PLC模块自动测试系统的设计与开发
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摘要
随着信息时代的来临,自动测试技术逐渐走入人们的眼帘,凭着其测试速度快,实时性强,测量精度高等特点,已经广泛应用于军事生产等各个领域,并且成为产品检测和质量控制的重要手段,自动测试技术的完善和发展推动着现代科学技术的进步。
本文是依据大连某PLC制造企业的需求,为了解决原有生产中PLC模块手工调试和校准的效率低,误差率高等缺点,以公司内部检验规范与标准为测试依据,设计与开发了一套PLC模块自动测试系统(PLCATS,PLC Automtic Test System)。系统的测试项目主要包括PLC通讯测试、内部参数校准、实时时钟测试、数字量输入输出(DIDO)测试、LED灯板测试、模拟量输入输出(AIAO)校准、冷端温度补偿校准、功能块测试。
根据对系统需求的分析,提出了PLCATS应具有通用性、可扩展性、自动测试、操作便捷等特点。从网络拓扑和体系架构两个方面诠释了整个测试系统的组建结构。按照检测作业流程式特点,并依据检测操作工作量分析各环节的测试复杂程度,将系统划分为四个工位,分别负责AI校准、AO校准、冷端校准、其他项目测试。通过企业提供的标准PLC模块作为检测设备和控制设备,完成被测通道切换,模拟量信号测量和数字量输入输出等功能,结合作为信号测量和输出设备的Agilent34401A,Fluke5500A组建成各工位的硬件测试系统,设计通用接口满足多种类型PLC模块测试连接。各工位工作保持相对独立,整个系统通过以太网连接形成局域网型自动测试系统。软件系统设计上应用模块化设计和面向对象编程思想,将软件架构分为参数配置、数据采集、程序测试和数据库管理四大部分,设计了通讯、检测标准、数据库操作等功能类。采用UDP和Modbus两种通讯协议,并结合EPA(Ethernet for Plant Automation)报文实现计算机与PLC设备通讯,利用SCPI(Standard Commands for Programmable Instruments,可程控仪器标准指令)实现对可程控仪表的控制。根据各测试项目要求,在程序测试中设计各功能测试校准的子模块,完成各测试功能实现、实时数据存储、故障预警等功能。系统中还添加了硬件线路屏蔽和软件数字滤波的抗干扰技术减少测量误差。采用ActiveX控件开发技术,实现功能块测试与ERP(Enterprise Resources Plan,企业资源计划)系统软件的完美结合。
该PLCATS自动测试系统已经验收并投入到公司生产部门的实际应用中,对现阶段的PLC模块自动测试系统设计具有一定的参考价值和现实意义。
With the advent of information age, automatic test technology is gradually coming into our view. Because of the high test speed, well real-time characteristic, high measurement accuracy and other features, it has been extensively applied in manufature, military and other fields, and becomes an important measure about product test and quality control. The development of automatic test technology promotes the advancement of modern science and technology.
The proposed project is based on the need of a company in Dalian which produces PLC module, in order to solve the disadvantage of the original manual calibration mode that manual calibration of the efficiency is low and the rate of misuse is high, relying on the test norms and standards provided by the company, design and develope a set of PLC Module Automatic Test System(PLCATS). Test items of the system includes PLC communication test, the internal parameters calibration, real-time clock test, digital input and output(DIDO) test, LED light board test, analog input and output(AIAO) calibration, cold junction temperature compensation calibration and fuction block test.
Based on the analysis of system requirement, it proposes PLCATS should be versatile, scalable, automatic test, convenient operation and so on. The configuration structure of entire test system is proposed from the two aspects of the network topology and architecture. According to the test workflow feature and analyzing the test complexity of each link based on the test operation workload, the system is divided into four stations, which are respectively responsible for AI calibration, AO calibration, cold junction calibration and other items test. Use the standard PLC modules provided by company as the test equipment and control equipment to realize the tested channel switching, analog signal measurement, digital input and output and other functions, and combine with the Agilent34401A and Fluke5500A as the signal measurement and output devices to construct the hardware test system of each work station, and design the common interfaces to meet the test connection of the various PLC modules. Each work station keeps the relative independence, and the system connected by ethernet forms the LAN automatic test system. The design of software system adopts the software modular design and object-oriented programming ideas and the software structure is divided into four parts as parameter configuration, data acquisition, procedure testing and database management, and design the communication, test standard, database operation and other functional classes. Apply UDP and Modbus protocols with EPA(Ethernet for Plant Automation) message to achieve the communication between PLC equipment and computer, and use the SCPI(Standard Commands for Programmable Instruments) to control the programmable instruments automatically. Relying on the requirements of each test items, it designs the test and calibration sub-modules in the procedure testing, in order to complete each test function, real data storage, fault warning and other functions. The line shield in hardware and digital filter in software are applied in the system in order to reduce the measurement error. Use the ActiveX control technique to achieve the perfect combination between fuction block test and ERP(Enterprise Resources Plan) system software.
The PLCATS quoted has been accepted and applied in the produce department of company, which has a certain extent of reference value and practical significance for the current PLC module automatic test system design.
本文是依据大连某PLC制造企业的需求,为了解决原有生产中PLC模块手工调试和校准的效率低,误差率高等缺点,以公司内部检验规范与标准为测试依据,设计与开发了一套PLC模块自动测试系统(PLCATS,PLC Automtic Test System)。系统的测试项目主要包括PLC通讯测试、内部参数校准、实时时钟测试、数字量输入输出(DIDO)测试、LED灯板测试、模拟量输入输出(AIAO)校准、冷端温度补偿校准、功能块测试。
根据对系统需求的分析,提出了PLCATS应具有通用性、可扩展性、自动测试、操作便捷等特点。从网络拓扑和体系架构两个方面诠释了整个测试系统的组建结构。按照检测作业流程式特点,并依据检测操作工作量分析各环节的测试复杂程度,将系统划分为四个工位,分别负责AI校准、AO校准、冷端校准、其他项目测试。通过企业提供的标准PLC模块作为检测设备和控制设备,完成被测通道切换,模拟量信号测量和数字量输入输出等功能,结合作为信号测量和输出设备的Agilent34401A,Fluke5500A组建成各工位的硬件测试系统,设计通用接口满足多种类型PLC模块测试连接。各工位工作保持相对独立,整个系统通过以太网连接形成局域网型自动测试系统。软件系统设计上应用模块化设计和面向对象编程思想,将软件架构分为参数配置、数据采集、程序测试和数据库管理四大部分,设计了通讯、检测标准、数据库操作等功能类。采用UDP和Modbus两种通讯协议,并结合EPA(Ethernet for Plant Automation)报文实现计算机与PLC设备通讯,利用SCPI(Standard Commands for Programmable Instruments,可程控仪器标准指令)实现对可程控仪表的控制。根据各测试项目要求,在程序测试中设计各功能测试校准的子模块,完成各测试功能实现、实时数据存储、故障预警等功能。系统中还添加了硬件线路屏蔽和软件数字滤波的抗干扰技术减少测量误差。采用ActiveX控件开发技术,实现功能块测试与ERP(Enterprise Resources Plan,企业资源计划)系统软件的完美结合。
该PLCATS自动测试系统已经验收并投入到公司生产部门的实际应用中,对现阶段的PLC模块自动测试系统设计具有一定的参考价值和现实意义。
With the advent of information age, automatic test technology is gradually coming into our view. Because of the high test speed, well real-time characteristic, high measurement accuracy and other features, it has been extensively applied in manufature, military and other fields, and becomes an important measure about product test and quality control. The development of automatic test technology promotes the advancement of modern science and technology.
The proposed project is based on the need of a company in Dalian which produces PLC module, in order to solve the disadvantage of the original manual calibration mode that manual calibration of the efficiency is low and the rate of misuse is high, relying on the test norms and standards provided by the company, design and develope a set of PLC Module Automatic Test System(PLCATS). Test items of the system includes PLC communication test, the internal parameters calibration, real-time clock test, digital input and output(DIDO) test, LED light board test, analog input and output(AIAO) calibration, cold junction temperature compensation calibration and fuction block test.
Based on the analysis of system requirement, it proposes PLCATS should be versatile, scalable, automatic test, convenient operation and so on. The configuration structure of entire test system is proposed from the two aspects of the network topology and architecture. According to the test workflow feature and analyzing the test complexity of each link based on the test operation workload, the system is divided into four stations, which are respectively responsible for AI calibration, AO calibration, cold junction calibration and other items test. Use the standard PLC modules provided by company as the test equipment and control equipment to realize the tested channel switching, analog signal measurement, digital input and output and other functions, and combine with the Agilent34401A and Fluke5500A as the signal measurement and output devices to construct the hardware test system of each work station, and design the common interfaces to meet the test connection of the various PLC modules. Each work station keeps the relative independence, and the system connected by ethernet forms the LAN automatic test system. The design of software system adopts the software modular design and object-oriented programming ideas and the software structure is divided into four parts as parameter configuration, data acquisition, procedure testing and database management, and design the communication, test standard, database operation and other functional classes. Apply UDP and Modbus protocols with EPA(Ethernet for Plant Automation) message to achieve the communication between PLC equipment and computer, and use the SCPI(Standard Commands for Programmable Instruments) to control the programmable instruments automatically. Relying on the requirements of each test items, it designs the test and calibration sub-modules in the procedure testing, in order to complete each test function, real data storage, fault warning and other functions. The line shield in hardware and digital filter in software are applied in the system in order to reduce the measurement error. Use the ActiveX control technique to achieve the perfect combination between fuction block test and ERP(Enterprise Resources Plan) system software.
The PLCATS quoted has been accepted and applied in the produce department of company, which has a certain extent of reference value and practical significance for the current PLC module automatic test system design.
引文
[1]秦红磊,路辉,郎荣玲.自动测试系统一硬件及软件技术[M].北京:高等教育出版社,2007.
[2]朱军,李健一,王增浩.程控仪器在自动测试系统中的应用[J].仪器仪表用户,2009,16(2):57-58.
[3]秦云川,徐大专,李彤.测量仪器总线技术的发展与现状[J].中国仪器仪表,2005,(8):48-52.
[4]Gupta P,Zhang R,Jha N.Automatic test generation for combinational threshold logic networks[J].IEEE Transactions on Very Large Scale Integration Systems,2008,16(8):1035-1045.
[5]于劲松,李行善.下一代自动测试系统体系结构与关键技术[J].计算机测量与控制,2005,13(1):1-4.
[6]Leung K,Leung H.On the efficiency of domain-based COTS product selection method[J].Information and Software Technology,2002,44(12):703-715.
[7]Neag Ⅰ.COTS software design minimizes ATS lifecycle cost[J].IEEE Aerospace and Electronic Systems Magazine,2004,19(6):29-34.
[8]孙宝江,沈士团,陈星.自动测试系统校准方法研究[J].宇航计测技术,2007,27(1):30-34.
[9]Nebut C,Fleurey F,Le T.Automatic test generation:A use case driven approach[J].IEEE Transactions on Software Engineering,2006,32(3):140-155.
[10]Muscas C,Peretto L,Sasdelli R.An automatic test equipment for the calibration of voltage transducers[J].IEEE Transactions on Instrumentation and Measurement,2001,50(6):1638-1643.
[11]仲崇权.工业现场数据采集与工业以太网若干关键技术[D]:(博士学位论文).大连:大连理工大学,2006.
[12]Navaro M.Tips on selecting a PLC for motion control[J].Power transmission design,1996,38(4):1-3.
[13]王俊霞.阀用电磁铁动静态性能自动测试平台的研制[D]:(硕士学位论文).杭州:浙江大学,2008.
[14]Hoffman A.Explaining IEEE 488.2 and SCPI[J].Evaluation Engineering,1991,30(3):1-4.
[15]朱兴邦,李兵.IEEE488与SCPI解释[J].仪器仪表标准化与计量,2007,1(6):15-16.
[16]柳爱利,周绍磊.自动测试技术[M].北京:电子工业出版社,2007.
[17]陈长龄,田书林,师弈兵等.自动测试及接口技术[M].北京:机械工业出版社,2005.
[18]邱立军,宋振宇,苏艳琴.自动测试系统互换性技术研究[J].仪器仪表用户,2008,15(4):15-16.
[19]Labrogere P.Com 2.0:A path towards web communicating applications[J].Bell Labs Technical Journal,2008,13(2):19-24.
[20]Thiers D,DeSalvo C.ActiveX control simplifies design of operator interface[J]. Evaluation Engineering,1999,38(3):76-79.
[21]秦开涌,胡业发,丁毓峰.条形码技术在生产信息采集系统中的应用[J].计算机工程与应用,2005,41(23):206-208.
[22]李青.基于LAN的分布式汽车安全性能检测系统研究[D]:(硕士学位论文).西安:长安大学,2008.
[23]大连理工计算机控制工程有限公司.产品选型手册.大连:大连理工计算机控制工程有限公司,2009.
[24]TOSHIBA Inc.亮度传感器TPS851数据手册.日本:TOSHIBA Inc,2002.
[25]李亚男.基于IEC61131_3标准的可编程控制器的设计与实现[D]:(硕士学位论文).大连:大连理工大学,2007.
[26]Baojiang Sun,Honglei Qin,Shituan shen.Automatic design technique for hardware system of ATS[C]//Proceedings of IEEE Systems Readi-ness Technology Conference.Anaheim:AUTOTESTCON,2007:386-396.
[27]刘传玺,袁照平.自动测试技术[M].北京:机械工业出版社,2008.
[28]冯平法,徐道春,陆冠玉等.乳化液泵综合性能自动测试系统设计与实现[J].仪器仪表学报,2007,28(12):2218-2221.
[29]王斐.通信电缆的抗干扰技术[J].电工电气,2009,(5):33-35.
[30]宋文绪.自动检测技术[M].北京:冶金工业出版社,2000.
[31]罗小巧.数据采集系统中数字滤波方法[J].电子测量技术,2004,(4):35-36.
[32]童时中.模块化与计算机软件设计[J].标准化报道,1997,18(4):20-25.
[33]Fu Xinhua,Xiao Mingqing.Automatic configuration approach for ATS test resource based on a kind of matching function[J].Journal of Beijing University of Aeronautics and Astronautics,2008,34(12):1392-1397.
[34]John S.微软 Visual C# 2008 step by step[M].Washington:微软 Press,2008.
[35]Schwarz C,Pothier C.Commercial ATS program management[J].IEEE Aerospace and Electronic Systems Magazine,2002,17(12):3-6.
[36]王恒.EPA网络协议栈开发及一致性测试研究[D]:(硕士学位论文).大连:大连理工大学,2008.
[37]Thompson W.Quality analyzer ensures:Power factor correction process[J].Water and Wastewater International,2005,20(6):25-26.
[38]兰江涛,郭占山,毕鹏.在Excel中实现对Agilent34401A的程控[J].计量技术,2005,(2):18-20.
[39]贾惠芹,刘君华.构造基于WEB的远程测控网络模型[J].仪器仪表学报,2001,22(3):307-308,324.
[40]饶强.用ActiveX控件实现PC与PLC之间的串行通信[J].工业控制计算机,2009,22(5):33-34.
[41]朱义毅.一种基于规格说明的Web应用测试用例生成方法[D]:(硕士学位论文).上海:上海大学,2008.
[42]Dejan S.SQL Server 2000存储过程与XML编程[M].北京:清华大学出版社,2003.
[2]朱军,李健一,王增浩.程控仪器在自动测试系统中的应用[J].仪器仪表用户,2009,16(2):57-58.
[3]秦云川,徐大专,李彤.测量仪器总线技术的发展与现状[J].中国仪器仪表,2005,(8):48-52.
[4]Gupta P,Zhang R,Jha N.Automatic test generation for combinational threshold logic networks[J].IEEE Transactions on Very Large Scale Integration Systems,2008,16(8):1035-1045.
[5]于劲松,李行善.下一代自动测试系统体系结构与关键技术[J].计算机测量与控制,2005,13(1):1-4.
[6]Leung K,Leung H.On the efficiency of domain-based COTS product selection method[J].Information and Software Technology,2002,44(12):703-715.
[7]Neag Ⅰ.COTS software design minimizes ATS lifecycle cost[J].IEEE Aerospace and Electronic Systems Magazine,2004,19(6):29-34.
[8]孙宝江,沈士团,陈星.自动测试系统校准方法研究[J].宇航计测技术,2007,27(1):30-34.
[9]Nebut C,Fleurey F,Le T.Automatic test generation:A use case driven approach[J].IEEE Transactions on Software Engineering,2006,32(3):140-155.
[10]Muscas C,Peretto L,Sasdelli R.An automatic test equipment for the calibration of voltage transducers[J].IEEE Transactions on Instrumentation and Measurement,2001,50(6):1638-1643.
[11]仲崇权.工业现场数据采集与工业以太网若干关键技术[D]:(博士学位论文).大连:大连理工大学,2006.
[12]Navaro M.Tips on selecting a PLC for motion control[J].Power transmission design,1996,38(4):1-3.
[13]王俊霞.阀用电磁铁动静态性能自动测试平台的研制[D]:(硕士学位论文).杭州:浙江大学,2008.
[14]Hoffman A.Explaining IEEE 488.2 and SCPI[J].Evaluation Engineering,1991,30(3):1-4.
[15]朱兴邦,李兵.IEEE488与SCPI解释[J].仪器仪表标准化与计量,2007,1(6):15-16.
[16]柳爱利,周绍磊.自动测试技术[M].北京:电子工业出版社,2007.
[17]陈长龄,田书林,师弈兵等.自动测试及接口技术[M].北京:机械工业出版社,2005.
[18]邱立军,宋振宇,苏艳琴.自动测试系统互换性技术研究[J].仪器仪表用户,2008,15(4):15-16.
[19]Labrogere P.Com 2.0:A path towards web communicating applications[J].Bell Labs Technical Journal,2008,13(2):19-24.
[20]Thiers D,DeSalvo C.ActiveX control simplifies design of operator interface[J]. Evaluation Engineering,1999,38(3):76-79.
[21]秦开涌,胡业发,丁毓峰.条形码技术在生产信息采集系统中的应用[J].计算机工程与应用,2005,41(23):206-208.
[22]李青.基于LAN的分布式汽车安全性能检测系统研究[D]:(硕士学位论文).西安:长安大学,2008.
[23]大连理工计算机控制工程有限公司.产品选型手册.大连:大连理工计算机控制工程有限公司,2009.
[24]TOSHIBA Inc.亮度传感器TPS851数据手册.日本:TOSHIBA Inc,2002.
[25]李亚男.基于IEC61131_3标准的可编程控制器的设计与实现[D]:(硕士学位论文).大连:大连理工大学,2007.
[26]Baojiang Sun,Honglei Qin,Shituan shen.Automatic design technique for hardware system of ATS[C]//Proceedings of IEEE Systems Readi-ness Technology Conference.Anaheim:AUTOTESTCON,2007:386-396.
[27]刘传玺,袁照平.自动测试技术[M].北京:机械工业出版社,2008.
[28]冯平法,徐道春,陆冠玉等.乳化液泵综合性能自动测试系统设计与实现[J].仪器仪表学报,2007,28(12):2218-2221.
[29]王斐.通信电缆的抗干扰技术[J].电工电气,2009,(5):33-35.
[30]宋文绪.自动检测技术[M].北京:冶金工业出版社,2000.
[31]罗小巧.数据采集系统中数字滤波方法[J].电子测量技术,2004,(4):35-36.
[32]童时中.模块化与计算机软件设计[J].标准化报道,1997,18(4):20-25.
[33]Fu Xinhua,Xiao Mingqing.Automatic configuration approach for ATS test resource based on a kind of matching function[J].Journal of Beijing University of Aeronautics and Astronautics,2008,34(12):1392-1397.
[34]John S.微软 Visual C# 2008 step by step[M].Washington:微软 Press,2008.
[35]Schwarz C,Pothier C.Commercial ATS program management[J].IEEE Aerospace and Electronic Systems Magazine,2002,17(12):3-6.
[36]王恒.EPA网络协议栈开发及一致性测试研究[D]:(硕士学位论文).大连:大连理工大学,2008.
[37]Thompson W.Quality analyzer ensures:Power factor correction process[J].Water and Wastewater International,2005,20(6):25-26.
[38]兰江涛,郭占山,毕鹏.在Excel中实现对Agilent34401A的程控[J].计量技术,2005,(2):18-20.
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