CN-121995804-A - Dual-channel control system and method for full-flow automatic operation

CN121995804ACN 121995804 ACN121995804 ACN 121995804ACN-121995804-A

Abstract

The invention discloses a dual-channel control system and method for full-flow automatic operation. The system comprises a central control unit, a double test station, a sensing detection unit and a man-machine interaction unit. The central control unit automatically loads clamping pose and motion parameters according to the product model, and drives the multidimensional electric adjustment platform to realize high-precision automatic positioning. The scheduler dynamically time-sharing schedules the two stations in 200 ms period, and prevents mechanical interference by safely locking the timer. The system independently executes real-time fault diagnosis on each station, wherein the current required by the overcurrent fault is more than 8.0A for 20 milliseconds, and the deviation required by the displacement out of tolerance is more than 1.5mm for 50 milliseconds. Once a single-station fault occurs, the single-station fault is immediately atomized and isolated, and the single-channel mode is reconstructed, so that the continuous operation of the test is ensured. The invention realizes high efficiency, safety, full automatic transformation and intelligent fault tolerance, and improves the test efficiency and the system reliability.

Inventors

LU ZHIYONG
ZHAO RENBIN
TANG YALU
LIN TINGYAN
MAO PENGFENG
YU CUNXU
CHEN HONG
LIN SHUO
WANG LINGQUAN

Assignees

中杭监测技术研究院有限公司

Dates

Publication Date: 20260508
Application Date: 20260210

Claims (10)

1. The utility model provides a binary channels control system of full flow automatic operation, includes central control unit, binary channels test execution unit, sensing detection unit and human-computer interaction unit, binary channels test execution unit includes two independent test stations, sensing detection unit corresponds every test station independent setting, its characterized in that: The central control unit is configured to execute a dual-channel dynamic time-sharing scheduling strategy to alternately drive the two test stations to execute a test action sequence; Based on the real-time data of the sensing detection unit, performing independent fault diagnosis on each test station in parallel, automatically isolating the fault station when a single station is diagnosed to have a preset type of fault, and dynamically adjusting the time-sharing scheduling strategy to ensure that the other healthy station continuously operates; the man-machine interaction unit is configured to receive product model selection instructions and test parameter inputs and display running states and fault alarm information of each station.
2. The full-process automatic operation dual-channel control system according to claim 1, wherein the central control unit comprises a scheduler configured to determine whether a target station meeting a scheduling condition exists based on a current state, a fault flag and a safety lock timer corresponding to the first station and the second station respectively in each fixed scheduling period; If the station exists, a starting instruction is sent to the target station, and a safety locking timer is started for the other station at the same time; The scheduling condition at least comprises that the target station is in an idle ready state and has no fault sign, and the other station is not in a predefined action state which can possibly generate physical interference.
3. The full-process, automatically operated two-channel control system of claim 2 wherein the initial duration of the safety lock timer is set to be greater than or equal to the maximum time required for the drive mechanism of any one station to return from its most remote operative position to a public safety position configured such that no physical interference between the two stations occurs.
4. The full-process, automatically operated dual-channel control system of claim 1 wherein the fault diagnosis comprises an over-current fault diagnosis module configured to continuously compare current sample values thereof with a preset over-current fault threshold for each station and maintain a counter; When the current sampling value exceeds the threshold value, the counter is increased, otherwise, the counter is cleared; If the value of the counter reaches or exceeds a preset counting threshold value, judging that the station has overcurrent faults; the counting threshold is obtained by converting the fault judgment holding time and the current sampling period.
5. The full-process automatic operation dual-channel control system according to claim 1, wherein the fault diagnosis comprises a displacement out-of-tolerance fault diagnosis module configured to continuously compare the absolute value of the difference between the command position and the feedback position with a preset tolerance limit value for each station after the driving mechanism action enters the holding phase; And if the absolute value of the difference continuously exceeds the tolerance limit value and reaches a preset stability judging time, judging that the station has a displacement out-of-tolerance fault.
6. The full-process, automatically operated dual-channel control system of claim 1, wherein the central control unit is configured to perform a sequence of atomization operations when isolating a failed workstation, comprising: Stopping sending motion enabling signals to all drivers of the failure station; Forcibly setting the internal state variable of the fault station to be a fault state; And modifying the global effective station identification to exclude the fault station from the subsequent scheduling decision.
7. The full-process automatic operation dual-channel control system according to claim 1, further comprising a multi-dimensional electric adjustment platform connected with the clamping mechanism of each test station, wherein the central control unit is further configured to drive each motion axis of the multi-dimensional electric adjustment platform to cooperatively move according to a pre-stored clamping target pose coordinate set uniquely corresponding to a product model, so that the clamping mechanism accurately reaches a target pose.
8. The full-process automatic operation dual-channel control system according to claim 7, wherein the central control unit is configured to call the clamping target pose coordinate set corresponding to a target model and associated motion control parameters from a parameter database when a change-type instruction is received, and simultaneously issue the motion control parameters to corresponding drivers of two stations; Wherein the motion control parameters include at least a linear drive stroke and a rotational drive angle.
9. The double-channel control method for full-flow automatic operation is characterized by comprising the following steps of: The parameter initialization is to load a structured parameter file corresponding to the model of the product to be tested, and drive each executing mechanism to adjust to a preset state based on the parameters in the file; starting a test flow; The dual-channel dynamic time-sharing scheduling and execution is that scheduling decisions are carried out in a fixed period based on the real-time states of a first station and a second station, when a target station meets the conditions of idle, no fault, release of a safety lock and the other station is not in an interference action state, the target station is scheduled to execute a test sequence, and the safety locking timing is started for the other station immediately; Performing diagnosis on each station independently, including judging whether the monitored physical quantity exceeds a preset threshold value continuously for a preset time; the intelligent fault isolation and system reconstruction, namely when a single station is diagnosed as faulty, immediately stopping driving the single station, removing the single station from the effective dispatching resources, and maintaining the system to operate so as to continue to dispatch healthy stations; and executing the loop until the test is completed.
10. The dual-channel control method for full-process automatic operation according to claim 9, wherein in the real-time parallel fault diagnosis, the specific step of overcurrent diagnosis comprises: acquiring current values of all stations in a constant sampling period; Comparing the current value with a fault threshold value set according to rated current; an overcurrent fault is determined only when the time for which the current value continues to exceed the fault threshold reaches a preset fault determination holding time in the range of 5 milliseconds to 20 milliseconds.

Description

Dual-channel control system and method for full-flow automatic operation Technical Field The invention belongs to the technical field of industrial automation test and control, and relates to a full-flow automatic operation double-channel control system and method. Background In the automatic test of a piezoelectric device (such as a miniature circuit breaker, a leakage protector and the like), the traditional equipment usually adopts a single-station design, and only one product can be tested at a time, so that the efficiency is low, and the requirements of a modern production line on high throughput and less manual intervention are difficult to meet. To increase efficiency, some systems begin to employ a double-station architecture. However, if the two stations are operated completely independently, the hardware cost is high, and if part of the mechanism (such as a test probe or a driving device) is shared, mechanical interference or electrical interference is easily caused by action collision, so that potential safety hazards exist. At present, most of the double-channel systems adopt a static scheduling mode of alternately working at fixed time, and cannot be dynamically adjusted according to the actual states (such as idle state or failure state) of stations, so that resources are wasted and beats are unstable. In addition, when changing the test product model, current system often needs manual adjustment anchor clamps position or manual input parameter, and complex operation just makes mistakes easily. Even if part of the system supports parameter configuration, the automatic clamping positioning capability strictly corresponding to the product model is lacking, and the testing precision and repeatability are affected. In the aspect of fault handling, the common practice is to stop immediately as long as current or position abnormality is detected, instantaneous interference and real faults are not distinguished, the false alarm rate is high, once faults occur, the whole machine is usually stopped, and the health station cannot work continuously, so that the availability of the system is reduced. Therefore, a full-flow automatic control scheme capable of realizing double-station safety coordination, automatic model changing, real-time diagnosis and intelligent fault tolerance is needed to achieve efficiency, precision and reliability. The present invention addresses the above-described problems. Disclosure of Invention In order to solve the problems in the background technology, the invention provides a full-flow automatic operation double-channel control system and a full-flow automatic operation double-channel control method. In order to achieve the purpose, the technical scheme adopted by the invention is that the full-flow automatic operation double-channel control system comprises a central control unit, a double-channel test execution unit, a sensing detection unit and a human-computer interaction unit, wherein the double-channel test execution unit comprises two independent test stations, and the sensing detection unit is independently arranged corresponding to each test station: The central control unit is configured to execute a dual-channel dynamic time-sharing scheduling strategy to alternately drive the two test stations to execute a test action sequence; Based on the real-time data of the sensing detection unit, performing independent fault diagnosis on each test station in parallel, automatically isolating the fault station when a single station is diagnosed to have a preset type of fault, and dynamically adjusting the time-sharing scheduling strategy to ensure that the other healthy station continuously operates; the man-machine interaction unit is configured to receive product model selection instructions and test parameter inputs and display running states and fault alarm information of each station. The central control unit comprises a scheduler, wherein the scheduler is configured to judge whether a target station meeting a scheduling condition exists or not based on a current state, a fault sign and a safety locking timer which respectively correspond to a first station and a second station in each fixed scheduling period; If the station exists, a starting instruction is sent to the target station, and a safety locking timer is started for the other station at the same time; The scheduling condition at least comprises that the target station is in an idle ready state and has no fault sign, and the other station is not in a predefined action state which can possibly generate physical interference. Specifically, the initial duration of the safety lock timer is set to be greater than or equal to the maximum time required for the drive mechanism of any one station to return from its most distal operative position to a public safety position configured such that no physical interference occurs between the two stations. The fault diagnosis comprises an overcurrent fault diagnosis module,