A power module testing device and method

Abstract

This invention relates to a power module testing device and method, belonging to the field of testing technology, and solves the problem of poor versatility of existing testing devices. A power module testing device includes: a power module testing substrate with pin sleeves soldered on it for plugging and unplugging connections to different power modules under test; an input filter board connected to the power module testing substrate via a first inter-board connector for filtering the input voltage of the power module under test; and an output filter board connected to the power module testing substrate via a second inter-board connector for filtering the output voltage of the power module under test. By allowing plugging and unplugging connections to different power modules under test via pin sleeves, different power modules can be tested, improving the reusability of the power module testing device.

Description

Technical Field

[0001] This invention relates to the field of testing technology, and in particular to a power module testing device and method. Background Technology

[0002] With the technological advancements and expanding application scenarios of brick-type modular power supplies, the power ratings and input / output ranges of standard-sized brick-type modular power supplies are becoming increasingly segmented. Consequently, the testing tasks for these modular power supplies are also increasing, and the requirements are becoming more stringent. A brick-type power supply refers to a power module whose small size and high power output, combined with its modular packaging resembling a brick, hence the name.

[0003] To perform comprehensive testing on brick-type power modules, a test fixture covering all functions of the power module needs to be designed. This generally involves two approaches: 1) Customizing power module test fixtures from relevant manufacturers; 2) Designing the test fixture circuit board in-house.

[0004] To conduct comprehensive testing of the functional performance of brick-type power modules (hereinafter referred to as modules), the following methods are generally used:

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

[0006] 2. Design a pluggable test circuit board and solder pin sleeves that can be plugged into the power module pins at the corresponding positions on the circuit board. The potential of the power module pins is led out to the test circuit board through the pin sleeves. However, due to the need for PCB layout design, the manufacturing cost is high and the cycle is long. In addition, due to the inconsistency of some pins of the module and the inconsistency of the input and output capacitors required for modules with different power ratings, the versatility is poor.

[0007] 3. Customized module testing fixtures can fully test the functions of each pin of the module, but this solution has high mold opening costs and long customization time, which is not suitable for some projects with cost or time requirements. Summary of the Invention

[0008] Based on the above analysis, the embodiments of the present invention aim to provide a power module testing device and method to solve the problems of long design cycle, high manufacturing cost and poor versatility of existing power module testing process equipment.

[0009] On one hand, embodiments of the present invention provide a power module testing device, including: a power module testing substrate, an input filter board, and an output filter board. The power module testing substrate has pin sleeves soldered on it for plugging and unplugging connections with different power modules under test. The input filter board is connected to the power module testing substrate via a first inter-board connector for filtering the input voltage of the power module under test. The output filter board is connected to the power module testing substrate via a second inter-board connector for filtering the output voltage of the power module under test.

[0010] The beneficial effects of the above technical solution are as follows: The test fixture, composed of input / output filter boards and a substrate that interlocks with the power module, enables functional performance testing of various types of power modules, ensuring comprehensive power module testing while minimizing fixture design and manufacturing costs. By using pin sleeves to connect to different power modules under test, different power modules can be tested, improving the reusability of the power module testing device.

[0011] Based on further improvements to the above-described device, the power supply module under test includes a positive input terminal and a negative input terminal, and 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 and negative terminals of the first capacitor are respectively connected to the positive and negative input voltage terminals of the input filter board; the third capacitor is connected to the positive and negative input terminals of the power supply module under test; the positive and negative input voltage terminals of the input filter board are grounded via the first and second ceramic capacitors; and the positive and negative input terminals of the power supply module under test are grounded via the third and fourth ceramic capacitors.

[0012] Based on a further improvement of the above device, 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. The common-mode manner includes a first winding of the input inductor connected between the positive plate of the first capacitor and the positive plate of the second capacitor, and a second winding of the input inductor connected between the negative plate of the first capacitor and the negative plate of the second capacitor. Alternatively, the differential-mode manner includes a first winding of the input inductor connected between the positive plate of the first capacitor and the positive plate of the second capacitor, and the negative plate of the first capacitor and the negative plate of the second capacitor connected together.

[0013] Based on a further improvement of the above device, the input filter board includes a single-pole three-throw switch, and the power supply module under test includes a control terminal. The control terminal of the power supply module under test is connected to a first terminal, a second terminal, or a third terminal of the single-pole three-throw switch. Specifically, when a high level is active, the control terminal is connected to the positive input terminal of the power supply module under test via the first terminal; or the control terminal is connected to an external power supply via the second terminal to remotely control the power supply module under test; and when a low level is active, the control terminal is connected to the negative input terminal of the power supply module under test via the third terminal.

[0014] Based on further improvements to the above-mentioned device, the power supply module under test includes a positive output terminal and a negative output terminal. 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 and negative terminals of the fourth capacitor are respectively connected between the positive and negative output terminals of the power supply module under test. The sixth capacitor is connected to the positive and negative terminals of the load. The positive and negative output terminals of the power supply module under test are grounded via the fifth and sixth ceramic capacitors, respectively. The positive and negative terminals of the load are grounded via the seventh and eighth ceramic capacitors, respectively.

[0015] Based on a further improvement of the above-described device, 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. The common-mode manner includes a first winding of the output inductor connected between the positive plate of the fourth capacitor and the positive plate of the fifth capacitor, and a second winding of the output inductor connected between the negative plate of the fourth capacitor and the negative plate of the fifth capacitor. Alternatively, the differential-mode manner includes a first winding of the output inductor connected between the positive plate of the fourth capacitor and the positive plate of the fifth capacitor, and the negative plate of the fourth capacitor and the negative plate of the fifth capacitor connected together.

[0016] Based on further improvements to the above-mentioned device, metal pins 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 connected via metal pins; and the following capacitors are selected according to the capacitance and voltage rating of the capacitors: the first capacitor to the sixth capacitor, the first ceramic capacitor to the eighth ceramic capacitor, and the selected capacitors are connected via metal pins.

[0017] Based on further improvements to the above-mentioned device, the power supply module under test includes a positive sampling terminal, a negative sampling terminal, and a voltage regulation 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 regulation terminal, and the positive sampling terminal is connected to the positive terminal of the load. The second resistor is connected between the negative sampling terminal and the voltage regulation terminal, and the negative sampling terminal is connected to the negative terminal of the load.

[0018] Based on further improvements to the above-mentioned device, the output filter board further includes a first single-pole double-throw switch and a second single-pole double-throw switch, wherein the positive sampling terminal is connected to the positive terminal of the load or to the test terminal of the first resistor via the first single-pole double-throw switch; and the negative sampling terminal is connected to the negative terminal of the load or to the test terminal of the second resistor via the second single-pole double-throw switch.

[0019] On the other hand, embodiments of the present invention provide a power module testing method, which utilizes the power module testing apparatus described in the above embodiments to perform the following steps: soldering pin sleeves onto a power module testing substrate for plugging and unplugging connections with different power modules under test via the pin sleeves; connecting an input filter board to the power module testing substrate via a first inter-board connector for filtering the input voltage of the power module under test; and connecting an output filter board to the power module testing substrate via a second inter-board connector for filtering the output voltage of the power module under test.

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

[0021] 1. By plugging and unplugging different power modules under test with pin sleeves, it is possible to test different power modules, which is highly versatile and improves the reusability of the power module testing device. This shortens the development cycle of power module testing devices (also known as test process equipment) for brick-type power products and reduces the manufacturing cost of test process equipment for brick-type power products.

[0022] 2. This avoids connecting the pins of modules, input / output capacitors, and test fixtures via soldering, ensuring that modules and capacitors can be repeatedly plugged in and out, thus avoiding unnecessary waste.

[0023] 3. The input and output filter boards are reusable. When there are new module testing requirements, it is only necessary to design the corresponding power module plug-in board according to the module product manual and reserve the input and output filter board interfaces, which saves design time and costs and reduces design difficulty.

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

[0025] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objects and other advantages of this invention can be realized and obtained from what is particularly pointed out in the description and drawings. Attached Figure Description

[0026] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0027] Figure 1A and Figure 1B These are schematic diagrams of a metal needle sleeve and its internal working principle according to embodiments of the present invention.

[0028] Figure 2 This is a peripheral test circuit diagram of a DC-DC brick module according to an embodiment of the present invention;

[0029] Figure 3 A schematic diagram of the input filter board of a power module testing device according to an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram showing the pin reservation of the input filter board of the power module testing device according to an embodiment of the present invention.

[0031] Figure 5 A schematic diagram of the output filter board of a power module testing device according to an embodiment of the present invention; and

[0032] Figure 6 This is a schematic diagram showing the pin reservation for the output filter board of the power module testing device according to an embodiment of the present invention.

[0033] Figure 7 This is a flowchart of a power module testing method according to an embodiment of the present invention. Detailed Implementation

[0034] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0035] One specific embodiment of the present invention discloses a power module testing device. For example... Figure 2 As shown, the power module testing device includes: a power module test board, an input filter board, and an output filter board. The power module test board has pin sleeves soldered on it for plugging and unplugging different power modules under test. That is, one power module under test is tested at a time, and other power modules under test can be used to replace the current power module under test for testing. The type of the current power module under test can be the same as or different from the other power modules under test. The input filter board is connected to the power module test board via a first inter-board connector and is used to filter the input voltage of the power module under test. The output filter board is connected to the power module test board via a second inter-board connector and is used to filter the output voltage of the power module under test.

[0036] Compared with existing technologies, the power module testing device provided in this embodiment uses a test fixture composed of an input / output filter board and a substrate that interlocks with the power module to perform functional performance tests on different types of power modules. Therefore, by plugging and unplugging different power modules under test with pin sleeves, different power modules can be tested, improving the reusability of the power module testing device.

[0037] The following text will refer to Figures 1A to 6 This document provides a detailed description of the power module testing apparatus. The power module testing apparatus includes: a power module test board, an input filter board, and an output filter board.

[0038] Specifically, the power module test board has pin sleeves soldered onto it (see reference). Figure 1A and Figure 1BThis allows for plugging and unplugging connections to different power supply modules under test (PSTs) via pin headers. This means one PST is tested at a time, and other PSTs can be substituted to test other PSTs. The type of the current PST can be the same as or different from the other PSTs. (Reference) Figure 2 The power supply module M under test includes a positive input terminal +VI, a negative input terminal -VI, a positive output terminal +VO, a negative output terminal -VO, a synchronization terminal StartSync, a control terminal REM, a positive sampling terminal +S, a negative sampling terminal -S, and a voltage regulation terminal Trim.

[0039] An input filter board, connected to the power module test substrate via a first inter-board connector, is used to filter the input voltage of the power module under test. Specifically, the input filter board is connected to the power module test substrate via the first inter-board connector to electrically connect to the input terminal of the power module under test, wherein the power module under test is inserted into the power module test substrate via pins. For example, the first inter-board connector includes PhoenixContact universal terminals, 2.54 pin header connectors, or 5.08 pin header connectors.

[0040] The input filter board 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 used for energy storage and filtering. The third capacitor C3 is a film capacitor 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 used to bypass most AC interference signals to ground.

[0041] Specifically, the first capacitor C1, the second capacitor C2, and the third capacitor C3 are connected in parallel; the positive and negative plates of the first capacitor C1 are connected to the positive input voltage terminal +Vin and the negative input voltage terminal -Vin, respectively; the third capacitor C3 is connected to the positive input terminal +V1 and the negative input terminal -V1 of the power supply module under test; the positive input voltage terminal +Vin and the negative input voltage terminal -Vin are grounded to FG via the first ceramic capacitor CY1 and the second ceramic capacitor CY2, respectively, where FG is the metal casing or frame of the machine; and the positive input terminal +V1 and the negative input terminal -V1 of the power supply module under test are grounded via the third ceramic capacitor CY3 and the fourth ceramic capacitor CY4, respectively. Specifically, the node between the positive plate of the second capacitor C2 and the positive plate of the third capacitor C3 is grounded via the third ceramic capacitor CY3, and the node between the negative plate of the second capacitor C2 and the negative plate of the third capacitor C3 is grounded via the fourth ceramic capacitor CY4. The input filter board includes an input inductor L1 connected between a first capacitor C1 and a second capacitor C2 in either common-mode or differential-mode. Specifically, in common-mode, the first winding of the input inductor L1 is connected between the positive plates of the first capacitor C1 and the second capacitor C2, and the second winding of the input inductor L1 is connected between the negative plates of the first capacitor C1 and the second capacitor C2; or in differential-mode, the first winding of the input inductor L1 is connected between the positive plates of the first capacitor C1 and the second capacitor C2, and the negative plates of the first capacitor C1 and the second capacitor C2 are connected together.

[0042] The input filter board includes a single-pole triple-throw switch KG1 or a single-pole double-throw switch K1. The control terminals of the power module under test can be active low or active high. Both the single-pole double-throw switch K1 and the single-pole triple-throw switch KG1 can be connected to an external power supply to test the remote control function of the power module under test. Therefore, this approach ensures comprehensive power module testing while minimizing tooling design and manufacturing costs.

[0043] refer to Figure 3The control terminal REM of the power supply module under test is connected via a current-limiting resistor R1 to either the upper terminal (also known as the first terminal of the single-pole triple-throw switch KG1), the middle terminal (also known as the second terminal of the single-pole triple-throw switch KG1), or the lower terminal (also known as the third terminal of the single-pole triple-throw switch KG1). The current-limiting resistor R1 limits current to protect the power supply module under test. When active low, the control terminal is connected to the negative input terminal -VI of the power supply module under test via the lower terminal. Specifically, the common terminal of the single-pole triple-throw switch KG1 is connected to the lower terminal while being disconnected from the upper and middle terminals, thus connecting the control terminal REG to the negative input terminal -VI of the power supply module under test. When active high, the control terminal REG can be connected to the positive input terminal of the power supply module under test via the upper terminal or to an external power supply via the middle terminal. Specifically, the common terminal of the single-pole three-throw switch KG1 is connected to the upper terminal while the common terminal is disconnected from the middle and lower terminals, so that the control terminal REG is connected to the positive input terminal +VI of the power module under test; or the common terminal of the single-pole three-throw switch KG1 is connected to the middle terminal while the common terminal is disconnected from the upper and lower terminals, so that the control terminal is connected to the external power supply.

[0044] In an optional embodiment, a single-pole double-throw switch K1 can be used instead of a single-pole triple-throw switch KG1. Specifically, refer to... Figure 2 The control terminal REM of the power supply module under test is connected to the common terminal and either the first or second terminal of the single-pole double-throw switch K1. When the low level is active, the control terminal REM is connected to the negative input terminal of the power supply module under test via the first terminal. Specifically, the common terminal of the single-pole double-throw switch K1 is connected to the first terminal while the common terminal is disconnected from the second terminal, thus connecting the control terminal REM to the negative input terminal of the power supply module under test. When the high level is active, the control terminal REM is connected to an external power supply via the second terminal. Specifically, the common terminal of the single-pole double-throw switch K1 is connected to the second terminal while the common terminal is disconnected from the first terminal, thus connecting the control terminal REM to an external power supply, enabling remote control function testing of the power supply module under test.

[0045] refer to Figure 4The first capacitor C1 has metal pins P5 and P6 reserved. The second capacitor C2 has metal pins P11 and P12 reserved. The third capacitor C3 has metal pins P13 and P14 reserved. The input inductor L1 has metal pins P7, P8, P9, and P10 reserved. The first ceramic capacitor CY1 has metal pins P1 and P2 reserved. The second ceramic capacitor CY2 has metal pins P3 and P4 reserved. The third ceramic capacitor CY3 has metal pins P15 and P16 reserved. The fourth ceramic capacitor CY4 has metal pins P17 and P18 reserved. Connect the positive input terminal +VI of the power supply module under test to the upper terminal of the single-pole triple-throw switch via short circuit P01. Connect the negative input terminal -VI of the power supply module under test to the lower terminal of the single-pole triple-throw switch via short circuit P02. The first resistor R1 has metal pins P19 and P20 reserved. Select the inductance value of the input inductor according to the filtering requirements of the input filter board, and connect the input inductor with the selected inductance value via metal pins. For example, select the inductance value of the input inductor according to the input voltage of the power supply module under test. Select the following capacitors according to their capacitance and voltage rating: first capacitor C1 to third capacitor C3, first ceramic capacitor CY1 to fourth ceramic capacitor CY4, and connect the selected capacitors via metal pins. For example, select first capacitor C1 to third capacitor C3 according to the input voltage of the power supply module under test, and select the capacitance values ​​of first ceramic capacitor CY1 to fourth ceramic capacitor CY4 according to the interference signal of the output voltage of the power supply module under test.

[0046] An output filter board, connected to the power module test substrate via a second inter-board connector, is used to filter the output voltage of the power module under test. Specifically, the output filter board is electrically connected to the power module test substrate via the second inter-board connector to the output terminal of the power module under test, wherein the power module under test is inserted into the power module test substrate via pins. For example, the second inter-board connector includes PhoenixContact universal terminals, 2.54 pin header connectors, or 5.08 pin header connectors.

[0047] refer to Figure 2 and Figure 5The output filter board includes: capacitor C4 (fourth capacitor), capacitor C5 (fifth capacitor), capacitor C6 (sixth capacitor), ceramic capacitor CY5 (fifth ceramic capacitor), ceramic capacitor CY6 (sixth ceramic capacitor), ceramic capacitor CY7 (seventh ceramic capacitor), and ceramic capacitor CY8 (eighth ceramic capacitor). Capacitors C4 and C5 are electrolytic capacitors used for energy storage and filtering. Capacitor C6 is a film capacitor used for filtering. Ceramic capacitors CY5, CY6, CY7, and CY8 are high-frequency and high-voltage capacitors used to bypass most AC interference signals to ground.

[0048] refer to Figure 2 and Figure 5 The fourth capacitor C4, the fifth capacitor C5, and the sixth capacitor C6 are connected in parallel. The positive and negative terminals of the fourth capacitor C4 are connected between the positive output terminal +VO and the negative output terminal -VO of the power supply module under test, respectively. The sixth capacitor C6 is connected between the positive terminal +Vout and the negative terminal -Vout of the load. The positive output terminal +VO and the negative output terminal -VO of the power supply module under test are grounded (e.g., FG) via the fifth ceramic capacitor CY5 and the sixth ceramic capacitor CY6, respectively; and the positive terminal +Vout and the negative terminal -Vout 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 a fourth capacitor C4 and a fifth capacitor C5 in common-mode or differential-mode configuration. In common-mode configuration, the first winding of the output inductor L2 is connected between the positive plates of the fourth capacitor C4 and the fifth capacitor C5, and the second winding of the output inductor L2 is connected between the negative plates of the fourth capacitor C4 and the fifth capacitor C5. Alternatively, in differential-mode configuration, the first winding of the output inductor L2 is connected between the positive plates of the fourth capacitor C4 and the fifth capacitor C5, and the negative plates of the fourth capacitor C4 and the fifth capacitor C5 are connected together.

[0049] refer to Figure 6The output inductor L2 has pre-reserved metal pins P11, P12, P13, and P14. The fourth capacitor C4 has pre-reserved metal pins P9 and P10. The fifth capacitor C5 has pre-reserved metal pins P15 and P16. The sixth capacitor C6 has pre-reserved metal pins P19 and P20. The fifth ceramic capacitor CY5 has pre-reserved metal pins P1 and P2. The sixth ceramic capacitor CY6 has pre-reserved metal pins P3 and P4. The seventh ceramic capacitor CY7 has pre-reserved metal pins P21 and P22. The eighth ceramic capacitor CY8 has pre-reserved metal pins P23 and P24. The inductance value of the output inductor is selected according to the filtering requirements of the output filter board, and the output inductor with the selected inductance value is connected via metal pins. For example, the inductance value of the output inductor is selected according to the output voltage of the power supply module under test. Select the following capacitors based on their capacitance and voltage rating: capacitors C4 through C6 (fourth capacitor), C5 through C8 (fifth ceramic capacitor), and connect the selected capacitors via metal pin headers. For example, select capacitors C4 through C6 based on the output voltage of the power supply module under test, and select the capacitance values ​​of capacitors CY5 through CY8 based on the interference signal of the output voltage of the power supply module under test.

[0050] refer to Figure 2 and Figure 5 The power supply module under test includes a positive sampling terminal +S, a negative sampling terminal -S, and a voltage regulation terminal trim. The output filter board also includes a first resistor R1 and a second resistor R2. The first resistor R1 is connected between the positive sampling terminal +S and the voltage regulation terminal trim, and the positive sampling terminal +S is connected to the positive terminal +Vout of the load. The second resistor R2 is connected between the negative sampling terminal -S and the voltage regulation terminal trim, and the negative sampling terminal -S is connected to the negative terminal -Vout of the load. (Reference) Figure 5The output filter board also includes a first single-pole double-throw switch K1 and a second single-pole double-throw switch K2. The first single-pole double-throw switch K1 connects the positive sampling terminal to the positive terminal +Vout of the load or to the test terminal P17 of the first resistor R1; and the second single-pole double-throw switch K2 connects the negative sampling terminal -S to the negative terminal -Vout of the load or to the test terminal P18 of the second resistor R2. Specifically, connecting the positive sampling terminal +S to the external terminal P17 via switch K1 allows the regulated voltage to be tested using a first resistor R1 with different resistance values ​​to select the first resistor R1, or connecting the positive sampling terminal +S to the positive terminal +Vout of the load allows for voltage adjustment between the regulating terminal and the positive sampling terminal +S. By connecting the negative sampling terminal -S to the external terminal P18 via switch K2, the regulated voltage can be tested using a second resistor R2 with a different resistance value, allowing selection of a second resistor R2 with a specific resistance value; alternatively, the negative sampling terminal -S can be connected to the negative terminal -Vout of the load to lower the voltage between the regulating terminal and the negative sampling terminal -S. Optionally, both voltage increases and decreases can be performed simultaneously via switches K1 and K2.

[0051] When testing multiple power supply modules connected in parallel simultaneously, each power supply module also includes a synchronization terminal StartSync, wherein the synchronization terminals StartSync of each power supply module are connected together; the positive input terminals +VI of each power supply module are connected together; the negative input terminals -VI of each power supply module are connected together; the positive output terminals +VO of each power supply module are connected together; and the negative output terminals -VO of each power supply module are connected together.

[0052] Another specific embodiment of the present invention discloses a power module testing method. (See reference...) Figure 7 The following steps are performed using the power module testing device described above: Step S702, a pin sleeve is soldered onto the power module testing substrate to allow for plugging and unplugging connections with different power modules under test; Step S704, an input filter board is connected to the power module testing substrate via a first inter-board connector for filtering the input voltage of the power module under test; and Step S706, an output filter board is connected to the power module testing substrate via a second inter-board connector for filtering the output voltage of the power module under test.

[0053] Furthermore, before testing the power supply module under test, the inductors for the input and output inductors are selected based on the input and output voltages of the power supply module under test, respectively. The capacitance values ​​of the first capacitor C1 to the third capacitor C3, and the first ceramic capacitor CY1 to the fourth ceramic capacitor CY4 are selected based on the input voltage of the power supply module under test. The capacitance values ​​of the fourth capacitor C4 to the sixth capacitor C6, and the fifth ceramic capacitor CY5 to the eighth ceramic capacitor CY8 are selected based on the output voltage of the power supply module under test.

[0054] In the following text, refer to Figures 1A to 6 The power module testing device is described in detail using specific examples.

[0055] This invention mainly uses a self-made power module test board and input / output filter board, along with readily available pin sleeves and connectors for inter-board electrical connections, to build a tooling (i.e., a power module test device) for testing the functional performance of brick-type power modules.

[0056] This invention utilizes metal pin sleeves to provide reliable structural fixation and electrical connection for capacitors and power modules without soldering. It allows the electrical signals from the required pins to be routed to a power module testing device for testing. The metal spring pin sleeves, such as… Figure 1A and Figure 1B As shown, the actual compatible male pin sizes range from Φ0.3mm to Φ1.5mm, and meet the pin-to-pin requirements of most capacitors on the market.

[0057] The peripheral test circuit of the DC-DC brick module is as follows: Figure 2 As shown, according to this test circuit, the input / output section is split into independent input / output filter boards, while other functional test circuits and power module pin headers are soldered onto the power module test substrate. For example, other functional test circuits include a programmable power on / off circuit, a secondary resistor voltage regulation circuit, and a communication function module.

[0058] The circuit is mainly divided into three parts. The first part is the input filter circuit, which mainly filters input noise. When a spike pulse suddenly enters the input voltage, the voltage across the capacitor will not rise rapidly, and the electrolytic capacitor has a large capacitance, so it can absorb the pulse and ensure that the voltage entering the module is not too high. Similarly, when a reverse pulse suddenly enters the input voltage, the voltage across the capacitor will not drop rapidly, and it can store some energy, so it will release some of the previously stored energy to ensure that the voltage entering the module is not too low, thus not affecting the normal function and performance of the power supply module. The second part is the circuit to be tested. The power module; the third part is the output filter circuit, which mainly plays the role of filtering out noise in the power module output and improving the module's anti-interference capability. When the load of the downstream stage suddenly increases, it will inevitably pull down the output voltage of the module. However, since the voltage across the capacitor will not drop rapidly and can store some energy, it will release some of the previously stored energy 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 will not rise rapidly and the electrolytic capacitor has a large capacitance, it can absorb the fluctuation and ensure that the output voltage of the module is not too high, thus ensuring the stability of the module's output voltage.

[0059] The appendix Figure 2 This is the most comprehensive implementation plan. In general, 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. Alternatively, in order to reduce the output voltage ripple of the module, the output common-mode voltage L2 will be retained.

[0060] 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.

[0061] 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

[0062] refer to Figure 3 and Figure 5 Reserve capacitor pins on the input and output filter boards, and insert capacitors with different voltage ratings and capacitance values ​​according to the needs of different power modules; install the filter inductors on the filter boards in the common mode inductor connection mode, and reserve shorting wire interfaces. When differential mode inductors are needed, the reserved interfaces can be shorted to convert the common mode inductors into differential mode inductors.

[0063] The most common function of inductors in circuits is to form LC filter circuits together with capacitors. We already know that capacitors can block DC and pass AC, while inductors can pass DC, block AC, pass low frequencies, and block high frequencies. If a DC current accompanied by many interfering signals is passed through an LC filter circuit, most of the AC interference signals will be absorbed and blocked by the inductor, becoming magnetic induction and heat energy. The remainder will be bypassed to ground by the capacitor. This suppresses the effects of interference signals, resulting in a relatively pure DC current at the output.

[0064] When a sudden voltage spike enters the input voltage range, the voltage across the capacitor will not rise rapidly, and because electrolytic capacitors have a large capacitance, they can absorb the pulse, ensuring that the voltage entering the module is not too high. Similarly, when a reverse voltage spike enters the input voltage range, the voltage across the capacitor will not drop rapidly, and because it can store some energy, it will release some of the previously stored energy, ensuring that the voltage entering the module is not too low, thus not affecting the normal function and performance of the power supply module.

[0065] like Figure 4 and Figure 6 As shown, when actually manufacturing the PCB board, metal pins are reserved at the positions of capacitors and inductors. In actual use, you can choose the appropriate capacitor to install according to the required capacitance and withstand voltage of the module; and select the appropriate inductor according to the filtering requirements.

[0066] Beneficial effects of the embodiments of the present invention:

[0067] 1) It avoids connecting the pins of modules, input / output capacitors and test fixtures to the test fixture board by soldering, ensuring that modules and capacitors can be repeatedly plugged in and out, avoiding unnecessary waste.

[0068] 2) The input and output filter boards are reusable. When there are new module testing requirements, it is only necessary to design the corresponding module mating board according to the module product manual and reserve the input and output filter board interfaces, which saves design time and costs and reduces design difficulty.

[0069] 3) The adapter tooling is easy to assemble, disassemble and replace, and the structural connection is firm and not easily deformed.

[0070] Key technical points and areas to be protected in this invention:

[0071] 1) By utilizing the conductive properties of metal pin sleeves, a stable electrical connection can be formed between the module and capacitor and the test fixture without soldering, ensuring the comprehensiveness of power module testing while minimizing the design and manufacturing costs of the fixture.

[0072] 2) The adapter tooling designed using this invention mainly achieves the following objectives:

[0073] ① All pins can be covered, and the function of each pin of the module can be fully tested by using a test fixture circuit board.

[0074] ② The input and output filter boards of the test fixture can be repeatedly plugged in and out. When there are new test requirements, only a new test substrate needs to be designed and plugged in with the input and output filter boards.

[0075] ③ By eliminating the need for soldering modules, the consistency of the module's state before and after testing is ensured.

[0076] ④ Input and output filter capacitors and inductors can be repeatedly plugged in and replaced, reducing the cost of test materials.

[0077] ⑤ It is inexpensive, simple in design, and saves costs and time.

[0078] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0079] 1. By connecting and disconnecting different power modules under test with pin sleeves, various power modules can be tested, improving the reusability of the power module testing device. This shortens the development cycle of the power module testing device (also known as testing process equipment) for brick-type power supply products and reduces the manufacturing cost of the testing process equipment for brick-type power supply products.

[0080] 2. This avoids connecting the pins of modules, input / output capacitors, and test fixtures via soldering, ensuring that modules and capacitors can be repeatedly plugged in and out, thus avoiding unnecessary waste.

[0081] 3. The input and output filter boards are reusable. When there are new module testing requirements, it is only necessary to design the corresponding module mating board according to the module product manual and reserve the input and output filter board interfaces, which saves design time and costs and reduces design difficulty.

[0082] 4. The adapter tooling is easy to assemble, disassemble and replace, and the structural connection is firm and not easily deformed.

[0083] Those skilled in the art will understand that all or part of the processes of the methods described in the above embodiments can be implemented by a computer program instructing related hardware, and the program can be stored in a computer-readable storage medium. The computer-readable storage medium may be a disk, optical disk, read-only memory, or random access memory, etc.

[0084] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A power module testing device, characterized in that, include: Power module test board, input filter board, and output filter board. The power module test board has pin sleeves soldered on it, so as to connect to different power modules under test through the pin sleeves. The input filter board is connected to the power module test substrate via a first inter-board connector for filtering the input voltage of the power module under test. The input filter board includes a single-pole three-throw switch, and the power module under test includes control terminals. The control terminals of the power module under test are connected to the first, second, or third terminal of the single-pole three-throw switch. When the high level is active, the control terminal is connected to the positive input terminal of the power supply module under test via the first terminal; or the control terminal is connected to an external power supply via the second terminal to remotely control the power supply module under test; and When the low level is active, the control terminal is connected to the negative input terminal of the power supply module under test via the third terminal; and The output filter board is connected to the power module test substrate via a second inter-board connector to filter the output voltage of the power module under test.

2. The power module testing device according to claim 1, characterized in that, The power supply module under test includes a positive input terminal and a negative input terminal, and 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. The first capacitor, the second capacitor, and the third capacitor are connected in parallel; The positive and negative terminals of the first capacitor are respectively connected to the positive and negative input voltage terminals of the input filter board. The third capacitor is connected to the positive input terminal and the negative input terminal of the power supply module under test; The positive and negative terminals of the input voltage of the input filter board are grounded via the first and second ceramic capacitors, respectively; and The positive and negative input terminals of the power module under test are grounded via the third and fourth ceramic capacitors, respectively.

3. The power module testing device according to claim 2, characterized in that, 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 configuration includes connecting the first winding of the input inductor between the positive plate of the first capacitor and the positive plate of the second capacitor, and connecting the second winding of the input inductor between the negative plate of the first capacitor and the negative plate of the second capacitor; or The differential mode includes connecting the first winding of the input inductor between the positive plate of the first capacitor and the positive plate of the second capacitor, and connecting the negative plate of the first capacitor and the negative plate of the second capacitor together.

4. The power module testing device according to claim 3, characterized in that, The power supply module under test includes a positive output terminal and a negative output terminal. 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 and negative plates of the fourth capacitor are respectively connected between the positive and negative output terminals of the power supply module under test; and The sixth capacitor is connected to the positive and negative terminals of the load; The positive and negative output terminals of the power supply module under test are grounded via the fifth and sixth ceramic capacitors, respectively; and The positive and negative terminals of the load are grounded via the seventh and eighth ceramic capacitors, respectively.

5. The power module testing device according to claim 4, characterized in that, 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 configuration includes the first winding of the output inductor being connected between the positive plate of the fourth capacitor and the positive plate of the fifth capacitor, and the second winding of the output inductor being connected between the negative plate of the fourth capacitor and the negative plate of the fifth capacitor; or The differential mode includes the first winding of the output inductor being connected between the positive plate of the fourth capacitor and the positive plate of the fifth capacitor, and the negative plate of the fourth capacitor and the negative plate of the fifth capacitor being connected together.

6. The power module testing device according to claim 5, characterized in that, Metal pins 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 connected via metal pins. as well as The following capacitors are selected based on their capacitance and voltage rating: the first capacitor to the sixth capacitor, the first ceramic capacitor to the eighth ceramic capacitor, and the selected capacitors are connected via metal pins.

7. The power module testing device according to claim 4, characterized in that, The power supply module under test includes a positive sampling terminal, a negative sampling terminal, and a voltage adjustment terminal. The output filter board also includes a first resistor and a second resistor. The first resistor is connected between the positive sampling terminal and the voltage regulating terminal, and the positive sampling terminal is connected to the positive terminal of the load; and The second resistor is connected between the negative sampling terminal and the voltage regulating terminal, and the negative sampling terminal is connected to the negative terminal of the load.

8. The power module testing device according to claim 7, characterized in that, The output filter board further includes a first single-pole double-throw switch and a second single-pole double-throw switch, wherein... The positive sampling terminal is connected to the positive terminal of the load or to the test terminal of the first resistor via the first single-pole double-throw switch; and The negative sampling terminal is connected to the negative terminal of the load or to the test terminal of the second resistor via the second single-pole double-throw switch.

9. A power module testing method, characterized in that, Perform the following steps using the power module testing apparatus according to any one of claims 1 to 8: A pin sleeve is soldered onto the power module test board to allow for plugging and unplugging connections with different power modules under test. The input filter board is connected to the power module test board via the first board connector to filter the input voltage of the power module under test. as well as The output filter board is connected to the power module test board via the second inter-board connector to filter the output voltage of the power module under test.

Images