CN222850700U

CN222850700U - A controller high voltage insulation test tool

Info

Publication number: CN222850700U
Application number: CN202421234998.7U
Authority: CN
Inventors: 刘蕾; 凌志; 解少康
Original assignee: Hefei JEE Power System Co Ltd
Current assignee: Hefei JEE Power System Co Ltd
Priority date: 2024-05-31
Filing date: 2024-05-31
Publication date: 2025-05-09
Anticipated expiration: 2034-05-31

Abstract

The utility model discloses a high-voltage-resistant insulation test fixture for a controller complete machine, which comprises a substrate, wherein a positioning mechanism, a clamping mechanism and a conductive mechanism are arranged on the substrate, the positioning mechanism comprises at least two positioning pin assemblies, positioning pins of the positioning pin assemblies are respectively matched with corresponding mounting threaded holes on the controller complete machine shell to realize positioning, the clamping mechanism comprises two clamping assemblies which are oppositely arranged left and right, the clamping of the left and right ends of the controller complete machine shell is realized through clamping parts of the two clamping blocks, the conductive mechanism comprises a plurality of conductive probe assemblies, probe contacts at the bottoms of conductive probes of the conductive probe assemblies are contacted with a high-voltage-resistant area of the controller complete machine, a current collecting plate is arranged on the substrate, and the tops of the conductive probes of the conductive probe assemblies are connected into the current collecting plate in a parallel mode through cables. Compared with the prior art, the utility model has the advantages of improving the testing operation efficiency and the safety and reducing the production and manufacturing cost.

Description

High-voltage-resistant insulation test tool for controller complete machine

Technical Field

The utility model relates to a testing tool, in particular to a high-voltage-resistant insulation testing tool for a controller whole machine.

Background

In the mass production and assembly process of the controller, the whole controller is subjected to high-voltage insulation test to verify the quality and electrical insulation performance of the controller, and the insulation resistance of the product is larger than the technical requirement, so that the safety accidents such as electric leakage or breakdown and the like of the controller in the normal operation process are avoided.

The controller mainly comprises a high-voltage driving circuit, a low-voltage control circuit and a circulating cooling water channel. The high-voltage driving circuit mainly comprises a direct-current bus input end, a filter circuit, a Hall current sensor, a supporting capacitor, an IGBT switch (or a MOS tube switch) and a three-phase power output end. The low-voltage control circuit mainly comprises a control board, a driving board, a DCDC module, a PTC module, UDS diagnosis service, an external charging management system and the like.

The vehicle-mounted ECU of the vehicle can send a control command to the controller according to the current working condition of the vehicle and the control action of a driver, after the control panel decodes, the control command is sent to the driving panel, the driving panel directly controls the high-voltage driving circuit to convert the high-voltage direct-current high-voltage power of the power battery pack into required three-phase alternating current, and power output of the driving motor is completed. At this time, the hall current sensor is responsible for monitoring the current of the three-phase alternating current, and the IGBT switch controls the frequency of the three-phase alternating current.

In order to ensure the reliability of the controller, a high-voltage driving circuit of the controller adopts a high-voltage insulation test method in the mass production process, so that the controller is ensured not to have safety accidents such as electric leakage or breakdown in the normal operation process. At present, the high voltage insulation test of the whole controller has two different schemes:

The scheme is that a special machine is adopted for testing, namely, a controller flows into a high-voltage-resistant insulation test procedure along with a tray, after the tray is lifted and positioned, a probe on a test machine table is positioned and pressed against a corresponding high-voltage-resistant test area of the controller, and the high-voltage-resistant insulation test of the whole machine of the controller is completed through the cooperation of a high-voltage power distribution cabinet and the control machine table;

The other scheme is that a voltage-resistant tester is adopted for testing, the voltage-resistant tester belongs to a mature product in the market, the quality is stable, the price is low, but when the method is operated, a conductive probe is matched with the voltage-resistant tester for use, a single probe is used for testing direct contact of a test point which is required to be subjected to high voltage resistance testing on the whole controller, the method is low in cost, only one point can be tested at a time, multiple tests are required for a plurality of points, and the probe is adopted for directly contacting and detecting the whole controller, so that potential safety hazards exist for both the controller product and operators.

Disclosure of utility model

The utility model aims to overcome the defects of the prior art, and provides a high-voltage-resistant insulation test tool for a controller complete machine, which is matched with a voltage-resistant tester for use, so that the test operation efficiency is improved, the production and manufacturing cost is reduced, and the test safety is improved.

The utility model is realized by the following technical scheme:

A high-voltage-resistant insulation test fixture for a controller complete machine comprises a substrate, wherein a positioning mechanism, a clamping mechanism and a conductive mechanism are arranged on the substrate;

The positioning mechanism comprises at least two positioning pin assemblies, positioning pins of each positioning pin assembly vertically extend downwards, and the positioning pins of each positioning pin assembly are respectively matched with corresponding mounting threaded holes on the whole controller shell to realize positioning;

the clamping mechanism comprises two clamping assemblies which are oppositely arranged left and right, one side of the two opposite clamping assemblies is the inner side, the other side of the two opposite clamping assemblies is the outer side, each clamping assembly comprises a clamping block, the top ends of the clamping blocks are fixed on the sliding plate, the bottom ends of the clamping blocks downwards extend out of the lower portion of the base plate to form clamping parts, the sliding plate is arranged on the base plate in a sliding mode and can slide along the left and right directions of the base plate, the inner sides of the sliding plate are connected with elastic components arranged on the base plate, in a natural state, the two clamping assemblies are mutually close to each other under the elastic tension action of the respective elastic components, and the clamping of the left and right ends of a whole controller shell is realized through the clamping parts of the two clamping blocks;

The conductive mechanism comprises a plurality of conductive probe assemblies, the bottom of each conductive probe assembly extends downwards below the substrate to form a probe contact, the probe contact is contacted with a high-voltage resistant area of the whole controller, the substrate is provided with a collector plate, and the tops of the conductive probes of each conductive probe assembly are connected into the collector plate in a summarizing way in parallel through cables.

As the preferable scheme of above-mentioned frock, every conductive probe subassembly still includes the probe seat, and probe seat fixed mounting is on the base plate, and conductive probe passes through a axle sleeve and installs in the interior pore of probe seat, and conductive probe hypomere stretches out under the probe seat and the cover is equipped with first spring, and both ends are pressed on axle sleeve and probe contact respectively to first spring upper and lower elasticity, and conductive probe top stretches out on the probe seat and threaded connection has two first installation nuts, and the cable presss from both sides between two first installation nuts.

As the preferable scheme of the tool, a plurality of tooth grooves are formed in the bottom surface of the probe contact of the conductive probe.

As the preferred scheme of above-mentioned frock, every locating pin subassembly includes the positioning seat, positioning seat fixed mounting is on the base plate, it has big-end-up's step locating hole to open on the positioning seat, the locating pin is big-end-up's step axle form, the locating pin slides and sets up in the step locating hole of positioning seat, the locating pin middle section cover is equipped with the second spring, the step face through the step locating hole of positioning seat and the step of locating pin are spacing to the upper and lower both ends of second spring, the locating pin bottom stretches out under the positioning seat, the locating pin top stretches out on the positioning seat and threaded connection has the second installation nut.

As the preferred scheme of above-mentioned frock, chucking mechanism still includes controlling two supporting shoes, two supporting shoes respectively fixed mounting is under the base plate, and two supporting shoes are located two chucking piece inboards respectively for limit position that two chucking pieces are close to each other carries out spacingly, and two chucking piece bottoms are equipped with inwards convex hook portion respectively, leave the clearance between the hook portion top of chucking piece and the supporting shoe bottom of corresponding side.

As the preferable scheme of above-mentioned frock, the base plate top still covers and is equipped with the safety protection cover, and the current collecting plate top upwards stretches out in the notch of opening on the safety protection cover.

As the preferable scheme of above-mentioned frock, in the chucking mechanism, every chucking piece outside is equipped with the handle, and the handle is located on the base plate, opens on the base plate and has two grooves of dodging that supply two chucking pieces to move about.

As the preferable scheme of above-mentioned frock, elastomeric element includes two extension springs, and two extension spring inboard are fixed respectively on the base plate, and two extension spring outsides are connected with the slide inboard respectively.

As a preferable scheme of the tool, the substrate is a plexiglass plate.

Compared with the prior art, the utility model has the following advantages:

The high-voltage-resistant insulation test tool for the whole controller provided by the utility model can be clamped on the whole controller shell to be tested through the clamping mechanism, the positioning of the tool on the whole controller shell is realized through the positioning mechanism, the simultaneous test of a plurality of high-voltage-resistant test points on the whole controller is realized by means of a plurality of conductive probe assemblies on the tool in cooperation with the voltage-resistant tester, the quality and the operation efficiency of the high-voltage-resistant test are improved, and meanwhile, the safety of the test is improved and the safety of testers and products is ensured compared with a mode of directly using the conductive probe for the test.

Drawings

Fig. 1 is a perspective view of the tooling of the present utility model.

Fig. 2 is a perspective view of the tool of the present utility model with the safety shield removed.

Fig. 3 is a front view of fig. 2.

Fig. 4 is a cross-sectional view of the dowel assembly of the present utility model.

Fig. 5 is a cross-sectional view of a conductive probe assembly of the present utility model.

Fig. 6 is a front view of the clamping assembly of the present utility model.

Fig. 7 is a top view of the clamping assembly of the present utility model.

Fig. 8 is a perspective view of the controller unit housing of the present utility model with the upper cover removed.

The drawing comprises a substrate 1, a locating pin assembly 2, a locating pin 3, a controller complete machine shell 4, a mounting threaded hole 5, a locating seat 6, a second spring 7, a second mounting nut 8, a clamping assembly 9, a clamping block 10, a sliding plate 11, a sliding block 12, a stretching spring 13, a supporting block 14, a hook 15, a handle 16, a 17 avoidance groove 18, a conductive probe assembly 19, a conductive probe 20, a probe contact 21, a current collecting plate 22, a probe seat 23, a shaft sleeve 24, a first spring 25, a first mounting nut 26, a safety protection cover 27, a direct current bus high voltage resistance test area 28, a three-phase power line high voltage resistance test area 29 and a flange.

Detailed Description

The following describes in detail the examples of the present utility model, which are implemented on the premise of the technical solution of the present utility model, and detailed embodiments and specific operation procedures are given, but the scope of protection of the present utility model is not limited to the following examples.

Referring to fig. 1 to 8, the embodiment discloses a high voltage insulation test fixture for a controller, which comprises a substrate 1, wherein the substrate 1 is an organic glass plate. The base plate 1 is provided with a positioning mechanism, a clamping mechanism and a conductive mechanism.

The positioning mechanism comprises at least two positioning pin assemblies 2, the embodiment comprises two positioning pin assemblies 2, the positioning pin 3 of each positioning pin assembly 2 extends vertically downwards, and the positioning pin 3 of each positioning pin assembly 2 is matched with a corresponding installation threaded hole 5 on the controller whole machine shell 4 respectively to realize positioning. Each positioning pin assembly 2 comprises a positioning seat 6, the positioning seat 6 is fixedly arranged on the base plate 1, a step positioning hole with a small upper part and a large lower part is formed in the positioning seat 6, the positioning pin 3 is in a step shaft form with a small upper part and a large lower part, the positioning pin 3 is slidably arranged in the step positioning hole of the positioning seat 6, a second spring 7 is sleeved in the middle section of the positioning pin 3, the upper end and the lower end of the second spring 7 are limited through the step surface of the step positioning hole of the positioning seat 6 and the step surface of the positioning pin 3, the bottom end of the positioning pin 3 extends out of the positioning seat 6, and the top end of the positioning pin 3 extends out of the positioning seat 6 and is in threaded connection with a second mounting nut 8. The locating pin assembly 2 adopts the structure form of the elastic floating locating pin 3, so that the installation threaded hole 5 of the whole controller shell 4 can be effectively protected, and the installation threaded hole 5 is prevented from being damaged in assembly.

The clamping mechanism comprises two clamping assemblies 9 which are oppositely arranged left and right, one sides of the two clamping assemblies 9 which are opposite are inner sides, one sides of the two clamping assemblies which are opposite are outer sides, each clamping assembly 9 comprises a clamping block 10, the top end of each clamping block 10 is fixed on a sliding plate 11, the bottom end of each clamping block downwards extends out of the lower portion of the base plate 1 to form a clamping part, the bottom of each sliding plate 11 is slidably arranged on the base plate 1 through a sliding block 12 and can slide along the left and right directions of the base plate 1, the inner sides of the sliding plates 11 are connected with elastic components arranged on the base plate 1, the elastic components comprise two extension springs 13, the inner sides of the two extension springs 13 are respectively fixed on the base plate 1, and the outer sides of the two extension springs 13 are respectively connected with the inner sides of the sliding plates 11. In a natural state, the two clamping assemblies 9 are close to each other under the action of the elastic tension of the respective elastic parts, and the clamping of the left end and the right end of the controller whole machine shell 4 is realized through the clamping parts of the two clamping blocks 10. The clamping mechanism further comprises a left supporting block 14 and a right supporting block 14, the two supporting blocks 14 are respectively and fixedly arranged below the base plate 1, the two supporting blocks 14 are respectively positioned on the inner sides of the two clamping blocks 10 and used for limiting the limiting positions of the two clamping blocks 10, the bottoms of the two clamping blocks 10 are respectively provided with a hook portion 15 protruding inwards, and a gap is reserved between the top ends of the hook portions 15 of the clamping blocks 10 and the bottoms of the supporting blocks 14 on the corresponding sides. In the clamping mechanism, a handle 16 is arranged on the outer side of each clamping block 10, the handle 16 is positioned on the base plate 1, and two avoidance grooves 17 for the left and right movement of the two clamping blocks 10 are formed in the base plate 1.

The conductive mechanism comprises a plurality of conductive probe assemblies 18, the bottom of a conductive probe 19 of each conductive probe assembly 18 extends downwards below the substrate 1 and forms a probe contact 20, the probe contact 20 is contacted with a high-voltage resistant area of the whole controller, a collector plate 21 is arranged on the substrate 1, and the tops of the conductive probes 19 of the conductive probe assemblies 18 are collectively connected into the collector plate 21 in a parallel mode through cables. Each conductive probe assembly 18 further comprises a probe seat 22, the probe seat 22 is fixedly arranged on the substrate 1, the conductive probe 19 is arranged in an inner pore canal of the probe seat 22 through a shaft sleeve 23, the lower section of the conductive probe 19 extends out of the lower part of the probe seat 22 and is sleeved with a first spring 24, the upper end and the lower end of the first spring 24 are respectively elastically pressed against the shaft sleeve 23 and the probe contact 20, the top of the conductive probe 19 extends out of the upper part of the probe seat 22 and is in threaded connection with two first mounting nuts 25, and the cable is clamped between the two first mounting nuts 25. The bottom surface of the probe contact 20 of the conductive probe 19 is provided with a plurality of tooth grooves.

The safety protection cover 26 is further covered above the base plate 1, the safety protection cover 26 is connected with the base plate 1 in a screw connection mode, the top end of the current collecting plate 21 extends upwards from a notch formed in the safety protection cover 26, and two handles 16 of the clamping mechanism extend from two sides of the safety protection cover 26, so that an operator can conveniently pull the handles 16.

When the controller is used, the upper cover of the controller whole machine shell 4 is opened, so that the direct current bus high voltage resistant test area 27 and the three-phase power line high voltage resistant test area 28 in the controller whole machine are exposed. The operator pulls two handles 16 on the frock for two chucking blocks 10 open and are located the left and right sides of the whole casing of controller respectively, insert two locating pins 3 of frock respectively in two corresponding installation screw holes 5 on the whole casing of controller 4, loosen two handles 16, under the elasticity pulling force effect of extension spring 13, two briquetting are close to each other, press from both sides flange 29 of both ends about the whole casing of controller 4, and hook the flange 29 bottom through the hook 15 of two briquetting bottoms, rely on two supporting shoe 14 bottom surfaces to lean on with the top surface of the whole casing of controller 4 flange 29 simultaneously, this kind of locating pattern of "one side two pins" has guaranteed firm centre gripping and accurate location to the whole casing of controller 4. At this time, the conductive mechanism includes a plurality of probe contacts 20 at the bottom of the conductive probe 19 respectively contacting the dc bus high voltage resistant test area 27 and the three-phase power line high voltage resistant test area 28 in the controller whole machine housing 4, and the probe contacts 20 at the bottom of the probe tightly abut against the tested area under the action of the elastic force of the first spring 24 at the lower section of the probe, so as to avoid ablation of the conductive probe 19 caused by poor contact. At this time, the safety shield 26 has safely isolated the above-mentioned energized part, and only leaves the protruding end at the top of the collector plate 21 for the contact of the withstand voltage tester probe, ensuring the safety of personnel and equipment during the insulation test. The operator starts the withstand voltage tester, takes out the probe of the withstand voltage tester, contacts the extending end of the collector plate 21 with the probe with test voltage, and conducts the test voltage to the direct current bus high voltage resistant test area 27 and the three-phase power line high voltage resistant test area 28 in the controller whole machine shell 4 through the conduction of the cable and the conductive probe 19, and reads the high voltage resistant insulation impedance of the controller whole machine in the specified test time to complete the high voltage resistant insulation test of the controller whole machine.

The tool provided by the utility model is matched with the pressure-resistant tester, so that a plurality of test points in a high-pressure-resistant test area on the whole controller shell 4 can be tested simultaneously, the working efficiency of the high-pressure-resistant test is improved, and meanwhile, the safety of the operation process is greatly improved due to the safety protection cover 26.

The foregoing description of the preferred embodiments of the utility model is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the utility model.

Claims

1. The high-voltage-resistant insulation test fixture for the whole controller is characterized by comprising a substrate, wherein a positioning mechanism, a clamping mechanism and a conductive mechanism are arranged on the substrate;

2. The high voltage insulation test fixture of the controller complete machine is characterized in that each conductive probe assembly further comprises a probe seat, the probe seats are fixedly arranged on the substrate, the conductive probes are arranged in inner pore channels of the probe seats through shaft sleeves, the lower sections of the conductive probes extend out of the lower parts of the probe seats and are sleeved with first springs, the upper ends and the lower ends of the first springs are respectively elastically pressed against the shaft sleeves and the probe contacts, the tops of the conductive probes extend out of the probe seats and are in threaded connection with two first mounting nuts, and the cable is clamped between the two first mounting nuts.

3. The high voltage insulation test fixture of a controller as set forth in claim 2, wherein the bottom surface of the probe contact of the conductive probe is provided with a plurality of tooth sockets.

4. The high-voltage insulation test fixture of the whole controller is characterized in that each locating pin assembly comprises a locating seat, the locating seats are fixedly arranged on a substrate, step locating holes with the upper parts smaller than the lower parts and the larger than the lower parts are formed in the locating seats, the locating pins are in the form of step shafts with the lower parts smaller than the upper parts and the larger than the lower parts, the locating pins are slidably arranged in the step locating holes of the locating seats, second springs are sleeved in the middle sections of the locating pins, limiting is conducted on the upper ends and the lower ends of the second springs through the step surfaces of the step locating holes of the locating seats and the step surfaces of the locating pins, the bottom ends of the locating pins extend out of the locating seats, and the top ends of the locating pins extend out of the locating seats and are in threaded connection with second mounting nuts.

5. The high voltage insulation test fixture of the whole controller is characterized in that the clamping mechanism further comprises a left supporting block and a right supporting block, the two supporting blocks are respectively and fixedly installed below the substrate, the two supporting blocks are respectively located on the inner sides of the two clamping blocks and used for limiting the limiting positions of the two clamping blocks, which are close to each other, the bottoms of the two clamping blocks are respectively provided with a hook part protruding inwards, and a gap is reserved between the top end of the hook part of each clamping block and the bottom of the supporting block on the corresponding side.

6. The high voltage insulation test fixture of a controller as set forth in claim 1, wherein a safety shield is further covered above the base plate, and the top end of the collector plate extends upwards from a notch formed in the safety shield.

7. The high voltage insulation test fixture of a controller whole machine according to claim 1, wherein a handle is arranged on the outer side of each clamping block in the clamping mechanism, the handle is positioned on a substrate, and two avoidance grooves for the two clamping blocks to move left and right are formed in the substrate.

8. The high voltage insulation test fixture of a controller whole machine according to claim 1, wherein the elastic component comprises two extension springs, the inner sides of the two extension springs are respectively fixed on the base plate, and the outer sides of the two extension springs are respectively connected with the inner sides of the sliding plates.

9. The high voltage insulation test fixture of a controller as set forth in claim 1, wherein the substrate is an organic glass plate.