CN114415006A - Electric element comprehensive test system - Google Patents

Abstract

The invention relates to an electrical element comprehensive test system, comprising: the alternating current-direct current power supply control device is used for providing a plurality of working power supplies with different amplitudes for a loop of the test system; the embedded control device is used for controlling power devices in the alternating current and direct current power supply control device so as to output working power supplies with different amplitudes, and collecting real-time voltages of the multiple paths of ADC channels in real time, processing the voltages and packaging the processed voltages to send out; the touch display device is connected with the data serial port of the embedded control device and is used for displaying the test waveform and carrying out man-machine interaction; the digital signal input and output circuit is respectively connected with the data input end and the data output end of the embedded control device; and the contact power supply circuit is electrically connected with the electrical element to be detected and used for triggering the operation of the electrical element. The method and the device can be suitable for testing of coil products in the low-voltage electrical appliance industry of different types, are high in testing precision and good in working reliability, can visually display a testing result, and are convenient for testers to judge and trace problems.

Description

A comprehensive testing system for electrical components

technical field

The invention relates to the technical field of testing equipment, in particular to testing equipment in the field of electronics and electricity, and in particular to a comprehensive testing system for electrical components.

Background technique

In order to measure the performance of electrical components, to achieve product quality control and to provide test basis for product development, the existing solutions for testing electrical components on the market are basically sampling through DSP chips, but the DSP chips themselves have parallel processing performance. It is very low, so it can only be sampled in serial time-sharing, resulting in a single-channel sampling frequency of only about 1KHz, that is, the sampling period is about 1ms, and for the contactor test system, the 1ms sampling period cannot be the key to the contactor at all. Performance testing results in insufficient measurement accuracy and sampling frequency, and large errors in measurement data. In addition to the above-mentioned problems, the existing test scheme also has the following defects: the waveform cannot be displayed in real time, so that the experimenter cannot judge the cause of the problem; because there is no isolation safety circuit, it also leads to poor reliability, easy to break, and poor compatibility. It is impossible to achieve one machine to cover the whole series of products of the customer, especially the electromagnetic coil control and electromagnet control products belonging to the low-voltage electrical industry, such as contactors, relays, universal circuit breakers, vacuum circuit breakers, etc., which leads to the test machine invested by customers more, the test cost is high, and it also affects the test efficiency.

Therefore, how to provide a comprehensive test system that is safe and reliable and capable of realizing one machine with multiple functions is a technical problem that needs to be solved at present.

SUMMARY OF THE INVENTION

The purpose of the present invention is to provide a comprehensive testing system for electrical components, which can be adapted to the testing of primary circuit and secondary circuit products in different types of high and low voltage electrical appliance industries, especially the testing of relays, contactors, and intelligent circuit breakers. , High test accuracy, good work reliability, and the test results can be displayed visually, which is convenient for testers to judge and trace the problem.

To achieve the above object, the technical scheme adopted in the present invention is:

The invention provides a comprehensive testing system for electrical components, including:

AC and DC power supply control device, used to provide multiple working power supplies with different amplitudes for the loop of the test system;

The embedded control device controls the power devices in the AC/DC power supply control device to output working power supplies of different amplitudes, collects real-time voltages of multiple ADC channels in real time, processes them, and packages them out;

a touch display device, connected to the data serial port of the embedded control device, for displaying test waveforms and performing human-computer interaction;

a digital signal input and output circuit, respectively connected to the data input end and the data output end of the embedded control device;

The contact power supply circuit is electrically connected to the electrical element to be detected, and is used for triggering the operation of the electrical element.

For the above technical solution, the applicant has further optimization measures.

Optionally, the AC/DC power control device includes a high-power power amplifier circuit, a toroidal transformer, a relay switching circuit, an isolated voltage sensor, and a rectifier bridge circuit. Each sub-level voltage is selected by the relay switching circuit, and then connected to the electrical element to be detected through the isolation voltage sensor and the rectifier bridge circuit.

Further, the AC/DC power supply control device also includes a current sensor, the current sensor is a current sensor with three gears of 100mA, 3A and 30A, the current sensor is arranged at the front end of the electrical component to be tested, and the sorted The grading voltage is connected to the electrical component to be measured through the current sensor.

Further, three electromagnetic relays are arranged in parallel on one power supply branch of the AC and DC power supply control device, which are used to provide power for the energy storage, closing and opening of the universal circuit breaker, forming three circuits of the single power supply branch. Switching the power output.

Optionally, the step of collecting and processing real-time voltages of multiple ADC channels in real time by the embedded control device is:

The real-time voltage values of 16 ADC channels in the test system loop are collected and processed, and then uploaded to the host computer or industrial computer through TCP/IP protocol or RS485 protocol, and the generation and control of two DAC modulation signals are completed at the same time, and 8 channels Control of digital input channels and 8 digital output channels.

Further, the embedded control device uses the direct digital frequency synthesis algorithm to calculate the output amplitude of the DAC, so as to realize a waveform whose amplitude, frequency and phase can be dynamically adjusted as the input signal of the power amplifier in the AC and DC power supply control device, and control the output of the DAC. The AC/DC power supply control device sends out a working voltage corresponding to the amplitude to drive the operation of the electrical component to be measured.

Optionally, the contact power supply circuit includes a contact, a contact power supply and a resistance voltage divider circuit, and the contact power supply is subjected to voltage division processing by the resistance voltage divider circuit before being electrically connected to the contacts, The trigger end of the electrical element to be detected is electrically connected with the contact.

Further, the contact power supply is a positive and negative 36 volt power supply, and eight controllable voltage outputs are formed by eight groups of OPA541 power amplifiers and resistor divider circuits, and the eight controllable voltage outputs are respectively connected to a contact for power supply. Test selection.

Optionally, the digital signal input and output circuit includes a power supply, an on-off indicator light, a digital isolation chip and a Darlington tube chip, and the digital isolation chip is disposed at the connection port.

Optionally, it also includes a high-speed analog-digital-digital-analog conversion circuit, through which the output of the AC and DC power supply control device and the contact power supply circuit performs corresponding power supply work through the high-speed analog-digital-digital-analog conversion circuit.

Due to the application of the above-mentioned technical solutions, the present invention has the following advantages compared with the prior art:

In the comprehensive testing system for electrical components of the present invention, the multi-level AC/DC power supply control device can provide multiple power supply voltages, and the output can be switched arbitrarily from 0-660V AC/DC, which can basically cover the power supply types of all products on the market, AC/DC The three-position current sensor in the power control device ensures to cover the current range of mainstream products on the market, and the high-precision isolated voltage sensor used in it ensures the voltage accuracy and safety of the AC and DC power supply. In addition, the embedded control The device adopts an efficient and flexible high-speed data acquisition module, which can meet the testing needs of any contactor, relay and universal circuit breaker and other products, so it can be adapted to the detection and experiment of relays, contactors and universal circuit breakers at the same time, which is convenient. customers, simplifying maintenance costs.

In addition, the contact voltage and AC/DC type in the contact power supply circuit can be flexibly set, and the combination of the resistance voltage divider circuit can ensure that the current of each contact is within the national standard range. In addition, the embedded control device combined with the touch display device can realize the upload and display of real-time test data waveforms, realize the pull-in and release voltage test, and realize the simulated power grid fault test, which is impossible for the previous test system.

Furthermore, the comprehensive test system of the present application is electrically isolated from power supply and signal in all circuits. After the actual measurement, the working reliability of the entire system circuit is high, and it can still operate efficiently even in a strong electromagnetic interference environment, effectively guaranteeing the system. Working reliability and stability.

Description of drawings

Hereinafter, some specific embodiments of the present invention will be described in detail by way of example and not limitation with reference to the accompanying drawings. The same reference numbers in the figures designate the same or similar parts or parts. It will be understood by those skilled in the art that the drawings are not necessarily to scale. In the attached picture:

1 is a block diagram of the working principle of a comprehensive testing system for electrical components according to an embodiment of the present invention;

FIG. 2 is an algorithm block diagram of a direct digital frequency synthesis (DDS) algorithm in an embedded control device in an integrated testing system for electrical components according to an embodiment of the present invention.

The reference numbers are as follows:

1. AC/DC power supply control device, 11. High-power amplifier circuit, 12. Toroidal transformer, 13. Relay switching circuit, 14. Isolated voltage sensor, 15. Rectifier bridge circuit, 16. Current sensor;

2. Embedded control device;

3. Touch display device;

4. Digital signal input and output circuit;

5. Contact power supply circuit, 51, Contact, 52, Contact power supply, 53, Resistor divider circuit;

6. Electrical components to be tested.

Detailed ways

The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

This embodiment describes a comprehensive testing system for electrical components, as shown in Figure 1, including:

The AC/DC power supply control device 1 is used to provide a plurality of working power supplies with different amplitudes for the loop of the test system;

The embedded control device 2 controls the power devices in the AC/DC power supply control device 1 to output working power supplies of different amplitudes, and collects real-time voltages of multiple ADC channels in real time, processes them, and packages them out;

The touch display device 3 is connected to the data serial port of the embedded control device 2, and is used for displaying test waveforms and performing human-computer interaction;

a digital signal input and output circuit 4, respectively connected to the data input end and the data output end of the embedded control device 2;

The contact power supply circuit 5 is electrically connected to the electrical component 6 to be detected, and is used to trigger the operation of the electrical component 6 .

Specifically, the AC/DC power supply control device 1 includes a high-power power amplifier circuit 11, a toroidal transformer 12, a relay switching circuit 13, an isolation voltage sensor 14, and a rectifier bridge circuit 15. The output of the high-power power amplifier circuit 11 passes through the toroidal transformer. 12 After the output voltage is divided into grades, each graded voltage is selected by the relay switching circuit 13 and then connected to the electrical component 6 to be detected through the isolation voltage sensor 14 and the rectifier bridge circuit 15 .

In addition, the AC/DC power supply control device 1 further includes a current sensor 16, the current sensor 16 is a current sensor 16 with three gears of 100mA, 3A and 30A, and the current sensor 16 is arranged on the electrical component 6 to be tested. At the front end, the sorted voltages are connected to the electrical component 6 to be measured through the current sensor 16 .

In the comprehensive test system for electrical components 6 in this embodiment, the multi-level AC and DC power supply control device 1 can provide multiple power supply voltages, and can switch the output from 0-660V AC and DC at will, which can basically cover the power supply types of all products on the market. , the three-position current sensor 16 in the AC and DC power supply control device 1 is guaranteed to cover the current range of mainstream products on the market, and the high-precision isolated voltage sensor 14 used in it ensures the voltage accuracy and safety of the AC and DC power supply. , In addition, the embedded control device 2 adopts an efficient and flexible high-speed data acquisition module, which can meet the testing needs of any contactor, relay and universal circuit breaker, so it can be adapted to relays, contactors and universal circuit breakers at the same time. It is convenient for customers and simplifies maintenance costs.

Since the universal circuit breaker needs three power sources for energy storage, closing and opening, three electromagnetic relays are correspondingly arranged in parallel on one power supply branch of the AC/DC power supply control device 1, which are used for the universal circuit breaker. The energy storage, closing and opening provide power supply, and the switching of three-way power output that constitutes a single-circuit power supply branch, thereby saving the space and resources of system equipment.

Optionally, the embedded control device 2 collects real-time voltages of multiple ADC channels in real time and processes them as follows: collecting the real-time voltage values of 16 ADC channels in the test system loop and performing data processing, and then using the TCP/IP protocol. Or upload the RS485 protocol to the host computer or industrial computer, and complete the generation and control of two DAC modulation signals, as well as the control of 8 digital input channels and 8 digital output channels. The embedded control device 2 may generally include two parts of program control: ARM and FPGA. Specifically, it includes two parts: sampling and communication, including:

The sampling part supports 8-channel synchronous AD conversion acquisition, sampling frequency 200Khz, AD number 16bit; supports 4-channel differential AD conversion acquisition, sampling frequency 200Khz, AD number 16bit; sampling input is ±10V; supports 8 channels at the same time high frequency continuous Sampling up to 1000ms; supports dynamic switching of multiple acquisition modes.

The communication part uses Lwip to transmit the collected data, and realizes the Modbus-RS485 command transmission, the DAC amplitude controllable (frequency/amplitude) transmission under the control of the algorithm, and the setting of various dynamic parameters. The data cache module mainly includes ARM extended 32M cache, and FPGA extended two 512K SRAM as high-speed data acquisition cache.

The embedded control device 2 uses a direct digital frequency synthesis (DDS) algorithm to calculate the DAC output amplitude, so as to realize a waveform whose amplitude, frequency and phase can be dynamically adjusted as the input signal of the power amplifier in the AC and DC power supply control device 1 , to control the AC/DC power supply control device 1 to send out a working voltage corresponding to the amplitude to drive the work of the electrical component 6 to be measured.

The direct digital frequency synthesis (DDS) algorithm is mainly composed of a phase accumulator, a phase modulator and a look-up table. Among them, the phase accumulator consists of a 32-bit adder and a 32-bit register. At each rising edge of the clock, the adder adds the frequency control word and the phase data output from the accumulating register, and the result of the addition is fed back to the data input of the accumulating register, so that the adder continues under the action of the next clock pulse. Add to frequency control word. In this way, the phase accumulator continuously performs linear phase accumulation on the frequency control word under the action of the clock. That is, when each clock pulse is input, the phase accumulator accumulates the frequency control word once. The data output by the phase accumulator is the phase of the synthesized signal. The overflow frequency of the phase accumulator is the signal frequency output by the DDS. The data output by the phase accumulator is used as the phase sampling address of the waveform memory, so that the waveform sampling value stored in the waveform memory can be found through the look-up table to complete the phase-to-amplitude conversion. The output data of the waveform memory is sent to the D/A converter, and the D/A converter converts the digital signal into an analog signal for output, and then displays it in the touch display device 3 .

In addition, the input and output part of the embedded control device 2 has 8 general-purpose inputs and 8 general-purpose outputs with a large DC24V. Among them, the output supports 24V, 0.5A power, external power supply, support rate 100Khz. 2-channel 16-bit DA adjustable output, output range: ±10V, the output uses a 200Khz resolution DAC, and generates a sine wave of not less than 1Khz.

In one embodiment, the contact power supply circuit 5 includes a contact 51 , a contact power supply 52 and a resistance voltage divider circuit 53 , and the contact power supply 52 is subjected to voltage division processing by the resistance voltage divider circuit 53 The contact 51 is then electrically connected, and the trigger end of the electrical component 6 to be detected is electrically connected to the contact 51 .

Specifically, the contact power supply 52 is a positive and negative 36-volt power supply, and eight groups of OPA541 power amplifiers and resistor divider circuits 53 form eight controllable voltage outputs, and the eight controllable voltage outputs are then connected to one touch. Click for test selection. Therefore, in this embodiment, the voltage and AC/DC type of the contacts 51 in the contact power supply circuit 5 can be flexibly set, and the combination of the resistance voltage divider circuit 53 can ensure that the current of each contact 51 is within the national standard range. In addition, the embedded control device 2 combined with the touch display device 3 can realize the upload and display of real-time test data waveforms, realize the pull-in and release voltage test, and realize the simulated power grid fault test, which cannot be achieved by the previous test systems.

The digital signal input and output circuit 4 includes a power supply, an on-off indicator light, a digital isolation chip and a Darlington tube chip, and the digital isolation chip is arranged at the connection port.

In a further embodiment, the comprehensive testing device for electrical components 6 further includes a high-speed analog-to-digital digital-to-analog conversion circuit, and the outputs of the AC/DC power supply control device 1 and the contact power supply circuit 5 pass through the high-speed analog-to-digital conversion circuit. The digital-to-analog conversion circuit then performs the corresponding power supply work. Specifically, the high-speed analog-to-digital-to-analog conversion circuit is mainly composed of an ADC circuit and a DAC circuit. The ADC circuit uses two AD7606 chips to form 16-channel 3.2MHz parallel acquisition, while the DAC circuit uses four DAC8562 chips to form eight DACs, which are responsible for the output power amplifier signal of the AC and DC power supply control device 1 and the contact power supply circuit 5 output and contact 51 signal output.

In addition, the comprehensive test system of this embodiment has electrical isolation of power supply and signal in all circuits. After the actual measurement, the working reliability of the entire system circuit is high, and it can still operate efficiently even in a strong electromagnetic interference environment, which effectively guarantees the work of the system. reliability and stability. Specifically, the communication between the main control and peripheral chips such as DAC and Darlington tube of this system is all isolated and protected by the isolation chip (ISO7240), which is the most important isolation measure. The main control, DAC, and relay parts use three isolated power supplies, which avoids the interference of the product coil, the relay coil and the field inverter and other strong interference sources to the entire system and irreversible hardware damage. The wiring and communication lines from this system to the outside are all shielded wires, such as SMA wires and RS485 shielded wires. Although the cost is slightly increased, it completely solves the problems of communication interruption and board damage that were unknown in the past.

The above-mentioned embodiments are only to illustrate the technical concept and characteristics of the present invention, and their purpose is to enable those who are familiar with the art to understand the content of the present invention and implement them accordingly, and cannot limit the scope of protection of the present invention with this. Equivalent changes or modifications made in the spirit and spirit should all be included within the protection scope of the present invention.

Claims (10)

1. An electrical component integrated test system, comprising:

the alternating current-direct current power supply control device is used for providing a plurality of working power supplies with different amplitudes for a loop of the test system;

the embedded control device controls power devices in the alternating current and direct current power supply control device so as to output working power supplies with different amplitudes, and collects real-time voltages of the multiple paths of ADC channels in real time, processes the voltages and packs the voltages to send out the voltages;

the touch display device is connected with the data serial port of the embedded control device and is used for displaying the test waveform and carrying out man-machine interaction;

the digital signal input and output circuit is respectively connected with the data input end and the data output end of the embedded control device;

and the contact power supply circuit is electrically connected with the electrical element to be detected and used for triggering the operation of the electrical element.

2. The integrated test system for the electrical elements according to claim 1, wherein the ac/dc power control device comprises a high-power amplifier circuit, a toroidal transformer, a relay switching circuit, an isolation voltage sensor, and a rectifier bridge circuit, wherein after the output of the high-power amplifier circuit is stepped by the toroidal transformer, each stepped voltage is selected by the relay switching circuit and then connected to the electrical element to be tested via the isolation voltage sensor and the rectifier bridge circuit.

3. The comprehensive test system for the electrical elements according to claim 2, wherein the alternating current/direct current power supply control device further comprises a current sensor, the current sensor is a current sensor with three gears of 100mA, 3A and 30A, the current sensor is arranged at the front end of the electrical element to be tested, and the sorted stepped voltage is connected to the electrical element to be tested through the current sensor.

4. The electrical component comprehensive test system according to claim 2, wherein three electromagnetic relays are connected in parallel to one power supply branch of the ac/dc power supply control device, and are used for supplying power to energy storage, closing and opening of the universal circuit breaker to switch three power supply outputs of the one power supply branch.

5. The integrated test system for electrical components of claim 1, wherein the embedded control device collects real-time voltages of multiple ADC channels in real time and processes the voltages by:

and acquiring real-time voltage values of 16 ADC channels in a test system loop, processing the real-time voltage values, uploading the real-time voltage values to an upper computer or an industrial personal computer through a TCP/IP protocol or an RS485 protocol, and simultaneously completing the generation and control of two DAC modulation signals and the control of 8 digital input channels and 8 digital output channels.

6. The integrated test system for the electrical elements according to claim 1 or 5, wherein the embedded control device calculates the output amplitude of the DAC by using a direct digital frequency synthesis algorithm, so as to realize a waveform with dynamically adjustable amplitude, frequency and phase as an input signal of a power amplifier in the AC/DC power supply control device, and control the AC/DC power supply control device to send out a working voltage with corresponding amplitude to drive the electrical element to be tested to work.

7. The integrated test system for the electrical elements according to claim 1, wherein the contact power supply circuit comprises a contact, a contact power supply and a resistance voltage dividing circuit, the contact power supply is electrically connected with the contact after being subjected to voltage dividing processing by the resistance voltage dividing circuit, and the trigger end of the electrical element to be detected is electrically connected with the contact.

8. An integrated test system for electrical components as claimed in claim 7 wherein said power supply for said contacts is a positive and negative 36 volt power supply, and eight controllable voltage outputs are formed through eight sets of OPA541 power amplifiers and resistive divider circuits, and said eight controllable voltage outputs are respectively connected to a contact for testing.

9. The electrical component integrated test system of claim 1, wherein the digital signal input output circuit comprises a power supply, an on-off indicator light, a digital isolation chip and a darning-ton chip, the digital isolation chip being disposed at the connection port.

10. The electrical component comprehensive test system according to claim 1, further comprising a high-speed analog-to-digital-to-analog conversion circuit, wherein the output of the alternating current/direct current power supply control device and the output of the contact power supply circuit perform corresponding power supply work through the high-speed analog-to-digital-to-analog conversion circuit.

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