A pressure scanning valve with real-time fault injection simulation function

Abstract

This utility model discloses a pressure scanning valve with real-time fault injection simulation function. The top of the middle frame is connected to the upper cover, and the bottom of the middle frame is connected to the bottom cover. Multiple pressure sensor assemblies are arranged through the top of the upper cover, which also has a power supply interface, a communication interface, a simulation test interface, a network port, and multiple temperature measurement interfaces. The circuit board assembly is housed within the cavity formed by the middle frame and the bottom cover. The pressure sensor assemblies, temperature measurement interfaces, power supply interface, communication interface, simulation test interface, and network port are all connected to the circuit board assembly via cables. This utility model, through optimized structural design and functional integration, enables real-time simulation of various fault scenarios when the pressure scanning valve is used in an automated control system. This improves the fault diagnosis and handling capabilities of the pressure scanning valve and the automated control system working together, enhancing the overall reliability and stability of the system in complex application scenarios such as aerospace and industrial automation. It has significant technical advantages and engineering practical value.

Description

Technical Field

[0001] This utility model relates to the technical field of multi-channel pressure measurement and fault simulation, specifically to a pressure scanning valve with real-time fault injection simulation function. Background Technology

[0002] In the field of pressure measurement technology, the coordinated operation of pressure scanning valves and automated control systems is crucial for the stable operation of complex systems such as aerospace and industrial automation. As the core control unit of the system, the automated control system must precisely regulate the system's operating state based on the pressure data collected by the pressure scanning valve; its reliability under fault conditions directly affects the safety and efficiency of the entire system. However, existing technologies face numerous insurmountable bottlenecks when conducting fault simulation tests on automated control systems.

[0003] On the one hand, most traditional pressure scanning valves lack the ability to simulate faults in automated control systems. Automated control systems may encounter various faults during actual operation, such as abnormal pressure, temperature deviations, and data transmission errors. However, conventional pressure scanning valves can only collect and transmit pressure and temperature data under normal operating conditions, lacking the ability to simulate complex fault scenarios. For example, in the aerospace field, pressure sensors may experience signal distortion in complex high-altitude environments, and automated control systems need to be able to accurately diagnose and handle such faults. However, traditional measuring equipment cannot simulate such abnormal operating conditions, making it difficult to fully verify the fault tolerance mechanisms and algorithms of automated control systems.

[0004] On the other hand, existing simulation testing heavily relies on external equipment. To simulate and model faults in automated control systems, it is often necessary to build complex external simulation platforms, which not only increases testing costs and equipment complexity but also extends the development cycle. Data interaction between external simulation platforms and pressure scanning valves and automated control systems is prone to delays and compatibility issues, affecting the accuracy and real-time performance of simulation tests and making it difficult to realistically reproduce the system's operating state under actual fault scenarios.

[0005] With the increasing demands for system reliability in fields such as aerospace and industrial automation, there is an urgent need for a pressure scanning valve that can reduce or even eliminate dependence on external equipment and achieve efficient and accurate fault simulation of automated control systems. This valve is designed to optimize the fault diagnosis and handling strategies for the collaborative operation of the two systems and improve the overall reliability of the system. This utility model is an innovative solution developed based on this background. Utility Model Content

[0006] This invention addresses the problem in existing technologies where it is difficult to conduct comprehensive and effective fault simulation of pressure signals in automated control systems, and where simulation testing relies on external equipment. By optimizing structural design and functional integration, it enables real-time simulation of various fault scenarios in automated control systems, improves the fault diagnosis and handling capabilities of the pressure scanning valve and the automated control system working together, and enhances the overall reliability and stability of the system in complex application scenarios such as aerospace and industrial automation.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0008] A pressure scanning valve with real-time fault injection simulation function includes: an upper cover, a middle frame, a bottom cover, a pressure sensor assembly, and a circuit board assembly; the top of the middle frame is connected to the upper cover, and the bottom of the middle frame is connected to the bottom cover; multiple pressure sensor assemblies are arranged through the top of the upper cover, and the top of the upper cover is also provided with a power supply interface, a communication interface, a simulation test interface, a network port, and multiple temperature measurement interfaces; the circuit board assembly is disposed in the cavity formed by the middle frame and the bottom cover, and the pressure sensor assembly, temperature measurement interface, power supply interface, communication interface, simulation test interface, and network port are all connected to the circuit board assembly via cables.

[0009] As a further improvement of this utility model, the circuit board assembly includes a power board, a fault injection simulation circuit board, a main control circuit board and a conditioning circuit board stacked from bottom to top, and the power board is fixed inside the bottom cover; the power board, the fault injection simulation circuit board and the conditioning circuit board are all connected to the main control circuit board through cables, and there is a cable connection between the fault injection simulation circuit board and the conditioning circuit board.

[0010] As a further improvement of this utility model, the pressure sensor assembly and the temperature measurement interface are both connected to the conditioning circuit board via cables; the network port is connected to the fault injection simulation circuit board via cables; the power supply interface is connected to the power board via cables; and the communication interface is connected to the main control circuit board via cables.

[0011] As a further improvement of this utility model, the four vertices of the upper cover are provided with first threaded holes, the four vertices of the middle frame are provided with third threaded holes, and the four vertices of the top of the bottom cover are provided with fourth threaded holes; when the upper cover, middle frame and bottom cover are fastened together in sequence, screws are screwed into the first threaded holes, third threaded holes and fourth threaded holes to achieve connection and fixation of the upper cover, middle frame and bottom cover.

[0012] As a further improvement of this utility model, the bottom cover has four vertices with lugs, which are used to install and fix the pressure scanning valve.

[0013] As a further improvement of this utility model, the bottom cover is provided with a plurality of fixing studs, which are used to connect the circuit board assembly.

[0014] As a further improvement of this utility model, the top of the cover is provided with multiple pressure measuring interface threaded holes, and second threaded holes are symmetrically provided on both sides of the pressure measuring interface threaded holes; the pressure sensor assembly is provided with a sealing nut and a fifth threaded hole; the pressure sensor assembly is screwed through the pressure measuring interface threaded hole, the pressure measuring interface is provided with a sealing nut, and screws are screwed into the fifth threaded holes and second threaded holes on both sides of the pressure sensor assembly to achieve the pressure sensor assembly through and fixed to the top of the cover.

[0015] As a further improvement of this utility model, the top of the upper cover is also provided with a plurality of first mounting holes, which are respectively used to install a temperature measurement interface, a power supply interface, a communication interface and a simulation test interface.

[0016] As a further improvement of this utility model, the top of the cover is also provided with a second mounting hole, which is used to install the mesh port.

[0017] As a further improvement of this utility model, the plurality of pressure sensor assemblies include a pressure sensor assembly with a range of 0 to 1 MPa, a pressure sensor assembly with a range of 0 to 4 MPa, a pressure sensor assembly with a range of 0 to 8 MPa, and a pressure sensor assembly with a range of 0 to 15 MPa.

[0018] This technical solution, through structural optimization and functional integration, achieves efficient and accurate fault simulation and real-time simulation of automated control systems using a pressure scanning valve, thereby improving the system's reliability and stability in complex application scenarios. Compared with existing technologies, the advantages of this invention are:

[0019] 1. This utility model discloses a pressure scanning valve with real-time fault injection simulation function. It integrates multiple pressure sensor assemblies, multiple temperature measurement interfaces, power supply interfaces, communication interfaces, simulation test interfaces, and network ports onto the top cover. The circuit board assembly is housed within the cavity formed by the middle frame and bottom cover. All components—pressure sensor assemblies, temperature measurement interfaces, power supply interfaces, communication interfaces, simulation test interfaces, and network ports—are connected to the circuit board assembly via cables, forming a robust and reliable overall structure for the pressure scanning valve. This highly integrated design eliminates reliance on external equipment. Traditional pressure scanning valves heavily depend on external simulation platforms for simulating faults in automated control systems, increasing equipment costs and setup difficulty, and easily causing data interaction delays. This utility model integrates the fault injection simulation circuit board inside the pressure scanning valve, interacting with the simulation host computer via the network port. Real-time injection simulation of various fault scenarios, such as pressure anomalies, temperature deviations, and data frame errors, can be achieved without additional external equipment, significantly simplifying the testing process and reducing testing costs and system complexity.

[0020] 2. The pressure scanning valve of this invention, equipped with real-time fault injection simulation, possesses precise and efficient fault simulation capabilities: Existing technologies struggle to simulate complex fault conditions in automated control systems, failing to fully verify their fault-tolerance mechanisms. This invention, however, utilizes a fault injection simulation circuit board, coupled with 20 high-precision pressure measurement interfaces and 4 temperature measurement interfaces, to accurately simulate various faults such as pressure sensor signal distortion, data packet loss, and communication protocol anomalies, and can inject simulated faults into the automated control system in real time. Simultaneously, combined with the efficient data processing of the main control circuit board and conditioning circuit board, it provides a comprehensive and realistic simulation environment for the reliability testing of automated control systems.

[0021] 3. The pressure scanning valve of this utility model with real-time fault injection simulation function improves system reliability through a robust and reasonable structural design: This utility model adopts a shell structure with a top cover, middle frame and bottom cover fastened with screws, and uses a multi-layer circuit board stacking and fixing method for the power board, fault injection simulation circuit board and other circuit boards. Each layer of the board is firmly installed with four studs, which effectively enhances the overall shock resistance and anti-interference performance of the equipment; all external interfaces (such as pressure measurement interface, communication interface) are fixed with screws. Compared with the traditional loose equipment connection method, it significantly reduces the risk of failure caused by loose parts and damaged interfaces, and improves the stability and reliability of the pressure scanning valve in complex environments.

[0022] 4. The pressure scanning valve of this utility model with real-time fault injection simulation function achieves multi-interface compatibility, which is conducive to expanding application scenarios: Traditional pressure scanning valves have a single interface and poor compatibility, which limits their application scope. However, this utility model is equipped with multiple types of interfaces such as power supply interface, communication interface, simulation test interface and network port on the top of the cover, supports multiple communication protocols, and can be adapted to different types of automatic control systems in aerospace, industrial automation and other fields. This greatly expands the application scenarios of the pressure scanning valve, meets diverse testing needs, and can achieve efficient fault diagnosis and collaborative processing in different complex systems. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall structure of the pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model.

[0025] Figure 2 This is a schematic diagram of the side structure of the pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model.

[0026] Figure 3 This is a schematic diagram of the front structure of a pressure scanning valve with real-time fault injection simulation function in a specific embodiment of the present invention.

[0027] Figure 4 for Figure 3 Schematic diagram of the structural principle of the cross-section along the AA direction;

[0028] Figure 5 This is a top view schematic diagram of the pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model.

[0029] Figure 6 This is a top view schematic diagram of the upper cover structure of the pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model.

[0030] Figure 7 This is a schematic diagram of the structural principle of the circuit board in a specific embodiment of this utility model;

[0031] Figure 8 This is a schematic diagram of the structural principle of the sensor assembly in a specific embodiment of this utility model;

[0032] Figure 9 This is a schematic diagram of the structural principle of the middle frame in a specific embodiment of this utility model;

[0033] Figure 10 This is a schematic diagram of the structural principle of the bottom cover in a specific embodiment of this utility model;

[0034] Figure 11 This is a connection diagram of a pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model;

[0035] Figure 12 This is a block diagram illustrating the working principle of a pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model.

[0036] Figure 13 This is a random noise simulation model of a pressure scanning valve with real-time fault injection simulation function in a specific embodiment of this utility model;

[0037] Legend: 1. Top cover; 2. Middle frame; 3. Bottom cover; 4. Pressure sensor assembly; 5. Circuit board assembly; 7. Network port; 8. Screw; 1001. Pressure measurement interface threaded hole; 1002. First mounting hole; 1003. Second mounting hole; 1004. First threaded hole; 1005. Second threaded hole; 2001. Third screw hole; 3001. Side of bottom cover; 3002. Fixing stud; 3003. Fourth threaded hole; 3004. Support lug; 4001. Sealing nut; 4002. Fifth threaded hole; 5001. Power board; 5002. Fault injection simulation circuit board; 5003. Main control circuit board; 5004. Conditioning circuit board; 6001. Temperature measurement interface; 6002. Power supply interface; 6003. Communication interface; 6004. Simulation test interface. Detailed Implementation

[0038] The present invention will be further described below with reference to the accompanying drawings and specific preferred embodiments, but this does not limit the scope of protection of the present invention.

[0039] In the description of this utility model, it should be understood that the terms "side", "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "multiple" means two or more, unless otherwise explicitly specified.

[0041] Example 1

[0042] like Figures 1 to 12 As shown, the pressure scanning valve of this utility model with real-time fault injection simulation function includes: an upper cover 1, a middle frame 2, a bottom cover 3, a pressure sensor assembly 4, and a circuit board assembly 5. The top of the middle frame 2 is connected to the upper cover 1, and the bottom of the middle frame 2 is connected to the bottom cover 3. Twenty pressure sensor assemblies 4 are arranged through the top of the upper cover 1 and connected to the pressure points to be measured through air tubes, used to measure the pressure distribution at different points on the surface of the aircraft model. The top of the upper cover 1 is also provided with a power supply interface 6002, a communication interface 6003, a simulation test interface 6004, a network port 7, and four temperature measurement interfaces 6001. The circuit board assembly 5 is set in the cavity formed by the middle frame 2 and the bottom cover 3. The signal terminals of the pressure sensor assemblies 4, the temperature measurement interfaces 6001, the power supply interfaces 6002, the communication interfaces 6003, the simulation test interfaces 6004, and the network ports 7 are all electrically connected to the circuit board assembly 5 through shielded cables to ensure stable signal transmission. The pressure sensor assembly 4 is used for pressure measurement; the simulation test interface 6004 is used to connect an external temperature sensor, compatible with PT100 / PT100 RTD and K-type thermocouple sensors, to acquire environmental and measurement point temperature information in real time; the power supply interface 6002 is used to connect an external stable power supply to power the various components inside the pressure scanning valve; the communication interface 6003 supports multiple communication protocols to realize data interaction with the automation control system and the simulation host computer; the simulation test interface 6004 has functions such as receiving synchronization signals to ensure the accuracy and real-time performance of fault simulation testing. Through the built-in simulation test interface 6004, control commands can be directly connected without additional configuration of external simulation equipment, which can accurately inject various fault scenarios such as sensor faults, communication interruptions, and data distortion, and efficiently simulate the operation performance of the automation control system under fault conditions; the network port 7 is used to receive fault simulation commands sent by the simulation host computer and to interact with the simulation host computer.

[0043] The pressure scanning valve in this embodiment adopts a highly integrated design, improving system stability. During operation, no complex peripherals or operating environment setup is required; parameter configuration and test startup can be completed solely through Ethernet port 7 or communication interface 6003, significantly simplifying the testing process and lowering the operational threshold for technicians. Furthermore, in this embodiment, the collaborative operation of the pressure scanning valve and the automated control system provides a precise fault verification platform. Technicians can optimize collaborative diagnostic algorithms and emergency response strategies based on simulation data, effectively enhancing their anti-interference capabilities and operational reliability in harsh environments such as aerospace and industrial automation, demonstrating significant technological innovation and engineering practical value.

[0044] like Figure 5 As shown in this embodiment, T1, T2, T3, and T4 represent four temperature measurement interfaces 6001; A1 to A8 represent eight pressure sensor assemblies 4 with a range of 0 to 1 MPa, capable of collecting and measuring pressure points below 1 MPa; B1 to B4 represent four pressure sensor assemblies 4 with a range of 0 to 4 MPa, capable of collecting and measuring pressure points below 4 MPa; C1 to C4 represent four pressure sensor assemblies 4 with a range of 0 to 8 MPa, capable of collecting and measuring pressure points below 8 MPa; and D1 to D4 represent four pressure sensor assemblies 4 with a range of 0 to 15 MPa, capable of collecting and measuring pressure points below 15 MPa. It is understood that the structure of the pressure sensor assembly 4 adopts conventional techniques in the art, and will not be described in detail here. Through multiple pressure sensor assemblies 4 and temperature measurement interfaces 6001, not only can on-site pressure and temperature parameters be collected in real time, but also the dynamic injection and simulation of real pressure fluctuations and temperature gradient changes can be achieved through the built-in control module, covering simulation of various environmental parameters from normal temperature and pressure to extreme working conditions.

[0045] like Figure 3 , Figure 4 and Figure 7 As shown, the circuit board assembly 5 includes a power board 5001, a fault injection simulation circuit board 5002, a main control circuit board 5003, and a conditioning circuit board 5004 stacked from bottom to top. The power board 5001 is fixed inside the bottom cover 3. The power board 5001, the fault injection simulation circuit board 5002, and the conditioning circuit board 5004 are all connected to the main control circuit board 5003 via cables, and there is a cable connection between the fault injection simulation circuit board 5002 and the conditioning circuit board 5004.

[0046] Furthermore, the pressure sensor assembly 4 and the temperature measurement interface 6001 are both connected to the conditioning circuit board 5004 via cables. The network port 7 is connected to the fault injection simulation circuit board 5002 via a cable. The power supply interface 6002 is connected to the power supply board 5001 via a cable. The communication interface 6003 is connected to the main control circuit board 5003 via a cable. Even further, the pressure sensor assembly 4 includes a pressure sensor board and a pressure sensor core. The pressure sensor board connects to the pressure sensor core and is also connected to the conditioning circuit board 5004 for signal transmission and data interaction.

[0047] In this embodiment, the bottom cover 3 is provided with a plurality of fixing studs 3002, which are used to connect the circuit board assembly 5. Specifically, as shown in the figure... Figure 3 and Figure 4 As shown, the power board 5001 is fixed to the fixing stud 3002 of the bottom cover 3 by screws 8, serving as the bottom support; the fault injection simulation circuit board 5002 is fixed to the stud of the power board 5001 by screws 8; the main control circuit board 5003 is fixed to the stud of the fault injection simulation circuit board 5002 by screws 8; and the conditioning circuit board 5004 is fixed to the stud of the main control circuit board 5003 by screws 8. Each layer of the board has four studs, achieving a compact and stable internal layout, which facilitates signal transmission and module collaboration.

[0048] like Figure 6 As shown, the upper cover 1 has first threaded holes 1004 at its four vertices, as... Figure 9 As shown, the four vertices of the middle frame 2 are provided with third screw holes 2001, as follows: Figure 10 As shown, the bottom cover 3 has four threaded holes 3003 at its four vertices. Figure 2 As shown, after the upper cover 1, middle frame 2 and bottom cover 3 are fastened together in sequence, screws 8 are screwed into the first threaded hole 1004, the third threaded hole 2001 and the fourth threaded hole 3003 to achieve a sealed connection and fixation of the upper cover 1, middle frame 2 and bottom cover 3, ensuring a stable structure and good shock resistance, dustproof and protective performance.

[0049] like Figure 10 As shown, the bottom cover 3 has four support ears 3004 at its four vertices. The support ears 3004 are used to install and fix the pressure scanning valve.

[0050] like Figure 5 , Figure 6 and Figure 8As shown, the top of the upper cover 1 has twenty pressure testing interface threaded holes 1001, and each pressure testing interface threaded hole 1001 has symmetrical second threaded holes 1005 on both sides; the pressure sensor assembly 4 has a sealing nut 4001 and a fifth threaded hole 4002. The pressure sensor assembly 4 is screwed through the pressure testing interface threaded hole 1001, and the pressure testing interface is provided with a sealing nut 4001. Screws 8 are screwed into the fifth threaded holes 4002 and second threaded holes 1005 on both sides of the pressure sensor assembly 4 to achieve through-fixation of the pressure sensor assembly 4 to the top of the upper cover 1. The sealing nut 4001 also prevents foreign objects from entering the pressure testing interface and prevents damage to the interface threads.

[0051] like Figure 5 and Figure 6 As shown, the top of the upper cover 1 is also provided with multiple first mounting holes 1002, and the outer periphery of each first mounting hole 1002 is provided with four threaded holes. Four temperature measuring interfaces 6001 are respectively installed in the four first mounting holes 1002 (T1 to T4) and fixed with fastening screws; the power supply interface 6002 is installed in the first mounting hole 1002 of XP1 and fixed with fastening screws; the communication interface 6003 is installed in the first mounting hole 1002 of XP2 and fixed with fastening screws; the simulation test interface 6004 is installed in the first mounting hole 1002 and then fixed with fastening screws. The top of the upper cover 1 is also provided with second mounting holes 1003, and the outer periphery of each second mounting hole 1003 is provided with four threaded holes. The mesh port 7 is placed in the second mounting hole 1003 and then fixed with fastening screws.

[0052] like Figure 12 As shown, in this embodiment, the core function and working principle of the pressure scanning valve are as follows:

[0053] Pressure and temperature acquisition: Pressure and temperature data are acquired through pressure sensor assembly 4 and temperature measurement interface 6001, respectively. Conditioning circuit board 5004 performs preprocessing such as filtering and amplification on the acquired analog signals to improve signal quality. Main control circuit board 5003 further processes the signals by performing A / D conversion, digital filtering, etc., to convert the analog signals into digital signals, and performs preliminary data integration and analysis.

[0054] Real-time simulation: In the real-time pressure anomaly simulation system, a gradual pressure anomaly simulation mechanism is added to the existing system for simulating sudden pressure changes and pressure values ​​exceeding the normal range. This mechanism allows users to customize parameters such as the rate and duration of pressure value changes, thereby simulating pressure values ​​slowly rising or falling at different rates and exceeding the normal range. For example, it can simulate slow pipeline pressure leakage caused by equipment aging, or a fault scenario where pressure gradually increases due to other reasons, making the simulation more closely resemble actual pressure anomalies caused by equipment wear and process changes in production. Superimposed noise interference: Noise signals that conform to the characteristics of the actual environment are superimposed on the real pressure data. Figure 13 As shown, the simulated noise includes white noise, salt-and-pepper noise, etc. By adjusting parameters such as noise intensity and frequency, the influence of factors such as sensor measurement errors and environmental electromagnetic interference on pressure measurements is simulated, making the simulated data closer to the fluctuations of real measurement data. Simulated signal delay: Considering the delay issues in signal transmission during actual production, a signal delay module is added to the simulation system. Users can set different delay times according to the actual scenario, simulating the delays generated by the signal in sensor transmission and data processing, to more realistically reflect the response process of pressure changes in the system. The real-time pressure anomaly simulation system will be able to more comprehensively and realistically simulate pressure change fault scenarios in actual production, providing relevant personnel with more effective simulation training and fault analysis tools.

[0055] Fault Injection Simulation: The fault injection simulation circuit board 5002 serves as the core unit, receiving preset fault commands from the simulation host computer via network port 7. Based on the command requirements, this module can simulate various fault scenarios, such as simulating pressure anomalies (sudden pressure changes, exceeding normal range, etc.) by modifying data collected by pressure sensors; simulating errors in data frame header information, loss of critical data segments, etc., making data frame error simulation more diverse. Regarding communication protocol anomaly simulation, it simulates data packet loss and retransmission delays under different network environments, and can also simulate parsing errors caused by incompatible communication protocol versions, enhancing the realism of the simulation. Real-time injection of simulated faults into the automated control system provides a diverse simulation environment for testing the fault response capabilities of the automated control system.

[0056] Real-time visualization interface: A dedicated real-time visualization interface was developed to graphically display various parameters and fault states during the simulation process. The interface uses dynamic curves to display real-time changes in pressure and temperature data. When a fault occurs, the relevant data curves are highlighted with a special color or flashing, intuitively showing the impact of the fault on the data. Simultaneously, information such as the type, time, and specific parameters of the fault injection are displayed in a list format, allowing technicians to quickly understand the simulation progress and fault status.

[0057] Interactive operation function: An interactive operation function has been added, allowing technicians to adjust fault parameters and injection strategies in real time during the simulation. For example, in pressure anomaly simulation, the time point and magnitude of pressure mutation can be manually set through the interface, or the rate of change of gradual pressure anomalies can be adjusted; for communication protocol anomaly simulation, parameters such as network latency and packet loss rate can be dynamically modified. In addition, operations such as pausing, resuming, and resetting the simulation are supported, facilitating flexible control of the simulation process.

[0058] Signal acquisition path: pressure and temperature sensors → conditioning circuit board 5004 filter and amplification → main control circuit board 5003 A / D conversion → generation of raw data frames with time stamps → XP2 communication interface 6003 → real-time display on host computer;

[0059] Real-time simulation injection path: The simulation host computer sends instructions through network port 7 → the fault injection board parses and generates fault signals → the main control circuit board 5003A / D → superimposed with the original signal or injects faults separately in real-time simulation → XP2 communication interface 6003 → automatic control system → real-time display by the host computer.

[0060] Simulation Fault Injection Path: Simulation host computer sends instructions through network port 7 → Fault injection board parses and generates fault signals → Main control circuit board 5003A / D → Fault simulation injection → XP2 communication interface 6003 → Automation control system → Host computer real-time display.

[0061] Data interaction path: After fault handling, data is transmitted to the automation control system via XP2 communication interface 6003 → system response data is collected → feedback is sent to the host computer through the communication interface → evaluation report is generated.

[0062] Example 2

[0063] In this embodiment, the pressure scanning valve with real-time fault injection simulation function of Embodiment 1 is applied to the aerospace engine test scenario.

[0064] In the wind tunnel test for aerodynamic performance evaluation of the aircraft, the pressure scanning valve of Example 1 is installed at a designated location in the wind tunnel test section. First, the twenty pressure sensor assemblies 4 on the top of the cover 1 are connected to the pressure points to be measured via air pipes to measure the pressure distribution at different points on the surface of the aircraft model. Simultaneously, four temperature measurement interfaces 6001 are connected to temperature sensors to monitor the ambient temperature changes within the wind tunnel test section in real time.

[0065] An external stable power supply is connected via the XP1 power interface 6002 to power the various components of the pressure scanning valve. A communication connection is established with the automated control system in the engine test control system via the XP2 communication interface 6003, using a serial communication protocol for data transmission; the network port 7 connects to the simulation host computer, allowing the pressure scanning valve to simulate an aircraft sending flight control commands.

[0066] During the experiment, the pressure signal collected by the pressure sensor and the temperature signal collected by the temperature sensor are first transmitted to the conditioning circuit board 5004 for preprocessing such as filtering to remove interference components and improve signal quality. The processed signal is then transmitted to the main control circuit board 5003 for A / D conversion, digital filtering, and other processing to convert the analog signal into a digital signal and perform data integration.

[0067] When simulating fault scenarios to test the capabilities of an automated control system, the simulation host computer sends preset fault commands to the fault injection simulation circuit board 5002 via network port 7. For example, sending a command to simulate a sudden pressure change will cause the fault injection simulation circuit board 5002 to immediately modify the pressure sensor data to induce an abnormal state of sudden pressure change, and transmit the fault data to the main control circuit board 5003. After integrating the data, the main control circuit board 5003 transmits the fault data to the automated control system via communication interface 6003. Simultaneously, the data recording function of the pressure scanning valve is activated to monitor the automated control system's response to the received fault data in real time, such as adjustments to control commands and fault alarm information, and records the relevant data. This data is then fed back to the simulation host computer via communication interface 6003 or network port 7 for technicians to analyze the fault diagnosis and handling capabilities of the automated control system.

[0068] Example 3

[0069] In this embodiment, the pressure scanning valve with real-time fault injection simulation function of Embodiment 1 is applied to the pressure monitoring scenario of an industrial automated production line.

[0070] In the pressure monitoring system of an industrial automated production line, a pressure scanning valve is installed near the critical pressure monitoring points of the production line. Corresponding pressure and temperature sensors are connected via the pressure sensor assembly 4 and the temperature measurement interface 6001 to monitor the pressure and temperature within the pipelines or equipment on the production line in real time.

[0071] The XP1 power supply interface 6002 connects to the production line's unified power supply system, ensuring stable operation of the pressure scanning valve. The XP2 communication interface 6003 uses a serial communication protocol to exchange data with the production line's automation control system, transmitting collected pressure and temperature data to the system in real time. This allows the automation control system to adjust the production line equipment operation based on pressure and temperature conditions. Network port 7 connects to the workshop's simulation host computer.

[0072] When it is necessary to test the ability of the production line automation control system to cope with fault conditions, the simulation host computer sends a fault command simulating a communication protocol anomaly (such as data packet loss) to the fault injection simulation circuit board 5002. After receiving the command, the fault injection simulation circuit board 5002 processes the data frame transmitted from the main control circuit board 5003 to simulate the data packet loss situation, and then transmits the processed data to the automation control system through the communication interface 6003.

[0073] Example 4

[0074] In this embodiment, the pressure scanning valve with real-time fault injection simulation function of Embodiment 1 is applied in the laboratory.

[0075] As shown in Figure 11, the connection preparation is as follows: prepare twenty pressure measurement channels to connect to the pressure testing equipment to simulate the real pressure environment; accurately connect four temperature channels to the temperature sensors to ensure accurate temperature measurement.

[0076] Connect a DC regulated power supply to the XP1 power supply interface 6002. Note that the power supply parameters must be compatible with the equipment to avoid damage to the equipment due to unstable voltage or overload.

[0077] The XP2 communication interface 6003 is reliably connected to the automation control system and the simulation host computer. Check that the interface connection is secure to prevent loosening from affecting data transmission.

[0078] The simulation test interface correctly receives the synchronization signal from the measurement and control equipment, ensuring stable signal transmission; network port 7 connects to the simulation host computer to establish a data interaction channel.

[0079] Data acquisition: After completing the device connection, power on the device and wait for it to complete self-test and initialization to ensure that the system is in a stable working state.

[0080] Open the simulation host computer data acquisition software and configure the acquisition parameters, including the sampling frequency (set it reasonably according to actual needs, such as 100Hz to meet the needs of high-precision data acquisition), data storage path, etc.

[0081] The system collects real-time data on the actual pressure values ​​of the twenty channels and the actual temperature data of the four channels of the pressure scanning valve. During the data acquisition process, the system closely monitors the data acquisition status to ensure that the data is complete, accurate, and free from any abnormalities such as frame loss or garbled characters.

[0082] Real-time simulation and fault injection: In the MATLAB / Simulink environment, an accurate simulation mathematical model is built based on the actual working principles and characteristics of the automated control system to ensure that the model can realistically reflect the system's operating state. After the model is built, it is downloaded to the pressure scanning valve via network cable. The download progress and status are monitored in real time during the download process to ensure that the model is transmitted to the target device completely and without errors. The simulation computer's host computer software is opened, and the fault injection parameters are dynamically adjusted according to the test requirements.

[0083] Simulate pressure changes: Set parameters such as the magnitude and rate of pressure change. For example, in a short period of time, the pressure of a certain channel is suddenly increased from the standard value to 120% of the rated pressure to simulate a sudden pressure change; or the pressure is set to fluctuate slowly within a certain range to simulate the pressure instability in actual operation.

[0084] Simulated temperature changes: Precisely control the simulated temperature data output by the temperature sensor, and set the temperature rise and fall curve, such as heating at a rate of 5°C per minute to simulate a high-temperature environment; or rapidly cooling down to a low-temperature threshold to simulate extreme low-temperature conditions.

[0085] Simulated data frame loss: By setting specific data frame loss ratios and intervals through software, such as discarding 1 frame every 10 frames of data, abnormal situations during data transmission are simulated, and the ability of the automated control system to cope with incomplete data is comprehensively tested.

[0086] Through the above operations, the operating status of the automated control system under different working conditions is simulated, providing diverse fault scenarios for system performance testing.

[0087] Testing and Optimization: During the simulated fault injection test, test data, including raw pressure and temperature data, system response data, etc., are saved in real time. After the test, host computer software can be run to analyze the data, or professional data analysis tools (such as Python data analysis libraries Pandas, MATLAB, etc.) can be used to conduct in-depth analysis of the test data. The analysis covers key performance indicators such as system response time, control accuracy, and stability, and generates data trend charts and comparative analysis graphs to intuitively present the system's operating performance under different operating conditions.

[0088] Software Upgrade and Repeat Testing: Based on data analysis results, accurately pinpoint system problems and performance bottlenecks, and conduct targeted software upgrades and optimizations. After the software upgrade is completed, strictly follow the above fault simulation and testing procedures to repeatedly conduct simulated fault injection tests. Detailed test data and system performance must be recorded for each test. Compare the test results before and after the upgrade, continuously optimize system performance until the test results fully meet the expected standards.

[0089] Throughout the entire operation, we strictly adhered to the equipment operating procedures and safety regulations, and performed equipment maintenance and data backup to ensure that the testing work was completed safely, efficiently, and accurately.

[0090] Through the above specific implementation methods in different practical scenarios, the effectiveness and practicality of the pressure scanning valve of this utility model in realizing real-time fault injection simulation and testing the performance of automated control systems are fully demonstrated. Those skilled in the art can operate and apply the pressure scanning valve based on the above implementation methods according to different application needs.

[0091] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.

Claims

1. A pressure scanning valve with a function of injecting a fault in real time for simulation, characterized in that, include: The structure comprises an upper cover (1), a middle frame (2), a bottom cover (3), a pressure sensor assembly (4), and a circuit board assembly (5). The top of the middle frame (2) is connected to the upper cover (1), and the bottom of the middle frame (2) is connected to the bottom cover (3). Multiple pressure sensor assemblies (4) are arranged through the top of the upper cover (1). The top of the upper cover (1) is also provided with a power supply interface (6002), a communication interface (6003), a simulation test interface (6004), a network port (7), and multiple temperature measurement interfaces (6001). The circuit board assembly (5) is set in the cavity formed by the middle frame (2) and the bottom cover (3). The pressure sensor assembly (4), temperature measurement interface (6001), power supply interface (6002), communication interface (6003), simulation test interface (6004), and network port (7) are all connected to the circuit board assembly (5) via cables.

2. The pressure scanning valve with a fault real-time injection simulation function according to claim 1, characterized in that, The circuit board assembly (5) includes a power board (5001), a fault injection simulation circuit board (5002), a main control circuit board (5003), and a conditioning circuit board (5004) stacked from bottom to top. The power board (5001) is fixed inside the bottom cover (3). The power board (5001), the fault injection simulation circuit board (5002), and the conditioning circuit board (5004) are all connected to the main control circuit board (5003) via cables, and there is a cable connection between the fault injection simulation circuit board (5002) and the conditioning circuit board (5004).

3. The pressure scanning valve with real-time fault injection simulation function according to claim 2, characterized in that, The pressure sensor assembly (4) and the temperature measurement interface (6001) are both connected to the conditioning circuit board (5004) via cables; the network port (7) is connected to the fault injection simulation circuit board (5002) via cables; the power supply interface (6002) is connected to the power board (5001) via cables; and the communication interface (6003) is connected to the main control circuit board (5003) via cables.

4. The pressure-scan valve with a failure real-time injection simulation function according to any one of claims 1 to 3, characterized in that, The top cover (1) has a first threaded hole (1004) at each of its four vertices, the middle frame (2) has a third threaded hole (2001) at each of its four vertices, and the bottom cover (3) has a fourth threaded hole (3003) at each of its four vertices. When the top cover (1), the middle frame (2) and the bottom cover (3) are fastened together in sequence, screws (8) are screwed into the first threaded hole (1004), the third threaded hole (2001) and the fourth threaded hole (3003) to achieve the connection and fixation of the top cover (1), the middle frame (2) and the bottom cover (3).

5. The pressure-scan valve with a failure real-time injection simulation function according to any one of claims 1 to 3, characterized in that, The bottom cover (3) has four apex supports (3004) at its bottom, which are used to install and fix the pressure scanning valve.

6. The pressure scanning valve with real-time fault injection simulation function according to any one of claims 1 to 3, characterized in that, The bottom cover (3) is provided with a plurality of fixing studs (3002), which are used to connect the circuit board assembly (5).

7. The pressure scanning valve with real-time fault injection simulation function according to any one of claims 1 to 3, characterized in that, The top of the cover (1) is provided with multiple pressure measuring interface threaded holes (1001), and the pressure measuring interface threaded holes (1001) are symmetrically provided with second threaded holes (1005) on both sides; the pressure sensor assembly (4) is provided with a sealing nut (4001) and a fifth threaded hole (4002); the pressure sensor assembly (4) is screwed through the pressure measuring interface threaded hole (1001), the pressure measuring interface is provided with a sealing nut (4001), and screws (8) are screwed into the fifth threaded hole (4002) and the second threaded hole (1005) on both sides of the pressure sensor assembly (4) to achieve the pressure sensor assembly (4) through and fixed on the top of the cover (1).

8. The pressure scanning valve with real-time fault injection simulation function according to claim 7, characterized in that, The top of the cover (1) is also provided with a plurality of first mounting holes (1002), which are used to install temperature measurement interface (6001), power supply interface (6002), communication interface (6003) and simulation test interface (6004), respectively.

9. The pressure scanning valve with real-time fault injection simulation function according to claim 7, characterized in that, The top of the cover (1) is also provided with a second mounting hole (1003), which is used to install the network port (7).

10. The pressure scanning valve with real-time fault injection simulation function according to claim 7, characterized in that, The plurality of pressure sensor assemblies (4) include a pressure sensor assembly (4) with a range of 0 to 1 MPa, a pressure sensor assembly (4) with a range of 0 to 4 MPa, a pressure sensor assembly (4) with a range of 0 to 8 MPa, and a pressure sensor assembly (4) with a range of 0 to 15 MPa.

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