An integrated test platform and test method applied to an injection molding machine controller

Abstract

The application relates to an integrated test platform and a test method applied to an injection molding machine controller, and relates to the technical field of the injection molding machine controller, which comprises the following: a communication packet sending simulation key module connected with a man-machine interface key plate on a measured controller and used for sending a simulation key instruction to the measured controller; a signal simulation module connected with a signal port of the measured controller to receive a motion signal output by the measured controller according to the simulation key instruction and used for performing simulation test on the measured controller; a communication test module connected with a communication interface of the measured controller and used for performing communication on-off test on the measured controller; a first relay on-off module connected between the communication test module and the measured controller and used for performing communication on-off; and a second relay on-off module connected with the communication test module and used for controlling on-off between the measured controller and the man-machine interface key plate. The application has the effect of conveniently testing long-term production conditions of the injection molding machine controller.

Description

Technical Field

[0001] This invention relates to the field of injection molding machine controller technology, and in particular to an integrated testing platform and testing method for injection molding machine controllers. Background Technology

[0002] An injection molding machine controller is an integrated control device that performs process control, parameter setting, status monitoring, and safety protection for an injection molding machine.

[0003] Testing of injection molding machine controllers generally focuses on the controller itself and mainly involves hardware testing. However, for injection molding machine manufacturers, targeted manual, small-scale, repetitive testing is necessary. This includes destructive testing of communication between different modules, destructive testing of control logic, and stability testing of system software.

[0004] With the maturity and development of injection molding machine technology, the number of peripheral devices connected to the injection molding machine has increased, and the types of communication protocols between modules have also increased. The connected devices may experience communication interference, electromagnetic interference, quality problems, etc. Moreover, currently, individual tests are generally conducted manually, making it inconvenient to test the long-term production status of the injection molding machine controller. Summary of the Invention

[0005] To facilitate the testing of the long-term production status of injection molding machine controllers, this invention provides an integrated testing platform and testing method for injection molding machine controllers.

[0006] In a first aspect, the present invention provides an integrated testing platform for injection molding machine controllers, employing the following technical solution: An integrated testing platform for injection molding machine controllers includes: The communication packet sending simulation button module is connected to the human-machine interface button panel on the controller under test and is used to send simulated button commands to the controller under test. The signal simulation module is connected to the signal port of the controller under test to receive the action signals output by the controller under test according to the simulated button commands and to perform simulation tests on the controller under test. The communication test module connects to the communication interface of the controller under test and is used to perform communication continuity tests on the controller under test. The first relay switching module is connected between the communication test module and the controller under test and is used to perform communication switching. The second relay switching module is connected to the communication test module and is used to control the connection and disconnection between the controller under test and the human-machine interface keypad.

[0007] By adopting the above technical solution, and integrating a communication packet sending simulation button module, a signal simulation module, a communication test module, a first relay on / off module, and a second relay on / off module, an integrated automated testing platform is constructed. This platform can simultaneously perform collaborative testing on the command issuance of the human-machine interface button panel, the simulation of the controller signal port, and the on / off status of the communication interface. It replaces repetitive manual operations, facilitates the testing of the long-term production status of the injection molding machine controller, and improves the test coverage and the ability to expose defects before delivery.

[0008] Optionally, the signal simulation module includes a logic execution unit, a digital I / O unit, and an analog output unit for performing simulation tests. The digital I / O unit is used to connect the logic execution unit to the digital port of the controller under test to simulate the injection molding process. The analog output unit is used to connect the logic execution unit to the analog port of the controller under test to simulate the position and travel changes on the injection molding machine.

[0009] By adopting the above technical solution, the signal simulation module is configured as a combination of logic execution unit, digital I / O unit and analog output unit. This enables the test platform to not only simulate the switching signal interaction during the injection molding process through digital I / O unit, but also simulate the position and travel changes of the injection molding machine through analog output unit. This allows the motion characteristics of the injection molding machine to be fully reproduced at the electrical signal level, enabling the controller under test to enter a fully automatic operation state without the real machine and achieve cyclic testing.

[0010] Optionally, the analog output unit includes a first analog output channel for simulating a switch mold ruler and a second analog output channel for simulating an injection ruler.

[0011] By adopting the above technical solution, the analog output unit is divided into a first analog output channel and a second analog output channel, so that the two position quantities of mold opening and injection can output continuous voltage signals independently and in parallel, which truly simulates the relative motion relationship between the two in the molding cycle, ensuring that the position feedback signal received by the controller is consistent with the actual injection molding condition, and effectively verifying the controller's synchronous processing capability for multi-axis position gauges.

[0012] Optionally, the digital I / O unit includes a digital input port and a digital output port. The digital input port includes corresponding ports for receiving mold opening signals, mold closing signals, and injection signals sent by the controller under test. The digital output port is used to send a mold closing signal to the controller under test.

[0013] By adopting the above technical solution and setting up digital input and output ports, a standardized switch command-feedback closed loop is formed between the logic execution unit and the controller under test, thereby strictly matching the logic timing of the fully automatic operation of the injection molding machine and accurately verifying whether there are defects in the program execution logic of the controller.

[0014] Optionally, the communication test module is equipped with a serial communication port, which is a CAN bus port or an RS485 bus port.

[0015] By adopting the above technical solution, the serial communication port connected to the controller under test via CAN bus or RS485 bus can cover the most common fieldbus forms in injection molding machine control systems. Furthermore, by performing continuity tests on the CAN bus or RS485 bus, on-site downtime caused by communication failures can be effectively prevented.

[0016] Optionally, the communication test module is equipped with a network communication port, which is an RJ45 network cable port.

[0017] By adopting the above technical solution, the network communication port connected to the controller under test via an RJ45 network cable facilitates the continuity test of the high-speed communication protocol, thereby effectively preventing on-site downtime caused by communication failures.

[0018] Optionally, a bus debugging tool for communication conversion is connected between the communication packet sending simulation button module and the human-machine interface button panel on the controller under test.

[0019] By adopting the above technical solution and using bus debugging tools for communication conversion, the platform can be quickly adapted to different models of human-machine interface keypads, improving the versatility and deployment efficiency of the testing platform.

[0020] Optionally, a data monitoring module may also be included, which is used to receive communication data packets between the communication test module and the controller under test.

[0021] By adopting the above technical solution, the data monitoring module receives communication data packets, thereby providing complete data evidence for subsequent analysis of abnormal behaviors such as packet loss, retransmission, and disconnection, and facilitating the transformation of destructive testing from qualitative observation to quantitative analysis.

[0022] Secondly, the present invention provides an integrated testing method for injection molding machine controllers, employing the following technical solution: An integrated testing method for injection molding machine controllers, employing an integrated testing platform for injection molding machine controllers as described in the first aspect, comprising: The communication packet sending simulation button module sends simulated button commands to the controller under test; The signal simulation module receives the action signal output by the controller under test according to the simulated button command, and feeds back the simulated position ruler signal and the position status signal to the controller under test, so that the controller under test enters the fully automatic cyclic operation state. The communication test module controls the first relay on / off module and the second relay on / off module to periodically or randomly switch the communication lines on and off. The data monitoring module intercepts and records communication data packets during and after communication interruption, analyzes and determines the test result information of the controller under test, and outputs it.

[0023] By adopting the above technical solution, the communication packet sending simulation button module cyclically sends commands, and the signal simulation module drives the controller to enter a fully automatic cyclic operation state. At the same time, the communication test module controls the first relay on / off module and the second relay on / off module to periodically or randomly switch the communication lines on and off, and the data monitoring module intercepts communication data packets. Thus, under the conditions of simulating long-term operation and superimposed complex communication faults, the test results information can be automatically analyzed, determined, and output, replacing manual repetitive operations. This facilitates the testing of the long-term production status of the injection molding machine controller and improves the test coverage and the ability to expose defects before leaving the factory.

[0024] Optionally, methods for determining test result information include: The number of heartbeat packets, data frames, number of times the master station sends data, number of times the slave station responds, and number of retransmissions are retrieved based on the communication data packets. The packet loss rate is calculated based on the number of heartbeat packets and the number of data frames. The packet loss error rate is calculated based on the number of packets sent from the main station and the number of packets returned from the slave station. The packet loss rate, packet error rate, and number of retransmissions are combined and used as test result information.

[0025] By adopting the above technical solution, the number of heartbeat packets, data frames, number of times the master station sends data, number of times the slave station responds data, and number of retransmissions are retrieved, and the communication packet loss rate, packet loss error rate, and number of retransmissions are calculated. These data are then combined as test result information, making it easier for testers to understand the specific quantitative parameters of the test.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: 1. By integrating a communication packet sending simulation button module, a signal simulation module, a communication test module, a first relay on / off module, and a second relay on / off module, an integrated automated testing platform was constructed. This platform can simultaneously perform collaborative testing on the command issuance of the human-machine interface button panel, the simulation of the controller signal port, and the on / off status of the communication interface. It replaces repetitive manual operations, facilitates the testing of the long-term production status of the injection molding machine controller, and improves the test coverage and the ability to expose defects before leaving the factory. 2. Communication conversion is performed through bus debugging tools, which facilitates the platform's rapid adaptation to different models of human-machine interface keypads, improving the versatility and deployment efficiency of the testing platform; 3. The data monitoring module receives communication data packets, providing complete data for subsequent analysis of abnormal behaviors such as packet loss, retransmission, and disconnection, facilitating the transformation of destructive testing from qualitative observation to quantitative analysis. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the system architecture of an integrated testing platform applied to injection molding machine controllers; Figure 2 This is a diagram illustrating communication connectivity. Figure 3 This is a flowchart of an integrated testing method applied to injection molding machine controllers.

[0028] The parts referred to by the numbers in the above attached diagrams are as follows: 1. Communication packet sending simulation button module; 2. Signal simulation module; 3. Communication test module; 4. First relay on / off module; 5. Second relay on / off module; 6. Data monitoring module; 7. Bus debugging tool. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0030] Reference Figure 1This invention discloses an integrated testing platform for injection molding machine controllers, comprising: a communication packet sending and simulating button module 1, a signal simulation module 2, a communication testing module 3, a first relay on / off module 4, a second relay on / off module 5, and a data monitoring module 6. The communication packet sending and simulating button module 1 is connected to the human-machine interface (HMI) button panel on the controller under test. Communication between the controller under test and the HMI button panel typically uses serial communication or CAN communication. The communication packet sending and simulating button module 1 pre-collects the communication interface types between the controller under test and the HMI button panel, and uses the communication packets corresponding to the communication interface types as simulated button commands and sends them to the controller under test, thereby simulating button presses. The communication packets can be data packets for numerical modification, screen switching, etc., and the communication packets are pre-set by the operator. A bus debugging tool 7 for communication conversion is connected between the communication packet sending and simulating button module 1 and the HMI button panel on the controller under test. For example, the communication packet sending simulation button module 1 can be connected to the bus debugging tool 7 via USB. Then, the CAN-H and CAN-L interfaces on the bus debugging tool 7 are connected to the controller under test. The communication packet sending simulation button module 1 sends simulated button commands to the controller under test to request relevant load information. The controller under test then returns the relevant information and sends it as an action signal to the test platform.

[0031] Reference Figure 1 The signal simulation module 2 is connected to the signal port of the controller under test (DUT) to receive the action signals output by the DUT according to simulated button commands and to perform simulation tests on the DUT. The signal simulation module 2 includes a logic execution unit, a digital I / O unit, and an analog output unit for simulation testing. The analog output unit includes a first analog output channel for simulating the switching mold ruler and a second analog output channel for simulating the injection ruler. The logic execution unit changes the output voltage through logic control, thereby simulating the position ruler stroke change on the injection molding machine. The logic execution unit has a preset output voltage logic control adjustment method; the specific adjustment method and value of the output voltage are set according to the position ruler stroke change of the injection molding machine corresponding to the DUT.

[0032] The digital I / O unit includes digital input ports and digital output ports. The digital outputs of the controller under test (DUT) are connected to the digital input ports, and the program logic defined in the logic execution unit is implemented through signal changes in the DUT. Similarly, the digital input ports are connected to the digital inputs of the DUT, and the program logic defined in the DUT is implemented through signal changes in the logic execution unit. The program logic in the logic execution unit and the DUT is preset by the operator, and the program logic can be the standard operating procedure of an injection molding machine. In this embodiment, the digital input ports include corresponding ports for receiving mold opening signals, mold closing signals, and injection signals from the DUT, and the digital output ports are used to send a mold closing signal to the DUT.

[0033] The communication test module 3 is connected to the communication interface of the controller under test (DUT) and is used to perform communication continuity tests on the DUT. The communication test module 3 is equipped with a serial communication port and a network communication port. The serial communication port can be a CAN bus port or an RS485 bus port, and the network communication port can be an RJ45 network cable port. The first relay continuity module 4 is connected between the communication test module 3 and the DUT and is used to perform communication continuity checks. The data monitoring module 6 is connected to the communication test module 3 and is used to receive communication data packets between the communication test module 3 and the DUT to facilitate understanding of the continuity status. The second relay continuity module 5 is connected to the communication test module 3 and is used to control the continuity between the DUT and the HMI keypad.

[0034] Reference Figure 2 For example, DA0 simulates the mold opening mechanism, and DA1 simulates the injection mechanism. When X0 is connected to the mold opening signal transmitted from the controller under test to the logic execution unit, X1 is connected to the mold closing signal transmitted from the controller under test to the logic execution unit, and X2 is connected to the injection signal transmitted from the controller under test to the logic execution unit; then, the mold closing final signal transmitted from the logic execution unit to the controller under test is output through Y0. When the controller under test is running in fully automatic mode, according to the X1 signal, DA0 outputs an analog quantity from 10V to 0V to control mold closing. After reaching the set position, Y0 is output as the mold closing final signal. At this time, the controller under test starts to perform the injection action logic. According to the X2 signal, DA1 outputs an analog quantity from 10V to 0V to control injection. After reaching the set position, the controller under test starts to perform the mold opening action. According to the X0 signal, DA0 outputs an analog quantity from 0V to 10V to control mold opening. After reaching the set position, the above cycle continues. X3 connects to the trigger signal transmitted from the controller under test to the logic execution unit, and Y1 connects to control the opening and closing of the relay contacts, thereby realizing the connection and disconnection of the network cable between the human-machine interface (HMI) button panel and the controller under test host.

[0035] Reference Figure 3Based on the same inventive concept, embodiments of the present invention provide an integrated testing method for injection molding machine controllers, employing an integrated testing platform for injection molding machine controllers as described above, including: S1: Communication packet sending: Simulated button module 1 sends simulated button commands to the controller under test.

[0036] The simulated button command refers to a string of data codes generated and sent by the communication packet sending simulated button module 1, which is completely identical in communication protocol and data structure to the message generated when a real physical button is pressed. Simulated button commands can include commands for value modification, screen switching, etc. The simulated button commands are obtained by manually pressing different physical buttons, intercepting the corresponding complete communication messages, and then forming a command database according to the test requirements.

[0037] By connecting the communication packet sending simulation button module 1 to the controller under test, simulated button commands are selected sequentially from the command database and sent to the controller under test, which facilitates subsequent testing.

[0038] S2: Signal simulation module 2 receives the action signal output by the controller under test according to the simulated button command, and feeds back the simulated position ruler signal and the position status signal to the controller under test, so that the controller under test enters the fully automatic cyclic operation state.

[0039] Among them, the action signal refers to the switching command actively issued by the controller under test to the actuator after receiving the analog button command, based on its internally fixed injection molding machine control logic.

[0040] The simulated position ruler signal refers to the electrical signal used to simulate the real-time output of the position ruler (electronic ruler) on an injection molding machine. The position status signal refers to the electrical signal used to inform the controller under test that the action has been completed.

[0041] Signal simulation module 2 continuously monitors the output of the controller under test through its digital input port. When the controller sets the corresponding output point to a high level due to receiving an analog button command, signal simulation module 2 captures this action signal and inputs it to the logic execution unit to form an analog position ruler signal and a position status signal, thereby enabling the controller under test to enter a fully automatic cyclic operation state.

[0042] For example, when the simulated button command is to close the mode, the corresponding output point of the action signal is set to a high level. The signal simulation module 2 receives the high-level signal corresponding to the mode closure and outputs it from 10V to 0V starting from the first analog output channel as a simulated position ruler signal. When the output of the first analog output channel is 0V, the final position status signal of the mode closure is output.

[0043] S3: The communication test module 3 controls the first relay switching module 4 and the second relay switching module 5 to perform periodic or random switching of the communication line.

[0044] Periodicity refers to the regular and repetitive closing and opening of the relay at fixed time intervals. Periodicity can be achieved by writing a timer program and setting the high and low levels corresponding to the fixed time intervals as switching signals and outputting them. Randomness refers to the irregular closing and opening of the relay at non-fixed time intervals. Randomness can be achieved by calling a random number generation function to use as the time interval and outputting the corresponding high and low levels as switching signals.

[0045] The communication test module 3 generates switching signals through its internal logic control unit or host computer software to drive the relay coils in the first relay switching module 4 and the second relay switching module 5, thereby controlling the first relay switching module 4 and the second relay switching module 5 to perform periodic or random communication line switching.

[0046] S4: The data monitoring module 6 intercepts and records communication data packets during and after communication interruption, analyzes and determines the test result information of the controller under test, and outputs it.

[0047] Communication data packets refer to message data intercepted during and after communication interruptions. Test result information refers to quantitative indicators used to indicate the communication reliability of the controller under test.

[0048] The data monitoring module 6 captures and records message data during and after communication interruption to form communication data packets. By analyzing the communication data packets, test results are determined and output, which facilitates the tester to understand the specific quantitative parameters when testing the long-term production status of the injection molding machine controller.

[0049] To further ensure the reasonableness of the test results, it is necessary to perform further separate analysis and calculation on the test results, which will be explained in detail through the steps shown below.

[0050] The method for determining test result information includes the following steps: S41: Retrieve the number of heartbeat packets, data frames, number of times the master station sends data, number of times the slave station responds data, and number of retransmissions based on communication data packets.

[0051] The heartbeat packet count refers to the total number of messages sent within a complete test cycle. The data frame count refers to the number of messages successfully intercepted within the same test cycle. The master station's transmission count refers to the total number of request or command messages sent within a complete test cycle that require a response from the slave station. The slave station's response count refers to the total number of successful response messages actually sent by the slave station to the master station's requests within the same test cycle. The retransmission count refers to the number of times the master station retransmits after not receiving a response from the slave station. The communication data packet includes the heartbeat packet count, data frame count, master station transmission count, slave station response count, and retransmission count.

[0052] The number of heartbeat packets, data frames, number of times the master station sends data, number of times the slave station responds, and number of retransmissions can be retrieved through communication data packets for convenient subsequent use.

[0053] S42: The packet loss rate is calculated based on the number of heartbeat packets and the number of data frames.

[0054] The packet loss rate refers to the percentage of data packets lost during a complete communication test cycle, relative to the total number of data packets that should theoretically be received.

[0055] The difference between the number of heartbeat packets and the number of data frames is calculated, and then the quotient between the difference and the number of heartbeat packets is calculated and used as the communication packet loss rate for convenient subsequent use.

[0056] S43: The packet loss error rate is calculated based on the number of packets sent from the main station and the number of packets returned from the slave station.

[0057] Packet loss error rate refers to the percentage of times the master station fails to receive a response from the slave station.

[0058] The difference between the number of packets sent by the main station and the number of packets returned by the slave station is calculated, and then the quotient between the difference and the number of packets sent by the main station is calculated and used as the packet loss error rate for convenient subsequent use.

[0059] S44: Combine the communication packet loss rate, packet error rate, and number of retransmissions as test result information.

[0060] In this method, by combining the communication packet loss rate, packet error rate, and number of retransmissions, a parameter set is formed and used as test result information, thereby improving the accuracy of the obtained test result information.

[0061] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An integrated testing platform for injection molding machine controllers, characterized in that, include: The communication packet sending simulation button module (1) is connected to the human-machine interface button panel on the controller under test and is used to send simulated button commands to the controller under test. The signal simulation module (2) is connected to the signal port of the controller under test to receive the action signal output by the controller under test according to the simulated button command and to perform simulation test on the controller under test. The communication test module (3) is connected to the communication interface of the controller under test and is used to perform communication continuity test on the controller under test. The first relay switching module (4) is connected between the communication test module (3) and the controller under test and is used to perform communication switching. The second relay switching module (5) is connected to the communication test module (3) and is used to control the connection and disconnection between the controller under test and the human-machine interface keypad.

2. The integrated testing platform for injection molding machine controllers according to claim 1, characterized in that: The signal simulation module (2) includes a logic execution unit, a digital I / O unit and an analog output unit for performing simulation tests. The digital I / O unit is used to connect the logic execution unit to the digital port of the controller under test to simulate the injection molding process. The analog output unit is used to connect the logic execution unit to the analog port of the controller under test to simulate the position and travel changes on the injection molding machine.

3. The integrated testing platform for injection molding machine controllers according to claim 2, characterized in that: The analog output unit includes a first analog output channel for simulating a switch mold ruler and a second analog output channel for simulating an injection ruler.

4. The integrated testing platform for injection molding machine controllers according to claim 3, characterized in that: The digital I / O unit includes a digital input port and a digital output port. The digital input port includes corresponding ports for receiving mold opening signals, mold closing signals, and injection signals sent by the controller under test. The digital output port is used to send a mold closing signal to the controller under test.

5. An integrated testing platform for injection molding machine controllers according to claim 1, characterized in that: The communication test module (3) is equipped with a serial communication port, which is a CAN bus port or an RS485 bus port.

6. The integrated testing platform for injection molding machine controllers according to claim 5, characterized in that: The communication test module (3) is equipped with a network communication port, which is an RJ45 network cable port.

7. The integrated testing platform for injection molding machine controllers according to claim 1, characterized in that: The communication packet sending simulation button module (1) is connected to the human-machine interface button panel on the controller under test by a bus debugging tool (7) for communication conversion.

8. An integrated testing platform for injection molding machine controllers according to any one of claims 1 to 7, characterized in that: It also includes a data monitoring module (6), which is used to receive communication data packets between the communication test module (3) and the controller under test.

9. An integrated testing method for injection molding machine controllers, characterized in that, The integrated testing platform for injection molding machine controllers as described in claim 8 includes: The communication packet sending simulation button module (1) sends simulation button commands to the controller under test; The signal simulation module (2) receives the action signal output by the controller under test according to the simulated button command, and feeds back the simulated position ruler signal and the position status signal to the controller under test, so that the controller under test enters the fully automatic cyclic operation state. The communication test module (3) controls the first relay switching module (4) and the second relay switching module (5) to periodically or randomly switch the communication lines on and off. The data monitoring module (6) intercepts and records communication data packets during and after the communication interruption, analyzes and determines the test result information of the controller under test, and outputs it.

10. An integrated testing method for an injection molding machine controller according to claim 9, characterized in that, Methods for determining test result information include: The number of heartbeat packets, data frames, number of times the master station sends data, number of times the slave station responds, and number of retransmissions are retrieved based on the communication data packets. The packet loss rate is calculated based on the number of heartbeat packets and the number of data frames. The packet loss error rate is calculated based on the number of packets sent from the main station and the number of packets returned from the slave station. The packet loss rate, packet error rate, and number of retransmissions are combined and used as test result information.

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