A device for testing discrete signal input interface modules

Abstract

This utility model relates to electrical engineering and control and measurement systems and is intended for monitoring the operability of interface devices for discrete signal controllers and discrete sensors, such as limit switches equipped with circuits for verifying the operability (presence) of the sensors in the control system. The proposed device for testing discrete signal interface input interface modules (hereinafter referred to as the testing device) is used to identify operational interface modules, such as the SMM-112 discrete signal input interface modules, which ensure the stable operation of automatic control systems for gas pumping units. The objective of this solution is to ensure the efficient use (low labor intensity) of the testing device when testing a large number of discrete signal interface input interface modules (5 or more).This utility model enables highly accurate monitoring of discrete signal input interface module functionality, while significantly reducing the labor intensity of conducting multiple module tests. The utility model is manufactured as a portable device. Its front panel features indicator lights indicating a fault in the discrete signal input interface module, indicator lights indicating successful testing, power on / off buttons, and a button to initiate the testing algorithm.

Description

[0001] The utility model relates to the field of electrical engineering, control and measuring systems and is intended to monitor the operability of interface devices for discrete signal controllers and discrete sensors, for example, limit switches, equipped with circuits for checking the operability (presence) of sensors in the control system.

[0002] The proposed device for testing interface modules for discrete signal input (hereinafter referred to as the testing device) is used to identify operational interface modules, for example, the СММ-112 discrete signal input interface modules, which ensure the stable operation of automatic control systems for gas pumping units.

[0003] As part of the commissioning of the gas compressor shop, maintenance and repair of the gas pumping unit, equipment manufacturers do not offer their own devices for testing the discrete signal input interface modules for the stability of their operation and quality control of the reliability of operation.

[0004] The following methods and devices are known for testing the operability of discrete input modules:

[0005] - Use specialized modules with self-diagnostic functions, such as the DIM765-01 from Fastwel. These modules have a circuit integrity monitoring function, providing verification of the status of input signals and connections;

[0006] - Use of programmable controllers with testing functions, such as the TREI-5B-04 M800 series. These are used for testing discrete input modules. These controllers allow you to create custom programs to check the status of input and output signals, as well as to simulate various operating conditions [https: / / trei.biz / produktsiya / kontrollery-trei / kontrollery-trei-5b-04 / seriya-modulej-m800.html]:

[0007] - Use of universal testers and signal simulators. These devices allow you to simulate the operation of sensors and other input devices, providing comprehensive testing of modules for signal processing accuracy;

[0008] - specialized test benches. These benches can include programmable logic controllers, signal simulators, and tools for visualizing and recording test results. This ensures comprehensive testing of modules under conditions similar to real-world use.

[0009] The closest analogue to the presented utility model from the listed methods and devices for testing the operability of discrete input modules are specialized test benches, for example, the test bench for microprocessor controllers and intelligent devices from Metrol-KIP [https: / / metrol-kip.ru / catalog / metrologicheskie-stendy / stend-dlya-proverki-mpk-i-intellektualnyh-priborov.html], which is a universal solution for testing and adjusting control and measuring instruments and automation, as well as for training in the field of automation. The bench is designed to work with both virtual and real control objects, as well as for studying various principles of building automated process control systems. The positive features of this analogue include its widespread use in industrial enterprises, control rooms, laboratories, and workshops for the repair and verification of automation equipment.The disadvantages of the analog include its static location, high cost of acquisition and maintenance, and the large amount of equipment required to complete the stand.

[0010] The problem that the claimed solution is aimed at solving is the efficiency of use (low labor intensity) of the testing device with a large number of tested discrete signal interface input interface modules (from 5 units and above).

[0011] The technical result of the claimed utility model is high accuracy of testing the operability of interface modules, low labor intensity of using the testing device, and its universal application to various types of interface modules.

[0012] The specified technical result is achieved by assembling the circuit of the testing device in Fig. 1, which consists of the following elements: a power source 1 of the circuit, a common button 2 for turning on / off the power supply of the circuit, a control microcontroller 3, a voltage generation unit U1 4, a voltage generation unit U2 5, a voltage generation unit U3 6, a voltage generation unit U4 7, an input contact 8 of the controlled signal, a tested (connected) module 9, an output contact 10 of the text channel, an output contact 11 of the information channel, a signal lamp 12 of the serviceability of the module being tested, a signal lamp 13 of the presence of an error in the operation of the module, a button 14 for starting the test of the operation of the module being tested, a signal lamp 15 of successful completion of the test (Step 1), a signal lamp 16 of successful completion of the test (Step 2), a signal lamp 15 of successful completion of the test (Step 3), a signal lamp 15 of successful completion of the test (Step 4).

[0013] The operation of the device for testing the interface modules for discrete signal input (using the example of the interface module СММ-112 for discrete signal input of the automatic control system of a gas pumping unit) is implemented in accordance with the algorithm presented in the block diagram of Fig.2, consisting of the following blocks: Start 19, turn on the device block 20, start the module test cycle block 21, start the test cycle block 22, check Step 1 block 23, test result condition block 24, turn on the signal lamp for a successful Step 1 test block 25, check Step 2 block 26, test result condition block 27, turn on the signal lamp for a successful Step 2 test block 28, check Step 3 block 29, test result condition block 30, turn on the signal lamp for a successful Step 3 test block 31, check Step 4 block 32, test result condition block 33, turn on the signal lamp for a successful Step 2 test block 34, check Step 5 block 35, test result condition block 36, turn on the signal lamp for a module test error block 37, turn on the signal lamp for a successful cyclic test of the module block 38, end of test block 39.

[0014] The described algorithm is implemented as follows: a +24 volt battery pack serves as power source 1 of the circuit. Contact 8 of the testing circuit corresponds to terminal 13 of the CMM-112 module, the negative potential from power source 1 is supplied to terminal 11 of the CMM-112, and the positive potential from the source is supplied to terminal +24 of the CMM-112. The output signals from terminals 32 and 31 are respectively supplied to microcontroller 3, for example, "Arduino Nano 3", to read the output voltages of the text and information channels of the CMM-112 module. Signal lamp 13 glows red, signal lamps 12, 14, 15, 16, 17, 18 glow green.

[0015] By pressing button 2, power is supplied to the circuit elements. Pressing button 14 initiates the test of the connected module. Each step of the test sequence lasts from 3 to 5 seconds, and the number of test cycles is 5 (sequential execution of steps: Step 1 - Step 2 - Step 3 - Step 4).

[0016] Step 1. Block 4 generates a constant voltage U1 = 3.7V and applies positive potential to input contact 8, which corresponds to terminal 13 of the CMM-112 module. The permissible range of voltage U1 at this test step is from 3.4V to 4.2V. The microcontroller checks the voltage level at output contact 10, which corresponds to terminal 32 of the CMM-112 module. If the voltage at output contact 10 is equal to a value in the range from 0V to 2V, microcontroller 3 remembers the positive test result from step 1. If the output voltage at contact 10 goes beyond the range, the microcontroller turns on indicator lamp 13, signaling an error in the operation of the module under test. Further test logic is not required. In case of a successful result, controller 3 turns on indicator lamp 15.

[0017] Step 2. Block 5 generates a constant voltage U2 = 2.2V and applies positive potential to input contact 8, which corresponds to terminal 13 of the CMM-112 module. The permissible range of voltage U2 at this test step is between 2.0V and 2.5V. Microcontroller 3 checks the voltage level at output contact 10, which corresponds to terminal 32 of the CMM-112 module. If the voltage at output contact 10 is equal to a value in the range from 20V to 24V, microcontroller 3 remembers the positive test result from step 2. If the output voltage at contact 10 goes beyond the range, the microcontroller turns on indicator lamp 13, signaling an error in the operation of the module under test. Further test logic is not required. In case of a successful result, controller 3 turns on indicator lamp 16.

[0018] Step 3. Block 6 generates a constant voltage U3 = 14.0V and applies positive potential to input contact 8, which corresponds to terminal 13 of the CMM-112 module. The permissible range of voltage U3 at this test step is from 13.5V to 14.8V. Microcontroller 3 checks the voltage level at output contact 11, which corresponds to terminal 31 of the CMM-112 module. If the voltage at output contact 11 is equal to a value from 0V to 2V, microcontroller 3 remembers the positive test result from step 2. If the output voltage at contact 11 goes beyond the range, the microcontroller turns on indicator lamp 13, signaling an error in the operation of the module under test. Further test logic is not required. If the result is successful, controller 3 turns on indicator lamp 17.

[0019] Step 4. Block 7 generates a constant voltage U4 = 11.0V and applies positive potential to input contact 8, which corresponds to terminal 13 of the CMM-112 module. The permissible range of voltage U4 at this test step is from 10.5V to 11.8V. Microcontroller 3 checks the voltage level at output contact 11, which corresponds to terminal 31 of the CMM-112 module. If the voltage at output contact 11 is equal to a value in the range from 20V to 24V, microcontroller 3 remembers the positive test result from step 2. If the output voltage at contact 11 goes beyond the range, the microcontroller turns on indicator lamp 13, signaling an error in the operation of the module under test. In case of a successful result, controller 3 turns on indicator lamp 18.

[0020] At the end of each cycle from 1 to 4, the signal lamps from 15 to 18 are turned off by microcontroller 3.

[0021] Upon completion of the fifth test cycle, microcontroller 3 turns on indicator lamp 12, which indicates the correct operation of the CMM-112 module. A deviation in the tested voltages at any stage of the test triggers an error signal on indicator lamp 13.

[0022] Practical application showed that the standard method for testing 10 CMM-112 discrete signal input interface modules resulted in over two working days or 48 hours of equipment downtime. The main time spent was dismantling the modules, transporting them to the test bench, and then returning them to the automatic control system.

[0023] When using the utility model, with the same number of modules being tested, equipment downtime was only 30 minutes. The majority of this time (approximately 2 minutes per module) was spent connecting the test device to the terminals of the module being tested.

[0024] Figure captions:

[0025] Fig. 1 - diagram of the testing device;

[0026] Fig. 2 - block diagram of the operating algorithm of the testing device.

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