A multi-dimensional feature fusion-based corner sensor intelligent testing system

Abstract

The application discloses a kind of intelligent test system of corner sensor based on multi-dimensional feature fusion, it is related to sensor intelligent test field, including main control calculation unit, test table, multi-channel pulse capture module and multidimensional electric parameter synchronous sampling module, the main control calculation unit is used to output global timing control instruction and receive fusion data stream to carry out analysis;Test table response control instruction establishes mechanical reference and drives sensor rotation output dynamic electric signal, respectively collect pulse time stamp and transient electrical characteristic parameter in the same time window, pulse time sequence dynamic mapping is absolute space angle sequence, multidimensional determination pulse distortion root and sensor electrical performance, the present application is by microsecond level synchronous sampling, space-time domain dynamic mapping algorithm and multi-dimensional feature fusion, it has solved the problems, such as time sequence correlation loss in traditional test, fault tracing is difficult, low degree of automation, realized the comprehensive test of high-precision, intelligent, visualized corner sensor.

Description

Technical Field

[0001] This invention relates to the field of intelligent sensor testing, specifically to an intelligent testing system for corner sensors based on multi-dimensional feature fusion. Background Technology

[0002] With the rapid development of automotive electronics and intelligent driving technologies, steering sensors, as key components in vehicle stability control, steer-by-wire, and autonomous driving perception systems, directly affect the vehicle's handling safety and control accuracy. Therefore, conducting high-precision, high-efficiency, and multi-dimensional testing and verification of steering sensors during research and development and production has become a necessary means to ensure their reliability.

[0003] Traditional angle sensor testing equipment often employs a single-channel pulse acquisition method. Limited by sampling frequency and synchronization mechanisms, it struggles to achieve high-precision capture of multi-phase pulse signal edges, leading to phase information loss and timing discrepancies, thus affecting the accuracy and consistency of angle calculations. Furthermore, traditional systems typically separate pulse signal acquisition from electrical parameter measurement, lacking a synchronization mechanism. This makes it difficult to accurately determine whether pulse distortion is caused by abnormal mechanical motion or fluctuations in electrical characteristics, resulting in weak tracing capabilities.

[0004] Regarding testing processes, existing equipment generally suffers from low automation, limited information dimensions in human-machine interfaces, and weak data visualization capabilities, making it difficult to meet diverse needs ranging from laboratory micro-verification to production line batch testing. In particular, the lack of effective hardware-level emergency control and closed-loop intervention mechanisms in anomaly handling and safety protection poses certain testing risks. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent testing system for steering wheel angle sensors based on multi-dimensional feature fusion. This system aims to solve the technical problems existing in traditional steering wheel angle sensor testing equipment, such as the loss of timing correlation caused by low pulse sampling accuracy, difficulty in locating the root cause of signal distortion due to single pulse acquisition, and the single data dimension and low degree of automation of the test interface. In this way, it provides a comprehensive testing solution covering mechanical closed loop, high-frequency microsecond-level synchronous sampling, multi-dimensional feature tracing and diagnosis, and intelligent visualization interaction.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent testing system for an angle sensor based on multi-dimensional feature fusion, which constructs a hardware closed loop and data analysis link from mechanical execution to multi-dimensional signal sampling, mainly including a main control computing unit, and an automatic clamping and positioning mechanism, a rotation drive mechanism, a multi-channel high-frequency synchronous pulse acquisition module, and a multi-dimensional electrical parameter synchronous sampling module that are connected to it in communication.

[0007] The automatic clamping and positioning mechanism responds to the instructions of the main control computing unit and uses the pneumatic system to provide power to the locking device in order to complete the clamping, positioning and automatic release of the sensor under test.

[0008] The rotary drive mechanism is coaxially linked with the sensor in the locked state, driving it to rotate forward and backward at a preset rate to generate dynamic electrical signals.

[0009] A hardware-level synchronous triggering link is established between the multi-channel high-frequency synchronous pulse acquisition module and the multi-dimensional electrical parameter synchronous sampling module. The pulse acquisition module embeds an edge-high-frequency tracking algorithm to scan each input channel in parallel at a set high-frequency sampling rate, extracting the high and low level transition edges of the multi-phase pulse signal and generating timestamps. Simultaneously, it sends a clock synchronization signal to the electrical parameter sampling module, forcing it to acquire corresponding transient electrical characteristic parameters, such as high and low level voltages and static operating current, within the same microsecond-level time window. The data acquired by both are aligned according to a common clock stamp, generating a spatiotemporal fused data stream and reporting it to the main control computing unit.

[0010] The main control computing unit has an embedded pulse spatiotemporal domain mapping engine. The specific logic of this engine is as follows: it extracts a complete pulse time length of a standard phase, such as phase B, from the spatiotemporal fusion data stream and forcibly calibrates it to a 360° reference value. Then, based on this, it calculates the proportion of the actual pulse time length of the other phases and dynamically converts the pulse width signal in the time dimension into an absolute spatial angle sequence, thereby outputting the high and low level pulse width angles and phase differences between phases for each phase.

[0011] Based on the above conversion, the system establishes a linkage diagnostic model of "spatial angle-transient electrical parameters". Combined with the synchronously acquired electrical characteristic parameters, it determines the pulse signal distortion from multiple dimensions, such as frame loss and width anomalies, whether they are caused by mechanical motion jamming or electrical anomalies such as power supply level jitter.

[0012] Preferably, the multi-channel pulse capture module is embedded with an edge high-frequency tracking algorithm unit. After receiving the enable signal from the main control computing unit, the edge high-frequency tracking algorithm unit independently and in parallel scans each input channel at a set high-frequency sampling rate, and captures the physical level flipping action of each phase pulse signal in real time, so as to ensure the absolute correlation and accuracy of the multi-phase pulse timing at the physical level before the spatial angle is converted.

[0013] Preferably, the multi-dimensional electrical parameter synchronous sampling module includes an analog-to-digital converter array and a timing latch unit. When the timing latch unit receives the clock synchronization signal from the pulse capture module, it immediately triggers the analog-to-digital converter array to perform a sample-and-hold operation, thereby achieving a strong binding between the electrical parameter sampling time and the pulse edge capture time and eliminating asynchronous errors caused by software and hardware communication delays.

[0014] Preferably, the transient electrical characteristic parameters include the high and low level output voltages of the multiphase pulse signal and the dynamic power supply voltage of the device. The main control calculation unit establishes a linkage diagnostic model between spatial angle and transient voltage based on the mapped feature fitting results. When frame loss or width abnormality of the pulse signal under the spatial angle is detected, the transient voltage feature matched at that moment is called to determine the cause of the abnormality.

[0015] Preferably, the main control computing unit is also equipped with a dynamic visualization interactive rendering engine. The interactive rendering engine continuously reads the parsed spatiotemporal fusion data stream, uses a multi-threading mechanism to convert the data point series into waveform curve data structures and pushes them to the user interface. At the same time, the engine listens to the user's interface interaction commands and dynamically adjusts the rendering ratio of the time axis and amplitude axis to achieve microscopic traceability of signal level uniformity.

[0016] Preferably, the main control computing unit is configured with automated state machine control logic, which is programmed to automatically flow through the following steps in a time-dependent manner:

[0017] The system outputs a positioning command to confirm that the locking is ready, controls the power supply to connect the sensor under test and verifies the static reference current, triggers the rotation drive mechanism to rotate forward and enables the synchronous capture and sampling module, triggers reverse rotation and continuous sampling, stops the rotation mechanism, cuts off the power supply and outputs a release command to the test bench.

[0018] Preferably, the main control computing unit is also equipped with a loop traversal and abnormal intervention module that interacts with the closed-loop control logic of the automated state machine. In the loop test mode, when a single state machine cycle ends and the test fails, the module triggers an abnormal alarm of the physical status indicator light according to a preset strategy, and can selectively suspend the next state machine cycle, waiting for manual intervention confirmation.

[0019] Preferably, a safety linkage control loop with a priority higher than that of the main control computing unit is also included. The safety linkage control loop is equipped with a physical emergency stop trigger terminal. When it is triggered, the loop directly cuts off the power supply link of the sensor under test at the physical level and disconnects the power to the rotary drive mechanism. At the same time, the loop blocks the release execution logic of the automatic clamping and positioning mechanism to ensure that the sensor under test will not be damaged due to loosening in the abnormal shutdown state.

[0020] In summary, the beneficial effects of this invention are:

[0021] 1. Breaking through the bottleneck of traditional sampling and achieving microsecond-level timing fidelity: Through an independent multi-channel high-frequency edge capture algorithm, the problem of pulse edge ambiguity caused by traditional single / dual-phase acquisition is solved, ensuring the absolute correlation of multi-phase pulse timing at the physical level and greatly improving the calculation accuracy of rotation angle and phase difference.

[0022] 2. Constructing a "pulse-electrical parameter" fusion model to deepen fault diagnosis: This breaks through the previous pain point of separating pulse acquisition and electrical parameters. By aligning the two within a microsecond window through a hardware-level synchronous triggering link, the system can accurately pinpoint and trace the root physical cause of pulse signal distortion through minute fluctuations in transient voltage or current.

[0023] 3. Pioneering spatiotemporal dynamic mapping algorithm to eliminate time dimension dependence: The specific pulse time period is dynamically calibrated as a spatial angle reference, so that the system is not affected by absolute speed fluctuations and directly outputs intuitive physical angle values, improving the robustness of data processing.

[0024] 4. Oscilloscope-level microscopic interaction and full-scene automation coverage: The waveform rendering engine gives operators strong data insight; at the same time, from one-click pneumatic clamping and state machine automatic testing flow to abnormal cycle intervention, it fully covers application scenarios from in-depth microscopic verification in R&D laboratories to mass aging tests on production lines, greatly improving testing efficiency. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the operation flow structure of an intelligent testing system for corner sensors based on multi-dimensional feature fusion according to the present invention.

[0027] Figure 2 This is a schematic diagram of the hardware structure of an intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to the present invention.

[0028] Figure 3 This is a schematic diagram of the parameter setting interface of an intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to the present invention.

[0029] Figure 4 This is a schematic diagram of the test piece installation for an intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to the present invention.

[0030] Figure 5This is a schematic diagram of the test piece locking mechanism of an intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to the present invention.

[0031] Figure 6 This is a schematic diagram showing the successful test pop-up interface of the intelligent testing system for corner sensors based on multi-dimensional feature fusion according to the present invention.

[0032] Figure 7 This is a schematic diagram showing the test failure pop-up interface of the intelligent testing system for corner sensors based on multi-dimensional feature fusion according to the present invention.

[0033] The labels in the attached diagram are as follows: 1. Test bench; 2. Test button; 3. Emergency stop button; 4. Indicator light; 5. PC interface. Detailed Implementation

[0034] The present invention will now be described in further detail with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0035] To facilitate understanding of the present invention, a more complete description of the invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of the invention will be more thorough and complete.

[0036] All features disclosed in this specification, or all steps in all disclosed methods or processes, may be combined in any way, except for mutually exclusive features and / or steps.

[0037] Any feature disclosed in this specification (including any appended claims, abstract, and drawings) may be replaced by other equivalent or similar features for a similar purpose, unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is merely one example of a series of equivalent or similar features.

[0038] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of at least two elements or the interaction relationship of at least two elements, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0039] Please see Figure 1 - Figure 7 The present invention provides an embodiment of an intelligent testing system for corner sensors based on multi-dimensional feature fusion. The system physically includes an industrial control computer (PC), a high-precision turntable, a pneumatic system, a signal acquisition module, etc., and its logical architecture constructs a tight hardware closed loop and data analysis link.

[0040] Specifically, the industrial control computer acts as the main control computing unit of the system and serves as the interactive scheduling hub. The pneumatic system and its end clamp constitute an automatic clamping and positioning mechanism. The drive motor and transmission shaft inside the high-precision turntable constitute a rotary drive mechanism. In the signal link, the signal acquisition module is internally divided into a multi-channel high-frequency synchronous pulse acquisition module and a multi-dimensional electrical parameter synchronous sampling module that communicate with each other. The main control computing unit drives the rotary drive mechanism by issuing motion control commands, which excites the sensor under test to generate dynamic electrical signals. The data is then captured and transmitted back by the two sampling modules, forming a complete interactive closed loop of "control-excitation-acquisition-feedback".

[0041] This embodiment breaks through the technical bottleneck of separate sampling of pulses and voltage / current in traditional test benches, and achieves microsecond-level hardware interaction synchronization. Specifically:

[0042] High-frequency pulse capture: During the operation of the rotary drive mechanism, the edge high-frequency tracking algorithm unit within the multi-channel high-frequency synchronous pulse capture module independently and in parallel scans the connected A, B, and C three-phase signal lines at a high-frequency sampling rate of 2MHz. This unit captures the physical level switching action in real time, recording timestamps accurate to ±0.1μs, and the synchronization error between channels is strictly suppressed to within 1μs.

[0043] Hard-wired synchronous triggering: At the moment the timestamp is generated, the pulse capture module sends a high-level trigger pulse to the timing latch unit in the multi-dimensional electrical parameter synchronous sampling module through the synchronous triggering link of the underlying hardware.

[0044] Transient Electrical Parameter Holding: Upon receiving the trigger signal, the timing latch unit immediately controls its internal 16-bit high-precision analog-to-digital converter (ADC) to perform sample-and-hold. This ensures that within the same microsecond-level time window for determining the pulse edge, with a time deviation ≤2μs, the transient output voltage of 0-5V with an accuracy of ±0.01V, the device power supply voltage of 12-24V with an accuracy of ±0.05V, and the operating current with an accuracy of ±0.001A are simultaneously acquired. Finally, the pulse timestamp and electrical parameters are packaged into a spatiotemporal fusion data stream with a common clock reference and reported to the main control computing unit via serial port.

[0045] After receiving the spatiotemporal fusion data stream, the main control computing unit uses its embedded pulse spatiotemporal domain mapping engine to perform data stripping and spatiotemporal transformation interactions, specifically including:

[0046] Dynamic Dimension Mapping: Due to the slight fluctuations in the actual rotation speed of the turntable caused by the acquisition of timestamps, the engine extracts a complete pulse duration of a standard phase (such as phase B) from the data stream and forces it to be mapped and calibrated to a 360° absolute physical space angle at the algorithm layer. Subsequently, using this duration as the denominator, the time proportion of the high and low level durations of the other phases (phases A and C) is calculated, thereby dynamically converting the time dimension into a spatial angle sequence (i.e., the pulse width angle and the phase difference angle between phases B and C).

[0047] Linked source tracing and diagnosis: After completing the spatiotemporal mapping, the main control computing unit establishes a linked diagnostic model of "spatial angle - transient voltage / current". For example, when the mapping engine detects a narrow pulse (frame drop or jitter) with a pulse width different from the 360° proportion at a certain spatial angle, the main control program will automatically retrieve the transient power supply voltage and current data bound to that timestamp. If the voltage is stable but the pulse width is abnormal, it can be diagnosed as a defect in the sensor's internal optical / magnetic encoder or a mechanical jam in the turntable; if it is accompanied by a transient voltage drop, it can be accurately determined to be caused by external electrical power supply jitter, greatly improving the accuracy of fault diagnosis.

[0048] To meet the needs of factory verification and mass production, this embodiment features a fully automated interactive design for the testing process.

[0049] Automated state machine control: The main control computing unit embeds an automated state machine control module. When the test starts, the main control computing unit first sends a level command to the automatic clamping and positioning mechanism, specifically the solenoid directional valve, to conduct the 8mm pneumatic hose with a working air pressure of 0.4MPa, driving the controlled cylinder to extend and complete the clamping and positioning.

[0050] Subsequently, the state machine proceeds in sequence: powering on the sensor — verifying the static reference current (e.g., set to 8mA±5mA) — driving the motor to rotate forward and enabling synchronous capture — driving the motor to rotate in reverse and enabling synchronous capture — stopping the motor — cutting off the power and driving the cylinder to retract and unlock.

[0051] Hardware-level safety linkage: A red emergency stop trigger is located on the physical operation panel of the test bench. This structure constitutes a hardware-level safety linkage control loop, with a higher logical priority than the main control software. When an abnormal noise occurs on the turntable and the emergency stop is pressed, this loop directly cuts off the 12-24V power supply to the sensor and applies a brake to the motor. Simultaneously, this loop forcibly cuts off the release signal of the electromagnetic reversing valve, maintaining a locking force of 0.4MPa in the cylinder to prevent the sensor from being thrown out and injuring people due to the high inertia of the emergency stop. The lock can only be released by manually rotating the emergency stop button clockwise and pressing the green reset button.

[0052] Dynamic Visualization Interaction: The main control computing unit's software is equipped with a dynamic visualization interaction rendering engine. This engine utilizes multi-threading technology to reconstruct the pulse transition points received from the front end into real-time dynamic waveform curves of phases A, B, and C while performing spatiotemporal mapping in the background. Operators can dynamically adjust the rendering scale of the time axis using the mouse wheel and dragging actions, and microscopically magnify and examine the level uniformity before and after a specific pulse, just like operating an oscilloscope.

[0053] Looping Intervention: For product aging tests, the system provides a looping and anomaly intervention module. Users can set the number of loops, and the state machine will automatically repeat the above test loop. When the phase difference or pulse width output by the "spatiotemporal mapping engine" exceeds the tolerance range in a single loop, this module will intervene immediately: illuminating the red warning light among the three-color indicator lights on the top of the test bench, displaying an interactive dialog box on the screen containing details of failed tests, and saving the spatiotemporal fusion data stream of that test to a local .bin file for later retrieval and analysis.

[0054] In this embodiment, the overall testing process is as follows:

[0055] S1: Connect the test piece to the signal interface of the test bench: Connect the power supply cable and signal output cable of the test piece to the corresponding adapter interface of the test bench, ensuring a secure and tight connection to avoid abnormal signal transmission. Then, place the test piece as described above. Figure 4 The test piece must be correctly installed in the position shown on the automatic clamping and positioning mechanism. If the test piece is not placed in the groove, the locking device will not rotate properly, resulting in deviations in the test results. Figure 5 It is in normal working condition;

[0056] S2: Click on the parameter settings in the upper left corner of the system interface, for reference. Figure 3Configure the parameters as required. After completion, click "Save" and exit the parameter setting interface. The system loads the factory default configuration upon first startup, which meets most testing needs. It is not recommended to modify it unless necessary. After setting the parameters, press the test button 2 on the operation panel on the front of the test bench to start the test. If abnormal noise from the turntable, loose test piece, or abnormal signal is found during the test, immediately press the red emergency stop button. The equipment will immediately cut off the power supply to the test piece and forcibly stop the subsequent test steps. After troubleshooting, rotate the emergency stop button clockwise to pop it out and reset it. Then press the green reset button below to return to the standby state. If the emergency stop button does not reset, the reset button below will be invalid.

[0057] S3: After the test is completed, the power supply to the test piece is disconnected from the test bench, the locking device is reset, and indicator light 4 illuminates. The status of the indicator lights on the test bench will reflect the test result.

[0058] Test passed: Signal light turns green; Test failed: Signal light turns red.

[0059] At the same time, the system will automatically pop up a test result window, which will intuitively display the final judgment of this test, success / failure, and list the pass status of all test items in the forward and reverse rotation tests:

[0060] Test passed: A pop-up window displays "Test successful." This pop-up will close automatically after 10 seconds by default. You can also click the "OK" button to close it manually. Figure 6 As shown;

[0061] Test Failure: A pop-up window displays a test failure message, clearly indicating the failed test items, such as... Figure 7 As shown;

[0062] S4: After the pop-up window is closed, the PC interface will simultaneously display the real-time waveforms and detailed test data of the A, B, and C phase pulse signals in this test, including core indicators such as static operating current, pulse width, and phase difference, which will facilitate operators to trace and analyze the performance of the test piece.

[0063] After completing the test, disconnect the power supply and signal output cables between the test piece and the test bench. Remove the test piece from the locking device and place it in the designated storage area. After each test, wipe the locking device and turntable surface with a clean, lint-free cloth to keep the equipment clean and prevent dust accumulation from affecting accuracy.

[0064] To better illustrate this embodiment, the present invention also provides a specific operational example.

[0065] At the end of the production line, the operator needs to conduct a full factory inspection on a batch of newly assembled steering wheel angle sensors that are "12V powered and output A / B / C three-phase pulses".

[0066] Step 1: One-click clamping and initialization

[0067] The operator places the sensor under test into the custom recess on the test bench and presses the green test button 2 on the physical control panel.

[0068] Upon receiving the instruction, the main control computing unit immediately controls the solenoid directional valve to operate. Compressed air at 0.4 MPa drives the cylinder through an 8 mm pneumatic hose, instantly locking the tooling and firmly fixing the sensor in place, eliminating mechanical backlash. The software interface status bar switches to "Position Locked".

[0069] Step 2: Static Electrical Characteristics Verification

[0070] The main control computing unit controls the power supply module to output a 12.00V DC voltage to the sensor.

[0071] The 16-bit ADC chip inside the multi-dimensional electrical parameter synchronous sampling module quickly reads the static loop current. The current static operating current is measured to be 8.2mA (within the preset acceptable range of 8mA±5mA). The corresponding test item is marked in green on the software interface, and the status enters the next stage.

[0072] Step 3: Dynamic rotational excitation and microsecond-level synchronous capture

[0073] The turntable motor starts, driving the sensor's central shaft to rotate clockwise at a preset speed. The sensor then begins to output three-phase pulses (A, B, and C).

[0074] The multi-channel high-frequency synchronous pulse acquisition module scans the three-phase signal lines in parallel at a frequency of 2MHz. At a certain moment, the module captures the rising edge of phase A transitioning from low to high level and timestamps it T1. 1μs later, the electrical parameter sampling module is hard-wired synchronously triggered, and the transient output voltage of phase A at this time is measured to be 4.98V, which meets the high-level requirement.

[0075] Step 4: Spatiotemporal mapping and calculation

[0076] After the sensor completes its forward and reverse rotation, the "spatiotemporal fusion data stream" with timestamps is packaged and sent to the main control program.

[0077] The pulse spatiotemporal mapping engine begins operation: the system extracts a complete pulse cycle of phase B, assuming its absolute time length is measured to be 50.00ms at the underlying layer. The system then forcibly calibrates this 50.00ms as a 360° spatial reference.

[0078] The system then measures the duration of the high level of phase A within that cycle, assuming it to be 22.50ms. The engine automatically calculates the time percentage: (22.50ms / 50.00ms)*360°=162.00°.

[0079] The system compared the calculated 162.00° with the preset standard parameters, which were within the allowable error range; similarly, the forward BC phase difference was calculated to be 67.50°. All angle and pulse width parameters were qualified.

[0080] Step 5: Visual Rendering and System Reset

[0081] The dynamic visualization and interactive rendering engine on the PC interface smoothly renders the tens of thousands of data points that were just collected into three square wave curves, A, B, and C, each with a distinct color. When the operator scrolls the mouse wheel, the waveforms zoom in instantly, clearly showing that the pulse edges are free of any glitches.

[0082] A large green pop-up window appeared in the center of the screen saying "Test successful," and at the same time, the three-color indicator light on the top of the test platform lit up green.

[0083] The main control unit cuts off the 12V power supply to the sensor, the solenoid reversing valve depressurizes, the cylinder retracts, the sensor unlocks, the operator removes the good product, and prepares to test the next one.

[0084] If an error occurs in step 4 above:

[0085] Pulse mapping anomaly: During data analysis of a certain inversion test, the spatiotemporal mapping engine discovered an abnormally shortened high-level pulse width time in phase C when calculating the 45th pulse cycle. After conversion based on phase B's 50.00ms (360°), the high-level pulse width angle of phase C was only 85.00°, significantly lower than the standard of approximately 153°, and the system immediately determined that this test had failed.

[0086] Step 5A: Multi-dimensional feature linkage for source tracing

[0087] Traditional testing benches would only report a "pulse width error" at this stage, forcing operators to discard the sensor. However, the main control computing unit of this system immediately activated the linkage diagnostic model.

[0088] The system retrieves the "transient electrical characteristic parameters" for the tens of milliseconds during the high-level period of phase C when the abnormal pulse occurs.

[0089] Data shows that within this microsecond-level time window, the device's power supply voltage dropped instantly from a stable 12.00V to 7.50V before recovering.

[0090] The system provides an intelligent diagnostic conclusion: the narrowing of the C-phase pulse is not due to damage to the magnet or Hall chip inside the sensor, and there is no abnormality in the physical structure. Rather, it is due to a momentary poor contact at the power supply interface of the test bench caused by the operator's excessive force during the last plugging and unplugging, resulting in an external electrical abnormality.

[0091] A red "Test Failed" window pops up on the screen, and the three-color indicator lights up red. However, the waveform graph will highlight the trough of the power supply voltage drop with a bright red box, prompting the engineer to prioritize checking the wiring harness connection.

[0092] The above description is merely a specific embodiment of the invention, but the scope of protection of the invention is not limited thereto. Any variations or substitutions conceived without inventive effort should be included within the scope of protection of the invention. Therefore, the scope of protection of the invention should be determined by the scope defined in the claims.

Claims

1. An intelligent testing system for an angle sensor based on multi-dimensional feature fusion, characterized in that: include: Main control computing unit: used to output global timing control commands and receive the fused data stream returned from the underlying layer for linkage measurement and analysis; Test bench: In response to the control command, it establishes a stable mechanical ground and position reference required for the test, and dynamically rotates the sensor under test to synchronously output dynamic electrical signals; Multi-channel pulse acquisition module and multi-dimensional electrical parameter synchronous sampling module: In response to the dynamic electrical signal, the multi-channel pulse acquisition module tracks the high and low level transition edges of the multi-phase pulse signal in real time and generates a timestamp, while the multi-dimensional electrical parameter synchronous sampling module collects the corresponding transient electrical characteristic parameters within the same time window; the data collected by the two are aligned and packaged according to a common clock stamp to generate a spatiotemporal fusion data stream and are reported to the main control computing unit in real time. Pulse Spatiotemporal Domain Mapping Engine: Embedded in the main control computing unit, it is configured to parse the spatiotemporal fusion data stream, use the pulse time period of a specific phase in the data stream as a dynamic spatial conversion ruler, dynamically map the timestamp sequence of the extracted multiphase pulse signal into an absolute spatial angle sequence, and perform feature fitting between the spatial angle sequence and the transient electrical characteristic parameters according to the timestamp alignment relationship in the data stream, and determine the root cause of pulse signal distortion and the electrical performance of the sensor in multiple dimensions; The specific interaction logic of the pulse spatiotemporal mapping engine includes the following steps: The system dynamically extracts the complete pulse duration of any standard phase in the spatiotemporal fusion data stream and forcibly calibrates it to a 360° reference value. Using this reference value as the denominator and the actual duration of the pulse output of the other phases as the numerator, it calculates the proportion of each phase, thus eliminating the limitations of absolute time dimensions and converting the high and low level pulse width angle values ​​and phase difference angle values ​​of each phase.

2. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 1, characterized in that: The multi-channel pulse capture module is embedded with an edge high-frequency tracking algorithm unit. After receiving the enable signal from the main control computing unit, the edge high-frequency tracking algorithm unit independently and in parallel scans each input channel at a set high-frequency sampling rate, and captures the physical level flipping action of each phase pulse signal in real time, so as to ensure the absolute correlation and accuracy of the multi-phase pulse timing at the physical level before the spatial angle is changed.

3. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 2, characterized in that: The multidimensional electrical parameter synchronous sampling module includes an analog-to-digital converter array and a timing latch unit. When the timing latch unit receives a clock synchronization signal from the pulse capture module, it immediately triggers the analog-to-digital converter array to perform a sample-and-hold operation, thereby achieving a strong binding between the electrical parameter sampling time and the pulse edge capture time and eliminating asynchronous errors caused by software and hardware communication delays.

4. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 3, characterized in that: The transient electrical characteristic parameters include the high and low level output voltages of the multiphase pulse signal and the dynamic power supply voltage of the equipment. The main control computing unit establishes a linkage diagnostic model between spatial angle and transient voltage based on the mapped feature fitting results. When frame loss or width anomalies are detected in the pulse signal under the spatial angle, the transient voltage characteristics matched at that moment are called to determine the cause of the anomaly.

5. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 1, characterized in that: The test bench includes an automatic clamping and positioning mechanism and a rotary drive mechanism; The automatic clamping and positioning mechanism responds to the positioning trigger command of the main control computing unit, and activates and locks the sensor under test; The rotary drive mechanism is controlled by the motion control command of the main control computing unit and is mechanically linked with the sensor under test in the locked state to drive it to rotate dynamically in both directions at a preset rate and stroke.

6. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 5, characterized in that: The main control computing unit is also equipped with a dynamic visualization interactive rendering engine. The interactive rendering engine continuously reads the parsed spatiotemporal fusion data stream, uses a multi-threading mechanism to convert the data point series into waveform curve data structures and pushes them to the user interface. At the same time, the engine listens to the user's interface interaction commands and dynamically adjusts the rendering ratio of the time axis and amplitude axis to achieve microscopic traceability of signal level uniformity.

7. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 6, characterized in that: The main control computing unit is configured with automated state machine control logic, which is programmed to automatically flow through the following steps in a time-dependent manner: The system outputs a positioning command to confirm that the locking is ready, controls the power supply to connect the sensor under test and verifies the static reference current, triggers the rotation drive mechanism to rotate forward and enables the synchronous capture and sampling module, triggers reverse rotation and continuous sampling, stops the rotation mechanism, cuts off the power supply and outputs a release command to the test bench.

8. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 7, characterized in that: The main control computing unit is also equipped with a loop traversal and abnormal intervention module that interacts with the closed-loop control logic of the automated state machine. In the loop test mode, when a single state machine cycle ends and the test fails, the module triggers an abnormal alarm of the physical status indicator light according to a preset strategy, and can selectively suspend the next state machine cycle, waiting for manual intervention confirmation.

9. The intelligent testing system for an angle sensor based on multi-dimensional feature fusion according to claim 1, characterized in that: It also includes a safety linkage control loop with a priority higher than the timing of the main control computing unit. The safety linkage control loop is equipped with a physical emergency stop trigger terminal. When it is triggered, the loop directly cuts off the power supply link of the sensor under test at the physical level and cuts off the power to the rotary drive mechanism. At the same time, the loop blocks the release execution logic of the automatic clamping and positioning mechanism to ensure that the sensor under test will not be damaged due to loosening in the abnormal shutdown state.

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