquires the button trigger time and relay contact switching time, calculates the time interval between the trigger time and the switching time, compares the time intervals, and obtains the trigger time interval sequence. The sequence comparison submodule analyzes the consistency between the time intervals and the triggering sequence based on the triggering time interval sequence, corresponding to the button triggering time point and the relay contact switching time point, and obtains the triggering sequence correspondence set. The relationship correspondence submodule associates the trigger sequence number with the time interval item by item based on the trigger sequence correspondence relationship set, determines the continuity of the time interval corresponding to the trigger sequence number, and obtains the key action sequence record by matching the trigger sequence number with the time interval.

[0009] As a further aspect of the present invention, the oscillation acquisition module includes: The voltage monitoring submodule records the sequence of button actions, monitors the voltage change process at the moment the control panel button contacts are disconnected, collects the voltage time series corresponding to the trigger sequence, extracts the time nodes of the voltage time series and reads the amplitude to obtain the voltage time series amplitude; The segmented comparison submodule, based on the voltage time series amplitude and the segmented voltage change process time, compares the voltage amplitude of the time segments, determines the difference in the voltage amplitude change amplitude of adjacent time segments, and obtains the waveform rise and fall trend; Based on the rising and falling trend of the waveform, the direction determination submodule determines the consistency of the change direction of adjacent time segments, associates the direction of continuous time segments, and corresponds to the direction of the trigger sequence to obtain the voltage waveform change when the contact is opened.

[0010] As a further aspect of the present invention, the resistance calculation module includes: The voltage and current acquisition submodule records the voltage waveform changes when the contacts are disconnected based on the button action sequence, acquires the voltage and current during the closing phase of the control panel button contacts, extracts the voltage and current values ​​corresponding to the trigger sequence, and obtains the voltage and current corresponding sequence. The change comparison submodule compares the voltage and current changes item by item under the triggering sequence based on the voltage and current corresponding sequence, determines the difference between the voltage change trend and the current change trend, associates the voltage and current change difference, and obtains the voltage and current change difference. The state association submodule, based on the voltage and current change difference and the voltage waveform change when the contact is disconnected, synchronously compares the trigger sequence change direction, associates the change direction and the difference result, determines the continuity of the trigger sequence contact state, and obtains the contact state change result.

[0011] As a further aspect of the present invention, the degradation assessment module includes: The waveform matching submodule performs corresponding matching according to the triggering order based on the voltage waveform change when the contact is open and the contact state change result. It calls the trigger sequence index value to align the oscillation amplitude sequence and the contact state identifier sequence point by point, and obtains the waveform alignment sequence based on the synchronous alignment relationship associated with the difference of adjacent trigger sequence indices. The segment determination submodule, based on the waveform alignment sequence, determines the oscillation change direction and the contact state change segment, calls the oscillation amplitude sign change and contact state jump identifier to divide the interval, and divides the time period boundary where anomalies occur simultaneously according to the consistency of the sign in the continuous trigger sequence index, thus obtaining the time period index set where anomalies occur simultaneously. The segment association submodule, based on the time period index set where anomalies occur simultaneously, compares the intervals between segments, calls the segment start-end index difference with the trigger sequence index to perform corresponding association, and identifies continuously associated segments according to the segment interval difference threshold to obtain the stage of abnormal change of the touch point.

[0012] As a further aspect of the present invention, the lifespan estimation module includes: The range extraction submodule extracts the corresponding trigger sequence range based on the abnormal change stage of the contact point and the change in the contact state of the contact point. It calls the start and end index values ​​of the segment and matches them with the trigger sequence index sequence. It identifies the trigger sequence interval based on the difference in the segment boundary index and obtains the trigger sequence range interval. The location discrimination submodule analyzes the location and triggering order of the corresponding segment based on the triggering order range, calculates the location by calling the segment center index and the triggering order index, and classifies the interval between segments according to the index offset threshold to obtain the segment interval classification identifier. The sequence segmentation submodule compares the segment interval classification identifier with the trend of the contact state change result, calls the state change direction sequence and the segment classification identifier for matching and sorting, and divides the segment distribution sequence according to the trigger order index arrangement relationship to obtain the contact degradation segment distribution result.

[0013] On the other hand, a control panel testing method, which is executed based on the aforementioned control panel testing system, includes the following steps: S1: Obtain the power supply voltage of the control panel button contacts, relay contacts, and indicator light circuits; compare the button triggering sequence with the relay contact switching time; and obtain the button action sequence record based on the correspondence between the triggering time point and the switching time difference. S2: Based on the recorded sequence of button actions, monitor the voltage change at the moment the control panel button contacts are disconnected, compare the voltage changes in segments and determine the direction, determine the voltage amplitude of the corresponding time segments, judge the consistency of the direction of adjacent segments, and obtain the voltage waveform change when the contacts are disconnected. S3: Based on the sequence of button actions and the voltage waveform changes when the contact is disconnected, collect the voltage and current during the closing phase of the control panel button contact, calculate the voltage and current accordingly, compare the voltage and current changes according to the trigger sequence, and compare them with the voltage waveform changes when the contact is disconnected to obtain the contact state change results. S4: Based on the voltage waveform change when the contact is disconnected and the contact state change result, match them according to the triggering sequence, determine the oscillation change direction and the contact state change segment, extract the time period when the abnormality occurs simultaneously in the continuous triggering sequence, compare the segment interval, and correlate the corresponding segment with the triggering sequence to obtain the abnormal change stage of the contact. S5: Based on the abnormal change stage of the contact point and the change result of the contact point contact state, extract the trigger sequence range, analyze the corresponding segment position and trigger sequence, and obtain the distribution result of the contact point degradation segment.

[0014] Compared with the prior art, the advantages and positive effects of the present invention are as follows: In this invention, by constructing the correlation between the sequence of actions and the time difference, and linking the waveform trend at the moment of disconnection with the state evolution during the closing stage, the originally scattered test information is transformed into a continuous changing process for comprehensive identification. This distinguishes between occasional disturbances and continuous degradation, highlights hidden unstable sections and change boundaries, and makes the degradation development path present a continuous traceability feature. At the same time, it enhances the ability to capture early weak abnormal evolution, iteratively deepens the characterization of contact state changes, and can extract change patterns from change sections to support trend analysis. Lifespan prediction is more in line with the actual consumption process, maintenance arrangements are more forward-looking and targeted, and the overall state assessment conclusions are more stable and have more reference value. Attached Figure Description

[0015] 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.

[0016] Figure 1 This is a system flowchart of the present invention; Figure 2 This is a system block diagram of the present invention; Figure 3 This is a flowchart of the signal triggering module in this invention; Figure 4 This is a flowchart of the oscillation acquisition module in this invention; Figure 5 This is a flowchart of the resistance measurement module in this invention; Figure 6This is a flowchart of the degradation assessment module in this invention; Figure 7 This is a flowchart of the lifespan estimation module in this invention; Figure 8 This is a flowchart of the method steps of the present invention. Detailed Implementation

[0017] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0018] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0019] This invention provides a control panel testing system, such as... Figure 1-2 The schematic diagram of the control panel test system shown includes: The signal triggering module acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, compares the button triggering sequence with the relay contact switching time, and performs item-by-item matching based on the difference between the triggering time and the relay contact switching time to obtain a record of the button action sequence. The oscillation acquisition module records the sequence of key actions, monitors the voltage change process at the moment the control panel key contacts are opened, compares the voltage change process in segments and determines the direction, analyzes the time of the voltage change amplitude of the corresponding time segments, analyzes the consistency of the change direction of adjacent time segments, and obtains the voltage waveform change when the contacts are opened. The resistance measurement module collects the voltage and current during the button closing phase based on the sequence of button actions and the voltage waveform changes when the contact is opened. It calculates the voltage and current accordingly, compares the differences in voltage and current changes according to the triggering sequence, and synchronously compares the change direction in the voltage waveform change results when the contact is opened to obtain the contact state change results. The degradation assessment module, based on the voltage waveform change and contact state change results when the contact is disconnected, performs corresponding matching according to the triggering sequence, identifies the oscillation change direction and contact state change segment, extracts the time period in the continuous triggering sequence where the oscillation change direction and contact state change are abnormal at the same time, compares the interval between segments, associates the correspondence between the segments and the triggering sequence, and obtains the abnormal change stage of the contact. The lifespan estimation module extracts the corresponding trigger sequence range based on the abnormal change stage of the contact and the change result of the contact contact state. It analyzes the location of the corresponding segment and the trigger sequence, classifies and judges the interval between segments, and compares it with the change trend in the result of the change of the contact contact state to divide the distribution sequence of the segment in the trigger sequence, and obtains the distribution result of the contact degradation segment.

[0020] The key action sequence record includes key number sequence, trigger timestamp sequence, contact switching delay value, and trigger order label. The voltage waveform change when the contact is disconnected includes voltage fluctuation segment sequence, direction determination indicator, oscillation peak and valley points, and segment duration. The contact contact state change results include contact resistance value, closed current curve, closed voltage curve, and contact stability parameters. The abnormal change stage of the contact includes degradation initiation segment, degradation duration segment, degradation interval segment, and segment association index. The contact degradation segment distribution results include segment distribution location sequence, interval classification label, degradation trend type, and life stage division.

[0021] Specifically, such as Figure 2 , 3 As shown, the signal triggering module includes: The time acquisition submodule acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, acquires the button trigger time and relay contact switching time, calculates the time interval between the trigger time and the switching time, compares the time intervals, and obtains the trigger time interval sequence. First, the time acquisition process acquires the raw level signals of the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits in real time through a hardware trigger interface. This aims to provide high-confidence raw input for subsequent fault prediction and health management through refined capture of low-level data. In the scenario of electric locomotive control circuit monitoring, an analog-to-digital converter with a sampling frequency of 5000 Hz continuously captures voltage value changes in the input channels. When the operator presses the start button on the control panel, the voltage comparison logic identifies the instant the level jumps from 24 volts to below 0.5 volts. The logic judgment unit records the current high-precision clock count as the button trigger time point and continuously monitors the output terminal of the intermediate relay associated with the button logic. By capturing the sudden change in circuit current caused by the relay armature action, the system determines the relay's trigger time. The electrical contact switching time point is determined by a subtraction operation logic. The time interval between the relay contact switching time point and the button triggering time point is subtracted. For example, in a certain experiment, the button triggering time point was 100.250 seconds and the relay contact switching time point was 100.312 seconds. The calculated triggering time interval for this operation was 0.062 seconds. Data backup was performed for 150 consecutive operations. The time interval obtained each time was compared with a preset standard response time benchmark value. This benchmark value is set between 0.040 seconds and 0.080 seconds according to the locomotive control standard. If the calculated time interval falls within this range, it is considered valid. Finally, all valid time intervals are linearly arranged in the order of acquisition to obtain the triggering time interval sequence.

[0022] The sequence comparison submodule analyzes the consistency between the time intervals and the trigger sequence based on the trigger time interval sequence, corresponding to the button trigger time and the relay contact switching time, and obtains the trigger sequence correspondence set. First, the sequential comparison process receives the trigger time interval sequence generated by the previous stage and retrieves the button trigger time point and relay contact switching time point recorded synchronously to construct a multi-dimensional data matrix. During the real-time self-test of the locomotive logic cabinet, each time node in the matrix is ​​extracted through a traversal algorithm, and the trigger sequence number of the physical button is matched one-to-one with the response sequence number of the relay action. Based on the trigger time interval sequence, the internal logic analysis unit performs consistency judgment on the changing trend of each time interval in the sequence, and analyzes whether the fluctuation pattern of the time interval is logically synchronized with the physical sequence of button triggering. Specifically, it calculates the time interval difference between two adjacent trigger actions and associates it with a preset error tolerance threshold of 0.010 seconds. If the judgment result shows that the difference is less than or equal to the threshold, the corresponding item is retained. If the sequence is reversed or the interval changes abnormally, the interference item is filtered out by a logic elimination algorithm. This process, through in-depth mining of the consistency between the time interval and the trigger sequence in the trigger time interval sequence, can identify minor anomalies caused by logical lag, providing key logical consistency evidence for fault prediction and obtaining a set of trigger sequence correspondences.

[0023] The relationship correspondence submodule associates each trigger sequence number with a time interval based on the trigger sequence correspondence relationship set, determines the continuity of the time interval corresponding to the trigger sequence number, and obtains the key action sequence record by matching the trigger sequence number with the time interval. First, the relation mapping process extracts metadata from the trigger sequence mapping relation set and initiates an item-by-item association program, binding each trigger sequence number to its actual time interval. In the running logic of the automated testing platform, discrete response time points are embedded into a continuous operation logic chain, and the discrimination logic performs continuity verification on the time interval corresponding to the trigger sequence number. By calculating the rate of change between adjacent elements in the sequence, i.e., the ratio of the time interval difference to the operation sequence number increment, it is determined whether there is an unreasonable step phenomenon in the response time. For example, when the time interval of 10 consecutive trigger numbers is stable at around 0.060 seconds and the difference between adjacent fluctuations is less than 0.005 seconds, the sequence is determined to have time continuity. If the response time suddenly increases from 0.060 seconds to 0.200 seconds at a certain boundary point, the threshold judgment logic is called to mark the point as a logic jump point. Then, the influence of random noise on the response sequence is eliminated through index alignment technology. This result is used as the basic timing model for evaluating the health status of the component, supporting the subsequent accurate measurement of the performance degradation magnitude, and obtaining the key action sequence record.

[0024] Specifically, such as Figure 2 , 4 As shown, the oscillation acquisition module includes: The voltage monitoring submodule records the sequence of key presses, monitors the voltage change process at the moment the control panel key contacts are disconnected, collects the voltage time series corresponding to the trigger sequence, extracts the time nodes of the voltage time series and reads the amplitude to obtain the voltage time series amplitude. First, the voltage monitoring process receives the recorded sequence of key presses and activates a high dynamic range voltage sampling unit. While monitoring the physical process of the control panel key contacts opening, it records the transient response of the voltage waveform at a sampling frequency of 200,000 times per second. An internal slope analysis algorithm identifies the starting moment when the voltage jumps from the steady-state closed voltage to the open voltage and locks in the residual voltage fluctuation process after the contacts are completely disconnected. The process collects the voltage time series corresponding to the trigger sequence. This process extracts features from the collected raw sequence, locating extreme points, inflection points, and the time points when the sequence returns to steady state. It reads the voltage amplitude of each key node. For example, during a contact disconnection process, a transition voltage of 12.5 volts is extracted at 0.0005 seconds after the start of the sequence, and a peak voltage of 36.8 volts is read at 0.0012 seconds. By traversing the voltage waveforms under all trigger sequences, the voltage abrupt change characteristics characterizing the contact wear state are extracted, providing a physical-level sensitive indicator for life prediction algorithms in health management, and obtaining the voltage time series amplitude.

[0025] The segmented comparison submodule is based on the voltage time series amplitude, the time of segmented voltage change process, and the comparison of the voltage amplitude of the time segment to determine the difference in the voltage amplitude change of adjacent time segments, thereby obtaining the waveform rise and fall trend; First, the segmented comparison process acquires voltage time series amplitude data and performs time segmentation according to the physical evolution stages of the contact disconnection process. In the contact erosion state analysis, the entire voltage rise process is divided into the arc initiation stage, oscillation stage, and stabilization stage. The average voltage amplitude within each time segment is calculated, and the change in voltage amplitude between two adjacent time segments is used to determine whether there is an abnormal level jump. If the absolute value of the change exceeds the preset 5-volt reference threshold, it is determined that the voltage in that segment has a violent fluctuation. For example, if the average voltage amplitude of the first segment is 24 volts, and the second segment jumps to 45 volts, the difference between the two is 21 volts, which is greater than the threshold. Then, the voltage evolution trend is calculated based on this change. If the average voltage of the later segment is greater than that of the previous segment, it is marked as an upward trend, and vice versa. This process quantifies and segments the contact energy dissipation, which is the core diagnostic step to determine whether the contact has entered the fault latency period, and obtains the waveform rise and fall trend.

[0026] The direction determination submodule determines the consistency of the change direction of adjacent time segments based on the rise and fall trend of the waveform, associates the direction of continuous time segments, and corresponds to the direction of the trigger sequence to obtain the voltage waveform change when the contact is opened. First, the direction determination process acquires the rising and falling trends of each waveform and starts the logic chain analysis program. The sliding window algorithm is used to determine the consistency of the changing direction of adjacent time segments. When evaluating the mechanical bounce phenomenon of relay contacts, the focus is on monitoring whether there are frequent alternating features of rising and falling in the direction sequence. If the direction reverses for three consecutive segments, that is, the level trend changes from positive to negative and then back to positive, it is determined that the contact has mechanically oscillated. The identified directional features are correlated with the button triggering sequence to ensure that each triggering sequence number corresponds to a specific set of direction vector sequences. For example, the combination of five consecutive segment directions corresponding to the 50th trigger action is defined as a specific contact bounce waveform. By dynamically monitoring the waveform complexity, the health degradation trend of the contact mechanical strength can be perceived in real time, and the voltage waveform change when the contact is opened can be obtained.

[0027] Specifically, such as Figure 2 , 5 As shown, the resistance measurement module includes: The voltage and current acquisition submodule records the voltage waveform changes when the contacts are open based on the sequence of button actions. It acquires the voltage and current during the closing phase of the control panel button contacts, extracts the voltage and current values ​​corresponding to the trigger sequence, and obtains the voltage and current sequence. First, the voltage and current acquisition process is based on the recording of the button action sequence and the voltage waveform changes when the contacts are open. A synchronous acquisition controller is activated. During the dynamic performance evaluation of the contact closure phase, a current transformer and a voltage divider are used to acquire the voltage and current signals at the instant the control panel button contacts close in real time. An internal clock synchronization mechanism ensures that the voltage and current sampling points are aligned at the microsecond level on the time axis. The voltage and current values ​​corresponding to the trigger sequence are extracted from the raw data stream. For example, in the 80th trigger action, when the contact enters the stable closing segment of the oscillating waveform, the extracted voltage value is 23.5 volts and the current value is 0.52 amperes. The extracted voltage and current values ​​are paired according to the trigger sequence to construct a two-dimensional relationship sequence. This synchronous acquisition technology ensures the accuracy of power consumption and thermal effect analysis, providing data support for subsequent assessment of health risks caused by contact resistance overload, resulting in a voltage and current correspondence sequence.

[0028] The change comparison submodule compares the voltage and current changes item by item under the trigger sequence based on the voltage and current corresponding sequence, judges the difference between the voltage change trend and the current change trend, and correlates the voltage and current change difference to obtain the voltage and current change difference. First, the change comparison process acquires the corresponding voltage and current sequences and executes item-by-item comparison logic. In the in-depth diagnosis of contact quality, the slope of voltage change and the slope of current change are compared item by item under the trigger sequence. By calculating the normalized difference, that is, the absolute value of the difference between the voltage slope and the current slope divided by their respective maximum values, the difference between the voltage change trend and the current change trend is determined. If the difference exceeds the preset normalization unit of 0.05, an anomaly is determined. For example, if the voltage rises by 10% in 0.01 seconds, while the current only rises by 2%, this mismatch reflects the presence of a high-resistivity oxide layer on the contact surface. The voltage and current change differences under all trigger sequences are correlated and converted into quantified performance deviation values. This quantitative analysis of trend mismatch is an important means of realizing early fault prediction. It can identify small impedance degradation before obvious faults and obtain the difference in voltage and current changes.

[0029] The state association submodule, based on the difference in voltage and current changes and the voltage waveform change when the contact is open, synchronously compares the direction of the trigger sequence change, associates the change direction with the difference results, determines the continuity of the trigger sequence contact state, and obtains the contact state change results. First, the state association process performs multi-dimensional synchronous comparison based on the difference in voltage and current changes and the voltage waveform change when the contact is disconnected. It correlates the change in the direction of the physical movement of the contact with the difference in electrical characteristics. By executing a logical discrimination program, it analyzes the continuity of the contact state in the trigger sequence. By constructing a logical association matrix, it matches each oscillation peak position with the corresponding voltage and current anomaly point. For example, if the oscillation waveform shows that the contact is in the rebound direction and the voltage and current difference value reaches the peak value at this time, it is determined that the contact is in a critical state of semi-disengagement at this moment. By scanning the full trigger sequence, it calculates the probability of the contact state transitioning from stable to abnormal, records the state migration path of the component from healthy to sub-healthy, provides key basis for constructing a full life cycle archive of health management, and obtains the result of the contact state change.

[0030] Specifically, such as Figure 2 , 6 As shown, the degradation assessment module includes: The waveform matching submodule performs corresponding matching according to the triggering sequence based on the voltage waveform change and the contact state change when the contact is opened. It calls the trigger sequence index value to align the oscillation amplitude sequence and the contact state identifier sequence point by point, and obtains the waveform alignment sequence based on the synchronous alignment relationship associated with the difference between adjacent trigger sequence indices. First, the waveform matching process acquires the voltage waveform change and contact state change results when the contact is opened, and then initiates the data alignment logic. The physical waveform data and electrical state data are matched according to the triggering sequence. The oscillation amplitude sequence and the contact state identifier sequence are aligned point by point using an interpolation algorithm. To ensure alignment accuracy, the offset correction amount of the time axis is calculated based on the difference between the indices of adjacent trigger sequences. For example, if the physical waveform shows the maximum amplitude at index point 500, while the electrical state shows an impedance change at index point 502, the offset correction amount locks these two feature points in the same event window and associates them for synchronous alignment. High-precision alignment ensures the accuracy of fault tracing, enabling health management to accurately locate the physical causes of electrical fluctuations and obtain the waveform alignment sequence.

[0031] The segment determination submodule identifies the oscillation change direction and contact state change segment based on the waveform alignment sequence, calls the oscillation amplitude sign change and contact state jump flag to divide the interval, and divides the time period boundary where anomalies occur simultaneously based on the consistency of the sign in the continuous trigger sequence index to obtain the time period index set where anomalies occur simultaneously. First, the segment determination process is based on the waveform alignment sequence. It executes the determination logic for the oscillation change direction and contact state change segment, calls the oscillation amplitude sign change discriminator and the contact state jump identifier extractor, and divides the aligned sequence into intervals. The boundaries of the time periods when anomalies occur simultaneously are divided according to the consistency of the signs within the continuous trigger sequence index. When the sign of the oscillation amplitude remains constant and the contact state identifier does not change, the sequence segment is defined as a stable interval. Once a sign reversal or state jump is detected, the current index position is immediately recorded as the segment boundary. For example, if the feature remains constant between index 1000 and 1500, then these 500 units are divided into a synchronization segment. By monitoring the duration of the stable interval, the current health margin of the component is quantitatively assessed, and the index set of time periods when anomalies occur simultaneously is obtained.

[0032] The segment association submodule is based on the time period index set where anomalies occur simultaneously. It compares the intervals between segments, calls the segment start and end index difference with the trigger sequence index to make corresponding associations, and identifies continuously associated segments based on the segment interval difference threshold to obtain the stage of abnormal change of the touch point. First, the segment association process, based on the time period index set where anomalies occur simultaneously, executes spatiotemporal comparison logic between segments. It calls the difference between the starting index of the subsequent segment and the ending index of the current segment, and associates it with the global trigger sequence index. Based on the segment interval difference threshold of 80 index units, it identifies continuously associated segments. If the interval difference is less than 80, a merge association operation is performed. For example, if segment A ends at index 2000 and segment B starts at index 2050, since the difference of 50 is less than the threshold of 80, it is determined that these two segments belong to the continuous degradation performance in the same contact closure process. This association logic helps to eliminate non-persistent interference noise and ensures that the fault prediction model only models the real degradation trend to obtain the contact abnormal change stage.

[0033] Specifically, such as Figure 2 , 7 As shown, the lifespan estimation module includes: The range extraction submodule extracts the corresponding trigger sequence range based on the abnormal change stage of the contact point and the change in the contact state of the contact point. It calls the start and end index values ​​of the segment and matches them with the trigger sequence index sequence. It identifies the trigger sequence interval based on the difference in the segment boundary index and obtains the trigger sequence range interval. First, the range extraction process, based on the abnormal change stage of the contact and the change in the contact state of the contact, starts the extraction program for the trigger sequence range. It calls the segment start and end index values ​​and the stored trigger sequence index sequence to perform a reverse lookup. Based on the difference of the segment boundary index, it determines the corresponding trigger operation number range. The starting index of the abnormal change stage is converted into the corresponding operation cycle number. By dividing the index value by the index length corresponding to a single trigger operation, for example, if the starting index is 5000 and a single trigger corresponds to 50 lengths, it is calculated that the phenomenon starts from the 100th trigger action. This range data directly serves the scheduling and maintenance strategy in health management. By accurately predicting the remaining service life through the operation frequency, the trigger sequence range range is obtained.

[0034] The location discrimination submodule analyzes the location and triggering order of the corresponding segment based on the triggering order range, calculates the location by calling the segment center index and the triggering order index, and classifies the interval between segments according to the index offset threshold to obtain the segment interval classification label. First, the location determination process is based on the trigger sequence range. It performs a correspondence analysis between the spatial location of the degraded segment and the trigger sequence, calls the segment center index and the starting index to calculate the relative position offset, determines the distribution characteristics of the degradation phenomenon throughout the entire stroke, and classifies the intervals between segments according to the index offset threshold of 150 index units. For example, if the calculated center index offset of a certain degraded segment is 80 units, it is determined to be located in the edge contact area of ​​the contact point and is assigned a specific edge loss classification label. By determining the location of all segments within the trigger sequence range, it provides a deep perspective on the degree of damage to the physical structure, enhances the accuracy of fault prediction, and obtains the segment interval classification label.

[0035] The sequence segmentation submodule is based on the segment interval classification identifier, and compares it with the trend of the contact state change result. It calls the state change direction sequence and matches and sorts it with the segment classification identifier. According to the trigger order index arrangement relationship, it divides the segment distribution sequence to obtain the contact degradation segment distribution result. First, the sequence segmentation sub-process, based on the segment interval classification identifier, combines the changing trend of the contact state change results to perform the final sequence classification. It retrieves the state change direction sequence and performs various condition matching and sorting with the segment classification identifier. According to the order of triggering time, segments with similar classification identifiers are combined into a continuous evolution sequence. For example, all segments identified as initial mechanical oscillations are classified as the first stage sub-sequence, and segments identified as severe electrical erosion jumps are classified as the final stage sub-sequence. This segmentation logic captures the turning point from quantitative to qualitative change in performance. Through the permutation and combination of the full data, health management can provide maintenance suggestions based on the sub-sequences, including initial monitoring, shortening the self-inspection cycle, preventive maintenance alarms, and mandatory replacement procedures, thereby constructing a closed-loop system for improving operational reliability and obtaining the distribution results of contact degradation segments.

[0036] Please see Figure 8 The control panel testing method is performed based on the aforementioned control panel testing system and includes the following steps: S1: Obtain the power supply voltage of the control panel button contacts, relay contacts, and indicator light circuits; compare the button triggering sequence with the relay contact switching time; and obtain the button action sequence record based on the correspondence between the triggering time point and the switching time difference. S2: Based on the recording of key action sequence, monitor the voltage change at the moment the control panel key contact is opened, compare the voltage changes in segments and determine the direction, the voltage amplitude of the corresponding time segments, judge the consistency of the direction of adjacent segments, and obtain the voltage waveform change when the contact is opened. S3: Based on the recording of the key action sequence and the voltage waveform change when the contact is opened, the voltage and current of the control panel key contact during the closing stage are collected, the voltage and current are calculated accordingly, the voltage and current changes are compared according to the trigger sequence, and the voltage waveform change when the contact is opened is compared to obtain the contact state change result. S4: Based on the voltage waveform change and contact state change results when the contact is disconnected, match them according to the triggering sequence, determine the oscillation change direction and contact state change segment, extract the time period when the abnormality occurs simultaneously in the continuous triggering sequence, compare the segment interval, and correlate the corresponding segment with the triggering sequence to obtain the abnormal change stage of the contact. S5: Based on the abnormal change stage of the contact and the change of the contact state, extract the trigger sequence range, analyze the corresponding segment position and trigger sequence, and obtain the distribution results of the contact degradation segment.

[0037] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A control panel testing system, characterized in that, include: The signal triggering module acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, compares the button triggering sequence with the relay contact switching time, and obtains the button action sequence record based on the switching time difference corresponding to the triggering time point. The oscillation acquisition module records the sequence of button actions, monitors the voltage change at the moment the control panel button contacts are disconnected, compares the voltage changes in segments, determines the voltage amplitude of the corresponding time segments, judges the direction of adjacent segments, and obtains the voltage waveform change when the contacts are disconnected. The resistance measurement module records the voltage waveform changes when the contact is disconnected based on the sequence of button actions, collects the voltage and current during the button closing phase, compares the voltage and current changes, and obtains the result of the contact state change of the contact point. The degradation assessment module, based on the voltage waveform change when the contact is disconnected and the contact state change result, determines the oscillation change direction and contact state change segment according to the trigger sequence, extracts the time period when the abnormality occurs simultaneously, and obtains the abnormal change stage of the contact. The lifespan estimation module extracts the trigger sequence range based on the abnormal change stage of the contact and the change in the contact state of the contact, analyzes the segment location and trigger sequence, and obtains the distribution result of the contact degradation segment.

2. The control panel testing system according to claim 1, characterized in that: The key action sequence record includes key number sequence, trigger timestamp sequence, contact switching delay value, and trigger order sorting label. The voltage waveform change when the contact is disconnected includes voltage fluctuation segment sequence, direction determination indicator, oscillation peak and valley points, and segment duration. The contact contact state change result includes contact resistance value, closed current curve, closed voltage curve, and contact stability parameters. The abnormal change stage of the contact includes degradation initiation segment, degradation duration segment, degradation interval segment, and segment association index. The contact degradation segment distribution result includes segment distribution location sequence, interval classification label, degradation trend type, and life stage division.

3. The control panel testing system according to claim 1, characterized in that: The corresponding switching time difference refers to the time interval when two adjacent states and segments switch; The determination of the direction of adjacent segments refers to judging the directional relationship between movement and change based on the changing trend of adjacent data segments.

4. The control panel testing system according to claim 1, characterized in that: The oscillation direction refers to the current trend direction of the signal during the oscillation process; The contact state change segment refers to the time and data interval corresponding to the transition from one contact state to another.

5. The control panel testing system according to claim 1, characterized in that, The signal triggering module includes: The time acquisition submodule acquires the power supply voltage of the control panel buttons, relay contacts, and indicator light circuits, acquires the button trigger time and relay contact switching time, calculates the time interval between the trigger time and the switching time, compares the time intervals, and obtains the trigger time interval sequence. The sequence comparison submodule analyzes the consistency between the time intervals and the triggering sequence based on the triggering time interval sequence, corresponding to the button triggering time point and the relay contact switching time point, and obtains the triggering sequence correspondence set. The relationship correspondence submodule associates the trigger sequence number with the time interval item by item based on the trigger sequence correspondence relationship set, determines the continuity of the time interval corresponding to the trigger sequence number, and obtains the key action sequence record by matching the trigger sequence number with the time interval.

6. The control panel testing system according to claim 1, characterized in that, The oscillation acquisition module includes: The voltage monitoring submodule records the sequence of button actions, monitors the voltage change process at the moment the control panel button contacts are disconnected, collects the voltage time series corresponding to the trigger sequence, extracts the time nodes of the voltage time series and reads the amplitude to obtain the voltage time series amplitude; The segmented comparison submodule, based on the voltage time series amplitude and the segmented voltage change process time, compares the voltage amplitude of the time segments, determines the difference in the voltage amplitude change amplitude of adjacent time segments, and obtains the waveform rise and fall trend; Based on the rising and falling trend of the waveform, the direction determination submodule determines the consistency of the change direction of adjacent time segments, associates the direction of continuous time segments, and corresponds to the direction of the trigger sequence to obtain the voltage waveform change when the contact is opened.

7. The control panel testing system according to claim 1, characterized in that, The resistance measurement module includes: The voltage and current acquisition submodule records the voltage waveform changes when the contacts are disconnected based on the button action sequence, acquires the voltage and current during the closing phase of the control panel button contacts, extracts the voltage and current values ​​corresponding to the trigger sequence, and obtains the voltage and current corresponding sequence. The change comparison submodule compares the voltage and current changes item by item under the triggering sequence based on the voltage and current corresponding sequence, determines the difference between the voltage change trend and the current change trend, associates the voltage and current change difference, and obtains the voltage and current change difference. The state association submodule, based on the voltage and current change difference and the voltage waveform change when the contact is disconnected, synchronously compares the trigger sequence change direction, associates the change direction and the difference result, determines the continuity of the trigger sequence contact state, and obtains the contact state change result.

8. The control panel testing system according to claim 1, characterized in that, The degradation assessment module includes: The waveform matching submodule performs corresponding matching according to the triggering order based on the voltage waveform change when the contact is open and the contact state change result. It calls the trigger sequence index value to align the oscillation amplitude sequence and the contact state identifier sequence point by point, and obtains the waveform alignment sequence based on the synchronous alignment relationship associated with the difference of adjacent trigger sequence indices. The segment determination submodule, based on the waveform alignment sequence, determines the oscillation change direction and the contact state change segment, calls the oscillation amplitude sign change and contact state jump identifier to divide the interval, and divides the time period boundary where anomalies occur simultaneously according to the consistency of the sign in the continuous trigger sequence index, thus obtaining the time period index set where anomalies occur simultaneously. The segment association submodule, based on the time period index set where anomalies occur simultaneously, compares the intervals between segments, calls the segment start-end index difference with the trigger sequence index to perform corresponding association, and identifies continuously associated segments according to the segment interval difference threshold to obtain the stage of abnormal change of the touch point.

9. The control panel testing system according to claim 1, characterized in that, The lifespan estimation module includes: The range extraction submodule extracts the corresponding trigger sequence range based on the abnormal change stage of the contact point and the change in the contact state of the contact point. It calls the start and end index values ​​of the segment and matches them with the trigger sequence index sequence. It identifies the trigger sequence interval based on the difference in the segment boundary index and obtains the trigger sequence range interval. The location discrimination submodule analyzes the location and triggering order of the corresponding segment based on the triggering order range, calculates the location by calling the segment center index and the triggering order index, and classifies the interval between segments according to the index offset threshold to obtain the segment interval classification identifier. The sequence segmentation submodule compares the segment interval classification identifier with the trend of the contact state change result, calls the state change direction sequence and the segment classification identifier for matching and sorting, and divides the segment distribution sequence according to the trigger order index arrangement relationship to obtain the contact degradation segment distribution result.

10. A method for testing a control panel, characterized in that, The operation of the control panel testing system according to any one of claims 1-9 includes the following steps: S1: Obtain the power supply voltage of the control panel button contacts, relay contacts, and indicator light circuits; compare the button triggering sequence with the relay contact switching time; and obtain the button action sequence record based on the correspondence between the triggering time point and the switching time difference. S2: Based on the recorded sequence of button actions, monitor the voltage change at the moment the control panel button contacts are disconnected, compare the voltage changes in segments and determine the direction, determine the voltage amplitude of the corresponding time segments, judge the consistency of the direction of adjacent segments, and obtain the voltage waveform change when the contacts are disconnected. S3: Based on the sequence of button actions and the voltage waveform changes when the contact is disconnected, collect the voltage and current during the closing phase of the control panel button contact, calculate the voltage and current accordingly, compare the voltage and current changes according to the trigger sequence, and compare them with the voltage waveform changes when the contact is disconnected to obtain the contact state change results. S4: Based on the voltage waveform change when the contact is disconnected and the contact state change result, match them according to the triggering sequence, determine the oscillation change direction and the contact state change segment, extract the time period when the abnormality occurs simultaneously in the continuous triggering sequence, compare the segment interval, and correlate the corresponding segment with the triggering sequence to obtain the abnormal change stage of the contact. S5: Based on the abnormal change stage of the contact point and the change result of the contact point contact state, extract the trigger sequence range, analyze the corresponding segment position and trigger sequence, and obtain the distribution result of the contact point degradation segment.

Images