Automatic power supply test system and method

Abstract

The invention relates to an automatic power supply test system and method. The automatic power supply test system comprises a programmable AC power supply module, an electrical performance acquisition module, a control module and a plurality of electronic load modules. The power output end of the programmable AC power supply module is connected with the power input end of a to-be-tested DC power supply, and the signal input end of the programmable AC power supply module is connected with the signal output end of the control module. The power output end of the to-be-tested DC power supply is connected with the signal input end of the electrical performance acquisition module, and is dynamically connected with the power input ends of the plurality of electronic load modules. The control module is used for determining a corresponding test mode, and generating a corresponding programmable power supply control signal and a dynamic connection control signal according to the test mode so as to simulate different power supply working conditions and realize load test processes under different load conditions. The testing device can adapt to various power supply and load working conditions, and solves the problems of dispersed functions and bloated structure of the existing testing device.

Description

Technical Field

[0001] This invention relates to the technical field of automated power supply testing, and more particularly to an automated power supply testing system and method. Background Technology

[0002] Currently, in the production, manufacturing, and other related application fields of power supplies, multiple functional tests are typically required for power supply products, such as electrical parameter testing and protection characteristic testing. Existing technologies often require various testing instruments with different functions to achieve these multiple testing objectives. However, the functions of different testing instruments are fragmented, system integration is low, and the overall structure is complex with cumbersome usage procedures, resulting in low testing efficiency and high operational difficulty, which is detrimental to the rapid verification and consistency management of power supply products. Summary of the Invention

[0003] To address the issues of low testing efficiency and high operational difficulty caused by the need for various testing instruments with different functions in traditional automated power supply testing, this application provides an automated power supply testing system and method.

[0004] An automated power supply testing system is used to test a DC power supply under test. The automated power supply testing system includes a main power input module, a power distribution module, a programmable AC power supply module, an electrical performance acquisition module, a control module, and multiple electronic load modules. The power output terminal of the main power input module is connected to the power input terminal of the power distribution module and the power input terminal of the programmable AC power module, respectively. The power output terminal of the power distribution module is connected to the power performance acquisition module, the control module, and the plurality of electronic load modules, respectively. The power output terminal of the programmable AC power module is connected to the power input terminal of the DC power supply under test, and the signal input terminal of the programmable AC power module is connected to the signal output terminal of the control module. The power output terminal of the DC power supply under test is connected to the signal input terminal of the electrical performance acquisition module, and is dynamically connected to the power input terminals of multiple electronic load modules. The control module is used to determine the corresponding test mode, and then generate corresponding programmable power control signals and dynamic connection control signals according to the test mode. The programmable power control signals are used to control the DC power supply under test to provide corresponding AC input power to simulate different power supply conditions. The dynamic connection control signals are used to control the load connection relationship between the power output terminal of the DC power supply under test and the multiple electronic load modules in the corresponding group of electronic load modules, so as to realize the load test process under different load conditions.

[0005] By adopting the above technical solutions, the entire process of power input, power distribution, load connection, waveform measurement and test control is integrated and controlled, which significantly improves the automation level and structural compactness of the test system. At the same time, it can adapt to various power supply and load conditions and solves the problems of scattered functions and bloated structure of existing test equipment.

[0006] Preferably, the electrical performance acquisition module includes at least an electrical parameter measurement unit and a waveform detection unit; The electrical parameter measurement unit is used to collect the voltage, current, power and power factor parameters of the DC power supply under test in each test mode; The waveform detection unit is used to collect the output voltage waveform or output current waveform of the DC power supply under test in each test mode.

[0007] By adopting the above technical solution, the electrical performance acquisition module is refined into an electrical parameter measurement unit and a waveform detection unit, which are used to acquire output parameters and output waveforms respectively. This enables efficient acquisition of the performance data of the power supply under test in different test modes, achieving a comprehensive evaluation of the power supply output quality, thereby improving test accuracy and diagnostic capabilities.

[0008] Preferably, the main power input module includes at least a plug, a leakage current protection switch and an AC contactor connected in series, with the end of the AC contactor furthest from the leakage current protection switch serving as the power output terminal of the main power input module to output power for supply.

[0009] By adopting the above technical solution, the main input circuit is formed by introducing a series plug, leakage protection switch and AC contactor in the main power input module, which can not only ensure power supply stability, but also have electrical safety protection capabilities, thereby improving the overall system's operational safety and reliability.

[0010] An automated power supply testing method, applied to an automated power supply testing system, the automated power supply testing method comprising: Determine the test mode; Based on the mapping relationship of the test modes, the corresponding process template is matched; Obtain and parse the test item information input by the user, and extract the test parameters associated with the process template; A test instruction sequence is generated based on the test parameters, and the test instruction sequence is filled into the preset operation node of the process template to generate the corresponding test process; The test process is executed, and the electrical performance acquisition module collects various test data in the test process. The test data is analyzed and judged, and the corresponding test results are output.

[0011] By adopting the above technical solution, a mapping mechanism between test modes and process templates is established. Test instruction sequences are generated by combining the test item information input by the user and filled into the preset operation nodes in the template. This achieves the standardization, automation and parameter-driven nature of the test process, effectively improving the flexibility and scalability of the test system.

[0012] Preferably, the step of executing the test process specifically includes: The testing process includes: The load setting sub-process is used to set the load mode, voltage, current range and load value of multiple electronic load modules; The AC power programming sub-process is used to set the output voltage, frequency, and output status of the programmable AC power module. The test target setting sub-process is used to set the target output voltage, current and output status of the DC power supply under test; The load setting sub-process, the AC power programming sub-process, and the test target setting sub-process are all scheduled according to the first preset execution order in the test process, and are selectively executed according to the enable state specified in the test process.

[0013] By adopting the above technical solution, the test process is broken down into multiple schedulable functional sub-processes, including load setting, AC power programming, and test target setting. The execution logic is determined according to the preset sequence and enable status, which improves the flexibility of the operation process and enables precise scheduling and control between different test steps.

[0014] Preferably, the step of collecting various test data in the test process through the electrical performance acquisition module and analyzing and judging the test data specifically includes: According to the test process, match the corresponding set of read threads and the second preset execution order; The set of reading threads is used to control the electrical parameter measurement unit or waveform detection unit in the electrical performance acquisition module to perform corresponding acquisition operations. The second preset execution order is used to determine the scheduling order and triggering time of each read thread in the read thread set.

[0015] By adopting the above technical solution, the system achieves time-sharing scheduling of electrical performance acquisition modules by matching the set of reading threads and the execution order according to different test data acquisition requirements. This ensures the accuracy of the data acquisition order and the reasonable use of acquisition units, thereby improving the timeliness and resource utilization of sampling operations.

[0016] Preferably, the step of collecting various test data in the test process through the electrical performance acquisition module and analyzing and judging the test data includes: Based on the test data obtained through the current reading thread, a first judgment threshold range corresponding to the test data is extracted from the test item information; Determine whether the test data falls within the range of the first determination threshold; If the test data does not fall within the first determination threshold range, the corresponding first abnormal information is recorded and the test data is marked as NG. If the value falls within the first determination threshold range, the next read value thread is executed based on the second preset execution order until all read value threads have been executed. When all the read threads have completed their execution, the corresponding data post-processing operations are matched and executed according to the test process.

[0017] By adopting the above technical solution, and by comparing each test data with the corresponding judgment threshold, abnormal items in the test can be accurately identified, and subsequent data acquisition threads can be automatically executed according to the preset order. This realizes automatic closed-loop control of the data acquisition and judgment process, and improves the system's response capability to abnormal states and the reliability of the test.

[0018] Preferably, in the step of matching and executing the corresponding data post-processing operation according to the test process when all the read threads have completed execution, the data post-processing operation includes a calculation operation, including: When a corresponding calculation indicator is matched according to the test process, a corresponding calculation operation is performed based on the calculation indicator. The calculation operation is used to calculate the corresponding indicator value based on the test data. Extract the second judgment threshold range corresponding to the test data from the test item information, and determine whether the indicator value falls within the second judgment threshold range; If it does not fall within the second judgment threshold range, then the corresponding second abnormal information is recorded and the indicator value is marked as NG. If the value falls within the second judgment threshold range, then other indicator values ​​are calculated to determine whether they are abnormal, until all indicator values ​​are judged.

[0019] By adopting the above technical solution, after completing all reading operations, the original test data is further calculated and judged according to the calculation indicators configured in the test process. This can output more complex performance evaluation results and screen out abnormal indicators through the threshold verification mechanism, thus realizing the integration of complex data post-processing and automatic judgment.

[0020] Preferably, in the step of matching and executing the corresponding data post-processing operation according to the test process when all the read threads have completed execution, the data post-processing operation includes a recovery operation, including: When the test process matches the corresponding recovery index, the corresponding recovery parameters are extracted from the test item information. The recovery parameters include at least the recovery load value and the recovery voltage value. The corresponding electronic load module is restored to its restored load value; Once the electronic load module recovers to the recovered load value, the current output voltage value of the DC power supply under test is read, and it is determined whether the current output voltage value has recovered to the recovered voltage value. If the voltage does not recover to the recovery value, the corresponding third abnormality information is recorded and the current output voltage value is marked as NG. If the voltage returns to the restored value, the data post-processing operation will end.

[0021] By adopting the above technical solution, when the test process includes fault recovery test items, the system can control the electronic load to recover to the set value based on the recovery parameters configured in the test item information, and monitor the output recovery status of the power supply, thereby determining the recovery capability after the fault and improving the detection coverage of the power supply robustness and recovery performance.

[0022] Preferably, after the step of outputting the corresponding test result, the method further includes: The test results are encapsulated into structured data and sent to a preset target address, the preset target address including at least the shared IP of the MES system provided by a third-party terminal; In the third-party terminal that receives the structured data, the structured data is parsed and the corresponding field content is extracted; A corresponding test report is generated based on the field content. A process capability index analysis result is generated in the test report, and the test report is stored in a specified path or sent to an external system interface.

[0023] By adopting the above technical solution, after the test is completed, the system encapsulates the test data into a structured format and sends it to the target address. Data sharing is achieved through integration with third-party systems (such as MES systems), and process capability analysis reports are automatically generated. This provides enterprise customers with real-time feedback and quality traceability of test results, thereby improving the enterprise-level application capabilities and integration level of the testing system.

[0024] In summary, this application includes at least one of the following beneficial technical effects: This application addresses the problems of fragmented functions, complex and cumbersome structures, and difficulties in unified scheduling and automated control in existing power supply testing equipment by adopting a unified architecture and integrated multi-module collaborative working mechanism. Utilizing a centralized scheduling test mode through a control module, it simulates different input voltage conditions based on programmable power supply modules and dynamically controls the connection relationships between multiple electronic load modules and the power supply under test, enabling flexible switching between various load test scenarios and improving the overall system adaptability and test scenario reusability. Simultaneously, a power distribution module uniformly allocates power to different sub-modules, simplifying the internal circuit connection structure and reducing system construction complexity. An electrical performance acquisition module uniformly collects and feeds back test results, providing a standard interface for subsequent data judgment and report generation. In summary, this significantly improves the integration and automation of the power supply testing process, enhances the system's adaptability to different test scenarios, and achieves the goal of integrated power supply testing with a simple structure, integrated functions, and controllable processes. Attached Figure Description

[0025] Figure 1 This is a structural block diagram of an automated power supply testing system according to one embodiment of this application.

[0026] Figure 2 This is a schematic diagram of the specific structure of an automated power supply testing system according to one embodiment of this application; Figure 3 This is a schematic diagram of the structure of a specific application device of an automated power supply testing system according to one embodiment of this application; Figure 4 This is a flowchart illustrating the implementation of an automated power supply testing method in one embodiment of this application; Figure 5 This is a schematic diagram of the actual process of an automated power supply testing method in one embodiment of this application, which is an input-output performance testing process; Figure 6 This is a schematic diagram of the actual process of an automated power supply testing method in one embodiment of this application, which is a test process of output change rate. Figure 7 This is a schematic diagram of the actual process of a single-channel efficiency test process in an automated power supply test method according to one embodiment of this application; Figure 8 This is a schematic diagram of the actual process of an overcurrent protection test process in an automated power supply test method according to one embodiment of this application; Figure 9 This is a schematic diagram of the actual process of an automated power supply testing method in one embodiment of this application, which is an overpower protection testing process. Figure 10 This is a schematic diagram of the actual process of a short-circuit protection test process in an automated power supply test method according to one embodiment of this application. Detailed Implementation

[0027] The present application will be further described in detail below with reference to the accompanying drawings.

[0028] In one embodiment, such as Figure 1-3 As shown, this application discloses an automated power supply testing system for testing a DC power supply under test. The automated power supply testing system includes a main power input module, a power distribution module, a programmable AC power supply module, an electrical performance acquisition module, a control module, and multiple electronic load modules. Figure 2 The AC power socket shown is the corresponding structural component in the power distribution module, and the control module includes... Figure 2 The PC host and monitor shown in the figure include an electrical performance acquisition module. Figure 2 The oscilloscope shown includes a programmable AC power module. Figure 2 The AC power supply PB2020 shown in the image has an electronic load module. Figure 2 The electron load shown; The power output terminal of the main power input module is connected to the power input terminal of the power distribution module and the power input terminal of the programmable AC power module, respectively. The power output terminal of the power distribution module is connected to the power performance acquisition module, the control module, and multiple electronic load modules, respectively. The power output terminal of the programmable AC power module is connected to the power input terminal of the DC power supply under test, and the signal input terminal of the programmable AC power module is connected to the signal output terminal of the control module. The power output terminal of the DC power supply under test is connected to the signal input terminal of the electrical performance acquisition module, and is dynamically connected to the power input terminals of multiple electronic load modules. The control module is used to determine the corresponding test mode, and then generate corresponding programmable power control signals and dynamic connection control signals according to the test mode. The programmable power control signals are used to control the DC power supply under test to provide the corresponding AC input power to simulate different power supply conditions. The dynamic connection control signals are used to control the load connection relationship between the power output terminal of the DC power supply under test and multiple electronic load modules in the corresponding group of electronic load modules, so as to realize the load test process under different load conditions.

[0029] Specifically, in the automated power supply testing system, the power output of the main power input module is connected via cables to the power input of the power distribution module and the programmable AC power module, ensuring a stable AC power supply to both modules when powered on. The power output of the power distribution module supplies power to downstream modules, connecting to the power inputs of the electrical performance acquisition module, control module, and multiple electronic load modules. By allocating independent power paths to different modules, reliable power support is ensured for each functional module at different stages of the test system, preventing load fluctuations from affecting system stability. The power output of the programmable AC power module is connected to the power input of the DC power supply under test, providing it with AC input signals under simulated operating conditions. Its signal input is connected to the signal output of the control module, receiving control signals from the control module to dynamically adjust parameters such as voltage, current, and frequency.

[0030] The output terminal of the DC power supply under test is connected to the signal input terminal of the electrical performance acquisition module to collect real-time performance data during the power output process. Simultaneously, the output terminal also establishes a controllable connection with the power input terminals of multiple electronic load modules through dynamic connection paths. The electronic load modules are grouped or connected individually via dynamic connection control signals issued by the control module to simulate operating states under various voltage, current, and load conditions. The control module plays a core control role in the system. Based on the user-defined test mode, it generates programmable power control signals and dynamic connection control signals. On one hand, it controls the programmable AC power modules to output AC signals with different parameters to simulate external environmental conditions such as power supply interference and voltage fluctuations. On the other hand, it schedules and controls the connection combinations of electronic load modules and the DC power supply under test to construct different load condition combinations and can dynamically switch the target state of the load combination according to process nodes. In the overall system, the control module not only coordinates the test logic but also leads the collaboration and signal interaction between various modules, realizing a closed-loop test process from power supply and test object to acquisition, judgment, and feedback. Ultimately, it achieves accurate testing and intelligent evaluation of the multi-condition and multi-dimensional performance of the DC power supply.

[0031] Furthermore, the electrical performance acquisition module includes at least an electrical parameter measurement unit and a waveform detection unit; The electrical parameter measurement unit is used to collect the voltage, current, power and power factor parameters of the DC power supply under test in various test modes; The waveform detection unit is used to acquire the output voltage waveform or output current waveform of the DC power supply under test in each test mode.

[0032] Specifically, the electrical parameter measurement unit is used to acquire real-time operating parameters of the DC power supply under test in different test modes, including output voltage, current, power, and power factor. Its output terminal establishes communication with the control module through a data channel to upload the acquired electrical parameters in real time for subsequent logical judgment and result processing. The waveform detection unit captures and analyzes the output waveform of the DC power supply under test under various operating conditions. It can detect the stability, integrity, and abnormal fluctuations of voltage or current waveforms in real time. Its output is also transmitted to the control module via a data interface to dynamically determine whether the test indicators meet the set threshold conditions.

[0033] The control module dynamically issues read command instructions based on the configuration content in the test process, scheduling the electrical parameter measurement unit or waveform detection unit in the electrical performance acquisition module to execute the acquisition task. Before executing the acquisition, it also determines the activation order and triggering conditions of each sub-unit according to the preset execution order of the process nodes, and uses logic to determine whether to skip acquisition actions in the disabled state. In different test items, the electrical parameter measurement unit and waveform detection unit may be enabled independently or jointly. The control module will determine the corresponding unit combination based on the sampling index type extracted from the test item information, and after sampling, match the corresponding data to the corresponding judgment threshold range to further determine whether the test of that node meets the standard. Therefore, the combined use of the electrical parameter measurement unit and waveform detection unit not only improves the perception dimension of the power supply's operating status, but also provides a basic support for the system's judgment accuracy and adaptability in complex electrical tests.

[0034] Furthermore, such as Figure 2 As shown, the main power input module includes at least a plug, a leakage current protection switch, and an AC contactor connected in series. The end of the AC contactor furthest from the leakage current protection switch serves as the power output terminal of the main power input module to supply power.

[0035] Specifically, the plug, residual current device (RCD), and AC contactor are connected in series to form the power supply path of the main power input module. The plug serves as the interface between the system and the external mains power or industrial power grid, used to introduce AC input power. The RCD monitors the leakage current in the line in real time and can automatically cut off the power supply when an abnormal leakage is detected, thereby ensuring the safety of the test system and operators. The AC contactor, as the final output node of the main power input module, has controlled switching capability. Its control terminal is connected to the control module and can automatically connect or disconnect the power circuit of the entire system according to the start or termination status of the test process, thereby realizing programmed control of the power-on and power-off of the test system, ensuring that the test process is carried out according to the preset logic, and preventing equipment damage or test errors caused by misoperation or unexpected power-on.

[0036] like Figure 4As shown, an automated power supply testing method is applied to an automated power supply testing system. The automated power supply testing method includes: S10. Determine the test mode; The test mode refers to a standardized set of test targets set for different operating conditions of the DC power supply under test. It is usually set according to the power supply application scenario or customer requirements, such as constant voltage test, short circuit test or efficiency evaluation, etc. Each test mode represents a complete set of operating condition simulation and verification scheme.

[0037] S20. Based on the mapping relationship of test modes, match the corresponding process template. The mapping relationship of test modes refers to the binding rules established between different test modes and their corresponding preset test process templates, which are used to quickly select a suitable test process template after the test objective is determined. A test process template is an abstract definition of a type of standardized test steps and sequence, containing multiple preset operation nodes. Each operation node corresponds to a test action, parameter configuration, or data collection task. The existence of templates allows the system to reuse standard processes to reduce configuration costs and improve consistency.

[0038] S30. Obtain and parse the test item information input by the user, and extract the test parameters associated with the process template; S40. Generate a test instruction sequence based on the test parameters and fill the test instruction sequence into the preset operation nodes of the process template to generate the corresponding test process. The test item information input by the user refers to the set of structured test instructions input by the operator or automated task, including parameters such as the test index, target value, and judgment threshold, which is the basis for the parameterized generation of the test process. Test parameters are configuration content closely related to the execution of the test process, parsed from the test item information, used to indicate the specific execution method or acquisition standard of each node in the test process, such as setting load value, voltage value, etc. Preset operation nodes are execution units in the test process template used to occupy specific operations. They are made specific by filling in the test instruction sequence. Each operation node usually has definitions such as enabling conditions, execution timing, and control objectives.

[0039] S50. Execute the test process and collect various test data in the test process through the electrical performance acquisition module. Analyze and judge the test data and output the corresponding test results. The test process refers to the process template filled with the test instruction sequence. It has a complete set of scheduling logic and control instructions, which are used to execute sequentially in the system and realize the test operation of DC power supply.

[0040] Furthermore, such as Figure 5-10 As shown, the specific steps in executing the test process are as follows: The testing process includes: The load setting sub-process is used to set the load mode, voltage, current range and load value of multiple electronic load modules; The AC power programming sub-process is used to set the output voltage, frequency, and output status of the programmable AC power module. The test target setting sub-process is used to set the target output voltage, current and output status of the DC power supply under test; Among them, the load setting sub-process, the AC power programming sub-process, and the test target setting sub-process are all scheduled according to the first preset execution order in the test process, and are selectively executed according to the enable state specified in the test process.

[0041] Specifically, the test process includes a load setting sub-process, an AC power programming sub-process, and a test target setting sub-process. The execution order of each sub-process and whether it is executed are determined by the first preset execution order and the enable state.

[0042] For the input / output performance test process, the load setting sub-process is executed first to configure the operating parameters of multiple electronic load modules; then the AC power programming sub-process is executed to set the output voltage, frequency and output control of the programmable AC power module; then the test target setting sub-process is executed to set the voltage, current and output of the DC power supply under test. After that, the delay, load start and stabilization delay operations are performed in sequence to ensure that the power supply completes the test task in a stable state.

[0043] For the output rate of change test process, the test target setting sub-process is executed first to set the output voltage, current and output status of the DC power supply under test, and then a delay is performed to stabilize the output; then the load setting sub-process is executed to configure the load mode, voltage, current range and load value of multiple electronic load modules, and then a short delay is performed; then the AC power supply programming sub-process is skipped and the test data is directly collected for subsequent rate of change calculation.

[0044] For the single-channel efficiency test process, the process first executes the test target setting sub-process to set the target output voltage, current and output control status of the DC power supply under test; then a delay is performed to wait for the power output to stabilize; next, the load setting sub-process is executed to set the load mode and related values ​​of the electronic load module, and another delay is performed to wait for the load to stabilize. The execution of the AC power supply programming sub-process is not involved in the process.

[0045] For the overcurrent protection test process, the initial stage first executes the load setting sub-process and immediately starts the load; then it enters the AC power programming sub-process, sets the output voltage and frequency of the programmable AC power module, and outputs it to the power supply under test; finally, it executes the test target setting sub-process, sets the target output parameters of the DC power supply under test, and uses them to drive the subsequent test process.

[0046] By systematically arranging and selectively executing sub-processes under specific test objectives, the system can maintain high flexibility and modularity when dealing with diverse test scenarios. At the same time, each sub-process runs collaboratively under a unified scheduling framework, ensuring complete test logic, accurate test operations, and valid result data. This meets the comprehensive performance requirements of automated power supply testing systems in terms of functional coverage, control efficiency, and result judgment.

[0047] Furthermore, such as Figure 5-10 As shown, the steps involved in collecting various test data during the testing process through the electrical performance acquisition module, and then analyzing and judging the test data, are as follows: According to the test procedure, a corresponding set of read-value threads and a second preset execution order are matched. The set of read-value threads refers to a logical collection of multiple threads used to perform data acquisition operations. Each read-value thread corresponds to a test data acquisition operation, such as reading output voltage, output current, and input power. Its execution is scheduled by the control module to achieve orderly calling of different acquisition units in the electrical performance acquisition module. The second preset execution order refers to the logical configuration used to arrange the specific execution order and trigger time of each read-value thread in the set. Its arrangement is determined by the information configured in the test procedure to ensure that the acquisition actions match the changes in the test state.

[0048] Among them, the read value thread set is used to control the electrical parameter measurement unit or waveform detection unit in the electrical performance acquisition module to perform corresponding acquisition operations; The second preset execution order is used to determine the scheduling order and triggering time of each read thread in the read thread set.

[0049] Specifically, taking the output change rate test process as an example, the test process only involves a portion of the sub-processes for setting up the DC power supply and electronic load module under test. After the test starts, one of the threads in the value reading thread set triggers the electrical parameter measurement unit to read the initial output voltage. Then, after a delay during the load switching process, another thread reads the new output voltage value. The difference in the execution order of the threads forms the basis for calculating the difference between the data before and after the change. In the output performance test process, the value reading thread set includes multiple threads, each responsible for collecting data such as AC input voltage, current, power factor, and DC output voltage, current, and power. Each thread must be called sequentially according to the second preset execution order to ensure that the data from setting the power supply parameters is accurate. Sampling is performed only after the load is applied, ensuring data accuracy. In the single-channel efficiency test process, after the test process completes the setting sub-process and stabilization delay, the threads in the read value thread set sequentially control the electrical parameter measurement unit to collect the input power and output power data items. The thread sequence ensures that the system is in a stable state during sampling, and the efficiency is finally calculated by the subsequent module. In the overcurrent protection test process, the thread configuration in the read value thread set includes voltage and current reading tasks before and after protection triggering. For example, it determines whether to trigger protection and whether to cut power after the load exceeds a set threshold. The effective capture of key data points throughout the test process is achieved through thread time control and corresponding channel selection. The above process, through the cooperation of the read value thread set and the second preset execution order, enables the system to achieve reasonable arrangement and accurate scheduling of data acquisition tasks in different types of test scenarios, improving the timeliness of test data and the integrity of the test process.

[0050] Furthermore, such as Figure 5-10 As shown, the steps of collecting various test data in the test process through the electrical performance acquisition module and analyzing and judging the test data include: Based on the test data obtained through the current reading thread, the first judgment threshold range corresponding to the test data is extracted from the test item information. The first judgment threshold range refers to the numerical range set for judging whether the current test data is qualified or not. This threshold is usually provided by the test item information, and its specific form can be an upper and lower limit of the value, an error percentage range, or a fixed standard value. This range is used to guide the system to judge whether the test data meets the expected technical indicators.

[0051] Determine whether the test data falls within the first judgment threshold range; If the data does not fall within the first judgment threshold range, the corresponding first anomaly information is recorded and the test data is marked as an NG item. The first anomaly information refers to the content generated by the system to record the abnormal situation when the test data does not fall within the first judgment threshold range. It usually includes the name of the abnormal data item, the read value, the corresponding threshold, the timestamp, and the judgment status, etc., and is used for subsequent report generation and defect tracing. NG items refer to data items marked as unqualified by the system, that is, test results that do not meet the judgment criteria. The system will classify this item into the failure result set during the analysis process and can further process it in the post-processing stage.

[0052] If the value falls within the first judgment threshold range, the next read value thread will be executed according to the second preset execution order until all read value threads have been executed. Once all read threads have completed their execution, the corresponding data post-processing operations are matched and executed according to the test process.

[0053] Specifically, in the output change rate test process, the system first collects an initial output voltage value, and then collects a second voltage value after load switching. The two voltage values ​​are used as before and after state data for comparison to calculate the instantaneous change amplitude. This change is compared with a preset first judgment threshold range. For example, the change value is set to not exceed 1V. If it exceeds this range, the first abnormal information is generated and the test item is marked as NG. In this process, the second preset execution sequence controls the voltage sampling thread to be executed accurately before and after the load, thereby ensuring that the data corresponds to the test state.

[0054] like Figure 5-10 As shown, in the input / output performance test process, multiple reading threads are triggered sequentially to collect different input and output parameters. For each test data item, such as input power and output voltage, the system has an independent first judgment threshold range. For example, the output voltage must be between 11.4V and 12.6V. When a certain acquisition thread obtains a voltage value of 11.2V, the system will immediately record the first abnormal information and judge the corresponding item of the voltage value as NG. Then, it will continue to call other reading threads to continue to collect the remaining data items according to the second preset execution order.

[0055] In the efficiency testing process, the collected input power and output power must first be judged to be valid data by the first judgment threshold range. If the input power is less than the set minimum start-up power, it may be judged that the power supply is not turned on and generate an anomaly. If the data is valid, it will then be processed by the efficiency calculation module. In this process, the second preset execution order ensures that the input power is sampled before the output power, so as to ensure the correct numerical logic of the efficiency calculation.

[0056] In the overcurrent protection test process, the system continuously increases the load until the power supply triggers the protection state. The system collects the voltage change value before and after the trigger through thread control. If the voltage drops to 0V after the protection is triggered, the value falls outside the first judgment threshold range. The system then determines that the test is a valid trigger and marks the current voltage value as NG to confirm whether the protection mechanism has responded. The abnormal information records the trigger current, voltage drop time and sampling time point, etc., to judge the accuracy of the protection point and the response capability.

[0057] Furthermore, such as Figure 5-7 As shown, when all read threads have completed execution, the data post-processing operation is matched and executed according to the test process. This data post-processing operation includes calculation operations, including: When the corresponding calculation metric is matched according to the test process, the corresponding calculation operation is executed based on the calculation metric. The calculation operation is used to calculate the corresponding metric value based on the test data. Extract the second judgment threshold range corresponding to the test data from the test item information, and determine whether the indicator value falls within the second judgment threshold range; If it does not fall within the second judgment threshold range, the corresponding second abnormal information is recorded and the indicator value is marked as NG. If the value falls within the second judgment threshold range, then other indicator values ​​are calculated to determine whether they are abnormal, until all indicator values ​​have been judged.

[0058] Specifically, the calculated indicators are used to further process and analyze the collected raw test data to obtain a comprehensive evaluation value reflecting the performance status of the DC power supply under test. After the test process is completed, the control module matches the corresponding calculated indicators according to the calculation tasks configured in the test process, such as the steady-state deviation of the output voltage, the load response change rate, the energy efficiency ratio, or the peak ripple, and calculates the test data according to the set algorithm to obtain the corresponding indicator values. Each calculated indicator represents a performance dimension reflecting the dynamic or steady-state characteristics of the power supply. The system compares the obtained indicator value with the second judgment threshold range set in the test item information. If it falls within the range, the indicator is judged to be normal; if it exceeds the range, the system automatically generates a second abnormal information and marks the indicator item as NG. The calculation operation supports the simultaneous judgment of multiple indicators. The system will calculate and complete the pass / fail judgment of each indicator in sequence until all indicators are calculated and marked. This mechanism improves the quantitative identification capability of power supply performance quality through refined judgment at the indicator level, so that the test results are not limited to the judgment of whether the data is qualified or not, but can also reflect potential performance fluctuations and boundary problems, enhancing the test depth and accuracy of the system. Furthermore, the explanations of the second abnormal information and the second judgment threshold range are similar to those of the first abnormal information and the first judgment threshold range, so they will not be repeated here.

[0059] Furthermore, such as Figure 8-10 As shown, when all read threads have completed execution, the data post-processing operation, which is matched and executed according to the test process, includes a recovery operation, including: When the test process matches the corresponding recovery index, the corresponding recovery parameters are extracted from the test item information. The recovery parameters include at least the recovery load value and the recovery voltage value. Restore the corresponding electronic load module to its restored load value; Once the electronic load module returns to the restored load value, read the current output voltage value of the DC power supply under test and determine whether the current output voltage value has returned to the restored voltage value. If the voltage does not recover to the recovery value, record the corresponding third abnormality information and mark the current output voltage value as NG. If the voltage is restored to the recovery value, the data post-processing operation will end.

[0060] Specifically, the recovery operation is used to calibrate and confirm the output state of the DC power supply under test after a specific test process, to verify whether it can automatically recover to the set stable operating state after abnormal disturbances. When the control module detects that the current test process matches an operation node containing a recovery task, it extracts the preset recovery parameters from the corresponding test item information, including the recovery load value for the electronic load module and the recovery voltage value for the DC power supply output. The system first switches the electronic load module from the test state to the recovery state and sets its load to the recovery load value, thereby placing the power supply output in a preset light load or no-load recovery condition. Subsequently, the system reads the current output voltage value of the DC power supply and compares it with the recovery voltage value to determine whether the power supply has self-recovery capability. If the detected output voltage still does not reach the set recovery voltage value, it is considered that the power supply has not recovered to a stable state, and the system will generate a third abnormality message and mark the item as NG; if the voltage value meets the recovery voltage requirement, it indicates that the power supply has reliable stable recovery performance, and the system ends the data post-processing process. This recovery mechanism can help verify the recovery characteristics of power products after being subjected to abnormal disturbances such as short circuits and overloads, further improving the completeness of the test process and the depth of power performance verification.

[0061] It can systematically simulate typical scenarios such as power outage recovery, recovery after short circuit removal, and OCP / OPP event recovery, to test the power supply's automatic recovery capability after sudden anomalies. It also constructs a stable and unified recovery verification model by combining the recovery load value and the recovery voltage value, providing key judgment basis for product stability assessment.

[0062] Furthermore, after the step of outputting the corresponding test results, it also includes: The test results are encapsulated into structured data and sent to a preset target address. This preset target address includes at least a shared IP address provided by a third-party terminal within the MES system. Structured data refers to a collection of information whose test results are encapsulated using a specific data model and field format. This collection has a fixed data structure format, such as organizing various test result fields in JSON or XML, facilitating program parsing and integration with external systems. The preset target address is the network identifier of the external terminal configured in the system to receive test data. It is typically a shared IP address or interface address provided by the client MES system, used to achieve data integration and linkage between the test platform and external information systems. A third-party terminal refers to a receiving system consisting of devices, servers, or platforms outside the power supply testing system, generally an enterprise MES system, database server, or automation control platform, used for further processing, storage, or utilization of the test data.

[0063] In the third-party terminal that receives the structured data, the structured data is parsed and the corresponding field content is extracted. The field content refers to the specific information items contained in the structured data, which usually cover specific data content such as test process number, test time, test item name, judgment result, voltage and current values, and whether it is abnormal, to support subsequent report generation and data visualization.

[0064] Based on the field content, a corresponding test report is generated. The test report then contains a process capability index analysis result, which is stored in a specified path or sent to an external system interface. The test report is a visual document automatically generated from key fields of structured data using a template. It is used to present test results, performance trends, and anomalies to engineers or clients. Common formats include PDF, Excel, or web reports. The process capability index analysis result evaluates the distribution range, deviation, and tolerance ratio of a specific parameter across multiple samples using statistical methods. It reflects the stability and consistency of the testing process; typical indicators include CP and CPK. The specified path refers to the local or network file storage location set by the system for saving the test report file for later retrieval or auditing. The external system interface refers to the data interaction channel with external management systems established through APIs, sockets, database synchronization, etc., ensuring that test results can be automatically pushed to other systems for closed-loop management.

[0065] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. An automated power supply testing system for testing a DC power supply under test, characterized in that, The automated power supply testing system includes a main power input module, a power distribution module, a programmable AC power module, an electrical performance acquisition module, a control module, and multiple electronic load modules. The power output terminal of the main power input module is connected to the power input terminal of the power distribution module and the power input terminal of the programmable AC power module, respectively. The power output terminal of the power distribution module is connected to the power performance acquisition module, the control module, and the plurality of electronic load modules, respectively. The power output terminal of the programmable AC power module is connected to the power input terminal of the DC power supply under test, and the signal input terminal of the programmable AC power module is connected to the signal output terminal of the control module. The power output terminal of the DC power supply under test is connected to the signal input terminal of the electrical performance acquisition module, and is dynamically connected to the power input terminals of multiple electronic load modules. The control module is used to determine the corresponding test mode, and then generate corresponding programmable power control signals and dynamic connection control signals according to the test mode. The programmable power control signals are used to control the DC power supply under test to provide corresponding AC input power to simulate different power supply conditions. The dynamic connection control signals are used to control the load connection relationship between the power output terminal of the DC power supply under test and the multiple electronic load modules in the corresponding group of electronic load modules, so as to realize the load test process under different load conditions.

2. The automated power supply testing system according to claim 1, characterized in that, The electrical performance acquisition module includes at least an electrical parameter measurement unit and a waveform detection unit; The electrical parameter measurement unit is used to collect the voltage, current, power and power factor parameters of the DC power supply under test in each test mode; The waveform detection unit is used to collect the output voltage waveform or output current waveform of the DC power supply under test in each test mode.

3. The automated power supply testing system according to claim 1, characterized in that, The main power input module includes at least a plug, a leakage current protection switch and an AC contactor connected in series. The end of the AC contactor away from the leakage current protection switch serves as the power output terminal of the main power input module to output power for supply.

4. An automated power supply testing method, characterized in that, An automated power supply testing method is applied to an automated power supply testing system, comprising: Determine the test mode; Based on the mapping relationship of the test modes, the corresponding process template is matched; Obtain and parse the test item information input by the user, and extract the test parameters associated with the process template; A test instruction sequence is generated based on the test parameters, and the test instruction sequence is filled into the preset operation node of the process template to generate the corresponding test process; The test process is executed, and the electrical performance acquisition module collects various test data in the test process. The test data is analyzed and judged, and the corresponding test results are output.

5. The automated power supply testing method according to claim 4, characterized in that, The specific steps for executing the test process are as follows: The testing process includes: The load setting sub-process is used to set the load mode, voltage, current range and load value of multiple electronic load modules; The AC power programming sub-process is used to set the output voltage, frequency, and output status of the programmable AC power module. The test target setting sub-process is used to set the target output voltage, current and output status of the DC power supply under test; The load setting sub-process, the AC power programming sub-process, and the test target setting sub-process are all scheduled according to the first preset execution order in the test process, and are selectively executed according to the enable state specified in the test process.

6. The automated power supply testing method according to claim 4, characterized in that, The step of collecting various test data in the test process through the electrical performance acquisition module and analyzing and judging the test data specifically includes: According to the test process, match the corresponding set of read threads and the second preset execution order; The set of reading threads is used to control the electrical parameter measurement unit or waveform detection unit in the electrical performance acquisition module to perform corresponding acquisition operations. The second preset execution order is used to determine the scheduling order and triggering time of each read thread in the read thread set.

7. The automated power supply testing method according to claim 6, characterized in that, The step of collecting various test data in the test process through the electrical performance acquisition module and analyzing and judging the test data includes: Based on the test data obtained through the current reading thread, a first judgment threshold range corresponding to the test data is extracted from the test item information; Determine whether the test data falls within the range of the first determination threshold; If the test data does not fall within the first determination threshold range, the corresponding first abnormal information is recorded and the test data is marked as NG. If the value falls within the first determination threshold range, the next read value thread is executed based on the second preset execution order until all read value threads have been executed. When all the read threads have completed their execution, the corresponding data post-processing operations are matched and executed according to the test process.

8. The automated power supply testing method according to claim 7, characterized in that, In the step of matching and executing the corresponding data post-processing operation according to the test process when all the read threads have completed execution, the data post-processing operation includes a calculation operation, including: When a corresponding calculation indicator is matched according to the test process, a corresponding calculation operation is performed based on the calculation indicator. The calculation operation is used to calculate the corresponding indicator value based on the test data. Extract the second judgment threshold range corresponding to the test data from the test item information, and determine whether the indicator value falls within the second judgment threshold range; If it does not fall within the second judgment threshold range, then the corresponding second abnormal information is recorded and the indicator value is marked as NG. If the value falls within the second judgment threshold range, then other indicator values ​​are calculated to determine whether they are abnormal, until all indicator values ​​are judged.

9. The automated power supply testing method according to claim 7, characterized in that, In the step of matching and executing the corresponding data post-processing operation according to the test process when all the read threads have completed execution, the data post-processing operation includes a recovery operation, including: When the test process matches the corresponding recovery index, the corresponding recovery parameters are extracted from the test item information. The recovery parameters include at least the recovery load value and the recovery voltage value. The corresponding electronic load module is restored to its restored load value; Once the electronic load module returns to the restored load value, the current output voltage value of the DC power supply under test is read, and it is determined whether the current output voltage value has returned to the restored voltage value. If the voltage does not recover to the recovery value, the corresponding third abnormality information is recorded and the current output voltage value is marked as NG. If the voltage returns to the restored value, the data post-processing operation will end.

10. An automated power supply testing method according to claim 4, characterized in that, Following the step of outputting the corresponding test results, the method further includes: The test results are encapsulated into structured data and sent to a preset target address, the preset target address including at least the shared IP of the MES system provided by a third-party terminal; In the third-party terminal that receives the structured data, the structured data is parsed and the corresponding field content is extracted; A corresponding test report is generated based on the field content. A process capability index analysis result is generated in the test report, and the test report is stored in a specified path or sent to an external system interface.

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