Multifunctional integrated insulation resistance tester and operation method thereof

Abstract

The invention relates to the technical field of electrical equipment detection, in particular to a multifunctional integrated insulation resistance tester and an operation method thereof.The multifunctional integrated insulation resistance tester comprises an insulation resistance tester body which is composed of a panel assembly, a case assembly and a detachable expansion cabin which can be disassembled and assembled, and a signal processing module collects environment data and sample signal data; carrying out filtering, amplification and temperature and humidity compensation correction on the data; the multifunctional integrated test module integrates multiple test functions and a cable length measurement function, can carry out flexible voltage adjustment, and supports seven fixed voltage ranges and a customized continuous adjustable mode. The intelligent control module performs task adaptive scheduling, and dynamically configures and coordinates a working time sequence and parameters; the man-machine interaction module is used for switching test functions, setting test parameters and displaying and recording test numerical values and dynamic states; the safety protection module comprises a structure protection mechanism and an active protection mechanism. Therefore, the problems of single function, lack of function extension, non-visual data presentation and the like are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electrical equipment detection, and in particular relates to a multifunctional integrated insulation resistance tester and a running method thereof. BACKGROUND

[0002] In the installation, debugging, operation and maintenance process of power systems, industrial electrical equipment and building electrical engineering, insulation resistance testing is a key link for evaluating the insulation performance of electrical equipment, predicting its service life and ensuring the safe operation of the system. Accurate insulation resistance measurement can effectively find insulation defects caused by aging, dampness, pollution or damage of insulation materials, thereby preventing electric shock, fire and other serious accidents. However, the mainstream insulation resistance testers on the current market still have many limitations in actual application, which are difficult to meet the increasingly complex and efficient on-site testing needs. Specifically, there are the following points: first, the function is single, which is difficult to cope with complex on-site diagnosis scenarios. Traditional insulation resistance testers usually only have basic insulation resistance measurement function, and some high-end models have integrated absorption ratio and polarization index test mode, but their functional boundaries are still limited to insulation performance evaluation. Second, there is a lack of function expansion and upgrading capability. The existing testers are mostly fixed-function closed systems, and their hardware architecture and software ecosystem do not support users to expand functions according to their specific, new testing needs. Third, the degree of intelligence is low, the operation is complex and requires high personnel. The testing process of many devices relies on manual setting of a large number of parameters (such as voltage, time, compensation coefficient, etc.) by the operator, which is tedious and prone to errors. The accuracy of the test results is seriously dependent on the environmental temperature and humidity, and most of the existing devices do not have automatic environmental sensing and data compensation capabilities, resulting in a lack of comparability of the data obtained in different test environments, affecting the accurate judgment of the development trend of the insulation state. Fourth, the data presentation is not intuitive, and the comprehensive analysis capability is weak. Although some testers are equipped with a display screen, most of them can only display instantaneous values or simple data lists, and lack intuitive and dynamic graphical display of the trends of insulation resistance, leakage current and other parameters over time. SUMMARY

[0003] The present application provides a multifunctional integrated insulation resistance tester and a running method thereof to solve the problems of single function, lack of function expansion, and non-intuitive data presentation.

[0004] The first aspect embodiment of the application provides a multifunctional integrated insulation resistance tester, comprising: an insulation resistance tester body, a signal processing module, a multifunctional integrated test module, an intelligent control module, a human-computer interaction module, and a safety protection module, wherein the insulation resistance tester body is composed of a detachable panel assembly, a case assembly, and a detachable expansion cabin, wherein the panel assembly integrates multiple circuit boards and anti-misoperation test terminals, the case assembly adopts a layered shielding design, and realizes electrical isolation of high-voltage and low-voltage areas (25kV) through a physical baffle, the detachable expansion cabin is connected with the case assembly through a standardized interface, supports external expansion modules, and realizes on-demand expansion of test functions; the signal processing module is used for collecting environmental temperature and humidity data and insulation resistance, loop current, and applied voltage signals of a test sample, filtering, amplifying, and temperature and humidity compensation correcting the collected data, and outputting standardized multidimensional test data; the multifunctional integrated test module is used for integrating multiple electrical parameter test functions and cable length measurement functions, wherein the multiple electrical parameter test functions can automatically calculate and display various parameter values, support user-defined test time, can flexibly adjust voltage, support seven fixed voltage ranges and a self-defined continuous adjustable mode, and the cable length measurement function calculates cable length according to the time domain reflection method principle by applying a test signal of a specific frequency to a cable, detecting a signal reflection time, and combining cable wave speed parameters; the intelligent control module is used for task adaptive scheduling of selected test functions through the human-computer interaction module, dynamically configuring and coordinating work timing and parameters of the signal processing module and the multifunctional integrated test module; the human-computer interaction module is used for test function switching and test parameter setting through a capacitive touch screen and an encoder fly shuttle, real-time display and recording of insulation resistance, test voltage, and current instantaneous values through the capacitive touch screen, dynamic curve drawing in the same coordinate system, real-time display and recording of parameter change trends; and the safety protection module includes structural protection and active protection mechanisms, wherein the structural protection includes electrical isolation structures and mechanical protection structures, and the active protection mechanisms include high-voltage overvoltage protection, test sample breakdown protection, and independent discharge protection.

[0005] Optionally, the insulation resistance tester body comprises a panel assembly, a case assembly, and a detachable expansion bay, wherein the panel assembly integrates multiple circuit boards and anti-misoperation test terminals, the multiple circuit boards include a master control board, a touch screen display module, an encoder board, a key board, a charging indicator light board, a USB interface board, and a communication interface board, the anti-misoperation test terminals are designed with an insulation sheath and a groove to prevent misoperation and are marked with a high-voltage warning; the case assembly includes an isolation power supply board, a high-voltage CPU board, a high-voltage power supply board, an AC-DC conversion board, a battery compartment, and a physical baffle, the physical baffle is made of glass fiber reinforced epoxy resin material and is located between the left high-voltage area and the right low-voltage area; the detachable expansion bay provides a standardized composite interface for connecting external functional expansion modules.

[0006] Optionally, the standardized interface of the detachable expansion bay is a composite interface that integrates a high-speed data communication bus, a low-voltage power supply circuit, and a state identification circuit, wherein the state identification circuit is used to report the module identity and function code to the intelligent control module when the expansion module is connected, and the intelligent control module automatically loads the corresponding driver program and operation interface element from the built-in driver library according to the identity and function code, to realize plug and play.

[0007] Optionally, the signal processing module comprises a data acquisition unit, a signal processing and calculation unit, and a multi-parameter fusion compensation unit, wherein the data acquisition unit is used to connect to a test sample through the test terminals to acquire the insulation resistance, loop current, and voltage signals flowing through the test sample under high voltage; the signal processing and calculation unit is used to convert the acquired analog signals into digital signals through filtering and amplification and ADC conversion, to calculate the insulation resistance value and other parameters in real time according to the built-in algorithm based on Ohm's law; and the multi-parameter fusion compensation unit is used to dynamically compensate and correct the insulation resistance test results by using a compensation model according to the real-time collected environmental temperature and humidity data.

[0008] Optionally, the multifunction integrated test module comprises a flexible voltage regulation unit, an electrical parameter integrated test unit, a cable length measurement unit, and an extension test unit, wherein the flexible voltage regulation unit is configured to provide seven fixed voltage ranges and support continuous self-defined adjustment of voltage in the range of 50V to 10000V; the electrical parameter integrated test unit is configured to integrate insulation resistance test, absorption ratio test, polarization index test, step voltage test, dielectric discharge rate test, DC voltage table, and AC voltage table functions, and support user-defined test time; the cable length measurement unit is configured to generate a test signal of a specific frequency through the main control board and apply it to the cable, when the test signal encounters impedance discontinuity points in the cable, reflection occurs, the time difference between signal emission and reflection is detected, and the cable length is calculated according to the time domain reflection principle in combination with the preset cable wave speed parameter; and the extension test unit is configured to load the corresponding extension test function when the extension module is detected.

[0009] Optionally, the intelligent control module comprises a task scheduler, a resource manager, and a fault self-diagnosis unit, wherein the task scheduler is configured to analyze the selected test function through the human-computer interaction module, generate a task instruction sequence containing timing logic, and schedule each module to execute in sequence; the resource manager is configured to automatically load a parameter configuration table according to the selected test function, dynamically allocate and configure the sampling rate and filtering parameters of the signal processing module, and the voltage output parameters and test mode of the multifunction integrated test module; and the fault self-diagnosis unit is configured to periodically or triggeredly diagnose each hardware unit inside the instrument during startup and operation, generate an alarm code when an abnormality is found, and display it on the human-computer interaction module.

[0010] Optionally, the human-computer interaction module comprises an operation unit and an intelligent display and recording unit, wherein the operation unit is configured to switch test functions and set test parameters through operation of the capacitive touch screen or rotary jog dial, and the generated operation instructions are transmitted to the main control board through the wire; and the intelligent display and recording unit is configured to display test values, curves, and state information in real time in different areas on the capacitive touch screen, support comparison and analysis of multiple sets of test data on the same screen, and the curves are curves of insulation resistance, test voltage, and leakage current parameters changing with time dynamically drawn in the same coordinate system, all curves and data can be recorded in the internal storage or exported through the USB interface.

[0011] Optionally, the safety protection module comprises a structural protection mechanism and an active protection mechanism, wherein the structural protection mechanism comprises an electrical isolation structure and a mechanical protection structure, the electrical isolation structure is designed with a full isolation power supply, 25kV electrical isolation between a high-voltage area and a low-voltage area is realized by an isolation transformer on an isolation power supply board in combination with an intermediate physical baffle, and the mechanical protection structure is a cabinet shell made of polypropylene alloy material or carbon fiber composite material; the active protection mechanism comprises high-voltage overvoltage protection, sample breakdown protection and independent discharge protection, wherein the high-voltage overvoltage protection is to monitor whether the output voltage exceeds a target safety value, and if so, to immediately cut off the output of the high-voltage power supply board; the sample breakdown protection is to quickly limit the current and maintain a controllable operating state when the sample is detected to be broken down to form a short circuit or an arc, and to help an operator accurately locate an insulation weak point; and the independent discharge protection is to automatically start a safety discharge circuit after the test is completed or in an emergency shutdown to ensure that the sample and internal energy storage elements of the instrument are quickly and safely discharged.

[0012] The second aspect embodiment of the application provides a running method of a multifunctional integrated insulation resistance tester, comprising the following steps: selecting a power supply mode; pressing a power supply key to run a self-diagnosis program to quickly detect each connection line to obtain a self-checking result, which is displayed on a capacitive touch screen, when the self-checking result is normal, the tester enters a standby state; if it is detected that a standardized interface of a detachable expansion cabin is connected with a module, it is selected whether to use the expansion module, if yes, the expansion module is identified and loaded and integrated into a test mode; through capacitive touch screen touch or rotary jog dial, a required test mode is selected in a main menu, the test mode comprises insulation resistance test, absorption ratio test, polarization index test, step voltage test, dielectric discharge rate test, cable length measurement, direct current voltmeter, alternating current voltmeter and expansion mode; voltage parameters are selected from seven fixed ranges or self-defined voltage parameters are set through the jog dial; after triggering a start test, test voltage is applied to a sample according to the set voltage parameters, a task adaptive scheduling program is started according to the selected test mode, insulation resistance, leakage current, applied voltage and environmental temperature and humidity data are collected in real time and filtered, amplified and temperature and humidity compensated and corrected, corresponding built-in algorithms are executed to obtain test results; the capacitive touch screen displays instantaneous values of insulation resistance, voltage and leakage current in real time, simultaneously, three curves of the parameters changing with time are dynamically drawn in the same coordinate system, and after the test is completed, test values and curves are saved in an internal storage area.

[0013] Optionally, the active protection mechanism is involved in the whole test process to ensure test process safety through high-voltage overvoltage protection, sample breakdown protection and independent discharge protection.

[0014] The application has the following beneficial effects: The embodiments of the present application solve the problems of needing to carry multiple instruments and repeatedly connecting wires by integrating multiple test functions, improve the efficiency of on-site testing, and reduce the cost of equipment purchase and maintenance; through the detachable expansion cabin, the user can flexibly add new functions according to the needs, prolong the technical life cycle of the product, protect the user's investment, and at the same time enable the instrument to continuously evolve to adapt to changing technical standards and application requirements; by introducing environmental temperature and humidity sensing and compensation mechanisms, the influence of environmental factors on test results can be automatically corrected, ensuring the accuracy, comparability and reliability of the data; by providing 7 fixed voltages and continuously adjustable modes within the range of the range, both standardized test requirements and non-standard tests under special working conditions can be met, the test range is wide, the application scenarios are comprehensive, and the user can flexibly choose according to the type of the test sample, significantly enhancing the applicability and flexibility of the instrument; through the change curve, the test personnel can intuitively observe the change trend of the insulation performance and the correlation between the three, facilitating the rapid capture of early features of insulation defects; through the structure protection and active protection mechanism, a double safety line is built to protect the safety of the operator and the measured equipment, and significantly reduce the risk of high-voltage test operation. Thus, the problems of single function, lack of function expansion, and non-intuitive data presentation are solved.

[0015] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0016] The above and / or additional aspects and advantages of the present application will become apparent and be readily appreciated from the following description, including the accompanying drawings, wherein: Figure 1 A structural schematic diagram of a multifunctional integrated insulation resistance tester according to an embodiment of the present application; Figure 2 A structural schematic diagram of an insulation resistance tester body according to an embodiment of the present application; Figure 3 A flowchart of a running method of a multifunctional integrated insulation resistance tester according to an embodiment of the present application. DETAILED DESCRIPTION

[0017] The embodiments of the present application are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference signs represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are intended to explain the present application, and cannot be understood as limiting the present application.

[0018] A multifunctional integrated insulation resistance tester and a method for operating the same are described below with reference to the accompanying drawings. In view of the above background art, the multifunctional integrated insulation resistance tester and the method for operating the same are provided to solve the problems of single function, lack of function expansion, and non-intuitive data presentation. The insulation resistance tester integrates multiple testing functions to solve the problems of needing to carry multiple instruments and repeatedly connecting wires, improve on-site testing efficiency, and reduce equipment purchase and maintenance costs. The insulation resistance tester supports users to flexibly add new functions according to needs through a detachable expansion cabin, prolongs the product's technical life cycle, protects user investment, and enables the instrument to continuously evolve to adapt to changing technical standards and application requirements. The insulation resistance tester automatically corrects the influence of environmental factors on test results through the introduction of environmental temperature and humidity sensing and compensation mechanisms, ensuring the accuracy, comparability, and reliability of data. The insulation resistance tester provides seven fixed voltages and a continuously adjustable mode within the range of the scale to meet standardized testing needs and adapt to non-standard testing under special working conditions, has a wide test range, covers a comprehensive application scenario, and enables users to flexibly select according to the type of test samples, significantly enhancing the applicability and flexibility of the instrument. The insulation resistance tester enables test personnel to intuitively observe the change trend of insulation performance and the correlation among the three through a change curve, facilitating the rapid capture of early features of insulation defects. The insulation resistance tester constructs a double safety line through structural protection and active protection mechanisms to protect the safety of operating personnel and measured equipment and significantly reduce the risk of high-voltage testing operations. Thus, the problems of single function, lack of function expansion, and non-intuitive data presentation are solved.

[0019] Specifically, Figure 1 A structural schematic diagram of a multifunctional integrated insulation resistance tester provided by an embodiment of the present application.

[0020] As Figure 1 shown, the multifunctional integrated insulation resistance tester 10 includes an insulation resistance tester body 100, a signal processing module 200, a multifunctional integrated testing module 300, an intelligent control module 400, a human-computer interaction module 500, and a safety protection module 600.

[0021] The insulation resistance tester body 100 is composed of a detachable panel assembly, a case assembly and a detachable expansion cabin, wherein the panel assembly integrates various circuit boards and anti-misoperation test terminals, the case assembly adopts a layered shielding design to realize electrical isolation of the high-voltage area and the low-voltage area 25kV through a physical baffle, the detachable expansion cabin is connected with the case assembly through a standardized interface, supports external expansion modules and realizes on-demand expansion of test functions; the signal processing module 200 is used for collecting environmental temperature and humidity data and insulation resistance, loop current and applied voltage signals of a test sample, filtering, amplifying and temperature and humidity compensation correcting the collected data and outputting standardized multi-dimensional test data; the multifunctional integrated test module 300 is used for integrating various electrical parameter test functions and cable length measurement functions, wherein the various electrical parameter test functions can automatically calculate and display various parameter values, support user-defined test time, can flexibly adjust voltage, support seven fixed voltage ranges and a self-defined continuous adjustable mode, and the cable length measurement function calculates the cable length according to the time domain reflection method principle by applying a test signal of a specific frequency to the cable, detecting the signal reflection time and combining a cable wave speed parameter; the intelligent control module 400 is used for task adaptive scheduling of the test functions selected through the man-machine interaction module, dynamic configuration and coordination of the working time sequence and parameters of the signal processing module and the multifunctional integrated test module; the man-machine interaction module 500 is used for test function switching and test parameter setting through a capacitive touch screen and an encoder flying shuttle, real-time display and recording of insulation resistance, test voltage and current instantaneous values through the capacitive touch screen, dynamic curve drawing in the same coordinate system and real-time display and recording of parameter change trends; the safety protection module 600 includes structural protection and active protection mechanisms, wherein the structural protection includes an electrical isolation structure and a mechanical protection structure, and the active protection mechanisms include high-voltage overvoltage protection, test sample breakdown protection and independent discharge protection.

[0022] It can be understood that the embodiments of the present application solve the problem of needing to carry multiple instruments and repeatedly wiring by integrating multiple test functions, improve the efficiency of on-site testing, and reduce the cost of equipment purchase and maintenance; through the detachable expansion cabin, the user can flexibly add new functions according to the needs, prolong the technical life cycle of the product, protect the user's investment, and at the same time enable the instrument to continuously evolve to adapt to changing technical standards and application requirements; by introducing environmental temperature and humidity sensing and compensation mechanism, the influence of environmental factors on the test results can be automatically corrected, ensuring the accuracy, comparability and reliability of the data; by providing 7 fixed voltages and continuously adjustable modes within the range of the range, both standardized test requirements and non-standard tests under special working conditions can be met, the test range is wide, the application scenarios are covered comprehensively, and the user can flexibly choose according to the type of test sample, significantly enhancing the applicability and flexibility of the instrument; through the change curve, the test personnel can intuitively observe the change trend of the insulation performance and the correlation between the three, which is convenient for quickly capturing the early characteristics of insulation defects; through the structure protection and active protection mechanism, a double safety line is built to protect the safety of the operator and the measured equipment, and significantly reduce the risk of high-voltage test operation.

[0023] In the embodiments of the present application, the insulation resistance tester body comprises: Figure 2 as shown, the panel assembly, the case assembly, and the detachable expansion cabin.

[0024] Among them, the panel assembly integrates multiple circuit boards and anti-mis touch test terminals, wherein the multiple circuit boards include a main control board, a touch screen display module, an encoder board, a key board, a charging indicator light board, a USB interface board, and a communication interface board. The anti-mis touch test terminals are designed with an insulating sheath and a groove to prevent accidental touching and identify high-voltage warnings; the case assembly includes an isolation power supply board, a high-voltage CPU board, a high-voltage power supply board, an AC-DC conversion board, a battery compartment, and a physical baffle. The physical baffle is made of glass fiber reinforced epoxy resin material and is located between the left high-voltage area and the right low-voltage area; the detachable expansion cabin provides a standardized composite interface for connecting external function expansion modules.

[0025] Specifically, the panel assembly is located on the front of the instrument, and is the core interface for users to interact with the tester. It integrates all the control, display and input / output interfaces. The main control board is located in the center of the panel, running the operating system and main control program, responsible for data processing, instruction distribution and collaborative scheduling between modules. The touch screen display module covers the main area of the panel and is connected to the main control board through a wire harness. It is responsible for rendering the graphical user interface, displaying test data, dynamic curves and system status in real time, and receiving user touch commands. The encoder board is located below the main control board and slightly to the left, integrated with a jog shuttle. Users can select menus and adjust parameters (especially continuous voltage adjustment) by rotating the jog shuttle, and the pulse signals generated by the jog shuttle are transmitted to the main control board. The key board is located below the main control board and slightly to the right, next to the encoder board, and is provided with physical keys (start test, menu, return). The key signals are first transmitted to the encoder board for integration, and then reported to the main control board. The USB interface board is located on the left side of the panel, used to connect external storage devices such as USB flash drives, to realize fast export of test data or import of configuration files. The communication interface board is located below the USB interface board, usually using standard industrial interfaces such as DB9, supporting RS232 / RS485 protocols, used for remote communication and control with host computers or other devices. The charging indicator light board is located in the upper left corner of the panel, close to the power interface. It visually displays the charging status and power level of the battery through the LED indicator light, and transmits the status information to the main control board. The test terminals are located on the right side of the panel, maintaining a safe distance from the internal circuit board. They use an insulating sheath and a recessed design, so that the metal conductor part of the terminal is sunken inside the insulating sheath, and the sheath is 8mm higher than the conductor part, ensuring that even when connecting test wires, the operator's fingers cannot directly touch the live metal part. The terminal sheath is clearly marked with a high-voltage warning symbol and text, providing visual safety warnings.

[0026] The chassis assembly is located at the rear of the instrument, responsible for energy conversion, distribution and high voltage output, and is divided into a high voltage area and a low voltage area. The high voltage area and the low voltage area are clearly separated by a physical baffle. The physical baffle is made of glass fiber reinforced epoxy resin material, which has very high dielectric strength, mechanical strength and arc resistance. The thickness of the baffle is not less than 4mm, and a grounded metal shielding layer is covered on the side facing the high voltage area. It physically separates the high voltage area from the low voltage area, ensuring that even if an abnormality occurs in the high voltage component, high voltage can effectively prevent high voltage from entering the low voltage area, achieving reliable electrical isolation of 25kV, which is a key guarantee for the safety of the operator. The left high voltage area includes a high voltage power supply board and a high voltage CPU board. The high voltage power supply board is located at the top of the left side and is a direct generation unit of high voltage energy, receiving control signals from the high voltage CPU board and inverting low voltage direct current into the required high voltage direct current. The high voltage CPU board is located at the bottom of the left side, which receives instructions from the main control board, accurately controls the output voltage and climbing rate of the high voltage power supply board, and monitors the status of the high voltage area. The right low voltage area includes an isolation power supply board, an AC-DC conversion board and a battery compartment. The isolation power supply board is located at the top of the right side and contains an isolation transformer to electrically isolate and convert the power from the AC-DC conversion board or the battery to provide stable and isolated multi-channel low voltage power for the high voltage area, main control board and the like. The AC-DC conversion board is located below the isolation power supply board and is responsible for converting the external power (alternating current) into stable low voltage direct current. The battery compartment is located at the bottom of the right side and contains a rechargeable battery to provide operating power when there is no external power supply.

[0027] The detachable expansion cabin is on the side of the chassis and is connected to the chassis assembly through a standardized composite interface. When the expansion cabin is inserted, its composite interface is connected to the female seat on the chassis. After the main control board detects the expansion module through the state identification line, it automatically loads the corresponding driver from the built-in driver library and generates function options for the expansion module on the user interface, realizing plug and play.

[0028] It can be understood that the embodiments of the present application concentrate the human-computer interaction core through the panel assembly, and the redundant design of the capacitive touch screen and the shuttle key ensures intuitive and efficient operation, and the 8mm deep groove anti-misoperation terminal and the global high voltage warning mark build the first safety line. The chassis assembly adopts physical partition design to realize 25kV electrical isolation by 4mm glass fiber reinforced epoxy resin baffle combined with metal shielding layer, completely eliminates the risk of high and low voltage circuit crosstalk, and makes the high voltage power supply and the low voltage control unit work cooperatively in a safe isolation state. The detachable expansion cabin realizes hardware level function expansion through a standardized composite interface, realizing plug and play of the test instrument. While maintaining the protection of the whole machine, it realizes a leapfrog upgrade from a single insulation test device to a comprehensive electrical detection device, which can not only meet the current full parameter test demand, but also reserve sufficient space for future function expansion.

[0029] In the embodiment of the present application, the standardized interface of the detachable expansion cabin is a composite interface, which integrates a high-speed data communication bus, a low-voltage power supply circuit and a state identification circuit. The state identification circuit is used to report the module identity and function code to the intelligent control module when the expansion module is connected. The intelligent control module automatically loads the corresponding driver and operation interface element from the built-in driver library according to the identity and function code, thereby realizing plug and play.

[0030] Specifically, the high-speed data communication bus is responsible for real-time data interaction between the expansion module and the host intelligent control module, and meets the high-speed transmission requirement of high-frequency test data. The transmission line adopts a twisted pair structure and is wrapped with an aluminum foil shielding layer to reduce interference. The low-voltage power supply circuit is responsible for providing stable direct current power supply for the expansion module, and has overcurrent and reverse connection protection functions to ensure the safe operation of the expansion module. The circuit is connected in series with a self-restoring fuse and in parallel with a TVS diode to prevent damage to the expansion module caused by short circuit or overvoltage. A P-channel MOS tube is used to form a reverse connection protection circuit. When the positive and negative electrodes of the expansion module are connected in reverse, the MOS tube automatically cuts off, cutting off the power supply circuit to avoid module burning. The state identification circuit realizes automatic identity recognition and function matching of the expansion module, and is the core trigger link for realizing the plug and play mechanism. The expansion module pre-stores the module identity and function code. The intelligent control module sends a reading instruction to read the module identity and function code after the power supply is stable. The intelligent control module checks the received code, and after the check is passed, the corresponding driver and operation interface element are automatically loaded according to the function code by searching the built-in driver library. After the driver and interface are loaded, the intelligent control module establishes a data link with the expansion module through the high-speed data communication bus to perform data interaction and testing.

[0031] It can be understood that the high-speed data communication bus of the embodiment of the present application is designed to be anti-interference to ensure stable transmission of high-frequency test data and provide support for accurate testing. The overcurrent, reverse connection and overvoltage protection mechanism of the low-voltage power supply circuit eliminates the risk of damage to the expansion module when it is connected, greatly improving safety. The linkage of the state identification circuit and the intelligent control module realizes automatic recognition, driver loading and interface generation of the expansion module, eliminates manual configuration processes, and achieves the convenient experience of plug and play. At the same time, the standardized design supports the compatibility and collaborative work of multiple types of expansion modules, significantly enhances the functional expandability and scene adaptability of the device, effectively reduces the user equipment procurement and operation cost, and improves the work efficiency in complex test scenarios.

[0032] In the embodiment of the present application, the signal processing module includes a data acquisition unit, a signal processing and calculation unit, and a multi-parameter fusion compensation unit.

[0033] The data acquisition unit is connected to the test sample through the test terminal to acquire the insulation resistance, loop current and voltage signal flowing through the test sample under high pressure; the signal processing and calculation unit converts the acquired analog signal into digital signal through filtering and amplification by ADC, and calculates the insulation resistance value and other parameters in real time according to Ohm's law; the multi-parameter fusion compensation unit compensates and corrects the insulation resistance test result dynamically by using the compensation model according to the real-time collected environmental temperature and humidity data.

[0034] Specifically, the insulation resistance associated signal and the environmental reference signal of the test sample are synchronously collected under high voltage excitation by establishing electrical connection through the test terminal. A high-precision closed-loop Hall current sensor is used to form a signal conditioning circuit with a low-noise operational amplifier to convert the weak current signal into a standard voltage signal of 0-3.3V. An integrated temperature and humidity sensor is used to communicate with the signal processing unit through the I2C bus to provide environmental reference data for subsequent compensation calculation.

[0035] The collected original analog signal is first subjected to preliminary anti-aliasing filtering by an analog filter, and then subjected to digital filtering by a digital signal processor to suppress power frequency interference, high frequency noise and the like, thereby significantly improving the signal-to-noise ratio. The weak leakage current signal needs to be amplified to adjust it to the optimal range suitable for the analog-to-digital converter. The adjusted analog signal is input to the high-resolution ADC to convert it into a digital signal, and the insulation resistance value is calculated by Ohm's law.

[0036] The temperature compensation coefficient and the humidity compensation coefficient corresponding to the insulation material of the test sample are obtained from the built-in temperature coefficient table and the humidity coefficient table, and the insulation resistance test result is dynamically compensated and corrected by using the compensation model. The formula of the compensation model is: ; wherein, is the final insulation resistance value after compensation; is the calculated insulation resistance value; is the real-time temperature, is the reference temperature, is the temperature compensation coefficient; is the real-time relative humidity, is the reference humidity, is the humidity compensation coefficient.

[0037] It can be understood that the embodiment of the application adopts a multi-parameter fusion compensation algorithm based on material characteristics, dynamically calls compensation coefficients matched with the insulation material of the test sample through the built-in temperature and humidity coefficient table, quantitatively corrects the influence of temperature and humidity by using a strict mathematical model, and finally outputs a standardized insulation resistance value. The problem of uncomparable test data caused by environmental fluctuations is solved, so that the data measured at different times and different places for the same equipment has consistent reference value, which provides a solid data cornerstone for accurately evaluating the long-term degradation trend of insulation performance and realizing predictive maintenance.

[0038] In the embodiment of the application, the multifunctional integrated test module includes a flexible voltage regulation unit, an electrical parameter integrated test unit, a cable length measurement unit and an extension test unit.

[0039] The flexible voltage regulation unit is used to provide seven fixed voltage ranges, and also supports continuous self-defined adjustment of voltage in the range of 50V to 10000V; the electrical parameter integrated test unit is used to integrate insulation resistance test, absorption ratio test, polarization index test, step voltage test, dielectric discharge rate test, direct current voltmeter and alternating current voltmeter functions, and supports user-defined test time; the cable length measurement unit is used to generate a test signal of a specific frequency through the control of the main control board and apply it to the cable. When the test signal encounters an impedance discontinuity point in the cable, reflection will occur. The time difference between the signal emission and reflection is detected, and the cable length is calculated according to the principle of time domain reflectometry in combination with the preset cable wave speed parameter; the extension test unit is used to load the corresponding extension test function when the connection of the extension module is detected.

[0040] Specifically, the insulation resistance test is to collect loop current through the signal processing module under the selected voltage, calculate the insulation resistance according to Ohm's law, and dynamically compensate and correct the insulation resistance according to temperature and humidity.

[0041] The absorption ratio test is to automatically calculate and display the ratio of 60-second and 15-second insulation resistance values, which is used to determine whether the insulation material is damp.

[0042] The polarization index test is to automatically calculate and display the ratio of 10-minute and 1-minute insulation resistance values, which is used to evaluate the insulation quality of the equipment.

[0043] The step voltage test is to gradually increase the test voltage by a set step and time interval, record the change of insulation resistance, and is used to identify insulation aging and pollution.

[0044] The dielectric discharge rate test is to apply a test voltage to the test sample until it is fully charged, then cut off the voltage and start timing, collect the residual voltage after 1s, 3s and 10s after power-off, calculate the discharge rate, and is used to evaluate the discharge characteristics of dielectric materials.

[0045] The DC voltmeter and the AC voltmeter can be used as independent high-precision voltmeters to measure the DC and AC voltages of external circuits.

[0046] The above test functions all support custom test time, and automatically stop and generate a report when the time is up.

[0047] When the connection extension module is detected, the corresponding extension test function is loaded, which can be partial discharge test or dielectric loss test or other test functions. Taking the partial discharge test as an example, when the extension module is connected, the extension test unit controls the output of 0-10kV adjustable voltage, synchronously collects the partial discharge pulse signal, calculates the discharge amount through the pulse counting method, and analyzes and evaluates the insulation aging state in association with the insulation resistance value.

[0048] It should be noted that the time domain reflection method is a non-destructive detection technology based on the propagation characteristics of electromagnetic waves. The core principle is to analyze the reflection behavior of electrical signals in a transmission line (such as a cable) to locate impedance discontinuities and calculate distances. The core advantage is that length measurement and fault location can be achieved without disconnecting the cable, and the precision is not affected by the length of the cable, suitable for various types of metal conductor cables. A test signal of a specific frequency is generated by the main control board and applied to the cable. When the test signal encounters an impedance discontinuity in the cable, it will be reflected. By detecting the time difference between the signal transmission and reflection, and combining the preset cable wave speed parameter, the cable length is calculated according to the principle of time domain reflection method. Among them, the cable wave speed parameter is determined according to the type of cable. The wave speed values of 12 common cables are pre-stored in the internal database. Users can directly select the cable type through the human-computer interaction module, and also support user-defined wave speed values. The formula for calculating the length of the cable is: ; Where L is the length of the cable at the measurement point; v is the cable wave speed parameter; is the time difference between signal transmission and reflection.

[0049] It can be understood that the embodiments of the present application support 7 fixed ranges and 50V-10kV continuous adjustable through a flexible voltage adjustment unit, adapt to the voltage requirements of different test samples, and improve the test adaptability; the electrical parameter integrated test unit integrates functions such as insulation resistance and absorption ratio, supports custom time and automatic report generation, replaces multiple devices, reduces procurement costs and reduces operation steps; the cable length measurement unit is based on the time domain reflection method combined with 12 built-in cable wave speed parameters, and can accurately measure the length and locate the fault without disconnecting the cable, meeting the non-destructive detection requirements; the extension test unit supports partial discharge, dielectric loss and other functions, which can be used as soon as possible, and can be associated with the insulation resistance data to comprehensively evaluate the aging state, expanding the application scenarios of the device.

[0050] In the embodiments of the present application, the intelligent control module comprises a task scheduler, a resource manager, and a fault self-diagnosis unit.

[0051] The task scheduler is configured to analyze the selected test function through the human-computer interaction module, generate a task instruction sequence containing timing logic, and schedule each module to execute in sequence. The resource manager is configured to automatically load a parameter configuration table according to the selected test function, dynamically allocate and configure the sampling rate and filtering parameters of the signal processing module, and the voltage output parameters and test mode of the multifunction integrated test module. The fault self-diagnosis unit is configured to periodically or triggeredly diagnose each hardware unit inside the instrument during startup and operation, and generate an alarm code and display it on the human-computer interaction module when an abnormality is found.

[0052] Specifically, the diagnosis modes of the fault self-diagnosis unit include power-on self-test, periodic inspection, and triggered diagnosis. The power-on self-test comprehensively checks the memory, storage, communication of each main chip, and connection of each circuit board when starting up. The periodic inspection periodically checks key parameters such as battery voltage, internal temperature, and reference voltage source stability during operation. The triggered diagnosis automatically performs a quick check on the high-voltage loop and discharge loop before performing a high-risk operation (such as starting high-voltage output). Once an abnormality is found, a unique alarm code (such as "Err_105: communication failure with high-voltage CPU") is generated immediately, and clear alarm information is sent to the human-computer interaction module for display. The system determines whether to prohibit high-voltage output or enter a safe state according to the fault level.

[0053] For example, for a polarization index test, the generated task instruction sequence containing timing logic can be: 01: configure the high-voltage output to 2500V with a ramp rate of 5kV / s; 02: configure the signal processing module to use high-speed sampling (10 times / s) for the first 60 seconds, and then switch to low-speed sampling (1 time / s); 03: start the high-voltage output and simultaneously start timing and data recording; 04: read and store the resistance value at the 1-minute and 10-minute time points; 05: calculate and display the polarization index value; and 06: execute the safety discharge process.

[0054] It can be understood that the embodiments of the application can analyze the test function selected by the user through the task scheduler, generate an instruction sequence with timing logic, schedule each module to execute in sequence, avoid mutual conflict of high-voltage signals and high-frequency detection signals, and ensure that the test process is coherent and efficient; the resource manager can automatically load the adaptive parameter configuration table, dynamically allocate the sampling rate, filtering parameters of the signal processing module, and voltage, mode parameters of the multifunction integrated test module, without manual repeated debugging, which not only reduces the operation error, but also ensures that the parameters are accurately matched with the test requirements; the three modes of the fault self-diagnosis unit comprehensively cover the equipment life cycle, the power-on self-test startup can check the hardware basic state, the periodic inspection can monitor the stability of the key parameters in real time, the trigger type diagnosis can check the core loop before high-risk operation, and the unique alarm code is generated and displayed clearly when an abnormality occurs, and the high-voltage output can be controlled according to the fault level and the safety state is switched, which can avoid equipment damage and safety accidents from the source, and greatly improve the reliability and operation safety of the equipment.

[0055] In the embodiments of the application, the human-computer interaction module includes: an operation unit, an intelligent display and recording unit.

[0056] The operation unit is configured to switch test functions and set test parameters by operating the capacitive touch screen or the rotating shuttle, and the generated operation instructions are transmitted to the main control board through the wire; the intelligent display and recording unit is configured to display test values, curves, and state information in real time in different regions on the capacitive touch screen, support comparison and analysis of multiple sets of test data on the same screen, and the curves are curves of changes of insulation resistance, test voltage, and leakage current parameters with time in the same coordinate system, and all curves and data can be recorded in the internal memory or exported through the USB interface.

[0057] Specifically, the capacitive touch screen adopts a 7-inch IPS industrial capacitive screen, with a resolution of 1280x720 (pixel density 217PPI) and a brightness of 400cd / m². The contrast ratio is 1000:1. The surface is covered with 2.5D scratch-resistant glass, and the edges are rounded to avoid scratches during operation.

[0058] The capacitance touch screen adopts a "top-middle-bottom" three-area layout when displaying the test results in real time. The top area is a key value display area, accounting for 30% of the screen ratio, and three columns of real-time values of insulation resistance (IR), test voltage (U), and leakage current (I) are displayed, with the unit automatically switched, the numerical value font size dynamically adjusted according to the numerical value magnitude, and the value next to the label "compensation state" (such as "compensated (20℃ / 60%RH)") to prompt whether the data has been environment corrected. The middle area is a dynamic curve drawing area, accounting for 50% of the screen ratio, and three curves are dynamically drawn in the same coordinate system (the horizontal axis is time and the vertical axis is the parameter value), with the curves distinguished by color (IR is red, U is blue, and I is green), the curve refresh frequency synchronized with the signal acquisition frequency, and the curve interaction (scaling, panning, and pausing) operation supported. The bottom area is a state and operation prompt area, accounting for 20% of the screen ratio, with the left side displaying device state icons (high voltage enable: red flashing; discharge complete: green constant; extension module connection: blue icon), and the right side displaying operation prompts (such as "please confirm the test line connection" and "high voltage output, please do not touch the terminal") and high-risk operations (such as "safety distance ≥ 1m" when starting 10kV high voltage), with a red border flashing warning.

[0059] It can be understood that the embodiments of the application adopt a capacitance touch screen and a rotary shuttle dual input, which facilitates quick switching of test functions and accurate setting of parameters, and the operation instructions are efficiently transmitted to the main control board through the wire, greatly reducing the operation threshold; the intelligent display and recording unit clearly presents the test values, dynamic curves, and device states in the touch screen, draws the insulation resistance, voltage, and current curves in the same coordinate system, supports multiple data comparison on the same screen, is convenient for intuitive analysis, and all data can be stored in the internal memory or exported through the USB, facilitating traceability management, and overall improving the test operation efficiency and data application convenience.

[0060] In the embodiments of the application, the safety protection module includes a structure protection mechanism and an active protection mechanism.

[0061] The structure protection mechanism includes an electrical isolation structure and a mechanical protection structure. The electrical isolation structure is designed with an isolated power supply. The electrical isolation structure is realized by an isolation transformer on an isolated power supply board and an intermediate physical baffle to achieve 25kV electrical isolation between the high-voltage area and the low-voltage area. The mechanical protection structure is that the cabinet shell is made of polypropylene alloy material or carbon fiber composite material. The active protection mechanism includes high-voltage overvoltage protection, sample breakdown protection, and independent discharge protection. The high-voltage overvoltage protection is to monitor whether the output voltage exceeds the target safety value. If it exceeds, the output of the high-voltage power supply board is immediately cut off. The sample breakdown protection is to detect when the sample is broken down to form a short circuit or an arc. The sample breakdown protection can quickly limit the current and maintain a controllable operating state to help the operator accurately locate the weak point of insulation. The independent discharge protection is to automatically start a safety discharge circuit after the test is completed or in an emergency shutdown to ensure that the sample and the internal energy storage elements of the instrument are discharged quickly and safely.

[0062] It can be understood that the embodiment of the application constructs a comprehensive protection system combining passive isolation and active intervention. The electrical isolation structure ensures that even in extreme cases, high voltage cannot break through the double isolation to reach the low-voltage side, fundamentally preventing the operator from being electrocuted and the damage of the low-voltage circuit of the device. The solid cabinet shell resists bumps and falls, preventing damage to the internal precision structure. The high protection level ensures that the electrical isolation performance inside will not decrease in a dusty and humid environment, maintaining long-term safety. The active protection mechanism is always vigilant. The overvoltage protection can cut off the output in the moment when the output voltage abnormally rises to prevent the device from being overloaded. The sample breakdown protection uses an intelligent algorithm to distinguish between real breakdown and transient interference and maintains a controllable state after breakdown to retain key data for locating weak points of insulation. The independent discharge protection automatically discharges residual charges when the test is completed or in an emergency shutdown, completely eliminating the risk of the operator contacting high voltage. Not only does it maximize the protection of personal safety, but also converts safety accidents into diagnosable data through the controllable breakdown mode, significantly improving the safety and professionalism of the test operation.

[0063] In summary, the embodiment of the present application provides a multifunctional integrated insulation resistance tester. By integrating multiple test functions, the problem of needing to carry multiple instruments and repeatedly connecting wires is solved, the on-site test efficiency is improved, and the equipment purchase and maintenance costs are reduced. Through the detachable expansion cabin, users can flexibly add new functions according to their needs, prolong the product's technical life cycle, protect user investment, and enable the instrument to continuously evolve to adapt to changing technical standards and application requirements. By introducing environmental temperature and humidity sensing and compensation mechanisms, the influence of environmental factors on test results can be automatically corrected, ensuring the accuracy, comparability, and reliability of the data. By providing seven fixed voltages and continuously adjustable modes within the range of the range, both standardized test requirements and non-standard tests under special working conditions can be met, the test range is wide, the application scenarios are comprehensive, and users can flexibly choose according to the type of test samples, significantly enhancing the applicability and flexibility of the instrument. By changing the curve, test personnel can intuitively observe the changing trend of insulation performance and the correlation between the three, making it easier to quickly capture early features of insulation defects. Through structural protection and active protection mechanisms, a double safety line is established to protect the safety of operators and measured equipment, significantly reducing the risk of high-voltage test operations. Thus, the problems of single function, lack of function expansion, and non-intuitive data presentation are solved.

[0064] Next, with reference to the accompanying drawings, a running method of a multifunctional integrated insulation resistance tester according to an embodiment of the present application is described.

[0065] Specifically, Figure 3 A flowchart of a running method of a multifunctional integrated insulation resistance tester provided by the embodiment of the present application.

[0066] As Figure 3 shown, the running method of the multifunctional integrated insulation resistance tester includes the following steps: In step S101, select the power supply mode.

[0067] Specifically, the power supply mode includes connecting to the mains and battery power supply. When the power cord is connected to the power supply interface, the mains is automatically selected first. If there is no mains, check the indicator light of the charging indicator light board to confirm that the battery has sufficient power. The intelligent switching unit built-in the instrument will automatically switch to battery power supply.

[0068] It can be understood that the embodiment of the present application ensures that the instrument can be immediately put into work in various field environments, greatly improving the continuity and mobility of test operations, and simplifying the user process through automation, avoiding power interruptions or operation errors caused by manual switching.

[0069] In step S102, the power key is pressed, a self-diagnosis program is run to quickly detect each connection line, a self-checking result is obtained, and the self-checking result is displayed on the capacitive touch screen. When the self-checking result is normal, the tester enters a standby state.

[0070] Specifically, after the user presses the power key, a fault self-diagnosis unit in the intelligent control module is activated, and a round of quick closed-loop detection is immediately performed on internal key hardware links of the instrument, including a communication bus between a main control board and a high-voltage CPU board, an ADC reference voltage of a signal processing module, a memory read-write channel, and a connection state between each board card. The detection result is intuitively displayed on the capacitive touch screen in clear "normal / warning / error" levels and specific description information. When the self-checking result is normal, the tester enters a standby state and waits for a test instruction.

[0071] It can be understood that the embodiments of the present application change the traditional device state confirmation depending on manual experience into an automatic and standardized detection process, fundamentally eliminates the risk of test data distortion or device failure caused by cable loosening, poor contact, or abnormal extension module, ensures that the instrument is always in good condition before being put into work, greatly improves the reliability of the test and the user experience, and significantly reduces the on-site operation risk caused by unknown device state.

[0072] In step S103, if it is detected that a standardized interface of a detachable extension cabin has a module connected, it is selected whether to use the extension module. If yes, the extension module is identified and loaded, and integrated into the test mode.

[0073] Specifically, when it is detected that a standardized interface of a detachable extension cabin has a module connected, the pre-stored identity and function code in the module are automatically read through a state identification line, and then an interactive prompt for confirming use of the extension function is popped up to the user. After obtaining the user confirmation, the intelligent control module will accurately match and load the corresponding driver program and user interface element from the built-in driver library according to the obtained function code, and finally seamlessly integrate the test function of the extension module into the test mode option of the main menu.

[0074] It can be understood that the embodiments of the present application make the function extension simple and fast, eliminate the cumbersome process of manual installation of drivers and configuration of parameters by the user, ensure the perfect integration of the extension function and the original system, enable the instrument to be flexibly transformed according to the on-site demand, keep the consistency of the operation experience, and greatly improve the functional flexibility and application range of the device.

[0075] In step S104, the desired test mode is selected in the main menu by capacitive touch screen touch or rotary jog dial, and the test modes include insulation resistance test, absorption ratio test, polarization index test, step voltage test, dielectric discharge rate test, cable length measurement, DC voltage meter, AC voltage meter, and expansion mode.

[0076] Specifically, the expansion mode is displayed only when the expansion module is used. The specific test modes have been described in the above tester, and will not be repeated here.

[0077] It can be understood that the embodiments of the present application integrate eight functions such as insulation resistance, absorption ratio, polarization index, and cable length measurement, AC and DC voltage measurement into a unified interface through the complementary operation of the capacitive touch screen and the rotary jog dial. It not only realizes the leap from a single function instrument to a comprehensive electrical test platform, allowing users to complete complex diagnostic tasks without switching equipment, but also converts professional testing into simple point selection operation through intuitive graphical interaction design, significantly reduces the operation threshold, and greatly improves the efficiency of on-site testing and equipment function coverage.

[0078] In step S105, the voltage parameter is selected from 7 fixed ranges or is self-defined by the jog dial.

[0079] It can be understood that the voltage setting mode of "fixed range + self-defined fine tuning" of the embodiments of the present application meets the efficiency requirements of standardized testing and the precision requirements of special testing. The 7 fixed ranges allow one-key quick start for regular testing, and the jog dial continuous adjustment function gives users the freedom to flexibly set any voltage according to the characteristics of the test sample, ensuring the convenience and standardization of test operation, and ensuring the parameter adaptation accuracy in non-standard testing scenarios, so that the instrument can perfectly meet various complex testing needs from standard quality inspection to scientific research diagnosis.

[0080] In step S106, after triggering the start of the test, the test voltage is output to the test sample according to the set voltage parameter, the task adaptive scheduling program is started according to the selected test mode, the insulation resistance, leakage current, applied voltage, and environmental temperature and humidity data are collected in real time and are filtered, amplified, and temperature and humidity compensation corrected, and the corresponding built-in algorithm is executed to obtain the test result.

[0081] Specifically, after the user triggers the start test instruction, the task adaptive scheduling program is started: first, the resource manager calls preset voltage, sampling rate and filtering parameters according to the selected test mode, drives the high-voltage output module to generate and apply test voltage to the test sample according to the set value; the high-precision sensor is used to acquire real-time original signals of insulation resistance, leakage current, applied voltage and environmental temperature and humidity, and the insulation resistance value is dynamically corrected based on real-time temperature and humidity data after analog filtering, amplification and ADC conversion; finally, the core algorithm corresponding to the test mode (such as polarization index calculation) is executed, and the standardized test results after environmental compensation and noise suppression are output in real time.

[0082] It can be understood that the task adaptive scheduling program seamlessly connects the complex links of high-voltage output, multi-parameter synchronous acquisition, signal processing and environmental compensation, and eliminates the timing errors and human interference introduced by manual step-by-step operation in traditional tests. Through real-time temperature and humidity compensation correction, the comparability and accuracy of test results under different environmental conditions are ensured, and the automatic execution of the built-in algorithm directly converts the original data into reliable insulation diagnosis conclusions, which not only makes professional testing simple and efficient, but also ensures the scientificity and consistency of data from the root, greatly improving the standardization level and diagnostic value of the test.

[0083] In step S107, the capacitive touch screen displays the instantaneous values of the insulation resistance, voltage and leakage current in real time, and dynamically draws three curves of the parameters changing with time in the same coordinate system. After the test is completed, the test values and curves are saved in the internal storage area.

[0084] It can be understood that the embodiments of the application enable the operator to not only read the instantaneous data, but also accurately capture the recovery characteristics of the insulation performance, the critical breakdown point and the synergistic change law through the shape, correlation and trend of the three curves in the same coordinate system. It not only greatly improves the depth and efficiency of on-site diagnosis, but also provides a data cornerstone with macro trends and micro details for subsequent insulation state evaluation, fault tracing and equipment life prediction.

[0085] In the embodiments of the application, the active protection mechanism is involved throughout the test process, and the test process safety is ensured through high-voltage overvoltage protection, test sample breakdown protection and independent discharge protection.

[0086] The high-voltage overvoltage protection is to monitor whether the output voltage exceeds the target safety value, and if it exceeds, the output of the high-voltage power supply board is immediately cut off; the test sample breakdown protection is to quickly limit the current and maintain a controllable operating state when the test sample is broken down to form a short circuit or an arc, helping the operator to accurately locate the weak point of insulation; the independent discharge protection is to automatically start the safety discharge circuit after the test is completed or in an emergency shutdown to ensure that the test sample and the internal energy storage elements of the instrument are discharged quickly and safely.

[0087] It can be understood that, through the intelligent prediction and rapid disposal of the active protection mechanism, the embodiments of the present application not only guarantee the safety of personnel and equipment, but also convert the sudden failure into diagnosable data, thereby realizing the unification of safety and professionalism.

[0088] The embodiments of the present application solve the problems of needing to carry multiple instruments and repeatedly connecting wires by integrating multiple test functions, thereby improving the efficiency of on-site testing and reducing the cost of equipment purchase and maintenance; through the detachable expansion cabin, the embodiments support users to flexibly add new functions according to needs, thereby prolonging the technical life cycle of the product, protecting the investment of the users, and enabling the instrument to continuously evolve to adapt to changing technical standards and application requirements; through the introduction of the environmental temperature and humidity sensor and the compensation mechanism, the embodiments can automatically correct the influence of environmental factors on the test results, thereby guaranteeing the accuracy, comparability and reliability of the data; through the provision of seven fixed voltages and continuously adjustable modes within the range of the scale, the embodiments not only meet the standardized test requirements, but also adapt to non-standard tests under special working conditions, thereby having a wide test range, covering a comprehensive application scenario, and enabling the users to flexibly select according to the type of the test sample, thereby significantly enhancing the applicability and flexibility of the instrument; through the change curve, the test personnel can intuitively observe the change trend of the insulation performance and the correlation among the three, thereby facilitating the rapid capture of the early characteristics of insulation defects; through the structural protection and the active protection mechanism, the embodiments build a double safety line, thereby guaranteeing the safety of the operating personnel and the measured equipment and significantly reducing the risk of high-voltage test operation. Thus, the embodiments solve the problems of single function, lack of function expansion, and non-intuitive data presentation.

[0089] In the description of the present specification, the description referring to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or N embodiments or examples in a suitable manner. Furthermore, the different embodiments or examples described in the present specification and the features of the different embodiments or examples can be combined and combined by those skilled in the art without contradiction.

[0090] In addition, the terms "first", "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "N" is at least two, such as two, three, etc., unless otherwise specifically limited.

[0091] Any process or method described in a flowchart or otherwise described herein can be understood as representing a module, segment, or portion of code that includes one or more executable instructions for implementing the specified logical functions or steps, and the preferred embodiments of the application include additional or fewer steps, or combinations of steps, or the order of the steps can be different from those shown or discussed. It is intended that additional or fewer steps be performed between any two steps, and one of ordinary skill in the art would recognize many variations based on the functional description.

[0092] It should be understood that portions of the present application can be implemented in hardware, software, firmware, or combinations thereof. In the above embodiments, the steps or methods can be implemented in software or firmware that is stored in memory and executed by a suitable instruction execution system. As with the hardware implementation, the software or firmware can be implemented using any of the well-known technologies or combinations thereof, including but not limited to: discrete logic circuitry having logic gates for implementing logic functions upon an application of data signals, application specific integrated circuits having appropriate combinational logic gates, programmable gate arrays (PGA), field programmable gate arrays (FPGA), and the like.

[0093] Those of ordinary skill in the art will appreciate that the steps carried out by the above-described embodiments can be implemented by a program instructing the relevant hardware, and the program can be stored in a computer-readable storage medium. When the program is executed, it includes one of the steps of the method embodiments or a combination thereof.

Claims

1. A multifunctional integrated insulation resistance tester, characterized in that, include: The insulation resistance tester body includes a signal processing module, a multi-functional integrated testing module, an intelligent control module, a human-machine interaction module, and a safety protection module. The insulation resistance tester consists of a detachable and assembleable panel assembly, a chassis assembly, and a detachable expansion compartment. The panel assembly integrates multiple circuit boards and anti-accidental contact test terminals. The chassis assembly adopts a layered shielding design, which achieves 25kV electrical isolation between high-voltage and low-voltage areas through physical baffles. The detachable expansion compartment is connected to the chassis assembly through a standardized interface, supports external expansion modules, and realizes on-demand expansion of test functions. The signal processing module is used to collect ambient temperature and humidity data, insulation resistance, loop current and applied voltage signals of the test sample, filter, amplify and correct the collected data for temperature and humidity compensation, and output standardized multi-dimensional test data. The multi-functional integrated test module integrates multiple electrical parameter testing functions and cable length measurement functions. The multiple electrical parameter testing functions can automatically calculate and display various parameter values, support user-defined test time, and allow for flexible voltage adjustment. It supports 7 fixed voltage ranges and a user-defined continuously adjustable mode. The cable length measurement function applies a test signal of a specific frequency to the cable, detects the signal reflection time, and calculates the cable length based on the time-domain reflection method principle in combination with the cable wave velocity parameter. The intelligent control module is used to perform adaptive task scheduling through the test function selected by the human-computer interaction module, and to dynamically configure and coordinate the working timing and parameters of the signal processing module and the multi-functional integrated test module. The human-machine interaction module is used to switch test functions and set test parameters through the capacitive touch screen and encoder shuttle. The instantaneous values ​​of insulation resistance, test voltage and current are displayed and recorded in real time through the capacitive touch screen. Curves are dynamically drawn in the same coordinate system and displayed and recorded in real time the parameter change trend. The safety protection module includes structural protection and active protection mechanisms. The structural protection includes an electrical isolation structure and a mechanical protection structure. The active protection mechanisms include high voltage overvoltage protection, sample breakdown protection, and independent discharge protection.

2. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The insulation resistance tester body includes: a panel assembly, a chassis assembly, and a detachable expansion compartment, wherein... The panel assembly integrates multiple circuit boards and anti-accidental touch test terminals. The multiple circuit boards include a main control board, a touch screen display module, an encoder board, a button board, a charging indicator board, a USB interface board, and a communication interface board. The anti-accidental touch test terminals adopt an insulating sleeve and a grooved design to prevent accidental touch and are marked with a high voltage warning. The chassis assembly includes an isolated power supply board, a high-voltage CPU board, a high-voltage power supply board, an AC-DC conversion board, a battery compartment, and a physical baffle. The physical baffle is made of glass fiber reinforced epoxy resin material and is located between the left high-voltage area and the right low-voltage area. The detachable expansion compartment provides a standardized composite interface for connecting external functional expansion modules.

3. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The standardized interface of the detachable expansion compartment is a composite interface, which integrates a high-speed data communication bus, a low-voltage power supply line, and a status identification line. The status identification line is used to report the module's identity and function code to the intelligent control module when the expansion module is connected. The intelligent control module automatically loads the corresponding driver and operation interface elements from the built-in driver library according to the identity and function code, so as to achieve plug and play.

4. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The signal processing module includes: a data acquisition unit, a signal processing and calculation unit, and a multi-parameter fusion compensation unit, wherein... The data acquisition unit is used to connect to the test sample via test terminals to acquire the insulation resistance, loop current and voltage signals flowing through the test sample under high voltage. The signal processing and calculation unit is used to filter and amplify the acquired analog signal, convert it into a digital signal by the ADC, and execute the built-in algorithm according to Ohm's law to calculate the insulation resistance value and other parameters in real time. The multi-parameter fusion compensation unit is used to dynamically compensate and correct the insulation resistance test results based on the real-time collected ambient temperature and humidity data and using a compensation model.

5. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The multi-functional integrated test module includes: a flexible voltage adjustment unit, an integrated electrical parameter test unit, a cable length measurement unit, and an extended test unit. The flexible voltage adjustment unit provides seven fixed voltage ranges and also supports continuous custom voltage adjustment within the range of 50V to 10000V. The electrical parameter integrated test unit integrates insulation resistance testing, absorption ratio testing, polarization index testing, step voltage testing, dielectric discharge rate testing, DC voltmeter, and AC voltmeter functions, and supports user-defined test time. The cable length measurement unit is used to generate a test signal of a specific frequency through the main control board and apply it to the cable. When the test signal encounters an impedance discontinuity in the cable, it will be reflected. By detecting the time difference between signal transmission and reflection, and combining it with the preset cable wave velocity parameters, the cable length is calculated based on the principle of time-domain reflection. The extended test unit is used to load the corresponding extended test function when a connected extended module is detected.

6. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The intelligent control module includes: a task scheduler, a resource manager, and a fault self-diagnosis unit, wherein... The task scheduler is used to parse the test function selected through the human-computer interaction module, generate a sequence of task instructions containing timing logic, and schedule each module to execute in sequence. The resource manager is used to automatically load the parameter configuration table according to the selected test function, dynamically allocate and configure the sampling rate and filtering parameters of the signal processing module, as well as the voltage output parameters and test mode of the multi-functional integrated test module; The fault self-diagnosis unit is used to periodically or trigger the diagnosis of each hardware unit inside the instrument during power-on and operation. When an abnormality is detected, an alarm code is generated and displayed on the human-machine interaction module.

7. The multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The human-computer interaction module includes: an operation unit and an intelligent display and recording unit, wherein... The operation unit is used to switch test functions and set test parameters by operating the capacitive touch screen or rotating shuttle, and the generated operation commands are transmitted to the main control board through the ribbon cable. The intelligent display and recording unit is used to display test values, curves, and status information in real time in different areas on the capacitive touch screen. It supports the comparison and analysis of multiple sets of test data on the same screen. The curves are dynamically plotted curves of insulation resistance, test voltage, and leakage current parameters changing over time in the same coordinate system. All curves and data can be recorded in the internal memory or exported via the USB interface.

8. A multifunctional integrated insulation resistance tester according to claim 1, characterized in that, The security protection module includes: a structural protection mechanism and an active protection mechanism, wherein, The structural protection mechanism includes an electrical isolation structure and a mechanical protection structure. The electrical isolation structure adopts a fully isolated power supply design, which uses an isolation transformer on the isolation power supply board combined with a physical baffle in the middle to achieve 25kV electrical isolation between the high voltage area and the low voltage area. The mechanical protection structure is that the chassis shell is made of polypropylene alloy or carbon fiber composite material. The active protection mechanism includes high-voltage overvoltage protection, test sample breakdown protection, and independent discharge protection. High-voltage overvoltage protection monitors whether the output voltage exceeds the target safety value; if it does, it immediately cuts off the output of the high-voltage power supply board. Test sample breakdown protection detects that the test sample has been broken down, forming a short circuit or arc, and quickly limits the current and maintains a controllable operating state, helping operators accurately locate weak points in the insulation. Independent discharge protection automatically activates the safety discharge circuit after the test or during an emergency shutdown, ensuring rapid and safe discharge of the test sample and the instrument's internal energy storage components.

9. A method for operating a multifunctional integrated insulation resistance tester, characterized in that, Includes the following steps: Select power supply mode; Press the power button to run the self-diagnostic program to quickly test each connection line and obtain the self-test results. The self-test results are displayed on the capacitive touch screen. When the self-test results are normal, the tester enters standby mode. If a module connection is detected at the standardized interface of the detachable expansion compartment, select whether to use the expansion module. If yes, identify and load the expansion module and integrate it into the test mode. By using the capacitive touchscreen or rotating the shuttle, select the desired test mode from the main menu. The test modes include insulation resistance test, absorption ratio test, polarization index test, step voltage test, dielectric discharge rate test, cable length measurement, DC voltmeter, AC voltmeter, and extended mode. Select voltage parameters from 7 fixed ranges or customize voltage parameters using the shuttle; After the test is triggered, the test voltage is applied to the test sample according to the set voltage parameters. The task adaptive scheduling program is started according to the selected test mode. The insulation resistance, leakage current, applied voltage and ambient temperature and humidity data are collected in real time and filtered, amplified and corrected for temperature and humidity compensation. The corresponding built-in algorithm is executed to obtain the test results. The capacitive touchscreen displays the instantaneous values ​​of insulation resistance, voltage, and leakage current in real time. At the same time, it dynamically plots three curves of parameters changing over time in the same coordinate system. After the test is completed, the test values ​​and curves are saved in the internal storage area.

10. The operating method of a multifunctional integrated insulation resistance tester according to claim 9, characterized in that, Active protection mechanisms are in place throughout the testing process, ensuring safety through high voltage overvoltage protection, sample breakdown protection, and independent discharge protection.

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