In the process of industrial production testing, it is often necessary to collect analog quantities such as temperature, flow rate, and pressure, and to control the amount of switches such as relays and contactors. In addition, stepping motors and servo motors perform precise displacement control. It is necessary to develop a computer-based machine tool testing system that integrates various control variables to form a closed-loop control system. This paper uses a computer as the main controller and uses Windows style interface software. It has fast calculation and test speed, strong information processing capability, high system integration, friendly working interface and convenient operation. It has realized the automation of multi-parameter test process and improved the test. Efficiency and accuracy. System main functions and features The main purpose of the system is to integrate the parameters that have a great influence on the performance of the machine tool. It has the following functions and features: (1) The system has a measuring load on the reducer and carries out the functions of no-load test, load test, inertia load test, clutch on/off test, hysteresis test, etc. The X, Y1, and Y2 triaxial tests can be performed at the same time; System hardware structure and composition The system uses a modular structure with a computer as the main controller. Computers have a wealth of hardware and software resources and powerful system functions, high speed of operation and control, and good control performance in field control. The rest of the system is connected to the computer through an interface card, controlled by it and provided with test data. By executing the interface software on the computer, the system hardware block diagram is shown in Figure 1. There are mainly the following sections: Figure 1 System block diagram The main controller of the system consists of an industrial computer, standard keyboard, mouse, CRT color display and printer. As the main controller of the system, the computer controls other actions through the interface card, collects test data, and performs complex calculations and analysis on these data to complete the test functions of the system integration. At the same time, during the test, the test results are obtained. Real-time dynamic display, if it is found that exceeds the standard, alarm processing is performed and the fault time is automatically recorded so that the operator can take relevant measures. The operator can perform man-machine operation through the display, keyboard and mouse, select corresponding test items, input necessary test parameters, monitor the entire test process, and perform corresponding file operations, and print the test results through the printer. Interface module The interface module mainly includes isolated driver cards, input and output interface cards. The input and output interface card is responsible for the computer's control and data acquisition of the test device. It is divided into digital signal interface and analog signal interface. The analog input (AI) adopts Advantech PCI-726, the analog output (AO) uses Advantech PCI-1710, and the isolation drive card. Digital input (DI) Digital output (DO) uses Advantech PCI-734. The number of specific channels is determined as follows: Digital Input (DI): Analog Input (AI): Digital output (DO): Analog Output (AO): Total DI: 24 channels, AI: 8 channels, DO: 18 channels, and AO: 6 channels. The input and output interface cards used in this system are all PCI buses. Because there are more tests and control, three interface cards are used. Through hardware adjustment, the base addresses are set to 300H and 330H, respectively. The analog signal input and output channels are independent of each other with a resolution of 12 bits and their signal ranges are as follows: Input range: -10V to +10V The digital input/output signals of the interface card are compatible with the TTL level and are easily connected to other parts. The characteristics are as follows: Input low level VIL≤0.8V In order to ensure the safety of the system operation, the system also uses an isolated driver card to ensure the separation of computer signals and external signals by means of optical isolation, etc., and to amplify the output signal of the interface card to the required strength control of servo drives and clutches, etc. signal. Motion Control Module Mainly includes servo system and loading system. The servo system consists of servo motor driver, servo motor and photoelectric encoder. Its main function is to control the tested speed reducer according to a movement law during the test process. In this system, three sets of Panasonic (MINAS) servo systems are used to control the three axes X, Y1, and Y2, respectively. The system has three control methods: speed control, position control, and torque control, which can satisfy various movements during the test. Control requirements, before use, need to set parameters, the relevant parameters are set as follows: NO.25=10000, NO.26=7200 The servo driver is controlled by the computer interface card. When the servo command output of the interface card is +3V, the servo motor speed is 1500 rpm. The computer also controls the servo driver's sign bit, output disable, SV-ON bit, and C-MODE bit through the interface card. When the sign is 1, it corresponds to the CCW direction (forward rotation). When the pulse output is 1, it is disabled, SV-ON is active low, C-MODE is the low speed control mode, and the high level is the position control mode during the test. In accordance with the test items, the computer changes these control signals according to the program, so that the servo motor works in different modes and states. The loading system is mainly responsible for providing a virtual load to the shaft end. The loading controller receives the analog signal output by the computer and adjusts the current flowing through the loading device according to this signal, thereby controlling the shaft end torque. Sensor module The proximity sensor has a 20mm range and an output voltage of 0 to 5V. The WYD series of DC displacement sensors are integrated with the electronic circuit. It is easy to install and use. It can be directly connected to the computer's input and output interface card without external amplifiers. Conversion and data processing, and then provide the relative displacement of the micro variables to the computer, the system uses a total of eight proximity sensors test adjustment accuracy. Torque sensor selection JN338 torque sensor, the sensor can achieve non-contact transmission of energy and signals, and to achieve the transmission and whether the rotation has nothing to do with the size of the speed, regardless of the direction of rotation, the output signal is a pulse signal. Incremental photoelectric encoder as a speed and displacement sensor, its output on the one hand to provide servo control system for motion control, on the other hand for computer acquisition, the computer through the software encoder output signal conversion and counting, total value and pulse count The product of the equivalent is the displacement, and the displacement in a short time is the instantaneous speed. Interface software development The main application of the system interface software is developed under the Windows operating system using the visual program development tool Visual Basic 6.0. The software operation interface adopts the Windows style. The block diagram is shown in Figure 2. Figure 2 System Software Block Diagram Visual Basic 6.0 is a powerful computer advanced visual programming language, but it can not directly access the computer input and output interfaces. To solve this problem, the system uses C++ language to compile a dynamic link library (DLL), the hardware port The access function is implemented in the connection library. When a port needs to be accessed, the corresponding connection library function is called to perform dynamic connection. This not only achieves the intended function, but also optimizes the software structure, saving a lot of system resources. in conclusion The machine tool test system designed by this system has stable operation, friendly interface, convenient operation and high control accuracy. The positioning accuracy of the X axis Y1 axis Y2 axis has reached 0.024 mm, and the repeated positioning accuracy X axis Y1 axis Y2 axis has reached 0.015 mm . 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(2) The system has on-line measurement for the automatic height-adjustment system; the high-precision function can be adjusted to test up to 8 heads at the same time, and the feed distance has automatic setting and user-supplied functions. The error value is calculated in real-time with the head feed. And show;
(3) With automatic test time setting, plus virtual load, load adjustment function;
(4) The control system has a high temperature aging test function to automatically monitor and record the system status;
(5) The dynamic display of measurement data, if you find the data exceeds the standard immediately alarm or stop the experiment;
(6) Test results are automatically analyzed and printed, and relevant documents can be manipulated for deep analysis and statistics of test results. 
main controller
Torque Transducer 3 Ways Code Plate 18 Ways Fault Alarm 3 Ways
Proximity sensor 8 way
Clutch 3-way pulse disable 3-way SV-ON 3-way burst 3-way sign 3-way C-MODE 3-way
Servo command: 3-way load control: 3-way
Output Range: -10V to +10V
Input high level VIH≥2.0V
Output low VOL ≤ 0.5V
Output high level VOH ≥ 2.4V
NO.27=1, NO.29=3 