A power module test system and method based on an input-output filter board

Abstract

The present invention relates to a power module test system and method based on an input / output filter board, belonging to the field of testing technology, and solves the problem of poor versatility of existing test devices. The power module test system includes: a power module test substrate, on which multiple sets of pin sleeves are welded, so as to respectively connect one of multiple power modules to be tested in a plug-and-play manner through each set of pin sleeves in the multiple sets of pin sleeves; an input filter board, connected to the power module test substrate via a first inter-board connector, and used for filtering the input voltage of the multiple power modules to be tested; an output filter board, connected to the power module test substrate via a second inter-board connector, and used for filtering the output voltage of the multiple power modules to be tested. By making plug-and-play connections with multiple power modules to be tested through the pin sleeves, the power module test system can test the power modules to be tested in parallel, improving the reuse rate of the power module test system.

Description

Technical Field

[0001] The present invention relates to the technical field of testing, and particularly to a power module testing system and method based on an input-output filter board. Background Art

[0002] With the technological development of brick-type module power supplies and the expansion of application scenarios, the power rating and input-output range of brick modules with standard package sizes have become more and more refined. The testing tasks for such module power supplies are also increasing continuously, and the requirements are getting higher and higher. A brick power supply refers to a power module that is small in size and large in power. After modular packaging, its shape is like a brick, so it is also called a brick power supply.

[0003] In order to conduct a complete test on brick-type power modules, it is necessary to design a test fixture that can cover all the functions of the power module. Generally, there are the following two directions: 1) Customize the test fixture for the power module from relevant manufacturers. 2) Design the test fixture circuit board by oneself.

[0004] In order to conduct a complete test on the functional performance of brick-type power modules (hereinafter referred to as modules), generally, there are the following several solutions:

[0005] 1. Design a test circuit board, directly weld the module on the test circuit board for testing. This method is simple to operate and the connection is stable, but it is very difficult to separate the welded module and the test circuit board. Even if the module is separated, it cannot be sold again. Therefore, this method is generally not used for testing modules.

[0006] 2. Design a pluggable test circuit board, weld the needle sleeves that can be inserted into the pins of the power module at the corresponding positions on the circuit board, and lead the potential of the pins of the power module to the test circuit board through the needle sleeves. However, due to the need for PCB layout design, the manufacturing cost is high, the cycle is long, and due to the inconsistent functions of some pins of the module and the inconsistent input-output capacitors required for modules with different powers, the universality is poor.

[0007] 3. Customize the module test fixture, which can completely test the functions of each pin of the module. However, the mold opening cost of this solution is relatively high, and the customization time is long, which is not suitable for some projects with cost or time requirements. Summary of the Invention

[0008] In view of the above analysis, the embodiments of the present invention aim to provide a power module testing system and method based on an input-output filter board to solve the problems of long design cycle, high manufacturing cost, and poor universality of the existing parallel power module testing process equipment.

[0009] On the one hand, an embodiment of the present invention provides a power module test system based on an input-output filter board, including: a power module test substrate, an input filter board, and an output filter board. Multiple sets of pin sleeves are welded on the power module test substrate, and each set of pin sleeves in the multiple sets of pin sleeves is respectively connected to one of multiple power modules to be tested in a pluggable manner; the input filter board is connected to the power module test substrate via a first inter-board connector and is used for filtering the input voltage of the multiple power modules to be tested; and the output filter board is connected to the power module test substrate via a second inter-board connector and is used for filtering the output voltage of the multiple power modules to be tested.

[0010] The beneficial effects of the above technical solution are as follows: The test tooling composed of the input-output filter board and the substrate inserted with the power module is used to perform functional and performance tests on the parallel brick-type power modules, ensuring the comprehensiveness of the power module test while minimizing the tooling design and manufacturing costs as much as possible. By connecting the multiple sets of pin sleeves to the multiple power modules to be tested in a pluggable manner, the parallel power modules to be tested can be tested, improving the reuse rate of the power module test system.

[0011] Based on a further improvement of the above system, each power module to be tested includes a synchronization terminal, a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. The input filter board includes a positive voltage output terminal and a negative voltage output terminal. The output filter board includes a positive voltage input terminal and a negative voltage input terminal. Among them, the synchronization terminals of the multiple power modules to be tested are connected together; the positive voltage output terminal of the input filter board is connected to the positive input terminal of each power module to be tested among the multiple power modules to be tested; the negative voltage output terminal of the input filter board is connected to the negative input terminal of each power module to be tested among the multiple power modules to be tested; the positive voltage input terminal of the output filter board is connected to the positive output terminal of each power module to be tested among the multiple power modules to be tested; and the negative voltage input terminal of the output filter board is connected to the negative output terminal of each power module to be tested among the multiple power modules to be tested.

[0012] Based on further improvement of the above system, the input filter board includes: a first capacitor, a second capacitor, a third capacitor, a first ceramic capacitor, a second ceramic capacitor, a third ceramic capacitor, and a fourth ceramic capacitor, wherein the first capacitor, the second capacitor, and the third capacitor are connected in parallel; the positive plate terminal and the negative plate terminal of the first capacitor are respectively used as the positive voltage input terminal and the negative voltage input terminal of the input filter board; the two plate terminals of the third capacitor are used as the positive voltage output terminal and the negative voltage output terminal of the input filter board; the positive voltage input terminal and the negative voltage input terminal of the input filter board are grounded via the first ceramic capacitor and the second ceramic capacitor respectively; and the positive voltage output terminal and the negative voltage output terminal of the input filter board are grounded via the third ceramic capacitor and the fourth ceramic capacitor respectively.

[0013] Based on further improvement of the above system, the input filter board includes an input inductor connected between the first capacitor and the second capacitor in a common-mode or differential-mode manner, wherein the common-mode manner includes connecting the first winding of the input inductor between the positive plate terminal of the first capacitor and the positive plate terminal of the second capacitor and connecting the second winding of the input inductor between the negative plate terminal of the first capacitor and the negative plate terminal of the second capacitor; or the differential-mode manner includes connecting the first winding of the input inductor between the positive plate terminal of the first capacitor and the positive plate terminal of the second capacitor and connecting the negative plate terminal of the first capacitor and the negative plate terminal of the second capacitor together.

[0014] Based on further improvement of the above system, the input filter board includes a single-pole triple-throw switch, and each of the plurality of power supply modules to be tested includes a control terminal, wherein the control terminals of the plurality of power supply modules to be tested are connected to the first terminal, the second terminal, or the third terminal of the single-pole triple-throw switch, wherein when the high level is valid, the control terminal is connected to the positive input terminal of the power supply module to be tested via the first terminal; when the low level is valid, the control terminal is connected to the negative input terminal of the power supply module to be tested via the third terminal; and when remotely controlling the power supply module to be tested, the control terminal is connected to an external power supply via the second terminal.

[0015] Based on further improvement of the above system, the output filter board includes: a fourth capacitor, a fifth capacitor, a sixth capacitor, a fifth ceramic capacitor, a sixth ceramic capacitor, a seventh ceramic capacitor, and an eighth ceramic capacitor. The fourth capacitor, the fifth capacitor, and the sixth capacitor are connected in parallel; the positive plate terminal and the negative plate terminal of the fourth capacitor are respectively connected to the positive voltage input terminal and the negative voltage input terminal of the output filter board; and the two plate terminals of the sixth capacitor serve as the positive voltage output terminal and the negative voltage output terminal of the output filter board. The positive voltage input terminal and the negative voltage input terminal of the output filter board are respectively grounded via the fifth ceramic capacitor and the sixth ceramic capacitor; and the positive voltage output terminal and the negative voltage output terminal of the output filter board are respectively grounded via the seventh ceramic capacitor and the eighth ceramic capacitor.

[0016] Based on further improvement of the above system, the output filter board includes an output inductor connected between the fourth capacitor and the fifth capacitor in a common-mode or differential-mode manner. Wherein, the common-mode manner includes that the first winding of the output inductor is connected between the positive plate terminal of the fourth capacitor and the positive plate terminal of the fifth capacitor, and the second winding of the output inductor is connected between the negative plate terminal of the fourth capacitor and the negative plate terminal of the fifth capacitor; or the differential-mode manner includes that the first winding of the output inductor is connected between the positive plate terminal of the fourth capacitor and the positive plate terminal of the fifth capacitor, and the negative plate terminals of the fourth capacitor and the fifth capacitor are connected together.

[0017] Based on further improvement of the above system, metal pin insertion holes are reserved at the positions of the input inductor, the output inductor, the first capacitor to the sixth capacitor, and the first ceramic capacitor to the eighth ceramic capacitor; the inductance values of the input inductor and the output inductor are selected according to the filtering requirements of the input filter board and the output filter board, and the input inductor and the output inductor with the selected inductance values are plugged in via the metal pin insertion holes; and the following capacitors are selected according to the capacitance and withstand voltage values of the capacitors: the first capacitor to the sixth capacitor, the first ceramic capacitor to the eighth ceramic capacitor, and the selected capacitors are plugged in via the metal pin insertion holes.

[0018] Based on further improvements to the above system, the power supply module to be tested includes a positive sampling terminal, a negative sampling terminal, and a voltage regulating terminal. The output filter board further includes a first resistor and a second resistor. The first resistor is connected between the positive sampling terminal and the voltage regulating terminal of each power supply module to be tested, and the positive sampling terminal of each power supply module to be tested is connected to the positive voltage output terminal of the output filter board; and the second resistor is connected between the negative sampling terminal and the voltage regulating terminal of each power supply module to be tested, and the negative sampling terminal of each power supply module to be tested is connected to the negative voltage output terminal of the output filter board.

[0019] On the other hand, an embodiment of the present invention provides a method for testing a power supply module based on an input-output filter board. Using the power supply module test system based on the input-output filter board described in the above embodiment, the following steps are performed: Multiple sets of pin sockets are welded on the power supply module test substrate, and one of the multiple power supply modules to be tested is respectively connected in a plug-and-play manner through each set of pin sockets in the multiple sets of pin sockets; the input filter board is connected to the power supply module test substrate via a first inter-board connector for filtering the input voltage of the multiple power supply modules to be tested; and the output filter board is connected to the power supply module test substrate via a second inter-board connector for filtering the output voltage of the multiple power supply modules to be tested.

[0020] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0021] 1. By making plug-and-play connections between multiple sets of pin sockets and multiple power supply modules to be tested, it is possible to test the power supply modules to be tested in parallel, improving the reuse rate of the power supply module test system based on the input-output filter board. Shorten the R & D cycle of the power supply module test system (also known as the test process equipment) for brick module power products, and reduce the manufacturing cost of the test process equipment for brick module power products.

[0022] 2. It avoids connecting the pins of the module and the input-output capacitors to the test tooling board by welding, ensuring that the module and the capacitors can be repeatedly plugged and unplugged for use, and avoiding unnecessary waste.

[0023] 3. The input-output filter board can be reused. When there are new module test requirements, only need to design a corresponding power supply module mating substrate according to the module product manual, and reserve the input-output filter board interface, saving the design time cost and reducing the design difficulty.

[0024] 4. The adapter tooling is simple to assemble, convenient to disassemble and replace, and the structural connection is firm and not easily deformed.

[0025] In the present invention, the above technical solutions can also be combined with each other to achieve more preferred combined solutions. Other features and advantages of the present invention will be described in the following description, and some advantages will be obvious from the description, or can be understood by implementing the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the content specifically pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings are only for the purpose of showing specific embodiments, and are not considered as a limitation of the present invention. Throughout the drawings, the same reference signs denote the same components.

[0027] Figure 1A and Figure 1B is a schematic diagram of a metal needle sleeve and its internal principle according to an embodiment of the present invention;

[0028] Figure 2 is a block diagram of a power module test system based on an input / output filter board according to an embodiment of the present invention, wherein the power module test system includes an input filter board, a plurality of power modules to be tested, and an output filter;

[0029] Figure 3 is a schematic diagram of the input filter board of the power module test system based on the input / output filter board according to an embodiment of the present invention;

[0030] Figure 4 is a schematic diagram of the pin reservation of the input filter board of the power module test system based on the input / output filter board according to an embodiment of the present invention.

[0031] Figure 5 is a schematic diagram of the output filter board of the power module test system based on the input / output filter board according to an embodiment of the present invention; and

[0032] Figure 6 is a schematic diagram of the pin reservation of the output filter board of the power module test system based on the input / output filter board according to an embodiment of the present invention.

[0033] Figure 7 is a flowchart of a power module test method based on an input / output filter board according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] The preferred embodiments of the present invention will be specifically described below with reference to the drawings, wherein the drawings form a part of the present application and are used together with the embodiments of the present invention to explain the principles of the present invention, and are not used to limit the scope of the present invention.

[0035] A specific embodiment of the present invention discloses a power module test system based on an input / output filter board. As Figure 2As shown in the figure, a power module test system based on an input / output filter board includes: a power module test substrate, an input filter board 106, and an output filter board 108. Specifically, for the power module test substrate, multiple sets of pin sockets are soldered thereon, and each set of pin sockets in the multiple sets of pin sockets is respectively connected to one of multiple power modules 102 and 104 to be tested in a plug-and-play manner. The power module to be tested is connected or installed to the pin socket on the power module test substrate in a plug-and-play manner, and the number of power modules to be tested connected in parallel can be adjusted; the input filter board 106 is connected to the power module test substrate via a first inter-board connector and is used for filtering the input voltage of multiple power modules to be tested; and the output filter board 108 is connected to the power module test substrate via a second inter-board connector and is used for filtering the output voltage of multiple power modules to be tested.

[0036] Compared with the prior art, in the power module test system based on the input / output filter board provided in this embodiment, through a test tooling composed of the input / output filter board and a substrate inserted with the power module, functional and performance tests are carried out on different brick-type power modules. Therefore, by plugging and unplugging different power modules to be tested with the pin sockets, different power modules to be tested can be tested, improving the reuse rate of the power module test system based on the input / output filter board.

[0037] In the following text, with reference to Figures 1A to 6 , a detailed description of the power module test system based on the input / output filter board. With reference to Figure 2 , the power module test system based on the input / output filter board includes: a power module test substrate, an input filter board 106, and an output filter board 108.

[0038] For the power module test substrate, multiple sets of pin sockets (refer to Figure 1A and Figure 1B ) are soldered thereon, and each set of pin sockets in the multiple sets of pin sockets is respectively connected to one of multiple power modules 102 and 104 to be tested in a plug-and-play manner. The power module to be tested is connected or installed to the pin socket on the power module test substrate in a plug-and-play manner, and the number of power modules to be tested connected in parallel can be adjusted. Refer to Figures 2 to 6 , the power module M to be tested includes a positive input terminal (which is connected to +VI of the input filter board), a negative input terminal (which is connected to -VI of the input filter board), a positive output terminal (which is connected to +VO of the output filter board), a negative output terminal (which is connected to -VO of the output filter board), a synchronization terminal (i.e., StartSync, which is connected to the synchronization terminals of other power modules to be tested), a control terminal (connected to REM of the input filter board), a positive sampling terminal (connected to +S of the output filter board), a negative sampling terminal (connected to -S of the output filter board), and a voltage regulation terminal (connected to Trim of the output filter board).

[0039] Reference Figure 2 , the input filter board 106 includes a positive voltage output terminal and a negative voltage output terminal, and the output filter board 108 includes a positive voltage input terminal and a negative voltage input terminal. The synchronization terminals of multiple power supply modules 102 and 104 to be tested are connected together. The number of power supply modules to be tested connected in parallel is optional. Specifically, the power supply modules to be tested are installed or connected in a pluggable manner to facilitate the selection of the number of power supply modules to be tested connected in parallel; the positive voltage output terminal of the input filter board 106 is connected to the positive input terminal of each power supply module to be tested among the multiple power supply modules to be tested; the negative voltage output terminal of the input filter board 106 is connected to the negative input terminal of each power supply module to be tested among the multiple power supply modules 102, 104, etc.; the positive voltage input terminal of the output filter board 108 is connected to the positive output terminal of each power supply module to be tested among the multiple power supply modules 102, 104, etc.; and the negative voltage input terminal of the output filter board 108 is connected to the negative output terminal of each power supply module to be tested among the multiple power supply modules 102, 104, etc.

[0040] The input filter board 106 is connected to the power module test substrate via a first inter-board connector and is used to filter the input voltage of multiple power supply modules 102 and 104 to be tested. Specifically, the input filter board 106 is inter-board connected to the power module test substrate via a first inter-board connector to be electrically connected to the input ends of multiple power supply modules 102 and 104 to be tested, wherein multiple power supply modules 102 and 104 to be tested are inserted onto the power module test substrate via multiple sets of pins. For example, the first inter-board connector includes PhoenixContact general terminals, 2.54 row-pin connectors or 5.08 row-pin connectors.

[0041] Reference Figure 3 , the input filter board 106 includes: a first capacitor C1, a second capacitor C2, a third capacitor C3, a first ceramic capacitor CY1, a second ceramic capacitor CY2, a third ceramic capacitor CY3, and a fourth ceramic capacitor CY4. The first capacitor C1 and the second capacitor C2 are electrolytic capacitors and are used for energy storage and filtering. The third capacitor C3 is a thin-film capacitor and is used for filtering. The first ceramic capacitor CY1, the second ceramic capacitor CY2, the third ceramic capacitor CY3, and the fourth ceramic capacitor CY4 are high-frequency and high-voltage capacitors and are used to bypass most of the AC interference signals to the ground.

[0042] Specifically, the first capacitor C1, the second capacitor C2, and the third capacitor C3 are connected in parallel; the positive plate terminal and the negative plate terminal of the first capacitor C1 are respectively used as the positive voltage input terminal and the negative voltage input terminal of the input filter board, that is, Figure 2The positive input voltage terminal +Vin and the negative input voltage terminal -Vin; the two plate terminals of the third capacitor C3 serve as the positive voltage output terminal +VI and the negative voltage output terminal -VI of the input filter board, and are respectively connected to the positive input terminal and the negative input terminal of a plurality of power supply modules to be tested; the positive voltage input terminal and the negative voltage input terminal of the input filter board, that is, the positive input voltage terminal +Vin and the negative input voltage terminal -Vin are respectively grounded to FG via the first ceramic capacitor CY1 and the second ceramic capacitor CY2. Specifically, FG is the metal shell or frame of the machine; and the positive voltage output terminal +VI and the negative voltage output terminal -VI of the input filter board are respectively grounded via the third ceramic capacitor CY3 and the fourth ceramic capacitor CY4. The input filter board includes an input inductor L1 connected between the first capacitor C1 and the second capacitor C2 in a common-mode or differential-mode manner. Specifically, the common-mode manner includes that the first winding of the input inductor L1 is connected between the positive plate terminal of the first capacitor C1 and the positive plate terminal of the second capacitor C2, and the second winding of the input inductor L2 is connected between the negative plate terminal of the first capacitor C1 and the negative plate terminal of the second capacitor C2; or the differential-mode manner includes that the first winding of the input inductor L1 is connected between the positive plate terminal of the first capacitor C1 and the positive plate terminal of the second capacitor C2, and the negative plate terminal of the first capacitor C1 and the negative plate terminal of the second capacitor C2 are connected together.

[0043] Reference Figure 3 , the input filter board includes a single-pole triple-throw switch KG1. The control terminals REM of a plurality of power supply modules to be tested are connected to the first terminal, the second terminal, or the third terminal of the single-pole triple-throw switch KG1 via a resistor R1. The current-limiting resistor R1 is used for current-limiting to protect a plurality of power supply modules to be tested. When it is low-level effective, the control terminal is connected to the negative voltage output terminal -VI of the input filter board via the third terminal. Specifically, the common terminal of the single-pole triple-throw switch KG1 is connected to the third terminal while the common terminal is disconnected from the first terminal and the second terminal, so that the control terminal REG is connected to the negative voltage output terminal -VI of the input filter board. When it is high-level effective, there are the following two situations: the control terminal REG is connected to the positive voltage output terminal +VI of the input filter board via the first terminal. Specifically, the common terminal of the single-pole triple-throw switch KG1 is connected to the first terminal while the common terminal is disconnected from the second terminal and the third terminal, so that the control terminal REG is connected to the positive voltage output terminal +VI of the input filter board; or the control terminal is connected to an external power supply via the middle second terminal. Specifically, the common terminal of the single-pole triple-throw switch KG1 is connected to the middle second terminal while the common terminal is disconnected from the first terminal and the third terminal, so that the control terminal is connected to the external power supply to be able to remotely control a plurality of power supply modules to be tested. Therefore, while ensuring the comprehensiveness of the parallel power supply module test, the tooling design and manufacturing costs are reduced as much as possible.

[0044] ReferenceFigure 4 , metal pin insertion holes P5 and P6 are reserved at the position of the first capacitor C1. Metal pin insertion holes P11 and P12 are reserved at the position of the second capacitor C2. Metal pin insertion holes P13 and P14 are reserved at the position of the third capacitor C3. Metal pin insertion holes P7, P8, P9, and P10 are reserved at the position of the input inductor L1. Metal pin insertion holes P1 and P2 are reserved at the position of the first ceramic capacitor CY1. Metal pin insertion holes P3 and P4 are reserved at the position of the second ceramic capacitor CY2. Metal pin insertion holes P15 and P16 are reserved at the position of the third ceramic capacitor CY3. Metal pin insertion holes P17 and P18 are reserved at the position of the fourth ceramic capacitor CY4. The positive input terminal +VI of each power module under test among the multiple power modules under test is connected to the upper terminal of the single-pole triple-throw switch via the shorting sub P01. The negative input terminal -VI of each power module under test among the multiple power modules under test is connected to the lower terminal of the single-pole triple-throw switch via the shorting sub P02. Metal pin insertion holes P19 and P20 are reserved at the position of the first resistor R1. In an alternative embodiment, in order to increase the withstand voltage values of the first capacitor C1, the second capacitor C2, and the third capacitor C3, an additional first capacitor, an additional second capacitor, and an additional third capacitor can be respectively connected in series, and additional metal pin insertion holes are reserved at the positions of the additional first capacitor, the additional second capacitor, and the additional third capacitor accordingly.

[0045] Select the inductance value of the input inductor L1 according to the filtering requirements of the input filter board and insert the input inductor with the selected inductance value via the metal pin insertion holes. For example, select the inductance value of the input inductor L1 according to the ripple of the input voltage (the voltage +Vin at the positive terminal of the input voltage and the voltage -Vin at the negative terminal of the input voltage) of the input filter board. Select the following capacitors according to the capacitance and withstand voltage values of the capacitors: the first capacitor C1 to the third capacitor C3, the first ceramic capacitor CY1 to the fourth ceramic capacitor CY4, and insert the selected capacitors via the metal pin insertion holes. For example, select the first capacitor C1 to the third capacitor C3 according to the input voltage of the input filter board, and select the capacitance values of the first ceramic capacitor CY1 to the fourth ceramic capacitor CY4 according to the ripple of the input voltage and the output voltage of the input filter board.

[0046] The output filter board 108 is connected to the power module test substrate via the second inter-board connector and is used to filter the output voltage of multiple power modules under test. Specifically, the output filter board is inter-board connected to the power module test substrate via the second inter-board connector to be electrically connected to the output terminals of the power modules under test, where the power modules under test are inserted into the power module test substrate via the pin sockets. For example, the second inter-board connector includes PhoenixContact Phoenix general terminals, 2.54 row pin connectors, or 5.08 row pin connectors.

[0047] Reference Figure 2 and Figure 5 ,the output filter board includes: a fourth capacitor C4, a fifth capacitor C5, a sixth capacitor C6, a fifth ceramic capacitor CY5, a sixth ceramic capacitor CY6, a seventh ceramic capacitor CY7, and an eighth ceramic capacitor CY8. The fourth capacitor C4 and the fifth capacitor C5 are electrolytic capacitors for energy storage and filtering. The sixth capacitor C6 is a thin-film capacitor for filtering. The fifth ceramic capacitor CY5, the sixth ceramic capacitor CY6, the seventh ceramic capacitor CY7, and the eighth ceramic capacitor CY8 are high-frequency and high-voltage capacitors for bypassing most of the AC interference signals to ground.

[0048] Reference Figure 2 and Figure 5 ,the fourth capacitor C4, the fifth capacitor C5, and the sixth capacitor C6 are connected in parallel. The positive plate terminal and the negative plate terminal of the fourth capacitor C4 serve as the positive voltage input terminal +VO and the negative voltage input terminal -VO of the output filter board to be connected to the positive output terminal and the negative output terminal of each power supply module to be tested, respectively. The two plate terminals of the sixth capacitor C6 serve as the positive voltage output terminal +Vout and the negative voltage output terminal -Vout of the output filter board. The positive voltage input terminal +VO and the negative voltage input terminal -VO of the output filter board are grounded (e.g., FG) via the fifth ceramic capacitor CY5 and the sixth ceramic capacitor CY6, respectively; and the positive voltage output terminal +Vout and the negative voltage output terminal -Vout of the output filter board, that is, when a load is connected between the positive voltage output terminal +Vout and the negative voltage output terminal -Vout, the positive terminal and the negative terminal of the load are grounded via the seventh ceramic capacitor CY7 and the eighth ceramic capacitor CY8, respectively. The output filter board includes an output inductor L2 connected between the fourth capacitor C4 and the fifth capacitor C5 in a common-mode or differential-mode manner, where the common-mode manner includes that the first winding of the output inductor L2 is connected between the positive plate terminal of the fourth capacitor C4 and the positive plate terminal of the fifth capacitor C5 and the second winding of the output inductor L2 is connected between the negative plate terminal of the fourth capacitor C4 and the negative plate terminal of the fifth capacitor C5; or the differential-mode manner includes that the first winding of the output inductor L2 is connected between the positive plate terminal of the fourth capacitor C4 and the positive plate terminal of the fifth capacitor C5 and the negative plate terminal of the fourth capacitor C4 and the negative plate terminal of the fifth capacitor C5 are connected together.

[0049] Reference Figure 6, metal pin inserts P11, P12, P13, and P14 are reserved at the position of the output inductor L2. Metal pin inserts P9 and P10 are reserved at the position of the fourth capacitor C4. Metal pin inserts P15 and P16 are reserved at the position of the fifth capacitor C5. Metal pin inserts P19 and P20 are reserved at the position of the sixth capacitor C6. Metal pin inserts P1 and P2 are reserved at the position of the fifth ceramic capacitor CY5. Metal pin inserts P3 and P4 are reserved at the position of the sixth ceramic capacitor CY6. Metal pin inserts P21 and P22 are reserved at the position of the seventh ceramic capacitor CY7. Metal pin inserts P23 and P24 are reserved at the position of the eighth ceramic capacitor CY8. In an alternative embodiment, in order to increase the breakdown voltage values of the fourth capacitor C4, the fifth capacitor C5, and the sixth capacitor C6, an additional fourth capacitor, an additional fifth capacitor, and an additional sixth capacitor may be connected in series respectively, and additional metal pin inserts are reserved at the positions of the additional fourth capacitor, the additional fifth capacitor, and the additional sixth capacitor accordingly.

[0050] Select the inductance value of the output inductor according to the filtering requirements of the output filter board (i.e., the ripple of the input voltage) and insert the output inductor with the selected inductance value via the metal pin inserts. For example, select the inductance value of the output inductor according to the output voltage of each power module to be tested. Select the following capacitors according to the capacitance and breakdown voltage values of the capacitors: the fourth capacitor C4 to the sixth capacitor C6, the fifth ceramic capacitor CY5 to the eighth ceramic capacitor CY8, and insert the selected capacitors via the metal pin inserts. For example, select the fourth capacitor C4 to the sixth capacitor C6 according to the input voltage of the output filter board (the output voltage of each power module to be tested), and select the capacitance values of the fifth ceramic capacitor CY5 to the eighth ceramic capacitor CY8 according to the input voltage of the output filter board (the output voltage of the power module to be tested) and the ripple of the output voltage.

[0051] Reference Figure 2 and Figure 5 , each power module to be tested includes a positive sampling terminal (i.e., connected to the terminal +S of the output filter board), a negative sampling terminal (i.e., connected to the terminal -S of the output filter board), and a voltage regulating terminal (i.e., connected to the terminal trim of the output filter board). The output filter board further includes a first resistor R1 and a second resistor R2. The first resistor R1 is connected between the positive sampling terminal and the voltage regulating terminal of each power module to be tested, and the positive sampling terminal of each power module to be tested is connected to the positive voltage output terminal +Vout of the output filter board; and the second resistor R2 is connected between the negative sampling terminal and the voltage regulating terminal of each power module to be tested, and the negative sampling terminal of each power module to be tested is connected to the negative voltage output terminal -Vout of the output filter board.

[0052] Specifically, the first resistor R1 is connected between the output filter board at terminal +S and terminal trim, and terminal +S is connected to the positive voltage output terminal +Vout of the output filter board; and the second resistor R2 is connected between terminal -S and terminal trim of the output filter board, and terminal -S of the output filter board is connected to the negative voltage output terminal -Vout of the output filter board. Refer to Figure 5 , the output filter board further includes a first single-pole double-throw switch K1 and a second single-pole double-throw switch K2. Among them, the positive sampling terminal is connected to the positive voltage output terminal +Vout of the output filter board or to the test terminal P17 of the first resistor R1 via the first single-pole double-throw switch K1; and the negative sampling terminal is connected to the negative voltage output terminal -Vout of the output filter board or to the test terminal P18 of the second resistor R2 via the second single-pole double-throw switch K2. Specifically, terminal +S is connected to the external terminal P17 via switch K1, so that the adjustment voltage is tested using the first resistor R1 with different resistance values to be able to select the first resistor R1, or terminal +S is connected to the positive voltage output terminal +Vout of the output filter board to increase the voltage between terminal trim and terminal +S. Terminal -S is connected to the external terminal P18 via switch K2, so that the adjustment voltage is tested using the second resistor R2 with different resistance values to be able to select the second resistor R2 with a determined resistance value; or terminal -S is connected to the negative voltage output terminal -Vout of the filter board to decrease the voltage between terminal trim and terminal -S. Optionally, the voltage increase and decrease are performed simultaneously through switches K1 and K2.

[0053] Another specific embodiment of the present invention discloses a power module testing method based on an input-output filter board. Refer to Figure 7 , using the power module testing system based on the input-output filter board described above to perform the following steps: Step S702, a plurality of sets of pin sockets are soldered on the power module testing substrate, and each set of pin sockets in the plurality of sets of pin sockets is respectively connected to one of the plurality of power modules to be tested in a plug-and-play manner; Step S704, the input filter board is connected to the power module testing substrate via the first inter-board connector for filtering the input voltage of the plurality of power modules to be tested; and Step S706, the output filter board is connected to the power module testing substrate via the second inter-board connector for filtering the output voltage of the plurality of power modules to be tested.

[0054] In addition, before testing the power supply modules to be tested in parallel, inductors for the input inductor and the output inductor are selected respectively according to the ripple of the input voltage and the output voltage ripple of the power supply module to be tested. Capacitors C1 to C3, and the capacitance values of ceramic capacitors CY1 to CY4 are selected according to the input voltage of the power supply module to be tested. Capacitors C4 to C6, and the capacitance values of ceramic capacitors CY5 to CY8 are selected according to the output voltage of the power supply module to be tested.

[0055] In the following, with reference to Figures 1A to 6 , the power supply module test system based on the input-output filter board will be described in detail by way of specific examples.

[0056] The present invention mainly uses a self-made power supply module test substrate and an input-output filter board, together with pin sleeves that are extremely easy to purchase in the market and connectors for electrical connection between boards, to jointly build a tooling for testing the functions and performance of brick-type power supply modules (i.e., the power supply module test system based on the input-output filter board).

[0057] The present invention mainly uses metal pin sleeves to provide reliable structural fixation and electrical connection for capacitors and power supply modules without welding, and lead out the electrical signals of the required pins to the power supply module test system based on the input-output filter board for testing. Metal spring pin sleeves are as shown in Figure 1A and Figure 1B . The actual mating male pin size ranges from Φ0.3mm to Φ1.5mm, and meets the plugging requirements of most capacitor pins on the market.

[0058] The peripheral test circuit of the DC-DC brick module is as shown in Figure 2 . According to this test circuit, the input and output parts are split into independent input-output filter boards, and other functional test circuits and the power module mating pin sleeves are all welded on the power supply module test substrate. For example, other functional test circuits include a programmed power-on / off circuit, a secondary side resistor voltage regulation circuit, and a communication function module.

[0059] The circuit is mainly divided into three parts. The first part is the input filter circuit, which mainly functions to filter out input clutter. When a spike pulse suddenly surges in the input voltage, since the voltage across the capacitor does not rise rapidly and the electrolytic capacitor has a large capacitance, this pulse can be absorbed to ensure that the voltage entering the module is not too high. Similarly, when a reverse pulse suddenly surges in the input voltage, since the voltage across the capacitor does not drop rapidly and it can store some energy, a part of the previously stored energy will be released to ensure that the voltage entering the module is not too low, thus not affecting the normal functions and performance of the power supply module. The second part is the power supply module to be tested. The third part is the output filter circuit, which mainly functions to filter out the output clutter of the power supply module and improve the anti-interference ability of the module. When the load of the subsequent stage suddenly increases, it will inevitably pull down the output voltage of the module. However, since the voltage across the capacitor does not drop rapidly and it can store some energy, a part of the previously stored energy will be released to ensure that the output voltage of the module is not too low. When the load suddenly decreases, it will inevitably raise the output voltage. Since the voltage across the capacitor does not rise rapidly and the electrolytic capacitor has a large capacitance, this fluctuation can be absorbed to ensure that the output voltage of the module is not too high, thus ensuring the stability of the module's output voltage.

[0060] This attachment Figure 2 is the most comprehensive implementation plan. Generally, the input common-mode inductor L1 and the output common-mode inductor L2 will be removed, and only the input and output filter capacitors will be retained. Or, in order to reduce the output voltage ripple of the module, the output common-mode voltage L2 will be retained.

[0061] For example, Table 1 shows the inductance values of the input inductor L1 and the output inductor L1, and the capacitance values of the first capacitor C1 to the sixth capacitor C6.

[0062] Type Specification Input Voltage (DC) 110V - 160V Output Voltage (DC) 24V C1, C2 100uF / 200V C3, C6 0.22uF / 250V L1, L2 15mH C4, C5 470uF / 50V

[0063] Reference Figure 3 and Figure 5 , reserve capacitor pin sockets on the input and output filter board, and plug in capacitors with different withstand voltage levels and capacitance values according to the requirements of different power supply modules; install the filter inductors on the filter board in the common-mode inductor connection method, and reserve short-circuit wire interfaces. When a differential-mode inductor is needed, the reserved interface can be short-circuited to convert the common-mode inductor into a differential-mode inductor.

[0064] The most common function of an inductor in a circuit is to form an LC filter circuit together with a capacitor. As we already know, a capacitor has the ability to "block direct current and pass alternating current", while an inductor has the functions of "passing direct current, blocking alternating current, passing low frequency, and blocking high frequency". If direct current with many interference signals passes through the LC filter circuit, then most of the alternating current interference signals will be blocked and absorbed by the inductor, becoming magnetic induction and heat energy, and most of the remaining will be bypassed to the ground by the capacitor. This can suppress the effect of interference signals, and a relatively pure direct current can be obtained at the output end.

[0065] When a sharp pulse suddenly surges into the input voltage, since the voltage across the capacitor will not rise rapidly and the electrolytic capacitor has a large capacitance, this pulse can be absorbed to ensure that the voltage entering the module will not be too high. Similarly, when a reverse pulse suddenly surges into the input voltage, since the voltage across the capacitor will not drop rapidly and it can store some energy, a part of the previously stored energy will be released to ensure that the voltage entering the module will not be too low, thus not affecting the normal functions and performance of the power supply module.

[0066] Such as Figure 4 and Figure 6 As shown, when actually manufacturing the PCB board, metal pin inserts are reserved for the positions of the capacitor and inductor. During actual use, the corresponding capacitor can be selected and installed according to the required capacitance and withstand voltage value of the module; the appropriate inductor can be selected according to the filtering requirements.

[0067] Advantages of the embodiments of the present invention:

[0068] 1) It avoids the connection between the pins of the module, input and output capacitors and the test tooling board by welding, ensuring that the module and capacitor can be repeatedly plugged and unplugged, and avoiding unnecessary waste.

[0069] 2) The input and output filter boards can be reused. When there is a new module test requirement, only the corresponding module docking substrate needs to be designed according to the module product manual, and the input and output filter board interfaces are reserved, saving the design time cost and reducing the design difficulty.

[0070] 3) The transfer tooling is simple to assemble, convenient to disassemble and replace, and the structural connection is firm and not easily deformed.

[0071] Technical key points and points to be protected in the embodiments of the present invention:

[0072] 1) Utilize the conductive characteristics of the metal pin sleeve to form a stable electrical connection between the module and the capacitor and the test tooling without welding, ensuring the comprehensiveness of the power module test while minimizing the tooling design and manufacturing costs as much as possible.

[0073] 2) By using the transfer tooling designed by the present invention, the following main purposes are achieved:

[0074] ① All pins can be covered, and the functions of each pin of the module can be fully tested by cooperating with the test tooling circuit board.

[0075] ② The input and output filter board of the test tooling can be plugged in and out repeatedly. When there is a new test requirement, you only need to design a new test substrate and plug it into the input and output filter board.

[0076] ③ No need to weld the module, ensuring the consistency of the module status before and after testing.

[0077] ④ Input and output filter capacitors and inductors can be repeatedly plugged in and out to reduce test material costs

[0078] ⑤Low price, simple design, saving cost and time.

[0079] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0080] 1. Through multiple sets of pin sleeves and multiple power modules to be tested for plugging and unplugging, the parallel power modules to be tested can be tested, which improves the reuse rate of the power module test system based on the input and output filter board. It shortens the research and development cycle of the power module test system (also known as test process equipment) of brick module power products and reduces the production cost of brick module power product test process equipment.

[0081] 2. Avoid connecting the pins of the module and input and output capacitors to the test fixture board by welding, ensuring that the module and capacitor can be repeatedly plugged in and out to avoid unnecessary waste.

[0082] 3. The input and output filter boards can be reused. When there is a new module testing requirement, you only need to design the corresponding power module plug-in substrate according to the module product manual and reserve the input and output filter board interface, which saves design time and reduces design difficulty.

[0083] 4. The transfer tooling is simple to assemble, easy to disassemble and replace, and the structural connection is firm and not easy to deform.

[0084] Those skilled in the art will appreciate that all or part of the processes of the above-mentioned embodiments can be implemented by instructing related hardware through a computer program, and the program can be stored in a computer-readable storage medium, wherein the computer-readable storage medium is a disk, an optical disk, a read-only storage memory, or a random access memory, etc.

[0085] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A power module test system based on an input-output filter board, characterized in that, Comprising: A power module test substrate, an input filter board, and an output filter board, The power module test substrate, on which multiple sets of pin sleeves are soldered, so as to respectively connect one of multiple power modules to be tested in a pluggable manner through each set of pin sleeves in the multiple sets of pin sleeves; The input filter board, which is connected to the power module test substrate via a first inter-board connector and is used for filtering the input voltage of the multiple power modules to be tested; And The output filter board, which is connected to the power module test substrate via a second inter-board connector and is used for filtering the output voltage of the multiple power modules to be tested, wherein, the input filter board includes a single-pole triple-throw switch, each of the multiple power modules to be tested includes a control terminal, and the control terminals of the multiple power modules to be tested are connected to the first terminal, the second terminal, or the third terminal of the single-pole triple-throw switch. When the high level is valid, the control terminal is connected to the positive voltage output terminal of the input filter board via the first terminal; or the control terminal is connected to an external power supply via the second terminal to remotely control the multiple power modules to be tested; and when the low level is valid, the control terminal is connected to the negative voltage output terminal of the input filter board via the third terminal.

2. The power module test system based on the input-output filter board according to claim 1, wherein Each power module to be tested includes a synchronization terminal, a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. The input filter board includes a positive voltage output terminal and a negative voltage output terminal. The output filter board includes a positive voltage input terminal and a negative voltage input terminal. Among them, the synchronization terminals of the multiple power modules to be tested are connected together; the positive voltage output terminal of the input filter board is connected to the positive input terminal of each power module to be tested among the multiple power modules to be tested; the negative voltage output terminal of the input filter board is connected to the negative input terminal of each power module to be tested among the multiple power modules to be tested; the positive voltage input terminal of the output filter board is connected to the positive output terminal of each power module to be tested among the multiple power modules to be tested; and the negative voltage input terminal of the output filter board is connected to the negative output terminal of each power module to be tested among the multiple power modules to be tested.

3. The power module test system based on the input / output filter board according to claim 2, wherein, The input filter board includes: a first capacitor, a second capacitor, a third capacitor, a first ceramic capacitor, a second ceramic capacitor, a third ceramic capacitor, and a fourth ceramic capacitor. Among them, the first capacitor, the second capacitor, and the third capacitor are connected in parallel; the positive plate end and the negative plate end of the first capacitor are respectively used as the positive voltage input terminal and the negative voltage input terminal of the input filter board; the two plate ends of the third capacitor are used as the positive voltage output terminal and the negative voltage output terminal of the input filter board; the positive voltage input terminal and the negative voltage input terminal of the input filter board are respectively grounded via the first ceramic capacitor and the second ceramic capacitor; and the positive voltage output terminal and the negative voltage output terminal of the input filter board are respectively grounded via the third ceramic capacitor and the fourth ceramic capacitor.

4. The power module test system based on the input-output filter board according to claim 3, wherein The input filter board includes an input inductor connected between the first capacitor and the second capacitor in a common-mode or differential-mode manner, wherein, the common-mode manner includes that a first winding of the input inductor is connected between the positive plate ends of the first capacitor and the second capacitor and a second winding of the input inductor is connected between the negative plate ends of the first capacitor and the second capacitor; or the differential-mode manner includes that a first winding of the input inductor is connected between the positive plate ends of the first capacitor and the second capacitor and the negative plate ends of the first capacitor and the second capacitor are connected together.

5. The power module testing system based on the input / output filter board according to claim 4, characterized in that The output filter board includes: a fourth capacitor, a fifth capacitor, a sixth capacitor, a fifth ceramic capacitor, a sixth ceramic capacitor, a seventh ceramic capacitor, and an eighth ceramic capacitor, the fourth capacitor, the fifth capacitor, and the sixth capacitor are connected in parallel; the positive plate end and the negative plate end of the fourth capacitor serve as the positive voltage input terminal and the negative voltage input terminal of the output filter board; and the two plate ends of the sixth capacitor serve as the positive voltage output terminal and the negative voltage output terminal of the output filter board; the positive voltage input terminal and the negative voltage input terminal of the output filter board are grounded via the fifth ceramic capacitor and the sixth ceramic capacitor respectively; and the positive voltage output terminal and the negative voltage output terminal of the output filter board are grounded via the seventh ceramic capacitor and the eighth ceramic capacitor respectively.

6. The power module test system based on the input-output filter board according to claim 5, wherein, The output filter board includes an output inductor connected between the fourth capacitor and the fifth capacitor in a common-mode or differential-mode manner, wherein, the common-mode manner includes that a first winding of the output inductor is connected between the positive plate ends of the fourth capacitor and the fifth capacitor and a second winding of the output inductor is connected between the negative plate ends of the fourth capacitor and the fifth capacitor; or the differential-mode manner includes that a first winding of the output inductor is connected between the positive plate ends of the fourth capacitor and the fifth capacitor and the negative plate ends of the fourth capacitor and the fifth capacitor are connected together.

7. The power module test system based on an input-output filter board according to claim 6, wherein, metal pin insertion holes are reserved at the positions of the input inductor, the output inductor, the first capacitor to the sixth capacitor, and the first ceramic capacitor to the eighth ceramic capacitor; the inductance values of the input inductor and the output inductor are selected according to the filtering requirements of the input filter board and the output filter board, and the input inductor and the output inductor with the selected inductance values are plugged in via the metal pin insertion holes; and the following capacitors are selected according to the capacitance and withstand voltage values of the capacitors: the first capacitor to the sixth capacitor, and the first ceramic capacitor to the eighth ceramic capacitor, and the selected capacitors are plugged in via the metal pin insertion holes.

8. The power module test system based on the input-output filter board according to claim 6, characterized in that, Each power module to be tested includes a positive sampling terminal, a negative sampling terminal, and a voltage regulating terminal. The output filter board further includes a first resistor and a second resistor. The first resistor is connected between the positive sampling terminal and the voltage regulating terminal of each power module to be tested, and the positive sampling terminal of each power module to be tested is connected to the positive voltage output terminal of the output filter board. And The second resistor is connected between the negative sampling terminal and the voltage regulating terminal of each power module to be tested, and the negative sampling terminal of each power module to be tested is connected to the negative voltage output terminal of the output filter board.

9. A power module testing method based on an input-output filter board, characterized in that Perform the following steps using the power module test system based on the input-output filter board according to any one of claims 1 to 8: Multiple sets of pin sockets are soldered on the power module test substrate, and one of the multiple power modules to be tested is respectively connected in a pluggable manner through each set of pin sockets in the multiple sets of pin sockets. Connect the input filter board to the power module test substrate via a first inter-board connector for filtering the input voltage of the multiple power modules to be tested. And Connect the output filter board to the power module test substrate via a second inter-board connector for filtering the output voltage of the multiple power modules to be tested.

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