CN109581244B - High-power portable noninductive load box - Google Patents
High-power portable noninductive load box Download PDFInfo
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- CN109581244B CN109581244B CN201811249221.7A CN201811249221A CN109581244B CN 109581244 B CN109581244 B CN 109581244B CN 201811249221 A CN201811249221 A CN 201811249221A CN 109581244 B CN109581244 B CN 109581244B
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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
- G01R31/40—Testing power supplies
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Abstract
The invention relates to a high-power portable non-inductive load box, and belongs to the technical field of power supply testing. The novel inductive power resistor comprises a front panel and a radiator, a printed circuit board assembly and an noninductive power resistor unit are arranged between the front panel and the radiator, a left handle and a right handle are arranged on two sides of the noninductive power resistor unit, one side of the noninductive power resistor unit is fixedly connected with the back of the radiator, a pin of the noninductive power resistor in the noninductive power resistor unit is electrically connected with the printed circuit board assembly, a jack is formed in the front panel, a load output terminal and a branch resistance reference point terminal are inserted in the jack, the load output terminal is electrically connected with the printed circuit board assembly, an upper cover plate and a lower cover plate are arranged between the left handle and. A high-power portable noninductive load box has the characteristics of being passive, noninductive, nonpolar, high-power, portable and the like, can safely work in the on-load characteristic detection of a non-isolated switch power supply, and can be widely applied to occasions such as conducted noise tests of various power supplies.
Description
Technical Field
The invention relates to a high-power portable non-inductive load box, which is used for index testing and other work when a low-frequency source is loaded and belongs to the technical field of technical power supply testing.
Background
With testing power supply performance, the load is one of the indispensable instruments. The power supply load can not be disconnected no matter the test of the source effect, the load effect, the power supply working efficiency and the like. There are various types of loads that can be used in testing, the most common being the electronic load type. The electronic load has various working modes, the output load value is continuously adjustable, the weight is light, the carrying is convenient, and the electronic load has a plurality of advantages. But the disadvantage is also obvious, firstly the load should be passive, but the electronic load is active and needs the external network voltage to supply power to work; the load should be non-polar, but the electronic load is polar; the impedance of the load is determined over a range of frequencies, but the electronic load is not determined.
An electronic load is a device that consumes electric power by controlling internal power or the amount of conduction of a transistor depending on the dissipation power of a power transistor. Meanwhile, the short circuit of the load can be simulated, and the inductive property, the capacitive property and the resistive property of the load can be simulated.
Generally, a load having a voltage hysteresis current characteristic is called a capacitive load, and a voltage cannot be abruptly changed during charging and discharging. Which corresponds to a negative power factor. In the high frequency domain, the imaginary part of the load is negative. The power factor of the inductive load is positive. Theoretically, a pure resistance circuit, a pure capacitance circuit and a pure inductance circuit do not exist in the full frequency domain range.
Another load that is more commonly used is a varistor, which can be used in more situations because of its passive and non-polar nature, but has the disadvantage that its inductance is large and significant, which affects the measurement result.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a high-power portable non-inductive load box aiming at the prior art, which has the characteristics of being passive, non-inductive, non-polar, high-power, portable and the like, can safely work on the load characteristic detection of a non-isolated switch power supply, can be widely applied to the occasions of conducting noise tests and the like of various power supplies, and can also be used as a pure resistive load of a low-frequency power supply.
The technical scheme adopted by the invention for solving the problems is as follows: a high-power portable non-inductive load box comprises a front panel, a radiator, a non-inductive power resistance unit and a printed circuit board component, an inner cavity is formed between the front panel and the radiator back panel, a printed circuit board assembly and a non-inductive power resistance unit are arranged in the cavity from front to back, a left handle and a right handle are fixedly arranged at two sides of the non-inductive power resistance unit, one side of the non-inductive power resistance unit is fixedly connected with the back plate of the radiator, the pins of the non-inductive power resistor in the non-inductive power resistor unit are electrically connected with the printed circuit board component, jacks arranged at equal intervals are arranged on the front panel, a load output binding post and a branch resistance reference point binding post are correspondingly inserted into the jacks one by one, the load output binding post is electrically connected with the printed circuit board assembly, an upper cover plate and a lower cover plate are arranged between the left handle and the right handle, and the upper cover plate and the lower cover plate are fixedly connected with the non-inductive power resistance unit.
Noninductive power resistance unit includes noninductive power resistance and many heat conduction strip, many heat conduction strip equidistant evenly distributed and both ends align respectively and set up, heat conduction strip arranges many perpendicularly with the load output terminal heat conduction strip both ends are fixed respectively and are equipped with the location strip, noninductive power resistance is evenly fixed respectively to heat conduction strip upper and lower surface, is close to the heat conduction strip side of printed wiring board subassembly one side sets up adiabatic support bar, heat conduction strip and radiator fixed connection.
The printed circuit board assembly comprises a first printed circuit board and a plurality of second printed circuit boards, wherein the first printed circuit board conductors are not connected in the middle, a plurality of non-inductive power resistors are connected in series, the second printed circuit board conductors are connected in the middle through a high-current connecting wire, the plurality of non-inductive power resistors are connected in parallel and then connected in series, holes for penetrating through the load output binding post are formed in the first printed circuit board and the second printed circuit board respectively, and copper is coated on the printed circuit board assembly and used for electrically connecting the load output binding post and the printed circuit board assembly.
A plurality of first supporting strips are arranged between the front panel and the printed circuit board assembly, a plurality of clamping grooves are formed in the first supporting strips, the number of the clamping grooves corresponds to the number of the vertically arranged load output wiring posts, and the clamping grooves are clamped at the bottoms of the load output wiring posts.
The number of the heat conducting strips is 12, and a part of the heat conducting strips are fixedly provided with heat insulation supporting strips, so that the heat conducting strips play a supporting role in the structure installation process and are convenient to install.
The left handle and the right handle are respectively provided with a heat dissipation hole.
91 jacks on the front panel are arranged, 7 rows are longitudinally arranged, 13 rows are transversely arranged, jacks corresponding to the branch resistance reference point binding posts are located at the bottom of the front panel, the number of the jacks is 6, and the rest jacks corresponding to the load output binding posts are arranged.
And heat-conducting silicone grease is respectively coated between the noninductive power resistor and the heat-conducting strip and on the contact surface of the heat-conducting strip and the radiator, so that the heat transfer effect is improved.
The radiator adopts the aluminium material to make the piece, the heat conduction strip adopts red copper material to make the piece.
The pins of the non-inductive power resistor are provided with two bends in opposite directions, and the single bend angle is 135 degrees.
Compared with the prior art, the invention has the advantages that: a high-power portable noninductive load box, the impedance magnitude of every branch road of the load is fixed, its impedance mainly depends on the frequency characteristic of the power component selected, choose the noninductive power component to make rationally, can make the noninductive load box of different characteristics; the device has the characteristics of being passive, non-polar, high in power, small in inductance introduced by electric connection in the box body and the like, can safely work in the on-load characteristic detection of a non-isolated switch power supply, can be widely applied to occasions such as conducted noise tests of various power supplies and the like, can also be used as a pure resistive load of a low-frequency power supply, and effectively avoids the problem of interference components introduced by the load in the small-signal test process.
Drawings
FIG. 1 is a schematic diagram of the overall external structure of a high-power portable noninductive load box according to an embodiment of the present invention;
FIG. 2 is a side view of a high power portable noninductive load box according to an embodiment of the present invention;
FIG. 3 is an exploded view of the components of a high power portable noninductive load box according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a printed circuit board assembly of a high power portable non-inductive load box according to an embodiment of the present invention;
FIG. 5 is a diagram of the connection of a printed circuit board assembly with non-inductive power resistors, heat conducting strips and load output terminals in a high power portable non-inductive load box according to an embodiment of the present invention;
FIG. 6 is a view of the connection of FIG. 5 with the thermal strip removed;
FIG. 7 is a block diagram of the non-inductive power resistor, the heat conducting bars, the positioning bars and the insulating support bars in the high-power portable non-inductive load box according to the embodiment of the invention;
FIG. 8 is a three-dimensional view of FIG. 7;
FIG. 9 is a side view of a high power portable noninductive load box with one side handle removed according to an embodiment of the present invention;
FIG. 10 is a top view of a non-inductive power resistor, insulating support bars, load output terminals and printed wiring board assembly in a high power portable non-inductive load box according to an embodiment of the present invention;
FIG. 11 is a three-dimensional view of the structure of the non-inductive power resistor, the heat conducting strip and the positioning strip in the high-power portable non-inductive load box according to the embodiment of the invention;
FIG. 12 is a partial three-dimensional view of a high power portable noninductive load box with a heat sink removed according to an embodiment of the present invention;
fig. 13 is a graph of a derating curve of a non-inductive power resistor selected in a high-power portable non-inductive load box according to an embodiment of the present invention;
in the figure, a front panel 1, a handle 2, a radiator 3, a load output terminal 4, a resistance reference point terminal 5 branch circuits, a cover plate 6, a printed circuit board assembly 7, a non-inductive power resistance unit 8, a first supporting strip 9, a second printed circuit board 10, a non-inductive power resistance 11, a heat conducting strip 12, a positioning strip 13, a heat insulating supporting strip 14, a first printed circuit board 15, copper 16, a heat dissipation hole 17, a pin 18 and a high-current connecting wire 19 are arranged.
Detailed Description
The invention is described in further detail below with reference to the accompanying examples.
As shown in fig. 1, the high-power portable non-inductive load box in this embodiment includes a front panel 1, a heat sink 3, a non-inductive power resistance unit 8 and a printed circuit board assembly 7, an internal cavity is formed between the front panel 1 and a back plate of the heat sink 3, the printed circuit board assembly 7 and the non-inductive power resistance unit 8 are arranged in the cavity from front to back, two sides of the non-inductive power resistance unit 8 are fixedly connected with left and right handles 2 through screws, one side of the non-inductive power resistance unit 8 is fixedly connected with the back plate of the heat sink 3 through screws, pins 18 of a non-inductive power resistance 11 of the non-inductive power resistance unit 8 are electrically connected with the printed circuit board assembly 7, jacks arranged at equal intervals are arranged on the front panel 1, 7 rows are longitudinally arranged, 13 rows are transversely arranged, 6 branch resistance reference point terminals 5 are inserted into the jacks at the bottom of the front panel 1, and load output terminals 4, all load output binding posts 4 are electrically connected with a printed circuit board assembly 7, upper and lower cover plates 6 are arranged at the upper and lower ends between the left and right handles 2, and the upper and lower cover plates 6 are fixedly connected with a non-inductive power resistance unit 8 through screws to form a box body.
The non-inductive power resistance unit 8 comprises non-inductive power resistors 11 and 12 heat conducting strips 12 horizontally placed, 12 heat conducting strips 12 are uniformly distributed at equal intervals from top to bottom, the heat conducting strips 12 are vertically arranged with the load output binding post 4, two ends of 12 heat conducting strips are aligned, two ends of 12 heat conducting strips are respectively fixed with the positioning strips 13 through the positioning screws, the upper surface and the lower surface of each heat conducting strip 12 are respectively connected with the non-inductive power resistors 11 and the heat conducting strips 12 through fastening screws, and the side surfaces of the heat conducting strips 12 close to one side of the printed circuit board assembly 7 are provided with the heat insulation supporting strips 14 according to proper positions, so that the non-inductive power resistor unit plays a supporting role in the structural installation process and. The heat conducting strips 12 are fixedly connected with the radiator 3 through screws, and the mounting screws of the heat conducting strips 12 with the heat insulation supporting strips 14 are 10mm longer than the mounting screws of the heat conducting strips without the heat insulation supporting strips.
The printed circuit board assembly 7 comprises a first printed circuit board 15 and 11 second printed circuit boards 10, the middle of the first printed circuit board 15 conductor is not connected, a plurality of non-inductive power resistors 11 are connected in series, the middle of the second printed circuit board 10 conductor is connected through a large-current connecting wire 17, a plurality of non-inductive power resistors 11 are connected in parallel and then connected in series, holes used for penetrating through the load output wiring terminal 4 are formed in the first printed circuit board 15 and the second printed circuit board 10 respectively, copper 16 is coated on the printed circuit board assembly 7, the load output wiring terminal 4 is directly connected with the copper 16 coated on the printed circuit board assembly 7 through a stud and a nut, and the output function of the load resistance value is completed. The pin 18 of the non-inductive power resistor 11 and the large-current connecting lead 17 connected between the printed circuit boards are welded on a copper-coated pad of the printed circuit board 17 through soldering tin, so that the lead inductance between the non-inductive power resistor 11 and the load output binding post 4 is reduced to the maximum extent.
7 first supporting strips 9 are arranged between the front panel 1 and the printed circuit board assembly 7, 13 clamping grooves are formed in the vertical direction of the first supporting strips 9, and the clamping grooves are clamped at the bottom of the load output binding post 4 and fixed through nuts.
The left handle 2 and the right handle 2 are respectively provided with the heat dissipation holes 17, so that the change of the resistance value of the noninductive power resistor can be reduced through good heat dissipation, and stable load impedance is provided.
And heat-conducting silicone grease is respectively coated between the non-inductive power resistor 11 and the heat-conducting strip 12 and on the contact surface of the heat-conducting strip 12 and the radiator 3, so that the heat transfer effect is improved.
The radiator 3 is made of aluminum materials, the heat conducting strip 12 is made of red copper materials, and the characteristics of different specific heat capacities of aluminum materials and copper materials are utilized to combine and apply the heat conduction of the red copper materials and the heat dissipation of the large surface area of the aluminum materials, so that the non-inductive power resistor 11 obtains the best heat conduction and heat dissipation effect, and the working stability and reliability of the load box are enhanced.
The pins 18 of the non-inductive power resistor 11 are provided with two bends in opposite directions, and the single bend angle is 135 degrees, so that the stress on the copper-clad 16 of the circuit board when the non-inductive power resistor 11 is overheated is reduced.
The invention utilizes a 1 ohm high-power non-inductive power resistor 11 of a TO-220 packaging structure, wherein a front panel 1 is provided with 85 load output binding posts 4 and 6 branch resistor reference point binding posts 5 which are vertically distributed TO form 7 mutually independent load resistor series branches, the side of the branch resistor reference point binding post 5 is marked with a numeral 0, the numeral in the branch close TO the load output binding post 4 relative TO the reference point is the resistance value between the load output binding post 4 and the branch resistor reference point binding post 5, and the connecting line between the adjacent binding posts is the connecting mode of the branch resistors. The number marked on the lowest part of each branch is the designed nominal value of the maximum working current of the branch. See table 1:
TABLE 1 noninductive load box branch line working current design
In order to ensure the heat dissipation effect of the non-inductive load box, the working current of the branch is strictly limited, so that the load box can work stably and reliably. For example, in the branch 6, 6 resistors of 50 watts and 1 ohm are connected in parallel between adjacent load output connection posts, and the resistors after parallel connection are as follows:
in the formula: r1＝R2＝R3＝R4＝R5＝R6＝1Ω
The total resistance is then:
the total power of 6 resistors of 50 watts is: p is 6 × 50W is 300W
The rated current is:
as seen by the quota curve: when the temperature of the non-inductive load box does not exceed 75 ℃, the power of the non-inductive power resistor 11 can be applied to 60 percent of the total power. 60% of 300 watts is 180 watts, the current is:
the maximum operating current of the branch is taken as 20A in consideration of the capacity of the load output terminal 4 itself when operating for a long time. The maximum working current of each other branch circuit is respectively as follows: 17A, 14A, 10A, 7A and 5A, as shown in table 1. The two branches of the 5A branch are designed, and after the two branches are short-circuited by the 12 omega wiring terminal through the short lead, the maximum resistance value of the 5A branch can be increased from 12 omega to 24 omega, so that a light load is provided for a measured source.
Wherein, two 5A branches are composed of the first printed circuit board 15; the 7A branch is formed by a second printed wiring board 10; the 10A branch circuit is composed of two second printed circuit boards 10, the printed circuit boards are electrically connected by a row of large-current connecting leads 19, and only one row of non-inductive power resistors 11 is welded on one second printed circuit board 10; the 14A branch is composed of two second printed circuit boards 10, the second printed circuit boards 10 are electrically connected by a large-current connecting lead 19, and noninductive power resistors 11 are fully distributed on the second printed circuit boards; the 17A branch consists of three second printed circuit boards 10, the second printed circuit boards 10 are electrically connected by two rows of large-current connecting wires 19, and only one row of noninductive power resistors 11 are welded on one second printed circuit board 10; the 20A branch is composed of three second printed circuit boards 10, the second printed circuit boards 10 are electrically connected by two rows of large-current connecting wires 19, and the non-inductive power resistors 11 are fully distributed on the printed circuit boards.
The loads of 7 different power branches are formed by series-parallel connection combination, and the maximum rated working current of each branch is regulated according to a derating curve. According to the principle of stable operation and low inductance introduction, the heat dissipation scheme and the electric connection method among the resistors are repeatedly planned, and the characteristics of different specific heat capacities of the aluminum material and the copper material are utilized to combine and apply the heat conduction of the red copper material and the heat dissipation of the large surface area of the aluminum material, so that the power resistor obtains the optimal heat conduction and heat dissipation effect, and the stability and the reliability of the operation of the load box are enhanced. In the resistance value leading-out method, a long lead is forbidden to be used, the two pins 18 of the non-inductive power resistor 11 are directly combined with the output terminal of the load box by using the printed circuit board, and the whole structure is similar to a U-shaped electric connection structure, so that the inductance value introduced by an external circuit is reduced to the maximum extent. The red copper heat conduction strips 12 are designed to be perpendicular to each output branch of the load, each single non-inductive power resistor 11 in each branch only occupies one red copper heat conduction strip 12, the red copper heat conduction strips 12 as many as possible are guaranteed to participate in heat conduction application of the branch resistors during load working, and heat conduction and heat dissipation effects of the non-inductive load box are achieved. The power design is given according to the derating value when the temperature rise of the load resistor does not exceed 80 ℃ in use, and a derating curve graph is shown, so that the load box is ensured to work safely and accurately under the specified current.
In addition to the above embodiments, the present invention also includes other embodiments, and any technical solutions formed by equivalent transformation or equivalent replacement should fall within the scope of the claims of the present invention.
Claims (9)
1. The utility model provides a high-power portable noninductive load box which characterized in that: the novel solar cell module comprises a front panel (1) and a radiator (3), an inner cavity is formed between the front panel (1) and a radiator (3) backboard, a printed circuit board assembly (7) and a non-inductive power resistance unit (8) are arranged in the cavity from front to back, left and right handles (2) are fixedly arranged on two sides of the non-inductive power resistance unit (7), one side of the non-inductive power resistance unit (8) is fixedly connected with the radiator (3) backboard, pins (18) of a non-inductive power resistor (11) in the non-inductive power resistance unit (8) are electrically connected with the printed circuit board assembly (7), jacks which are arranged at equal intervals are formed in the front panel (1), load output binding posts (4) and branch resistance reference points binding posts (5) are correspondingly inserted in the jacks one by one, and the load output binding posts (4) are electrically connected with the printed circuit board assembly (7), an upper cover plate and a lower cover plate (6) are arranged between the left handle and the right handle (2), and the upper cover plate and the lower cover plate (6) are fixedly connected with a non-inductive power resistance unit (8);
noninductive power resistance unit (8) are including noninductive power resistance (11) and many heat conduction strip (12), many heat conduction strip (12) equidistant evenly distributed and both ends align the setting respectively, heat conduction strip (12) are arranged perpendicularly with load output terminal (4), many heat conduction strip (12) both ends are fixed respectively and are equipped with location strip (13), noninductive power resistance (11) are evenly fixed respectively to the surface about heat conduction strip (12), are close to heat conduction strip (12) side of printed wiring board subassembly (7) one side sets up adiabatic support bar (14), heat conduction strip (12) and radiator (3) fixed connection.
2. The high power portable noninductive load box of claim 1, wherein: the printed circuit board assembly (7) comprises a first printed circuit board (15) and a plurality of second printed circuit boards (10), the conductors of the first printed circuit board (15) are not connected in the middle, a plurality of non-inductive power resistors (11) are connected in series, the conductors of the second printed circuit board (10) are connected through a large-current connecting wire (19), the non-inductive power resistors (11) are connected in series after being connected in parallel, holes for penetrating through a load output binding post (4) are formed in the first printed circuit board (15) and the second printed circuit board (10) respectively, and copper (16) is covered on the printed circuit board assembly (7) and used for electrically connecting the load output binding post (4) and the printed circuit board assembly (7).
3. The high power portable noninductive load box of claim 1, wherein: a plurality of first supporting strips (9) are arranged between the front panel (1) and the printed circuit board assembly (7), a plurality of clamping grooves are formed in the first supporting strips (9), the number of the clamping grooves corresponds to that of the vertically arranged load output binding posts (4), and the clamping grooves are clamped at the bottom of the load output binding posts (4).
4. The high power portable noninductive load box of claim 1, wherein: the number of the heat conduction strips (12) is 12, wherein a part of the heat conduction strips (12) are fixedly provided with heat insulation support strips (14), so that the heat conduction strips play a supporting role in the structure installation process and are convenient to install.
5. The high power portable noninductive load box of claim 1, wherein: the left handle (6) and the right handle (6) are respectively provided with a heat dissipation hole (17).
6. The high power portable noninductive load box of claim 1, wherein: 91 jacks on the front panel (11) are formed, jacks corresponding to the branch resistance reference point binding posts (11) are located at the bottom of the front panel (11), the number of the jacks is 6, and the rest jacks corresponding to the load output binding posts (4) are formed.
7. The high power portable noninductive load box of claim 1, wherein: and heat-conducting silicone grease is respectively coated between the noninductive power resistor (11) and the heat-conducting strip (12) and on the contact surface of the heat-conducting strip (12) and the radiator (3), so that the heat transfer effect is improved.
8. The high power portable noninductive load box of claim 1, wherein: the radiator (3) is made of aluminum, and the heat conducting strip (12) is made of red copper.
9. The high power portable noninductive load box of claim 1, wherein: the pins (18) of the non-inductive power resistor (11) are provided with two bends in opposite directions, and the single bend angle is 135 degrees.
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| CN201811249221.7A CN109581244B (en) | 2018-10-25 | 2018-10-25 | High-power portable noninductive load box |
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| CN201811249221.7A CN109581244B (en) | 2018-10-25 | 2018-10-25 | High-power portable noninductive load box |
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| CN109581244B true CN109581244B (en) | 2021-03-30 |
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| CN109581244A (en) | 2019-04-05 |
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