A semi-automatic testing machine with intelligent controller

Abstract

This utility model discloses a semi-automatic testing machine for intelligent controllers, including a frame, a processor, multiple testing mechanisms, multiple power-on mechanisms, a response module, and a control module. The testing mechanisms include pressing cylinders, and the power-on mechanisms include liftable conductive probes. The frame is equipped with a drawer-type product tooling box for holding multiple intelligent controllers. During operation, the probes are inserted into the interfaces of the intelligent controllers to connect the response modules. The pressing cylinders press physical buttons, triggering the response modules to operate. The processor, in conjunction with sensors and a vision system, judges the test results and displays them on a screen. This utility model achieves multi-station synchronous testing, significantly improving efficiency, reducing labor costs, and increasing testing accuracy. It is suitable for batch testing of intelligent controllers with adjustable height tables.

Description

Technical Field

[0001] This utility model relates to the technical field of intelligent controller testing equipment, specifically to a semi-automatic testing machine for intelligent controllers of height-adjustable desks, which is particularly suitable for batch automated testing of the physical button functions and electrical performance of intelligent controllers. Background Technology

[0002] With the rapid development of smart homes and office automation, the market demand for height-adjustable desks, as a type of office furniture that combines health and efficiency, continues to grow. The intelligent controller, as the core control component of a height-adjustable desk, is responsible for receiving commands from users via physical buttons (such as raising / lowering, resetting, starting / stopping, etc.) and driving the motor to execute the corresponding actions. Its performance and stability directly determine the user experience and safety of the height-adjustable desk.

[0003] Currently, the functional testing of intelligent controllers in factories is still mainly done manually. The testing process is roughly as follows: operators need to connect the interface of a single intelligent controller to a test power supply, manually press each physical button on the controller, and observe the response status of the external motor or indicator light to determine whether the controller is working properly. This testing method has many drawbacks: 1. Low efficiency: Manual testing requires operating each intelligent controller individually, and only one product can be tested at a time. For factories with large-scale production, the testing process can easily become a bottleneck in production capacity, making it difficult to meet the needs of mass production. 2. High labor costs: The testing process consumes a lot of manpower, especially during peak seasons, when additional operators are needed to ensure the testing progress, leading to increased production costs. 3. Unstable testing accuracy: Individual differences in the force and frequency of manually pressing buttons can lead to misjudgments; at the same time, prolonged repetitive operation can easily cause operator fatigue, further reducing testing accuracy. 4. Incomplete functional coverage: Manual testing relies heavily on visual observation of the motor or indicator light status, which poses a risk of quality errors. 5. Difficult data traceability: Manual recording of test results is prone to clerical errors, and it is difficult to systematically store test data, which is not conducive to subsequent quality analysis and traceability.

[0004] Therefore, developing an intelligent controller testing device that can achieve multi-station synchronous testing, reduce manual intervention, and improve testing efficiency and accuracy has become the key to solving the pain points of existing technologies. Utility Model Content

[0005] The purpose of this invention is to overcome the problems of low efficiency, high cost, and poor accuracy in manual testing of intelligent controllers in the prior art, and to provide a semi-automatic testing machine for intelligent controllers, which realizes synchronous physical pressing and functional testing of multiple intelligent controllers, thereby improving the level of testing automation.

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution:

[0007] A semi-automatic testing machine for an intelligent controller includes a frame and a processor mounted on the frame. Multiple testing mechanisms are installed on the frame, each including several pressing cylinders. Multiple energizing mechanisms are installed on the frame below the testing mechanisms, each including several movable and conductive probes. Each probe in each energizing mechanism is connected to a response module, and each pressing cylinder in each testing mechanism is connected to a control module. Both the response module and the control module are electrically connected to the processor and powered. The probes in each energizing mechanism can be inserted into the interface of the intelligent controller to activate the corresponding response module. The telescopic rods of the pressing cylinders in each testing mechanism can contact and press physical buttons on the intelligent controller to trigger the corresponding response module for functional testing.

[0008] Preferably, the rack is equipped with a drawer-type product tooling box for placing multiple intelligent controllers; the testing mechanism is located on the rack above the product tooling box, and the power-on mechanism is located on the rack below the product tooling box.

[0009] Preferably, each group of response modules includes an electrically connected relay and a motor, and each group of control modules includes a solenoid valve; the relay, motor, and solenoid valve are all electrically connected to the processor.

[0010] Preferably, a control panel is installed on the rack, the control panel includes several function keys, and the control panel is connected to the processor to realize the operation response module and the control module.

[0011] Preferably, it also includes a multi-port load board, through which the relays, motors, and solenoid valves are electrically connected to the processor.

[0012] Preferably, a vision system, an infrared sensor, and a fiber optic sensor are connected to the top of the rack, and the vision system, infrared sensor, and fiber optic sensor are all connected to the processor.

[0013] Preferably, the product tooling box has openings at the top and bottom, and the inner wall of the product tooling box has slots. The intelligent controllers are arranged in sequence inside the product tooling box and are limited by the slots.

[0014] Preferably, the motor is mounted on the front end face of the frame (using a perforated plate and cable ties for fixation) to facilitate observation of its working status.

[0015] Preferably, a display system is installed on the rack, the display system includes several display screens, each of which is connected to a motor to display the working status of the motor connected to different intelligent controllers in real time.

[0016] Preferably, the processor is a microcontroller, and the vision system includes a movable visual recognition camera.

[0017] Beneficial effects: Improved testing efficiency: Through the coordinated work of multiple testing mechanisms and power-on mechanisms, multiple intelligent controllers can be tested simultaneously. Only one operator is needed to complete operations such as loading, starting, and unloading, which greatly reduces manpower input, lowers production costs, and improves testing efficiency by 5-8 times compared to manual testing. This effectively solves the production capacity bottleneck and reduces labor costs.

[0018] Improved testing accuracy: The mechanical structure standardizes the pressure and frequency, avoiding errors caused by manual testing.

[0019] Comprehensive functionality: It can simulate all physical button operations of an intelligent controller and detect complex functions through motors and relays to ensure product quality.

[0020] Facilitates data traceability: Data can be exported via the processor, facilitating subsequent quality analysis and traceability, which meets the management needs of industrialized production.

[0021] Easy to operate: The drawer-type product tooling box and function key design reduce the labor intensity of operators and require low operator skills. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0023] Figure 2 This is a partial structural schematic diagram of this utility model.

[0024] Figure 3 This is one of the principle block diagrams of this utility model.

[0025] Figure 4 This is the second block diagram of the principle of this utility model.

[0026] Figure 5 This is a 3D view of an intelligent controller in one embodiment.

[0027] Figure 6 This is a rear view of an intelligent controller in one embodiment. Detailed Implementation

[0028] The following will refer to the appendix in the embodiments of this utility model. Figures 1-6 The technical solutions in the embodiments of this utility model are clearly and completely described herein. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0029] In the description of the utility model, it should be noted that the terms "upper", "lower", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the utility model.

[0030] This embodiment provides a semi-automatic testing machine for intelligent controllers. The overall structure is based on a frame constructed from industrial aluminum profiles, offering high strength and lightweight characteristics while facilitating modular installation and debugging of components. A drawer-type product tooling box is located in the middle of the frame. This tooling box is made of aluminum or ABS engineering plastic, with openings at both the top and bottom. Its inner wall has six sets of slots spaced along its length. The size of these slots matches the shape of the intelligent controllers, allowing for the simultaneous placement of six controllers. The slots precisely limit the controller's position, ensuring uniformity of physical buttons and interfaces for each controller, providing a positioning reference for subsequent testing. The product tooling box can be equipped with slide rails on both sides, cooperating with the slides on the frame for smooth pulling, or alternatively, without slide rails, facilitating loading and unloading by the operator.

[0031] Above the product tooling box, six sets of testing mechanisms are installed on the crossbeam of the frame. Each set of testing mechanisms corresponds independently to an intelligent controller within the product tooling box. Each set of testing mechanisms has at least 4-6 pressing cylinders (the specific number can be set according to the number of function keys on the intelligent controller). The cylinder body is fixed to the mounting plate, and the end of its telescopic rod is equipped with a PTFE pressure head, which ensures pressing hardness while avoiding scratching the surface of the function keys on the intelligent controller. The pressing cylinders of the six testing mechanisms are connected to an air source through air pipes. Solenoid valves from the control module are connected in series on the air pipes. The solenoid valves are electrically connected to the processor. The electrical signals output by the processor control the extension and retraction of the telescopic rods of the pressing cylinders, realizing the simulated pressing of physical buttons such as "up," "down," "reset," and "start / stop" on the intelligent controller.

[0032] Below the product tooling box, on the base of the frame, are six sets of power-on mechanisms, each corresponding to one of the testing mechanisms above. Each set of power-on mechanisms includes multiple conductive probes (made of phosphor bronze with gold plating to improve conductivity and wear resistance) that match the interface of the intelligent controller. The lifting and lowering of the probes precisely inserts into or detaches from the interface of the intelligent controller. The lifting and lowering of the probes can be achieved using existing technologies such as cylinders or lifting motors driving the lifting platform.

[0033] The rear of the rack integrates an electrical control area, housing a processor and a multi-channel load board. The load board connects to the response module, control module, and various sensors via ribbon cables, enabling centralized signal processing and distribution. Each response module consists of a relay and an analog motor. The motor is mounted on the front panel of the rack, and its output shaft is connected to an encoder via a coupling, which monitors the rotation status in real time and converts it into a height signal. The relay, mounted on the multi-channel load board, receives output signals from the intelligent controller and controls the motor's forward rotation (simulating a raised table, corresponding to a larger display value), reverse rotation (simulating a lowered table, corresponding to a smaller display value), or stop. A control panel is located at the front of the rack, featuring a power button, start button, emergency stop button, and multiple independent test buttons. Operators can use these buttons to send commands to the processor, such as initiating batch testing or testing a specific workstation's controller. The top of the rack is equipped with a vision system, infrared sensors (such as E18-D80NK), and fiber optic sensors (such as FT-310) mounted on a gantry. The vision system includes a vision recognition camera (such as MV-CE050-30GC) that can move along the X-axis and capture the status of six smart controllers. The infrared sensor is used to detect whether the product tooling box is fully pushed into the rack. The fiber optic sensor is installed next to the slot of the product tooling box to detect whether a smart controller is correctly placed.

[0034] A display system is installed on the front side of the frame corresponding to the motor position. The system contains 6 small LCD screens, each of which is connected to the processor via a ribbon cable. It displays the test progress of the corresponding intelligent controller in real time (such as "testing", "pass", "fail"), simulated height value (range 50-120cm) and fault code (such as "button unresponsive" and "value unchanged").

[0035] The workflow of this embodiment is as follows:

[0036] The operator places the six smart controllers to be tested sequentially into the slots of the product fixture box, ensuring that the interface of each controller faces downwards and the physical buttons face upwards. The fixture box is then pushed into the frame along the slide rail until the infrared sensor detects that the fixture box is in place and sends a signal. Upon receiving the fixture box arrival signal, the processor controls the servo motor of the power-on mechanism to start. For example, using existing technology, a ball screw slide is raised to drive the probe into the interface of the smart controller, thus establishing a circuit connection between the smart controller and the response module. Simultaneously, a fiber optic sensor detects whether each slot has a controller; if an empty slot exists, the corresponding test is not initiated. The operator presses the start button on the control panel, and the processor enters automatic test mode: it sequentially sends signals to the solenoid valves of the six test mechanisms, controlling the extension rods of the pressing cylinders to extend in a preset sequence (up button → down button → reset button → start / stop button, etc.), with each press lasting 1.5 seconds before resetting, simulating the rhythm of manual operation. When the "Up" button is pressed, the intelligent controller outputs a corresponding control signal, which is transmitted to the relay in the response module via a probe. The relay activates and controls the motor to rotate forward. The encoder converts the rotation signal into a height value, and the value on the display screen continuously increases (e.g., from 70cm to 110cm). When the "Down" button is pressed, the motor reverses, and the value on the display screen continuously decreases (e.g., from 110cm to 70cm). When the "Reset" button is pressed, the value should automatically return to the initial set value (e.g., 75cm). When the "Start / Stop" button is pressed, the motor should stop immediately, and the value remains unchanged. A visual recognition camera moves along the X-axis to capture the status of each intelligent controller (e.g., power light, running light) and determine whether it matches the button operation. The processor can integrate the motor action signal, the value change curve, the indicator light status, and the sensor data to determine the function of each intelligent controller (this is a function of the processor itself and not part of the program development in this application; the specific function may vary depending on the processor's specifications and model). After the test is completed, the processor controls the cylinder to reset and the probe to descend and disengage from the interface. At the same time, the test results can be displayed on the screen (e.g., a green "PASS" for passing and a red "FAIL" and fault code for failing). The operator pulls out the product tooling box, takes out the tested controller and replaces it with a new test piece to complete one test cycle.

[0037] Finally, it should be noted that this utility model is not limited to the above embodiments, and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of this utility model should be considered within the protection scope of this utility model.

Claims

1. A semi-automatic testing machine with an intelligent controller, comprising a frame (1) and a processor mounted on the frame (1), characterized in that: Multiple test mechanisms are installed on the frame (1). Each test mechanism includes several pressing cylinders (2). Multiple power-on mechanisms are installed on the frame (1) below the test mechanism. Each power-on mechanism includes several probes that can be raised and lowered and are conductive. Each probe in each power-on mechanism is connected to a response module. Each pressing cylinder (2) in each test mechanism is connected to a control module. The response module and the control module are electrically connected to the processor and connected to a power source. The probes in each power-on mechanism can be inserted into the interface (6) of the intelligent controller to connect the corresponding response module. The telescopic rod of the pressing cylinder (2) in each test mechanism can contact and press the physical button of the intelligent controller to trigger the corresponding response module to work and achieve functional testing.

2. The intelligent controller semi-automatic testing machine according to claim 1, characterized in that: The rack (1) is equipped with a drawer-type product tooling box (3) for placing multiple intelligent controllers; the testing mechanism is located on the rack (1) above the product tooling box (3), and the power-on mechanism is located on the rack (1) below the product tooling box (3).

3. The intelligent controller semi-automatic testing machine according to claim 1, characterized in that: Each response module includes an electrically connected relay and a motor, and each control module includes a solenoid valve; the relay, motor, and solenoid valve are all electrically connected to the processor.

4. A semi-automatic testing machine with an intelligent controller according to claim 1, 2, or 3, characterized in that: The rack (1) is equipped with a control panel, which includes several function keys (4). The control panel is connected to the processor to realize the operation response module and the control module.

5. A semi-automatic testing machine with an intelligent controller according to claim 3, characterized in that: It also includes a multi-port load board, through which the relays, motors, and solenoid valves are electrically connected to the processor.

6. A semi-automatic testing machine with an intelligent controller according to claim 1 or 3, characterized in that: The top of the rack (1) is connected to a vision system, an infrared sensor, and a fiber optic sensor, all of which are connected to the processor.

7. A semi-automatic testing machine with an intelligent controller according to claim 2, characterized in that: The product tooling box (3) has openings at the top and bottom, and the inner wall of the product tooling box (3) is provided with a slot. The intelligent controllers are arranged in sequence and placed inside the product tooling box (3) and are limited by the slot.

8. A semi-automatic testing machine with an intelligent controller according to claim 3, characterized in that: The motor is mounted on the front end of the frame (1) for easy observation of its working status.

9. A semi-automatic testing machine with an intelligent controller according to claim 3 or 8, characterized in that: A display system is installed on the frame (1). The display system includes several display screens (7). Each display screen (7) is connected to a motor in a one-to-one correspondence to display the working status of the motor connected to different intelligent controllers in real time.

10. A semi-automatic testing machine with an intelligent controller according to claim 6, characterized in that: The processor is a single-chip microcontroller; the vision system includes a movable visual recognition camera (5).

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