Design of fault diagnosis device based on PC104 bus

A certain device is a large-scale complex equipment integrating machine, electricity and liquid. The device controls the closing of the solenoid valve through the relay through the computer, and then controls the hydraulic system to complete the functions of leveling, erecting, and recycling of the device. The temperature control system controls the internal temperature of the launching cylinder to keep it within a certain range. The logic relationship of the entire system is complex, and there are many signal channels. Once a fault occurs during use, it is very difficult to locate and queue the fault. In view of this situation, the device's fault diagnosis device was developed , which can quickly locate the fault without disassembling it, and uses the combination of expert system and multimedia to guide ordinary operators to troubleshoot. The device can also be connected to the network to realize the use of online information exchange between troops and colleges or research institutes, fully exert the role of domain experts, and eliminate the fault location.

In order to solve the problem of fault diagnosis of a device, a design scheme of a portable fault diagnosis device based on PC104 bus is proposed. The hardware with modular structure design is analyzed, and the expert system realized by multimedia technology is introduced. The device can also provide a reference for fault diagnosis of other large electromechanical equipment.

1 The main working principle of system hardware composition

The device adopts a box type clamshell mechanism based on PC104 bus. According to the different functions, the hardware of the device can be divided into two parts: the diagnosis and adjustment part and the temperature control part of the device itself. The hardware schematic diagram of the system is shown in Figure 1. Among them, CZ1 ～ CZ8 are the sockets connected to the equipment: CZ1 is used to detect cable short circuit and break faults; CZ2, CZ3 are mainly used to detect whether the working signal of the device is normal, or whether the response signal is applied after the excitation signal is applied to the device Normal; CZ5, CZ6 are connected to the pressure sensor, supply power to the pressure sensor, and collect pressure signals; CZ7 is used to adjust the liquid pendulum; CZ8 is used to switch the power supply of the manual console, and the 27V voltage of the manual console is introduced into the system as a diagnosis Reference place.

1.1 Diagnosis adjustment part of the diagnosis device

The hardware of the diagnosis adjustment part of the diagnosis device can be divided into three parts according to the structure and function: the dedicated industrial computer part, the data acquisition part and the liquid pendulum adjustment and calibration part.

1.1.1 Dedicated industrial computer part

The main hardware of the dedicated industrial computer part adopts Advantech's products, and experiments have verified that there is no hardware conflict between the products. ECM-3610 is a PC104 motherboard, which integrates VIA Eden ESP6000 (667 MHz) EBGA low power onboard CPU, VIA VT8606 chip of Savage4 AGP 4X graphics card, AC 97 2.0 sound card, two onboard 10 / 100Base-Tx network cards, etc. , Can access the network.

1.1.2 Data collection

In order to maintain the hardware compatibility of the device, Advantech products are also used in the peripheral boards. There are mainly three types of board cards: PEM-AIO, PCM-3724, PCLD-788. PEM-AIO is an A / D data acquisition card with a PC104 bus structure. A / D conversion can receive up to sixteen channels of single-ended analog inputs and convert these analog inputs into 12-bit data. It is mainly used to collect the electrical control of the device, the control signal when the temperature control system works, the pressure signal output by the hydraulic system sensor, and the resistance signal output by the liquid pendulum reflecting different levels, and give specific values. PCM-3724 is a 48-channel I / O board based on PC / 104 bus, emulation 8255 PPI mode is 0, input and output TTL level. It is mainly used to control relays, relay boards and self-made signal conditioning analog circuit boards and detect cable faults. PCLD-788 provides 16 input channels and 1 output channel. Its 16 input channels are connected to the output of external signals. One output channel is controlled by PCM-3724 or PEM-AIO, and the signal to be tested is input to the A / D data acquisition board. A total of two PCLD-788s are used in the device, which saves the number of required A / D conversion channels.

1.1.3 Liquid pendulum adjustment part

This part is mainly composed of signal conditioning analog circuit board, A / D data acquisition board, socket and liquid pendulum, used to adjust the liquid pendulum. Its adjustment principle is shown in Figure 2. The signal conditioning analog circuit board emits a 1kHz square wave signal, which is applied to the input end of the liquid pendulum via CZ7. The signal output by the liquid pendulum feedback is filtered, followed, and amplified by the signal conditioning analog circuit board and then sent to the A / D board input At the end, the liquid pendulum is accurately calibrated according to the results collected by the A / D.

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