CN112630652A - Method for testing maximum current level of vehicle-mounted connector - Google Patents
Method for testing maximum current level of vehicle-mounted connector Download PDFInfo
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- 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
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
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Abstract
The invention provides a method for testing the maximum current level of a vehicle-mounted connector, which comprises the following steps: selecting a plurality of vehicle-mounted connectors, and determining the highest temperature position of the matching part of each vehicle-mounted connector; connecting the plurality of pretreated vehicle-mounted connectors with a power supply to form a series circuit; determining a group of step test currents according to the design current of the vehicle-mounted connector; sequentially conducting each test current for the series circuit, and acquiring the actual highest temperature of the matching part of each vehicle-mounted connector within a preset time by using a temperature measuring element; and determining the maximum current level of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of the lead, the design maximum temperature of the vehicle-mounted connector and the maximum temperature difference. According to the scheme, the influence of multiple factors on the maximum current grade is considered, so that the obtained maximum current grade is more accurate. Therefore, in the subsequent development and manufacturing process, the appropriate development part can be quickly and accurately selected through the maximum current level.
Description
Technical Field
The invention relates to the technical field of automobile electrical testing, in particular to a method for testing the maximum current level of a vehicle-mounted connector.
Background
The maximum current level refers to determining the maximum current when the automotive electrical connection system is operating under ambient conditions.
With the increasingly stringent technical requirements of automobile manufacturers or other host factories on electronic and electric appliances at home and abroad, higher requirements are provided for the evaluation of rated current. The accuracy of the maximum current of the electrical connection system under various environmental conditions is critical to subsequent manufacturing operations.
In the production and manufacturing process of the current automobile, the connector is frequently used for realizing the connection of each electrical component, and the maximum current of the connector is usually selected by adopting the design current provided by a connector manufacturer or the design current provided by an electrical component manufacturer. These design currents do not take into account the vehicle environment of the vehicle, and therefore the maximum current selection for the connector is not accurate.
Disclosure of Invention
The invention aims to solve the problem that the maximum current selection accuracy of a connector in the prior art is not high.
In order to solve the above problems, an embodiment of the present invention discloses a method for testing a maximum current level of a vehicle-mounted connector, including the following steps:
s1: selecting a plurality of vehicle-mounted connectors, determining the highest temperature position of the matching part of each vehicle-mounted connector, and preprocessing each vehicle-mounted connector, wherein the preprocessing comprises the step of connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector;
s2: connecting the plurality of preprocessed vehicle-mounted connectors in series, and forming a series circuit after connecting the plurality of vehicle-mounted connectors with a power supply;
s3: determining a group of step test currents according to the design current of the vehicle-mounted connector, wherein the group of step test currents comprises at least three test currents;
s4: sequentially conducting each test current for the series circuit, and acquiring the actual highest temperature of the matching part of each vehicle-mounted connector within a preset time by using a temperature measuring element;
s5: measuring the environment temperature corresponding to each test current, and respectively calculating the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the difference value of the highest temperatures under each test current, wherein the difference value of the highest temperatures is the difference value between the average value of the highest temperatures under each test current and the environment temperature;
s6: and determining the maximum current level of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of the lead, the design maximum temperature of the vehicle-mounted connector and the maximum temperature difference.
By adopting the scheme, the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the highest temperature difference under each test current are calculated, and then the maximum current grade of the vehicle-mounted connectors at each environmental temperature is determined according to the design current of the vehicle-mounted connectors, the design current of the lead, the design highest temperature of the vehicle-mounted connectors and the maximum temperature difference. The influence of the design current of the vehicle-mounted connector, the design current of the lead, the design highest temperature of the vehicle-mounted connector and the maximum temperature difference on the maximum current level is considered, so that the finally determined maximum current level is more accurate. In the subsequent development and manufacturing process, a developer can quickly and accurately select a proper development part through the maximum current level. The development efficiency is improved, and the development cost is reduced.
According to another specific embodiment of the invention, the testing method for the maximum current level of the vehicle-mounted connector disclosed by the embodiment of the invention is characterized in that the mating part is a combination part of a male end of the vehicle-mounted connector and a female end of the vehicle-mounted connector; in step S1, the step of acquiring the highest temperature position of the mating portion of the in-vehicle connector includes the steps of: selecting one vehicle-mounted connector from a plurality of vehicle-mounted connectors, and connecting a matching part of the vehicle-mounted connector with an external direct-current power supply through a lead to form a series circuit; the male end of the vehicle-mounted connector is connected with the anode of the external direct-current power supply, and the female end of the vehicle-mounted connector is connected with the cathode of the external direct-current power supply; and applying a preset voltage to the external direct current power supply, and adjusting the current of the series loop to determine the highest temperature position of the matching part of the vehicle-mounted connector.
According to another specific embodiment of the present invention, in the method for testing the maximum current level of the vehicle-mounted connector according to the embodiment of the present invention, in step S1, the preprocessing for each vehicle-mounted connector includes: welding pin headers at two ends of the wire, and welding enameled wires at welding spots at two ends of the wire; and connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector, wherein the temperature measuring element is arranged at the position of the pin header at the female end of the vehicle-mounted connector, and a temperature measuring probe of the temperature measuring element is arranged at the highest temperature position.
According to another specific embodiment of the present invention, in the method for testing the maximum current level of the vehicle-mounted connector disclosed in the embodiment of the present invention, the step S2 includes: connecting the preprocessed multiple vehicle-mounted connectors in a series connection mode to form a test loop; fixing a test loop in the test box body, and connecting a power supply to the test loop to form a series loop; and checking the validity of each vehicle-mounted connector and each temperature measuring element in the test loop.
By adopting the scheme, after the test loop is formed, the effectiveness of each vehicle-mounted connector and each temperature measuring element in the test loop is checked, so that the problem that the subsequent measurement and calculation accuracy is reduced due to the faults of the vehicle-mounted connectors and the temperature measuring elements can be solved.
According to another specific embodiment of the present invention, in the method for testing the maximum current level of the vehicle-mounted connector disclosed in the embodiment of the present invention, the step S3 includes: determining a group of step test currents according to a preset proportionality coefficient and a design current of the vehicle-mounted connector; the minimum value of the step test current in one group is not less than 5% of the design current of the vehicle-mounted connector; and the maximum value of the step test current is not more than 80% of the design current of the vehicle-mounted connector.
By adopting the scheme, the maximum value of the step test current is limited in 80% of the design current of the vehicle-mounted connector, and the vehicle-mounted connector can be protected from being damaged due to overlarge current.
According to another embodiment of the invention, the proportionality coefficient of the method for testing the maximum current level of the vehicle-mounted connector is in the range of 5% to 20%, and the interval proportionality coefficient of each test current in a group of step test currents is the same.
According to another specific embodiment of the invention, the method for testing the maximum current level of the vehicle-mounted connector disclosed by the embodiment of the invention divides the design current of the vehicle-mounted connector into a low current interval and a high current interval; in a low current interval, determining a plurality of first step test currents according to a preset first proportional coefficient; in a high current interval, determining a plurality of second step test currents according to a preset second proportionality coefficient; the first step test current and the second step test current form a group of step test currents; wherein the first and second scaling factors are both in the range of 5% to 20%; the range of the low current interval is 5% to 50% of the design current of the vehicle-mounted connector; the high current range is in the range of 50% to 80% of the design current of the vehicle-mounted connector.
According to another specific embodiment of the invention, in the method for testing the maximum current level of the vehicle-mounted connector disclosed by the embodiment of the invention, in the step S4, the preset time duration is 10 minutes to 20 minutes after the external direct-current power supply conducts each test current; wherein, the preset voltage range of the external direct current power supply is 10V to 20V.
By adopting the scheme, the preset time is set to be 10-20 minutes after the external direct-current power supply conducts each test current, the subsequent operation is carried out after the external direct-current power supply is electrified for a certain time and the temperature is stable, and the accuracy of measurement and calculation is improved.
According to another specific embodiment of the present invention, in the method for testing the maximum current level of the vehicle-mounted connector disclosed in the embodiment of the present invention, the step S6 includes:
obtaining safe current according to the design current of the vehicle-mounted connector and a preset safety coefficient; drawing a coordinate graph about the designed maximum temperature of the vehicle-mounted connector, the designed current of the lead and the safe current by taking the environmental temperature as an abscissa and the current grade as an ordinate; the design highest temperature of the vehicle-mounted connector, the design current of the lead and the overlapping part of the safety current are used as the maximum current levels under different environmental temperatures.
According to another embodiment of the invention, the preset safety factor ranges from 70% to 90% in the method for testing the maximum current level of the vehicle-mounted connector disclosed by the embodiment of the invention.
The invention has the beneficial effects that:
the invention provides a method for testing the maximum current grade of a vehicle-mounted connector, which comprises the steps of firstly calculating the average value of the maximum temperatures of a plurality of vehicle-mounted connectors under each test current and the maximum temperature difference under each test current, and then determining the maximum current grade of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of a lead, the design maximum temperature of the vehicle-mounted connector and the maximum temperature difference. The influence of the design current of the vehicle-mounted connector, the design current of the lead, the design highest temperature of the vehicle-mounted connector and the maximum temperature difference on the maximum current level is considered, so that the finally determined maximum current level is more accurate. In the subsequent development and manufacturing process, a developer can quickly and accurately select a proper development part through the maximum current level. The development efficiency is improved, and the development cost is reduced.
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FIG. 1 is a schematic flow chart illustrating a method for testing a maximum current level of an on-board connector according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of the mating portion connected to an external dc power supply through a wire according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a test loop provided in an embodiment of the present invention;
FIG. 4 is a table comparing the design current and the step test current of the vehicle connector according to the embodiment of the present invention;
FIG. 5 is a table for obtaining parameters of the mating portion of each vehicle-mounted connector at an actual maximum temperature for a preset duration according to an embodiment of the present invention;
FIG. 6 is a table showing the results of actual maximum temperature, ambient temperature, average maximum temperature, and difference maximum temperature of the mating portion of the vehicle-mounted connector for a predetermined period of time according to the embodiment of the present invention;
FIG. 7 is a table comparing results of a design current of the vehicle connector, a design current of the lead, a design maximum temperature of the vehicle connector, and a maximum temperature difference, according to an embodiment of the present invention;
FIG. 8 is a schematic diagram of maximum current levels at various ambient temperatures for a vehicle connector according to an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure. While the invention will be described in conjunction with the preferred embodiments, it is not intended that features of the invention be limited to these embodiments. On the contrary, the invention is described in connection with the embodiments for the purpose of covering alternatives or modifications that may be extended based on the claims of the present invention. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The invention may be practiced without these particulars. Moreover, some of the specific details have been left out of the description in order to avoid obscuring or obscuring the focus of the present invention. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
It should be noted that in this specification, like reference numerals and letters refer to like items in the following drawings, and thus, once an item is defined in one drawing, it need not be further defined and explained in subsequent drawings.
In the description of the present embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings or orientations or positional relationships that are conventionally placed when the products of the present invention are used, and are only used for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the devices or elements indicated must have specific orientations, be configured in specific orientations, and operate, and thus, should not be construed as limiting the present invention.
The terms "first," "second," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance.
In the description of the present embodiment, it should be further noted that, unless explicitly stated or limited otherwise, the terms "disposed," "connected," and "connected" are to be interpreted broadly, e.g., as a fixed connection, a detachable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present embodiment can be understood in specific cases by those of ordinary skill in the art.
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
In order to solve the problem that the maximum current selection accuracy of the connector in the prior art is not high, the embodiment of the invention discloses a method for testing the maximum current level of a vehicle-mounted connector. Specifically, referring to fig. 1, the method for testing the maximum current level of the vehicle-mounted connector disclosed by the embodiment of the invention comprises the following steps:
s1: selecting a plurality of vehicle-mounted connectors, determining the highest temperature position of the matching part of each vehicle-mounted connector, and preprocessing each vehicle-mounted connector, wherein the preprocessing comprises the step of connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector;
s2: connecting the plurality of preprocessed vehicle-mounted connectors in series, and forming a series circuit after connecting the plurality of vehicle-mounted connectors with a power supply;
s3: determining a group of step test currents according to the design current of the vehicle-mounted connector, wherein the group of step test currents comprises at least three test currents;
s4: sequentially conducting each test current for the series circuit, and acquiring the actual highest temperature of the matching part of each vehicle-mounted connector within a preset time by using a temperature measuring element;
s5: measuring the environment temperature corresponding to each test current, and respectively calculating the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the difference value of the highest temperatures under each test current, wherein the difference value of the highest temperatures is the difference value between the average value of the highest temperatures under each test current and the environment temperature;
s6: and determining the maximum current level of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of the lead, the design maximum temperature of the vehicle-mounted connector and the maximum temperature difference.
By adopting the scheme, the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the highest temperature difference under each test current are calculated, and then the maximum current grade of the vehicle-mounted connectors at each environmental temperature is determined according to the design current of the vehicle-mounted connectors, the design current of the lead, the design highest temperature of the vehicle-mounted connectors and the maximum temperature difference. The influence of the design current of the vehicle-mounted connector, the design current of the lead, the design highest temperature of the vehicle-mounted connector and the maximum temperature difference on the maximum current level is considered, so that the finally determined maximum current level is more accurate. In the subsequent development and manufacturing process, a developer can quickly and accurately select a proper development part through the maximum current level. The development efficiency is improved, and the development cost is reduced.
Next, a method for testing the maximum current level of the vehicle-mounted connector according to the embodiment of the present invention will be described in detail with reference to fig. 1 to 8.
First, step S1 is executed to select a plurality of in-vehicle connectors, determine the highest temperature position of the mating portion of each in-vehicle connector, and perform preprocessing for each in-vehicle connector.
The mating portion is a coupling portion between a male end of the in-vehicle connector and a female end of the in-vehicle connector.
Vehicle connectors, i.e. car connectors, are used for connecting connections between electrical devices, between electrical devices and circuit elements. And one vehicle-mounted connector comprises a male end and a female end, wherein the two ends are respectively connected with two pieces of electrical equipment, so that the two pieces of electrical equipment can be electrically connected.
Those skilled in the art can select the number of the vehicle-mounted connectors according to actual needs, which may be 10, 15, 20, etc., and this embodiment is not limited thereto. In the present embodiment, the number of the in-vehicle connectors is 10 as an example.
Specifically, referring to fig. 2, the step S1 of acquiring the highest temperature position of the mating portion of the vehicle-mounted connector includes the following steps: firstly, one vehicle-mounted connector is selected from a plurality of vehicle-mounted connectors, and the matching part of the vehicle-mounted connector is connected with an external direct current power supply through a lead to form a series circuit. And then, applying a preset voltage to the external direct-current power supply, and adjusting the current of the series loop to determine the highest temperature position of the matching part of the vehicle-mounted connector.
It should be noted that the male end of the vehicle-mounted connector is connected to the positive electrode of the external dc power supply, and the female end of the vehicle-mounted connector is connected to the negative electrode of the external dc power supply.
In this embodiment, the materials of the plurality of vehicle-mounted connectors are the same, and therefore the highest temperature position is also the same. In order to improve the efficiency, the embodiment only needs to select the highest temperature position of one vehicle-mounted connector.
In this embodiment, the male terminal and the female terminal are respectively connected to a wire, the wire is connected to an external dc power supply, voltage is input to the external dc power supply, a current is limited to the serial circuit, and then the highest temperature position can be observed and selected by using an instrument capable of measuring temperature, such as a thermal detector.
It should be noted that, a person skilled in the art can set the preset voltage applied to the external dc power supply and the current of the series circuit according to actual needs. In this embodiment, the case where a voltage of 14V is applied to an external dc power supply and the series circuits are each limited in current by 10A, 15A, and 20A will be described as an example.
Further, in step S1, the preprocessing for each vehicle-mounted connector includes: and the pin headers are welded at two ends of the wire, and enameled wires are welded at welding spots at two ends of the wire. And connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector.
It should be noted that the temperature measuring element is arranged at the position of the pin header at the female end of the vehicle-mounted connector, and the temperature measuring probe of the temperature measuring element is arranged at the highest temperature position.
The pin header is welded at two ends of the lead, and specifically, the pin header is welded at two ends of the lead. It should be noted that, during welding, the welding points at the two ends of the wires cannot prevent the matching of the male end and the female end, and the length of each female end wire is the same according to the test requirement.
It should be further noted that, in this embodiment, the temperature measuring element is a thermocouple. When the temperature measuring element is actually connected, the thermocouple probe is placed at the highest temperature position of the matching part, the thermocouple is plugged into the female-end pin header, the gap is filled with heat-conducting silica gel for fixation, and the thermocouple probe is placed at normal temperature for four hours to be dried.
In this embodiment, all the vehicle-mounted connectors need to be pretreated for connecting the temperature measuring elements.
Next, step S2 is executed to connect the plurality of preprocessed vehicle-mounted connectors in series, and to form a series circuit after connecting the plurality of vehicle-mounted connectors to a power supply.
Specifically, referring to fig. 3, step S2 specifically includes the following steps: first, a plurality of pre-processed on-board connectors are connected in series to form a test circuit. Then, the test loop is fixed inside the test box body, and a power supply is connected to the test loop to form a series loop. Then, the validity of each on-board connector and each temperature measuring element in the test circuit is checked.
In this embodiment, after the plurality of preprocessed vehicle-mounted connectors are connected in series, all the welding portions need to be provided with heat shrink tubes.
When the test loop is fixed in the test box body for testing, the interior of the test box body needs to ensure a windless environment. When the test loop is connected with a power supply, a current shunt can be arranged between the power supply and the vehicle-mounted connector.
The validity of each vehicle-mounted connector and each temperature measuring element in the test loop can be checked through a universal meter. And detecting the voltage and the current at two ends of the vehicle-mounted connector and the temperature measuring element to judge the effectiveness of the temperature measuring element and the vehicle-mounted connector.
In this embodiment, in the actual test, a thermocouple needs to be fixed at the middle position of the top end of the test box, and the distance between the thermocouple and the matching part of the vehicle-mounted connector is 50 mm.
Next, step S3 is executed to determine a set of step test currents according to the design current of the vehicle-mounted connector, where the set of step test currents includes at least three test currents.
That is, in the present embodiment, the number of test currents in the step test current may be three, five, six, or even more. This example will be described by taking 13 test currents as an example.
Specifically, step S3 includes: and determining a group of step test currents according to a preset proportionality coefficient and the design current of the vehicle-mounted connector.
It should be noted that the minimum value of the set of step test currents is not less than 5% of the design current of the vehicle-mounted connector. And the maximum value of the step test current is not more than 80% of the design current of the vehicle-mounted connector.
It should also be noted that the scaling factor is in the range of 5% to 20%, and the interval scaling factor for each test current in a set of stepped test currents is the same.
In this embodiment, the method for determining the step test current specifically includes: the design current of the vehicle-mounted connector is divided into a low current interval and a high current interval. In a low current interval, determining a plurality of first step test currents according to a preset first proportional coefficient; and in a high current interval, determining a plurality of second step test currents according to a preset second proportionality coefficient. The first step test current and the second step test current form a set of step test currents.
Preferably, the first and second scaling factors are both in the range of 5% to 20%; the range of the low current interval is 5% to 50% of the design current of the vehicle-mounted connector; the high current range is in the range of 50% to 80% of the design current of the vehicle-mounted connector.
In this embodiment, referring to fig. 4, the first proportionality coefficient is 5% and the second proportionality coefficient is 10%; the low current section is 50% of the design current of the in-vehicle connector, the high current section is in the range of 80% of the design current of the in-vehicle connector, and the design current of the in-vehicle connector is 25A. First, the design current of the vehicle-mounted connector is increased in 5% and the design current is increased in 5% intervals until the design current of the vehicle-mounted connector reaches 50%. And then sequentially increasing from 50% of the design current of the vehicle-mounted connector to 80% of the design current of the vehicle-mounted connector at intervals of 10%.
In fig. 4, the design current of a certain terminal is the design current of the vehicle-mounted connector, and the Basic current is the step test current.
Of course, in other embodiments of the present invention, those skilled in the art may start from 5% of the design current of the vehicle connector and increase the design current of the vehicle connector by 5% in turn until 80% of the design current of the vehicle connector is achieved. Of course, the design current of the vehicle-mounted connector can be increased by 10% and then sequentially increased by 10% intervals until the design current of the vehicle-mounted connector reaches 90%, and no creative labor is needed.
It should be noted that, in the present embodiment, when determining the step test current, the design current of the in-vehicle connector needs to be obtained from the specification of the design manufacturer or the product. The design current of the in-vehicle connector is a maximum current value that the in-vehicle connector can withstand when shipped.
Next, step S4 is executed to sequentially conduct each test current for the series circuit, and obtain the actual maximum temperature of the mating portion of each vehicle-mounted connector for a preset time period by using the temperature measuring element.
Preferably, the preset time period is 10 minutes to 20 minutes after the external direct-current power supply conducts each test current. The specific preset time period may be 10 minutes, 12.5 minutes, 15 minutes, 17.5 minutes, 20 minutes or other values within the range, and can be set by those skilled in the art according to actual needs.
And the preset voltage range of the external direct current power supply is 10V to 20V. The specific preset voltage of the external dc power supply may be 10V, 12.5V, 15V, 17.5V, 20V or other values within this range, and those skilled in the art can set the preset voltage according to actual needs.
Referring to fig. 5, in this embodiment, when a specific operation is performed, the preset time period is set to 900S, that is, 15 minutes, the preset voltage of the external dc power supply is 14V, and the current is set as the step test current obtained in step S3.
It should be noted that, the cycle in fig. 5 refers to setting and measuring each vehicle-mounted connector respectively; the numbers 1 to 13 indicate that the number of step test currents is 13. Time is a preset duration, Voltage is a preset Voltage of an external direct-current power supply, current is a specific current value of test current, Output is Output, OVP is overvoltage protection (Voltage), and OCP is overcurrent protection (current).
Next, step S5 is executed to measure the ambient temperature corresponding to each test current, and calculate the average of the maximum temperatures of the plurality of vehicle-mounted connectors at each test current and the maximum temperature difference at each test current.
The maximum temperature difference is a difference between the average of the maximum temperatures at the respective test currents and the ambient temperature.
Referring to fig. 6, Ambient temperature at each test current is Ambient.
In fig. 6, current application is the current value of the test current; the temperature is the ambient temperature.
31# to 40# refer to the highest temperature of each in-vehicle connector at each test current. Of these, 31# to 40# represent 10 connectors in the present embodiment, respectively.
Ave is the average value of the highest temperature of the connectors from 31# to 40 #.
The difference delta of the Ambient temperature is the difference between the Ambient and the Ave.
Next, step S6 is executed to determine the maximum current level of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of the lead, the design maximum temperature of the vehicle-mounted connector, and the maximum temperature difference.
Specifically, step S6 includes the steps of: firstly, the safety current is obtained according to the design current of the vehicle-mounted connector and a preset safety factor. Then, a coordinate diagram of the maximum design temperature of the vehicle-mounted connector, the design current of the lead, and the safety current is plotted with the ambient temperature as an abscissa and the current level as an ordinate. Then, the overlapping portion of the design maximum temperature of the vehicle-mounted connector, the design current of the lead, and the safety current is set as the maximum current level at different environmental temperatures.
Preferably, in the present embodiment, the preset safety factor ranges from 70% to 90%. Specifically, the safety factor may be 70%, 75%, 80%, 85%, 90%, or other values within this range, and those skilled in the art can select the safety factor according to actual needs, and this embodiment is described with the safety factor of 80% as an example.
In this embodiment, the designed maximum temperature of the vehicle-mounted connector is the maximum temperature that the vehicle-mounted connector can withstand when it is shipped from the factory. Which can be obtained by querying the product specification.
The designed current of the wire refers to the maximum current that the wire used can bear when the connector is actually used in an automobile.
In this embodiment, the step test current, the safety currents corresponding to the step test current, the difference between the ambient temperatures, the maximum design temperature of the vehicle-mounted connector, the design current of the lead, and the ambient temperature are output to obtain a table as shown in fig. 7, and then a drawing is performed according to the table to obtain a coordinate graph as shown in fig. 8.
In fig. 7, Basic current is a current value of the test current, and 80% Basic current is a current value of the safety current; limitation is the designed maximum Temperature of the vehicle-mounted connector, Cable Current Capability is the designed Current of the lead, and Ambient Temperature is the Ambient Temperature.
Specifically, the overlapping portion of the design maximum temperature of the vehicle-mounted connector, the design current of the lead, and the safety current serves as the maximum current level at different ambient temperatures.
By adopting the scheme, the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the highest temperature difference under each test current are calculated, and then the maximum current grade of the vehicle-mounted connectors at each environmental temperature is determined according to the design current of the vehicle-mounted connectors, the design current of the lead, the design highest temperature of the vehicle-mounted connectors and the maximum temperature difference. The influence of the design current of the vehicle-mounted connector, the design current of the lead, the design highest temperature of the vehicle-mounted connector and the maximum temperature difference on the maximum current level is considered, so that the finally determined maximum current level is more accurate. In the subsequent development and manufacturing process, a developer can quickly and accurately select a proper development part through the maximum current level. The development efficiency is improved, and the development cost is reduced.
While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing is a more detailed description of the invention, taken in conjunction with the specific embodiments thereof, and that no limitation of the invention is intended thereby. Various changes in form and detail, including simple deductions or substitutions, may be made by those skilled in the art without departing from the spirit and scope of the invention.
Claims (10)
1. A method for testing the maximum current level of vehicle-mounted connectors is disclosed, wherein each vehicle-mounted connector comprises a matching part; the method is characterized by comprising the following steps:
s1: selecting a plurality of vehicle-mounted connectors, determining the highest temperature position of the matching part of each vehicle-mounted connector, and preprocessing each vehicle-mounted connector, wherein the preprocessing comprises the step of connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector;
s2: connecting the plurality of preprocessed vehicle-mounted connectors in series, and forming a series circuit after connecting the plurality of vehicle-mounted connectors with a power supply;
s3: determining a group of step test currents according to the design current of the vehicle-mounted connector, wherein the group of step test currents comprises at least three test currents;
s4: sequentially conducting each test current for the series circuit, and acquiring the actual highest temperature of the matching part of each vehicle-mounted connector within a preset time by using the temperature measuring element;
s5: measuring the environment temperature corresponding to each test current, and respectively calculating the average value of the highest temperatures of the plurality of vehicle-mounted connectors under each test current and the difference value of the highest temperatures under each test current, wherein the difference value of the highest temperatures is the difference value between the average value of the highest temperatures under each test current and the environment temperature;
s6: and determining the maximum current grade of the vehicle-mounted connector at each environmental temperature according to the design current of the vehicle-mounted connector, the design current of the lead, the design maximum temperature of the vehicle-mounted connector and the maximum temperature difference.
2. The method for testing the maximum current rating of a vehicle-mounted connector according to claim 1, wherein the mating portion is a joint portion of a male end of the vehicle-mounted connector and a female end of the vehicle-mounted connector; and the number of the first and second electrodes,
in step S1, the step of obtaining the highest temperature position of the mating portion of the vehicle-mounted connector includes:
selecting one vehicle-mounted connector from a plurality of vehicle-mounted connectors, and connecting a matching part of the vehicle-mounted connector with an external direct-current power supply through a lead to form a series circuit; the male end of the vehicle-mounted connector is connected with the positive electrode of the external direct-current power supply, and the female end of the vehicle-mounted connector is connected with the negative electrode of the external direct-current power supply; and
and applying a preset voltage to the external direct-current power supply, and adjusting the current of the series loop to determine the highest temperature position of the matching part of the vehicle-mounted connector.
3. The method for testing the maximum current level of the vehicle-mounted connector according to claim 2, wherein in the step S1, the preprocessing of each vehicle-mounted connector comprises:
the pin header is welded at two ends of the lead, and enameled wires are welded at welding spots at two ends of the lead; and
and connecting a temperature measuring element at the highest temperature position of the matching part of each vehicle-mounted connector, wherein the temperature measuring element is arranged at the position of the pin header at the female end of the vehicle-mounted connector, and the temperature measuring probe of the temperature measuring element is arranged at the highest temperature position.
4. The method for testing the maximum current level of the vehicle-mounted connector according to claim 3, wherein the step S2 comprises:
connecting the preprocessed vehicle-mounted connectors in a series connection mode to form a test loop;
fixing the test loop in a test box body, and connecting the test loop with the power supply to form a series loop; and
and checking the validity of each vehicle-mounted connector and each temperature measuring element in the test loop.
5. The method for testing the maximum current level of the vehicle-mounted connector according to claim 4, wherein the step S3 includes:
determining a group of step test currents according to a preset proportionality coefficient and the design current of the vehicle-mounted connector; wherein
The minimum value of the group of step test currents is not less than 5% of the design current of the vehicle-mounted connector; and is
The maximum value of the group of step test currents is not more than 80% of the design current of the vehicle-mounted connector.
6. The method for testing the maximum current rating of a vehicle-mounted connector according to claim 5,
the scaling factor is in the range of 5% to 20%, and the interval scaling factor of each test current in the set of stepped test currents is the same.
7. The method for testing the maximum current rating of a vehicle-mounted connector according to claim 6,
dividing the design current of the vehicle-mounted connector into a low current interval and a high current interval; and is
In the low current interval, determining a plurality of first step test currents according to a preset first proportional coefficient;
in the high current interval, determining a plurality of second gradient test currents according to a preset second proportionality coefficient;
the first step test current and the second step test current constitute the set of step test currents; wherein
The first and second scaling factors are both in the range of 5% to 20%; and is
The range of the low current interval is 5% to 50% of the design current of the vehicle-mounted connector;
the high current interval ranges from 50% to 80% of the design current of the vehicle-mounted connector.
8. The method for testing the maximum current level of the vehicle-mounted connector according to claim 7, wherein in the step S4, the preset time period is 10 minutes to 20 minutes after the external dc power supply conducts each test current;
the preset voltage range of the external direct current power supply is 10V to 20V.
9. The method for testing the maximum current level of the vehicle-mounted connector according to claim 8, wherein the step S6 includes:
obtaining safe current according to the design current of the vehicle-mounted connector and a preset safety factor;
drawing a coordinate graph about the designed maximum temperature of the vehicle-mounted connector, the designed current of the lead and the safe current by taking the ambient temperature as an abscissa and the current grade as an ordinate;
and taking the design highest temperature of the vehicle-mounted connector, the design current of the lead and the overlapping part of the safety current as maximum current levels at different environmental temperatures.
10. The method for testing the maximum current level of the vehicle-mounted connector according to claim 9, wherein the preset safety factor ranges from 70% to 90%.
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| CN202011378657.3A CN112630652A (en) | 2020-11-30 | 2020-11-30 | Method for testing maximum current level of vehicle-mounted connector |
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