Programmable intelligent controller fault injection and test system based on relay matrix

Abstract

The utility model discloses a programmable intelligent controller fault injection and test system based on a relay matrix, which comprises a fault injection device, a general data acquisition unit and an upper computer, and the fault injection device and the general data acquisition unit are connected with the upper computer through Ethernet signals. The fault injection device comprises an ADC acquisition board card, an analog signal fault injection board card, a switch signal fault injection board card, a CAN signal fault injection board card and an Ethernet signal fault injection board card. According to the programmable intelligent controller fault injection and test system based on the relay matrix, fault injection can be carried out on various types of signals in the programmable intelligent controller in an energy system, a basis is provided for reliability design analysis of the system, and in addition, the fault injection and test system can be used for testing the fault of the programmable intelligent controller. And fault analysis and diagnosis can be carried out by collecting each signal, and a fault state is transmitted back to an upper computer for analysis.

Description

Technical Field

[0001] The utility model relates to the technical field of programmable intelligent controllers, in particular to a fault injection and testing system of a programmable intelligent controller based on a relay matrix. Background Art

[0002] The energy system is a super-large and complex industrial system. Once the system fails, it will cause huge losses to the energy environment. The programmable intelligent controller is the center of energy conversion and utilization, which is used to ensure the effective and reliable operation of the energy industrial system. Its autonomous controllability is related to the safety of the energy system. There are many types of faults that occur in the actual application of the system, and they are very sporadic. Traditional testing methods are difficult to accurately test the fault detection capabilities of programmable intelligent controllers. Therefore, it is necessary to design a set of multi-fault injection devices to realize the system safety and reliability testing of self-developed programmable intelligent devices. Through hardware simulation of multiple types of faults in the control process of programmable intelligent controllers, multiple signal fault simulations on the same system are realized. Utility Model Content

[0003] The purpose of the utility model is to provide a programmable intelligent controller fault injection and testing system based on a relay matrix, which can perform fault injection on various types of signals in the programmable intelligent controller in the energy system, and provide a basis for system reliability design analysis. In addition, it can also perform fault analysis and diagnosis by collecting various signals, and transmit the fault status back to the host computer for analysis.

[0004] The technical solution of the utility model is as follows:

[0005] A programmable intelligent controller fault injection and test system based on a relay matrix, comprising a fault injection device, a universal data acquisition unit and a host computer, wherein the fault injection device and the universal data acquisition unit are connected to the host computer via Ethernet signals, and the fault injection device comprises an ADC acquisition board, an analog signal fault injection board, a switch signal fault injection board, a CAN signal fault injection board and an Ethernet signal fault injection board;

[0006] The analog input interface of the analog signal fault injection board is connected to the sensor signal of the programmable intelligent controller, and the analog output interface of the analog signal fault injection board is respectively connected to the digital input interface of the ADC acquisition board and the universal data acquisition unit signal;

[0007] The switch quantity input interface of the switch signal fault injection board is connected with the switch and button signals of the programmable intelligent controller, and the switch quantity output interface of the switch signal fault injection board is connected with the universal data acquisition unit signal;

[0008] The CAN signal input interface of the CAN signal fault injection board is connected to the CAN node signal of the programmable intelligent controller, and the CAN signal output interface of the CAN signal fault injection board is connected to the universal data acquisition unit signal;

[0009] The Ethernet signal input interface of the Ethernet signal fault injection board is connected to the Ethernet node signal of the programmable intelligent controller, and the Ethernet signal output interface of the Ethernet signal fault injection board is connected to the universal data acquisition unit signal.

[0010] Furthermore, the analog signal fault injection board, the switch signal fault injection board, the CAN signal fault injection board, and the Ethernet signal fault injection board all have a relay matrix, and different fault injections are achieved by controlling the relay matrix.

[0011] Furthermore, the analog input interface of the analog signal fault injection board superimposes a 16-bit analog fault signal with an amplitude of -1V to 1V and an adjustable frequency range of 0Hz-40kHz on the injection signal, and the injection signal amplitude range is -1V to 1V; the analog output interface of the analog signal fault injection board outputs the injection signal after fault superposition, and affected by the acquisition circuit, the output signal amplitude range is -1V to 1V. The analog fault module adopts a top plate and a bottom plate combination, and the top plate and the bottom plate communicate through SPI to realize multi-channel analog fault injection.

[0012] Furthermore, the switch quantity input interface of the switch signal fault injection board has a high level range of 12V to 36V for the switch quantity injection signal; the switch quantity output interface of the switch signal fault injection board can convert the original signal into a short circuit, open circuit, forced high, forced low fault output, or maintain the original signal output.

[0013] Furthermore, the CAN_H of the CAN signal input interface of the CAN signal fault injection board is 3.5V, the CAN_L is 1.5V, and the differential voltage is 2V; the CAN signal output interface of the CAN signal fault injection board can realize the CAN signal of the programmable intelligent controller.

[0014] Furthermore, the Ethernet signal input interface of the Ethernet signal fault injection board adopts a shielded Category 5e network cable to input the original signal; the Ethernet signal output interface of the Ethernet signal fault injection board can inject short circuit fault, speed reduction fault, open circuit fault and impedance mismatch fault into the original signal.

[0015] Compared with the prior art, the beneficial effect of the utility model is that the utility model provides a new fault injection system for programmable intelligent controllers, which realizes the injection of multiple types of faults of various signals by controlling the relay matrix. At the same time, the system can detect and identify related faults, thereby improving the real-time safety of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 A system block diagram of a programmable intelligent controller fault injection and testing system based on a relay matrix provided by the utility model;

[0018] Figure 2 This is a control schematic diagram of the relay matrix of the utility model. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical solution and advantages of the utility model more clear, the utility model is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the utility model and are not used to limit the utility model.

[0020] In order to illustrate the technical solution of the present invention, specific embodiments are provided below for illustration.

[0021] Example

[0022] See also Figure 1, this embodiment provides a fault injection and testing system for a programmable intelligent controller based on a relay matrix, including a fault injection device, a universal data acquisition unit and a host computer, wherein the fault injection device and the universal data acquisition unit are connected to the host computer via Ethernet signals. The fault injection device includes an ADC acquisition board, an analog signal fault injection board, a switch signal fault injection board, a CAN signal fault injection board and an Ethernet signal fault injection board. The analog input interface of the analog signal fault injection board is connected to the sensor signal of the programmable intelligent controller, and the analog output interface of the analog signal fault injection board is respectively connected to the digital input interface of the ADC acquisition board and the universal data acquisition unit signal. The switch input interface of the switch signal fault injection board is connected to the switch and button signals of the programmable intelligent controller, and the switch output interface of the switch signal fault injection board is connected to the universal data acquisition unit signal. The CAN signal input interface of the CAN signal fault injection board is connected to the CAN node signal of the programmable intelligent controller, and the CAN signal output interface of the CAN signal fault injection board is connected to the universal data acquisition unit signal. The Ethernet signal input interface of the Ethernet signal fault injection board is connected to the Ethernet node signal of the programmable intelligent controller, and the Ethernet signal output interface of the Ethernet signal fault injection board is connected to the universal data acquisition unit signal.

[0023] Among them, the analog input interface of the analog signal fault injection board superimposes a 16-bit analog fault signal with an amplitude of -1V to 1V and an adjustable frequency range of 0Hz-40kHz on the injection signal, and the injection signal amplitude range is -1V to 1V; the analog output interface of the analog signal fault injection board outputs the injection signal after fault superposition. Affected by the acquisition circuit, the output signal amplitude range is -1V to 1V. The analog fault module adopts a top plate and a bottom plate combination, and the top plate and the bottom plate communicate through SPI to realize multi-channel analog fault injection.

[0024] Among them, the switch input interface of the switch signal fault injection board has a high level range of 12V to 36V for the switch injection signal. The switch output interface of the switch signal fault injection board can convert the original signal into a short circuit, open circuit, forced high, forced low fault output, or maintain the original signal output.

[0025] Among them, the CAN signal input interface of the CAN signal fault injection board has CAN_H of 3.5V, CAN_L of 1.5V, and a differential voltage of 2V. This state is a dominant level, indicating a logic 0; when CAN_H and CAN_L are both 2.5V, the differential voltage is 0V, and this state is a recessive level, indicating a logic 1. The CAN signal output interface of the CAN signal fault injection board can realize the CAN signal of the programmable intelligent controller; CAN_H is directly pulled up to 5V, CAN_H line is short-circuited, CAN_H and CAN_L lines are short-circuited, the impedance of the CAN bus is changed, etc. Fault injection, or directly maintain the original injection signal output.

[0026] Among them, the Ethernet signal input interface of the Ethernet signal fault injection board uses a shielded Category 5e network cable to input the original signal; the Ethernet signal output interface of the Ethernet signal fault injection board can inject short circuit fault, speed reduction fault, open circuit fault, and impedance mismatch fault into the original signal.

[0027] Among them, the analog signal fault injection board, switch signal fault injection board, CAN signal fault injection board, and Ethernet signal fault injection board all have relay matrices, and different fault injections are achieved by controlling the relay matrix. The idea of ​​implementing channel switching in relays is similar to that of analog switches, but the implementation method is different. Relays achieve the on-off of physical lines by controlling the coil to attract, avoiding problems such as crosstalk between channels. The connection diagram of a single relay in the relay matrix of the channel switching circuit is shown in the figure below. Figure 2 As shown; when the relay maintains the initial state, the original signal Signal1 is directly transmitted to OUT1; when the relay is activated, the two single-pole double-throw switches are activated at the same time, and the original signal Siganl1 is connected to in1 as an input end of the superposition circuit. After superposition, it is output to OUT1 through out1 and sent to the data acquisition unit to realize the injection of fault signals.

[0028] The fault injection device simulates multiple faults by controlling relays. Each channel realizes different types of fault injection through relay collaborative control, where 1 indicates that fault injection is required and 0 indicates normal transmission.

[0029] Table 1 Correspondence between Channel array elements and channels

[0030]

[0031] There are four types of faults, which can be represented by 2 bits in binary, that is, 00 represents an open circuit fault, 01 represents a short circuit fault, 10 represents a forced high fault, and 11 represents a forced low fault.

[0032] Table 2 Correspondence between Fault array elements and channels

[0033]

[0034] The host computer can configure the relevant information of the fault injection device and receive the data uploaded by the communication module of the fault injection device.

[0035] Universal data acquisition unit: collects various signals from the programmable intelligent controller and uploads them to the host computer. At the same time, the host computer performs fault analysis on the relevant signals, which can improve the efficiency of diagnosing various related faults inside the programmable intelligent controller.

[0036] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A fault injection and testing system for a programmable intelligent controller based on a relay matrix, characterized in that: It includes a fault injection device, a universal data acquisition unit and a host computer, wherein the fault injection device and the universal data acquisition unit are connected to the host computer via Ethernet signals, and the fault injection device includes an ADC acquisition board, an analog signal fault injection board, a switch signal fault injection board, a CAN signal fault injection board and an Ethernet signal fault injection board; The analog input interface of the analog signal fault injection board is connected to the sensor signal of the programmable intelligent controller, and the analog output interface of the analog signal fault injection board is respectively connected to the digital input interface of the ADC acquisition board and the universal data acquisition unit signal; The switch quantity input interface of the switch signal fault injection board is connected with the switch and button signals of the programmable intelligent controller, and the switch quantity output interface of the switch signal fault injection board is connected with the universal data acquisition unit signal; The CAN signal input interface of the CAN signal fault injection board is connected to the CAN node signal of the programmable intelligent controller, and the CAN signal output interface of the CAN signal fault injection board is connected to the universal data acquisition unit signal; The Ethernet signal input interface of the Ethernet signal fault injection board is connected to the Ethernet node signal of the programmable intelligent controller, and the Ethernet signal output interface of the Ethernet signal fault injection board is connected to the universal data acquisition unit signal.

2. The programmable intelligent controller fault injection and testing system based on relay matrix according to claim 1, characterized in that: The analog signal fault injection board, the switch signal fault injection board, the CAN signal fault injection board, and the Ethernet signal fault injection board all have a relay matrix, and different fault injections are achieved by controlling the relay matrix.

3. The programmable intelligent controller fault injection and testing system based on relay matrix according to claim 1, characterized in that: The analog input interface of the analog signal fault injection board superimposes a 16-bit analog fault signal with an amplitude of -1V to 1V and an adjustable frequency range of 0Hz-40kHz on the injection signal, and the injection signal amplitude range is -1V to 1V; the analog output interface of the analog signal fault injection board outputs the injection signal after the fault is superimposed. Affected by the acquisition circuit, the output signal amplitude range is -1V to 1V. The analog fault module adopts a top plate and a bottom plate combination, and the top plate and the bottom plate communicate through SPI to realize multi-channel analog fault injection.

4. The programmable intelligent controller fault injection and testing system based on relay matrix according to claim 1, characterized in that: The switch quantity input interface of the switch signal fault injection board has a high level range of 12V to 36V for the switch quantity injection signal; the switch quantity output interface of the switch signal fault injection board can convert the original signal into a short circuit, open circuit, forced high, forced low fault output, or maintain the original signal output.

5. The programmable intelligent controller fault injection and testing system based on relay matrix according to claim 1, characterized in that: The CAN_H of the CAN signal input interface of the CAN signal fault injection board is 3.5V, the CAN_L is 1.5V, and the differential voltage is 2V; the CAN signal output interface of the CAN signal fault injection board can realize the CAN signal of the programmable intelligent controller.

6. The programmable intelligent controller fault injection and testing system based on relay matrix according to claim 1, characterized in that: The Ethernet signal input interface of the Ethernet signal fault injection board adopts a shielded Category 5e network cable to input the original signal; the Ethernet signal output interface of the Ethernet signal fault injection board can inject short circuit fault, speed reduction fault, open circuit fault and impedance mismatch fault into the original signal.

Images