GB2505167A

GB2505167A - Test system for testing busbars during mass production

Info

Publication number: GB2505167A
Application number: GB1213912.7A
Authority: GB
Inventors: Fangxiang Cheng
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-08-03
Filing date: 2012-08-03
Publication date: 2014-02-26
Anticipated expiration: 2032-08-03
Also published as: GB2505167B; GB201213912D0

Abstract

A system for controlling tests on electrical products, such as busbars, during manufacturing comprises a control means and a switch means to connect at least a first test instrument to at least one of a first and a second product. The control means comprises one or more interfaces to control the test instrument(s) and to receive test data from them, a database to store test instructions and product specification data, a database to store test data from the test instrument(s), a user interface to create test instructions and to display test results, and analysis means to compare test data with product specification data. Product identification, such as a barcode, may be read or created by the system and used to store test results or select test routines for the product. Several production lines may be monitored simultaneously via a multiplex switch. Insulation breakdown voltage, earth continuity or insulation resistance may be tested.

Description

An automatic test system for electrical products

Field of the Invention

The present invention relates to test systems for electrical products, more particularly to test systems usable to test performance of electrical products such as busbars during a production process.

Background -*10

Busbars are tested during manufacture for parameters such as high potential DC/AC withstanding voltage, insulation resistance and earth continuity. Each product type will require a certain set of tests and the same test protocol will be followed for each individual busbar of a given type as it is manufactured. Standard test instruments exist and the protocol may be followed manually using each instrument for each product individually. This results in a repetitive process which is labour intensive, and requires a large amount of data handling and entry. An automated sistem that carries out testing of busbars or other similar electrical products would have value in speeding testing and reducing the burden of manual test procedures.

Prior Art

Accordingly a number of patent applications have been filed in an attempt to resolve the problem or similar, including the following: W0201209146 discloses a system (100) for detecting an improperly secured busway joint (14) in an electrical distribution busway includes a busway joint parameter sensor (122), a transmission circuit (140) and a remote computer (160). The busway joint parameter sensor (122) is disposed so as to sense a selected parameter of the busway joint (14). The transmission circuit (140) is in data communication with the busway joint parameter sensor (122) and is configured to transmit real time busway joint parameter data. The remote computer (160) is in data communication with the transmission circuit (140) and is configured to present an indication upon detection of abnormal real time busway joint parameter data.

This disclosure is specific to a single possible fault Condition is adapted to operation in use of the busbar rather than in production, and does not disclose means to carry out multiple tests on a single busbar or to store and manage the test data arising from the tests.

GB2396019 discloses a testing apparatus for testing the condition of the Cores of a multicore cable comprises a main unit which has a testing device (14) for supplying test signals to the cores and a Control unit (10) for controlling automatic application of the test signals to the cable cores. The unit can carry out an insulation test by measuring resistance of each core insulation between it and earth and between it and other cores. The results can be recorded by a computing device (16) such as a portable computer and displayed as a spreadsheet A slave unit (20) can also be provided for carrying out a continuity test. In use! the cores of the multicore cable are connected to the testing apparatus via relays 28 and relay drivers 26.

US20020194547 discloses a wiring fault detection, diagnostic and reporting technique that enables linking devices within a process control system to measure the electrical characteristics of a segment protocol bus and the electrical characteristics of the signals transmitted via the protocol bus. The technique conneots a signal line of a segment protocol bus to one of a plurality of measurement blocks within a wiring fault detection unit. The one of the plurality of measurement blocks measures an electrical characteristic associated with the segment protocol bus and sends the measured electrical characteristic to a wiring fault diagnostic manager. The wiring fault diagnostic manager analyzes the measured electrical characteristic to determine a type of the wiring fault and reports the type of the wiring fault via a user interface.

These and other prior art patents and patent applications do not meet the need of being able to control external test equipment in order to apply a predetermined set of tests to multiple products, such as busbars, and to collect and store data resulting from those tests.

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In contrast the present invention provides a system and a method to achieve the above in an effective and labour saving manner.

Summary of the Invention

Busway/Busbar products need safety tests. The invented system is a multi-functional and fully automated system to provide a cost effective, highly efficient, high reliability test solution. The test system can be used at the end of the busway/busbar production lines for production quality control and production management.

According to the present invention there is provided a test system for controlling test measurements on one or more products comprising: a control means; and a switch means comprising connections to at least a first test instrument and connections to at least a first and a second product, wherein the switch means is controllable by the control means to connect the first test instrument electrically to at least one of the first and the second product, wherein the control means comprises: one or more interfaces adapted to enable the control means to control external test instruments; one or more interfaces adapted to receive test data from one or more external test instruments; a database adapted to store test instructions to control the test instrument(s) and

product specification data;

a database adapted to store test data from the external test instrument(s); a user interface adapted to create test instructions and to display test results; and analysis means adapted to compare test data with product specification data.

In a preferred embodiment the control means comprises a test software programme comprising a test software suite comprising means to create a test instruction set usable by the control means to command an external test instrument to perform a sequence of test operations. In preferred embodiments the control means comprises test timing means to schedule a first test instruction followed by transmission of a first test result from the external test instrument to the control means, then a second test instruction followed by transmission of a second test result from the external test instrument to the control means.

In a preferred embodiment the control means cOmprises a GUI (Graphical User Interface) usable to create a test instruction set.

in a preferred embodiment the control means comprises a product test and result database in which a test instruction set and a result set are associated with a unique product identifier.

Herein by associated with' includes the meaning that multiple data items are linked together in the database under categories such that retrieval of a data item in a first category results in retrieval of a specific data item in a second category.

in a preferred embodiment the control means comprises an interface to an Enterprise Resource Planning (ERP) system.

In a preferred embodiment the control means comprises one or more software routines adapted to control and/or communicate test data to/from one or more external test instruments or sensors.

in preferred embodiments the system further comprises one or more external test instruments, herein also described as testers. In a preferred embodiment the system comprises one or more of the following testers: Kikusui 1086200, 1089200, TOSG21O, 10S9210 and T0S9220.

In preferred embodiments the system further comprises one or more sensors, for example temperature and humidity sensors.

In an embodiment the switch means comprises a first switch means adapted to connect selectively to at least a first test line that is connected electrically to a product to one of a plurality of testers.

In an embodiment the switch means comprises a second switch means adapted to connect selectively at least a first test line that is connected electrically to a tester to one of a plurality of products.

In preferred embodiments the switch means comprises multiplex switch means adapted to connect at east one of a plurality of testers to at least one of a plurality of 4.

products. In preferred embodiments the switch means comprises at least first and second multiplex switch means adapted to connect a first tester to a first product and a second tester to a second product simultaneously.

In preferred embodiments the system further comprises ID scanning means to identify a specific product under test and means to store ID data relating to said identity in a database. In preferred embodiments the ID scanning means comprises a barcode scanner or an RFID (RF identification) reader as known in the art.

In a preferred embodiment the system further comprises ID creation means to create an identification for a product in order to allow it to be identified during the test process or later. For example, such ID creation means may comprise a barcode label printer, the barcode label comprising data associated with a product ideptifier stored within the database. Test instruction sets and test results may later be associated with the product identifier in the database.

In preferred embodiments the control system further comprises a user administration means comprising one or more of: access control means to allow access to the system by a user, to allow a user to create a test instruction set, to allow a user to initiate a test sequence, to allow a user to create a report from data in the database.

In a preferred embodiment the control system further comprises OC control means usable to authorise release f a product for supply to a user or for further processing following analysis of data in the database and preferably to record such release authorisation in the database associated with product identifier.

In a preferred embodiment the control system further comprises product administration means usable for one or more of: to create and/or store product ID data comprising a product identifier, to enter and store details of individual products associated with the product identifier, to associate test results in the database with the product identifier, to record product OC data associated with the product identifier.

In a preferred embodiment the control means comprises product specification data stored in a database, analysis means to compare one or more test results with the product specification data, and reporting means to present the results from the analysis means to a user. Preferably the analysis means comprises an analysis algorithm that operates on test data to produce analysis data. The analysis algorithm may be chosen considering environmental factors such as temperature and humidity.

In a preferred embodiment analysis data fromthe analysis means is stored in the database associated with the product identifier. In one embodiment the system comprises QC decision means adapted to determine whether the product passes a QC test and to indicate to a user whether the product passes the test. Preferably the QC decision means stores data in the database assobiated with the product identifier! for example a QC pass/fail flag.

Preferably the control means comprises means to create and to store a number of pre-set test sequences. Preferably the control means comprises means to associate an analysis algorithm with a test sequence, so as to apply the analysis algorithm to the test results from a test sequence in order to generate analysis data. The stored test sequence and stored algorithm may then be applied repeatedly to a number of products, and for each product analysis data and optionally QC data may be stored in the database associated with the test sequence and the product identifier. A combination of a given test sequence and given algorithm may be used repeatedly for a given product type and the combination may be selected by a user according to the product type to be tested. In a preferred embodiment the system may select the combination in response to product ID data read from the product by the system.

In preferred embodiments the system is adapted to be operable with multiple products on multiple production lines simultaneously. Preferably product ID data comprises production line ID data, allowing one or more of the identity of the production line, data from the production process, and data relating to processes applied to an individual product to be associated in the database with the product ID data.

The system is not limited to specific testers or product types. While it has been described herein in relation to busbars, the system may be applied to other electrical systems requiring routine testing, in which a given test sequence may be applied to a number of products of a given type, and particularly in situations where more than one product type is to be produced, and each product type needs a different test sequence.

Preferably all test parameters are configurable and user administration and product administration interfaces form part of the software.

Preferably the system further comprises test cables connecting the testers to the busbar/busway, Preferably all tests are carried out automatically and results are stored in the database or transferred by a data link to an external database or system for ERP purposes.

In a preferred embodiment the system comprises a means to control, store and manage data from a test process using test instruments such as the Kikusui T0S620019200/9220 testers, and may be usedsimultaneously for multiple test lines.

Preferably the system comprises an ERP reporting system. The system in a typical embodiment may be used for multiple tests including withstanding voltage, insulation resistance and earth continuity tests, and comprises a tester user administration system and a busbarfbusway product administration system for high-level management control: According to a further aspect the invention provides a method for testing an electrical property of a product and deriving analysis data from the test results comprising the steps of: providing a system substantially as described herein; connecting the product to the system; selecting a test sequence; applying the test sequence; and carrying out an analysis using the test data.

In preferred embodiments the product is a busbar or busway and the system comprises one or more testers adapted to measure one or more properties of the busbar or busway comprising: insulation breakdown voltage, earth continuity, and insulation resistance.

In a preferred embodiment the method further comprises the step of comparing one or more items of test data with one or more pre-chosen parameters and providing a pass/fail indication to a user.

The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention.

With respect to the above description then, it is to be realised that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further since numerous modifications and changes will readily occur to those skilled in the art, it is not des Wed to hmit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Brief Description of Figures

Figure 1 shows a diagram of a first embodiment of the invention.

Detailed Description of Embodiments of the Invention Figure 1 shows a block diagram of a system according to the invention. The system comprises a control means in the form of a central control unit, comprising a test software suite comprising a test control means and administration GUI; a database adapted to store product test sequences and test results; a user database to contain data pertaining to users of the system and preferably comprising user ID data; a tester database comprising data pertaining to the testers in use with the system; an interface to an ERP system and tester and peripheral controls to allow the system to operate with the testers and other peripherals such as ID scanners and printers. The control means is interoperabje with such peripherals as a keboard/mouse a thermal/humidity meter, optionally a label printer and optionally a barcode and/or RFID scanner, The system is shown as comprising a number of testers, and switching means in the form,of a probe cable switcher that connects one or more a testers sequentially to one or more products on one or more production lines 0 to n.

An alarm may be used to give an alarm if a busbar fails a test, and the system is preferably adapted to indicate to a user which product on which production line has failed.

In a preferred embodiment the system operation may comprise some or all of the * following steps, and the system may comprise means to carry out some or all of the steps.

Step Action 1 Start 2 User identifies product type. Is test sequence already programmed into system? If yes select the appropriate test sequence for that product and go to 4.

3 Program test sequence 4 Connect test probes from switch unit to product, connect testers to switch unit and to control means Is product ID means in place on product? If yes go to 7 6 Produce product ID means associated with a unique product identifier in database and attach to product 7 Read product ID and associate with unique product identifier in database.

Optionally if more than one production line read production line ID and data and store in the database associated with the product identifier.

8 Apply tests according to chosen test sequence and store test results in database associated with the product identifier 9 Run analysis means. Algorithm uses test data and specificatibn data to produce analysis data that are then optionally stored in the database associated with the product identifier.

Indicate OC data (eg pass/fail) for the product and store in the database 11 Test another product othe same type yin? If y then go to 5.

12 Test a product of a different iype (yin)? If y then go to 2 13 If required, output a test report and produce a product dompliance certificate.

In a preferred embodiment the system, comprising a control HMI (Human-Machine Interface) PC, testers and accessories are installed in a common industrial case. A software program installed onto the HMI PC controls the control system, and preferably an operator can control the test through a touch screen interface.

The HMI PC may control the testers via GRIB or RS232 as known in the art..

Connections, such as the ground, may be changed via mechanical or electrical switches based on individual test requirement.

A system according to the invention may comprise the following components: An industrial HMI PC (such as the Simens touch screen) with windows OS, or an embedded Linux system with ARM processor and touch screen.

Kikusui T036200, TOS 9200 testers and TOS 9220 scanner.

Barcode scanner for the buswaytbusbar barcode scanning.

Thermo-humidity meter.

Mechanical-electrical switches.

In use, the testers and the HMI PC can be mounted in an industrial rack. The rack is located at the end of the busbar/busway assembly line, acting as the main quality control station. The manufactured busway/busbar is identified by its barcode, using the barcode scanner attached to the system. All test parameters are fully customized by the operator. The busway/busbar is then attached to the test station with the test cables from the tester. A software program on the PC controls all the GUI, test control and administration work. The system is plugged into the industry network for ERP, communication and administration tasks. The busbar/busway is automatically set to the testing system for test. All test results are generated and stored to the ERP system. In addition, the test system can be plugged into multiple busway/busbar assembly lines, as a cost effective solution.

Claims

Claims 1. A test system for controlling the test measurements on one or more products comprising: a control means; and a switch means comprising connections to at least a first test instrument and connections to at least a first and a second product, wherein the switch means is controllable by the control means to connect the first test instrument electrically to at least one of the first and the second product; wherein the control means comprises: one or more interfaces adapted to enable the control means to control external test instruments; one or more interfaces adapted to receive test data from one or more external test instruments a database adapted to store test instructions to control the test instrument(s)and product specification data;a database adapted to store test data from the external test instrument(s); a user interface adapted to create test instructions and to display test results; and analysis means adapted to compare test data with product specification data.
2. A test system as claimed in claim 1, wherein the control means comprises means to store a plurality of pre-determined test sequences and to apply a stored test sequence to a selected product.
3. A system as claimed in either of claims 1 and 2, in which the system further comprises an ID scanning means and means to store product ID data in the database associated with test results.
4. A system as claimed in claim 3, in which the system further comprising means to select and control a test sequence in response to product ID data scanned from the product.
S. A system as claimed in any preceding claim, wherein the switch means comprises multiplex switch means adapted to connect at least one of a plurality of testers to at least one of a plurality of products.
6. A system as claimed in any preceding claim, in which the system comprises a tester adapted to test a property of a busbar or busway selected from the list of: insulation breakdown voltage, earth continuity, and insulation resistance.
7. A method for testing an electrical property of a product and deriving analysis data from the test results comprising the steps of: providing a system as * claimed in any preceding claim; connecting the product to the system; selecting a test sequence; applying the test sequence; and carrying outan analysis using the test data.

*
8. A method as claimed in claim 7, wherein the product is a busbar or busway and the tester is adapted to test one or more of: insulation breakdown voltage, earth continuity, and insulation resistance.
9. A method as claimed in either of claims 7 and 8, in which the method further comprises the step of comparing one or more items of test data with one or more items of product specification data and providing a pass/fail indication to a user. *-AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS: Claims 1. A test system for controlling the test measurements on one or more products comprising: a control means; and a switch means comprising connections to at least a first test instrument and connections to at least a first and a second product, wherein the switch means is controllable by the control means to connect the first test instrument electrically to at least one of the first and the second product; wherein the control means comprises: one or more interfaces adapted to enable the control means to control external test instruments; one or more interlaces adapted to receive test data from one or more external test instruments; a database adapted to store a plurality of pre-determined test instructions sequences to control the test instrument(s) and product specification data; a product ID scanning means; a means to apply a stored test instructions sequence to a selected product; a database adapted to store test data from the external test instrument(s); a means to store the product ID in the database associated with the test data; a user interface adapted to create test instructions and to display test data; and analysis means adapted to compare test data with product specification data.*r 25 2. A test system as claimed in claim I further comprising a product administration interlace. S *3. A system as claimed in any preceding claim, in which the system further * comprising means to select and control a test sequence in response to product ID data scanned from the product. * * * * * *4. A system as claimed in any preceding claim, wherein the switch means comprises multiplex switch means adapted to connect at least one of a plurality of testers to at least one of a plurality of products.5. A system as claimed in any preceding claim, in which the system comprises a tester adapted to test a property of a busbar or busway selected from the list of: insulation breakdown voltage, earth continuity, and insulation resistance.6. A method for testing an electrical property of a product and deriving analysis data from the test results comprising the steps of: providing a system as claimed in any preceding claim; connecting the product to the system; scanning the product ID, selecting a test sequence; applying the test sequence; storing the product ID in the database associated with the test data; and carrying out an analysis using the test data.7. A method as claimed in claim 6, wherein the product is a busbar or busway and the tester is adapted to test one or more of: insulation breakdown voltage, earth continuity, and insulation resistance.8. A method as claimed in either of claims 6 or 7, in which the method further comprises the step of comparing one or more items of test data with one or more items of product specification data and providing a pass/fail indication to a user. *&,*** .**.* * * * **.*** * * *o. *s 0* * * * * *