Multifunctional testing equipment and method for high-voltage connectors

Abstract

The present invention discloses multifunctional testing equipment and methods for high-voltage connectors. The equipment includes a positioning device for supporting and positioning the connector; a high-voltage testing device, located on one side of the positioning device, for testing the withstand voltage performance of each jack within the connector; a continuity testing device, located on the other side of the positioning device and cooperating with the high-voltage testing device, for testing the conductivity between a second conductor and a terminal piece; and a tension testing device, movable relative to the positioning device, for testing the tensile strength of a first conductor and a terminal housing. This invention improves connector testing efficiency by integrating tension testing, high-voltage testing, and continuity testing into automated testing, effectively detecting connector failures.

Description

Technical Field

[0001] The present invention belongs to the technical field of connector testing, and in particular relates to multifunctional testing equipment for high-voltage connectors and a method thereof. Background Art

[0002] In the new energy vehicle sector, high-voltage connectors are crucial components, primarily consisting of contacts, insulators, housings, and accessories. As the operating voltage range of new energy vehicles increases from the 12V of conventional vehicles to 400V, higher requirements are placed on the quality and precision of connectors, which are used in both the vehicle and charging infrastructure. High-voltage connectors require materials with high-temperature resistance, and the sealing, shielding, and waterproofing requirements are also higher than those of traditional automotive connectors. To ensure that socket products meet performance standards, they undergo continuity testing before shipment to ensure reliable performance. Furthermore, according to relevant national regulations and standards, as well as other international standards, there are also certain requirements for the high-voltage resistance of plug-in products. Therefore, all plug-in product manufacturers are required to conduct relevant high-voltage resistance testing before their products ship.

[0003] For example, patent number CN201210074944.4 discloses a system and method for testing the high-voltage resistance and continuity performance of sockets synchronized with production lines. The system discloses an electronic control unit including a PLC controller and its control circuit; a detection device including a probe and a detection plug, a probe drive mechanism, and a plug drive mechanism; a plug provided with a pin, with the probe corresponding to the input end of the socket and the pin corresponding to the output end of the socket; and a PLC controller controls the detection device to perform continuity performance testing on the socket or controls the detection device and a withstand voltage tester to perform high-voltage resistance testing on the socket. Existing socket detection methods are designed for products with sockets. The normal continuity test approach is to connect one end to the input end of the product and the other end to the output end of the product.

[0004] In addition to sockets, plug-in products also come in connectors. Depending on the application requirements, plug-in connectors are also designed with extended wires. Obviously, the traditional socket positioning method mentioned above is not applicable.

[0005] For connectors with wires, if we still follow the traditional electrical performance testing approach and directly connect and test the input and output ends, when the wire part and the connector are poorly assembled, it will directly affect the test results of the electrical performance, and the entire connector will need to be repaired and inspected, which will reduce the testing efficiency. Summary of the Invention

[0006] The purpose of the present invention is to solve the above technical problems and provide a multifunctional test device and method for high-voltage connectors, thereby improving the detection efficiency of connectors, integrating tensile testing, high-voltage testing, and continuity testing into an automatic test, and effectively detecting problems in connectors. In order to achieve the above objectives, the technical solutions of the present invention are as follows:

[0007] Multifunctional testing equipment for high-voltage connectors, the connector comprising a connecting shell, a plurality of first wires and a plurality of second wires arranged at one end of the connecting shell, and a first jack corresponding to the first wires and a second jack corresponding to the second wires respectively arranged at the other end of the connecting shell, the ends of the plurality of first wires being merged and connected to the terminal shell, and the ends of the plurality of second wires being respectively connected to a terminal piece, comprising a positioning device for supporting and positioning the connector, a high-voltage testing device arranged on one side of the positioning device for testing the withstand voltage performance of each jack in the connector, a continuity testing device arranged on the other side of the positioning device and cooperating with the high-voltage testing device for testing the conductivity performance of the second wires and the terminal piece, and a tensile testing device movable relative to the positioning device for testing the tensile performance of the first wires and the terminal shell.

[0008] A multifunctional test method for high-voltage connectors includes the following steps:

[0009] According to the specifications of the connector, set the tensile test range of the tensile test device, set the current test range of the high-voltage test device, and set the current test range of the continuity test device;

[0010] Positioning the connector on the positioning device, passing the first wire of the connector around the driving rod of the tensile testing device, positioning the terminal shell of the first wire in the clamping assembly, and positioning the terminal piece of the connector on the third support plate;

[0011] Start the PLC controller to start testing;

[0012] The driving rod of the tension test device is driven to pull the first wire, and the first wire at the upper edge of the driving rod and the lower edge of the driving rod are in a parallel state. The sensor in the clamping assembly detects the tension of the terminal shell. The tension tester feeds back the tension value to the PLC controller, and the PLC controller determines whether the tension reaches the set value. When the tension reaches the set value, it indicates that the first wire, the terminal shell and the connector are assembled correctly and in place, and the next step is carried out. On the contrary, when the tension does not meet the set value, the device stops testing.

[0013] The test socket of the high-voltage test device is driven to be inserted into the connection shell of the plug-in component, the pins in the test socket are matched and docked with the sockets in the plug-in component, the pins apply high voltage to the plug-in component, and the withstand voltage tester detects whether there is leakage current in the plug-in component. The withstand voltage tester feeds back the current data to the PLC controller, and the PLC controller determines whether the current exceeds the set value. When the current value is within the set value range, the next step is carried out. On the contrary, when the current value does not meet the set value range, the device stops testing;

[0014] The test board of the conductivity test device is driven close to the terminal piece of the connector, and the pins in the test board are matched and docked with the inner holes in the terminal piece. At the same time, the pins of the high-voltage test device remain connected to the connector, and the conductivity tester detects whether the socket of the connector and the terminal piece are a valid conductive circuit. The conductivity tester feeds back the current data to the PLC controller, and the PLC controller determines whether the current exceeds the set value. When the current value is within the set value range, the subsequent steps are carried out. Conversely, when the current value does not meet the set value range, the equipment stops testing.

[0015] Compared with the prior art, the beneficial effects of the multifunctional testing device and method for high-voltage connectors of the present invention are mainly reflected in:

[0016] The connector is first subjected to a tensile test. The driving rod and the clamping assembly cooperate to effectively test the proper assembly of the first conductor and the terminal housing into the connector. During the test, the first conductor is parallel to the reaction force, and the first conductor is arranged around the driving rod, which provides the first conductor with a larger force area, reducing the probability of tearing damage to the first conductor. Furthermore, the conductor has a certain degree of deformation elasticity, which avoids excessive deformation caused by linear pulling of the first conductor under the same set tensile force. This embodiment facilitates the driving rod to easily reach the set tensile force and stop pulling, accurately verifying the stability and quality of the connector assembled with the first conductor. Furthermore, the method of bypassing the driving rod significantly shortens the stroke and rationalizes the spatial structure. The connector is subjected to a tensile test before the high-voltage test and the continuity test. Physical testing of the first conductor and the terminal housing of the connector can greatly eliminate problematic links and improve the efficiency of subsequent electrical performance testing. The tensile test device, high-voltage test device, and continuity test device are integrated into the same device, reducing the cost of assembly at each workstation. Furthermore, the integration of the tensile test without affecting the high-voltage test and the continuity test greatly improves the efficiency of multi-function testing. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematic diagram of the structure of an embodiment of the present invention;

[0018] Figure 2 This is one of the schematic diagrams of the connector structure in this embodiment;

[0019] Figure 3 This is the second schematic diagram of the connector structure in this embodiment;

[0020] Figure 4 Schematic diagram of the high voltage testing device in this embodiment;

[0021] Figure 5 Schematic diagram of the tensile testing device in this embodiment;

[0022] Figure 6 This is an enlarged schematic diagram of the positioning device in this embodiment;

[0023] The numbers in the figure represent:

[0024] 1 connector, 11 connecting shell, 12 first wire, 13 second wire, 14 first jack, 15 second jack, 16 terminal shell, 17 terminal piece, 18 mounting ring, 19 limiting ring,

[0025] 2 positioning device, 21 first support plate, 22 second support plate, 23 third support plate, 24 first groove, 25 second groove, 26 third groove, 27 triangular block,

[0026] 3 high voltage test device, 31 test socket, 32 first pin, 33 second pin, 34 positioning hole,

[0027] 4 conduction test device, 41 test board, 42 third pin,

[0028] 5 tensile testing device, 51 driving rod, 52 driving rod, 53 ring groove, 54 supporting body, 55 lower clamping plate, 56 upper clamping plate, 57 sensor,

[0029] 6. Dotting device, 61. Dotting plate, 62. Dotting needle. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments.

[0031] Example 1:

[0032] Reference Figure 2-3As shown, in this embodiment, the connector 1 is a product to be tested. The connector 1 includes a connecting shell 11, a group of first wires 12 and a group of second wires 13 arranged at one end of the connecting shell 11, and a group of first jacks 14 and a group of second jacks 15 corresponding to the group of second wires 13 respectively arranged at the other end of the connecting shell 11. The first wires 12 and the first jacks 14 are electrically conductively connected, and the second wires 13 and the second jacks 15 are electrically conductively connected. The ends of the group of first wires 12 are merged and connected to the terminal shell 16. The ends of the group of second wires 13 are respectively connected to a terminal piece 17. The first jacks 14 are arranged side by side and close to each other, and the second jacks 15 are arranged side by side and close to each other, and the aperture of the second jacks 15 is larger than that of the first jacks 14.

[0033] The outer periphery of the connecting shell 11 is provided with a mounting ring 18 for assembling the entire connector 1 into the desired position. A limit ring 19 is provided at the end of the connecting shell 11, near the mounting ring 18. This limit ring 19 has a positioning function, not only for positioning the connector 1 during assembly but also for positioning during testing.

[0034] According to the structural characteristics of the connector 1, the wire can be subjected to an additional tensile test to evaluate whether the wire part is poorly assembled with the connector, which plays a leading role in the electrical performance test of the connector. The test of traditional connector products requires the design of multiple devices, and the transfer of different stations for conductivity test, high voltage test and tensile test respectively. Therefore, it is necessary to design a multifunctional testing all-in-one machine suitable for connectors with wires, referring to Figure 1-6 As shown, a multifunctional testing device for high-voltage connectors is provided, which includes a positioning device 2 for supporting and positioning the connector 1, a high-voltage testing device 3 arranged on one side of the positioning device 2 for testing the pressure resistance performance of each jack in the connector 1, a conductivity testing device 4 arranged on the other side of the positioning device 2 and cooperating with the high-voltage testing device 3 for testing the conductivity performance of the second wire 13 and the terminal piece 17, and a tensile testing device 5 movable relative to the positioning device 2 for testing the tensile performance of the first wire 12 and the terminal shell 16.

[0035] The high-voltage test device 3, the continuity test device 4, and the tensile test device 5 are all connected to a PLC controller. The PLC controller provides unified operation and control of these devices. A multifunctional high-voltage connector testing device also includes a marking device 6, located on the side of the high-voltage test device 3, for marking connectors 1 that have passed the marking test.

[0036] Positioning device 2 includes a first support plate 21, a second support plate 22 positioned to the side of first support plate 21, and a third support plate 23 spaced apart to the side of second support plate 22. The second support plate 22 is positioned adjacent to the first support plate 21. A first groove 24 shaped like the connector housing 11 of connector 1 is located at the top of the first support plate 21. A second groove 25 shaped like the retaining ring 19 of connector 1 is located at the top of the second support plate 22. The retaining ring 18 is located at the abutting connection between the first and second support plates 21, 22. Connecting housing 11 of connector 1 is stably positioned within positioning device 2 and remains stationary under axial load. A third groove 26 is provided on the top of the third support plate 23 to limit the connection position of the terminal piece 17 and the second wire 13. A triangular block 27 is provided on the side of the third support plate 23 to support a group of terminal pieces 17. The oblique sides of the triangular block 27 respectively abut against the corresponding terminal pieces 17, providing support force for the terminal pieces 17 to form a certain placement angle, so that the terminal pieces 17 keep their inner holes consistent with the axis direction of the connector 1.

[0037] The high-voltage test device 3 includes a movably arranged test socket 31, a first pin 32 arranged on the end face of the test socket 31 corresponding to the first jack 14, and a second pin 33 arranged on the end face of the test socket 31 corresponding to the second jack 15. The first pin 32 and the second pin 33 are both electrically connected to the withstand voltage tester. The end face of the test socket 31 is provided with positioning holes 34 for accommodating a group of first pins 32 and a group of second pins 33. The positioning holes 34 correspond to the plug-in guides of the outer wall of the connecting shell 11. The test socket 31 is driven to move horizontally, and the center of the positioning hole 34 is located in the same straight line direction as the axial direction of the connecting shell 11. During the high-voltage test, the first pin 32 and the second pin 33 apply a high voltage to the connector 1, and the withstand voltage tester detects whether there is a leakage current and determines whether the leakage current exceeds the set value.

[0038] The continuity tester 4 includes a movable test board 41 and a third pin 42 positioned on the test board 41, corresponding to the inner hole of the terminal strip 17. The third pin 42 is electrically connected to a continuity tester. The test board 41 is driven to move horizontally, and the third pin 42 mates with the inner hole of the terminal strip 17. During the continuity test, the second pin 33 is connected to the connector 1 as the input, and the third pin 42 is connected to the terminal strip 17 as the output. The continuity tester detects whether current conduction forms a valid circuit, thereby confirming the effective conduction between the second jack 15, the second wire 13, and the terminal strip 17.

[0039] The tensile testing device 5 includes a driving rod 51 for pulling a set of first conductors of the connector 11, and a clamping assembly positioned between the driving rod 51 and the positioning device 2 for clamping the terminal housing 16 to create a reaction force against the first conductors 12 around the driving rod 51. Drive rods 52 are axially connected at both ends of the driving rod 51. These two driving rods 52 are connected to a drive mechanism that synchronously drives their telescopic movement. This drive mechanism utilizes a conventional motor-screw structure. The surface of the driving rod 51 is provided with a set of annular grooves 53 corresponding to the first conductors 12. A set of annular grooves 53 are provided, each corresponding to a set of first conductors 12 passing around it.

[0040] The clamping assembly includes a support body 54, a lower clamping plate 55 with a retractable, movable design located on the side of the support body 54, and an upper clamping plate 56 with a retractable design located on the top of the support body 54 and correspondingly covering the lower clamping plate 55. A sensor 57, a torque sensor, is located within the upper clamping plate 56 and extends through the lower clamping plate 66. A clamping groove is formed between the upper and lower clamping plates 56, 55, to position the terminal housing 16. The torque sensor acts on the terminal housing 16 within the clamping groove. A cavity is provided on the support body 54 to accommodate the lower clamping plate 55. The lower clamping plate 55 can translate within the cavity without hindering its movement and preventing it from falling out of the cavity. The upper clamping plate 56 is pivotally connected to the top of the support body 54. When the upper and lower clamping plates 56 and 55 are covered, they can stably engage and position the terminal housing 16. The sensor 57 is connected to a tensile tester.

[0041] During the tension test, the first conductor 12 passes around the driving rod 51, and the terminal shell 16 is positioned in the clamping assembly. The driving rod 51 is driven to pull the first conductor 12, and the torque sensor tests whether the tension of the terminal shell 16 meets certain numerical requirements to determine whether the first conductor 12 and the terminal shell 16 are assembled accurately. The above tension test takes precedence over the high-voltage test and the continuity test. It can first determine the connection and assembly status of the first conductor 12, and at the same time, it can further confirm the problem link. Then, the electrical performance test is performed again, which is a test of the connector 1 body. The test is accurate. The tension test device 5 is combined and set between the high-voltage test device 3 and the continuity test device 4, which reduces equipment costs and improves the efficiency of the integrated multi-functional test.

[0042] The marking device 6 comprises a telescopic marking plate 61 positioned below the test socket 31 and a marking pin 62 positioned to the side of the marking plate 61. The marking plate 61 is driven to move horizontally in the same direction as the test socket 31. The top of the marking plate 61 extends into the positioning hole 34. The marking pin 62 physically applies a dot directly to the end face of the connector 1, creating a mark. Once the connector passes the tensile test, high-voltage test, and continuity test, the marking pin 62 performs the marking.

[0043] Example 2:

[0044] The test method of this embodiment, based on the multifunctional test equipment for high-voltage connectors of embodiment 1, includes the following steps:

[0045] According to the structural characteristics of the connector 1 , a positioning device is designed to limit the connector 1 to prevent its axial movement; the positioning device 2 includes a terminal piece 17 supporting the connector 1 and a third support plate 23 guiding several wires of the connector 1 .

[0046] According to the specification of the connector 1 , the tension test range of the tension test device 5 , the current test range of the high voltage test device 3 , and the current test range of the conduction test device 4 are set.

[0047] Position the connector 1 on the positioning device 2, the first wire 12 of the connector 1 passes around the driving rod 51 of the tensile testing device 5, the terminal shell 16 of the first wire 12 is positioned in the clamping assembly, and the terminal piece 17 of the connector 1 is positioned on the third support plate 23; start the PLC controller to start the test.

[0048] The driving rod 51 of the tension testing device 5 is driven to pull the first wire 12, and the first wire 12 at the upper edge of the driving rod 51 and its lower edge are in a parallel state. The sensor 57 in the clamping assembly detects the tension of the terminal shell 16, and the tension tester feeds back the tension value to the PLC controller. The PLC controller determines whether the tension reaches the set value. When the tension reaches the set value, it indicates that the first wire 12 and the terminal shell 16 are assembled accurately with the connector 1, and the next step is performed; on the contrary, when the tension does not meet the set value, the equipment stops testing, and the display screen of the PLC controller displays the test data.

[0049] The test socket 31 of the high-voltage test device 3 is driven to connect to the connection housing 11 of the connector 1. The pins in the test socket 31 mate with the sockets in the connector 1. The pins apply a high voltage to the connector 1. The voltage tester detects whether there is leakage current in the connector 1. The voltage tester feeds the current data back to the PLC controller, which determines whether the current exceeds the set value. If the current value is within the set value range, the next step is carried out; otherwise, if the current value does not exceed the set value range, the device stops testing.

[0050] The test board 41 of the continuity test device 4 is driven close to the terminal strip 17 of the connector 1. The pins in the test board 41 mate with the inner holes in the terminal strip 17. At the same time, the pins of the high-voltage test device 3 remain connected to the connector 1. The continuity tester detects whether the socket of the connector 1 and the terminal strip 17 form a valid conductive circuit. The continuity tester feeds the current data back to the PLC controller, which determines whether the current exceeds the set value. If the current value is within the set value range, the next step is carried out; otherwise, if the current value is not within the set value range, the device stops testing.

[0051] The dotting needle 62 of the dotting device 6 is driven to move and physically dot the end surface of the connector 1 that has passed the test.

[0052] The connector 1 is cut after completing the tensile test, high voltage test, continuity test, and dot marking.

[0053] When the above embodiment is applied, the connector 1 is first subjected to a tension test, and the driving stick 51 and the clamping assembly are cooperated to effectively test whether the first wire 12 and the terminal shell 16 are assembled to the connector 1 in place. During the test, the first wire 12 is allowed to form a reaction force in a parallel direction, and the first wire 12 is arranged to bypass the driving stick 51, so that the first wire 12 has a larger force area, reducing the probability of tearing damage to the first wire 12. At the same time, the wire has a certain deformation elasticity, which avoids excessive deformation caused by pulling the first wire 12 in a straight line under the same set tension. This embodiment is conducive to the driving stick 51 to control the setting tension and stop pulling, accurately verifying The stability and quality of the connector 1 assembled by the first conductor 12 are improved. Secondly, the way in which the first conductor 12 bypasses the driving rod 51 can greatly shorten the stroke and reasonably arrange the spatial structure. The connector 1 is subjected to a tensile test before the high-voltage test and the conduction test, and the first conductor 12 and the terminal shell 16 of the connector 1 are physically tested, which can greatly eliminate the problem links and improve the efficiency of subsequent electrical performance tests. The tensile test device, the high-voltage test device, and the conduction test device are integrated into the same equipment to reduce the cost of assembly at different workstations. At the same time, the tensile test is integrated without affecting the high-voltage test and the conduction test, which greatly improves the efficiency of the multi-functional test.

[0054] Throughout this specification, the term "specific embodiment" means that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0055] Although the embodiments disclosed herein are as described above, the contents described herein are merely embodiments for facilitating understanding of the present invention and are not intended to limit the present invention. Any person skilled in the art may make any modifications and variations in the form and details of the embodiments without departing from the spirit and scope of the present invention. However, the scope of patent protection of the present invention shall remain subject to the scope defined by the appended claims.

Claims

1. Multifunctional testing equipment for high-voltage connectors, the connector comprising a connecting shell, a plurality of first and second conductors disposed at one end of the connecting shell, and a first jack corresponding to the first conductors and a second jack corresponding to the second conductors, respectively, disposed at the other end of the connecting shell. The ends of the plurality of first conductors are connected to the terminal shell, and the ends of the plurality of second conductors are connected to a terminal piece, characterized in that: The device comprises a positioning device for supporting and positioning the connector, a high-voltage testing device provided on one side of the positioning device for testing the withstand voltage performance of each jack in the connector, a continuity testing device provided on the other side of the positioning device and cooperating with the high-voltage testing device for testing the conductivity performance of the second wire and the terminal piece, and a tension testing device provided to be movable relative to the positioning device for testing the tension performance of the first wire and the terminal shell; The high-voltage test device includes a movable test socket, a first pin provided on the end surface of the test socket and corresponding to the first socket, and a second pin provided on the end surface of the test socket and corresponding to the second socket; the first pin and the second pin are both electrically connected to the withstand voltage tester; The continuity test device includes a movable test board and a third pin disposed on the test board corresponding to an inner hole of the terminal piece; the third pin is electrically connected to the continuity tester; During the continuity test, the second pin is connected to the connector as the input end, and the third pin is connected to the terminal piece as the output end. The continuity tester detects whether the current is conducted to form a valid circuit, and then determines whether the second jack, the second wire, and the terminal piece are effectively conducted.

2. The multifunctional testing device for high-voltage connectors according to claim 1, characterized in that: A mounting ring is provided on the outer periphery of the connecting shell, and a limiting ring is provided on the end portion of the connecting shell near the mounting ring in the circumferential direction.

3. The multifunctional testing device for high-voltage connectors according to claim 1, characterized in that: The high voltage test device, the conduction test device and the tension test device are all connected to the PLC controller.

4. The multifunctional testing device for high-voltage connectors according to claim 2, characterized in that: The positioning device includes a first support plate, a second support plate arranged on the side of the first support plate, and a third support plate arranged at intervals on the side of the second support plate; the second support plate is arranged against the first support plate, the top of the first support plate is provided with a first groove corresponding to the connecting shell of the plug-in component, the top of the second support plate is provided with a second groove corresponding to the limiting ring of the plug-in component, and the first support plate and the second support plate are connected at abutting connection with a limiting mounting ring.

5. The multifunctional testing device for high-voltage connectors according to claim 4, characterized in that: A third groove for limiting the connection position of the terminal piece and the second wire is provided on the top of the third support plate, and a triangular block for supporting a group of terminal pieces is provided on the side of the third support plate, and the oblique sides of the triangular block respectively abut against the corresponding terminal pieces.

6. The multifunctional testing device for high-voltage connectors according to claim 5, characterized in that: The end surface of the test socket is provided with positioning holes for accommodating a group of first pins and a group of second pins, and the positioning holes correspond to the outer wall of the connection shell for plugging and guiding.

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