An electrical equipment fault detector

Abstract

The present invention discloses an electrical equipment fault detector, which collects relay switch instantaneous electromagnetic signals through a signal acquisition module, and sends the electromagnetic signals to a fault detection module, which first pre-processes the electromagnetic signals, extracts features and sends them to a preset fault analysis model to obtain fault detection results, and sends the fault detection results to a result display module, which displays the fault detection results on a user interface. The electrical equipment fault detector detects the state of the relay in real time and reliably by collecting and analyzing the relay electromagnetic signals, and does not need to disassemble the relay, thereby reducing the loss of circuit damage and reducing the man-hour cost of automobile electrical appliance repair and maintenance.

Description

Technical Field

[0001] The invention relates to the technical field of electrical equipment maintenance, and in particular to an electrical equipment fault detector. Background Art

[0002] In recent years, my country's automobile industry has made great progress and gradually realized electrification. With the continuous development of automobile technology, modern cars have become highly intelligent machines with complex electronic appliances. The electronic and electrical systems of vehicles involve engine control, safety devices, entertainment systems, navigation systems and other aspects, providing drivers with a higher level of comfort, safety and convenience. Electronic and electrical equipment plays a vital role in the safety, stability and reliability of automobiles. However, with the increasing complexity of electronic and electrical systems, the corresponding fault detection and maintenance work has become more challenging.

[0003] The vehicle electronic and electrical system contains a large number of relays, and it is particularly important for them to maintain stable performance during vehicle operation and not fail at critical moments. This requires regular inspection of the relays, and by measuring and analyzing certain parameters that can reflect their status, the current use of the relays can be understood, and finally maintenance or replacement can be selected according to needs.

[0004] At present, most of the detection of relays on automobiles requires removing the relays from the circuit and measuring their characteristic parameters to detect the failure mode or damage degree of the relays. This method is time-consuming and labor-intensive, and the labor cost of automobile repair and maintenance is high. Summary of the invention

[0005] In view of the defects in the prior art, the present invention provides an electrical equipment fault detector, which determines the fault state of a relay by collecting and analyzing the electromagnetic signal of the relay, identifies the fault, and achieves the purpose of saving labor costs and reducing losses.

[0006] In order to achieve the above-mentioned object, the present invention provides an electrical equipment fault detector, comprising a trigger module, a signal acquisition module, a fault detection module and a result display module; wherein,

[0007] The trigger module is used to receive user operation instructions to control the switch of the relay;

[0008] The signal acquisition module is used to collect the instantaneous electromagnetic signal of the relay switch and send the electromagnetic signal to the fault detection module;

[0009] The fault detection module pre-processes the electromagnetic signal, extracts features and sends them into a preset fault analysis model to obtain a fault detection result, and sends the fault detection result to the result display module;

[0010] The result display module displays the fault detection result on a user interface.

[0011] Further, the signal acquisition module includes a detection antenna, an A / D conversion unit and an FPGA unit connected in sequence;

[0012] The detection antenna is used to obtain the instantaneous electromagnetic signal of the relay switch;

[0013] The A / D conversion unit is used to convert the electromagnetic signal from an analog signal into a digital signal to obtain a digital electromagnetic signal;

[0014] The FPGA unit uploads the digital electromagnetic signal to the signal acquisition module through a signal line.

[0015] Furthermore, the operating frequency of the detection antenna is 23 MHz, and the return loss is less than -10 dB.

[0016] Furthermore, the detection antenna includes a substrate and a coil integrated on the substrate, the coil is rectangular in shape, the line width of the coil is 0.2 mm, and the line spacing of the coil is 0.3 mm.

[0017] Furthermore, the frequency of the A / D conversion unit is 32 MHz.

[0018] Further, the trigger module includes a control circuit board and an optical coupler, the control circuit board has a manual switch, and the optical coupler is connected in series with the relay;

[0019] The control circuit board receives the trigger signal sent by the manual switch and generates a PWM wave as the input of the optical coupler to control the on and off of the relay.

[0020] Furthermore, the fault detection module pre-processes the electromagnetic signal, including:

[0021] The electromagnetic signal is subjected to peak detection, and effective peak signal segments are intercepted to separate a number of signal segments centered around the peak.

[0022] Furthermore, the features of the pre-processed electromagnetic signal extracted by the fault detection module include:

[0023] Mean, standard deviation, RMS, skewness, kurtosis, peak-to-peak value, margin factor, crest factor.

[0024] Furthermore, the fault analysis model is obtained by training a BP neural network model.

[0025] Furthermore, the trigger module, fault detection module and result display module are all packaged in a protective box.

[0026] The beneficial effects of the present invention are embodied in:

[0027] The present application provides an electrical equipment fault detector which collects instantaneous electromagnetic signals of relay switches through a signal acquisition module and sends the electromagnetic signals to the fault detection module. The fault detection module first pre-processes the electromagnetic signals, extracts features and sends them into a preset fault analysis model to obtain fault detection results, and sends the fault detection results to a result display module. The result display module displays the fault detection results on a user interface.

[0028] The electrical equipment fault detector collects and analyzes the electromagnetic signal of the relay to reliably detect the status of the relay in real time without disassembling the relay, thereby reducing the loss of circuit damage and the labor cost of automotive electrical repair and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the specific embodiments or the description of the prior art. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn according to the actual scale.

[0030] The accompanying drawings herein are incorporated into and constitute a part of the specification, illustrate embodiments consistent with the present application, and together with the specification are used to explain the principles of the present application. For ordinary technicians in this field, other accompanying drawings can also be obtained based on these accompanying drawings without paying creative labor.

[0031] Figure 1 An electrical structure block diagram of an electrical equipment fault detector provided by an embodiment of the present invention;

[0032] Figure 2 An electrical structure block diagram of a signal acquisition module provided in an embodiment of the present invention;

[0033] Figure 3 An electrical structure block diagram of a trigger module provided in an embodiment of the present invention;

[0034] Figure 4 A schematic diagram of the structure of an electrical equipment fault detector provided by an embodiment of the present invention;

[0035] Figure 5 A schematic diagram of the structure of a detection antenna provided in an embodiment of the present invention;

[0036] Figure 6 A schematic diagram of the external structure of a protection box provided in an embodiment of the present invention;

[0037] Figure 7 A schematic diagram of the structure of a shock-absorbing cushion layer provided in an embodiment of the present invention;

[0038] Figure 8 A schematic diagram of the internal structure of a protective box provided in an embodiment of the present invention.

[0039] The realization of the purpose, functional features and advantages of this application will be further described in conjunction with the embodiments and with reference to the accompanying drawings. The above-mentioned drawings have shown clear embodiments of this application, which will be described in more detail later. These drawings and textual descriptions are not intended to limit the scope of the concept of this application in any way, but to illustrate the concept of this application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0040] The following embodiments of the technical solution of the present invention are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore only used as examples, and cannot be used to limit the protection scope of the present invention.

[0041] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by those skilled in the art to which the present invention belongs.

[0042] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0043] In addition, the terms "first", "second", etc. are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. In the description of the present invention, the meaning of "plurality" is more than two, unless otherwise clearly and specifically defined.

[0044] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0045] In the present application, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being “above”, “above”, and “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below”, and “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0046] like Figure 1 As shown, an electrical equipment fault detector provided by an embodiment of the present invention includes a trigger module 1, a signal acquisition module 2, a fault detection module 3 and a result display module 4. Among them, the trigger module 1 is used to receive user operation instructions to control the switch of the relay; the signal acquisition module 2 is used to collect the instantaneous electromagnetic signal of the relay switch, and send the electromagnetic signal to the fault detection module 3; the fault detection module 3 pre-processes the electromagnetic signal, extracts the features and sends them into the preset fault analysis model to obtain the fault detection result, and sends the fault detection result to the result display module 4; the result display module 4 displays the fault detection result on the user interface.

[0047] In this embodiment, Figure 4 As shown, the trigger module 1, the fault detection module 3 and the result display module 4 are all packaged in a protective box 10, which is convenient for carrying. The result display module 4 can be a liquid crystal display.

[0048] Specifically, Figure 2 As shown, the signal acquisition module 2 includes a detection antenna 18, an A / D conversion unit and an FPGA unit connected in sequence. Among them, the detection antenna 18 is used to obtain the instantaneous electromagnetic signal of the relay switch; the A / D conversion unit is used to convert the electromagnetic signal from an analog signal to a digital signal to obtain a digital electromagnetic signal. The FPGA unit uploads the digital electromagnetic signal to the signal acquisition module 2 through the data line 6. The internal logic circuit of the FPGA can run in parallel, which is suitable for processing a large amount of data; and the FPGA can achieve high-speed data processing and low latency, which is suitable for applications with high real-time requirements, and is used in high-speed interface circuits to achieve high-speed data transmission.

[0049] The A / D conversion unit and the FPGA unit can be integrated and packaged in a housing, and data cable jacks are provided on the FPGA unit and the protective box 10. Both ends of the data cable 6 are plugged into the corresponding data cable jacks for data transmission. When not in use, the data cable 6 can be removed, and the signal acquisition module 2 and the data cable 6 can also be stored in the protective box 10. The data cable 6 can be a USB2.0 data cable or a type-C data cable.

[0050] The electromagnetic signal changes when the relay is switched on and off, and the intensity reaches 30-50dBμV / m, and the frequency is around 23MHz. Therefore, the indicators of the detection antenna are set as follows: the operating frequency is 23MHz, and the return loss is less than -10dB.

[0051] like Figure 5 As shown, the detection antenna 18 includes a substrate 7 and a coil 8 integrated on the substrate 7. The coil 8 is rectangular in shape, the line width of the coil 8 is 0.2mm, the line spacing of the coil 8 is 0.3mm, and the coil 8 is connected to the A / D conversion unit through a wire 17. The material of the substrate 7 is FR-4. Since the inductor material will affect the coil resistance loss, this antenna selects copper foil to reduce the influence of the material on the resistance value. Specifically, the size of the substrate 7 is 80mm×50mm×1mm, and the antenna is small in size, which is convenient for measurement.

[0052] The amount of signal data collected within 1 second by the relay switch is 32×10 6 Considering the data volume and transmission quality of electromagnetic signals, this scheme uses an A / D conversion unit with a frequency of 32MHz to convert the analog signal obtained by the antenna into a digital signal.

[0053] Further, if Figure 3 As shown, the trigger module 1 includes a control circuit board and an optical coupler. The control circuit board has a manual switch, and the optical coupler is connected in series with the relay. The control circuit board receives the trigger signal sent by the manual switch to generate a PWM wave as the input of the optical coupler to control the on and off of the relay. The trigger module 1 is more convenient to collect the electromagnetic signal of the relay for testing and detection.

[0054] In this embodiment, the fault detection module 3 pre-processes the electromagnetic signal, including: performing peak detection on the electromagnetic signal, intercepting effective peak signal segments, and dividing into a number of signal segments centered on the peak.

[0055] Specifically, since the amount of signal data collected by the relay switch within 1 second is 32×10 6 Before extracting its features, it is necessary to preprocess it. The effective signal is the signal jump caused by the switch action, and the noise signal of other fragments must be removed first. According to the signal characteristics, it is peak detected, the detection threshold is 10, and the detection interval is 2×10 6 , if the interval between two peaks exceeds this value, it is determined to be a valid peak, and then the valid peak signal segment is intercepted with a length of 10000. Several signal segments centered on the peak are divided.

[0056] The features of the pre-processed electromagnetic signal extracted by the fault detection module 3 include: mean, standard deviation, root mean square, skewness, kurtosis, peak-to-peak value, margin factor, and peak factor.

[0057] In this embodiment, the fault analysis model is obtained by training the BP neural network model, and the learning rate of the BP neural network model is set to 2×10 -4 , Adam is selected as the optimization algorithm. Since relay fault detection is a nonlinear problem, the introduction of the excitation function is helpful for the convergence of the neural network. In this embodiment, a unipolar S-type function is selected as the excitation function, the number of hidden layers is set to 2, and the loss function is selected as the cross entropy.

[0058] Before training the BP neural network model, several relays of different common brands and voltage of 24V were selected and labeled according to the status of the relays, namely normal, weakly corroded, strongly corroded, and damaged. 3276 signals were collected to establish a relay signal-related database, which was divided into a training set and a validation set at a ratio of 8:2. The BP neural network model was trained and validated using the training set and validation set to obtain a fault analysis model.

[0059] According to the above data preprocessing results, the mean, standard deviation, root mean square, skewness, kurtosis, peak-to-peak value, margin factor, and peak factor variables are selected as the input parameters of the neural network, and the corresponding relay damage degree is divided into 4 categories as the output results: normal, weak corrosion, strong corrosion, and damage. In this application, the state definition is determined according to the contact resistance of the relay. 80% of the damage to the relay is contact damage, and the degree of damage is positively correlated with the contact resistance value. The specific definition standard is: the contact resistance is below 0.2Ω for normal state, 0.2Ω-20Ω for weak corrosion, 20Ω-200Ω for strong corrosion, and greater than 200Ω for damage.

[0060] like Figure 6-Figure 8 As shown, in order to prevent the protective box 10 from being accidentally broken during use or carrying, the protective box 10 includes an outer box shell 11 and an inner box shell 12 arranged in the outer box shell 11, and a buffer assembly is arranged between the inner box shell 12 and the outer box shell 11, and the trigger module 1, the fault detection module 3 and the result display module 4 are all arranged in the inner box shell 12.

[0061] When the protective box 10 accidentally falls to the ground, the outer box shell 11 contacts the ground and withstands the impact force through the buffer component, thereby achieving the purpose of shock absorption for the inner box shell 12, thereby protecting the trigger module 1, fault detection module 3 and result display module 4 in the inner box shell 12 to avoid damage.

[0062] In addition, the four side edges and four corners of the bottom surface of the outer box shell 11 are also provided with shock-absorbing pads 13, such as Figure 7As shown, the shock-absorbing pad layer 13 is evenly distributed with longitudinally extending through holes 14, and when the shock-absorbing pad layer 13 contacts the ground, the shock-absorbing pad layer 13 squeezes the through holes 14 to generate shock absorption, thereby reducing the impact on the inner box shell 12. The shock-absorbing pad layer 13 can be made of flexible silicone material.

[0063] In this embodiment, Figure 8 As shown, the buffer component can be filled with a spring 15 or a flexible material such as a sponge pad 16, or the spring 15 and the sponge pad 16 can be used together as the buffer component.

[0064] In summary, the electrical equipment fault detector collects and analyzes the electromagnetic signal of the relay to reliably detect the status of the relay in real time without disassembling the relay, thereby reducing the loss of circuit damage and the labor cost of automotive electrical repair and maintenance.

[0065] Finally, it should be noted that the various technical features of the technical solution of the present application can be combined arbitrarily. In order to make the description concise, not all possible combinations of the various technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of the present application.

[0066] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments may still be modified, or some or all of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention, and should all be included in the scope of the claims and specification of the present invention.

Claims

1. An electrical equipment fault detector, characterized in that: It comprises a trigger module (1), a signal acquisition module (2), a fault detection module (3) and a result display module (4); wherein, The trigger module (1) is used to receive user operation instructions to control the switching of the relay; The signal acquisition module (2) is used to collect instantaneous electromagnetic signals of relay switches and send the electromagnetic signals to the fault detection module (3); The fault detection module (3) pre-processes the electromagnetic signal, extracts features and sends them into a preset fault analysis model to obtain a fault detection result, and sends the fault detection result to the result display module (4); The result display module (4) displays the fault detection result on a user interface; The signal acquisition module (2) comprises a detection antenna, an A / D conversion unit and an FPGA unit which are connected in sequence; The detection antenna is used to obtain the instantaneous electromagnetic signal of the relay switch; The A / D conversion unit is used to convert the electromagnetic signal from an analog signal into a digital signal to obtain a digital electromagnetic signal; The FPGA unit uploads the digital electromagnetic signal to the fault detection module (3) via a data line (6); The operating frequency of the detection antenna is 23MHz, and the return loss is less than -10dB; The detection antenna comprises a substrate (7) and a coil (8) integrated on the substrate (7); the coil (8) is rectangular in shape; the line width of the coil (8) is 0.2 mm; and the line spacing of the coil (8) is 0.3 mm; The frequency of the A / D conversion unit is 32 MHz.

2. An electrical equipment fault detector as claimed in claim 1, characterized in that: The trigger module (1) comprises a control circuit board and an optical coupler, the control circuit board is provided with a manual switch, and the optical coupler is connected in series with the relay; The control circuit board receives the trigger signal sent by the manual switch and generates a PWM wave as the input of the optical coupler to control the on and off of the relay.

3. An electrical equipment fault detector as claimed in claim 1, characterized in that: The fault detection module (3) pre-processes the electromagnetic signal, including: The electromagnetic signal is subjected to peak detection, and effective peak signal segments are intercepted to separate a number of signal segments centered around the peak.

4. An electrical equipment fault detector as claimed in claim 1, characterized in that: The features of the pre-processed electromagnetic signal extracted by the fault detection module (3) include: Mean, standard deviation, RMS, skewness, kurtosis, peak-to-peak value, margin factor, crest factor.

5. An electrical equipment fault detector as claimed in claim 1, characterized in that: The fault analysis model is obtained by training a BP neural network model.

6. An electrical equipment fault detector as claimed in claim 1, characterized in that: The trigger module (1), the fault detection module (3) and the result display module (4) are all packaged in a protective box (10).

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