A safety mechanism tester

Abstract

The application belongs to the technical field of safety test, and particularly relates to a safety mechanism tester. The safety mechanism tester comprises an operation panel and a back panel. The operation panel is provided with an upper computer and a power supply interface. The upper computer is used for receiving and sending signals. The power supply interface is used for electrical connection with an external power supply. The back panel is provided with an electronic simulator module and a power supply module used for supplying power to the electronic simulator module. The electronic simulator can be directly connected with a safety mechanism for detection. Only simple cable connection is needed, and the safety mechanism tester does not need to be disassembled, thereby saving time and effort, being convenient to carry, and improving the detection efficiency of the safety mechanism.

Description

Technical Field

[0001] This application belongs to the field of security testing technology, specifically relating to a security mechanism tester. Background Technology

[0002] A safety mechanism is a safety device specifically designed for the ignition mechanism of a solid rocket motor. The safety mechanism has two states: a safe state and a working state. When the solid rocket motor does not need to ignite for launch, such as during the pre-launch phase, storage, or transportation, the safety mechanism is in the safe state, ensuring that the solid rocket motor will not be accidentally ignited. When the solid rocket motor needs to be ignited for launch, the safety mechanism switches to the working state, ensuring that the solid rocket motor can ignite reliably and avoids a misfire.

[0003] Safety mechanisms require testing to ensure they meet performance standards during production and factory inspection. They also need to be tested before being assembled into solid rocket motors. Furthermore, safety mechanisms are periodically tested while the solid rocket motor is awaiting launch or during storage. The main test items include: reading the safety mechanism's status (safe or operational); verifying the normal transition between safe and operational states; confirming the state transition time is within the specified range; checking the resistance of the safety or operational state feedback loop within the specified range; and verifying that the insulation resistance between the safety mechanism's casing and the safe state circuit, the casing and the operational state circuit, and the casing and the power-off dual-holding electromagnet circuit are greater than the specified insulation resistance. If these electrical performance parameters are within normal ranges, the safety mechanism is considered qualified, providing a basis for screening and selecting qualified safety mechanisms. Therefore, a safety mechanism tester is needed to perform comprehensive performance testing on safety mechanisms.

[0004] When conducting tests using a safety mechanism, a properly functioning safety mechanism is first required to calibrate the test instrument, thus determining whether the test instrument is operating correctly. This process is known as test instrument calibration. However, actual safety mechanisms are bulky and heavy, making them inconvenient to integrate into the test instrument, which introduces many inconveniences into the calibration process. Furthermore, the parameters of actual safety mechanisms vary slightly. Therefore, even when using a fully functional, real safety mechanism to calibrate the test instrument, it is still impossible to determine whether the measured parameters are accurate or whether the test instrument is functioning correctly. Thus, a safety mechanism test instrument with self-testing capabilities is also needed. Summary of the Invention

[0005] To address the aforementioned technical issues, this application proposes a safety mechanism tester that tests the state of a safety mechanism and the transitions between states, as well as the electrical performance parameters of the safety mechanism, and also enables the safety mechanism tester to perform self-testing.

[0006] To achieve the above objectives, the present invention provides a safety mechanism tester, including a host computer and a test module having an electrical port J1Y that is electrically connected to the safety mechanism;

[0007] The host computer is used to issue command signals and communicate with the test module.

[0008] The test module is used to receive and execute the instruction signal, and includes a tester power supply, a microcontroller U0Y, a test execution unit, and a multi-meter test unit. The microcontroller U0Y and the test execution unit are electrically connected.

[0009] The microcontroller U0Y receives and executes the instruction signal from the host computer. The corresponding pin of the microcontroller U0Y outputs a switch signal, which is sent to the test execution unit. The test execution unit receives the switch signal and completes the execution of the switch signal. The instruction signal includes a safety mechanism status confirmation signal, a safety mechanism (or electronic simulator) status transition signal, and a signal to acquire (the electrical performance of the safety mechanism (or electronic simulator)) corresponding parameter signal. The result data of executing the switch signal is fed back to the microcontroller U0Y, which then outputs the result data to the host computer.

[0010] After receiving the signal for acquiring the corresponding parameters of the electrical performance of the safety agency (or electronic simulator), the test execution unit executes the test circuit of the multi-meter test unit to test the corresponding parameters, and the multi-meter test unit directly acquires the corresponding parameters of the electrical performance of the safety agency (or electronic simulator).

[0011] The power supply of the tester is used to provide operating voltage to the microcontroller U0Y, the test execution unit, and the multi-meter test unit.

[0012] In some embodiments, a safety mechanism electronic simulator is also included. The safety mechanism electronic simulator includes a microcontroller U1, a power module U2, a relay K1, and a port J1. The microcontroller U1 is electrically connected to the coil of the relay K1, and the contacts of the relay K1 are electrically connected to the port J1. The port J1 is used to connect to the electrical port J1Y of the safety mechanism tester. The power module U2 is used to provide operating voltage to the electronic simulator.

[0013] It also includes an optocoupler isolation module, used to provide status signals to the microcontroller U1; the optocoupler isolation module includes two anti-parallel connected first optocoupler X1 and second optocoupler X2.

[0014] The anode of the input diode of the first optocoupler X1 and the cathode of the input diode of the second optocoupler X2 are connected to the first switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The cathode of the input diode of the first optocoupler X1 and the anode of the input diode of the second optocoupler X2 are connected to the second switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The collector of the output transistor of the first optocoupler X1 is electrically connected to the working state pin of the microcontroller U1 through a first clamping resistor. The emitter of the output transistor of the first optocoupler X1 is grounded. The collector of the output transistor of the second optocoupler X2 is electrically connected to the safety state pin of the microcontroller U1 through a second clamping resistor. The emitter of the output transistor of the second optocoupler X2 is grounded.

[0015] In some embodiments, the electronic simulator further includes a driving optocoupler isolation module, which includes a third optocoupler Y1 disposed between the microcontroller U1 and the relay K1. The anode of the input diode of the third optocoupler Y1 is electrically connected to the output terminal of the power supply module U2, the cathode of the input diode of the optocoupler Y1 is electrically connected to the state transition pin of the microcontroller U1, the collector of the output transistor of the optocoupler Y1 is electrically connected to the coil of the relay K1, and the emitter of the output transistor of the optocoupler Y1 is grounded.

[0016] In some implementations, the test execution unit receives the instruction signal and executes the instruction signal, specifically including:

[0017] The test execution unit includes a conduction feedback resistance test circuit, a housing-core wire insulation resistance test circuit, a safety-operating state mutual conversion circuit, a safety or operating state reading (or confirmation) circuit, and a power-off dual-holding electromagnet operating voltage test circuit for the safety mechanism.

[0018] The test execution unit receives and acquires corresponding parameter signals. When the corresponding parameter is the safety mechanism conduction feedback resistor, the conduction feedback resistor test circuit is turned on to obtain the safety state conduction feedback resistor, the working state conduction feedback resistor, and the feedback resistor of the power-off dual-holding electromagnet conduction circuit of the safety mechanism.

[0019] The test execution unit receives and acquires the corresponding parameter signal. When the corresponding parameter is the insulation resistance between the housing and the core wire of the safety mechanism, the housing-core wire insulation resistance test circuit is turned on to obtain the insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit.

[0020] The test execution unit receives and acquires the corresponding parameter signal. When the corresponding parameter is the working voltage of the power-off double-holding electromagnet, the power-off double-holding electromagnet working voltage test circuit is turned on to obtain the working voltage of the power-off double-holding electromagnet.

[0021] When the test execution unit receives the safety mechanism state transition signal, it connects the safety-operation state mutual transition circuit to obtain the feedback signal for the safety-operation state mutual transition.

[0022] When the test execution unit receives a safety mechanism status confirmation signal, it activates the safety or working status reading (or confirmation) circuit to obtain a feedback signal confirming the safety or working status.

[0023] In some embodiments, the power supply of the tester includes a 220V to 24V power supply U1Y, a 24V to 5V power supply U3Y, and a 220V to 28V power supply U4Y.

[0024] The power supply U1Y provides operating voltage to all relays of the test execution unit;

[0025] The power supply U3Y provides the operating voltage for the microcontroller U0Y;

[0026] The power supply U4Y provides the operating voltage for the power-off dual-holding electromagnet of the safety mechanism.

[0027] In some implementations, the power supply U4Y is a wide-range test power supply that provides three operating voltages: 22V, 28V, and 32V.

[0028] In some implementations, the multi-table test unit directly obtains the corresponding parameters, specifically including:

[0029] The multi-meter test unit includes an ohmmeter, a megohmmeter, and a voltmeter;

[0030] The ohmmeter is electrically connected to the test execution unit and is used to obtain the feedback resistance of the safety state conduction circuit, the feedback resistance of the working state conduction circuit, and the feedback resistance of the power-off double-holding electromagnet conduction circuit of the safety mechanism.

[0031] The megohmmeter is electrically connected to the test execution unit and is used to obtain the insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit.

[0032] The voltmeter is electrically connected to the test execution unit and is used to obtain three operating voltages of the wide-range test power supply and the operating voltage of the power-off double-holding electromagnet.

[0033] In some implementations, the host computer is communicatively connected to the testing module, specifically including:

[0034] The host computer communicates with the test module via RS485_1 and RS485_2 buses. The RS485_2 bus is used to communicate with the multi-meter test unit. The corresponding parameters acquired by the multi-meter test unit are directly transmitted to the host computer. These corresponding parameters include:

[0035] Feedback resistors for the safety state conduction circuit, the working state conduction circuit, and the power-off double-holding electromagnet conduction circuit of the safety mechanism.

[0036] The insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit.

[0037] The wide-range test power supply has three operating voltages and the operating voltage of the power-off double-holding electromagnet.

[0038] In some implementations, the host computer is a tablet computer.

[0039] In some implementations, a data transmission USB interface for transmitting the test parameters is also provided.

[0040] In general, the above-described technical solutions conceived in this application can achieve the following beneficial effects:

[0041] The safety mechanism tester of the present invention integrates the testing of the status confirmation and state transition of the safety mechanism, the testing of the electrical performance parameters of the safety mechanism, and the self-testing of the safety mechanism tester.

[0042] Specifically, the test execution unit includes a feedback resistance test circuit, a housing-core wire insulation resistance test circuit, a safety-operation state switching circuit, and a safety or operation state reading (or confirmation) circuit. The test execution unit receives and acquires corresponding parameter signals. When the corresponding parameter is the safety mechanism conduction feedback resistance, the conduction feedback resistance test circuit is activated to obtain the safety state conduction feedback resistance, the operation state conduction feedback resistance, and the feedback resistance of the safety mechanism's power-off dual-holding electromagnet conduction circuit. When the corresponding parameter is the safety mechanism housing-core wire insulation resistance, the housing-core wire insulation resistance test circuit is activated to obtain the insulation resistance between the safety mechanism's housing and the safety state conduction feedback resistance. The insulation resistance between the circuits, the insulation resistance between the housing and the working state conducting circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conducting circuit are measured. When the corresponding parameter is the working voltage of the power-off double-holding electromagnet, the power-off double-holding electromagnet working voltage test circuit is activated to obtain the working voltage. When the test execution unit receives the safety mechanism state transition signal, the safety-working state mutual conversion circuit is activated to obtain the feedback signal for the safety-working state mutual conversion. When the test execution unit receives the safety mechanism state confirmation signal, the safety or working state reading (or confirmation) circuit is activated to obtain the feedback signal confirming the safety or working state. An integrated safety mechanism electronic simulator is included, with a converter cable connecting one end to the simulator's J1 port and the other end to the safety mechanism tester's J1Y port for self-testing of the safety mechanism tester.

[0043] This safety mechanism tester requires only simple cable connections and does not require disassembly or assembly of the safety mechanism, saving time and effort. It effectively achieves miniaturization and lightweight design, making it easy to carry and use, and greatly improving the testing efficiency of safety mechanisms. Attached Figure Description

[0044] Figure 1 This is a structural block diagram of the safety mechanism tester in the embodiment;

[0045] Figure 2 The circuit diagram of the electronic simulator of the safety mechanism tester as an example;

[0046] Figure 3 The electrical schematic diagram of the safety mechanism tested by the safety mechanism tester in this embodiment;

[0047] Figure 4 This is a circuit diagram for reading (confirming) the status of a security mechanism, as shown in the embodiment.

[0048] Figure 5 The circuit diagram for the state transition of the safety mechanism in the embodiment, and the circuit for testing the working voltage of the power-down dual-holding electromagnet;

[0049] Figure 6The following is a test circuit diagram of the feedback resistor for the safety state conduction feedback resistor, the working state conduction feedback resistor, and the feedback resistor for the power-off dual-holding electromagnet conduction circuit of the safety mechanism, as shown in the embodiment.

[0050] Insulation resistance between the housing and the safety state conduction circuit, insulation resistance between the housing and the working state conduction circuit, and insulation resistance between the housing and the power-off dual-holding electromagnet conduction circuit; test circuit diagram.

[0051] Figure 7 The electrical port J1Y wiring diagram for this embodiment;

[0052] Figure 8 The circuit diagram of the microcontroller U0Y, power supply, and ISP is shown in the embodiment. Detailed Implementation

[0053] 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. Furthermore, the technical features involved in the various embodiments described below can be combined with each other as long as they do not conflict with each other.

[0054] like Figure 1As shown, a safety mechanism tester according to this embodiment includes a host computer and a test module with an electrical port J1Y for electrical connection with the safety mechanism, but does not include an electronic simulator. The host computer is used to issue command signals and communicate with the test module. In this embodiment, the host computer is a tablet computer with touch function, which is connected to an external power supply through a power interface. It is also equipped with a USB interface for downloading data stored in the host computer. The communication connection with the test module is through an RS-485 bus to transmit all data. The test module is used to receive and execute command signals. It includes a tester power supply, a microcontroller U0Y, a test execution unit, and a multi-meter test unit. The microcontroller U0Y and the test execution unit are electrically connected. The microcontroller U0Y receives command signals from the host computer and sends them to the test execution unit. The test execution unit receives the command signals and executes them. The command signals include a safety mechanism status confirmation signal, a safety mechanism (in another embodiment, an electronic simulator replaces the safety mechanism) status transition signal, and a signal to obtain the corresponding electrical performance parameters of the safety mechanism (in another embodiment, an electronic simulator replaces the safety mechanism). The result data of the execution switch signal is fed back to the microcontroller U0Y, which then outputs the result data to the host computer. The microcontroller U0Y also needs to receive switch signals. Its pins can be configured as input pins or output pins. For example, it can read the feedback signal of the safety mechanism status and input it to the pin of the microcontroller. After reading the pin signal, the microcontroller reports it to the host computer through the RS-485 communication interface.

[0055] like Figure 3 As shown, the safety mechanism tester of this embodiment is designed based on the safety mechanism of the test object. Figure 3 This is an electrical schematic diagram showing the transition between the safe and operational states of a safety mechanism. Pins 1, 2, 3, 4, 5, 6, 7, 8, 9, 12, 13, and 15 in the diagram correspond to the pins of the electrical port J1Y on the safety mechanism tester. If pins 1 and 9 are red (+) (positive) and pins 8 and 15 are black (-) (negative), it indicates a transition from the safe to the operational state, and the mechanism remains in the operational state. Conversely, if pins 1 and 9 are red (-) (negative) and pins 8 and 15 are black (+) (positive), it indicates a transition from the operational to the safe state, and the mechanism remains in the safe state. In the diagram, pins 1 and 9 are red (-) (negative) and pins 8 and 15 are black (+) (positive), indicating a transition from the operational to the safe state, and the mechanism remains in the safe state.

[0056] like Figure 8The microcontroller U0Y is model STC15W408AS. Its first pin is connected to the cathode of the diode in optocoupler Y9; its second pin is connected to the collector of the transistor in optocoupler isolator X2Y; its third pin is connected to the cathode of the diode in optocoupler Y10; its fourth pin is connected to the cathode of the diode in optocoupler Y8; its seventh pin is connected to the cathode of the diode in optocoupler Y3; its eighth pin is connected to the cathode of the diode in optocoupler Y6; its ninth pin is connected to the cathode of the diode in optocoupler Y2; its tenth pin is connected to the cathode of the diode in optocoupler Y5; its eleventh pin is connected to the cathode of the diode in optocoupler Y1; and its twelfth pin is connected to the cathode of the diode in optocoupler Y1. The four pins are connected to the positive and negative terminals of the 5V power supply, respectively. The thirteenth pin is connected to the cathode of the diode in optocoupler Y4. The fifteenth and sixteenth pins are connected to the P3.0 and P3.1 pins of the ISP1 interface, respectively. The seventeenth pin is connected to the collector of the transistor in optocoupler isolator X1Y. The eighteenth pin is connected to the cathode of the diode in optocoupler Y7. The nineteenth pin is connected to the cathode of the diode in optocoupler Y13. The twentieth pin is connected to the cathode of the diode in optocoupler Y12. The twenty-first, twenty-second, and twenty-eighth pins are connected to the RS485_RX, RS485_TX, and RS485_RE pins of U2Y, respectively.

[0057] In another embodiment, two RS-485 buses are used to transmit the corresponding data respectively. The RS-485 communication interface U2Y between the microcontroller U0Y and the host computer uses an RS-485 transceiver RSM485ECHT, and the power supply module U3Y uses an F2405S-2WR2. Specifically, the host computer uses RS485_1 bus and RS485_2 bus to communicate with the test module. Figure 8 J4 is the RS485_1 communication interface. Figure 6 J5 is an RS485_2 communication interface, which uses an RS485_2 bus to communicate with the multi-meter test unit. The relevant parameters obtained by the multi-meter test unit are directly transmitted to the host computer. The relevant parameters include:

[0058] Feedback resistors for the safety state conduction circuit, the working state conduction circuit, and the power-off double-holding electromagnet conduction circuit of the safety mechanism.

[0059] The feedback resistor for the safe state conduction circuit and the feedback resistor for the working state conduction circuit are the state feedback resistors of the electromagnet.

[0060] The insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit.

[0061] The wide-range test power supply has three operating voltages and the operating voltage of the power-off double-holding electromagnet.

[0062] The RS485_1 bus is connected to the microcontroller UOY for communication. The status confirmation result data of the safety mechanism and the status transition result data of the safety mechanism (in another embodiment, an electronic simulator is used to replace the safety mechanism) are transmitted from the microcontroller UOY to the host computer.

[0063] like Figure 5 and Figure 8 The power supply of the tester is used to provide operating voltage to the microcontroller U0Y, the test execution unit, and the multi-meter test unit.

[0064] The power supply for the tester includes a 220V to 24V power supply U1Y, a 24V to 5V power supply U3Y, and a 220V to 28V power supply U4Y.

[0065] Power supply U1Y provides operating voltage to all relays of the test execution unit;

[0066] Power supply U3Y provides operating voltage for microcontroller U0Y;

[0067] Power supply U4Y provides operating voltage for the power-off double-holding electromagnet of the safety mechanism.

[0068] The power supply U4Y is a wide-range test power supply, which provides three operating voltages: 22V, 28V, and 32V.

[0069] The test execution unit receives and executes instruction signals, specifically including:

[0070] like Figure 6 As shown, K1, K2, K3, K4, K5, K6, K7, K8, K9, and K10 in the circuit are relays. The test execution unit includes a conduction feedback resistance test circuit. The test execution unit receives and acquires corresponding parameter signals. When the corresponding parameter is the conduction feedback resistance of the safety mechanism, K4 is energized, which can detect the safety feedback resistance of the safety mechanism (i.e., the resistance between AQ1 and AQ2), that is, the conduction feedback resistance in the safe state; K5 is energized, which can detect the coil feedback resistance of the safety mechanism (i.e., the resistance between XQ1 and XQ2), that is, the feedback resistance of the conduction circuit of the power-off double-holding electromagnet of the safety mechanism; K6 is energized, which can detect the working feedback resistance of the safety mechanism (i.e., the resistance between GZ1 and GZ2), that is, the conduction feedback resistance in the working state.

[0071] The test execution unit also includes a housing-core wire insulation resistance test circuit. When the corresponding parameter is the housing-core wire insulation resistance, K1 is activated, which can detect the safety insulation resistance of the safety mechanism, i.e., the insulation resistance between the housing and the safety state conduction circuit; K2 is activated, which can detect the coil insulation resistance of the safety mechanism, i.e., the insulation resistance between the housing and the conduction circuit of the power-off dual-holding electromagnet; K3 is activated, which can detect the working insulation resistance of the safety mechanism, i.e., the insulation resistance between the housing and the working state conduction circuit.

[0072] like Figure 5 As shown, the test execution unit also includes a safety-operation state switching circuit; when K9 is energized, the safety mechanism switches from a safety state to an operating state; when K10 is energized, the safety mechanism switches from an operating state to a safety state; H1 and H2 are the H-bridge circuits, which are responsible for the safety mechanism state switching. When relay K9 is energized, XQ1+, XQ2-, safety switches to operating; when relay K10 is energized, XQ1-, XQ2+, operating switches to safety.

[0073] like Figure 4 As shown, the test execution unit also includes a safety or working status reading (or confirmation) circuit; K7 and K8 provide feedback signals for the safety and working status of the safety mechanism to the microcontroller, respectively; optocouplers X1Y and X2Y provide feedback signals to the microcontroller STC15W408AS. When relay K7 is energized, the transistor of optocoupler X1Y is turned on, and the corresponding DIAQ becomes low, and the signal is sent to the seventeenth pin of the microcontroller STC15W408AS. At this time, the safety mechanism is determined to be in a safe state; when relay K8 is energized, the transistor of optocoupler X2Y is turned on, and the corresponding DIGZ becomes low, and the signal is sent to the second pin of the microcontroller STC15W408AS. At this time, the safety mechanism is determined to be in a working state.

[0074] like Figure 5 As shown, the test execution unit also includes a power-down dual-holding electromagnet operating voltage test circuit for the safety mechanism. The test execution unit receives and acquires the corresponding parameter signal, which is the operating voltage of the power-down dual-holding electromagnet. The power module U4Y can convert 220V voltage to 28V, 22V, and 32V as needed. The voltage conversion is controlled by the microcontroller STC15W408AS. When the host computer issues a corresponding command, the microcontroller STC15W408AS receives the signal and can correspondingly pull Y22V low and turn on the optocoupler Y12. At this time, the power module U4Y outputs a voltage of 22V. When the microcontroller STC15W408AS outputs a signal, or correspondingly pulls Y32V low and turns on the optocoupler Y13, the power module U4Y outputs a voltage of 32V.

[0075] The pull-in time of relays K1-K10 is only 0.5 seconds to avoid damage caused by overheating of the electromagnet due to prolonged energization. Additionally, relays K1-K10 are equipped with freewheeling diodes D1, D2, D3, D4, D5, D6, D7, D8, D9, and D10 respectively to absorb high voltage spikes, preventing the generation of high voltage pulses the moment the relay coil is de-energized, thus protecting the circuit for safe and stable operation.

[0076] The multi-meter test unit directly obtains the corresponding electrical performance parameters, specifically including:

[0077] The multi-meter test unit includes an ohmmeter, a megohmmeter, and a voltmeter;

[0078] like Figure 6 As shown, the ohmmeter electrical connection test execution unit is used to obtain the feedback resistance of the safety state conduction circuit, the feedback resistance of the working state conduction circuit, and the feedback resistance of the power-off double-holding electromagnet conduction circuit of the safety mechanism.

[0079] like Figure 6 As shown, the megohmmeter electrical connection test execution unit is used to obtain the insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit.

[0080] like Figure 4 As shown, the voltmeter is electrically connected to the test execution unit to obtain the three operating voltages of the wide-range test power supply and the operating voltage of the power-off double-holding electromagnet.

[0081] In summary, XQ1 and XQ2 in each diagram are the two terminals of the electromagnet coil. When testing the coil resistance, these two terminals are connected to the ohmmeter on the three-meter board; when switching states, these two terminals are connected to the output of the H-bridge; when testing the insulation resistance of the coil core and shell, either of these two terminals is connected to one end of the megohmmeter, and the other end of the megohmmeter is connected to the casing. All the above tests and switching are performed by relays. When relays K1-K10 are switching, they cannot be engaged simultaneously; they can only be engaged one at a time, and only one relay can be switched at a time.

[0082] In another embodiment, such as Figure 1 and Figure 2As shown, the safety mechanism tester of the present invention also includes a safety mechanism electronic simulator for self-testing of the safety mechanism tester. The safety mechanism electronic simulator includes a microcontroller U1, a power module U2, a relay K0 and a port J1. The microcontroller U1 is electrically connected to the coil of the relay K0, and the contacts of the relay K0 are electrically connected to the port J1. The port J1 is used to connect to the electrical port J1Y of the safety mechanism tester. The power module U2 is used to provide operating voltage to the electronic simulator.

[0083] It also includes an optocoupler isolation module, which provides status signals to the microcontroller U1; the optocoupler isolation module includes two anti-parallel connected first optocoupler X1 and second optocoupler X2;

[0084] The anode of the input diode of the first optocoupler X1 and the cathode of the input diode of the second optocoupler X2 are connected to the first switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The cathode of the input diode of the first optocoupler X1 and the anode of the input diode of the second optocoupler X2 are connected to the second switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The collector of the output transistor of the first optocoupler X1 is electrically connected to the working state pin of the microcontroller U1 through a first clamping resistor. The emitter of the output transistor of the first optocoupler X1 is grounded. The collector of the output transistor of the second optocoupler X2 is electrically connected to the safety state pin of the microcontroller U1 through a second clamping resistor. The emitter of the output transistor of the second optocoupler X2 is grounded.

[0085] The electronic simulator also includes a drive optocoupler isolation module, which includes a third optocoupler Y0 disposed between the microcontroller U1 and the relay K0. The anode of the input diode of the third optocoupler Y0 is electrically connected to the output terminal of the power supply module U2, the cathode of the input diode of the optocoupler Y0 is electrically connected to the state transition pin of the microcontroller U1, the collector of the output transistor of the optocoupler Y0 is electrically connected to the coil of the relay K0, and the emitter of the output transistor of the optocoupler Y0 is grounded.

[0086] Relay K0 has a pair of normally closed contacts and a pair of normally open contacts. In this embodiment, the pair of normally closed contacts are the first normally closed contact 3 and the second normally closed contact 4; the pair of normally open contacts are the first normally open contact 6 and the second normally open contact 8. Port J1 has feedback signal line pins, namely a pair of port safety state pins and a pair of port operating state pins. In this embodiment, the pair of port safety state pins are the first port safety state pin P2 and the second port safety state pin P4; the pair of port operating state pins are the first port operating state pin P6 and the second port operating state pin P12.

[0087] When the first normally closed contact 3 and the second normally closed contact 4 are connected, the corresponding first port safety status pin P2 and the second port safety status pin P4 are connected; when the first normally open contact 6 and the second normally open contact 8 are connected, the corresponding pair of port operating status pins, namely the first port operating status pin P6 and the second port operating status pin P12, are connected.

[0088] In another embodiment, it can also be configured such that when the first normally closed contact 3 and the second normally closed contact 4 are connected, the corresponding first port operating status pin P6 and the second port operating status pin P12 are connected; when the first normally open contact 6 and the second normally open contact 8 are connected, the corresponding pair of port operating status pins, namely the first port safety status pin P2 and the second port safety status pin P4, are connected.

[0089] The microcontroller U1 is equipped with an ISP interface for loading programs. Pin 1 of the ISP interface is electrically connected to the Vcc pin of the microcontroller U1, pin 2 of the ISP interface is electrically connected to the first program loading pin P3.0 of the microcontroller U1 (pin 5), pin 3 of the ISP interface is electrically connected to the second program loading pin P3.1 of the microcontroller U1 (pin 6), and pin 4 of the ISP interface is grounded.

[0090] In order to provide the microcontroller U1 with signals simulating the safety or working status of the safety mechanism, and to ensure the stability and safety of the control signals, this embodiment also includes a conversion optocoupler isolation module, which includes two anti-parallel first optocouplers X1 and second optocouplers X2. The anode of the input diode of the first optocoupler X1 and the cathode of the input diode of the second optocoupler X2 are connected to the first switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The cathode of the input diode of the first optocoupler X1 and the anode of the input diode of the second optocoupler X2 are connected to the second switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The collector of the output transistor of the first optocoupler X1 is electrically connected to the working state pin P3.3 (GZin) of the microcontroller U1 through the first clamping resistor R6. The emitter of the output transistor of the first optocoupler X1 is grounded. The collector of the output transistor of the second optocoupler X2 is electrically connected to the safety state pin P3.2 (AQin) of the microcontroller U1 through the second clamping resistor R7. The emitter of the output transistor of the second optocoupler X2 is grounded. In this embodiment, a transistor optocoupler EL3H7 is used. Utilizing the photoelectric effect, an electrical signal is converted into an optical signal via a light-emitting diode, and then the optical signal is converted back into an electrical signal via a phototransistor. This protects the sensitive microcontroller from high voltage or high noise and improves the system's anti-interference capability. When an external interruption occurs, the two optocouplers perform signal conversion, causing the microcontroller U1's operating status pin P3.3 (GZin) and safety status pin P3.2 (AQin) to go high or low, respectively, thus providing instantaneous switching between safety and operating status indications.

[0091] This embodiment also includes a driving optocoupler isolation module, which includes a third optocoupler Y0 located between the microcontroller U1 and the relay K0. The anode of the input diode of the third optocoupler Y0 is electrically connected to the output terminal of the power supply module U2. A resistor R9 is provided between the anode of the input diode of the third optocoupler Y1 and the output terminal of the power supply module U2. The cathode of the input diode of the optocoupler Y1 is electrically connected to the state transition pin P3.4 (ZH) of the microcontroller U1. The collector of the output transistor of the optocoupler Y1 is electrically connected to the coil of the relay K0 through diode D01. The emitter of the output transistor of the optocoupler Y1 is grounded.

[0092] The first normally closed contact 3 of relay K0 is connected to the first port safety state pin P2 of port J1 through a simulated safety state feedback resistor R11. The second normally closed contact 4 of relay K0 is connected to the second port safety state pin P4 of port J1. The first normally open contact 6 of relay K0 is connected to the first port working state pin P6 of port J1 through a simulated working state feedback resistor R12. The second normally open contact 8 of relay K0 is connected to the second port working state pin P12 of port J1. R11 and R12 are both 10Ω resistors used to simulate the feedback resistance of the safety mechanism in the safety state and working state. The normal feedback resistance is less than 20Ω.

[0093] The second conversion pin P1, the first port safety status pin P2, and the first port operating status pin P6 of port J1 are connected in series with the coil insulation resistance R1 of the simulated coil, the safety insulation resistance R2 for simulated safety status feedback, and the operating insulation resistance R3 for simulated operating status feedback. The insulation resistance of a real safety mechanism is typically 50MΩ. To broaden the application range of the simulator in this application, R1, R2, and R3 can be selected with insulation resistances of 50-100MΩ. In this embodiment, the resistance values ​​of R1, R2, and R3 are all 100MΩ. If the test result of the tester is 100±5MΩ, it indicates that the insulation resistance test function of the tester is normal.

[0094] A resistor R4 for simulating the electromagnet coil of the safety mechanism is connected in series between the first conversion pin P8 and the second conversion pin P1. In this embodiment, its resistance is 15Ω, but it can be other values ​​in other embodiments. If the tester detects that the current simulator's electromagnet coil resistance is 15±1Ω, it indicates that the tester's electromagnet coil resistance test function is normal. Correspondingly, in other embodiments, if the tester detects that the current simulator's electromagnet coil resistance is the same as the electromagnet coil resistance R4, it indicates that the tester's electromagnet coil resistance test function is normal.

[0095] Furthermore, the function of resistor R4 in the electromagnet coil is not only to simulate the coil resistance value, but also to test the load capacity of the testing instrument. Because R4 is a 100W high-power resistor with a resistance of 15Ω, at a voltage of 28V, this resistor can deliver a power of 28W. 2 ÷15=52W, and the working current can reach about 2A. This load power is the same as the power of the electromagnetic actuator of the real safety mechanism. Therefore, it can be used to test whether the tester can carry an electrical load of more than 50W. If the tester can make the simulator work normally and the measured current is also about 2A, it means that the tester can also make the real safety mechanism work normally.

[0096] Pin P3.5 of the microcontroller U1 is connected in series with a safety LED D02 through a current-limiting resistor R8. When the circuit is in a safe state, LED D02 emits green light. The collector of the output transistor of the optocoupler Y1 is connected in series with a working LED D03 through a current-limiting resistor R10. When the circuit is in a working state, that is, when Y0 is on, the cathode of D03 is grounded, and D03 is connected to a 28V power supply through the current-limiting resistor R10. The working LED D03 emits red light to indicate that the safety mechanism is in a working state.

[0097] The simulated safety mechanism state transition execution procedure includes:

[0098] When the electronic simulator is powered on, the safety mechanism tester is connected. By default, the electronic simulator is in a safe state. A pair of normally closed contacts, namely the first normally closed contact 3 and the second normally closed contact 4, are connected. Correspondingly, a pair of port safety state pins, namely the first port safety state pin P2 and the second port safety state pin P4, are connected. In the safe state, the LED D02 emits green light.

[0099] When the microcontroller U1 receives a switching signal from the safety mechanism tester indicating a transition from the safety state to the working state, the first switching pin P8 is powered on as positive, and the second switching pin P1 is powered on as negative. The pulse width is 0.5 seconds, the voltage is 28 volts, and the current is 2 amps. Then, the first optocoupler X1 is turned on, and the working state pin P3.3 (i.e., pin 8) of the microcontroller U1 goes low. The timing starts from the falling edge of the working state pin P3.3. To calibrate the accuracy of the tester's test results, a time value for the safety mechanism to switch from the safety state to the working state can be set. In this embodiment, the time is set to 0.1 seconds (100ms). If the tester's test result is also around 0.1 seconds (100ms), it indicates that the tester's test result is normal. At this time, the state transition pin P3.4 (i.e., pin 1) outputs a low level, the third optocoupler Y0 is turned on, the relay K0 is energized and closes the first normally open contact 6 and the second normally open contact 8, the electronic simulator changes from the safe state to the working state, and at the same time the working state LED D03 emits red light to indicate the working state.

[0100] When the microcontroller U1 receives a switching signal from the safety mechanism tester to the working state and then to the safety state, the second switching pin P1 is powered on as positive, and the first switching pin P8 is powered on as negative. The pulse width is 0.5 seconds, the voltage is 28 volts, and the current is 2 amps. Then, the second optocoupler X2 is turned on, and the safety state pin P3.2 (i.e., pin 7) of the microcontroller U1 goes low. The timing starts from the falling edge of the safety state pin P3.2. When the set time of 0.1 seconds in this embodiment is reached, the state switching pin P3.4 (i.e., pin 1) outputs a high level, the third optocoupler Y0 is turned off, the first optocoupler X1 is turned on, the relay K0 is de-energized, and the first normally closed contact 3 and the second normally closed contact 4 are closed. The electric simulator changes from the working state to the safety state. At the same time, the safety state LED D02 emits green light to indicate that the state is safe.

[0101] The working principle of the electronic simulator for calibrating a safety mechanism tester according to this application is as follows: When the electronic simulator is initially powered on, the default state is safe. At this time, pin 3 of the microcontroller U1 is pulled to ground, causing indicator light D02 to light up, indicating that it is in safe state. When the tester outputs drive signal P8 positive and P1 negative (pulse width 0.5 seconds, voltage 28 volts, current 2 amps), optocoupler X1 is turned on, pin 8 of the microcontroller U1 becomes low level, and timing starts from the falling edge of pin 8. When the set time is reached, for example, 0.1 seconds, this time is the transition time of the safety mechanism from safe to working. Less than 1 second is considered qualified, causing pin 1 to output a low level, optocoupler Y1 to turn on, and relay K0 to... When the electric actuator is activated, normally open contacts 6 and 8 close, and the simulator switches from the safe state to the working state. At the same time, D03 lights up, indicating that it is in the working state. When the tester outputs drive signal P1 positive and P8 negative (pulse width 0.5 seconds, voltage 28 volts, current 2 amps), optocoupler X2 conducts, pin 7 of microcontroller U1 goes low, and the timing starts from the falling edge of pin 7. When the set time is reached, for example, 0.1 seconds, this time is the transition time of the safety mechanism from working to safe. Less than 1 second is acceptable. Pin 1 outputs a high level, optocoupler Y1 is cut off, relay K0 is de-energized, and normally closed contacts 3 and 4 close. The simulator switches from the working state to the safe state, and D02 lights up, indicating that it is in the safe state.

[0102] The safety mechanism tester of this application includes the following functions: status reading, status transition, device self-test, automatic testing, device zeroing, and spring-load testing. Status reading can only read the current status of the safety mechanism and cannot perform status transition operations to prevent accidental operation; status transition allows the safety mechanism to change from a safe state to a working state, or vice versa; device self-test is used for automatic detection of the device to confirm whether the tester is working properly; automatic testing enables one-click testing of the safety mechanism.

[0103] The working principle of the safety mechanism tester in this application is as follows: It receives the working status signal transmitted from the safety mechanism simulator, which is then received by a microcontroller and transmitted to a host computer. The safety or working signal transmitted from the safety mechanism simulator is transmitted through two pairs of signal lines. One pair represents the safety state, and the other represents the working state. The pair of lines at a 5V high potential (converted to 0V / 5V by an optocoupler) indicates the current working state.

[0104] In terms of circuit design, optocouplers are mainly used for implementation. When a high-potential voltage is applied, one end of the optocoupler's LED is turned on. When the photosensitive device is illuminated, it also turns on the other end of the circuit. The two ends of the other end of the circuit are connected to a pin of the microcontroller and a low-potential pin, respectively. When the optocoupler is conducting, the microcontroller pin drops from a high potential to a low potential. The falling edge of the voltage triggers the microcontroller to receive a signal and read its operating status.

[0105] When testing safety mechanisms, a safety mechanism tester is needed to examine them under different conditions. This requires switching the safety mechanism's operating state between its active and safe states. This switching is primarily achieved using a double-holding electromagnet. A double-holding electromagnet has unique operating characteristics. Its working principle is that when current flows through the electromagnet's coil, a magnetic field is generated, attracting and fixing the iron core in a certain position. When the position of the iron core needs to be changed, the direction of the current is changed, thus changing the direction of the magnetic field, and the iron core is attracted to another position. After the current is interrupted, due to the mechanical inertia of the iron core during the transition between the two positions, it can maintain its current state, achieving bistable characteristics. Therefore, to achieve the state switching of the safety mechanism, the input voltage of the double-holding electromagnet needs to be changed, thereby changing the direction of the current and thus the direction of the magnetic field, allowing the iron core to drive the switch and switch states.

[0106] To achieve signal conversion, this application adopts the commonly used H-bridge circuit connection method, which consists of optocoupler X1Y and optocoupler X2Y forming an H-bridge. X1Y and X2Y are respectively connected to two pins of the microcontroller. The state of the safety mechanism is selected through X1Y and X2Y. By selecting the low-level output of X1Y and X2Y, the voltage changes, causing the double-holding electromagnet to switch positions, thereby driving the switch to change position and realizing the state conversion function.

Claims

1. A safety mechanism testing instrument, characterized in that, Includes a host computer and a test module equipped with an electrical port J1Y for electrical connection with the safety mechanism; The host computer is used to issue command signals and communicate with the test module. The test module is used to receive and execute the instruction signal, and includes a tester power supply, a microcontroller U0Y, a test execution unit, and a multi-meter test unit. The microcontroller U0Y and the test execution unit are electrically connected. The microcontroller U0Y receives the instruction signal from the host computer and executes the instruction signal. The corresponding pin of the microcontroller U0Y outputs a switch signal, which is sent to the test execution unit. The test execution unit receives the switch signal and completes the execution of the switch signal. The instruction signal includes a safety mechanism status confirmation signal, a safety mechanism status transition signal, and a signal to obtain corresponding parameters. The result data of executing the switch signal is fed back to the microcontroller U0Y, and the microcontroller U0Y outputs the result data to the host computer. After receiving the signal for acquiring the corresponding electrical performance parameters, the test execution unit executes the test circuit of the multi-meter test unit to test the corresponding parameters, and the multi-meter test unit directly acquires the corresponding parameters. The power supply of the tester is used to provide operating voltage to the microcontroller U0Y, the test execution unit, and the multi-meter test unit.

2. The safety mechanism tester according to claim 1, characterized in that, It also includes a safety mechanism electronic simulator, which includes a microcontroller U1, a power module U2, a relay K0, and a port J1. The microcontroller U1 is electrically connected to the coil of the relay K0, and the contacts of the relay K0 are electrically connected to the port J1. The port J1 is used to connect to the electrical port J1Y of the safety mechanism tester. The power module U2 is used to provide operating voltage to the electronic simulator. It also includes an optocoupler isolation module, used to provide status signals to the microcontroller U1; the optocoupler isolation module includes two anti-parallel connected first optocoupler X1 and second optocoupler X2. The anode of the input diode of the first optocoupler X1 and the cathode of the input diode of the second optocoupler X2 are connected to the first switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The cathode of the input diode of the first optocoupler X1 and the anode of the input diode of the second optocoupler X2 are connected to the second switching pin of the safety mechanism of port J1 for switching between the safety state and the working state. The collector of the output transistor of the first optocoupler X1 is electrically connected to the working state pin of the microcontroller U1 through a first clamping resistor. The emitter of the output transistor of the first optocoupler X1 is grounded. The collector of the output transistor of the second optocoupler X2 is electrically connected to the safety state pin of the microcontroller U1 through a second clamping resistor. The emitter of the output transistor of the second optocoupler X2 is grounded.

3. A safety mechanism testing instrument according to claim 2, characterized in that, The electronic simulator also includes a drive optocoupler isolation module. The drive optocoupler isolation module includes a third optocoupler Y0 disposed between the microcontroller U1 and the relay K0. The anode of the input diode of the third optocoupler Y0 is electrically connected to the output terminal of the power module U2. The cathode of the input diode of the optocoupler Y0 is electrically connected to the state transition pin of the microcontroller U1. The collector of the output transistor of the optocoupler Y0 is electrically connected to the coil of the relay K0. The emitter of the output transistor of the optocoupler Y0 is grounded.

4. A safety mechanism testing instrument according to claim 3, characterized in that, The test execution unit receives the instruction signal and executes the instruction signal, specifically including: The test execution unit includes a conduction feedback resistance test circuit, a housing-core wire insulation resistance test circuit, a safety-operation state switching circuit, a safety or operation state confirmation circuit, and a power-off dual-holding electromagnet operating voltage test circuit for the safety mechanism. The test execution unit receives and acquires corresponding parameter signals. When the corresponding parameter is the safety mechanism conduction feedback resistor, the conduction feedback resistor test circuit is turned on to obtain the safety state conduction feedback resistor, the working state conduction feedback resistor, and the feedback resistor of the power-off dual-holding electromagnet conduction circuit of the safety mechanism. The test execution unit receives and acquires the corresponding parameter signal. When the corresponding parameter is the insulation resistance between the housing and the core wire of the safety mechanism, the housing-core wire insulation resistance test circuit is turned on to obtain the insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit. The test execution unit receives and acquires the corresponding parameter signal. When the corresponding parameter is the working voltage of the power-off double-holding electromagnet, the power-off double-holding electromagnet working voltage test circuit is turned on to obtain the working voltage of the power-off double-holding electromagnet. When the test execution unit receives the safety mechanism state transition signal, it connects the safety-operation state mutual transition circuit to obtain the feedback signal for the safety-operation state mutual transition. When the test execution unit receives a safety mechanism status confirmation signal, it activates the safety or working status confirmation circuit to obtain a feedback signal confirming the safety or working status.

5. A safety mechanism testing instrument according to claim 1, characterized in that, The power supply of the tester includes a 220V to 24V power supply U1Y, a 24V to 5V power supply U3Y, and a 220V to 28V power supply U4Y. The power supply U1Y provides operating voltage to all relays of the test execution unit; The power supply U3Y provides the operating voltage for the microcontroller U0Y; The power supply U4Y provides the operating voltage for the power-off dual-holding electromagnet of the safety mechanism.

6. A safety mechanism testing instrument according to claim 5, characterized in that, The power supply U4Y is a wide-range test power supply, which provides three operating voltages: 22V, 28V, and 32V.

7. A safety mechanism testing instrument according to claim 5, characterized in that, The multi-table test unit directly obtains the corresponding parameters, specifically including: The multi-meter test unit includes an ohmmeter, a megohmmeter, and a voltmeter; The ohmmeter is electrically connected to the test execution unit and is used to obtain the feedback resistance of the safety state conduction circuit, the feedback resistance of the working state conduction circuit, and the feedback resistance of the power-off double-holding electromagnet conduction circuit of the safety mechanism. The megohmmeter is electrically connected to the test execution unit and is used to obtain the insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit. The voltmeter is electrically connected to the test execution unit and is used to obtain three operating voltages of the wide-range test power supply and the operating voltage of the power-off double-holding electromagnet.

8. A safety mechanism testing instrument according to claim 1 or 7, characterized in that, The communication connection between the host computer and the testing module specifically includes: The host computer communicates with the test module via RS485_1 and RS485_2 buses. The RS485_2 bus is used to communicate with the multi-meter test unit. The corresponding parameters acquired by the multi-meter test unit are directly transmitted to the host computer. These corresponding parameters include: Feedback resistors for the safety state conduction circuit, the working state conduction circuit, and the power-off double-holding electromagnet conduction circuit of the safety mechanism. The insulation resistance between the housing of the safety mechanism and the safety state conduction circuit, the insulation resistance between the housing and the working state conduction circuit, and the insulation resistance between the housing and the power-off double-holding electromagnet conduction circuit. The wide-range test power supply has three operating voltages and the operating voltage of the power-off double-holding electromagnet.

9. A safety mechanism testing instrument according to claim 1, characterized in that, The host computer is a tablet computer.

10. A safety mechanism testing instrument according to claim 1, characterized in that, It is also equipped with a data transmission USB interface for transmitting the test parameters.

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