A multi-channel automated detection device and method

Abstract

The present application relates to the technical field of multi-channel detection, and specifically relates to a multi-channel automatic detection device and method, which comprises an outer box, an intermediate relay is arranged in the outer box, a relay module is arranged at the bottom of the intermediate relay, and a PLC is arranged at the bottom of the relay module. The method realizes multi-channel switching control through the relay module, adopts a standard 19-inch machine box to integrate components such as an intermediate relay and a switching power supply to form a hardware platform, inputs power supply to start the system during work, the PLC executes preprogrammed six-state polling detection logic, 8-channel parallel detection is scheduled through a time slice round-robin algorithm, high-frequency signals and large-current signals are respectively transmitted through a BNC interface and a banana socket, 24-bit sigma-delta ADC collects signals at a rate of 1kSPS / channel, after digital filtering and dynamic threshold analysis, the channel state is visually displayed through a touch screen, and the system adopts a three-level fault diagnosis mechanism to realize accurate fault positioning in combination with a KNN algorithm and a DTW waveform matching technology.

Description

Technical Field

[0001] This invention relates to the field of multi-channel detection technology, and specifically to a multi-channel automatic detection device and method. Background Technology

[0002] With the continuous development of automation technology, multi-channel automatic testing devices have become indispensable tools in the testing of various electronic devices, communication systems, and industrial equipment. Especially in the maintenance and testing of electronic products, communication equipment, and power systems, automated testing devices not only improve testing efficiency but also ensure the accuracy and stability of test results.

[0003] Existing testing equipment mostly adopts manual or semi-automatic testing modes. This traditional mode has problems such as excessive human intervention, low testing efficiency, and large errors. Especially when multiple signal channels or complex systems need to be tested simultaneously, it often cannot guarantee high efficiency and high accuracy. In the process of fault diagnosis and equipment identification, existing equipment relies heavily on manual analysis, which is inefficient and easily affected by human factors.

[0004] Existing multi-channel detection devices often suffer from drawbacks such as slow system response, untimely switching, and low fault diagnosis accuracy. Traditional detection systems typically rely on single-channel or fixed-channel switching methods, making it difficult to maintain efficient operation when multiple signal sources are detected in parallel. Furthermore, delays may occur during switching, resulting in an overall less smooth testing process. Many existing devices lack intelligent control and fault location mechanisms, relying on manual inspection and analysis, which is inefficient and prone to errors. Existing equipment type identification and signal analysis technologies are mostly static, unable to automatically adapt to different equipment types based on real-time signal changes, and lack sufficient dynamic adjustment capabilities. Most detection devices lack the ability to upload data to the cloud in real time, making data storage and sharing during the detection process inconvenient. Therefore, we provide a multi-channel automatic detection device and method. Summary of the Invention

[0005] In view of the above-mentioned shortcomings of the prior art, the first objective of the present invention is to provide a multi-channel automatic detection device and method to solve the problems in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A multi-channel automatic detection device and method includes: an outer casing, an intermediate relay disposed within the outer casing, a relay module disposed at the bottom of the intermediate relay, a PLC disposed at the bottom of the relay module, a switching power supply disposed at one end of the PLC, a switch disposed on the outer surface of the intermediate relay, an input power supply disposed at one end of the outer casing, a network communication interface disposed on one side of the input power supply, a reserved upgrade interface disposed at the upper end of the network communication interface and the input power supply, a voltage feedback signal disposed at one end of the reserved upgrade interface, a voltage output signal disposed at the bottom of the voltage feedback signal, a current feedback signal disposed at the end of the voltage feedback signal away from the reserved upgrade interface, a current output signal disposed at the end of the voltage output signal away from the network communication interface, and a touch screen disposed on the outer casing;

[0008] The intermediate relay is installed in the outer casing. The relay module is installed in the outer casing at the bottom of the intermediate relay. The PLC is installed in the outer casing on the side of the relay module away from the intermediate relay. The switching voltage is installed in the outer casing at one end of the PLC. The input power supply is installed on the outer casing and connected to the switching power supply. The network communication interface, reserved upgrade interface, voltage feedback signal, voltage output signal, current feedback signal, and current output signal are all installed on the outer casing and connected to the PLC. The outer surface of the touch screen is nested in the outer casing and connected to the PLC.

[0009] The present invention is further configured to include the following steps:

[0010] S1. System hardware architecture construction;

[0011] S2, Test Logic Programming;

[0012] S3, Test fixture integration and debugging;

[0013] S4. Test device docking specifications;

[0014] S5, implementation of automated testing processes;

[0015] S6. Signal Acquisition and Processing;

[0016] S7. Fault diagnosis and location;

[0017] S8, maintenance and upgrade of multi-channel automatic detection system.

[0018] The present invention is further configured such that, in step S1, system hardware architecture construction:

[0019] S1.1 An industrial-grade PLC is selected as the main controller, paired with a 16-channel relay module to achieve multi-channel switching selection. A 5.7-inch HMI touch screen is used as the human-machine interface, and a 24V / 5A switching power supply is configured to meet the system power supply requirements.

[0020] S1.2. High-frequency signal transmission is achieved using BNC interfaces, and banana sockets are responsible for high-current channel connections. All interfaces meet the IP67 protection standard.

[0021] S1.3. An optocoupler isolation circuit is set between the PLC and the relay module, and a varistor is configured for protection at the relay output terminal;

[0022] S1.4 adopts a 19-inch standard chassis structure, with internal layout arranged according to functional zones, and high-voltage and low-voltage lines routed separately.

[0023] The present invention is further configured such that, in step S2, the test logic program design:

[0024] S2.1 Design a six-state polling detection logic (initialization → channel selection → signal excitation → feedback acquisition → result judgment → report generation), and set a timeout protection mechanism for each state;

[0025] S2.2 Develop a channel scheduling algorithm based on time slice rotation, supporting parallel detection of 8 channels, and the detection frequency of key channels can be set to increase to 3 times / cycle;

[0026] S2.3 Establish a three-level fault classification system (communication failure → signal abnormality → hardware failure) and design corresponding handling strategies such as automatic retry, channel shielding, and system emergency stop;

[0027] S2.4 Embed a digital filtering algorithm in the PLC program to perform moving average processing on the acquired signal and set a dynamic threshold fluctuation range of ±5%.

[0028] The present invention is further configured such that: in step S3, during the integration and debugging of the test fixture:

[0029] S3.1. Use a network analyzer to calibrate the BNC interface impedance (50Ω±1%), and use the four-wire method to measure the banana socket contact resistance (≤10mΩ);

[0030] S3.2. Use an oscilloscope to measure the switching delay of each channel (≤10ms) to ensure that the excitation signal is phase-aligned with the acquisition window;

[0031] S3.3. Conduct a 72-hour aging test within a temperature range of -20℃ to 60℃ to verify the contact stability of the relay contacts;

[0032] S3.4. Perform surge (4kV) and electrostatic (8kV) tests according to GB / T17626 standard, and add magnetic ring filters to unqualified ports.

[0033] The present invention is further configured such that: in step S4, the device under test docking specification:

[0034] S4.1 Define the pin assignment and anti-mismating structure design for TYPE-C connectors;

[0035] S4.2. Define the RS485 communication protocol (baud rate 115200bps, 8N1 format), including fields such as start character, address code, data field, and CRC checksum.

[0036] S4.3. A star grounding topology is adopted, with the signal ground and power ground connected in parallel through a 10Ω resistor, and an independent copper busbar is set at the chassis grounding point;

[0037] S4.4 Develop a cable detection module based on TDR technology that can identify fault types such as short circuit (<5Ω), open circuit (>1MΩ), and miswiring.

[0038] The present invention is further configured such that, in step S5, the automated testing process is implemented as follows:

[0039] S5.1 Integrate three-level operation permissions (engineer → technician → operator) in the HMI interface, and include MD5 encryption verification in the startup command;

[0040] S5.2 Automatically identify the type of connected device through impedance scanning technology (10Hz-1MHz) and dynamically load the corresponding test parameter template;

[0041] S5.3. A ping-pong buffering mechanism is adopted, and the parameters of the next channel are preset when the current channel is acquired, so as to achieve zero waiting time when switching channels.

[0042] S5.4 Build a visual interface on the touch screen and use a chromatogram to display the status of each channel (green for normal / yellow for warning / red for fault).

[0043] The present invention is further configured such that in step S6, signal acquisition and processing:

[0044] S6.1 Design a programmable gain amplifier (PGA) circuit that supports adaptive switching of voltage (0-10V), current (4-20mA), and frequency (0-1kHz) signals;

[0045] S6.2, adopts a 24-bit Σ-Δ ADC, configured with a 50Hz power frequency notch filter, and the sampling rate can reach 1kSPS / channel;

[0046] S6.3. Apply FIR digital filters to eliminate high-frequency noise, use median filtering to remove pulse interference, and establish an 8-point sliding window for data smoothing.

[0047] S6.4 Calculate key parameters such as the effective value of the signal (RMS), harmonic distortion rate (THD), and signal-to-noise ratio (SNR) to generate feature vectors.

[0048] The present invention is further configured such that in step S7, fault diagnosis and location:

[0049] S7.1 Establish a fault classification model based on the KNN algorithm, with training samples containing 12 typical fault waveform features;

[0050] S7.2 Construct a three-layer diagnostic logic (physical layer → protocol layer → application layer) and develop a reasoning mechanism based on a rule engine;

[0051] S7.3. The Dynamic Time Warping (DTW) algorithm is used to match the measured waveform with the standard waveform based on similarity (the threshold is set to 85%).

[0052] S7.4 Records raw data for 10 seconds before the fault occurs and supports exporting detailed diagnostic reports in CSV format via USB.

[0053] The present invention is further configured such that: in step S8, during the maintenance and upgrade of the multi-channel automatic detection system:

[0054] S8.1: A Wi-Fi module interface is reserved, supporting the uploading of device operation logs to the cloud platform via the HTTPS protocol;

[0055] S8.2 adopts a dual-bank storage architecture and realizes PLC program hot update via CAN bus (supports breakpoint resume);

[0056] S8.3, Integrated standard signal source (accuracy 0.01%), can automatically perform zero-point and full-scale calibration periodically;

[0057] S8.4 Establish a critical component replacement early warning mechanism based on the number of relay actions (>100,000 times) and power supply operating time (>5,000 hours).

[0058] Beneficial effects

[0059] Compared with known public technologies, the technical solution provided by this invention has the following beneficial effects:

[0060] 1. This invention connects the power cord to the input power supply, which allows the PLC3 in the outer casing to be powered on and put into operation. This allows the operator to connect the network communication interface, the reserved upgrade interface, the voltage feedback signal, the voltage output signal, the current feedback signal, and the current output signal for installation and use. This enables the PLC to receive the corresponding instructions and perform the specified operations for testing.

[0061] 2. This method achieves multi-channel switching control through relay modules. A standard 19-inch chassis integrates intermediate relays, switching power supplies, and other components to form a hardware platform. During operation, the system is powered on by an input power supply. The PLC executes pre-programmed six-state polling detection logic, scheduling eight channels for parallel detection using a time-slice round-robin algorithm. High-frequency and high-current signals are transmitted via BNC interfaces and banana plugs, respectively. A 24-bit Σ-Δ ADC acquires signals at a rate of 1kSPS / channel. After digital filtering and dynamic threshold analysis, the channel status is visualized on a touchscreen. The system employs a three-level fault diagnosis mechanism, combining KNN algorithm and DTW waveform matching technology for precise fault location. It also supports impedance scanning for automatic device type identification and interacts with the device under test via RS485 communication protocol. A ping-pong buffering mechanism ensures zero-delay channel switching throughout the detection process. Test data can be stored in real-time and uploaded to the cloud via a reserved Wi-Fi module, achieving fully automated detection from signal acquisition and processing to fault diagnosis. Attached Figure Description

[0062] Figure 1 This is a schematic diagram of the program logic for a multi-channel automatic detection method according to the present invention;

[0063] Figure 2 This is a schematic diagram of the external test wiring for a multi-channel automatic detection method according to the present invention;

[0064] Figure 3 This is a schematic diagram of the internal structure of a multi-channel automatic detection device according to the present invention;

[0065] Figure 4 This is a schematic diagram showing the completed installation of a multi-channel automatic detection device according to the present invention;

[0066] Figure 5 This is a schematic diagram of the slot surface of a multi-channel automatic detection device according to the present invention;

[0067] Figure 6 This is a schematic diagram showing the overall structure of a multi-channel automatic detection device according to the present invention;

[0068] Figure 7 This is a schematic diagram of the electrical principle of a multi-channel automatic detection method according to the present invention;

[0069] Figure 8This is a schematic diagram of the banana plug voltage output of a multi-channel automatic detection method according to the present invention;

[0070] Figure 9 This is a schematic diagram of the BNC board output of a multi-channel automatic detection method according to the present invention;

[0071] Figure 10 This is a schematic diagram of the banana plug voltage input for a multi-channel automatic detection method according to the present invention;

[0072] Figure 11 This is a schematic diagram of the BNC board current input for a multi-channel automatic detection method according to the present invention;

[0073] Figure 12 This is a schematic diagram of the product relationship in a multi-channel automatic detection method according to the present invention.

[0074] Legend:

[0075] 1. Intermediate relay; 2. Relay module; 3. PLC; 4. Switching power supply; 5. Switch; 6. Input power supply; 7. Network communication interface; 8. Reserved upgrade interface; 9. Voltage feedback signal; 10. Voltage output signal; 11. Current feedback signal; 12. Current output signal; 13. Touch screen; 14. Outer casing. Detailed Implementation

[0076] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. 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.

[0077] The present invention will be further described below with reference to embodiments.

[0078] Example 1

[0079] like Figure 1-6As shown, the present invention provides a technical solution: a multi-channel automatic detection device, comprising: an outer casing 14, an intermediate relay 1 disposed in the outer casing 14, a relay module 2 disposed at the bottom of the intermediate relay 1, a PLC 3 disposed at the bottom of the relay module 2, a switching power supply 4 disposed at one end of the PLC 3, a switch 5 disposed on the outer surface of the intermediate relay 1, an input power supply 6 disposed at one end of the outer casing 14, a network communication interface 7 disposed on one side of the input power supply 6, a reserved upgrade interface 8 disposed at the upper end of the network communication interface 7 and the input power supply 6, a voltage feedback signal 9 disposed at one end of the reserved upgrade interface 8, a voltage output signal 10 disposed at the bottom of the voltage feedback signal 9, a current feedback signal 11 disposed at the end of the voltage feedback signal 9 away from the reserved upgrade interface 8, a current output signal 12 disposed at the end of the voltage output signal 10 away from the network communication interface 7, and a touch screen 13 disposed on the outer casing 14;

[0080] The intermediate relay 1 is installed in the outer casing 14. The relay module 2 is installed in the outer casing 14 at the bottom of the intermediate relay 1. The PLC 3 is installed in the outer casing on the side of the relay module 2 away from the intermediate relay 1. The switching voltage 4 is installed in the outer casing 14 at one end of the PLC 3. The input power supply 6 is installed on the outer casing 14 and connected to the switching power supply 4. The network communication interface 7, the reserved upgrade interface 8, the voltage feedback signal 9, the voltage output signal 10, the current feedback signal 11, and the current output signal 12 are all installed on the outer casing 14 and connected to the PLC 3. The outer surface of the touch screen 13 is nested in the outer casing 14 and connected to the PLC 3.

[0081] In this embodiment, when the operator uses this testing device to perform multi-channel testing, they can first connect the power cord to the input power supply 6, which will power on the PLC3 in the outer casing 14. Then, the operator can connect to the network communication interface 7, the reserved upgrade interface 8, the voltage feedback signal 9, the voltage output signal 10, the current feedback signal 11, and the current output signal 12 for installation and use. This will allow the PLC3 to receive the corresponding instructions and perform the specified operations for testing.

[0082] Example 2

[0083] like Figure 1-12 As shown, the present invention provides a technical solution: a multi-channel automatic detection method, comprising the following steps:

[0084] S1. System hardware architecture construction;

[0085] S2, Test Logic Programming;

[0086] S3, Test fixture integration and debugging;

[0087] S4. Test device docking specifications;

[0088] S5, implementation of automated testing processes;

[0089] S6. Signal Acquisition and Processing;

[0090] S7. Fault diagnosis and location;

[0091] S8, maintenance and upgrade of multi-channel automatic detection system;

[0092] In step S1, during the construction of the system hardware architecture:

[0093] S1.1, An industrial-grade PLC3 is selected as the main controller, paired with a 16-channel relay module to achieve multi-channel switching selection. A 5.7-inch HMI touch screen 13 is used as the human-machine interface, and a 24V / 5A switching power supply is configured to meet the system power supply requirements.

[0094] S1.2. High-frequency signal transmission is achieved using BNC interfaces, and banana sockets are responsible for high-current channel connections. All interfaces meet the IP67 protection standard.

[0095] S1.3. An optocoupler isolation circuit is set between PLC3 and relay module 2, and a varistor is configured for protection at the relay output terminal.

[0096] S1.4. It adopts a 19-inch standard chassis structure, with the internal layout arranged according to functional areas, and the power and low-voltage lines are laid out in layers.

[0097] In step S2, the test logic program design:

[0098] S2.1 Design a six-state polling detection logic (initialization → channel selection → signal excitation → feedback acquisition → result judgment → report generation), and set a timeout protection mechanism for each state;

[0099] S2.2 Develop a channel scheduling algorithm based on time slice rotation, supporting parallel detection of 8 channels, and the detection frequency of key channels can be set to increase to 3 times / cycle;

[0100] S2.3 Establish a three-level fault classification system (communication failure → signal abnormality → hardware failure) and design corresponding handling strategies such as automatic retry, channel shielding, and system emergency stop;

[0101] S2.4 Embed a digital filtering algorithm in the PLC3 program to perform moving average processing on the acquired signal and set a dynamic threshold fluctuation range of ±5%.

[0102] In step S3, during the integration and debugging of the testing fixtures:

[0103] S3.1. Use a network analyzer to calibrate the BNC interface impedance (50Ω±1%), and use the four-wire method to measure the banana socket contact resistance (≤10mΩ);

[0104] S3.2. Use an oscilloscope to measure the switching delay of each channel (≤10ms) to ensure that the excitation signal is phase-aligned with the acquisition window;

[0105] S3.3. Conduct a 72-hour aging test within a temperature range of -20℃ to 60℃ to verify the contact stability of the relay contacts;

[0106] S3.4. Perform surge (4kV) and electrostatic (8kV) tests according to GB / T17626 standard, and add magnetic ring filters to unqualified ports;

[0107] In step S4, the device under test docking specifications are as follows:

[0108] S4.1 Define the pin assignment and anti-mismating structure design for TYPE-C connectors;

[0109] S4.2. Define the RS485 communication protocol (baud rate 115200bps, 8N1 format), including fields such as start character, address code, data field, and CRC checksum.

[0110] S4.3. A star grounding topology is adopted, with the signal ground and power ground connected in parallel through a 10Ω resistor, and an independent copper busbar is set at the chassis grounding point;

[0111] S4.4 Develop a cable detection module based on TDR technology that can identify fault types such as short circuit (<5Ω), open circuit (>1MΩ), and miswiring;

[0112] In step S5, the automated testing process is implemented as follows:

[0113] S5.1 Integrate three-level operation permissions (engineer → technician → operator) in the HMI interface, and include MD5 encryption verification in the startup command;

[0114] S5.2 Automatically identify the type of connected device through impedance scanning technology (10Hz-1MHz) and dynamically load the corresponding test parameter template;

[0115] S5.3. A ping-pong buffering mechanism is adopted, and the parameters of the next channel are preset when the current channel is acquired, so as to achieve zero waiting time when switching channels.

[0116] S5.4 Build a visualization interface on the touch screen 13 and use a chromatogram to display the status of each channel (green normal / yellow warning / red fault);

[0117] In step S6, signal acquisition and processing:

[0118] S6.1 Design a programmable gain amplifier (PGA) circuit that supports adaptive switching of voltage (0-10V), current (4-20mA), and frequency (0-1kHz) signals;

[0119] S6.2, adopts a 24-bit Σ-Δ ADC, configured with a 50Hz power frequency notch filter, and the sampling rate can reach 1kSPS / channel;

[0120] S6.3. Apply FIR digital filters to eliminate high-frequency noise, use median filtering to remove pulse interference, and establish an 8-point sliding window for data smoothing.

[0121] S6.4 Calculate key parameters such as the effective value of the signal (RMS), harmonic distortion rate (THD), and signal-to-noise ratio (SNR) to generate feature vectors;

[0122] In step S7, fault diagnosis and location:

[0123] S7.1 Establish a fault classification model based on the KNN algorithm, with training samples containing 12 typical fault waveform features;

[0124] S7.2 Construct a three-layer diagnostic logic (physical layer → protocol layer → application layer) and develop a reasoning mechanism based on a rule engine;

[0125] S7.3. The Dynamic Time Warping (DTW) algorithm is used to match the measured waveform with the standard waveform based on similarity (the threshold is set to 85%).

[0126] S7.4 Records raw data for 10 seconds before the fault occurs, and supports exporting detailed diagnostic reports in CSV format via USB;

[0127] Step S8, multi-channel automatic detection system maintenance and upgrade:

[0128] S8.1: A Wi-Fi module interface is reserved, supporting the uploading of device operation logs to the cloud platform via the HTTPS protocol;

[0129] S8.2. Adopts a dual-bank storage architecture and realizes PLC (3) program hot update (supports breakpoint resume) through CAN bus;

[0130] S8.3, Integrated standard signal source (accuracy 0.01%), can automatically perform zero-point and full-scale calibration periodically;

[0131] S8.4 Establish a critical component replacement early warning mechanism based on the number of relay actions (>100,000 times) and power supply operating time (>5,000 hours).

[0132] In this embodiment, the system uses an industrial-grade PLC3 as the core controller and achieves multi-channel switching control through a relay module 2. The hardware platform is constructed by integrating intermediate relays 1, switching power supplies 4, and other components in a standard 19-inch chassis. During operation, the system is powered by the input power supply 6. The PLC3 executes the pre-programmed six-state polling detection logic and schedules 8 channels for parallel detection through a time-slice round-robin algorithm. High-frequency signals and high-current signals are transmitted through the BNC interface and banana plug, respectively.

[0133] During the test, the 24-bit Σ-Δ ADC acquires signals at a rate of 1kSPS / channel. After digital filtering and dynamic threshold analysis, the channel status is displayed on the touch screen 13. The system adopts a three-level fault diagnosis mechanism, combining the KNN algorithm and DTW waveform matching technology to achieve accurate fault location. It also supports impedance scanning to automatically identify the device type and interacts with the device under test through the RS485 communication protocol.

[0134] The entire testing process employs a ping-pong buffering mechanism to ensure zero-delay channel switching. Test data can be stored in real time and uploaded to the cloud via a reserved Wi-Fi module, achieving fully automated testing from signal acquisition and processing to fault diagnosis.

[0135] Working principle:

[0136] like Figure 1-12 As shown, in actual use, the present invention powers the system via input power supply 6, enabling the PLC3 main controller to start working. After the operator selects the test mode via the 5.7-inch HMI touch screen 13, the PLC3 controls the relay module 2 to switch between multiple channels according to the pre-programmed six-state polling detection logic (initialization → channel selection → signal excitation → feedback acquisition → result judgment → report generation). The system uses a time-slice rotation algorithm to achieve parallel detection of 8 channels, and the detection frequency of key channels can be increased to 3 times / cycle. At the same time, the stability of signal transmission is ensured by optocoupler isolation circuit and varistor protection. The test signal is transmitted through a BNC interface (impedance 50Ω±1%) conforming to the IP67 standard and a banana plug (contact resistance ≤10mΩ). The relay switching delay is controlled within 10ms, meeting the industrial-grade real-time requirements.

[0137] During the signal acquisition and processing stage, the 24-bit Σ-Δ ADC acquires test data at a sampling rate of 1kSPS / channel. The 0-10V voltage, 4-20mA current, and 0-1kHz frequency signals are adaptively conditioned by a programmable gain amplifier (PGA). The acquired signals are filtered by an FIR digital filter to eliminate high-frequency noise, and a median filter is used to remove pulse interference. An 8-point sliding window is established for data smoothing. The system dynamically sets a floating threshold range of ±5%, calculates characteristic parameters such as the effective value (RMS) and harmonic distortion (THD) of the signal in real time, and interacts with the device under test via RS485 communication protocol (baud rate 115200bps, 8N1 format). During the test, a ping-pong buffer mechanism is used to achieve seamless channel switching. All status information is displayed in real time on the chromatogram interface of the touch screen (green for normal / yellow for warning / red for fault).

[0138] In terms of fault diagnosis and system maintenance, a three-level diagnostic system (physical layer → protocol layer → application layer) is adopted, combined with KNN algorithm and DTW waveform matching technology (similarity threshold 85%) for fault location. It can identify 12 typical fault modes. The system automatically records the raw data of the 10 seconds before the fault and supports exporting diagnostic reports in CSV format via USB. It realizes hot updating of PLC3 program through dual-bank storage architecture. It has a built-in 0.01% accuracy standard signal source for periodic self-calibration and predicts component life based on the number of relay actions (>100,000 times) and power supply operating time (>5,000 hours). The reserved Wi-Fi module supports uploading operation logs to the cloud platform via HTTPS protocol. The TYPE-C connector anti-misinsertion design and star grounding topology (signal ground and power ground are connected in parallel through a 10Ω resistor) further ensure system reliability and realize a complete automated testing process from hardware detection to software analysis.

[0139] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A multi-channel automatic detection device, characterized in that, include: The outer casing (14) contains an intermediate relay (1), a relay module (2) is located at the bottom of the intermediate relay (1), a PLC (3) is located at the bottom of the relay module (2), a switching power supply (4) is located at one end of the PLC (3), a switch (5) is located on the outer surface of the intermediate relay (1), an input power supply (6) is located at one end of the outer casing (14), and a network communication interface (7) is located on one side of the input power supply (6). 7) and the upper end of the input power supply (6) are provided with a reserved upgrade interface (8), one end of the reserved upgrade interface (8) is provided with a voltage feedback signal (9), the bottom of the voltage feedback signal (9) is provided with a voltage output signal (10), the end of the voltage feedback signal (9) away from the reserved upgrade interface (8) is provided with a current feedback signal (11), the end of the voltage output signal (10) away from the network communication interface (7) is provided with a current output signal (12), and the outer casing (14) is provided with a touch screen (13); The intermediate relay (1) is installed in the outer casing (14). The relay module (2) is installed in the outer casing (14) at the bottom of the intermediate relay (1). The PLC (3) is installed in the outer casing on the side of the relay module (2) away from the intermediate relay (1). The switching voltage (4) is installed in the outer casing (14) at one end of the PLC (3). The input power supply (6) is installed on the outer casing (14) and connected to the switching power supply (4). The network communication interface (7), the reserved upgrade interface (8), the voltage feedback signal (9), the voltage output signal (10), the current feedback signal (11), and the current output signal (12) are all installed on the outer casing (14) and connected to the PLC (3). The outer surface of the touch screen (13) is nested in the outer casing (14) and connected to the PLC (3).

2. A multi-channel automatic detection method, characterized in that, Includes the following steps: S1. System hardware architecture construction; S2, Test Logic Programming; S3, Test fixture integration and debugging; S4. Test device docking specifications; S5, implementation of automated testing processes; S6. Signal Acquisition and Processing; S7. Fault diagnosis and location; S8, maintenance and upgrade of multi-channel automatic detection system.

3. The multi-channel automatic detection method according to claim 1, characterized in that: In step S1, during the construction of the system hardware architecture: S1.

1. An industrial-grade PLC (3) is selected as the main controller and paired with a 16-channel relay module to achieve multi-channel switching selection. A 5.7-inch HMI touch screen (13) is used as the human-machine interface and a 24V / 5A switching power supply is configured to meet the system power supply requirements. S1.

2. High-frequency signal transmission is achieved using BNC interfaces, and banana sockets are responsible for high-current channel connections. All interfaces meet the IP67 protection standard. S1.

3. An optocoupler isolation circuit is set between the PLC (3) and the relay module (2), and a varistor is configured to protect the relay output terminal. S1.4 adopts a 19-inch standard chassis structure, with internal layout arranged according to functional zones, and high-voltage and low-voltage lines routed separately.

4. The multi-channel automatic detection method according to claim 1, characterized in that: In step S2, the test logic program design: S2.1 Design a six-state polling detection logic (initialization → channel selection → signal excitation → feedback acquisition → result judgment → report generation), and set a timeout protection mechanism for each state; S2.2 Develop a channel scheduling algorithm based on time slice rotation, supporting parallel detection of 8 channels, and the detection frequency of key channels can be set to increase to 3 times / cycle; S2.3 Establish a three-level fault classification system (communication failure → signal abnormality → hardware failure) and design corresponding handling strategies such as automatic retry, channel shielding, and system emergency stop; S2.

4. Embed a digital filtering algorithm in the PLC (3) program to perform a moving average processing on the acquired signal and set a dynamic threshold floating range of ±5%.

5. The multi-channel automatic detection method according to claim 1, characterized in that: In step S3, during the integration and debugging of the testing fixtures: S3.

1. Use a network analyzer to calibrate the BNC interface impedance (50Ω±1%), and use the four-wire method to measure the banana socket contact resistance (≤10mΩ); S3.

2. Use an oscilloscope to measure the switching delay of each channel (≤10ms) to ensure that the excitation signal is phase-aligned with the acquisition window; S3.

3. Conduct a 72-hour aging test within a temperature range of -20℃ to 60℃ to verify the contact stability of the relay contacts; S3.

4. Perform surge (4kV) and electrostatic (8kV) tests according to GB / T17626 standard, and add magnetic ring filters to unqualified ports.

6. The multi-channel automatic detection method according to claim 1, characterized in that: In step S4, the device under test docking specifications are as follows: S4.1 Define the pin assignment and anti-mismating structure design for TYPE-C connectors; S4.

2. Define the RS485 communication protocol (baud rate 115200bps, 8N1 format), including fields such as start character, address code, data field, and CRC checksum. S4.

3. A star grounding topology is adopted, with the signal ground and power ground connected in parallel through a 10Ω resistor, and an independent copper busbar is set at the chassis grounding point; S4.4 Develop a cable detection module based on TDR technology that can identify fault types such as short circuit (<5Ω), open circuit (>1MΩ), and miswiring.

7. The multi-channel automatic detection method according to claim 5, characterized in that, In step S5, the automated testing process is implemented as follows: S5.1 Integrate three-level operation permissions (engineer → technician → operator) in the HMI interface, and include MD5 encryption verification in the startup command; S5.2 Automatically identify the type of connected device through impedance scanning technology (10Hz-1MHz) and dynamically load the corresponding test parameter template; S5.

3. A ping-pong buffering mechanism is adopted, and the parameters of the next channel are preset when the current channel is acquired, so as to achieve zero waiting time when switching channels. S5.

4. Construct a visualization interface on the touch screen (13) and display the status of each channel (green normal / yellow warning / red fault) using a chromatogram.

8. The multi-channel automatic detection method according to claim 5, characterized in that, In step S6, signal acquisition and processing: S6.1 Design a programmable gain amplifier (PGA) circuit that supports adaptive switching of voltage (0-10V), current (4-20mA), and frequency (0-1kHz) signals; S6.2, adopts a 24-bit Σ-Δ ADC, configured with a 50Hz power frequency notch filter, and the sampling rate can reach 1kSPS / channel; S6.

3. Apply FIR digital filters to eliminate high-frequency noise, use median filtering to remove pulse interference, and establish an 8-point sliding window for data smoothing. S6.4 Calculate key parameters such as the effective value of the signal (RMS), harmonic distortion rate (THD), and signal-to-noise ratio (SNR) to generate feature vectors.

9. The multi-channel automatic detection method according to claim 5, characterized in that, In step S7, fault diagnosis and location: S7.1 Establish a fault classification model based on the KNN algorithm, with training samples containing 12 typical fault waveform features; S7.2 Construct a three-layer diagnostic logic (physical layer → protocol layer → application layer) and develop a reasoning mechanism based on a rule engine; S7.

3. The Dynamic Time Warping (DTW) algorithm is used to match the measured waveform with the standard waveform based on similarity (the threshold is set to 85%). S7.4 Records raw data for 10 seconds before the fault occurs and supports exporting detailed diagnostic reports in CSV format via USB.

10. A multi-channel automatic detection method according to claim 5, characterized in that, Step S8, multi-channel automatic detection system maintenance and upgrade: S8.1: A Wi-Fi module interface is reserved, supporting the uploading of device operation logs to the cloud platform via the HTTPS protocol; S8.

2. Adopts a dual-bank storage architecture and realizes PLC (3) program hot update (supports breakpoint resume) through CAN bus; S8.3, Integrated standard signal source (accuracy 0.01%), can automatically perform zero-point and full-scale calibration periodically; S8.4 Establish a critical component replacement early warning mechanism based on the number of relay actions (>100,000 times) and power supply operating time (>5,000 hours).

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