CN111830376A - Comprehensive detection platform for distributor - Google Patents
Comprehensive detection platform for distributor Download PDFInfo
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- CN111830376A CN111830376A CN202010674235.4A CN202010674235A CN111830376A CN 111830376 A CN111830376 A CN 111830376A CN 202010674235 A CN202010674235 A CN 202010674235A CN 111830376 A CN111830376 A CN 111830376A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
- G01R31/52—Testing for short-circuits, leakage current or ground faults
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/12—Testing dielectric strength or breakdown voltage ; Testing or monitoring effectiveness or level of insulation, e.g. of a cable or of an apparatus, for example using partial discharge measurements; Electrostatic testing
- G01R31/1227—Testing dielectric strength or breakdown voltage ; Testing or monitoring effectiveness or level of insulation, e.g. of a cable or of an apparatus, for example using partial discharge measurements; Electrostatic testing of components, parts or materials
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
- G01R31/54—Testing for continuity
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
- G01R31/66—Testing of connections, e.g. of plugs or non-disconnectable joints
- G01R31/67—Testing the correctness of wire connections in electric apparatus or circuits
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Testing Of Short-Circuits, Discontinuities, Leakage, Or Incorrect Line Connections (AREA)
Abstract
The invention provides a distributor comprehensive detection platform which comprises a PXI bus backboard, a CPU industrial control board card, a matrix switch control board card, an insulation test high-voltage board card and a universal meter four-wire test board card which are mutually connected and communicated, wherein the CPU industrial control board card is mutually connected and communicated with a display screen and a code scanning gun; and the matrix switch control board card, the universal meter four-wire test board card and the detection platform interface are mutually connected and communicated. By adopting the scheme, the on-off and insulation functions of the wiring relation of the tested distributor can be automatically, quickly and accurately detected by combining a four-wire measuring method; the scanning speed reaches more than 500 points/second, and the on-off and insulation detection can be accurately finished in the complex wiring relation of the instrument.
Description
Technical Field
The invention belongs to the technical field of distributor detection, and particularly relates to an automatic test device which can perform sequence test of conduction, insulation and self-editing scripts of various distributors in the whole processes of electricity fitting, debugging and inspection.
Background
The working principle of the power distribution isolator is that a two-wire system transmission mode is generally needed in an industrial field, a 25V-31V power distribution power supply is provided for primary instruments such as a transmitter, and isolated current and voltage signals are output after input current signals are collected, amplified, operated and subjected to anti-interference processing and are used by the following secondary instruments or other instruments. After the distributor is electrically assembled, faults such as wrong lines, missing lines, welding errors and the like of the distributor can cause the power-on test of products in a problem state, and damage to components is caused. In order to avoid the faults, at present, the manual static measurement of short-circuit points, precise resistors, insulation performance and wiring relation is mainly adopted, the detection coverage is incomplete, the workload is huge, errors are prone to occurring, reports cannot be generated, data tracking performance and data contrast performance do not exist, and the situations of wrong welding, missing welding, insufficient welding and the like of a power distribution instrument in a non-powered state cannot be comprehensively eliminated.
Disclosure of Invention
In order to change the current situation of manually measuring a channel and an insulation resistance after an electric fitting, the invention discloses a comprehensive detection platform of a distributor, which improves the test efficiency and test coverage in the whole process of self-checking, debugging and inspection after the electric fitting, simplifies the operation steps by an automatic test method, reduces the product damage caused by human factors, ensures the product quality and achieves nondestructive detection in a certain sense.
The invention discloses a comprehensive detection platform for a distributor, which comprises: the system comprises a PXI bus backboard, a CPU industrial control board card, a matrix switch control board card, an insulation high-voltage board card, a universal meter four-wire test board card, a display screen and a code scanning gun, wherein the CPU industrial control board card is mutually connected and communicated with the display screen and the code scanning gun; the matrix switch control board card, universal meter four-wire test board card and testing platform interface interconnect and communication.
Furthermore, the PXI bus backboard adopts a customized 5-slot or 8-slot PXI structure, the CPU industrial control board card, the matrix switch control board, the insulation high-voltage board card and the universal meter four-wire test board card are integrated on the customized backboard, and the PXI bus backboard provides high-speed bus working frequency and a board card inter-module communication protocol for each functional board card, and coordinates system data communication and control logic in order.
Furthermore, the CPU industrial control board card is used for completing control of the insulation high-voltage board card and the matrix switch control board card, data acquisition of the universal meter four-wire test board card, data acquisition of the code scanning gun and control interface management of the display screen.
Further, the matrix switch control board card is composed of a plurality of single 128-channel matrix switches, and a mapping relation between a connector pin of the detection platform interface and a node of the tested power distributor is established.
Further, the matrix switch control board card is composed of 5 or 8 monoblock 128-channel matrix switches.
Furthermore, the testing platform interface comprises an ITTDDR interface, wherein 156 pin nodes of the ITTDDR interface are respectively provided, the total number of the pin nodes is 156, the first 128 pin nodes are respectively correspondingly connected with 128 matrix relay switches, static and dynamic states of the pin nodes are controlled by the 128 matrix relays, and the rest pin nodes are vacant, so that the testing platform is convenient to expand.
Furthermore, the insulation test high-voltage board card is used for generating a direct current voltage of 100V-1000V and used for insulation performance test of instruments.
Furthermore, the universal meter four-wire test board is loaded between connector pins of the tested power distributor in real time, and short circuit, open circuit and insulation test of the instrument are completed.
Furthermore, the display screen is respectively connected to the CPU industrial control card through a USB drive wire and a video wire.
Further, the code scanning gun is connected to the CPU industrial control board card through a USB drive wire.
The invention provides a detection method using a distributor comprehensive detection platform, which is characterized in that a Central Processing Unit (CPU) industrial control board card of the distributor comprehensive detection platform automatically performs short circuit test in groups, arrays and combinations by combining the control of a matrix switch control board card and a universal meter four-wire test board card with a four-wire measurement principle, accurately detects slight resistance value changes, and further analyzes error welding, missing welding and rosin joint faults.
Advantageous effects
Compared with the prior art, the invention provides the comprehensive detection platform for the power distributor, which integrates computer control and test and has the advantages of high test precision, high speed and good consistency. The external interface passes through special distribution instrument four-wire test cable, and all kinds of instruments of nimble adaptation are applicable to multiple distribution instrument test. The automatic detection of the whole item in the current stage only needs 10 minutes, and the efficiency value is 24 times of that of manual detection. The labor cost can be saved by 115 yuan for each product. The maximum benefit is that the quality problem management and production cost is obviously reduced.
(1) The comprehensive detection platform of the power distributor can realize the functions of automatically and rapidly detecting on-off, insulation and the like; the scanning speed can reach more than 500 points/second, so that the connection relation of hundreds or even thousands of complex instruments can accurately complete access and insulation detection in seconds;
(2) by combining a software algorithm and a four-wire test method, short circuit test is carried out by automatic grouping and permutation combination, fine resistance value change can be accurately detected, and all possible welding problems can be found out through analysis of the fine resistance value change;
(3) various wiring fault types of the instrument can be detected quickly and accurately;
(4) the insulation characteristics of any two insulation points of the rapid combination detection instrument are realized by controlling and adjusting high-voltage (insulation) test parameters, all defects such as poor insulation and the like which may exist are found out, the reliability of products is ensured, the test requirements of different power distributors are met, the test efficiency is improved, and the test precision is ensured;
(5) through the database management technology, the method has the functions of visually displaying the instrument test report, calling and inquiring and the like.
Drawings
Fig. 1 is a schematic diagram of boards inside a product.
Fig. 2 shows the detection of the fault type:
where (a) represents a correct connection mode, fig. (b) represents a short circuit between the instrument connector terminal 3 and the terminal 4, fig. (c) represents an open circuit between the instrument connector terminal 1 and the terminal 7, and fig. (d) represents a misbonding between the instrument connector terminal 3 and the terminal 8.
Detailed Description
In order that the above objects, features and advantages of the present invention can be more clearly understood, a more particular description of the invention will be rendered by reference to the appended drawings.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced in other ways than those specifically described herein, and therefore the scope of the present invention is not limited by the specific embodiments disclosed below.
Example 1: power distribution instrument XX-1 test procedure
and step 3: the test was started: and connecting the tested power distributor and detecting the wiring relation condition of the tested power distributor. And testing is carried out on the basis of established testing engineering and known normal connection relation. The fault condition of the tested distributor can be quickly detected.
The invention is provided with a computer inside, can continuously work for more than 48 hours, the total weight does not exceed 25KG, a single person can finish the test work, the standard 128X5 test channel can be used, and the insulation voltage can be supported to DC 1000V.
As shown in fig. 1, the power distributor comprehensive detection platform of the present invention includes: the system comprises a PXI bus backboard, a CPU industrial control board card, a matrix switch control board card, an insulation high-voltage board card, a universal meter four-wire test board card, a display screen and a code scanning gun, wherein the CPU industrial control board card is mutually connected and communicated with the display screen and the code scanning gun; the matrix switch control board card, universal meter four-wire test board card and testing platform interface interconnect and communication.
PXI bus backboard
The PXI bus is a novel measurement and control instrument bus standard, is an extension of CPCI in the instrument field, and is an advanced modular instrument system. The PXI bus system has the characteristics of high data transmission rate, compatibility with industrial computer software and the like. The PXI bus backboard adopts a 330mm 8-slot PXI structural mode with compact structure and strong environment adaptability, and integrates a CPU industrial control board card, a multi-channel matrix switch control board card, an insulation test high-voltage board card and a universal meter four-wire test board card into the PXI board slot to form a PXI framework detection platform with a plurality of main control and peripheral board cards. The PXI bus backboard provides high-speed bus working frequency and a communication protocol among board card modules for each functional board card, and coordinates system data communication and control logic in order.
The CPU industrial control board card is a control center of the detection platform. The Windows operating system can be loaded, and the basic environment for software development and test system operation is provided. The CPU industrial control board card is used for completing tasks such as control of an insulation high-voltage board card, control of a matrix switch control board card (such as a 128-channel matrix switch), data acquisition of a universal meter four-wire test board card, data acquisition of a code scanning gun, management of a control interface of a display screen and the like; and automatically coordinating the working time sequence of other modules, completing various tasks of the instrument test, and displaying a test result report through a display screen.
The matrix switch control board card is composed of a plurality of single 128-channel matrix switches. Under the control of the system, the mapping relation between the detection platform interface and each point of the tested distributor connector is flexibly established, the test engineering is memorized, and the wiring relation of different types of distributors can be processed. The fault conditions of wrong and missing welding, insufficient welding and the like of the instrument can be directly and quickly detected when the same instrument is tested by memorizing once. The following examples are given:
the detection platform interface is an ITTDDR interface; 156 ITTDDR interface pin nodes are provided, and the total number of the pin nodes is 156; the first 128 plug contacts are respectively and correspondingly connected with the 128 matrix relay switches, static and dynamic states of the plug contacts are controlled by the 128 matrix relays, and the rest are free space, so that the expansion of the detection platform is facilitated.
The relay is defined to be static when not powered on, and dynamic when the power-on switch is powered on. In a static state, 128 matrix relay switches are in a null connection state, and ITTDDR connection points are suspended; when the equipment is powered on and changed into a dynamic state according to the test requirement, the corresponding matrix relays are powered on and attracted, the switches are switched on, and 128 matrix relay switches are automatically connected with the pin nodes of the ITTDDR interface under the intelligent control of the system. When the tested distributor is connected to the interface of the detection platform in an inserting mode and connection relation testing is conducted, the universal meter four-wire measurement board card is loaded to two ends of a node of the ITTDDR interface, and conducting, short circuit, open circuit, poor welding and other conditions of instrument wiring relation are tested. When insulation test is carried out, high voltage is loaded on an instrument of the ITTDDR interface, the matrix switch control board card is subjected to rapid combined scanning, the universal meter board card is controlled to be loaded between two parallel nodes of the ITTDDR interface respectively, combination test of insulation resistance values is carried out, and insulation characteristics between insulation points of the instrument are detected. The clutching of 128 matrix relay switches is controlled by the matrix switch control board card, rather than being fixedly connected to the node of the ITTDDR interface, and the on-off and insulation function test can be performed between any insulation points at any time.
When the tested distributor connector is not in an ITTDDR interface mode and is incompatible with the ITTDDR interface of the local device, the adapter cable of the ITTDDR interface is required to be converted into the packaging form of the tested distributor connector, and the tested distributor connectors of different types can be connected into the detection platform.
The insulating high-voltage board card generates a direct-current voltage of 100V-1000V for the insulation performance test of the instrument.
The universal meter four-wire test board card has an automatic digital universal meter test function, and is loaded among nodes of a tested distributor in real time under system control, so that test tasks of conditions such as short circuit, open circuit and insulation of an instrument are completed. The display screen and the human-computer interaction media are respectively connected to the CPU industrial control board card through the USB drive wire and the video wire, and an operator can execute corresponding operation by clicking a button of the software interface to obtain a required result.
Sweep a yard rifle, human-computer interaction's main device, it is connected to CPU industrial control integrated circuit board through the USB drive wire on, the operator can directly scan user information label and log in the operation, scans the engineering name and carries out instrument product test, convenient and fast just avoids the maloperation.
And the detected distributor is butted with the detection platform interface to realize the mapping connection of the detection platform and the detected distributor and finish the test task of the detected entity.
The detection platform is connected and communicated with the tested distributor, the detection platform connector is used for fixing a test interface of the tested distributor, and the tested distributor achieves testing by butting the detection platform connector interface; the instrument testing interface can be flexibly used for converting the packaging form of the plug of the tested distributor through the adapter cable, so that the packaging form of the connector of the tested distributor is matched with the interface of the detection platform.
The four-wire measuring method is characterized in that a CPU industrial control board card of a distributor comprehensive detection platform is automatically grouped and arranged to perform short circuit test by combining the control of a multi-channel matrix switch control board card (128-channel matrix switch) and a universal meter four-wire test board card with a four-wire measuring principle, so that fine resistance value changes can be accurately detected, and all possible welding problems (wrong welding, missing welding and rosin joint) can be analyzed and found out through the fine resistance value changes. As shown in fig. 2, (a) represents a correct connection, (b) represents a short circuit between the instrument connector terminal 3 and the terminal 4, (c) represents an open circuit between the instrument connector terminal 1 and the terminal 7, and (d) represents a misbonding between the instrument connector terminal 3 and the terminal 8.
The detection platform conduction measurement method is not only aimed at the measurement of test point positions in the established project, but also aims at the permutation and combination measurement among all the point positions of the connected connector, namely, if the conduction relation exists in the measurement of other point positions except the established project point positions, the measurement value of the measurement point position can be displayed, and the error report of the project test result is prompted.
The insulation inspection and measurement method has the advantages that the points which do not need to be measured can be closed before the insulation points of the built test project, manual setting errors are avoided, when the insulation test is executed, conduction measurement (without high voltage) among the set insulation points is carried out by default, and after the insulation resistance of each point meets the requirements, high-voltage insulation resistance inspection can be carried out, so that the tested product is further protected. The sequence script runs, different engineering arrangement time sequences are freely selected, continuous testing is carried out, manual calling is avoided, and one-time selection can be realized for memorizing.
The comprehensive detection platform for the power distributor can detect faults such as wrong lines, missing lines, welding errors and the like of the power distributor in advance, avoids damage to components caused by power-on test of products in a problem state, and can save a large amount of material labor cost every year according to the conventional fault frequency. Taking a certain production plant as an example: in the past, a single distributor (300 welding spots) manually detects about 2h x 30 yuan/h x 2 persons, and comprises the items of passage measurement, insulation, electricity resistance, accurate resistance measurement and the like.
The automatic detection of the whole item by using the comprehensive detection platform provided by the invention only needs 10 minutes, and the efficiency value is 24 times. The labor cost of each product is saved by 115 yuan. About 2000 production task instruments in 2018 and nearly 3000 production task instruments in 2019, and the accumulated economic benefit is about 55 ten thousand yuan. The maximum benefit is to reduce the quality problem management and production cost.
Claims (10)
1. A distributor integrated test platform, the test platform comprising: the system comprises a PXI bus backboard, a CPU industrial control board card, a matrix switch control board card, an insulation high-voltage board card, a universal meter four-wire test board card, a display screen and a code scanning gun, wherein the CPU industrial control board card is mutually connected and communicated with the display screen and the code scanning gun; the matrix switch control board card, universal meter four-wire test board card and testing platform interface interconnect and communication.
2. The comprehensive detection platform for the power distributor according to claim 1, wherein the PXI bus backplane adopts a customized 5-slot or 8-slot PXI structure, the CPU industrial control board, the matrix switch control board, the insulation high-voltage board and the universal meter four-wire test board are integrated on the customized backplane, and the PXI bus backplane provides high-speed bus working frequency and inter-board module communication protocols for each functional board, and coordinates system data communication and control logic in order.
3. The power distributor comprehensive testing platform according to any one of claims 1 or 2, wherein the CPU industrial control board is used for completing control of the insulating high-voltage board and the matrix switch control board, data acquisition of the multimeter four-wire test board, data acquisition of the code scanning gun and management of a control interface of the display screen.
4. A power distributor comprehensive test platform according to any one of claims 1 or 2, wherein the matrix switch control board is composed of a plurality of monolithic 128-channel matrix switches, and a mapping relationship between connector pins of the test platform interface and the power distributor node under test is established.
5. The power distributor comprehensive testing platform of claim 4, wherein the matrix switch control board card is composed of 5 or 8 monolithic 128-channel matrix switches.
6. The power distributor comprehensive detection platform according to claim 5, wherein the detection platform interface comprises an ITTDDR interface, the number of pin nodes of the ITTDDR interface is 156, the total number of pin nodes is 156, the first 128 pin nodes are respectively connected with 128 matrix relay switches, the static and dynamic states of the first 128 pin nodes are controlled by the 128 matrix relays, and the rest are free, so that the detection platform is convenient to expand.
7. The power distributor comprehensive testing platform according to claim 6, wherein the insulation testing high-voltage board is used for generating a direct-current voltage of 100V-1000V for insulation performance testing of instruments.
8. The power distributor comprehensive testing platform according to claim 7, wherein the multimeter four-wire test board is loaded between connector pins of the power distributor to be tested in real time to complete short circuit, open circuit and insulation tests on the instrument.
9. The power distributor comprehensive detection platform according to claim 8, wherein the display screen is connected to the CPU industrial control card through a USB drive wire and a video wire, respectively, and the code scanning gun is connected to the CPU industrial control card through a USB drive wire.
10. A testing method using the power distributor comprehensive testing platform as claimed in claims 1-9, wherein the testing platform is connected and communicates with the power distributor under test, the testing platform connector is used to fix the testing interface of the power distributor under test, and the power distributor under test is tested by butting the testing platform connector interface; the power distributor comprehensive detection platform CPU industrial control board card combines the four-wire measurement principle through the control to matrix switch control board card and universal meter four-wire test board card, and automatic grouping, permutation and combination carry out short circuit test, and minute resistance change is detected out to the accuracy, and then the analysis is made mistakes and is welded, is leaked and is welded the trouble.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112858952A (en) * | 2020-11-04 | 2021-05-28 | 昆明海威机电技术研究所(有限公司) | Rapid detection method for cable connectivity |
| CN113533949A (en) * | 2021-05-28 | 2021-10-22 | 中电科思仪科技股份有限公司 | Large-scale switch matrix rapid detection device and method |
| CN113534004A (en) * | 2021-06-23 | 2021-10-22 | 北京航天新立科技有限公司 | Automatic change distributor detecting system |
| CN113534003A (en) * | 2021-06-23 | 2021-10-22 | 北京航天新立科技有限公司 | Distributor testing method |
| CN115932667A (en) * | 2023-01-09 | 2023-04-07 | 广东氧迪力电气科技有限公司 | Electrical component wiring relation acquisition device and wiring relation detection method |
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| CN113534004A (en) * | 2021-06-23 | 2021-10-22 | 北京航天新立科技有限公司 | Automatic change distributor detecting system |
| CN113534003A (en) * | 2021-06-23 | 2021-10-22 | 北京航天新立科技有限公司 | Distributor testing method |
| CN115932667A (en) * | 2023-01-09 | 2023-04-07 | 广东氧迪力电气科技有限公司 | Electrical component wiring relation acquisition device and wiring relation detection method |
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Application publication date: 20201027 |