Automatic multi-channel solid-state relay testing device

Abstract

The invention discloses an automatic multi-channel solid-state relay testing device, and belongs to the technical field of electrical element detection and intelligent manufacturing testing. The device comprises an insulation and voltage resistance test module, a direct current function test module, an alternating current function test module, an automatic load test module and an MES execution management module. The device has the advantages of complete testing functions, high precision, high automation degree, wide adaptation range and the like, and is suitable for delivery inspection and life verification of various solid-state relays.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of relay testing equipment, in particular to a solid-state relay automatic testing system integrated with multiple testing modules, which is suitable for comprehensive evaluation of the conduction characteristics, insulation performance, phase modulation zero-crossing capability and load response of solid-state relays. BACKGROUND

[0002] Solid-state relays are widely used in automation equipment due to their non-contact and high reliability characteristics. However, current testing equipment is often scattered and single-function, unable to achieve comprehensive testing of key performance of solid-state relays from insulation withstand voltage to phase modulation behavior. At the same time, zero-crossing detection under AC input requires extremely high phase synchronization accuracy, and existing systems are difficult to achieve precise capture and automatic evaluation in one test.

[0003] In traditional solid-state relay testing, there are DC control DC, DC control AC, AC control AC, and DC control AC models, and the test items all contain high-voltage testing, with test voltage often reaching several thousand volts, slow generation efficiency, and poor safety.

[0004] In solid-state relay (SSR) testing, different models and application scenarios have different requirements for load types. Traditional devices use fixed resistance loads, which are difficult to balance precision, response speed and thermal efficiency, and manual configuration is tedious and lacks intelligent optimization mechanism.

[0005] For example, in the prior art CN117706347A, a multi-station solid-state relay automatic reliability test can be supported, which is suitable for batch relay verification, but its test purpose is single, it does not support insulation testing, such as action time parameter performance testing, in addition, the load uses three 12Ω wire-wound resistors in parallel, the load is nonlinearly regulated, and cannot be adjusted in real time to maintain standard working conditions, and the test flexibility is limited.

[0006] Therefore, an integrated solid-state relay testing solution is needed, which can test multiple key parameters in one device, only needs manual feeding and discharging, automatically tests all test items, uses automatic load to be compatible with multiple models, multiple channels, automatically determines product OK / NG, improves production line efficiency and safety, simplifies the process, improves precision and efficiency, and is suitable for solid-state relay manufacturers, system integrators and research institutions. SUMMARY

[0007] The present application provides a solid-state relay testing device integrated with insulation withstand voltage, DC function, AC function, automatic load and MES system, which realizes high-precision, high-universality and high-automation testing requirements, and improves testing efficiency and system stability.

[0008] An automated multi-channel solid-state relay testing device, comprising:

[0009] Insulation withstand voltage test module, the withstand voltage test power supply provides high-voltage DC voltage or high-voltage AC voltage, connected to the withstand voltage test bus, multiple relays to be tested are connected to the withstand voltage test bus through multiple high-voltage matrix switches, to achieve automatic withstand voltage test;

[0010] DC function test module: provides a programmable DC power supply, which is connected to the input control terminal of the relay to be tested through a first selection switch for DC function test;

[0011] AC function test module: provides a programmable AC power supply, which is connected to the input control terminal of the relay to be tested through the first selection switch for AC function test;

[0012] An automatic load module, using a programmable load matrix, is connected to the output end of the relay to be tested, a current transformer, a second data acquisition module and a load power supply to form a loop for automatic load adjustment, wherein the current transformer is connected to the first data acquisition module;

[0013] The MES execution module connects to the host computer software of the test device, is used to scan the code to identify the product number and automatically configure the test parameters. It connects to the factory MES system and records the product test performance data.

[0014] Preferably, the plurality of high-voltage matrices are used to connect any two points between the input control terminal, the output terminal and the housing of the relay to be tested to the withstand voltage test bus.

[0015] Preferably, the load power supply includes an AC load power supply, a DC load power supply and a load power supply selection switch.

[0016] Preferably, the first selection switch and the load power selection switch in the DC function test module and the AC function test module are selectively controlled according to the model and test items of the test product.

[0017] Preferably, the second data acquisition module is used to perform high-precision voltage sampling on the input control terminal and the output terminal, and to sample the leakage current of the output circuit.

[0018] Preferably, the first data acquisition module is further used to perform voltage sampling on the input control terminal.

[0019] Preferably, the programmable load matrix has constant current, constant resistance and constant power modes.

[0020] Preferably, the programmable load matrix adopts a four-area block-type programmable electronic-resistance hybrid load matrix.

[0021] Preferably, the four-region block-type programmable electronic-resistive hybrid load matrix uses reinforcement learning to determine the optimal load path, wherein the reward function R is set to:

[0022] R=α·(ΔV) 2 +β·T-γ·B

[0023] Among them, ΔV is the path voltage drop, T is the path temperature rise, and B is the path load balancing index.

[0024] Among them, α, β, and γ are empirical weighting factors, which are determined using the path equilibrium model.

[0025] An automated multi-channel solid-state relay testing method employing any of the aforementioned automated multi-channel solid-state relay testing devices is provided for performing insulation withstand voltage testing, control terminal function testing, output terminal performance testing, and data collection and archiving on the relay under test, the method comprising:

[0026] Product code scanning and configuration file calling;

[0027] Automatic selection and application of power supply signal at input control terminal;

[0028] Automatic matching of output load;

[0029] Use the first data acquisition module and the second data acquisition module to collect and record test data;

[0030] The host computer automatically saves the test data and uploads it to the MES system.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. High degree of test automation and significantly improved efficiency. Through a multi-channel test structure design, combined with a high-voltage matrix switch, programmable power supply, and automatic load system, multiple solid-state relays can be tested in parallel, greatly reducing manual plugging and switching, and increasing test throughput. It is suitable for factory testing or aging screening of large quantities of relays.

[0033] 2. Modular design, adaptable to various testing needs.

[0034] The device integrates an insulation withstand voltage test module, a DC function test module, an AC function test module and an automatic load test module. It can automatically switch the test power supply and control mode, and supports unified platform testing of solid-state relays of different models and types (DC / AC control input), thereby improving the versatility and flexibility of the equipment.

[0035] 3. Automatic load adjustment, covering typical operating scenarios. The programmable electronic-resistive hybrid load matrix has multiple operating modes such as constant current, constant resistance, and constant power. It adapts to the characteristics of relays with different rated output currents or powers, simulates actual working conditions, and improves test accuracy and effectiveness.

[0036] 4. Support intelligent algorithms to optimize load configuration

[0037] Combined with intelligent algorithms based on reinforcement learning, the system automatically selects the optimal load path and operating mode for different types of solid-state relays, improving test efficiency and avoiding overheating, misjudgment, or equipment waste caused by improper load configuration.

[0038] 5. Fully integrated MES system to ensure production traceability

[0039] Through the MES execution module communicating with the host computer, the product QR code or barcode is automatically identified, the corresponding test program and standard are quickly called, and the test data is automatically uploaded and archived, realizing closed-loop traceability of test data throughout the product life cycle and meeting the requirements of the quality management system.

[0040] 6. Strong scalability, conducive to subsequent maintenance and upgrades

[0041] The modules of this device use standard interfaces for communication. The number of test channels can be expanded and test functions (such as life test, high-temperature aging test, etc.) can be added according to product specifications. This supports subsequent system maintenance and technology upgrades, thereby improving the return on investment. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 Schematic diagram of the overall framework of the device in an embodiment of the present invention;

[0043] Figure 2 A schematic diagram of a framework for an insulation withstand voltage test according to an embodiment of the present invention;

[0044] Figure 3 A schematic diagram of a framework for a DC functional test and an AC functional test according to an embodiment of the present invention;

[0045] Figure 4 Schematic diagram of on-time test signal in an embodiment of the present invention;

[0046] Figure 5 Schematic diagram of the visual interface of the host computer in an embodiment of the present invention. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0048] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as limiting the present invention.

[0049] Reference Figure 1 The system framework diagram is shown below. The embodiments of the present disclosure are described in detail in conjunction with the accompanying drawings. An automated multi-channel solid-state relay test device comprises: an insulation withstand voltage test module, a DC function test module, an AC function test module, an automatic load module, and an MES execution module.

[0050] Specifically, the insulation withstand voltage test module, the withstand voltage test power supply provides a high-voltage DC voltage or a high-voltage AC voltage, is connected to the withstand voltage test bus, and multiple relays to be tested are respectively connected to the withstand voltage test bus through multiple high-voltage matrix switches to realize automatic withstand voltage test;

[0051] Specifically, see Appendix Figure 2 , a schematic diagram of the framework of the insulation withstand voltage test module for performing insulation withstand voltage test, the module consists of a withstand voltage test power supply, a withstand voltage test bus, and a high-voltage matrix switch module, wherein the withstand voltage test power supply includes a leakage current detection circuit.

[0052] Specifically, the withstand voltage test power supply: output type: switchable between high-voltage direct current (DC) and high-voltage alternating current (AC); voltage range: DC 0–5000V / AC 0–3000V; output power: supports maximum current output 5mA; has leakage current limiting and flashover protection functions; is equipped with soft start and voltage ramp-up and ramp-down control to prevent breakdown of the device under test.

[0053] Withstand voltage test bus: High-voltage bus design, using insulation materials with a withstand voltage rating of up to 10kV; can carry multiple relays for parallel testing, ensuring high-voltage consistency and safe isolation; the bus is connected to the high-voltage matrix module through arc-proof sockets.

[0054] High-voltage matrix switch module: composed of a multi-channel controllable high-voltage relay / high-voltage solid-state switch array; the input control terminal, output terminal, and housing terminal of each relay under test are connected to the high-voltage matrix respectively; it can automatically complete the high-voltage connection between all combination paths (such as input-output, input-housing, output-housing); the control terminal communicates with the host computer through an optical isolation control board to ensure control safety.

[0055] Leakage current detection circuit: Used to detect leakage current flowing through the insulation path under high voltage conditions; resolution is better than 0.01mA, and the maximum supported value is 10mA; if the leakage current exceeds the set threshold (for example, 0.5mA), the system automatically alarms and terminates the test.

[0056] In addition, it also includes a safety interlock system: including a casing switch, an emergency stop button, and a test area access interlock; if the door is opened or an abnormality occurs during the test, the system automatically cuts off the high voltage to ensure personal safety.

[0057] Specifically, the specific work flow for insulation withstand voltage test is as follows:

[0058] 1. The host computer reads the product QR code and calls the preset test program (test voltage, current upper limit, duration, path combination, etc.);

[0059] 2. The withstand voltage power supply outputs high voltage DC or AC signals as required;

[0060] 3. Control the high-voltage matrix switch to connect the specified channel and apply the high-voltage signal to the two specified endpoints (such as input and output) of the SSR to be tested;

[0061] 4. At the same time, the leakage current detection circuit continuously monitors the leakage current value flowing through the test circuit;

[0062] 5. If the leakage current is less than the threshold value within the voltage duration, the “qualified” result is automatically recorded and the next path test is carried out;

[0063] 6. After all combination path tests are completed, the system records all test data and uploads it to the MES system.

[0064] The technical solution of the present invention has the following technical effects: high efficiency: automatic matrix switching + multi-channel batch testing, 16 to 64 SSRs can be tested in a single batch, and the testing efficiency is greatly improved; safety: it has multiple safety interlocking mechanisms to meet the personnel and equipment protection in high-voltage testing scenarios; flexibility: it supports high-voltage connection testing of any path combination and is adaptable to a variety of relay structures (single control, dual control, asynchronous control, etc.); data integrity: the test results of each channel are automatically recorded, including test time, voltage, current, whether it is broken down, leakage current size, etc., for easy traceability.

[0065] DC function test module: provides a programmable DC power supply, which is connected to the input control terminal of the relay to be tested through a first selection switch for DC function testing.

[0066] The DC functional test module in the present invention is used to automatically detect the response behavior of the solid-state relay (SSR) under the input of a DC control signal, including key indicators such as conduction action, electrical characteristic parameters (such as conduction voltage drop, input current, input control terminal voltage), switching logic, trigger voltage, etc., to ensure that it meets the design and safety specifications.

[0067] Specifically, see Appendix Figure 3 In the middle frame diagram, the DC functional test module includes a programmable DC power supply module, a first selection switch module, and a data acquisition module.

[0068] Specifically, the programmable DC power supply module has the following features: output voltage range: 0–60V; maximum output current: 5A; supports voltage and current programming control, with overcurrent protection and short-circuit protection functions; supports voltage scanning function, which can be used to determine the trigger voltage threshold; accuracy: voltage <0.1%, current <0.2%.

[0069] The first selection switch module: a low-voltage multi-channel matrix structure, used to connect the output of the programmable DC power supply to the input control terminal of the relay under test as needed; the control signal is issued by the system master control or PLC to achieve fast multi-channel switching; each switch is equipped with overvoltage protection and reverse clamping functions to prevent abnormal input from damaging the test equipment.

[0070] Data acquisition module: includes the first data acquisition module and the second data acquisition module, which contain a high-precision ADC and an isolated measurement unit; collects and records the voltage and current of the input control terminal; determines in real time whether the SSR conduction condition is met; and can be used to identify whether there are failure modes such as open circuit, short circuit, abnormal resistance, etc. at the control terminal.

[0071] Test functions and processes:

[0072] 1. DC continuity test:

[0073] Set the target control voltage (such as 5V / 12V / 24V and other common input standards);

[0074] Programmable DC power supply is output to the target SSR input control terminal;

[0075] Monitor whether the SSR output terminal is conducting (determined by output load current and loop voltage drop);

[0076] Record whether it is conductive, conduction time, output current, etc.

[0077] 2. Input characteristics test:

[0078] Scanning control input voltage (e.g. 0–10V linear increase);

[0079] Record the starting voltage of SSR conduction to determine whether the trigger voltage is compliant;

[0080] It can be determined whether there is an early turn-on or late turn-on failure.

[0081] 3. Input current detection:

[0082] At a fixed voltage, record the current absorbed by the SSR input control terminal;

[0083] Determine whether the input impedance is normal and whether there is an overcurrent risk;

[0084] Compare to historical standards to identify potential consistency anomalies.

[0085] The technical solution of the present invention has the following technical effects: automatic switching channel test: it can automatically switch between dozens of relays, and the efficiency is more than 10 times higher than that of manual testing; programmable input voltage waveform: supports static / dynamic / scanning tests, and is suitable for different types of SSR products; input current monitoring: realizes online screening of control end abnormalities (such as internal short circuit, insufficient driving capability); safety protection design: with input current limiting, reverse connection protection and short circuit protection, to ensure test safety and equipment life.

[0086] AC function test module: provides a programmable AC power supply, which is connected to the input control terminal of the relay to be tested through the first selection switch for AC function test.

[0087] Specifically, the AC functional test module in this invention is primarily used to automatically detect the response performance of solid-state relays (SSRs) under AC input signal control. It is suitable for SSR products that use AC input signals or are compatible with AC / DC control. The module can simulate AC input signals of different amplitudes, frequencies, and phases to test their conduction, shutdown, trigger voltage, electrical response characteristics, and other characteristics, meeting the needs of various industrial applications.

[0088] Specifically, see Appendix Figure 3 In the middle frame diagram, the AC function test module includes a programmable AC power supply module, a first selection switch module, and a data acquisition module.

[0089] The programmable AC power source module can output a 0–300V sinusoidal AC voltage with a frequency range of 40Hz–500Hz. It supports single-phase and three-phase output modes, and dual closed-loop control of voltage and current. It also features programmable output waveforms (sine, square, and distorted waveforms). It also includes internal functions such as power factor adjustment, output current limiting, and overload protection. Its communication interface supports Modbus, CAN, or RS485 protocols, enabling remote control by the test system.

[0090] First selection switch module (low voltage matrix relay array):

[0091] The control signal selection switch can connect the programmable AC power output to the input control terminals of multiple SSRs under test; the switch array is shared with the DC functional test module to achieve AC / DC control test multiplexing; and it supports channel rotation and automatic switching control mode to improve multi-channel testing efficiency.

[0092] Data acquisition module: includes the first data acquisition module and the second data acquisition module, which collect the AC waveform of the SSR input control terminal in real time; detect whether the SSR can be normally turned on or off under different phases of the AC voltage; provide characteristic analysis support such as zero voltage triggering / zero current disconnection; the sampled signal will be uploaded to the main control system to determine whether it meets the product design indicators.

[0093] Test functions and processes:

[0094] 1. AC continuity test:

[0095] Start the AC power supply to output the set voltage (such as 220V AC);

[0096] Connected to the input control terminal of the SSR under test through the first selection switch;

[0097] Monitor whether the SSR output is on and determine whether its input control terminal responds normally;

[0098] Synchronous detection of current waveform, conduction time, phase difference and other performance indicators during conduction, see the attached Figure 4 Schematic diagram of AC on-time test signal.

[0099] 2. Trigger characteristic test:

[0100] Gradually adjust the AC control voltage amplitude and record the minimum effective voltage that triggers the SSR to conduct;

[0101] Analyze whether the control input and conduction logic relationship are compliant (for example, some SSRs need to be turned on in the positive half cycle);

[0102] For SSRs with zero-crossing triggering function, it is possible to monitor whether they are turned on only at the voltage / current zero-crossing point.

[0103] 3. Input power consumption and leakage current detection:

[0104] When the SSR is in the off state, monitor its input control terminal for leakage current;

[0105] When the SSR is in the on state, record the input power and power factor of the input control terminal;

[0106] It can determine whether there are problems such as short circuit, leakage conduction, inconsistent response, etc. at the input control terminal.

[0107] The technical solution of the present invention has the following technical effects: rich adjustable parameters: programmable control of AC voltage amplitude, frequency, and waveform to adapt to various SSR input specifications; comprehensive analysis of AC characteristics: support for advanced functions such as zero-crossing detection, conduction delay test, and trigger phase analysis; sharing the switching matrix with the DC test system: saving system resources and improving test efficiency.

[0108] The automatic load module adopts a programmable load matrix, is connected with the output end of the relay to be tested, the current transformer, the second data acquisition module and the load power supply to form a loop for automatic load adjustment, and the current transformer is connected to the first data acquisition module.

[0109] Specifically, the automatic load module is a key component in the present invention for testing the dynamic load capacity of multi-channel solid-state relays (SSRs). This module flexibly switches load types and adjusts load parameters according to different test conditions, enabling simulation of real-world loads in the relay's on state, output capacity evaluation, and thermal aging testing.

[0110] Specifically, the automatic load module mainly includes the following components:

[0111] Programmable Load Matrix:

[0112] It supports three operating modes: constant current (CC), constant resistance (CR), and constant power (CP). It uses a combination of electronic load and analog resistive load to achieve wide-range, high-precision load regulation. It has internal overcurrent, overvoltage, and overtemperature protection logic. It also features multi-channel switching and matrix selection capabilities, allowing it to be connected to any number of relay outputs under test.

[0113] Current Transformer (CT):

[0114] High-precision sampling element, real-time acquisition of the operating current in the relay load circuit; non-contact measurement to improve system safety; can detect indicators such as conduction current, inrush current, and shutdown residual current.

[0115] Second data acquisition module:

[0116] It is mainly responsible for collecting the voltage value, leakage current signal, current waveform, etc. at the output end of the relay; the accuracy is as high as ±0.2%, and it supports multi-channel concurrent sampling; it supports real-time uploading of data to the host computer system for analysis.

[0117] Load Power Supply:

[0118] Provides switchable DC load power supply and AC load power supply; automatically connects to different test circuits through the load power selection switch; ensures that the output circuit has a real adjustable load environment when the SSR is working.

[0119] The MES execution module connects to the host computer software of the test device, is used to scan the code to identify the product number and automatically configure the test parameters. It connects to the factory MES system and records the product test performance data.

[0120] Specifically, the MES execution module is the core information interface used in this invention to implement product identification, automatic configuration of test process parameters, result recording, and quality tracking. By connecting with the factory's existing Manufacturing Execution System (MES), it enables seamless integration of test equipment and production information systems, significantly improving testing efficiency, reducing human error, and meeting traceability and quality control requirements.

[0121] Specifically, the MES execution module mainly includes the following subsystems or functional units:

[0122] Scan code recognition subsystem:

[0123] Supports handheld barcode scanners and automatic barcode scanning devices (such as cameras and OCR); automatically extracts the product's unique serial number (SN) by reading the QR code or barcode on the relay body or packaging; compatible with one-dimensional code (Code 128) and two-dimensional code (QR Code, DataMatrix) standards; supports a manual input fallback mechanism to prevent interruptions caused by scanning failures.

[0124] Parameter automatic configuration module:

[0125] The MES system presets a test parameter template for each product model (including withstand voltage value, test time, load current, etc.); the MES execution module queries the model and version of the product based on the product number obtained by scanning the code; the upper computer software calls the parameter database and sends it to the test system to achieve automatic configuration of "one object, one code, one code, one parameter".

[0126] Data acquisition and recording module:

[0127] Collects test results and process data of each test submodule (voltage resistance, function, load, etc.) in real time; including pass / fail judgment, detailed fault code, voltage / current waveform data, timestamp, etc.; supports recording test process logs and abnormal events; local temporary cache and automatic retransmission of failed data packets to ensure data is not lost.

[0128] MES data upload interface:

[0129] Interface with MES platform through standard industrial communication protocol (such as OPC UA, HTTP / RESTful API, TCP Socket) ; pack test data of each product into structured data and upload to MES system; upload content includes product number, test time, test personnel, test station number, test result (PASS / FAIL), main parameter value; support returning MES feedback state (success / failure / need to retest).

[0130] Result visualization and alarm module:

[0131] Referring to the accompanying drawings Figure 5 Visual interface diagram of host computer, real-time display of historical data query, test data, equipment running state and data upload state on host computer interface; once upload fails or test fails, trigger sound and light alarm or red light indication, prompt operator to intervene; display qualified / unqualified identification after test completion, can be linked to print label equipment or drive mechanical arm to remove unqualified products.

[0132] Specifically, the operation process is as follows:

[0133] 1. Scan code to identify product information:

[0134] The operator puts the relay to be tested into the tool fixture; the system automatically or manually scans the code to identify the unique product number; the MES interface requests product parameters and returns the corresponding test scheme.

[0135] 2. Issue parameters and automatically execute test:

[0136] The host computer software receives the parameter template and automatically configures the test module; the test process automatically runs according to the configuration order without manual intervention; if parameter abnormalities (such as voltage setting exceeding specifications) are found during the test, the system automatically alarms and stops the test.

[0137] 3. Collect results and upload to MES:

[0138] Each step of the test process data is recorded and associated with the product number; after the test is completed, all data is summarized and sent to the MES system; the MES system judges whether it is qualified and indicates the subsequent process or retest.

[0139] The plurality of high-voltage matrices are used to connect any two points between the input control end, the output end and the shell of the relay to be tested to the withstand voltage test bus.

[0140] Specifically, in the withstand voltage test system of the application, a plurality of high-voltage matrices constitute a flexible programmable high-voltage connection path, which is used to dynamically connect any two points between the input control end, the output end and the shell of the relay to be tested to the withstand voltage test bus, so as to realize an automatic and reconfigurable withstand voltage test process.

[0141] 1. Each high-voltage matrix switch module consists of the following parts:

[0142] 1. High-voltage controllable switch array:

[0143] Use high-voltage relays, solid-state relays, or high-voltage MOS switch arrays; able to withstand DC or AC test voltages above 1kV; the switches are controlled by the lower computer and are dynamically turned on or off according to the configuration.

[0144] 2. Control logic unit:

[0145] Communicate with the host computer and receive test configuration instructions; drive the switch matrix action through IO control or bus protocols (such as CAN, Modbus); support fast switching and multi-channel parallel control.

[0146] 3. Insulation protection and detection module:

[0147] Each channel has an isolation design to prevent high voltage from entering the control system; switch status feedback detection can be set to improve safety; and it supports automatic detection and alarm of abnormal open circuit / short circuit.

[0148] 2. Connection method and principle

[0149] Each relay under test typically has three types of conductive points:

[0150] Input control terminal (control line);

[0151] Output terminal (switch output);

[0152] Shell grounding terminal (contacting the metal shell or grounding pin).

[0153] To verify its dielectric strength (insulation performance), the system needs to select any two points between the three to perform high voltage withstand test. To achieve the above flexible connection requirements, the present invention introduces a high voltage matrix for switching, as shown below:

[0154] Test items High voltage matrix connection method Control end-output end voltage test The control terminal is connected to high voltage and the output terminal is grounded Control end-shell pressure test Control terminal connected to high voltage, shell grounded Output end-shell pressure test The output terminal is connected to high voltage and the shell is grounded

[0155] The system control unit instructs the high-voltage matrix to switch channels according to the MES or test process logic to ensure that each test is completed between different points without manual line changing. The technical effect of this solution: Fully automatic switching: avoids traditional manual wiring or transfer bench methods; improves test efficiency, and is suitable for batch rapid shipment testing. Any point-to-point connection capability: not limited to a few fixed sets of test paths; supports customer-customized test logic, such as three-point full mutual testing, shell grounding testing, etc. Safety isolation design: The high-voltage channel is completely isolated from the control circuit; it has leakage detection, forced disconnection and other protection mechanisms. Strong scalability: The high-voltage matrix is ​​modular in design, and the number of channels can be expanded according to the number of pins of the relay to be tested; one system supports mixed testing of multiple models and multi-pin devices.

[0156] Preferably, the load power supply includes an AC load power supply, a DC load power supply and a load power supply selection switch.

[0157] Specifically, the load power supply module in the present invention is used to provide an adaptive working power supply for different test scenarios to ensure the normal operation of the automatic load test function. The module includes:

[0158] AC load power supply: Outputs stable AC voltage (such as 220V, 380V, frequency 50Hz / 60Hz) to simulate AC power supply environment and is suitable for testing AC relay components.

[0159] DC load power supply: outputs adjustable DC voltage and current (such as 12V, 24V, 48V, 110V, etc.), suitable for testing DC control relays.

[0160] Load power selector switch: Used to switch between AC and DC load power, connecting the selected power source to the automatic load module to form a test loop. This selector switch can be a mechanical relay, electronic switcher, or multiplexer module, and is dynamically controlled by the system control logic.

[0161] Preferably, the first selection switch and the load power selection switch in the DC function test module and the AC function test module are selectively controlled according to the model and test items of the test product.

[0162] Specifically, the control system of the present invention (such as host computer software, PLC or embedded controller) has a built-in product model identification and test process library to implement the following automatic configuration logic:

[0163] Product identification: The MES execution module scans the code to identify the unique number of each product to be tested; the system queries the corresponding model, structure, voltage level, load type and other parameters based on the number.

[0164] Function module selection control:

[0165] If a DC relay is identified, the control system will: enable the first selector switch in the DC function test module; select a DC load power supply; and configure the load value of the automatic load module (such as resistance, constant current, etc.). If an AC relay is identified, the control system will: enable the first selector switch in the AC function test module; switch to an AC load power supply; and adjust the frequency, voltage, etc. to match the test requirements.

[0166] Switch state control: The first selector switch controls the on / off of the test signal, ensuring that the test source is correctly connected to the control terminal of the relay under test; the load power selector switch determines the power supply mode of the load path; all switch states can be automatically configured through logic tables, scripts or preset processes without manual operation.

[0167] Flexible expansion and customization: The system supports the dynamic addition of new models and their test plans; default plans can be set or manually overwritten to meet various factory scenarios such as trial production and change management.

[0168] Preferably, the second data acquisition module is used to perform high-precision voltage sampling on the input control terminal and the output terminal, and to sample the leakage current of the output circuit.

[0169] Specifically, the second data acquisition module provided in the present invention is mainly used to perform high-precision acquisition and monitoring of the input control terminal voltage, output terminal voltage and output circuit leakage current of the solid-state relay to be tested, providing basic data support for function judgment and performance evaluation.

[0170] The second data acquisition module includes the following core components:

[0171] Voltage sampling unit:

[0172] Used to collect the voltage values ​​of the input control terminal and output terminal of the relay under test; uses a high-resolution ADC (analog-to-digital converter) sampling chip (such as 16-bit, 24-bit accuracy); the input control terminal sampling circuit has isolation protection and overvoltage clamping protection, which can accurately reflect the relay drive signal; output terminal sampling is used to determine the relay conduction state and voltage drop characteristics.

[0173] Leakage current detection unit:

[0174] Through precision shunts or leakage detection chips, combined with signal conditioning circuitry, weak currents are captured. Leakage current detection is performed on relays in the off state, with typical resolution reaching μA levels. This can be used to determine relay isolation performance and insulation degradation. Isolation and sampling protection: All sampling channels utilize high-voltage optocoupler isolation or isolation amplifiers (such as the ISO124 and ADuM series) to ensure electrical isolation between test signals and the control system, improving equipment safety and system reliability.

[0175] Communication and interface:

[0176] The module uses SPI, I 2 C, CAN or Ethernet and other means to communicate with the main control system; the sampling data is uploaded to the host computer or control PLC in real time for judgment logic analysis or storage.

[0177] Preferably, the first data acquisition module is further used to perform voltage sampling on the input control terminal.

[0178] Specifically, in the automated multi-channel solid-state relay test device of the present invention, the first data acquisition module is mainly used to monitor and sample the voltage state of the relay input control terminal and the current state of the current transformer of the output circuit in real time, to assist in judging the integrity and validity of the control signal and ensure the accuracy and repeatability of the test data. Before performing the DC functional test, AC functional test, and withstand voltage test, the system first confirms through this module whether the input signal has been added and whether the signal amplitude is compliant; it supports real-time reporting of sampled data to the host computer system, and can perform input response curve analysis (such as rising edge, falling edge) or abnormal control signal alarm; for example, for a relay whose input voltage should be 5V, if the actual sampled value is 3.2V, it can be judged that the control terminal signal is abnormal or the drive source performance is insufficient.

[0179] Preferably, the programmable load matrix has constant current, constant resistance and constant power modes.

[0180] Specifically, the programmable load matrix set in the output circuit of the test device of the present invention can provide three different operating modes: constant current (CC), constant resistance (CR), and constant power (CP) to adapt to the test requirements and actual application scenarios of different types of solid-state relays.

[0181] Preferably, the programmable load matrix adopts a four-area block-type programmable electronic-resistance hybrid load matrix.

[0182] Specifically, the entire load matrix area is divided into four rectangular areas (for example, A, B, C, and D), and the functions are configured according to the diagonal pattern of the chessboard:

[0183] Area A (upper left): electronic load array;

[0184] Area C (lower right corner): electronic load array (symmetrical with area A);

[0185] Area B (upper right): resistor load array;

[0186] Area D (lower left corner): resistor load array (symmetrical with area B);

[0187] The load array within each zone is modularly designed, using, for example, a 4×4 grid of subunits. Controllable switch arrays connect the subunits, the load matrix and external connection terminals, and each zone. This diagonally symmetrical arrangement creates a balanced configuration for both functionality and path scheduling, facilitating path shortening.

[0188] Preferably, the four-region block-type programmable electronic-resistive hybrid load matrix uses reinforcement learning to determine the optimal load path, wherein the reward function R is set to:

[0189] R=α·(ΔV) 2 +β·T-γ·B

[0190] Where ΔV is the path voltage drop, T is the path temperature rise, and B is the path load balancing index.

[0191] Among them, α, β, and γ are empirical weighting factors, which are determined using the path equilibrium model.

[0192] Specifically, in the automated solid-state relay test system described herein, the choice of load path directly impacts the accuracy and efficiency of the test. Because the electronic load and resistive load matrix can be combined in a variety of ways, each combination path corresponds to a different load mode, response speed, power efficiency, and thermal stability.

[0193] To achieve optimal performance matching, the present invention introduces a reinforcement learning (RL) algorithm to dynamically select the optimal load path under different relay models and test tasks by autonomously learning the mapping relationship between test results and path selection.

[0194] Reinforcement Learning Modeling:

[0195] 1. State space (State, S):

[0196] The state space represents the current test conditions and system status, including:

[0197] Relay model and rated parameters (voltage, current, control voltage);

[0198] Current test mode (constant current / constant resistance / constant power);

[0199] The load type and occupancy of each branch in the current load matrix;

[0200] Operational feedback such as temperature rise level, voltage drop, response time, etc.

[0201] For example, a state can be represented as:

[0202] S=[Relay_Type=SSR_24V, Mode=CP, Load_Branch_1=Resistor, Load_Branch_2=Electronic, Temp_Rise=Low]

[0203] 2. Action Space (Action, A):

[0204] Actions represent the selection of one or a combination of load paths, for example:

[0205] Enable a certain group of electronic loads;

[0206] Switch to a certain set of power resistors;

[0207] Electronic load + resistance load parallel path;

[0208] Toggle load mode parameters.

[0209] 3. Reward function (Reward, R):

[0210] The reward function is a performance feedback indicator of the system operation after path selection, which is used to guide the learning direction:

[0211] ΔV: Path voltage drop (the larger the voltage drop, the higher the power consumption). The smaller the voltage drop, the higher the reward.

[0212] T: Path temperature rise (affects life and safety). The lower the temperature rise, the faster the response, the lower the energy consumption, and the higher the reward.

[0213] B: Path load balancing indicator (the inverse of the path usage frequency). The larger the value, the more deviation from the balance, and a negative reward is given.

[0214] For example, the reward function can be set as:

[0215] R=α·(ΔV) 2 +β·T-γ·B

[0216] Where α, β, and γ are empirical weighting factors. The specific process of determining the empirical weighting factors α, β, and γ using the path equilibrium model is as follows:

[0217] Define the path comprehensive cost function:

[0218] J i =α·(ΔV i ) 2 +β·T i -γ·B i

[0219] The goal is to make the J values ​​of all paths as close as possible (balanced) to form path balance in the system.

[0220] Construct a path dataset: Collect sample data (voltage drop, temperature rise, and load balancing indicators) of N historical load paths:

[0221] {(ΔV1,T1,B1),(ΔV2,T2,B2),...,(ΔV N ,T N ,B N )}

[0222] Set the minimum balanced deviation objective function: minimize the variance of each path cost J (the more balanced the better):

[0223]

[0224] in

[0225] Add regularization constraints: such as α+β+γ=1 to ensure a reasonable ratio; or add L2 regularization to control overfitting.

[0226] Solve using an optimization algorithm: use constrained minimization calculations; output the final values ​​of α, β, and γ, which are the empirical weighting factors under path equilibrium.

[0227] 4. Strategy learning method:

[0228] Reinforcement learning algorithms such as Q-learning or DQN (Deep Q-Network) are used to achieve policy optimization by iteratively updating each state-action pair Q(S,A).

[0229] The update formula is as follows (Q-learning):

[0230] Q(S,A)←Q(S,A)+η[R+γmaxQ(S',A')-Q(S,A)]

[0231] in:

[0232] η is the learning rate; γ is the discount factor; R is the current reward; S' is the new state after executing the action.

[0233] 3. Execution process (operation process)

[0234] Initialize the policy table or neural network weights;

[0235] Read test requirements (input parameters: relay model, target current, etc.);

[0236] Perceive system status (current load occupancy, thermal status, sampling error, etc.);

[0237] Select a load path combination based on the current strategy;

[0238] Perform tests and obtain data such as current, voltage, temperature rise, and test time;

[0239] Calculate rewards and update strategies;

[0240] Repeat the training to gradually approach the optimal strategy.

[0241] In practical applications, after the initial stage of data training, the reinforcement learning model can achieve the following: rapid adaptation of the optimal load path for different product models; high load balancing and efficiency under limited resources; avoid human experience intervention and improve the level of test intelligence.

[0242] An automated multi-channel solid-state relay testing method employing any of the aforementioned automated multi-channel solid-state relay testing devices is provided for performing insulation withstand voltage testing, control terminal function testing, output terminal performance testing, and data collection and archiving on the relay under test, the method comprising:

[0243] Product code scanning and configuration file calling;

[0244] Automatic selection and application of power supply signal at input control terminal;

[0245] Automatic matching of output load;

[0246] Use the first data acquisition module and the second data acquisition module to collect and record test data;

[0247] The host computer automatically saves the test data and uploads it to the MES system.

[0248] Compared with the prior art, the present invention has the following beneficial effects:

[0249] 1. High degree of test automation and significantly improved efficiency. Through a multi-channel test structure design, combined with a high-voltage matrix switch, programmable power supply, and automatic load system, multiple solid-state relays can be tested in parallel, greatly reducing manual plugging and switching, and increasing test throughput. It is suitable for factory testing or aging screening of large quantities of relays.

[0250] 2. Modular design, adaptable to various testing needs.

[0251] The device integrates an insulation withstand voltage test module, a DC function test module, an AC function test module and an automatic load test module. It can automatically switch the test power supply and control mode, and supports unified platform testing of solid-state relays of different models and types (DC / AC control input), thereby improving the versatility and flexibility of the equipment.

[0252] 3. Automatic load adjustment, covering typical operating scenarios. The programmable electronic-resistive hybrid load matrix has multiple operating modes such as constant current, constant resistance, and constant power. It adapts to the characteristics of relays with different rated output currents or powers, simulates actual working conditions, and improves test accuracy and effectiveness.

[0253] 4. Support intelligent algorithms to optimize load configuration

[0254] Combined with intelligent algorithms based on reinforcement learning, the system automatically selects the optimal load path and operating mode for different types of solid-state relays, improving test efficiency and avoiding overheating, misjudgment, or equipment waste caused by improper load configuration.

[0255] 5. Fully integrated MES system to ensure production traceability

[0256] Through the MES execution module communicating with the host computer, the product QR code or barcode is automatically identified, the corresponding test program and standard are quickly called, and the test data is automatically uploaded and archived, realizing closed-loop traceability of test data throughout the product life cycle and meeting the requirements of the quality management system.

[0257] 6. Strong scalability, conducive to subsequent maintenance and upgrades

[0258] The modules of this device use standard interfaces for communication. The number of test channels can be expanded and test functions (such as life test, high-temperature aging test, etc.) can be added according to product specifications. This supports subsequent system maintenance and technology upgrades, thereby improving the return on investment.

[0259] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. An automated multi-channel solid-state relay test device, characterized in that: include: Insulation withstand voltage test module, the withstand voltage test power supply provides high-voltage DC voltage or high-voltage AC voltage, connected to the withstand voltage test bus, multiple relays to be tested are connected to the withstand voltage test bus through multiple high-voltage matrix switches, to achieve automatic withstand voltage test; DC function test module: provides a programmable DC power supply, which is connected to the input control terminal of the relay to be tested through a first selection switch for DC function test; AC function test module: provides a programmable AC power supply, which is connected to the input control terminal of the relay to be tested through the first selection switch for AC function test; An automatic load module, using a programmable load matrix, is connected to the output end of the relay to be tested, a current transformer, a second data acquisition module and a load power supply to form a loop for automatic load adjustment, wherein the current transformer is connected to the first data acquisition module; The MES execution module connects to the host computer software of the test device, is used to scan the code to identify the product number and automatically configure the test parameters. It connects to the factory MES system and records the product test performance data.

2. The testing device according to claim 1, wherein: The multiple high-voltage matrices are used to connect any two points between the input control terminal, the output terminal, and the housing of the relay to be tested to the withstand voltage test bus.

3. The testing device according to claim 1, wherein: The load power supply includes an AC load power supply, a DC load power supply and a load power supply selection switch.

4. The testing device according to claim 3, characterized in that: According to the model and test items of the test product, the first selection switch and the load power selection switch in the DC function test module and the AC function test module are selected and controlled.

5. The testing device according to claim 1, wherein: The second data acquisition module is used to perform high-precision voltage sampling on the input control terminal and the output terminal, and to sample the leakage current of the output circuit.

6. The testing device according to claim 1, wherein: The first data acquisition module is further used to sample the voltage of the input control terminal.

7. The testing device according to claim 1, characterized in that The programmable load matrix has constant current, constant resistance and constant power modes.

8. The testing device according to claim 7, characterized in that: The programmable load matrix adopts a four-area block-type programmable electronic-resistance hybrid load matrix.

9. The testing device according to claim 8, characterized in that: The four-region block-type programmable electronic-resistive hybrid load matrix uses reinforcement learning to determine the optimal load path, where the reward function R is set as: R=α·(ΔV) 2 +β·T-γ·B Where ΔV is the path voltage drop, T is the path temperature rise, and B is the path load balancing index. α, β, and γ are empirical weighting factors, which are determined using the path balancing model.

10. An automated multi-channel solid-state relay testing method, using the automated multi-channel solid-state relay testing device according to any one of claims 1 to 9, for performing insulation withstand voltage testing, control terminal function testing, output terminal performance testing, and data acquisition and archiving on a relay under test, the method comprising: Product code scanning and configuration file calling; Automatic selection and application of power supply signal at input control terminal; Automatic matching of output load; Use the first data acquisition module and the second data acquisition module to collect and record test data; The host computer automatically saves the test data and uploads it to the MES system.

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