Insulating material multi-channel voltage withstand test system and method
The multi-channel withstand voltage testing system enables parallel testing of insulating material samples across multiple channels and full life-cycle performance retrospective analysis. This solves the problem of difficulty in monitoring and evaluating insulating materials during withstand voltage testing in existing technologies, and improves testing efficiency and evaluation accuracy.
Patent Information
- Application Number
- CN202511093873.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-05
- Publication Date
- 2025-11-11
AI Technical Summary
Existing withstand voltage testing systems typically operate in a single-channel manner, making it difficult to monitor the behavior of insulating materials during withstand voltage testing and to trace their performance throughout their entire life cycle. They also cannot support the modeling of the electrical aging process of insulating materials and the study of breakdown mechanisms, resulting in insufficient depth and accuracy in insulation performance evaluation.
A multi-channel withstand voltage testing system is adopted, including a control unit and a testing unit. Through components such as a signal output module, a signal acquisition module, a status monitoring module, and a high-voltage switch module, it can realize multi-channel parallel withstand voltage testing and full life cycle performance backtracking of insulating material samples, and support electrical aging process modeling and breakdown mechanism research.
It significantly improves testing efficiency, adapts to the high-efficiency testing needs of different batches and types of materials, has good adaptability and flexibility, and can achieve in-depth and accurate evaluation of insulation performance.
Smart Images
Figure CN120928128A_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to the field of material performance testing technology, and in particular to a multi-channel withstand voltage testing system and method for insulating materials. Background Technology
[0002] Insulating materials are widely used in power, electronics, and communications fields, and their long-term withstand voltage capability directly affects the stability and safety of the system. To ensure the safety and lifespan of various application devices and equipment under actual operating conditions, the insulation performance of the insulating materials used must be systematically evaluated during the design and manufacturing process. Among the performance evaluation methods for insulating materials, withstand voltage testing is one of the most basic and critical. It is mainly used to verify the insulation strength of the material under specific voltage conditions and to determine the presence of local defects. This test plays a vital role in material selection, process development, and electrical safety standard verification.
[0003] However, current withstand voltage testing systems typically operate in a single-channel manner and employ relatively traditional testing methods. They focus more on the breakdown voltage as a result-oriented indicator and cannot monitor the behavior of insulating materials during withstand voltage testing or trace their performance throughout their entire life cycle. This makes it difficult to support the modeling of the electrical aging process of insulating materials and the study of breakdown mechanisms, which is not conducive to achieving in-depth and accurate evaluation of insulation performance. Summary of the Invention
[0004] In view of this, this disclosure proposes a multi-channel withstand voltage testing system and method for insulating materials.
[0005] According to one aspect of this disclosure, a multi-channel withstand voltage testing system for insulating materials is provided. The system includes a control unit and a testing unit, the control unit comprising:
[0006] The signal output module is used to send the first control command to the test unit;
[0007] The signal acquisition module is used to receive the status monitoring signals of each test channel collected by the test unit during the withstand voltage test. The status monitoring signals include current signals, which are used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test.
[0008] The test unit includes:
[0009] One or more high-voltage switch modules are used to control the opening of the test channel corresponding to the high-voltage switch module in response to a first control command, so as to perform a withstand voltage test on the insulating material sample in the test channel.
[0010] In one possible implementation, the control unit further includes:
[0011] The condition monitoring module is used to determine whether the insulation material sample corresponding to each test channel has broken down based on the condition monitoring signal;
[0012] The signal output module is also used for:
[0013] When a breakdown of the insulating material sample in a certain test channel is detected, a second control command is sent to the test unit for the test channel in which the breakdown occurred.
[0014] High-voltage switch modules are also used for:
[0015] In response to the second control command, the control disconnects the test channel corresponding to the high-voltage switch module to stop the withstand voltage test of the insulation material sample in the test channel.
[0016] In one possible implementation, the status monitoring module is used for:
[0017] When the current signal value corresponding to the test channel meets the preset conditions, it is determined that the insulating material sample of the test channel has broken down. The preset conditions include:
[0018] The current signal value exceeds the preset breakdown current threshold, or the duration for which the current signal value exceeds the preset breakdown current threshold is greater than the preset breakdown time threshold.
[0019] In one possible implementation, the system further includes a signal conversion module, which is located between the control unit and the test unit, and is used for:
[0020] The control signal output by the signal output module is converted from a level control signal to a switch control signal;
[0021] The switch control signal is converted into a voltage control signal that meets the driving requirements of the high-voltage switch module and sent to the high-voltage switch module.
[0022] In one possible implementation, the test unit also includes:
[0023] The high-voltage generation and regulation module is connected to the high-voltage switch module and is used for:
[0024] Generate and maintain the high-voltage waveform required for withstand voltage testing, and send the high-voltage waveform to one or more high-voltage switching modules;
[0025] One or more high-voltage switch modules are used for:
[0026] In response to the first control command, a high-voltage waveform is sent to the corresponding test channel of the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
[0027] In one possible implementation, the test unit also includes:
[0028] One or more current limiting modules are provided, which are located between the high voltage generation and regulation module and the high voltage switch module, and are used to limit the short circuit current when the insulating material sample breaks down to less than a preset short circuit current threshold.
[0029] In one possible implementation, each test channel includes a high-voltage electrode and a low-voltage electrode, with an insulating material sample placed between the high-voltage and low-voltage electrodes.
[0030] The test unit also includes:
[0031] One or more current signal acquisition modules are connected to the low-voltage electrode and are used to acquire the status monitoring signals of each test channel.
[0032] If the current signal acquisition module and control unit do not have voltage limiting functionality, the system also includes:
[0033] The protection module is located between the control unit and the test unit and is used to limit the instantaneous voltage to be less than a preset voltage threshold.
[0034] In one possible implementation, the system also includes:
[0035] The host computer unit is connected to the control unit and is used to set the parameters of the withstand voltage test, control the start and stop of the withstand voltage test, control the opening / closing of each test channel, and visually display at least one of the status monitoring signals of each test channel and the breakdown state of the insulating material sample.
[0036] In one possible implementation, the control unit is a data acquisition card, the signal conversion module consists of an optocoupler relay group and a programmable logic controller (PLC), the protection module is a transient voltage suppressor group, the high-voltage switch module is a high-voltage relay, the high-voltage generation and regulation module consists of a signal generator and a power amplifier, the current limiting module is a current limiting resistor, and the current signal acquisition module is a sampling resistor.
[0037] According to another aspect of this disclosure, a multi-channel withstand voltage test method for insulating materials is provided. The method includes:
[0038] The control unit's signal output module sends the first control command to the test unit;
[0039] During the withstand voltage test, the signal acquisition module of the control unit receives the status monitoring signals of each test channel acquired by the test unit. The status monitoring signals include current signals, which are used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test.
[0040] One or more high-voltage switch modules in the test unit respond to the first control command and control the opening of the test channel corresponding to the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
[0041] In one possible implementation, the method further includes:
[0042] The control unit's status monitoring module determines whether the insulation material sample corresponding to each test channel has broken down based on the status monitoring signal.
[0043] When the signal output module detects that the insulation material sample of a certain test channel has broken down, it sends a second control command to the test unit for the test channel that has broken down.
[0044] In response to the second control command, the high-voltage switch module controls the disconnection of the test channel corresponding to the high-voltage switch module to stop the withstand voltage test of the insulating material sample in the test channel.
[0045] In one possible implementation, determining whether the insulating material sample corresponding to each test channel has broken down is based on the condition monitoring signal, including:
[0046] When the current signal value corresponding to the test channel meets the preset conditions, it is determined that the insulating material sample of the test channel has broken down. The preset conditions include:
[0047] The current signal value exceeds the preset breakdown current threshold, or the duration for which the current signal value exceeds the preset breakdown current threshold is greater than the preset breakdown time threshold.
[0048] In one possible implementation, the method further includes:
[0049] A signal conversion module located between the control unit and the test unit converts the control signal output by the signal output module from a level control signal into a switch control signal.
[0050] The signal conversion module converts the switch control signal into a voltage control signal that meets the driving requirements of the high-voltage switch module and sends it to the high-voltage switch module.
[0051] In one possible implementation, the method further includes:
[0052] The high voltage generation and regulation module in the test unit, which is connected to one or more high voltage switch modules, generates and maintains the high voltage waveform required for the withstand voltage test, and sends the high voltage waveform to one or more high voltage switch modules.
[0053] In response to the first control command, the corresponding test channel of the high-voltage switch module is activated to perform a withstand voltage test on the insulating material sample in the test channel, including:
[0054] In response to the first control command, a high-voltage waveform is sent to the corresponding test channel of the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
[0055] In one possible implementation, the method further includes:
[0056] One or more current-limiting modules located between the high-voltage generation and regulation module and the high-voltage switch module in the test unit limit the short-circuit current when the insulating material sample breaks down to a preset short-circuit current threshold.
[0057] In one possible implementation, each test channel includes a high-voltage electrode and a low-voltage electrode, with an insulating material sample positioned between the high-voltage and low-voltage electrodes. The method further includes:
[0058] The status monitoring signals of each test channel are acquired by one or more current signal acquisition modules connected to the low-voltage electrode in the test unit;
[0059] In cases where the current signal acquisition module and control unit do not have voltage limiting functionality, the method further includes:
[0060] The protection module limits the instantaneous voltage to below a preset voltage threshold.
[0061] In one possible implementation, the method further includes:
[0062] The host computer unit connected to the control unit sets the parameters of the withstand voltage test, controls the start and stop of the withstand voltage test, controls the opening / closing of each test channel, and visualizes at least one of the status monitoring signals of each test channel and the breakdown state of the insulating material sample.
[0063] In one possible implementation, the control unit is a data acquisition card, the signal conversion module consists of an optocoupler relay group and a programmable logic controller (PLC), the protection module is a transient voltage suppressor group, the high-voltage switch module is a high-voltage relay, the high-voltage generation and regulation module consists of a signal generator and a power amplifier, the current limiting module is a current limiting resistor, and the current signal acquisition module is a sampling resistor.
[0064] According to embodiments of this disclosure, by sending a first control command to the test unit via the signal output module, the signal acquisition module receives status monitoring signals from each test channel acquired by the test unit during the withstand voltage test. These status monitoring signals include current signals, enabling monitoring of the behavior of the insulating material during the withstand voltage test and full life-cycle performance retrospective analysis, thus supporting subsequent in-depth evaluation of the insulating material's insulation performance. Furthermore, by using one or more high-voltage switch modules in response to the first control command to control the opening of the corresponding test channel, and performing withstand voltage tests on the insulating material samples in that test channel, multi-channel parallel withstand voltage testing can be achieved. This multi-channel parallel testing mechanism not only significantly improves testing efficiency but also adapts to the high-efficiency testing needs of different batches and types of materials, meeting the requirement of completing tests on large batches of samples within a limited time, demonstrating good adaptability and flexibility.
[0065] Compared to current withstand voltage testing schemes, the withstand voltage testing scheme disclosed herein can operate in a multi-channel mode and does not only focus on the breakdown voltage as a result indicator. It can realize the behavior monitoring of insulating materials during the withstand voltage process and the performance backtracking of the entire life cycle, thereby supporting the modeling of the electrical aging process of insulating materials and the study of breakdown mechanisms, which is conducive to achieving in-depth and accurate evaluation of insulation performance.
[0066] Other features and aspects of this disclosure will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description
[0067] The accompanying drawings, which are included in and form part of this specification, illustrate exemplary embodiments, features, and aspects of this disclosure together with the specification and serve to explain the principles of this disclosure.
[0068] Figure 1 A structural diagram of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of the present disclosure is shown.
[0069] Figure 2 A schematic diagram of the structure of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of the present disclosure is shown.
[0070] Figure 3 A schematic diagram of the structure of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of the present disclosure is shown.
[0071] Figure 4 A schematic flowchart of a multi-channel withstand voltage test for insulating materials according to an embodiment of the present disclosure is shown.
[0072] Figure 5 A flowchart is shown for a multi-channel withstand voltage test method for insulating materials according to an embodiment of the present disclosure. Detailed Implementation
[0073] Various exemplary embodiments, features, and aspects of this disclosure will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.
[0074] As used herein, the terms “comprising,” “including,” “having,” or variations thereof are open-ended and include one or more of the stated features, integrals, elements, steps, components, or functions, but do not exclude the presence or addition of one or more other features, integrals, elements, steps, components, functions, or groups thereof.
[0075] When an element is referred to as “connected,” “coupled,” “responding,” or a variation thereof relative to another element, it may be directly connected, coupled, or responding to another element, or there may be an intermediate element present.
[0076] Although the terms first, second, third, etc., may be used herein to describe various elements / operations, these elements / operations should not be limited by these terms. These terms are only used to distinguish one element / operation from another. Therefore, without departing from the teachings of the inventive concept, a first element / operation in some embodiments may be referred to as a second element / operation in other embodiments.
[0077] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.
[0078] Furthermore, to better illustrate this disclosure, numerous specific details are set forth in the following detailed description. Those skilled in the art will understand that this disclosure can be practiced without certain specific details. In some instances, methods, means, components, and circuits well known to those skilled in the art have not been described in detail in order to highlight the main points of this disclosure.
[0079] Insulating materials are widely used in power, electronics, and communications fields, and their long-term withstand voltage capability directly affects the stability and safety of the system. To ensure the safety and lifespan of various application devices and equipment under actual operating conditions, the insulation performance of the insulating materials used must be systematically evaluated during the design and manufacturing process. Among the performance evaluation methods for insulating materials, withstand voltage testing is one of the most basic and critical. It is mainly used to verify the insulation strength of the material under specific voltage conditions and to determine the presence of local defects. This test plays a vital role in material selection, process development, and electrical safety standard verification.
[0080] However, current withstand voltage testing systems typically operate in a single-channel manner and employ relatively traditional testing methods. They focus more on the breakdown voltage as a result-oriented indicator and cannot monitor the behavior of insulating materials during withstand voltage testing or trace their performance throughout their entire life cycle. This makes it difficult to support the modeling of the electrical aging process of insulating materials and the study of breakdown mechanisms, which is not conducive to achieving in-depth and accurate evaluation of insulation performance.
[0081] In view of this, this disclosure proposes a multi-channel withstand voltage testing system and method for insulating materials. The system of this disclosure is suitable for parallel withstand voltage testing of multiple insulating material samples and realizes full-process monitoring and data recording functions. The system of this disclosure includes a control unit and a testing unit. The control unit includes: a signal output module for sending a first control command to the testing unit; and a signal acquisition module for receiving status monitoring signals of each test channel acquired by the testing unit during the withstand voltage test. The status monitoring signals include current signals, used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test, thereby enabling behavior monitoring and full life-cycle performance backtracking of the insulating material during the withstand voltage test, supporting subsequent in-depth evaluation of the insulating performance of the insulating material. The testing unit includes: one or more high-voltage switch modules for responding to the first control command to control the opening of the test channel corresponding to the high-voltage switch module, so as to perform withstand voltage testing of the insulating material sample in the test channel, thereby realizing multi-channel parallel withstand voltage testing. This multi-channel parallel testing mechanism not only significantly improves testing efficiency but also adapts to the high-efficiency testing needs of different batches and types of materials, meeting the need to complete testing of large batches of samples within a limited time, and possessing good adaptability and flexibility.
[0082] Figure 1 A structural diagram of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of this disclosure is shown. Figure 1 As shown, the system may include a control unit 100 and a testing unit 200.
[0083] The control unit 100 includes:
[0084] Signal output module 101 is used to send a first control command to test unit 200;
[0085] The signal acquisition module 102 is used to receive the status monitoring signals of each test channel acquired by the test unit 200 during the withstand voltage test;
[0086] Test unit 200 includes:
[0087] One or more high-voltage switch modules 201 are configured to control the opening of the test channel corresponding to the high-voltage switch module 201 in response to a first control command, so as to perform a withstand voltage test on the insulating material sample in the test channel.
[0088] Among them, the control unit 100 can be a data acquisition card with data processing and control functions, the signal output module 101 and the signal acquisition module 102 can be data sending interfaces or data receiving interfaces based on any data transmission protocol, and the high-voltage switch module 201 can be implemented using a high-voltage relay.
[0089] Condition monitoring signals may include current signals during the withstand voltage test, as well as voltage signals, temperature signals, humidity signals, and equipment status signals, to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test.
[0090] Among them, the current signal can be used to reflect the leakage current or breakdown current characteristics of the insulating material sample under high voltage, and is the basis for judging whether the insulating sample has broken down. The voltage signal can be used to provide real-time feedback on the voltage changes applied to the insulating material sample to help judge the level of electrical stress. Temperature and humidity signals can be used to reflect changes in the test environment around the test channel to reflect the impact of environmental factors on the electrical performance of the insulating material sample. Equipment status signals may include the output status of the high voltage source (such as the status and output voltage changes of the subsequent high voltage generation and regulation module 202), the conduction status of the high voltage switch module 201, the grounding status of the test unit, etc., to monitor the operation and safety of the test unit. Through the synchronous acquisition and comprehensive analysis of the above multi-dimensional status monitoring signals, it is possible to achieve comprehensive perception and data modeling of the electrical aging process, breakdown behavior and evolution trend of the insulating material during the withstand voltage test, providing key support for material life prediction and insulation performance evaluation. The status monitoring signals can be acquired through integrated current sensors, voltage probes, thermistors, humidity sensors, etc. in the test unit 200.
[0091] According to embodiments of this disclosure, by using a signal output module to send a first control command to the test unit, and a signal acquisition module to receive status monitoring signals from each test channel acquired by the test unit during the withstand voltage test, including current signals, the behavior of the insulating material during the withstand voltage test and the performance backtracking throughout its entire life cycle can be achieved, supporting subsequent in-depth evaluation of the insulation performance of the insulating material. Furthermore, by using one or more high-voltage switch modules to respond to the first control command and control the opening of the test channel corresponding to the high-voltage switch module to perform the withstand voltage test on the insulating material sample in that test channel, multi-channel parallel withstand voltage testing can be achieved. This multi-channel parallel testing mechanism not only significantly improves testing efficiency but also adapts to the high-efficiency testing needs of different batches and types of materials, meeting the requirement of completing the testing of large batches of samples within a limited time, and possessing good adaptability and flexibility.
[0092] Figure 2A schematic diagram of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of the present disclosure is shown. Figure 2 As shown, the system may include a control unit 100, a test unit 200, a signal conversion module 300, and an optional protection module 400. This system is suitable for performing withstand voltage performance tests on multiple insulating material samples in parallel or serially, and features flexible structure, controllable channels, and high safety.
[0093] The test unit 200 can be equipped with multiple parallel and independent test channels. Each test channel may include a pair of high-voltage and low-voltage electrodes located on the upper and lower surfaces of the sample, respectively, with the two electrodes used to clamp the insulating material sample (such as a silicone rubber sample). To ensure the test effect, the high-voltage and low-voltage electrodes can be made of conductive and corrosion-resistant materials and have good contact stability to avoid problems such as air bubbles or uneven contact during the test, thereby improving the reliability of the test.
[0094] Each test channel corresponds to a high-voltage switch module 201, which is used to control whether voltage is applied to the insulating material sample in the corresponding test channel, thereby controlling the on / off state of the test channel.
[0095] The first control command can be used to select and turn on any one or more of the multiple high-voltage switch modules 201, thereby selectively applying voltage to the insulating material sample in one or more test channels to perform a withstand voltage test on the insulating material sample.
[0096] In one possible implementation, the test unit 200 further includes:
[0097] High voltage generation and regulation module 202, which is connected to one or more high voltage switch modules 201, is used for:
[0098] Generate and maintain the high-voltage waveform required for withstand voltage testing, and send the high-voltage waveform to one or more high-voltage switching modules 201;
[0099] One or more high-voltage switch modules 201 can be used for:
[0100] In response to the first control command, a high-voltage waveform is sent to the test channel corresponding to the high-voltage switch module 201 to perform a withstand voltage test on the insulating material sample in the test channel.
[0101] The high voltage generation and regulation module 202 can be composed of a signal generator and a power amplifier, or it can be replaced by other devices. The test unit 200 can also be adapted to a variety of general or special high voltage sources, so that the system does not depend on a specific integrated power supply platform, has good portability and adaptability, and can be widely used in different withstand voltage test scenarios.
[0102] The output of the high voltage generation and regulation module 202 can be connected to the above-mentioned multiple parallel test channels, and the input can receive the test voltage configured by the signal output module 101 and output a high voltage waveform (such as AC, DC or custom waveform) that meets the requirements of each test channel to start multi-channel testing.
[0103] In one possible implementation, the test unit 200 further includes:
[0104] One or more current signal acquisition modules 204 are connected to the low-voltage electrode and are used to acquire the status monitoring signals of each test channel.
[0105] The current signal acquisition module 204 can be implemented by a sampling resistor.
[0106] See Figure 2 Each test channel can be configured as follows: the output terminal of the high voltage generation and regulation module 202 can be connected to the first terminal of the high voltage switch module 201, the second terminal of the high voltage switch module 201 can be connected to the high voltage electrode, the first terminal of the current signal acquisition module 204 can be connected to the low voltage electrode, and the second terminal of the current signal acquisition module 204 can be grounded, thereby forming a complete withstand voltage test circuit.
[0107] In one possible implementation, to improve test safety and prevent the effects of breakdown short circuits, the test unit 200 may further include:
[0108] One or more current limiting modules 203 can be connected in series in each test channel, for example, between the high voltage generation and regulation module 202 and the high voltage switch module 201, to limit the short circuit current when the insulation material sample breaks down to less than a preset short circuit current threshold.
[0109] The current limiting module 203 can be implemented by a current limiting resistor.
[0110] When the high voltage generation and regulation module 202 has a current limiting function, the current limiting module 203 is optional. For example, when the high voltage generation and regulation module 202 itself has a fast-response electronic current limiting function, the current limiting module 203 can be omitted or a smaller resistance resistor can be selected.
[0111] In one possible implementation, if the signal output by the signal output module 101 does not match the control signal required by the high-voltage switch module 201, the system may further include a signal conversion module 300, which can be implemented by an optocoupler relay group and a programmable logic controller (PLC) to complete the conversion between different signal types. The signal conversion module 300 can be located between the control unit 100 and the test unit 200, and is used for:
[0112] The control signal output by the signal output module 101 is converted from a level control signal into a switch control signal;
[0113] The switch control signal is converted into a voltage control signal that meets the driving requirements of the high-voltage switch module 201 and sent to the high-voltage switch module 201.
[0114] The control signal can be either the first control signal mentioned above, or the subsequent second control signal.
[0115] The level control signal can be a logic level signal, such as a transistor-transistor logic level (TTL) level. The switch control signal can be a low-voltage reference signal used to control electronic switching devices. Since high-voltage devices require a higher voltage or power level drive signal (such as a 24V DC coil voltage) to operate reliably, the switch control signal can be further converted into a voltage control signal, which can then drive the element in the high-voltage switch module 201 that actually performs the switch.
[0116] The driving requirements for the high-voltage switch module 201 may include specific power ratings and voltage levels.
[0117] See Figure 2 The signal output module 101 can also be connected to the high voltage generation and regulation module 202 through the signal conversion module 300 to control the start, stop and output of the high voltage generation and regulation module 202. This allows for flexible adjustment of the test voltage level applied to each insulating material sample according to test requirements, thereby improving the automation and accuracy of the test process.
[0118] The output terminal of the aforementioned current signal acquisition module 204 can be connected to the signal acquisition module 102 of the control unit 100. The current signal acquisition module 204 can also send the acquired current signal to the signal acquisition module 102 in the form of a voltage signal (e.g., 0-10V). In actual testing, a sudden large current may occur at the moment of breakdown, causing the current signal acquisition module 204 to output a sudden high voltage peak. To protect system safety, if the current signal acquisition module 204 and the control unit 100 do not have voltage limiting functions, the system may also include:
[0119] The protection module 400 is located between the control unit 100 and the test unit 200 and is used to limit the instantaneous voltage from being less than a preset voltage threshold.
[0120] The protection module 400 can be implemented by a transient voltage suppressor group.
[0121] See Figure 2 One end of the protection module 400 can be connected to the current signal acquisition module 204, and the other end can be connected to the signal acquisition module 102, thereby effectively preventing damage to the signal acquisition module 102 due to instantaneous voltage rise. Furthermore, the output terminal of the high-voltage generation and regulation module 202 can also be connected to the signal acquisition module 102 through the protection module 400, enabling the high-voltage generation and regulation module 202 to safely return its status and output voltage changes to the signal acquisition module 102 via the protection module 400, thus achieving real-time monitoring of its operating status.
[0122] The control unit 100 may also include a data storage module 104, which may be implemented by non-volatile memory or volatile memory to cache or store various types of data during the test process.
[0123] The signal acquisition module 102 can store various received status monitoring signals in the data storage module 104 to support subsequent data analysis and result traceability.
[0124] In one possible implementation, the control unit 100 may further include:
[0125] The condition monitoring module 103 is used to determine whether the insulation material sample corresponding to each test channel has broken down based on the condition monitoring signal;
[0126] The signal output module 101 is also used for:
[0127] When a breakdown of the insulating material sample in a certain test channel is detected, a second control command is sent to the test unit 200 for the test channel that has broken down.
[0128] The high-voltage switch module 201 is also used for:
[0129] In response to the second control command, the test channel corresponding to the high-voltage switch module 201 is cut off to stop the withstand voltage test of the insulating material sample in the test channel.
[0130] The condition monitoring module 103 can be implemented using an application-specific integrated circuit (ASIC) or a programmable logic device to execute corresponding logic control instructions, enabling real-time monitoring and response to the condition monitoring signals of each test channel. The condition monitoring module 103 can acquire the condition monitoring signals collected and stored in real-time by the signal acquisition module 102 from the data storage module 104, and process them. This processing may include real-time filtering of the condition monitoring signals to remove background noise or transient interference, improving the accuracy and response speed of breakdown detection. Through real-time analysis of the condition monitoring signals (especially current signals), the condition monitoring module 103 can identify drastic changes or abnormal fluctuations in the current signal, serving as an important basis for identifying breakdown events.
[0131] Breakdown refers to the physical process during high-voltage testing where the dielectric properties of insulating materials fail under a specific voltage, leading to a sudden increase in current in the insulating layer. This is typically manifested as a sudden change in the current signal in the test channel.
[0132] In one possible implementation, the state monitoring module 103 can be used for:
[0133] When the current signal value corresponding to the test channel meets the preset conditions, it is determined that the insulating material sample of the test channel has broken down. The preset conditions include:
[0134] The current signal value exceeds the preset breakdown current threshold, or the duration for which the current signal value exceeds the preset breakdown current threshold is greater than the preset breakdown time threshold.
[0135] The breakdown current threshold and breakdown time threshold (e.g., exceeding 10ms) can be set according to the material type, test specifications, or empirical parameters, and can be dynamically adjusted based on historical test data to adapt to the testing requirements of materials with different electrical properties. The breakdown current threshold and duration of different test channels can be set to the same or different values.
[0136] The current signal can refer to the current flowing through the insulation test sample in real time. If the current signal value exceeds the preset breakdown current threshold, it can be that the current signal value of any current sampling point among multiple current sampling points (e.g., 50 sampling points) under the test channel exceeds the preset breakdown current threshold, or it can be that the average value of the current signal values of multiple current sampling points under the test channel exceeds the preset breakdown current threshold.
[0137] By combining current amplitude and duration as dual criteria, the accuracy of breakdown detection can be effectively improved, avoiding false alarms or missed alarms caused by transient fluctuations. This composite judgment strategy is beneficial for studying self-healing phenomena. For example, in some test scenarios, the surface of insulating materials needs to be gold-plated to enhance conductivity. Such metallized polymer films may experience brief overcurrent situations during testing, but the material can recover its insulation performance through its own mechanism within a short time. In this case, if only current amplitude is used as the breakdown judgment condition, the instantaneous overcurrent signal generated at the very beginning of the self-healing process may be directly judged as breakdown, thus failing to identify and observe the material's self-healing ability. However, by adopting a method that considers both current amplitude and duration, and setting a breakdown condition only when the overcurrent lasts for a certain period of time, the present disclosure can effectively distinguish between the brief self-healing process and the true breakdown behavior.
[0138] Similar phenomena also occur in the withstand voltage tests of dielectric elastomers using carbon nanotubes as electrode materials. These materials may also exhibit self-healing under high voltage. Therefore, the dual-condition breakdown judgment mechanism of "breakdown current threshold + breakdown time threshold" introduced in this disclosure is of great significance for improving the sensitivity and fault tolerance of the test system and accurately evaluating the electrical properties of materials.
[0139] When the status monitoring module 103 determines that the corresponding insulating material sample in a certain test channel has broken down, the signal output module 101 will send a second control command to the high-voltage switch module 201 corresponding to the broken-down test channel in the test unit 200. The second control command can be used to control the corresponding high-voltage switch module 201 to disconnect the high-voltage waveform output of the broken-down test channel. The control unit 100 can also record the breakdown time (including the breakdown time and the identification of the test channel that broke down) for subsequent visualization and analysis.
[0140] Meanwhile, the second control command can be issued only to the test channel that has experienced a breakdown, while other channels that have not experienced a breakdown can continue to perform their original withstand voltage test tasks without affecting each other. This channel-level independent control strategy helps improve the stability, safety, and testing efficiency of the entire multi-channel testing system.
[0141] When all the insulation material samples in all test channels break down, or when the withstand voltage test time exceeds the preset threshold, the signal output module 101 can send a relevant control signal to the high voltage generation and regulation module 202 to stop outputting the high voltage waveform, thereby ending the withstand voltage test of all test channels.
[0142] In one possible implementation, during the withstand voltage test, the data storage module 104 can return information such as status monitoring signals collected during the test to the host computer unit 500. The system may also include:
[0143] The host computer unit 500 is connected to the control unit 100 and is used to set the parameters of the withstand voltage test, control the start and stop of the withstand voltage test, control the opening / closing of each test channel, and visually display at least one of the status monitoring signals of each test channel and the breakdown state of the insulating material sample.
[0144] The host computer unit 500 can be a device running supporting test and control software. The host computer unit 500 can establish communication with the control unit 100 through a wired or wireless communication interface.
[0145] Relevant testing personnel can use the software interface in the host computer unit 500 to set the parameters for the withstand voltage test, control the start and stop of the withstand voltage test, and control the opening / closing of each test channel. The above control operations can be sent to the test unit through the signal output module 101 of the control unit 100. The parameters for the withstand voltage test may include voltage level, test duration, breakdown current threshold, breakdown judgment condition, state monitoring signal sampling rate, data storage method, and test termination condition (such as all test channels breaking down or the test duration exceeding the threshold).
[0146] The host computer unit 500 can also receive the status monitoring signals of each test channel and the breakdown status of the insulating material sample sent by the data storage module 104, and display them visually on the software interface. For example, the current status of each test channel (normal, breakdown and disconnection) can be dynamically displayed through channel indicator lights. It can also draw and display the voltage and current test waveforms of each test channel in real time, and display information such as the breakdown time and test duration of each test channel, which is convenient for users to monitor, record and analyze.
[0147] During the withstand voltage test, the host computer unit 500 can synchronously store all received raw sampling data, including timestamps, and the configured withstand voltage test parameters. It also supports data querying, filtering, and exporting based on conditions such as time and test channel. Through this data recording, users can not only reproduce the waveform changes and accurately locate the breakdown point after the withstand voltage test, but also conduct in-depth analysis of data change trends before and after breakdown (such as the slow increase in leakage current). This provides a reliable basis for the life assessment and performance comparison of relevant insulating materials.
[0148] Therefore, the entire testing process can be visualized and controlled by the host computer unit 500, and the data records of all test channels can be exported. This not only improves the operational efficiency and security of the test, but also enables the unified archiving and export of multi-channel test results, meeting the needs of subsequent data traceability and analysis.
[0149] Figure 3 A schematic diagram of a multi-channel withstand voltage testing system for insulating materials according to an embodiment of the present disclosure is shown. Figure 3 As shown, the high-voltage generation and regulation module 202 in the aforementioned test unit 200 can be composed of a signal generator and a power amplifier. The signal generator can be used to generate a low-voltage reference signal, and the power amplifier is used to amplify the low-voltage reference signal to the required high-voltage test voltage, generating a high-voltage waveform.
[0150] In each test channel, the current limiting module 203 can be a current limiting resistor (e.g., a high-power resistor) to protect the high-voltage source, switch, and electrodes. The high-voltage switch module 201 can be a high-voltage relay with contact withstand voltage much higher than the test voltage and capable of withstanding the short-circuit current after current limiting, used to control the on / off switching of the high voltage in the corresponding test channel. For a larger current range (e.g., μA to mA level), the current signal acquisition module 204 can use a high-precision sampling resistor. The current signal value is calculated by measuring the voltage drop across the resistor. In this case, a transient voltage suppression diode (TVS) group must be connected in parallel across the sampling resistor to absorb the high-energy voltage spikes generated during breakdown and protect subsequent circuits. For smaller leakage currents (e.g., nA, pA level) during the withstand voltage test, a more accurate electrometer or a dedicated current sensing amplifier module can be selected. Figure 3 (Not shown in the image).
[0151] The signal conversion module 300 can be implemented by an optocoupler relay group and a PLC controller. The optocoupler relay group can receive the output signal (i.e., the aforementioned level control signal) from the signal output module 101 and provide electrical isolation and preliminary signal conversion, converting the level control signal into a switching control signal. The PLC controller can be used to further convert the output of the optocoupler relay group into a voltage control signal that meets the requirements for the high-voltage relay coil to engage or disengage. Thus, in the event of a breakdown, the high-voltage relay of the corresponding test channel can be driven to quickly disconnect, safely removing the broken-down silicone rubber sample from the high-voltage circuit.
[0152] The control unit 100 can be an independent data acquisition card or an embedded functional module in a PLC or industrial control equipment, and can be connected to the host computer unit 500 through a Universal Serial Bus (USB) interface.
[0153] The system of this disclosure, while maintaining the ability to automatically determine breakdown in each channel during long-term withstand voltage testing, utilizes a modular circuit structure design to enable various single-channel high-voltage power supplies to be extended to multi-channel withstand voltage testing systems. This enhances the portability and versatility of the testing platform, supporting customized needs for long-cycle withstand voltage performance testing of insulating materials under different voltage conditions. It overcomes the problems in related technologies where high-voltage power supplies are typically tightly integrated with the entire system, lacking good interface separation and platform compatibility. This facilitates the migration of withstand voltage testing to various high-voltage power supply platforms and expands the application of withstand voltage testing of insulating materials under complex testing conditions.
[0154] Figure 4 A schematic flowchart of a multi-channel withstand voltage test for insulating materials according to an embodiment of this disclosure is shown. Figure 4 As shown, after the withstand voltage test begins, the signal output module 101 controls the closure of the high-voltage switch module 201 of all test channels and enables the high-voltage generation and regulation module 202 to output the set test voltage (i.e., high-voltage waveform) to be applied to the insulating material sample under test. Subsequently, the signal acquisition module 102 can continuously acquire the status monitoring signals (such as voltage and current signals) of each test channel (channels 1, 2, ..., n in the figure "1...n").
[0155] The status monitoring module 103 analyzes the current signal values of each test channel in real time. When a test channel is determined to have broken down (e.g., the measured current exceeds the set current threshold), the signal conversion module 300 can control the disconnection of the high-voltage switch module 201 corresponding to that test channel, thereby effectively isolating the broken-down insulation material sample. The host computer unit 500 can synchronously display and update the status and record relevant breakdown event information.
[0156] The test process will continue until any of the following termination conditions are met: all samples in all test channels have been determined to be broken down and the corresponding test channels have been disconnected; the relevant test personnel manually stop the test; or the preset test duration threshold is reached. When the termination condition is triggered, the control unit 100 can first control the high voltage generation and regulation module 202 to stop outputting voltage (i.e., return the voltage to zero), and then disconnect all high voltage switch modules 201 that are still in the closed state to ensure that the system is in a safe state. Finally, the host computer unit 500 stops data recording, completes data storage, and ends the test process.
[0157] The system of this disclosure significantly improves the efficiency, reliability, and data value of long-term withstand voltage life testing of insulating materials through multi-channel parallel testing and real-time status monitoring, providing an advanced technical platform for in-depth research on the long-term withstand voltage behavior and service life prediction of insulating materials.
[0158] Figure 5A flowchart illustrating a multi-channel withstand voltage test method for insulating materials according to an embodiment of this disclosure is shown. Figure 5 As shown, the method may include:
[0159] In step S501, the signal output module of the control unit sends a first control command to the test unit.
[0160] In step S502, the signal acquisition module of the control unit receives the status monitoring signals of each test channel acquired by the test unit during the withstand voltage test.
[0161] The condition monitoring signals include current signals, which are used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test.
[0162] In step S503, one or more high-voltage switch modules in the test unit respond to the first control command and control the opening of the test channel corresponding to the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
[0163] In one possible implementation, the method further includes:
[0164] The control unit's status monitoring module determines whether the insulation material sample corresponding to each test channel has broken down based on the status monitoring signal.
[0165] When the signal output module detects that the insulation material sample of a certain test channel has broken down, it sends a second control command to the test unit for the test channel that has broken down.
[0166] In response to the second control command, the high-voltage switch module controls the disconnection of the test channel corresponding to the high-voltage switch module to stop the withstand voltage test of the insulating material sample in the test channel.
[0167] In one possible implementation, determining whether the insulating material sample corresponding to each test channel has broken down is based on the condition monitoring signal, including:
[0168] When the current signal value corresponding to the test channel meets the preset conditions, it is determined that the insulating material sample of the test channel has broken down. The preset conditions include:
[0169] The current signal value exceeds the preset breakdown current threshold, or the duration for which the current signal value exceeds the preset breakdown current threshold is greater than the preset breakdown time threshold.
[0170] In one possible implementation, the method further includes:
[0171] A signal conversion module located between the control unit and the test unit converts the control signal output by the signal output module from a level control signal into a switch control signal.
[0172] The signal conversion module converts the switch control signal into a voltage control signal that meets the driving requirements of the high-voltage switch module and sends it to the high-voltage switch module.
[0173] In one possible implementation, the method further includes:
[0174] The high voltage generation and regulation module in the test unit, which is connected to one or more high voltage switch modules, generates and maintains the high voltage waveform required for the withstand voltage test, and sends the high voltage waveform to one or more high voltage switch modules.
[0175] Step S503 includes:
[0176] In response to the first control command, a high-voltage waveform is sent to the corresponding test channel of the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
[0177] In one possible implementation, the method further includes:
[0178] One or more current-limiting modules located between the high-voltage generation and regulation module and the high-voltage switch module in the test unit limit the short-circuit current when the insulating material sample breaks down to a preset short-circuit current threshold.
[0179] In one possible implementation, each test channel includes a high-voltage electrode and a low-voltage electrode, with an insulating material sample positioned between the high-voltage and low-voltage electrodes. The method further includes:
[0180] The status monitoring signals of each test channel are acquired by one or more current signal acquisition modules connected to the low-voltage electrode in the test unit;
[0181] In cases where the current signal acquisition module and control unit do not have voltage limiting functionality, the method further includes:
[0182] The protection module limits the instantaneous voltage to below a preset voltage threshold.
[0183] In one possible implementation, the method further includes:
[0184] The host computer unit connected to the control unit sets the parameters of the withstand voltage test, controls the start and stop of the withstand voltage test, controls the opening / closing of each test channel, and visualizes at least one of the status monitoring signals of each test channel and the breakdown state of the insulating material sample.
[0185] In one possible implementation, the control unit is a data acquisition card, the signal conversion module consists of an optocoupler relay group and a programmable logic controller (PLC), the protection module is a transient voltage suppressor group, the high-voltage switch module is a high-voltage relay, the high-voltage generation and regulation module consists of a signal generator and a power amplifier, the current limiting module is a current limiting resistor, and the current signal acquisition module is a sampling resistor.
[0186] According to embodiments of this disclosure, by sending a first control command to the test unit via the signal output module, the signal acquisition module receives status monitoring signals from each test channel acquired by the test unit during the withstand voltage test. These status monitoring signals include current signals, enabling monitoring of the behavior of the insulating material during the withstand voltage test and full life-cycle performance retrospective analysis, thus supporting subsequent in-depth evaluation of the insulating material's insulation performance. Furthermore, by using one or more high-voltage switch modules in response to the first control command to control the opening of the corresponding test channel, and performing withstand voltage tests on the insulating material samples in that test channel, multi-channel parallel withstand voltage testing can be achieved. This multi-channel parallel testing mechanism not only significantly improves testing efficiency but also adapts to the high-efficiency testing needs of different batches and types of materials, meeting the requirement of completing tests on large batches of samples within a limited time, demonstrating good adaptability and flexibility.
[0187] In some embodiments, the system provided in this disclosure may have functions or include modules that can be used to execute the methods described in the above method embodiments. The specific implementation of these methods can be referred to the description in the above method embodiments, and for the sake of brevity, they will not be repeated here.
[0188] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems and methods according to various embodiments of the present disclosure. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of an instruction containing one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions marked in the blocks may occur in a different order than those shown in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.
[0189] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or technical improvements to the embodiments in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.
Claims
1. A multi-channel withstand voltage testing system for insulating materials, characterized in that, The system includes a control unit and a testing unit, the control unit comprising: The signal output module is used to send a first control command to the test unit; The signal acquisition module is used to receive the status monitoring signals of each test channel acquired by the test unit during the withstand voltage test. The status monitoring signals include current signals, which are used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test. The test unit includes: One or more high-voltage switch modules are configured to, in response to the first control command, control the opening of the test channel corresponding to the high-voltage switch module, so as to perform a withstand voltage test on the insulating material sample in the test channel.
2. The system according to claim 1, characterized in that, The control unit further includes: The status monitoring module is used to determine whether the insulating material sample corresponding to each test channel has broken down based on the status monitoring signal. The signal output module is also used for: When a breakdown of the insulating material sample in a certain test channel is detected, a second control command is sent to the test unit for the test channel that has experienced the breakdown. The high-voltage switch module is also used for: In response to the second control command, the test channel corresponding to the high-voltage switch module is cut off to stop the withstand voltage test of the insulating material sample in the test channel.
3. The system according to claim 2, characterized in that, The status monitoring module is used for: When the current signal value corresponding to the test channel meets a preset condition, it is determined that the insulating material sample of that test channel has broken down. The preset condition includes: The current signal value exceeds a preset breakdown current threshold, or the duration for which the current signal value exceeds the preset breakdown current threshold is greater than a preset breakdown time threshold.
4. The system according to claim 1, characterized in that, The system further includes a signal conversion module, which is disposed between the control unit and the test unit, and is used for: The control signal output by the signal output module is converted from a level control signal into a switch control signal; The switch control signal is converted into a voltage control signal that meets the driving requirements of the high-voltage switch module and sent to the high-voltage switch module.
5. The system according to claim 1, characterized in that, The test unit also includes: A high-voltage generation and regulation module, connected to the one or more high-voltage switch modules, is used for: Generate and maintain the high-voltage waveform required for the withstand voltage test, and send the high-voltage waveform to one or more high-voltage switching modules; The one or more high-voltage switch modules are used for: In response to the first control command, the high-voltage waveform is sent to the test channel corresponding to the high-voltage switch module to perform a withstand voltage test on the insulating material sample in the test channel.
6. The system according to claim 5, characterized in that, The test unit also includes: One or more current limiting modules are provided, wherein the current limiting modules are disposed between the high voltage generation and regulation module and the high voltage switch module, and are used to limit the short circuit current when the insulating material sample breaks down to less than a preset short circuit current threshold.
7. The system according to claim 1, characterized in that, Each of the test channels includes a high-voltage electrode and a low-voltage electrode, with an insulating material sample placed between the high-voltage electrode and the low-voltage electrode. The test unit also includes: One or more current signal acquisition modules, wherein the current signal acquisition modules are connected to the low-voltage electrode and are used to acquire the status monitoring signals of each test channel; If the current signal acquisition module and the control unit do not have voltage limiting functions, the system further includes: A protection module is provided between the control unit and the test unit to limit the instantaneous voltage from falling below a preset voltage threshold.
8. The system according to claim 1, characterized in that, The system also includes: The host computer unit, which is connected to the control unit, is used to set the parameters of the withstand voltage test, control the start and stop of the withstand voltage test, control the opening / closing of each test channel, and visually display at least one of the status monitoring signals of each test channel and the breakdown state of the insulating material sample.
9. The system according to any one of claims 1-8, characterized in that, The control unit is a data acquisition card, the signal conversion module consists of an optocoupler relay group and a programmable logic controller (PLC), the protection module is a transient voltage suppressor group, the high-voltage switch module is a high-voltage relay, the high-voltage generation and regulation module consists of a signal generator and a power amplifier, the current limiting module is a current limiting resistor, and the current signal acquisition module is a sampling resistor.
10. A multi-channel withstand voltage test method for insulating materials, characterized in that, The method includes: The control unit's signal output module sends the first control command to the test unit; The signal acquisition module of the control unit receives the status monitoring signals of each test channel acquired by the test unit during the withstand voltage test. The status monitoring signals include current signals, which are used to analyze the electrical aging process and breakdown characteristics of each insulating material sample during the withstand voltage test. One or more high-voltage switch modules in the test unit respond to the first control command by controlling the opening of the test channel corresponding to the high-voltage switch module, so as to perform a withstand voltage test on the insulating material sample in the test channel.