Abstract: Mechanical high-pressure hydraulic pump testing equipment suffers from drawbacks such as poor testing accuracy, weak real-time performance, and low automation. The application of the new WinCE-Based controller WinCon8000 and measurement and control technology can effectively solve these problems and enable fault detection, pollution control, and functional development of the testing equipment. Keywords: CC-Link, MELSECNET/H, Fieldbus, Teaching Practice 1, Requirements Overview With the rapid development of hydraulic technology and its increasingly wide application, the requirements for the variety and performance of hydraulic components, assemblies, and systems are becoming increasingly stringent, correspondingly placing higher demands on hydraulic testing technology. The rapid development of computer technology has opened up new avenues for the application of measurement and control technology in hydraulic accessory testing equipment. The performance and reliability of hydraulic equipment mainly depend on the performance of its various components and accessories. Due to the continuous advancement of hydraulic technology and the increasing demands of equipment use, hydraulic pumps are increasingly adopting new technologies and processes, resulting in higher pressures and flow rates. This brings about problems such as accurate parameter measurement, compatibility with multiple pump types, and system stability. Therefore, in order to determine and evaluate the complete performance parameters and quality indicators of hydraulic systems and their components, testing work needs to meet higher requirements. To meet standards and achieve high-precision testing of hydraulic components, the Wincon8000 module from ICP DAY, a new type of WinCE-based module with an industrial Ethernet interface, was used as the main on-site testing unit, forming a distributed hydraulic testing system. The test principle diagram based on WinCon8000 is shown in Figure 1. [align=center] Figure 1: Test principle diagram based on WinCon8000[/align] 2 High-Pressure Hydraulic Pump Testing System When researching and designing new high-pressure hydraulic pumps, type testing of the hydraulic pump is necessary. Type testing includes: ① Structural integrity testing, including airtightness, external leakage, pressure resistance, and fatigue tests; ② Performance testing, including displacement verification, efficiency, variable characteristics, self-priming, and noise tests; ③ Durability testing, including high temperature, overspeed, overload, impact, continuous overload, and continuous full load tests. Ordinary hydraulic test benches use secondary instruments to measure parameters such as flow rate, speed, torque, and pressure, directly or indirectly measuring the working performance characteristics of the hydraulic pump through calculation. Due to the large number of measurement parameters and the dispersed measurement points, the measurement intensity is increased, and the time consumption is long. Furthermore, the time difference in parameter readings introduces errors that affect measurement accuracy. In addition, the long testing time and extremely high power consumption are significant during high-pressure hydraulic pump durability testing. This study, based on the characteristics of high-pressure hydraulic pump type testing, utilizes one microcomputer, three Wincon8000 units, and corresponding sensors to achieve computer-aided testing for high-pressure hydraulic pump type testing. A power recovery hydraulic circuit for the pump is employed to recover test power, thereby reducing measurement intensity, improving test accuracy, and saving energy. The high-pressure hydraulic pump test bench is driven by a dual-output-shaft DC motor, equipped with a phase-controlled thyristor DC speed regulation system. This speed regulation system uses a dual-closed-loop system consisting of a three-phase bridge fully controlled current small closed loop and a speed large closed loop for speed regulation, meeting the requirements of high-pressure hydraulic pump testing for precise and stable speed regulation, frequent speed changes, and stiff mechanical characteristics. 3. Basic Testing Principles 3.1 Composition of the Wincon8000-Based Measurement and Control System The Wincon8000-based measurement and control system mainly consists of a host computer, three WinCon8000 units and their 8K series I/O modules, a signal amplification circuit, a ZAZP type electric direct-flow single-seat regulating valve, a DF type pilot-operated electromagnetic high-pressure oil valve, and a high-precision hydraulic sensor SR345, etc. 3.2 Control Process First, the host computer sends test commands to the three local control units, the ICPIC WinCon-8331-G compact embedded control system. The three Wincon8000 units' ICPDAS I-8017MR 8K units acquire in real time the voltage signal corresponding to the oil pressure in the oil chamber of the tested pump, sent by the hydraulic sensor. This voltage signal is then converted into a numerical value, processed, and calculated to obtain the numerical control quantity. Then, the numerical control quantity is converted into the corresponding analog control voltage via the ICPDAS I-8024 8K conversion module, and the solenoid valve is controlled by the ICPDAS I-8050 8K input/output digital signal, ultimately achieving constant controlled hydraulic pressure. The test principle diagram is shown in Figure 2. [align=center] Figure 2: Test Principle Diagram[/align] 3.3 Real-time Control Algorithm Considering the characteristics of the control system's mathematical model, control requirements, long pure time delay and inertia time, unknown dynamic parameters, and the controlled object often being under random disturbances, the minimum variance self-tuning control algorithm, i.e., the minimum variance self-tuning controller, is adopted through comprehensive consideration. The minimum variance self-tuning controller is a comprehensive self-tuning control law that optimizes performance indicators based on the minimum output variance, and uses the recursive least squares parameter estimation method to directly estimate the controller parameters. It consists of two parts: the first part is the controller parameter estimator, and the second part is the self-tuning controller. Its structure is shown in Figure 3. [align=center]Figure 3: Control Algorithm[/align] 4 Hardware System 4.1 WinCon8000 Based on the requirements of the test system for the local control unit, the WinCon-8331-G compact embedded control system was selected. The WinCon-8000 has signal module slots and the same architecture as PLCs and other controllers. The host is PC hardware and the WinCE operating system, cleverly transforming it into a PC-based environment while possessing PLC control signal functions—a dual-purpose "PC + PLC" combination. Signal modules include various specifications such as analog signals and digital signals. Windows CE.NET is pre-installed inside the WinCon8000. Since Windows CE.NET is a strong real-time system, it provides a powerful control solution. The WinCon-8000 series is a diskless real-time control platform, a powerful integration of traditional PLCs and Windows PCs. 4.2 A/D Module: ICPDAS I-8017MR 8K Analog Input Module • Single-channel polling mode: 100kHz; • 8-channel scan mode: 8kHz; • Input bandwidth: 40kHz; • Resolution: 14 bits; • Input type: Differential; 4.3 D/A Module: ICP DAS I-8024 8K Analog Input/Output Module • 4-channel opto-isolated analog output module; • Voltage output: ±10V; • Current output: 0～20mA/4～20mA; • Isolation: 3000VDC 4.4 DI/O Module: ICP DAS I-8050 8K Digital Input/Output Module • Number of digital input/output channels: 16 Input/Output Type: Selected by Route • Switch Input: +2V (0), +4V～30V (1) • Switch Output: Open Collector Output: 125mA/channel 5 System Software The system software is developed using Visual C++ based on Windows 2000, with an SQL Server database, and loads the OPC service of Wincon8000 provided by ICP DAY to implement the host computer management program. The system program framework is shown in Figure 4. [align=center] Figure 4: System Software Architecture[/align] The program development of the WinCon8000 local unit is developed using Visual Basic .NET tools on its internal WinCE platform. ICP DAY provides a large number of examples, making programming relatively simple. 6 Conclusion ICP DAY's WinCE-Based WinCon-8000 controller is a standard information architecture, and ICP DAY provides the ability to drive I/O signals. The measurement and control system using the Wincon8000 architecture has the dual advantages of PLC and PC. Due to the real-time performance and stability of the WinCE operating system, WinCE-based controllers represent a future trend in industrial control. This system, utilizing the Wincon8000 architecture for testing mechanical high-pressure hydraulic equipment, is a typical example of such an application.