CN116224819A - High-risk simulation test platform and test method - Google Patents

Abstract

The invention discloses a high-risk simulation test platform and a test method, which injects normal signals and fault signals into the semi-physical simulation method, and constructs the equipment and system to be tested on the basis of the simulation analysis method, test design and test method The integrated test verification and evaluation system supports multiple stages of test work such as test design, test, and evaluation according to the failure mode and test diagnosis process of the equipment and system under test.

Description

A high-risk simulation test platform and test method

technical field

The invention relates to the technical field of industrial testing, and more specifically relates to a high-risk simulation testing platform and testing method.

Background technique

The industrial site environment is harsh and dangerous, and it is a good way to use simulation to verify the safety instrumented system that will work in a high-risk environment. The device under test is connected to the simulation platform, and the platform provides signal excitation, fault injection and status monitoring services. This method can effectively improve the real-time performance and accuracy of test verification.

Therefore, how to realize the simulation test based on the high-risk environment of the industrial site is an urgent problem to be solved by those skilled in the art.

Contents of the invention

In view of this, the present invention provides a high-risk simulation test platform and test method, which injects normal signals and fault signals in the form of semi-physical simulation, and builds on the basis of test case design, simulation analysis methods and test methods. The integrated test design verification evaluation system of the equipment under test, and according to the failure mode and test diagnosis process of the equipment under test, supports the work of multiple stages such as test design, test verification, and test analysis.

In order to achieve the above object, the present invention adopts the following technical solutions:

A high-risk simulation test platform, comprising a software simulation management unit, a simulation lower computer, a signal interface layer, and a hardware simulation unit; the software simulation management unit is connected to the simulation lower computer; the software simulation management unit sends the simulated lower computer Transmission of digital signals; the simulation lower computer transmits drive signals to the signal interface layer; the hardware simulation unit is connected to the signal interface layer; the software simulation management unit creates simulation scenarios, complex safety loop logic and fault signals, and Carry out relevant logic management settings; the simulated lower computer is connected to the upper computer, and the data of the upper computer is converted into a driving signal; the signal interface layer outputs the electrical signal generated by the software simulation management unit and the hardware simulation unit to the device under test and system.

The software simulation management unit is the core unit for data processing, storage and interaction of the entire simulation evaluation platform. The hardware simulation unit is a simulated diesel hydrogenation platform, which generates data after running. These data can be transmitted to the software simulation management unit through the OPC server, and can be directly transmitted to the equipment and system under test through the signal interface layer.

Preferably, the data signals include excitation signals, fault signals and the like.

Preferably, the software simulation management unit includes a three-dimensional simulation scene module, a test data management module, a signal excitation module, a fault injection module, a signal monitoring module and a test index evaluation module;

The 3D simulation scene module provides a highly visualized 3D operating environment, establishes a 3D scene according to relevant parameters, receives the configuration parameters of the software simulation management unit and the feedback data of the device under test and the system, and dynamically displays the 3D scene in a 3D form. Behavioral status of the equipment and system under test;

The test data management module is responsible for managing the common failure sample database, and classifying and storing historical test cases and test results;

The fault injection module can output a single fault or multiple fault signals; the fault injection module generates the logic of the faults required by the equipment under test and the system, and injects the faults into the equipment under test in a predetermined order, and passes through the equipment under test and the system. Judging whether the safety mechanism of the equipment under test and the system is effective according to the fault handling; the fault injection module can create project projects for different fault modes, set corresponding fault types and parameter configurations, and have a help module to assist users in operation and record fault operation logs . Parameters can be sent to each device and system under test through electrical signals;

The signal excitation module outputs predetermined signals in the simulation scene;

The signal monitoring module completes the monitoring, recording and playback of signals and data in the testing process;

The test index evaluation module performs statistical analysis on indicators such as failure pass rate, failure sensitivity and anti-interference noise ability; provides data analysis and chart generation functions, and can calculate and analyze the data obtained from multi-dimensional and multi-condition queries or generate line charts, Various charts such as histograms and pie charts can be downloaded. And in the data analysis function, various analysis methods such as filtering and sampling can be added according to the actual situation, and it is closer to the user's needs to obtain the failure pass rate through analysis.

Preferably, the signal interface layer is provided with a CPCI/PCI interface board, including RS232 interface, RS422 interface, RS485 interface, DA/AD interface or DI/DO interface. Output normal signal and fault signal, the signal type includes analog signal and digital signal.

Preferably, the simulation test platform also includes test equipment, which includes general-purpose equipment such as computers, switches, cables, and signal adapters, as well as electric soldering irons, multimeters, tin suction devices, tin suction ropes, hot air tables, hot air Plug-in fault injection equipment such as guns and electrostatic brushes mainly provide auxiliary tools for the disassembly of some underlying components during the test process.

A test method for a high-risk simulation test platform, comprising the following steps:

Step 1: Carry out safety analysis of the equipment and system under test through FMEA method, and propose test indicators based on the equipment and system under test according to the analysis results, and formulate a verification and evaluation plan;

Step 2: Use the software simulation management unit to determine the simulation scenarios and faults required for test evaluation, and establish a fault sample library based on the equipment to be tested and the system;

Step 3: Simulate the signal logic in the fault sample library based on the equipment under test and the system, the software simulation management unit configures the output signal during the test verification process, and the signal excitation module completes the output of normal signals in the simulation scenario and fault injection The module completes the output of the abnormal signal;

Step 4: Receive the signals and data of the equipment under test and the system, and monitor, record and playback them;

Step 5: display the received data in the three-dimensional simulation scene;

Step 6: The software simulation management unit calculates the test indicators of the actual tested equipment and system based on the received data, compares them with the expected test indicators of the equipment and system to be tested, and evaluates the equipment to be tested according to the verification evaluation plan The degree of compliance of the test indicators of the equipment and system, and finally give the evaluation report of the test design results of the equipment and system under test.

It can be seen from the above-mentioned technical solutions that, compared with the prior art, the present invention discloses a high-risk simulation test platform, which starts with test design and injects normal signals and fault signals in a semi-physical simulation mode. On the basis of design and simulation analysis methods and test methods, build an integrated test design verification evaluation system for equipment and systems under test, and support test design, testing, and finalization according to the failure modes and test diagnosis procedures of equipment and systems under test Wait for multiple stages of testing work. Through the unified organization and management of the test design, verification and evaluation process, the test work process of the equipment under test and the system becomes a systematic and digital integrated design process. The simulation evaluation platform covers multiple stages of the design and test of the equipment and system under test, and is an integrated solution that can complete the test design, analysis, simulation, verification, and evaluation tasks of the equipment and system under test.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only It is an embodiment of the present invention, and those skilled in the art can also obtain other drawings according to the provided drawings without creative work.

Accompanying drawing of Fig. 1 is the simulation test platform structure schematic diagram provided by the present invention;

Figure 2 is a schematic diagram of the structure of the software emulation management unit provided by the present invention.

Detailed ways

The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

The embodiment of the present invention discloses a high-risk simulation test platform, including a software simulation management unit, a simulation lower computer, a signal interface layer and a hardware simulation unit; the software simulation management unit is connected to the simulation lower computer; the software simulation management unit transmits digital data to the simulation lower computer Signal; the simulation lower computer transmits drive signals to the signal interface layer; the hardware simulation unit connects to the signal interface layer; the software simulation management unit creates simulation scenarios, complex safety loop logic and fault signals, and manages related logic settings; the simulation lower computer connects to the upper The computer converts the data of the upper computer into a driving signal; the signal interface layer outputs the electrical signals generated by the software simulation management unit and the hardware simulation unit to the equipment and system under test. The software simulation management unit is the core unit for data processing, storage and interaction of the entire simulation evaluation platform.

In order to further optimize the above technical solution, the data signal includes an excitation signal and a fault signal.

In order to further optimize the above technical solutions, the software simulation management unit includes a three-dimensional simulation scene module, a test data management module, a signal excitation module, a fault injection module, a signal monitoring module and a test index evaluation module;

The 3D simulation scene module provides a highly visualized 3D operating environment, establishes a 3D scene according to relevant safety parameters, receives the configuration parameters of the simulation management software and the feedback data of the equipment under test and the system, and dynamically displays the equipment under test and the system in a three-dimensional form. Behavioral state;

The test data management module is responsible for managing the common fault sample database, and classifying and storing historical test cases and test results;

The fault injection module completes the fault mode injection of the test; the fault injection module generates the fault mode required by the equipment under test, injects the fault mode into the equipment under test and the system to generate corresponding faults, and detects the fault through the test design of the equipment under test and the system Mode processing to judge the test design capability of the equipment under test; the fault injection module can create project projects for different fault modes, set corresponding fault types and parameter configurations, and has a help module to assist users in operation and record fault operation logs. Parameters can be sent to each device under test through electrical signals, and the fault injection operation is performed by the device under test and the system itself;

The signal excitation module outputs the predetermined signal in the simulation scene;

The signal monitoring module completes the monitoring, recording and playback of signals and data during the test process;

The on-site signal processing module completes the output of electrical signals, including normal signals and abnormal signals;

The test index evaluation module conducts statistical analysis on indicators such as fault pass rate, fault sensitivity, and anti-interference noise ability; provides data analysis and chart generation functions, and can calculate and analyze data obtained from multi-dimensional and multi-condition queries or generate line charts and histograms , pie charts and other charts and download them. And in the data analysis function, various analysis methods such as filtering and sampling can be added according to the actual situation, and it is closer to the user's needs to obtain the failure pass rate through analysis.

In order to further optimize the above technical solution, the signal interface layer is provided with a CPCI/PCI interface board, including RS232 interface, RS422 interface, RS485 interface, DA/AD interface or DI/DO interface. Output normal signal and fault signal, the signal type includes analog signal and digital signal.

In order to further optimize the above technical solutions, the simulation test platform also includes test equipment, which includes general equipment such as computers, switches, cables, signal adapters, electric soldering irons, multimeters, tin suction devices, tin suction ropes, and hot air tables , hot air gun, electrostatic brush and other plug-in fault injection equipment, mainly to provide auxiliary tools for the disassembly of some underlying components during the test process.

A test method for a high-risk simulation test platform, comprising the following steps:

S1: Analyze and optimize the test design of the equipment and system to be tested through the FMEA method, and predict the test indicators; and analyze the failure mode of the equipment and system to be tested, and formulate a verification evaluation plan based on the results and the test indicators required for verification;

S2: Use the software simulation management unit to determine the required fault sample space for test evaluation, and establish a fault sample library for the equipment under test and the system;

S3: Simulate the failure mode in the failure sample library of the equipment under test and the system, and the on-site signal processing unit completes the test diagnosis and signal excitation of the equipment under test and the system; the software simulation management unit configures the output signal during the test verification process, The output of normal signals in the simulation scenario is completed by the signal excitation module, and the output of abnormal signals is completed by the fault injection module;

S4: Receive the signals and data of the equipment under test and the system, and monitor, record, and playback them; monitor and analyze the data and signals output from the equipment under test and the system during the test;

S5: The control is displayed on a three-dimensional screen; the process is intuitively displayed through three-dimensional simulation;

S6: The software simulation management unit calculates the test indicators of the actual tested equipment under test and the system based on the received data, compares them with the expected test indicators of the equipment under test and the system, and evaluates the equipment under test according to the verification evaluation plan The degree of compliance of the test indicators, and finally give the evaluation report of the test design results of the equipment and system under test.

Example

The simulation test platform will configure various functions in the software simulation management unit, such as switching to each scene, each scene has a default signal output, and can also be reconfigured, or add some interference signals on this basis for fault injection. Of course, the mode can also be switched to hardware simulation. In the hardware simulation environment, the normal signal is input by the hardware simulation unit, and the fault signal is configured and output in the software simulation management unit.

Test based on the simulation test platform. Firstly, the test design, analysis and optimization of the equipment and system to be tested are carried out through the FMEA method, the test model is established, and the test indicators are predicted. Analyze the failure mode of the equipment and system to be tested, and formulate a verification evaluation plan based on the results and the test indicators required for verification.

Secondly, if the software simulation environment is used, the steps are as follows: use the software simulation management unit to determine the required fault sample space for test evaluation, and establish the fault mode sample library of the equipment under test and the system. Simulate the failure modes in the failure mode sample library of the equipment under test and the system. The on-site signal processing unit completes the test diagnosis and signal excitation of the equipment under test and the system. During the test, the data and signals output from the equipment under test and the system are analyzed. Monitor and analyze, and can visually display the process through 3D simulation. During the whole test verification test process, the software simulation management unit configures the output signal during the test verification test process, calls the on-site signal processing unit to output the simulation signal; receives the signal and data of the equipment under test and the system, and monitors it , record, playback; control the display of 3D images.

If the hardware simulation environment is used, the steps are as follows: connect the hardware simulation environment and the software environment through the hardware interface and OPC communication, the relevant data generated in the hardware simulation unit will be displayed in the software simulation management unit interface, and the test results will also be displayed in the software interface.

Finally, the software simulation management unit calculates the test indicators of the equipment under test and the system actually tested according to the received data, and compares them with the test design indicators of the equipment under test and the system to evaluate the test design of the equipment under test and the system According to the degree of compliance of the indicators, the evaluation report of the test design results of the equipment and system under test is finally given.

Functions of the software emulation snap-in:

1) Able to perform test modeling and analysis

a) Graphical modeling;

b) It can communicate with other software such as FMEA management and failure mode analysis; it has an OPC communication module, and can connect with other systems through the OPC communication module for OPC protocol communication connection;

c) Data exchange.

2) Capable of performing test verification test management and evaluation functions:

a) project management;

b) It can be connected to the general database to obtain historical fault information, combined with FMEA analysis, to complete the design of the test experiment plan;

c) Data entry, test data modification, data export and evaluation method selection during the execution of the test to obtain the evaluation value of the fault detection rate and isolation rate;

d) The test plan is automatically generated;

e) Automatic design and generation of test cases;

f) test implementation data management and form generation;

g) Statistical analysis of test data and calculation of indicators;

h) Test problem statistics and impact analysis.

3) Capable of test data management:

a) Test modeling data management;

b) test design data management;

c) Test program and test program data management;

d) Test report data management;

4) Capable of fault injection management:

a) fault injection control function;

b) Signal acquisition and analog control;

c) Fault injection testing and control.

Each embodiment in this specification is described in a progressive manner, each embodiment focuses on the difference from other embodiments, and the same and similar parts of each embodiment can be referred to each other. As for the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and for relevant details, please refer to the description of the method part.

The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention will not be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (6)

1. The high-risk simulation test platform is characterized by comprising a software simulation management unit, a simulation lower computer, a signal interface layer and a hardware simulation unit; the software simulation management unit is connected with the simulation lower computer; the software simulation management unit transmits a digital signal to the simulation lower computer; the simulation lower computer transmits a driving signal to the signal interface layer; the hardware simulation unit is connected with the signal interface layer;

the software simulation management unit creates a simulation scene, complex safety loop logic and fault signals, and performs management setting;

the simulation lower computer is connected with the upper computer and converts the data of the upper computer into a driving signal;

the signal interface layer outputs the electric signals generated by the software simulation management unit and the hardware simulation unit to the equipment to be tested and the system to be tested.

2. The high-risk simulation test platform of claim 1, wherein the data signals comprise stimulus signals and fault signals.

3. The high-risk simulation test platform according to claim 1, wherein the software simulation management unit comprises a three-dimensional simulation scene module, a test data management module, a signal excitation module, a fault injection module, a signal monitoring module and a test index evaluation module;

the three-dimensional simulation scene module provides a three-dimensional running environment with high visualization degree, establishes a three-dimensional scene according to related parameters, receives configuration parameters of a software simulation management unit and feedback data of the equipment and the system to be tested, and dynamically displays the behavior states of the equipment and the system to be tested in a three-dimensional form;

the test data management module is responsible for managing a common fault sample database, classifying historical test cases and test results and storing the test cases and the test results;

the fault injection module can output single fault or multiple fault signals;

the signal excitation module outputs a set signal in a simulation scene;

the signal monitoring module is used for monitoring, recording and playing back signals and data in the testing process;

and the test index evaluation module performs statistical analysis on the fault passing rate, the fault sensitivity and the anti-interference noise capability index and provides an analysis report.

4. The high-risk simulation test platform of claim 1, wherein the signal interface layer is provided with a CPCI/PCI interface board card, and comprises an RS232 interface, an RS422 interface, an RS485 interface, a DA/AD interface or a DI/DO interface.

5. The high-risk simulation test platform according to claim 1, wherein the simulation test platform comprises test equipment, the test equipment comprises general equipment and plug-in fault injection equipment, and an auxiliary tool is provided for the disassembly process of some bottom components in the test process.

6. A method of testing a high risk simulation test platform according to any of claims 1-5, comprising the steps of:

step 1: performing safety analysis on equipment and a system to be tested by an FMEA method, providing test indexes based on the equipment and the system to be tested according to analysis results, and formulating a verification evaluation scheme;

step 2: determining simulation scenes and faults required by test evaluation, and establishing a fault sample library based on the equipment to be tested and the system;

step 3: simulating to configure output signals in a test verification process based on signal logic in a fault sample library of the equipment and the system to be tested, and completing the output of normal signals and abnormal signals in a simulation scene;

step 4: receiving signals and data of equipment and systems to be tested, and monitoring, recording and playing back the signals and data;

step 5: displaying the received data in a three-dimensional simulation scene;

step 6: and calculating test indexes of the equipment to be tested and the system to be tested which are actually tested according to the received data, comparing the test indexes with the expected test indexes of the equipment to be tested and the system to be tested, evaluating the test indexes of the equipment to be tested and the system to be tested according to a verification evaluation scheme, and finally giving a test design result evaluation report of the equipment to be tested and the system to be tested.

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