A cable withstand voltage test system and method applied to urban rail vehicles

Abstract

The application provides a kind of applied urban rail vehicle cable withstand voltage test system and method.The system includes a vehicle to be tested, a cable to be tested led from the wire slot in the vehicle, the free end of the cable to be tested is provided with an electrical cabinet plug, the cable to be tested includes several cables;A withstand voltage test platform, a high-voltage line led from the withstand voltage test platform is used to conduct high voltage generated based on the withstand voltage test platform;Socket conversion tool, the socket conversion tool includes several loose wires, the first end of each loose wire is connected to a conversion socket, the conversion socket matches the electrical cabinet plug provided at the free end of the cable to be tested, the second end of each loose wire is short-circuited and connected to the high-voltage line led from the withstand voltage test platform for withstand voltage test.The application mainly connects the line through the socket adapter tool, the electrical cabinet plug can be prefabricated when the vehicle is wired once, without secondary wiring, which is convenient and fast and easy to operate.

Description

Technical Field

[0001] This invention relates to the field of rail vehicle testing technology, and more particularly to a system and method for testing the withstand voltage of cables used in urban rail vehicles. Background Technology

[0002] To ensure the quality of cables in urban rail vehicles, a withstand voltage test is required for all cables after wiring assembly. The withstand voltage test is one of the main methods for verifying the overvoltage resistance of electrical appliances, equipment, devices, circuits, and electrical safety tools. Conducting withstand voltage tests on vehicle cables before use effectively detects and prevents cable insulation defects, ensuring vehicle safety. According to design requirements, tests should be conducted separately for different line voltage levels. To prevent electrical equipment from being damaged by high voltage, all installed electrical equipment and low-voltage switches should be disconnected and the circuits short-circuited before testing.

[0003] like Figure 1 As shown, before the withstand voltage test, the vehicle undergoes primary wiring, which involves crimping wire harness terminals. After the withstand voltage test, secondary wiring is performed to connect the cables to the equipment. Previously, the primary wiring of the electrical cabinet involved routing the connector wires within the vehicle's wiring ducts and along the wiring path to the electrical cabinet connection point, requiring reserved wire lengths. Before the withstand voltage test, male pin terminal crimping and connector plug fabrication are not performed to avoid damaging the connector plug's male pin terminals when the electrical cabinet plug's loose wires are short-circuited during the withstand voltage test.

[0004] During the test, all connector plugs connected to the electrical cabinet connector sockets should have their insulation stripped and short-circuited, then connected to the high-voltage line leading from the test bench for a withstand voltage test. Electrical components not involved in the withstand voltage test and other cables of different voltage levels should be disconnected or short-circuited before the test.

[0005] After the withstand voltage test is completed, secondary wiring is performed in the vehicle's wiring ducts. Excess wire length is cut off, the cables are stripped and crimped to the terminals, the electrical cabinet connector plug is fabricated, and the connector plug is connected to the electrical cabinet connector socket. For example... Figure 2 As shown.

[0006] Using the above two-way wiring test scheme, the electrical cabinet plugs cannot be prefabricated. Before each test, the loose wires of the plugs connected to the electrical cabinet need to be stripped, which is time-consuming and requires reserving wire length. When wiring again after the test, the wires need to be cut, resulting in waste.

[0007] In addition, during the test, all connector plug wires are shorted together, which makes it difficult to find the fault if flashover or breakdown occurs during the withstand voltage test. Summary of the Invention

[0008] In view of the shortcomings of the existing technology, this application provides a cable withstand voltage test system and method for urban rail vehicles. This invention mainly uses a socket adapter fixture for wiring connection, allowing for prefabrication of electrical cabinet plugs during the primary wiring of the vehicle, eliminating the need for secondary wiring, making it convenient, quick, and easy to operate.

[0009] The technical means employed in this invention are as follows:

[0010] A withstand voltage testing system for cables used in urban rail vehicles, comprising:

[0011] The vehicle under test, the cable to be tested led out from the wiring duct inside the vehicle under test, the free end of the cable to be tested is provided with an electrical cabinet connector plug, the cable to be tested includes several cables, each cable is crimped to one terminal of the electrical cabinet connector plug;

[0012] A withstand voltage test bench, wherein a high-voltage line drawn from the withstand voltage test bench is used to conduct the high voltage generated by the withstand voltage test bench;

[0013] A socket conversion fixture includes several loose wires. The first end of each loose wire is connected to a conversion socket, which is matched with an electrical cabinet plug located at the free end of the cable to be tested. The second end of each loose wire is short-circuited and connected to a high-voltage line led out from a withstand voltage test bench for withstand voltage testing.

[0014] Furthermore, the adapter socket is of the same specification as the connector socket of the electrical cabinet.

[0015] Furthermore, the conversion socket is a full-point wiring configuration.

[0016] This invention also provides a method for withstand voltage testing of cables in urban rail vehicles, implemented based on any of the above-described testing systems, comprising the following steps:

[0017] The loose wires to be tested are led out from the wiring duct inside the vehicle for wiring, and several electrical cabinet connector plugs are made, with each loose wire corresponding to one terminal of the electrical cabinet connector plug;

[0018] The socket adapter assembly line is constructed using cables and pins with the same core specifications as the electrical cabinet sockets, and the cable length is sufficient to connect to the high-voltage line leading out from the withstand voltage test bench.

[0019] Strip the insulation from the cables supplied with the socket adapter and short-circuit the stripped cables using copper wire.

[0020] Connect the socket adapter to the electrical cabinet plug, and short-circuit the other end of the loose wire to the high-voltage line of the withstand voltage test bench. Before the test, disconnect the electrical components that are not involved in the withstand voltage test and ground other cables of different voltage levels that are not involved in the withstand voltage test. Check whether the withstand voltage circuit is complete and ensure that there is no leakage. According to the test requirements, increase the voltage of the withstand voltage test bench to the test voltage and conduct the withstand voltage test.

[0021] Furthermore, when flashover or breakdown occurs during the withstand voltage test, a megohmmeter is used to test the insulation resistance of each electrical cabinet connector plug connected to the socket adapter to locate cable faults.

[0022] Furthermore, the wiring of the loose wires to be tested led out from the vehicle's wiring duct also includes: determining the cable length between the electrical cabinet connector plug led out from the vehicle's wiring duct and the connector socket on the electrical cabinet.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. This invention provides a vehicle cable withstand voltage test system. By designing a socket adapter fixture, the plug manufacturing process can be moved forward, eliminating the need for secondary wiring of the electrical cabinet plug, reducing operation time and labor intensity, and improving production efficiency.

[0025] 2. Since the test method disclosed in this application only requires one wiring and does not require stripping the wire to reserve the wire length, it avoids wire cutting errors and can reduce the cost of the wiring.

[0026] 3. Compared to processing loose wires during the initial wiring process, the prefabricated connector plugs in this application make it easier to troubleshoot fault points during withstand voltage testing. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of an existing vehicle insulation withstand voltage test device.

[0029] Figure 2 This is a schematic diagram of the wiring between the vehicle's cables and electrical cabinet after the insulation withstand voltage test of an existing vehicle.

[0030] Figure 3 This is a schematic diagram of the vehicle cable withstand voltage test system of the present invention.

[0031] Figure 4This is a schematic diagram of the socket conversion tooling structure of the present invention.

[0032] Figure 5 This is a flowchart of the vehicle cable withstand voltage test method of the present invention.

[0033] In the diagram: 1. In-vehicle wiring duct; 101. Electrical cabinet connector plug; 2. Withstand voltage test bench; 3. Electrical cabinet; 301. First connector area; 302. Terminal block area; 303. Brake maintenance port; 304. Input / output unit; 305. Second connector area; 306. Traction maintenance port; 307. Repeater; 4. Socket conversion fixture; 401. Adapter socket. Detailed Implementation

[0034] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0035] This invention provides a cable withstand voltage testing system for urban rail vehicles. It primarily utilizes a socket conversion fixture to achieve a detachable connection between the vehicle's cable trays and the test bench. Furthermore, it allows for quick connection of the cable to the electrical cabinet after the test, avoiding the risks of errors associated with double wiring and improving testing efficiency. Specifically, as... Figure 3 As shown, the test system provided in this application mainly includes: the vehicle under test, the pressure test bench, and the socket conversion fixture.

[0036] The cable to be tested is led out from the wiring duct 1 inside the vehicle under test (the wiring harness connected to the electrical cabinet is generally a DC 110V control line, and the cable core type includes 0.75mm² wire). 2 1mm 2 1.5mm 2 2mm 2 4mm 2 6mm 2 The cable under test has an electrical cabinet connector plug 101 at its free end. The cable under test includes several cables, each of which is crimped to one terminal of the electrical cabinet connector plug 101. The electrical cabinet connector plug 101 matches the connector socket in the electrical cabinet connector area, and pre-wiring is performed according to the wiring scheme of the connector socket.

[0037] The high-voltage line leading from the withstand voltage test bench is used to conduct the high voltage generated by the withstand voltage test bench. Using the GSD type power frequency AC withstand voltage test bench, different AC voltages (0~5kV) can be provided according to the test requirements.

[0038] The socket conversion fixture includes several loose wires. The first end of each loose wire is connected to a conversion socket 401, which matches the electrical cabinet plug located at the free end of the cable to be tested. The second end of each loose wire is short-circuited and connected to a high-voltage line from a withstand voltage test bench for withstand voltage testing. Preferably, the conversion socket and the connector socket of the electrical cabinet are of the same specification, so that after the withstand voltage test is completed, the electrical cabinet connector plug 101 can be quickly disconnected from the conversion socket 401, allowing for rapid connection between the electrical cabinet connector plug 101 and the socket in the electrical cabinet connection area. Furthermore, the conversion socket is a full-point wiring configuration.

[0039] The electrical cabinet in this application includes a first connector area 301, a terminal block area 302, a brake maintenance port 303, an input / output unit 304, a second connector area 305, a traction maintenance port 306, and a repeater. The first connector area 301 and the second connector area 305 are used to connect the control signal lines of the vehicle entering the electrical cabinet. The terminal block area 302 is used to connect various control signal lines inside the vehicle electrical cabinet to the air circuit breaker. The repeater extends the transmission distance of the vehicle network by retransmitting or forwarding data signals. The input / output unit 304 (ROM) can verify vehicle input / output signals by communicating with the TCMS. The traction maintenance port 306 and the brake maintenance port 303 are used to download vehicle traction system, braking system speed curves, and other relevant data.

[0040] This invention utilizes a socket adapter fixture to conduct a withstand voltage test. The connector plug corresponding to the electrical cabinet connector socket is prefabricated during the initial wiring process, and the cable length for installation with the electrical cabinet socket is determined. No secondary wiring is required after the test.

[0041] The loose wires of the socket adapter need to be stripped before connecting to the high-voltage line of the withstand voltage test bench for withstand voltage testing. During the test, connect the socket adapter to the electrical cabinet plug, short-circuit the loose wires of the socket, and connect them to the high-voltage line of the withstand voltage test bench.

[0042] If flashover or breakdown occurs in the cable during withstand voltage testing, the insulation resistance of each plug cable can be tested individually to facilitate troubleshooting.

[0043] After the withstand voltage test, restore the plug installation, such as... Figure 2 As shown.

[0044] This invention also provides a method for withstand voltage testing of cables in urban rail vehicles, implemented based on the aforementioned testing system, such as... Figure 5 As shown, it includes the following steps:

[0045] S1. The loose wires to be tested are led out from the vehicle's wiring duct and wired, and several electrical cabinet connector plugs are fabricated, with each loose wire corresponding to one terminal of the electrical cabinet connector plug. This includes determining the cable length between the electrical cabinet connector plug led out from the vehicle's wiring duct and the connector socket on the electrical cabinet.

[0046] S2. Use cables and pins with the same core specifications as the electrical cabinet sockets to assemble the socket adapter line. The cable length should be sufficient to connect to the high-voltage line leading out from the withstand voltage test bench.

[0047] Specifically, the first step is to fabricate a withstand voltage test socket adapter fixture. A socket adapter fixture of the same specifications as the electrical cabinet connector socket is fabricated. Electrical cabinet connectors are generally available in 32-pin, 46-pin, and 64-pin configurations; this embodiment uses a 46-pin connector. The socket adapter fixture is assembled using cables and pins with the same core specifications as the electrical cabinet socket. The cable length should be sufficient to connect to the high-voltage line leading out from the withstand voltage test bench. For ease of use, the socket adapter fixture is fully wired. Full-point wiring is only for connectors without shielded cables (shielded cables are used for signal transmission, contain a shielding layer, have a lower withstand voltage rating, and do not participate in withstand voltage testing). This meets the withstand voltage test requirements for different connection points of the plug (if the connector has its own shielded cable, a dedicated socket adapter fixture matching the connection points of other cables within the connector can be fabricated).

[0048] S3. Strip the insulation from the cable supplied with the socket adapter and short-circuit the stripped cable using copper wire.

[0049] Specifically, before using the socket adapter, the supplied cable should be stripped (stripping should be done at the cable root; after stripping, the insulation does not need to be completely removed from the wire core to ensure the wire core is not too loose). Figure 4 (As shown.) A short circuit is established using copper wire. During the test, the high-voltage line of the withstand voltage test bench is connected to the copper wire of the socket adapter fixture. Before the test, disconnect the electrical components not involved in this withstand voltage test, and short-circuit and ground other cables of different voltage levels not involved in this withstand voltage test. Multiple socket adapter fixtures can also be made according to the test requirements, and all cable ends can be short-circuited together to complete the withstand voltage test of the same voltage level cables connected to the electrical cabinet in one go.

[0050] S4. Connect the socket adapter to the electrical cabinet plug, and short-circuit the other end of the adapter to the high-voltage line of the withstand voltage test bench. Control the output of the withstand voltage test bench to perform the withstand voltage test according to the test requirements.

[0051] Specifically, connect the socket adapter to the electrical cabinet plug, and short-circuit the other end of the adapter to connect it to the high-voltage line leading out from the withstand voltage test bench. Once the withstand voltage test bench is powered on, the withstand voltage test can be performed.

[0052] Furthermore, the method also includes: S6, when flashover or breakdown occurs during the withstand voltage test, using a megohmmeter to test the insulation resistance of each electrical cabinet connector plug connected to the socket adapter tool to find cable faults.

[0053] After the withstand voltage test is completed, disconnect the socket adapter from the electrical cabinet plug and the high voltage line leading out of the withstand voltage test bench, and reinstall the electrical cabinet connector plug onto the electrical cabinet socket.

[0054] This wiring method can be applied to withstand voltage tests on subway vehicles, and is not limited to the 46-pin connector plug in the onboard electrical cabinet. It is also applicable to connector plugs on the offboard. This solution has been implemented in subway vehicles on Shenyang Line 4 and Dalian Line 5.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A withstand voltage testing system for cables used in urban rail vehicles, characterized in that, include: The test cable is led out from the vehicle wiring trough (1) of the test vehicle. The free end of the test cable is provided with an electrical cabinet connector plug (101). The test cable includes several cables, and each cable is crimped to one terminal of the electrical cabinet connector plug (101). The high-voltage test bench (2) is used to conduct the high voltage generated by the high-voltage test bench (2); The socket conversion fixture (4) includes several loose wires. The first end of each loose wire is connected to the conversion socket (401). The conversion socket (401) is matched with the electrical cabinet connector plug (101) set at the free end of the cable to be tested. The second end of each loose wire is short-circuited and connected to the high voltage line led out from the withstand voltage test bench (2) for withstand voltage test. The adapter socket (401) has the same specifications as the connector socket of the electrical cabinet (3) and is fully wired; The wiring is connected by a socket conversion tool (4). The connector plug of the electrical cabinet (3) is prefabricated during the primary wiring of the vehicle, so there is no need for secondary wiring.

2. A method for withstand voltage testing of cables used in urban rail vehicles, implemented based on the testing system described in claim 1, characterized in that, Includes the following steps: The loose wires to be tested are led out from the wiring duct inside the vehicle for wiring, and several electrical cabinet connector plugs are made, with each loose wire corresponding to one terminal of the electrical cabinet connector plug; The socket conversion assembly line is constructed using cables and pins with the same core specifications as the electrical cabinet sockets, and the cable length is sufficient to connect to the high-voltage line leading out from the withstand voltage test bench. Strip the insulation from the cables supplied with the socket conversion tool and short-circuit the stripped cables using copper wire. Connect the socket adapter socket end to the electrical cabinet connector plug end, and short-circuit the other end of the loose wire to connect to the high voltage line leading out of the withstand voltage test bench. Before the test, disconnect the electrical components that are not involved in the withstand voltage test and ground other cables of different voltage levels that are not involved in the withstand voltage test. Check whether the withstand voltage circuit is complete and ensure that there is no leakage. According to the test requirements, increase the voltage of the withstand voltage test bench to the test voltage and conduct the withstand voltage test.

3. The method for withstand voltage testing of cables used in urban rail vehicles according to claim 2, characterized in that, When flashover or breakdown occurs during the withstand voltage test, use a megohmmeter to test the insulation resistance of each connector plug in the electrical cabinet connected to the socket conversion tool to find cable faults.

4. The method for withstand voltage testing of cables used in urban rail vehicles according to claim 2, characterized in that, Wiring the loose wires to be tested from the vehicle's wiring duct also includes: determining the cable length between the electrical cabinet connector plug and the electrical cabinet connector socket.

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