A current detection circuit for a probe station and a probe station

Abstract

The embodiment of the application provides a current detection circuit and a probe station, and relates to the technical field of equipment detection. The current detection circuit comprises an industrial computer and a current detection module; wherein the industrial computer comprises a main control unit and a motion control unit; the main control unit is electrically connected with the motion control unit and the current detection module, and the motion control unit is electrically connected with the current detection module; the current detection module is used for electrically connecting an electric appliance; the main control unit is used for controlling the motion control unit to send a trigger signal; wherein the trigger signal changes according to a preset time period; the current detection module is used for collecting current data of the electric appliance when detecting the change of the trigger signal; and the main control unit is further used for comparing the current data with a rated current parameter of the electric appliance to determine whether the working state of the electric appliance is a normal state or an abnormal state. The embodiment of the application can guarantee the timeliness of electric appliance detection and reduce detection cost.

Description

Technical Field

[0001] This application relates to the field of equipment testing technology, and in particular to a current detection circuit for a probe station and a probe station. Background Technology

[0002] A probe station is a device used for testing the electrical performance of semiconductor devices. The input or output terminals of a probe station are typically connected to electrical components such as relays, solenoid valves, and photoelectric switches. During operation, the probe station needs to monitor the operating status of these components to avoid testing products (such as wafers or chips) during component malfunctions, which could lead to erroneous test results.

[0003] Currently, the main method for detecting the electrical components in the probe station relies on routine inspections by commissioning personnel, or on checking for malfunctions in the components only when the entire probe station experiences a system-wide anomaly. However, current methods for detecting components have long fault response times, making it difficult to promptly detect their operational status and incurring significant manpower costs.

[0004] Therefore, ensuring the timeliness of electrical appliance testing and reducing testing costs have become urgent technical problems to be solved. Utility Model Content

[0005] The main objective of this application is to provide a current detection circuit and a probe station for a probe station, which aims to automatically detect the working status of electrical appliances, ensure the timeliness of electrical appliance detection, and reduce the labor cost of detection.

[0006] To achieve the above objectives, a first aspect of this application provides a current detection circuit for a probe station, the current detection circuit comprising:

[0007] An industrial control computer and a current detection module; wherein the industrial control computer includes a main control unit and a motion control unit;

[0008] The main control unit is electrically connected to the motion control unit and the current detection module, and the motion control unit is electrically connected to the current detection module; the current detection module is used to electrically connect to electrical appliances.

[0009] The main control unit is used to control the motion control unit to send a trigger signal; wherein the trigger signal changes according to a preset time period;

[0010] The current detection module is used to collect the current data of the electrical appliance when the trigger signal changes; the main control unit is also used to compare the current data with the rated current parameter of the electrical appliance to determine whether the working state of the electrical appliance is normal or abnormal.

[0011] In some embodiments, the current detection module includes a current detection control unit, a switching unit, a power supply unit, and a voltage sampling unit;

[0012] The current detection and control unit is electrically connected to the main control unit and the motion control unit; the current detection and control unit, the voltage sampling unit, and the power supply unit are electrically connected in sequence; the current detection and control unit is electrically connected to the switching unit, and the switching unit is electrically connected to the power supply unit; the power supply unit is used to electrically connect to the electrical appliance.

[0013] The current detection and control unit is used to start collecting the voltage of the voltage sampling unit when the trigger signal is detected to change at the first moment;

[0014] The current detection and control unit is also used to switch the opening and closing state of the switch unit at a second time after the first time, so that the power supply state of the electrical appliance switches between the power-on state and the power-off state.

[0015] The current detection control unit is also used to stop collecting the voltage of the voltage sampling unit when it detects that the trigger signal changes at a third time after the second time, so as to obtain the voltage signal from the first time to the third time and calculate the current data based on the voltage signal.

[0016] In some embodiments, the voltage signal is an analog voltage signal; the current detection module further includes an amplification unit and an analog-to-digital conversion unit;

[0017] The current detection and control unit, the analog-to-digital conversion unit, the amplification unit, and the voltage sampling unit are electrically connected in sequence;

[0018] The amplification unit is used to amplify the analog voltage signal; the analog-to-digital conversion unit is used to perform analog-to-digital conversion on the amplified analog voltage signal to obtain a digital voltage signal; the current detection and control unit is used to calculate current data based on the digital voltage signal.

[0019] In some embodiments, the amplification unit includes a differential operational amplifier; the voltage sampling unit includes a shunt resistor;

[0020] The differential operational amplifier is electrically connected to the shunt resistor; the differential operational amplifier is used to amplify the voltage difference signal of the shunt resistor.

[0021] In some embodiments, the current detection circuit for the probe station further includes at least two terminal block modules;

[0022] The current detection module comprises at least two modules, and the number of the current detection modules is the same as the number of the connection port modules.

[0023] Each current detection module is electrically connected to one of the terminal modules, and each terminal module is electrically connected to at least two of the electrical appliances.

[0024] In some embodiments, the main control unit has a first serial interface, and the current detection module has a second serial interface;

[0025] The first serial interface of the main control unit is communicatively connected to the second serial interface of the current detection module.

[0026] The current detection module is also used to send the current data to the first serial interface of the main control unit through the second serial interface according to a preset serial communication protocol.

[0027] The main control unit is also used to determine the sampling current change characteristics based on the current data, and to compare the sampling current change characteristics with the preset standard current change characteristics to determine whether the working state of the electrical appliance is normal or abnormal.

[0028] In some embodiments, the current detection circuit further includes an oscilloscope;

[0029] The oscilloscope is electrically connected to the current detection module; the oscilloscope is used to display the current waveform based on the current data.

[0030] In some embodiments, the current detection circuit further includes a temperature detection module;

[0031] The temperature detection module is electrically connected to the main control unit;

[0032] The temperature detection module is used to collect the temperature of the electrical appliance; the main control unit is used to perform temperature compensation on the current data according to the temperature to obtain the compensated current, and to determine whether the working state of the electrical appliance is normal or abnormal based on the compensated current.

[0033] In some embodiments, the current detection circuit further includes an overcurrent protection module;

[0034] The overcurrent protection module is electrically connected to the current detection module and the electrical appliance; the overcurrent protection module is used to control the current detection module and the electrical appliance to disconnect or connect based on the current data, so as to perform overcurrent protection.

[0035] To achieve the above objectives, a second aspect of the present application provides a probe station, which includes the current detection circuit and electrical appliance described in the first aspect above;

[0036] The current detection module of the current detection circuit is electrically connected to the electrical appliance.

[0037] The current detection circuit and probe station proposed in this application control a motion control unit via a main control unit to send periodically changing trigger signals. These signals drive the current detection module to collect current data from the appliance when the trigger signal changes. This enables automated current acquisition of the appliance, allowing the system to determine its operating status based on current variation characteristics. The main control unit then compares the current data with the appliance's rated current parameter to determine whether the appliance is operating normally or abnormally. For example, if the current data is greater than the rated current parameter, the appliance is operating normally. This automated detection of the appliance's operating status, rather than relying on manual inspection, reduces human error, improves detection efficiency, ensures timely detection, and lowers labor costs. Attached Figure Description

[0038] Figure 1 This is a module block diagram of a current detection circuit for a probe station provided in an embodiment of this application;

[0039] Figure 2 This is a data flow timing diagram of current detection provided in an embodiment of this application;

[0040] Figure 3 This is a module block diagram of a current detection circuit for a probe station provided in another embodiment of this application;

[0041] Figure 4 This is a schematic diagram of current detection for an electrical appliance provided in one embodiment of this application;

[0042] Figure 5 This is a schematic diagram of current detection for an electrical appliance provided in another embodiment of this application;

[0043] Figure 6 This is a module block diagram of a current detection circuit for a probe station provided in another embodiment of this application;

[0044] Figure 7 This is a module block diagram of a current detection circuit for a probe station provided in another embodiment of this application.

[0045] Reference numerals: Industrial computer 100; Current detection module 200; Main control unit 110; Motion control unit 120; Current detection control unit 210; Switching unit 220; Power supply unit 230; Voltage sampling unit 240; Amplification unit 250; Analog-to-digital conversion unit 260. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0047] It should be noted that although functional modules are divided in the device schematic diagram and a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in a different order than the module division in the device or the order in the flowchart. The terms "first," "second," etc., in the specification, claims, and the aforementioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0049] First, let's analyze some of the terms used in this application:

[0050] A probe station is a device used for testing the electrical performance of semiconductor devices. Probe stations are primarily used in the semiconductor, optoelectronic, integrated circuit, and packaging industries to ensure quality and reliability.

[0051] Electrical appliances are devices in a circuit that convert electrical energy into other forms of energy. They consume electrical energy to perform specific functions. Examples of electrical appliances include relays, solenoid valves, and photoelectric switches.

[0052] A relay is an electrical control device used to cause a predetermined step change in the output circuit when the input quantity changes. Relays are commonly used in automatic control systems for automatic adjustment, safety protection, and circuit switching.

[0053] Solenoid valves are electronic components that control the flow of fluid media using electromagnetic force and are widely used in various industrial control systems.

[0054] Photoelectric switch: A switch that uses the photoelectric effect to control the on / off state of a circuit. Photoelectric switches are commonly used in position detection and automatic control.

[0055] Motion control card: A type of upper-level control unit. Based on the PC (Personal Computer) bus, a motion control card utilizes a high-performance microprocessor and large-scale programmable devices to achieve multi-axis coordinated control of multiple servo motors. It is a high-performance stepper / servo motor motion control card. The motion control card has functions such as pulse output, pulse counting, digital input, digital output, and D / A output. It can emit continuous, high-frequency pulse trains; by changing the frequency of the emitted pulses, the motor speed is controlled; by changing the number of emitted pulses, the motor position is controlled.

[0056] Artificial Intelligence (AI) is a new technical science that studies and develops theories, methods, technologies, and application systems for simulating, extending, and expanding human intelligence. A branch of computer science, AI attempts to understand the essence of intelligence and produce intelligent machines that can react in a way similar to human intelligence. Research in this field includes robotics, speech recognition, image recognition, natural language processing, and expert systems. AI can be a simulation of the information processes of human consciousness and thought. It can also be the theory, methods, technologies, and application systems that use digital computers or machines controlled by digital computers to simulate, extend, and expand human intelligence, perceive the environment, acquire knowledge, and use that knowledge to obtain optimal results. Fundamental AI technologies generally include sensors, dedicated AI chips, cloud computing, distributed storage, big data processing technology, operating / interactive systems, and mechatronics. AI software technologies mainly include computer vision, robotics, biometrics, speech processing, natural language processing, and machine learning / deep learning. This application can acquire and process relevant data based on AI technology.

[0057] Neural Networks (NNs) are machine learning techniques inspired by biological nervous systems. They process information by mimicking the connections between neurons and are widely used in the field of artificial intelligence. A neural network consists of multiple interconnected nodes (neurons) arranged hierarchically. By adjusting the connection weights, it learns the complex relationships between input data and output results.

[0058] The current detection circuit and probe station provided in this application are described in detail through the following embodiments. First, the current detection circuit for the probe station in this application embodiment is described.

[0059] It should be noted that in all specific embodiments of this application, when processing data related to user identity or characteristics, such as user information, user behavior data, user historical data, and user location information, user permission or consent is obtained first. Furthermore, the collection, use, and processing of this data comply with relevant laws, regulations, and standards. In addition, when embodiments of this application require access to sensitive personal information of users, separate permission or consent from the user is obtained through pop-ups or redirection to confirmation pages. Only after obtaining the user's separate permission or consent is the necessary user-related data required for the proper functioning of these embodiments acquired.

[0060] Figure 1 This is an optional module block diagram of the current detection circuit for the probe station provided in the embodiments of this application. Figure 1 The current detection circuit for the probe station includes:

[0061] The industrial control computer 100 and the current detection module 200 are included; wherein, the industrial control computer 100 includes a main control unit 110 and a motion control unit 120.

[0062] The main control unit 110 is electrically connected to the motion control unit 120 and the current detection module 200. The motion control unit 120 is electrically connected to the current detection module 200. The current detection module 200 is used to electrically connect to electrical appliances.

[0063] The main control unit 110 is used to control the motion control unit 120 to send a trigger signal; wherein the trigger signal changes according to a preset time period;

[0064] The current detection module 200 is used to collect the current data of the appliance when a change in the trigger signal is detected; the main control unit 110 is also used to compare the current data with the rated current parameters of the appliance to determine whether the appliance is in a normal or abnormal state.

[0065] The beneficial effects of this application embodiment include, but are not limited to: The main control unit 110 controls the motion control unit 120120 to send periodically changing trigger signals to drive the current detection module 200 to collect current data of the electrical appliance when the trigger signal changes. This enables automated current acquisition of the electrical appliance, allowing the determination of its operating status based on the current change characteristics. Then, the main control unit 110110 compares the current data with the rated current parameter of the electrical appliance to determine whether the appliance's operating status is normal or abnormal. For example, if the current data is greater than the rated current parameter, it indicates that the appliance's operating status is normal. This automates the detection of the appliance's operating status, rather than relying on manual inspection, thereby reducing human delays, improving appliance detection efficiency, ensuring timely appliance detection, and reducing the labor costs of appliance detection.

[0066] In some embodiments, the industrial control computer 100 is also referred to as a host computer. For example, the industrial control computer 100 can be a personal computer (PC) or other types of computers. It should be noted that the main control unit 110 is a unit used to execute the host computer software, such as the central processing unit (CPU) of a central control computer. Specifically, the motion control unit 120 can be a motion control card. In some embodiments, the main control unit 110 can communicate with the motion control card via a PCI (Peripheral Component Interconnect) bus, a PCIE (Peripheral Component Interconnect Express) bus, or an EtherCat (Ethernet Control Automation Technology) bus.

[0067] In some embodiments, a trigger signal can be emitted through the output pin of the motion control card. The trigger signal functions similarly to a clock signal, changing according to a preset time period to periodically trigger the current detection module 200 to perform current acquisition. Based on the periodically acquired current data, the module detects whether the appliance is in an abnormal state, improving the efficiency of appliance status detection and achieving automated detection.

[0068] For example, such as Figure 2As shown, the main control unit 110 can communicate with the microcontroller (i.e., the current detection control unit 210 below) in the current detection module 200 via an RS232 serial port to set the current sampling frequency, such as 1KHz (kilohertz), which is the time interval between two current samples, such as the interval between time T1 and time T2 below being 1ms (milliseconds). The number of samples per sampling can also be set, such as sampling 10 current data points each time. Sampling begins at time T0. Assuming the trigger signal changes at time T1, the microcontroller acquires the current data d1 at time T1 and stores it in register 1. It should be noted that the current data acquired by the microcontroller can be based on an analog voltage signal (i.e.,... Figure 2 The digital voltage signal converted from the ADC value (i.e.) Figure 2 The current value is calculated from the voltage value in the register. At time T2, after time T1, the trigger signal changes, and the microcontroller acquires the current data d2 at time T2 and stores it in register 2. This process continues until 10 current data points are acquired, and then the current data stored in registers 1 to 10 are sent sequentially to the main control unit 110 via serial port. The above process can then be repeated to continuously monitor the operating status of the electrical appliance. It should be noted that this current detection mechanism has a fast response speed; the time from detecting a change in the trigger signal to starting to collect current data can be shortened to the microsecond level, thereby reducing the current sampling time, improving the accuracy of the current data, and benefiting subsequent data analysis.

[0069] In some embodiments, the current detection module 200 can be an embedded circuit board, such as an embedded current monitoring and distribution circuit board. For example, the probe station may include an industrial computer 100 and a junction box, and the embedded current monitoring and distribution circuit board may be housed in the junction box. The motion control card in the industrial computer 100 is connected to the embedded current monitoring and distribution circuit board in the junction box via cables, and the embedded current monitoring and distribution circuit board is connected to multiple electrical appliances via cables.

[0070] In some embodiments, electrical appliances can be classified into two types based on the direction of signal transmission: input signal appliances and output signal appliances. For example, multiple input signal appliances may include photoelectric switches, limit sensors, emergency stop switches, etc. Multiple output signal appliances may include solenoid valves, relays, indicator lights, etc.

[0071] In some embodiments, for example, assuming the electrical appliance is a photoelectric switch, the operating state of the photoelectric switch can be detected by utilizing the characteristic that the light beam emitted by the photoelectric switch changes in voltage level (e.g., from 24V to 0V) when it changes from being unobstructed to being obstructed. Specifically, this voltage level change can be detected by an optocoupler, and the voltage level change signal can be sent to the main control unit 110. The main control unit 110 determines whether the operating state of the photoelectric switch is normal or abnormal based on the voltage level change signal and the actual obstruction situation.

[0072] In some embodiments, the main control unit 110 can calculate the absolute value of the difference between the collected current data and the rated current parameter of the appliance to obtain the current deviation, and make a threshold judgment based on the current deviation to determine whether the working state of the appliance is normal or abnormal.

[0073] In some embodiments, it should be noted that the rated current parameter of the electrical appliance is a pre-set engineering parameter. For example, the rated current parameter can be found in the appliance's datasheet. Alternatively, the rated current parameter can be measured and determined using a multimeter.

[0074] For example, referring to Table 1, for each of multiple (e.g., 10) electrical appliances, such as appliance 1, the absolute value of the difference between the actual measured parameter (i.e., current data) and the rated current parameter of appliance 1 can be calculated to obtain the current deviation of appliance 1. If the current deviation is greater than or equal to a preset deviation threshold, the operating state of the appliance is determined to be abnormal; otherwise, the operating state of the appliance is determined to be normal. The calculation process for the current deviation of other electrical appliances, such as appliances 2 to 10, is the same and will not be repeated here.

[0075] Rated current parameters Actual measured parameters Current deviation Appliance 1 Ir1 Ia1 |Ir1-Ia1| Appliance 2 Ir2 Ia2 |Ir2-Ia2| Appliance 3 Ir3 Ia3 |Ir3-Ia4| Appliance 4 Ir4 Ia4 |Ir4-Ia4| Appliance 5 Ir5 Ia5 |Ir5-Ia5| 6 electrical appliances Ir6 Ia6 |Ir6-Ia6| Appliance 7 Ir7 Ia7 |Ir7-Ia7| 8 electrical appliances Ir8 Ia8 |Ir8-Ia8| 9 electrical appliances Ir9 Ia9 |Ir9-Ia9| 10 electrical appliances Ir10 Ia10 |Ir10-Ia10|

[0076] Table 1

[0077] In some embodiments, it should be noted that current probe station devices lack cost-controllable detection mechanisms for electrical components. Specifically, after the CPU in the probe station sends an open command to an electrical component (such as a relay or photoelectric switch), it often assumes the component is in the open state, ignoring the possibility of relay failure. If the component is damaged, the wiring is broken, the plug has poor contact, or other electrical faults occur, the actual operating state of the probe station will differ from the expected state, and the device will malfunction. For example, the common solution currently is to rely on technicians to inspect and confirm the operating status of the components in the probe station, or to perform maintenance only when the entire system malfunctions. This makes it difficult to reduce the maintenance costs of the components, the manpower costs for testing, and the fault response time. Furthermore, the software used to detect the probe station's status may not be able to detect an anomaly in a specific component in a timely manner, causing the probe station to continue operating for a period of time even when the component is faulty. This results in quality risks for products (such as wafers and chips) tested during the period of component failure.

[0078] Based on this, the current detection circuit for the probe station proposed in this application adds an embedded current monitoring and branch circuit board (i.e., current detection module 200) to the probe station's junction box. The current detection module 200 acquires the current change characteristic data of the electrical appliances, and then the main control unit 110 analyzes the operating status of each electrical appliance. This enables accurate detection of the operating status of each electrical appliance, thereby improving the intelligence level of probe station equipment operation and maintenance decisions.

[0079] Please see Figure 3 In some embodiments, the current detection module 200 includes a current detection control unit 210, a switching unit 220, a power supply unit 230, and a voltage sampling unit 240.

[0080] The current detection control unit 210 is electrically connected to the main control unit 110 and the motion control unit 120; the current detection control unit 210, the voltage sampling unit 240 and the power supply unit 230 are electrically connected in sequence; the current detection control unit 210 is electrically connected to the switch unit 220, and the switch unit 220 is electrically connected to the power supply unit 230; the power supply unit 230 is used to electrically connect electrical appliances.

[0081] The current detection control unit 210 is used to start acquiring the voltage of the voltage sampling unit 240 when a change in the trigger signal is detected at the first moment;

[0082] The current detection control unit 210 is also used to switch the opening and closing state of the switching unit 220 at a second time after the first time, so as to switch the power supply state of the electrical appliance between the power-on state and the power-off state.

[0083] The current detection control unit 210 is also used to stop collecting the voltage of the voltage sampling unit 240 when the trigger signal changes at a third time after the second time, so as to obtain the voltage signal from the first time to the third time and calculate the current data based on the voltage signal.

[0084] The advantage of this embodiment is that by starting voltage sampling unit 240 at a first moment, and then controlling whether power supply unit 230 supplies power to the appliance by switching the on / off state of switch unit 220 at a second moment after the first moment (e.g., switching the appliance from a powered-on state to a powered-off state), and then stopping voltage sampling unit 240 at a third moment after the second moment, the voltage signal from the first moment to the third moment is obtained. In this way, the voltage signal acquired during the period from the first moment to the third moment can characterize the voltage change characteristics of the appliance during the process of changing from a powered-on state to a powered-off state (or from a powered-off state to a powered-on state). The current data calculated based on this voltage signal can also characterize the current change characteristics of the appliance during this process, thereby enabling more comprehensive detection of the appliance's operating status and improving the reliability of appliance detection.

[0085] In some embodiments, the current detection control unit 210 may be a single-chip microcomputer (also known as a microcontroller unit, MCU).

[0086] In some embodiments, it should be noted that the power supply unit 230 is used to supply power to the appliance when the switch unit 220 is closed. The opening and closing state of the switch unit 220 affects the connection and disconnection of the power supply circuit between the power supply unit 230 and the appliance. Specifically, the switch unit 220 may include a MOSFET. It should be noted that the main control unit 110 can control the appliance to open or close, that is, control the power supply state of the appliance to be either powered on or powered off. For example, assuming the appliance is a relay, the main control unit 110 can send an instruction (or I / O signal) to the motion control unit 120 to open the relay at a second moment. When the motion control unit 120 receives the instruction (that is, at the second moment, the instruction transmission time is negligible), it controls the MOSFET to change from off to on, so that the corresponding relay power supply circuit is connected, and the power supply state of the appliance is switched from powered off to powered on.

[0087] In some embodiments, if the trigger signal is detected to change from 1 (high level) to 0 (low level), the current detection control unit 210 starts to collect the voltage of the voltage sampling unit 240; if the trigger signal is detected to change from 0 to 1, the current detection control unit 210 stops collecting the voltage of the voltage sampling unit 240.

[0088] For example, such as Figure 4As shown, the current sampling frequency and the time intervals between times T16, T17, T18, and T19 can be preset. The trigger signal changes from 1 to 0 at time T16 (the first time), and from 0 to 1 at time T19 (the third time). Therefore, the monitoring device (i.e., the current detection and control unit 210) can collect the current data from time T16 to T19, that is... Figure 4 The current simulation curve is shown in the figure. At time T17, the current detection and control unit 210 controls the switch circuit 1 (i.e., switch unit 220) to switch from ON to OFF. At this time, the current simulation curve changes from steady state 1 to steady state 2. Then, at time T18, the current detection and control unit 210 controls the switch circuit 1 to switch from OFF to ON. At this time, the current simulation curve changes from steady state 2 to steady state 3. Thus, based on the current data sampled during the transition from steady state 1 to steady state 2 and the current sampling frequency, the power-off discharge time of the appliance connected to switch circuit 1 can be calculated. Based on the current data sampled during the transition from steady state 2 to steady state 3 and the current sampling frequency, the power-on start-up time of the appliance connected to switch circuit 1 can be calculated. Then, the power-off discharge time, power-on start-up time, and other data of the appliance can be compared with preset time parameters to determine whether the appliance's operating state is abnormal.

[0089] In some embodiments, it should be noted that throughout the entire lifecycle of the probe station device, it is necessary to ensure that each electrical appliance maintains a good working condition during its use. To accurately determine whether an electrical appliance is operating normally, detection and analysis can be performed from multiple dimensions, such as acquiring current change characteristics during the switch from a power-on state to a power-off state. For example, if the electrical appliance can successfully change its on / off state according to preset logic, and the detected current data fluctuates within a preset reasonable current threshold range, it can be preliminarily determined that the current working state of the electrical appliance is normal.

[0090] In some embodiments, the operating status of an electrical appliance can also be determined based on current data collected from two adjacent time periods. For example, Figure 5As shown, multiple electrical appliances can be divided into different areas, such as area A, area B, etc. At time T11, appliance 1 in area A is in the on state. Simultaneously, the trigger signal changes from 1 to 0 at time T11 (i.e., the first time), and the monitoring device (i.e., the current detection control unit 210) begins collecting current data. At time T12 (i.e., the third time), the trigger signal changes from 0 to 1, and the current detection control unit 210 stops collecting current data. By statistically analyzing the current data collected from time T11 to time T12, the current detection control unit 210 can obtain the average value Iavg1, peak value, and standard deviation of the current when appliance 1 in area A is in the on state. Then, at time T13, appliance 1 in area A changes from on to off, and the current changes accordingly; for example, the average current changes from average value Iavg1 to average value Iavg2. At time T14, the trigger signal changes from 1 to 0, and the current detection control unit 210 begins collecting current data. At time T15, the trigger signal changes from 0 to 1, and the current detection control unit 210 stops collecting current data. The current detection and control unit 210 statistically analyzes the current data collected from time T14 to T15 to obtain the average current Iavg2, peak current, and standard deviation of appliance 1 in area A when it is in the off state. In some embodiments, the difference between the average current Iavg1 when the appliance is in the on state and the average current Iavg2 when the appliance is in the off state can be compared with preset appliance current characteristic data to determine whether the appliance's operating state is abnormal.

[0091] It should be noted that, in Figure 4 and Figure 5 In the diagram, the upward arrow indicates the execution of a current acquisition operation. The current simulation curve can be a current-time characteristic curve generated by fitting the acquired current data.

[0092] In some embodiments, the current can be continuously monitored over a longer operating period of the electrical appliance to obtain the peak value and standard deviation of the current. This allows for the detection of anomalies such as short circuits, overcurrent, overload, poor contact, and sudden load changes, enabling preliminary fault diagnosis and early warning of potential appliance faults, thus triggering automatic adjustment mechanisms. For example, current change characteristics can be recorded, such as a significant increase in the standard deviation of the current. Anomaly detection of the electrical appliance can be performed based on these current change characteristics, and the current change characteristics can be displayed on the display screen of the industrial control computer 100.

[0093] In some embodiments, such as Figure 5As shown, current characteristics, time, and action data can be displayed in charts to intuitively illustrate the operating status of electrical appliances, helping engineers quickly understand their operation. For example, the current characteristics (such as average value) of the collected current data can be plotted on a time axis to generate a current simulation curve (also known as a current time series diagram). The action status data of the electrical appliance, such as its open or closed state, can also be plotted on a time axis to generate an action time series diagram. Specifically, current time series diagrams and action time series diagrams can be plotted separately for each electrical appliance. In some embodiments, current characteristics and action status data can also be recorded and stored in a host computer for post-event safety checks. For example, after an electrical appliance malfunctions, the detailed current characteristics and action status data in the data records can be used for data backtracking, allowing for faster and more convenient identification of the cause of the malfunction.

[0094] Please see Figure 6 In some embodiments, the voltage signal is an analog voltage signal; the current detection module 200 also includes an amplification unit 250 and an analog-to-digital conversion unit 260;

[0095] The current detection and control unit 210, the analog-to-digital conversion unit 260, the amplification unit 250 and the voltage sampling unit 240 are electrically connected in sequence.

[0096] Amplification unit 250 is used to amplify the analog voltage signal; analog-to-digital conversion unit 260 is used to perform analog-to-digital conversion on the amplified analog voltage signal to obtain a digital voltage signal; current detection and control unit 210 is used to calculate current data based on the digital voltage signal.

[0097] The advantage of this embodiment is that the amplification unit 250 amplifies the analog voltage signal output by the voltage sampling unit 240, thereby amplifying the small analog voltage signal into a voltage signal that matches the range of the analog-to-digital converter 260, avoiding sampling distortion due to insufficient signal strength. Then, the analog-to-digital converter 260 converts the amplified analog voltage signal into a digital voltage signal, thus converting a continuous analog quantity into a discrete digital quantity, allowing the current detection and control unit 210 to calculate the current data based on the digital voltage signal. This enables automated detection of the appliance's current, thereby improving the efficiency of appliance operation status detection, ensuring timely appliance detection, and reducing labor and time costs associated with detection.

[0098] In some embodiments, the analog voltage signal output by the voltage sampling unit 240 can be amplified by the amplification unit 250, thereby amplifying the small analog voltage signal to the range of the analog-to-digital conversion unit 260, such as 1 to 3V (volts). Specifically, the analog-to-digital conversion unit 260 can be an analog-to-digital converter (ADC).

[0099] In some embodiments, it should be noted that the magnitude and duration of the current flowing through an appliance at the moment of power-on or power-off can reflect the internal state of the appliance and the performance of its electronic components. For example, excessive current may indicate an internal fault such as a short circuit or component aging. Insufficient current may indicate poor contact or component failure. The current spike during appliance startup typically lasts from tens of microseconds to milliseconds, and may even be as short as 1 to 10 microseconds, such as during the startup of a switching power supply. In this case, the analog-to-digital conversion unit 260 needs to have a sampling rate of 1 MHz or higher.

[0100] In some embodiments, the current detection and control unit 210 can calculate the current data based on Ohm's law and the digital voltage signal.

[0101] In some embodiments, the amplification unit 250 includes a differential operational amplifier; the voltage sampling unit 240 includes a shunt resistor;

[0102] The differential operational amplifier is electrically connected to the shunt resistor; the differential operational amplifier is used to amplify the voltage difference signal from the shunt resistor.

[0103] The advantage of this embodiment is that the differential operational amplifier amplifies the voltage difference signal across the shunt resistor, thereby amplifying the small analog voltage signal to a voltage signal that conforms to the range of the analog-to-digital conversion unit 260, avoiding sampling distortion due to weak signal, and thus improving the reliability and robustness of electrical appliance detection.

[0104] In some embodiments, the current detection circuit for the probe station further includes at least two terminal block modules;

[0105] There are at least two current detection modules 200, and the number of current detection modules 200 is the same as the number of connection port modules;

[0106] Each current detection module 200 is electrically connected to a terminal module, and each terminal module is electrically connected to at least two electrical appliances.

[0107] The advantage of this embodiment is that by setting at least two connection port modules and the same number of current detection modules 200, modular expansion can be achieved to meet the parallel detection requirements of multiple electrical appliances on the probe station. By connecting each current detection module 200 to a connection port module and connecting each connection port module to at least two electrical appliances, multiple electrical appliances can share the same current detection module 200 for current detection, instead of configuring a separate current detection module 200 for each electrical appliance, thereby reducing hardware redundancy and lowering the hardware cost of electrical appliance detection.

[0108] In some embodiments, it should be noted that multiple electrical appliances can be divided into different zones, and electrical appliances connected to the same wiring port module belong to the same zone. For example, assuming multiple wiring port modules include wiring port A, wiring port B, wiring port C, and wiring port D, wiring port A connects to electrical appliances in zone A, such as limit sensors; wiring port B connects to electrical appliances in zone B, such as relays; wiring port C connects to electrical appliances in zone C, such as solenoid valves; and wiring port D connects to electrical appliances in zone D, such as photoelectric switches. In some embodiments, the basis for dividing multiple electrical appliances into different zones may include the principle of proximity to save wiring and reduce assembly costs. Other bases may also be used to divide the areas to which electrical appliances belong, such as dividing areas according to wiring positions, and are not limited to this. For example, multiple electrical appliances can be divided into 6 areas, including areas A to F, according to the wiring position relationship between the various electrical appliances.

[0109] For example, such as Figure 7 As shown, area A, connected to terminal A, includes six electrical appliances. Appliance 1, Appliance 2, and Appliance 3 are relays, i.e. Figure 7 Relays 1, 2, and 3; and electrical appliances 4, 5, and 6 are photoelectric switches, i.e. Figure 7 Photoelectric switch 1, photoelectric switch 2 and photoelectric switch 3 are included.

[0110] In some embodiments, the main control unit 110 has a first serial interface and the current detection module 200 has a second serial interface;

[0111] The first serial interface of the main control unit 110 is communicatively connected to the second serial interface of the current detection module 200;

[0112] The current detection module 200 is also used to send current data to the first serial interface of the main control unit 110 through the second serial interface according to a preset serial communication protocol.

[0113] The main control unit 110 is also used to determine the sampling current change characteristics based on the current data, and to compare the sampling current change characteristics with the preset standard current change characteristics to determine whether the working state of the electrical appliance is normal or abnormal.

[0114] The advantage of this embodiment is that a communication connection is established between the first serial interface of the main control unit 110 and the second serial interface of the current detection module 200, allowing current data to be sent to the main control unit 110 using a serial communication protocol. Then, the main control unit 110 analyzes the characteristics of the current data to obtain the sampled current change characteristics, and compares them with preset standard current change characteristics. This allows for automated determination of whether the appliance's operating status is normal based on the dynamic characteristics of the current (such as the peak value of the current waveform, the difference between the maximum and minimum current values, etc.), thereby improving the detection efficiency of the appliance's operating status, ensuring the timeliness of appliance detection, and reducing the labor and time costs of detection.

[0115] It should be noted that the first serial interface refers to the serial interface of the main control unit 110, and the second serial interface refers to the serial interface of the current detection module 200. In some embodiments, the first serial interface and the second serial interface are of the same type. For example, both the first serial interface and the second serial interface can be RS232 interfaces or RS485 interfaces.

[0116] In some embodiments, the preset serial communication protocol may include the Modbus communication protocol. It should be noted that the Modbus communication protocol is a serial communication protocol widely used in industrial automation.

[0117] In some embodiments, the current detection circuit further includes an oscilloscope;

[0118] The oscilloscope is electrically connected to the current detection module 200; the oscilloscope is used to display the current waveform based on the current data.

[0119] The advantage of this embodiment is that by electrically connecting the current detection module 200 to the oscilloscope and displaying the current waveform based on the current data, the changing trend of the current of the appliance can be intuitively presented. For example, the transient changes in current during the state switching process of the appliance, or the steady-state change trend of the current, can be presented. The abstract current data is transformed into intuitively interpretable graphical information, so that users (such as the maintenance personnel of the probe station) can directly observe the current change characteristics of the appliance, thereby more intuitively displaying the working status of the appliance of the probe station.

[0120] In some embodiments, an oscilloscope can visually display the magnitude and duration of current at the moment of power-on or power-off of an electrical appliance. This data can reflect the internal state of the appliance, enabling engineers to debug and maintain probe station equipment.

[0121] It should be noted that during the current detection process of the electrical appliances in the probe station, the current detection circuit can repeatedly execute a preset set of current detection actions. Throughout the entire lifecycle of the probe station device, the software commands, the actions of the electrical appliances, and the detected current data are all in real time.

[0122] In some embodiments, the current detection circuit further includes a temperature detection module;

[0123] The temperature detection module is electrically connected to the main control unit 110;

[0124] The temperature detection module is used to collect the temperature of the electrical appliance; the main control unit 110 is used to perform temperature compensation on the current data according to the temperature, obtain the compensated current, and determine whether the working state of the electrical appliance is normal or abnormal based on the compensated current.

[0125] The advantage of this embodiment is that, considering that temperature fluctuations can cause changes in resistance and thus introduce errors in current data, a temperature detection module (such as a temperature sensor) is used to collect the temperature of the appliance, thereby detecting the impact of temperature changes on current measurement in real time. The main control unit 110 performs temperature compensation on the current data based on the collected temperature to obtain the compensated current. This corrects temperature-induced drift, improves the accuracy of current detection, enhances the anti-interference capability of current acquisition from the appliance, and ultimately improves the reliability of appliance operating status detection.

[0126] In some embodiments, the main control unit 110 can perform temperature compensation on the current data using a preset temperature compensation algorithm, such as the least squares method or a neural network algorithm.

[0127] In some embodiments, the current detection circuit further includes an overcurrent protection module;

[0128] The overcurrent protection module is electrically connected to the current detection module 200 and the appliance; the overcurrent protection module is used to control the disconnection or connection between the current detection module 200 and the appliance based on current data to perform overcurrent protection.

[0129] The advantage of this embodiment is that, through the overcurrent protection module, the on / off state between the current detection module 200 and the appliance is controlled based on the current data. For example, when the current data is too large, the current detection module 200 is controlled to disconnect from the appliance, thereby performing overcurrent protection and improving the safety of the current detection circuit.

[0130] In some embodiments, specifically, the overcurrent protection module may include a fuse, a thermistor, etc.

[0131] This application embodiment also provides a probe station, which includes the above-described current detection circuit and electrical appliance;

[0132] The current detection module 200 of the current detection circuit is electrically connected to the electrical appliance.

[0133] The specific implementation of this probe station is basically the same as the specific embodiment of the current detection circuit for the probe station described above, and will not be repeated here.

[0134] It should be noted that the software tools or components not belonging to our company that appear in the embodiments of this application are merely examples and do not represent actual use.

[0135] The embodiments described in this application are intended to more clearly illustrate the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. Those skilled in the art will know that with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0136] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer modules than shown, or combine certain modules, or different modules.

[0137] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0138] Those skilled in the art will understand that the functional modules / units in the systems and devices disclosed above can be implemented as software, firmware, hardware, and appropriate combinations thereof.

[0139] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0140] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0141] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and devices can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of the units described above is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. The coupling or direct coupling or communication connection between the shown or discussed units may be through some interfaces, or the indirect coupling or communication connection between the apparatus or units may be electrical, mechanical, or other forms.

[0142] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0143] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0144] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes multiple instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing programs, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0145] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A current detection circuit for a probe station, characterized in that, The current detection circuit includes: An industrial control computer and a current detection module; wherein the industrial control computer includes a main control unit and a motion control unit; The main control unit is electrically connected to the motion control unit and the current detection module, and the motion control unit is electrically connected to the current detection module; the current detection module is used to electrically connect to electrical appliances. The main control unit is used to control the motion control unit to send a trigger signal; wherein the trigger signal changes according to a preset time period; The current detection module is used to collect the current data of the electrical appliance when the trigger signal changes; the main control unit is also used to compare the current data with the rated current parameter of the electrical appliance to determine whether the working state of the electrical appliance is normal or abnormal.

2. The current detection circuit for a probe station according to claim 1, characterized in that, The current detection module includes a current detection control unit, a switching unit, a power supply unit, and a voltage sampling unit; The current detection and control unit is electrically connected to the main control unit and the motion control unit; the current detection and control unit, the voltage sampling unit, and the power supply unit are electrically connected in sequence; the current detection and control unit is electrically connected to the switching unit, and the switching unit is electrically connected to the power supply unit; the power supply unit is used to electrically connect to the electrical appliance. The current detection and control unit is used to start collecting the voltage of the voltage sampling unit when the trigger signal is detected to change at the first moment; The current detection and control unit is also used to switch the opening and closing state of the switch unit at a second time after the first time, so that the power supply state of the electrical appliance switches between the power-on state and the power-off state. The current detection control unit is also used to stop collecting the voltage of the voltage sampling unit when it detects that the trigger signal changes at a third time after the second time, so as to obtain the voltage signal from the first time to the third time and calculate the current data based on the voltage signal.

3. The current detection circuit for a probe station according to claim 2, characterized in that, The voltage signal is an analog voltage signal; the current detection module also includes an amplification unit and an analog-to-digital conversion unit. The current detection and control unit, the analog-to-digital conversion unit, the amplification unit, and the voltage sampling unit are electrically connected in sequence; The amplification unit is used to amplify the analog voltage signal. The analog-to-digital conversion unit is used to perform analog-to-digital conversion on the amplified analog voltage signal to obtain a digital voltage signal; the current detection and control unit is used to calculate current data based on the digital voltage signal.

4. The current detection circuit for a probe station according to claim 3, characterized in that, The amplification unit includes a differential operational amplifier; the voltage sampling unit includes a shunt resistor; The differential operational amplifier is electrically connected to the shunt resistor; the differential operational amplifier is used to amplify the voltage difference signal of the shunt resistor.

5. The current detection circuit for a probe station according to any one of claims 1 to 4, characterized in that, The current detection circuit for the probe station also includes at least two terminal block modules; The current detection module comprises at least two modules, and the number of the current detection modules is the same as the number of the connection port modules. Each current detection module is electrically connected to one of the terminal modules, and each terminal module is electrically connected to at least two of the electrical appliances.

6. The current detection circuit for a probe station according to any one of claims 1 to 4, characterized in that, The main control unit has a first serial interface, and the current detection module has a second serial interface; The first serial interface of the main control unit is communicatively connected to the second serial interface of the current detection module. The current detection module is also used to send the current data to the first serial interface of the main control unit through the second serial interface according to a preset serial communication protocol. The main control unit is also used to determine the sampling current change characteristics based on the current data, and to compare the sampling current change characteristics with the preset standard current change characteristics to determine whether the working state of the electrical appliance is normal or abnormal.

7. The current detection circuit for a probe station according to any one of claims 1 to 4, characterized in that, The current detection circuit also includes an oscilloscope; The oscilloscope is electrically connected to the current detection module; the oscilloscope is used to display the current waveform based on the current data.

8. The current detection circuit for a probe station according to any one of claims 1 to 4, characterized in that, The current detection circuit also includes a temperature detection module; The temperature detection module is electrically connected to the main control unit; The temperature detection module is used to collect the temperature of the electrical appliance; the main control unit is used to perform temperature compensation on the current data according to the temperature to obtain the compensated current, and to determine whether the working state of the electrical appliance is normal or abnormal based on the compensated current.

9. The current detection circuit for a probe station according to any one of claims 1 to 4, characterized in that, The current detection circuit also includes an overcurrent protection module; The overcurrent protection module is electrically connected to the current detection module and the electrical appliance; the overcurrent protection module is used to control the current detection module and the electrical appliance to disconnect or connect based on the current data, so as to perform overcurrent protection.

10. A probe station, characterized in that, The probe station includes the current detection circuit and electrical appliance as described in any one of claims 1 to 9; The current detection module of the current detection circuit is electrically connected to the electrical appliance.

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