An inspection device and method for flexible production of tunneling machine electrical control boxes

Abstract

This invention discloses an inspection device and method suitable for the flexible production of tunneling machine electrical control boxes. The inspection device includes a human-machine interface terminal, a signal generating device, and an output detection device. The inspection method includes the following steps: S1, connecting the human-machine interface terminal, the signal generating device, the electrical control box under test, and the output detection device; S2, the human-machine interface terminal selects the output circuit to be tested; S3, the human-machine interface terminal sends a test command to the signal generating device according to the output circuit under test; S4, the signal generating device simulates the corresponding input signal according to the test command and sends it to the electrical control box under test; S5, after receiving the input signal, the electrical control box under test drives the output circuit under test to perform an action; S6, the output detection device detects and judges the output state of the output circuit under test and obtains the test result; S7, the output detection device feeds back the test result to the human-machine interface terminal, and the human-machine interface terminal displays the test result.

Description

Technical Field

[0001] This invention relates to the field of tunneling machine electrical control systems, and more particularly to an inspection device and method suitable for the flexible production of tunneling machine electrical control boxes. Background Technology

[0002] Currently, during production testing, the electrical control box of a tunneling machine typically requires connection to the control box, remote control, and some peripheral equipment before the input / output circuits can be verified. However, the following problems exist in actual production: 1. Production lines typically lack a complete real-world environment for the tunneling machine, making it impossible to establish a complete control chain; 2. Different customers may have different definitions of the output circuit function, but the internal output hardware structure of the electrical control box is basically the same. 3. The functions of the customized control boxes and remote controls vary greatly, and some output circuits cannot be directly controlled by the actual operating equipment; 4. Testing some output circuits requires manual intervention by engineers through programming equipment, resulting in engineers spending a lot of time on repetitive testing work; 5. The electrical control box has complex wiring and a large number of output channels, which can easily lead to problems such as incorrect wiring, missing connections, short circuits, and cross-wiring. 6. Traditional testing methods are difficult to meet the flexible production requirements of tunneling machine electrical control boxes.

[0003] Therefore, there is a need for a flexible production inspection device and method that can be used to perform unified testing of the output circuit of the electrical control box, without being limited to the actual environment of the tunneling machine or the actual customer's peripheral equipment. Summary of the Invention

[0004] The purpose of this invention is to address the above-mentioned problems by providing an inspection device and method for the flexible production of electrical control boxes for tunneling machines, which is simple in structure, convenient in operation, and improves the inspection efficiency of electrical control boxes.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: An inspection device suitable for the flexible production of tunneling machine electrical control boxes includes a human-machine interface terminal for sending test commands and displaying test results, a signal generating device for generating analog input signals, and an output detection device for detecting the status of the output circuit. The signal output terminal of the human-machine interface terminal is connected to the signal input terminal of the signal generating device, the signal output terminal of the signal generating device is connected to the signal input terminal of the electrical control box under test, the signal output terminal of the electrical control box under test is connected to the signal input terminal of the output detection device, and the signal output terminal of the output detection device is connected to the signal input terminal of the human-machine interface terminal.

[0006] Furthermore, the testing device also includes a wiring adapter module, through which the signal input terminal of the electrical control box under test is connected to the signal output terminal of the signal generating device, and through which the signal output terminal of the electrical control box under test is connected to the signal input terminal of the output testing device.

[0007] Furthermore, the signal generating device includes an operation box signal simulation module for simulating operation box input signals, a remote control signal simulation module for simulating remote control input signals, an interlocking state simulation module for simulating interlocking state input signals, and a safety circuit simulation module for simulating safety circuit input signals. The signal input terminals of the operation box signal simulation module, remote control signal simulation module, interlocking state simulation module, and safety circuit simulation module are all connected to the signal output terminal of the human-machine interface terminal, and the signal output terminals of the operation box signal simulation module, remote control signal simulation module, interlocking state simulation module, and safety circuit simulation module are all connected to the signal input terminal of the electrical control box under test.

[0008] Furthermore, the output detection device includes a voltage detection module, a current detection module, a digital signal acquisition module, an opto-isolation detection module, an output load module, a relay detection module, and a status indication module. The signal input terminals of the voltage detection module, current detection module, digital signal acquisition module, opto-isolation detection module, output load module, relay detection module, and status indication module are all connected to the signal output terminals of the electrical control box under test. The signal output terminals of the voltage detection module, current detection module, digital signal acquisition module, opto-isolation detection module, output load module, relay detection module, and status indication module are all connected to the signal input terminals of the human-machine interface terminal.

[0009] A testing method applicable to the flexible production of tunneling machine electrical control boxes includes the following steps: S1. Connect the human-machine interface terminal, signal generating device, electrical control box under test, and output detection device with wiring; S2. Select the output circuit to be tested using the human-computer interaction terminal; S3. The human-machine interface terminal sends a test command to the signal generating device according to the output circuit to be tested. S4. The signal generating device simulates the corresponding input signal according to the test command and sends it to the electrical control box under test; S5. After receiving the input signal, the control box under test drives the output circuit under test to perform an action. S6. The output detection device detects and judges the output status of the output circuit to be tested and obtains the detection result. S7. The output testing device feeds back the test results to the human-machine interface terminal. The human-machine interface terminal displays the test results of the output circuit to be tested based on the test results and determines whether to perform the test operation of the next output circuit. If the test operation of the next output circuit is to be performed, steps S1 to S8 are repeated. If the test operation of the next output circuit is not performed, the process ends.

[0010] Furthermore, step S6 specifically includes the following steps: S61. The output detection device determines whether the output state of the output circuit to be tested is detected. If yes, proceed to the next step; otherwise, proceed to step S64. S62. Determine if there are other circuits outputting simultaneously in the output circuit under test. If yes, it is determined to be a cross-connection fault, and the test result is output; otherwise, proceed to the next step. S63. Determine whether the voltage and current of the output circuit under test are normal. If they are normal, the output is considered normal and the test result is output. If they are not normal, the output is considered abnormal and the test result is output. S64. Detect whether there is a short circuit in the output circuit under test. If so, it is judged as a short circuit fault and the detection result is output; if not, it is judged as a missing connection fault and the detection result is output.

[0011] Compared with the prior art, the advantages and positive effects of this invention are: This invention provides a closed-loop production testing fixture for flexible production scenarios of tunnel boring machine (TBM) electrical control boxes. Through a closed-loop testing method of "signal simulation—output response—result detection," it achieves unified production testing of the electrical control box output circuit even without a real TBM or actual peripheral equipment. Under different customer function definitions, it no longer relies on a real control box, real remote control, or real peripheral equipment. It directly constructs the electrical control box input conditions through reconfigurable signal simulation and performs path-by-path testing of the output circuit, thereby achieving unified flexible production testing. The entire inspection and testing process is simple and fast, requiring less frequent engineer involvement in production testing. It can quickly identify incorrect connections, missing connections, short circuits, and cross-wiring issues, effectively reducing the difficulty of manual testing, improving the efficiency of electrical control box production testing, and bringing convenience to the production and testing operations of electrical control boxes. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present 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 present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1To verify the overall framework diagram of the device; Figure 2 A flowchart to demonstrate the framework of the verification method; Figure 3 This is a schematic diagram of the working principle of a signal generating device; Figure 4 To output the working principle diagram of the testing equipment; Figure 5 This is a flowchart outlining the framework for path-by-path testing. Detailed Implementation

[0014] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, any modifications, equivalent substitutions, improvements, etc., made by those skilled in the art to all other embodiments obtained without creative effort should be included within the protection scope of the present invention.

[0015] This invention provides an inspection device and method suitable for the flexible production of tunneling machine electrical control boxes. By building a test environment independent of the actual machine and customer peripherals, functions such as controlling each output circuit of the electrical control box, detecting each output status, verifying the correctness of wiring, and conducting unified production tests on the output circuits are realized. This reduces the degree of engineer involvement, improves production testing efficiency, and meets the flexible production needs of different customer configurations.

[0016] I. Overall Structure of the Testing Device like Figure 1 As shown, the testing device disclosed in this invention includes a human-computer interaction terminal, a signal generating device, an output detection device, and a wiring adapter module.

[0017] The human-computer interaction terminal is used to send test commands and display test results; the human-computer interaction terminal is connected to both the signal generating device and the output detection device. The signal generator is used to simulate input signals from the control box, remote controller, and peripheral control devices; the signal generator is connected to the input terminal of the control box under test; the control box under test drives the corresponding output circuit according to the input signal. The output detection device is used to detect the status of the output circuit and return the detection results to the human-machine interface terminal; the output detection device is connected to the output terminal of the electrical control box under test. The wiring adapter module is used to enable quick connection between the electrical control box under test and the test fixture.

[0018] The above structures together form a set of flexible production and testing fixtures that are independent of the actual tunneling machine environment.

[0019] II. The functions and effects of each working module are explained below: 1. Human-computer interaction terminal The human-machine interface terminal is used for: selecting the output circuit to be tested, sending test control commands, displaying output test results, displaying abnormal statuses, and displaying test results.

[0020] Human-computer interaction terminals can be configured screens, industrial touch screens, industrial computers, or other industrial display devices.

[0021] The human-computer interaction terminal itself does not directly drive the output of the electrical control box. Instead, it sends test commands to the signal generating device, which then constructs the corresponding input conditions.

[0022] like Figure 2 As shown, its workflow is as follows: After the human-machine interface terminal selects the circuit to be tested, it sends a test command to the signal generating device; the signal generating device constructs the corresponding input conditions; the control box under test drives the corresponding output circuit after the input conditions are met; the output detection device detects the output status and returns the detection result; finally, the human-machine interface terminal displays the test result.

[0023] 2. Signal generating equipment The function of the signal generating device is not simply to output switching signals, but to simulate the external control equipment and operating conditions of the tunneling machine, thereby constructing the input environment of the electrical control box under test.

[0024] After receiving the test command sent by the human-machine interface terminal, the signal generating device inputs the corresponding control signal to the electrical control box under test.

[0025] The control signals include control box control signals, remote control control signals, start / stop control signals, interlock status signals, safety status signals, digital input signals, and analog input signals.

[0026] Although different customers may have different definitions of the output circuit function, the internal output hardware structure of the control box is basically the same. Therefore, this invention does not rely on specific function definitions, but directly controls and verifies the output circuit itself.

[0027] For example: The same output circuit can be defined as: spray control, support control, hydraulic control, braking control, and auxiliary equipment control in different customer equipment.

[0028] This invention is not concerned with which specific device the output circuit controls, but rather with verifying: whether the output circuit can output correctly; whether the output correspondence is correct; whether the circuit wiring is correct; and whether there are short circuits, missing connections, or cross-wiring.

[0029] Therefore, this invention achieves the decoupling of "functional definition" and "hardware testing".

[0030] like Figure 3 As shown, the signal generating device is used to simulate the external input environment of the actual tunneling machine; it includes an operation box signal simulation module, a remote control signal simulation module, an interlocking state simulation module, and a safety circuit simulation module; by constructing different input conditions, it realizes the unified testing of the output circuit of the electrical control box under test.

[0031] 3. Output testing equipment Output testing equipment is used to perform closed-loop testing on the output circuit of the electrical control box under test.

[0032] The output testing device is connected to the output terminal of the control box under test and is used for: detecting the output on / off status; detecting the output correspondence; detecting the output stability; detecting the integrity of the output circuit; detecting whether there are missing connections; detecting whether there are short circuits; detecting whether there are cross-wiring; and detecting whether the output malfunctions.

[0033] The output testing device returns the test results to the human-computer interaction terminal for display.

[0034] Output testing equipment may include: a voltage detection module, a current detection module, a digital acquisition module, an opto-isolation detection module, an output load module, a relay detection module, and a status indication module. The output load module is used to simulate the actual output load environment, thereby improving the realism of the test.

[0035] like Figure 4 As shown, the output testing device is used to test the output circuit of the control box under test, including output correspondence detection, cross-connection detection, short circuit detection, missing connection detection, and output stability detection; the test results are returned to the human-machine interface terminal for display.

[0036] 4. Wiring adapter module Since there are many wiring connections for different models of electrical control boxes, this invention includes a wiring adapter module to improve production and testing efficiency.

[0037] The wiring adapter module is used to: enable quick connection between test fixtures and electrical control boxes; reduce repetitive manual wiring; reduce test wiring error rate; and improve production line testing efficiency.

[0038] Wiring adapter modules can use aviation plugs, terminal adapter boards, quick-plug connectors, or custom adapter harnesses.

[0039] Third, the testing method in this invention can perform path-by-path testing of multiple loops, such as... Figure 5 As shown, the steps are as follows: Step 1: Connect the electrical control box under test to the test fixture via a wiring adapter module.

[0040] Step Two: The human-computer interaction terminal selects the output circuit to be tested.

[0041] Step 3: The human-computer interaction terminal sends test commands to the signal generating device.

[0042] Step Four: The signal generating device constructs the corresponding input conditions and inputs control signals to the electrical control box under test.

[0043] Step 5: After the input conditions are met, the control box under test drives the corresponding output circuit to operate.

[0044] Step Six: The output detection device detects the corresponding output status.

[0045] Step Seven: Output detection equipment judgment: • Is the output correct? • Check if the output correspondence is correct; • Is there a cross-connection? • Are there any missing connections? • Is there a short circuit? • Is there any erroneous action?

[0046] Step 8: The output testing device returns the test results to the human-computer interaction terminal.

[0047] Step Nine: The human-computer interaction terminal displays the test results.

[0048] The above method enables closed-loop testing of each output circuit of the electrical control box. During the testing process, the following judgments can be made: • Is the output circuit outputting correctly? • Is the output circuit wired correctly? • Is there a short circuit in the output circuit? • Is there a cross-connection in the output circuit? • Whether the output circuit is working stably; • Are the output channels one-to-one?

[0049] The following testing effects can be achieved: • Control each output circuit of the electrical control box individually; • Detect the output status one path at a time; • Verify the correctness of the wiring; • Conduct unified production testing on the output circuit.

[0050] Therefore, the same set of test fixtures in this invention can be applied to different customer configuration requirements, while reducing the degree of engineer involvement and improving production testing efficiency.

[0051] IV. The following specific embodiments will be used to operate and verify this technical solution; Example 1 The electrical control box under test is a KXJ1-400 / 1140(660)E type electrical control box.

[0052] During production testing: 1. Connect the electrical control box under test to the test fixture; 2. The human-computer interaction terminal selects a certain output circuit; 3. The signal generating equipment inputs the corresponding control signal to the electrical control box; 4. The output circuits corresponding to the output of the electrical control box; 5. The testing equipment detects the output status; 6. The human-computer interaction terminal displays the test results; 7. Complete the tests of all output circuits in sequence.

[0053] Example 2 When an output circuit is wired incorrectly: 1. Select the corresponding output circuit on the human-computer interaction terminal; 2. The signal generating device outputs the corresponding control signal; 3. The detection equipment detected a discrepancy between the actual output and the target output; 4. Abnormal results are displayed on the human-computer interaction terminal; 5. Production personnel inspect and repair the wiring.

[0054] Example 3 When a short circuit exists in a certain output circuit: 1. The signal generating device outputs the corresponding control signal; 2. The testing equipment detected an abnormal output; 3. The human-computer interaction terminal displays an abnormal status; 4. Production personnel inspect for short circuit faults.

[0055] This invention provides a closed-loop production testing fixture for flexible production scenarios of tunnel boring machine (TBM) electrical control boxes. Through a closed-loop testing method of "signal simulation—output response—result detection," it achieves unified production testing of the electrical control box output circuit even without a real TBM or actual peripheral equipment. Under different customer function definitions, it no longer relies on a real control box, real remote control, or real peripheral equipment. It directly constructs the electrical control box input conditions through reconfigurable signal simulation and performs path-by-path testing of the output circuit, thereby achieving unified flexible production testing. The entire inspection and testing process is simple and fast, requiring less frequent engineer involvement in production testing. It can quickly identify incorrect connections, missing connections, short circuits, and cross-wiring issues, effectively reducing the difficulty of manual testing, improving the efficiency of electrical control box production testing, and bringing convenience to the production and testing operations of electrical control boxes.

Claims

1. An inspection device suitable for the flexible production of tunneling machine electrical control boxes, characterized in that: The detection device includes a human-machine interface terminal for sending test commands and displaying test results, a signal generator for generating analog input signals, and an output detection device for detecting the status of the output circuit. The signal output terminal of the human-machine interface terminal is connected to the signal input terminal of the signal generator, the signal output terminal of the signal generator is connected to the signal input terminal of the electrical control box under test, the signal output terminal of the electrical control box under test is connected to the signal input terminal of the output detection device, and the signal output terminal of the output detection device is connected to the signal input terminal of the human-machine interface terminal.

2. The inspection device for flexible production of tunneling machine electrical control boxes as described in claim 1, characterized in that: The testing device also includes a wiring adapter module. The signal input terminal of the electrical control box under test is connected to the signal output terminal of the signal generating device through the wiring adapter module, and the signal output terminal of the electrical control box under test is connected to the signal input terminal of the output testing device through the wiring adapter module.

3. The inspection device for flexible production of tunneling machine electrical control boxes as described in claim 1, characterized in that: The signal generating device includes an operation box signal simulation module for simulating operation box input signals, a remote control signal simulation module for simulating remote control input signals, an interlocking state simulation module for simulating interlocking state input signals, and a safety circuit simulation module for simulating safety circuit input signals. The signal input terminals of the operation box signal simulation module, remote control signal simulation module, interlocking state simulation module, and safety circuit simulation module are all connected to the signal output terminal of the human-machine interface terminal, and the signal output terminals of the operation box signal simulation module, remote control signal simulation module, interlocking state simulation module, and safety circuit simulation module are all connected to the signal input terminal of the electrical control box under test.

4. The inspection device for flexible production of tunneling machine electrical control boxes as described in claim 1, characterized in that: The output detection device includes a voltage detection module, a current detection module, a digital signal acquisition module, an opto-isolation detection module, an output load module, a relay detection module, and a status indication module. The signal input terminals of the voltage detection module, current detection module, digital signal acquisition module, opto-isolation detection module, output load module, relay detection module, and status indication module are all connected to the signal output terminals of the control box under test. The signal output terminals of the voltage detection module, current detection module, digital signal acquisition module, opto-isolation detection module, output load module, relay detection module, and status indication module are all connected to the signal input terminals of the human-machine interface terminal.

5. A method for inspecting the flexible production of tunneling machine electrical control boxes, implemented by the inspection device for flexible production of tunneling machine electrical control boxes as described in claim 1, characterized in that: Includes the following steps: S1. Connect the human-machine interface terminal, signal generating device, electrical control box under test, and output detection device with wiring; S2. Select the output circuit to be tested using the human-computer interaction terminal; S3. The human-machine interface terminal sends a test command to the signal generating device according to the output circuit to be tested. S4. The signal generating device simulates the corresponding input signal according to the test command and sends it to the electrical control box under test; S5. After receiving the input signal, the control box under test drives the output circuit under test to perform an action. S6. The output detection device detects and judges the output status of the output circuit to be tested and obtains the detection result. S7. The output testing device feeds back the test results to the human-machine interface terminal. The human-machine interface terminal displays the test results of the output circuit to be tested based on the test results and determines whether to perform the test operation of the next output circuit. If the test operation of the next output circuit is to be performed, steps S1 to S8 are repeated. If the test operation of the next output circuit is not performed, the process ends.

6. The inspection method for flexible production of tunneling machine electrical control boxes as described in claim 5, characterized in that: Step S6 specifically includes the following steps: S61. The output detection device determines whether the output state of the output circuit to be tested is detected. If yes, proceed to the next step; otherwise, proceed to step S64. S62. Determine if there are other circuits outputting simultaneously in the output circuit under test. If yes, it is determined to be a cross-connection fault, and the test result is output; otherwise, proceed to the next step. S63. Determine whether the voltage and current of the output circuit under test are normal. If they are normal, the output is considered normal and the test result is output. If they are not normal, the output is considered abnormal and the test result is output. S64. Detect whether there is a short circuit in the output circuit under test. If so, it is judged as a short circuit fault and the detection result is output; if not, it is judged as a missing connection fault and the detection result is output.

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