A full-state simulation system and method for power supply module

Abstract

This invention provides a full-state simulation system and method for power supply module test benches. The system includes a voltage input switching and monitoring unit for acquiring and measuring the current input voltage value and transmitting the result to a processor; a state input switching and monitoring unit connected to the terminals of an electrical connector for acquiring state input and transmitting it to the processor; a state output switching and control unit for setting state outputs according to processor instructions; an adjustable AC / DC voltage supply unit for adjusting AC / DC voltage values ​​according to processor instructions and sending them to the power output switching and control unit; and a power output switching and control unit for adjusting the output voltage and sending it to the terminals of the electrical connector. The processor responds to simulation state commands, configuring the state or value of corresponding units, changing the corresponding units to different states, thus achieving full-state simulation of the system. This system can effectively evaluate the functionality and performance of power supply module test benches.

Description

Technical Field

[0001] This invention belongs to the field of full-state simulation of power supply modules, and specifically relates to a full-state simulation system and method for power supply modules. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Railway systems typically use power supply panels to power various signaling equipment. These power supply panels have a modular structure; the modules are complex, require high reliability, and are expensive. Therefore, regular testing of online and standby power supply panel modules, as required by the Ministry of Railways, is a routine task for the railway system. Various intelligent testing benches for power supply panel modules have gradually emerged on the market, enabling automated load testing of various modules and ending the previous reliance on manual testing.

[0004] Power supply module test benches are emerging specialized large-scale testing equipment. Evaluating their performance and functionality before use is essential, but currently, the necessary technical means are lacking. Operators must rely on subjective judgment and evaluation of the test bench's performance by selecting representative modules for actual testing. This method has the following two drawbacks:

[0005] First: It cannot cover all power supply module types.

[0006] The Ministry of Railways standardized the modular structure and classification of power supply panels, dividing them into three main categories: AC modules, DC modules, and 25Hz modules. The aim was to unify the types and interfaces of power supply modules in the market and enable interchangeability between modules from different manufacturers. However, because this was not a mandatory standard and the classification was too general, power supply panel manufacturers did not implement this standard, only standardizing the physical form of the dimensions and interfaces. In practice, power supply panel modules are divided into eight main categories: power frequency AC modules, high-frequency AC modules, power frequency DC modules, high-frequency DC modules, voltage regulator modules, isolation modules, input modules, and 25Hz modules. Within each major category, the input voltage may be single-phase or three-phase AC, and the voltage may be 99V, 220V, or 380V. The output voltage may be different AC or DC voltages such as 9V, 12V, 24V, 36V, 48V, 50V, 60V, 110V, 220V, and 380V. The input and output status may include one or more of the following: alarm, over-temperature, current sharing, main / standby interlock input, main / standby interlock output, module main / standby signal, main / standby module parallel output, main / standby module switching input, standby module switching output, main / supplementary power supply working indication, and standby package power supply direct auxiliary point introduction. The output may be one, two, or even eight channels, or even a design that combines two functions into one module. In addition, each manufacturer arbitrarily chooses the 37 pins of the JMD-37 electrical connector as input, output, or status terminals, resulting in many types of modules within each major category. In fact, there are nearly a thousand types of power supply modules available on the market. Furthermore, driven by commercial considerations, manufacturers continuously introduce new types of power supply modules. Even modules with the same function have constantly adjusted interface definitions, leading to a continuous increase in the variety of power supply module types. However, not every electrical maintenance section uses all types of modules from all manufacturers; typically, only 50-150 types are used. Even if users manually test all modules locally, it cannot cover all power supply module types. Therefore, it cannot be guaranteed that the power supply module test bench will function properly when encountering new power supply modules, thus ensuring the tested power supply module is qualified.

[0007] Second: It cannot cover all working states of the power supply module.

[0008] As mentioned above, in addition to power input and one or more load outputs, power supply modules generally have alarm outputs and over-temperature status outputs. They may also include one or more of the following states: alarm, over-temperature, current sharing, master / slave interlock input, master / slave interlock output, module master / slave signal, master / slave module parallel output, master / slave module switching input, master / slave module switching output, master / slave power supply operation indication, and backup module power supply direct auxiliary point introduction. Generally, power supply modules in the online and spare parts warehouses are basically normal. The most common problems are modules failing to work upon power-up, or, after long-term storage, module capacity decreasing, resulting in output voltage exceeding the specified error range when operating at high current. However, the various status signals are generally normal. Therefore, simply testing stocked modules using a test bench cannot guarantee that all operating states of the power supply module test bench will provide correct test results. Summary of the Invention

[0009] To address the aforementioned problems, this invention proposes a full-state simulation system and method for power supply module test benches. This invention enables full-state testing of power supply module test benches, meeting the needs of power supply module test bench manufacturers to conduct thorough pre-shipment testing of their products, identify and correct potential problems in the product's hardware and software systems, and also allows railway users to effectively evaluate the functionality and performance of the purchased power supply module test benches, ensuring that the test results for power supply modules are always reliable.

[0010] According to some embodiments, the present invention adopts the following technical solution:

[0011] A full-state simulation system for a power supply module includes a voltage input switching and monitoring unit, a state input switching and monitoring unit, a state output switching and control unit, a power output switching and control unit, an adjustable AC / DC voltage supply unit, and a processor, wherein:

[0012] The voltage input switching and monitoring unit is used to detect the first set of terminals of the electrical connector connected to the test bench of the power supply panel module under test, obtain the current input voltage value, and transmit the result to the processor.

[0013] The status input switching and monitoring unit is connected to the second set of terminals of the electrical connector, acquires status input, and transmits it to the processor;

[0014] The status output switching and control unit is connected to the processor and sets the status output according to the processor's instructions to send it to the third set of terminals of the electrical connector.

[0015] An adjustable AC / DC voltage supply unit is connected to the processor and adjusts the AC / DC voltage value according to the processor's instructions, then sends it to the power output switching and control unit.

[0016] The power output switching and control unit is connected to the adjustable AC / DC voltage supply unit and is used to adjust the output voltage to be fed into the fourth set of terminals of the electrical connector.

[0017] The processor is used to respond to simulation status commands, configure the status or value of the corresponding unit, change the corresponding unit to different states, and realize the full-state simulation of the system.

[0018] It should be noted that each of the first, second, third, and fourth terminal groups includes at least one terminal.

[0019] As an alternative implementation, the voltage input switching and monitoring unit obtains the power supply provided by the power supply panel module test bench under test.

[0020] As an alternative implementation, the power output switching and control unit sends the output power back to the test bench of the power supply panel module under test via an electrical connector, consuming a specified power.

[0021] As an alternative implementation, the status input includes at least one of the following: master-slave interlock input, module master-slave signal input, master-slave module switching input, master-slave power supply working indication input, and backup module power supply direct auxiliary point.

[0022] As an optional implementation, the status output includes at least one of the following: alarm information, over-temperature information, current sharing information, main / standby interlock output, module main / standby signal output, main / standby module parallel operation output, main / standby module switching output, main / supplementary power supply working indication output, and standby module power supply direct supply auxiliary point lead-out.

[0023] As an alternative implementation, the processor is configured with simulation software, which is used to receive user input and adjust the output of the state output switching and control unit and the adjustable AC / DC voltage supply unit according to the user input to realize state configuration.

[0024] Furthermore, the status configuration includes normal working status and abnormal working status configuration.

[0025] As an alternative implementation, the processor is configured to acquire the current input voltage value and status input, and compare them with the AC / DC voltage supply voltage and status output configured in the simulation to determine whether the function / performance of the power supply module test bench under test is normal.

[0026] The working method of the above system includes the following steps:

[0027] The full-state simulation system of the power supply module and the test bench of the power supply module under test are connected using electrical connectors.

[0028] The power supply module full-state simulation system is used to simulate different power supply modules one by one, and the simulated power supply modules are set to be in different working states.

[0029] The test bench for the power supply module under test is used to test the working status of the simulated power supply module and analyze the test results. If the test results of the test bench for the power supply module under test can correctly reflect the status of the simulated power supply module, then the test bench for the power supply module under test is considered to be functioning / performing normally.

[0030] As an alternative implementation method, the process of simulating different power supply modules one by one using a power supply module full-state simulation system, and setting the simulated power supply modules to be in different working states includes:

[0031] Determine the model and parameters of the power supply module to be simulated;

[0032] The power supply module full-state simulation system receives the determined power supply module model and parameters, as well as the configured voltage input, power output, input status, and output status.

[0033] Based on the configured voltage input, power output, input state, and output state, the output of the state output switching and control unit and the adjustable AC / DC voltage supply unit are adjusted to achieve state adjustment;

[0034] Based on the results obtained by the voltage input switching and monitoring unit and the status input switching and monitoring unit, determine whether they match the information after status adjustment. If they do, the test bench for the power supply panel module under test is functioning / performing normally under the current status.

[0035] Change the configured voltage input, power output, input status, and output status, repeat the status adjustment and determination process until all statuses or target statuses of the power supply module to be simulated are traversed, and the test is completed.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] This invention provides a full-state simulation system for power supply modules, which can simulate all working states of all modules. By comparing the test results of the power supply module test bench with the set values ​​of the simulation system, the functions and performance of the power supply module test benches provided by various manufacturers can be evaluated.

[0038] The system provided in this embodiment can be used by power supply module test bench manufacturers for factory testing of their test benches, and also by the railway system for functional evaluation of test benches provided by various manufacturers. The use of this system is of great significance for the railway system to configure high-quality power supply module test benches, thereby ensuring the quality of power supply modules and the safety of railway operations.

[0039] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0040] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0041] Figure 1 This is a system connection diagram of a power supply module test bench in the prior art when testing the module;

[0042] Figure 2 This is a system connection diagram of a power supply module full-state simulation system testing a power supply module test bench according to one embodiment.

[0043] Figure 3 This is a schematic diagram of the full-state simulation system structure of a power supply module according to one embodiment. Detailed Implementation

[0044] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0045] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0046] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0047] Where there is no conflict, the embodiments and features described in this application may be combined with each other.

[0048] Example 1

[0049] As described in the background section, due to the wide variety of power supply modules, and the fact that a user only uses a small portion of them and only in a certain state (e.g., most are normal, but a small portion may have insufficient capacity, i.e., voltage error exceeds the range under full load output, or alarm terminals do not short-circuit after power-on), it is impractical for users to use a test bench to test actual modules to determine whether the test bench can achieve the functions claimed by the manufacturer. Furthermore, because railway operation safety is of paramount importance, there are strict requirements for the quality of power supply modules, which also places strict quality requirements on power supply module test benches.

[0050] First, some necessary explanations are needed. The existing power supply module test bench connects the power supply module as follows when testing the power supply module: Figure 1 As shown. Since all power supply modules use a standardized JMD-37 electrical connector (or DL-37 electrical connector in some embodiments) as their interface with the power supply backplane, all power supply module test benches provide a cable with a JMD-37 electrical connector for users to connect the module under test and complete the module testing.

[0051] This embodiment provides a full-state simulation system for a power supply module, such as... Figure 2 As shown, replacing Figure 1 The power supply module under test is simulated by the full-state simulation system of the power supply module to simulate all states of all modules, thereby verifying whether the power supply module test bench can effectively test all modules and all states of the modules, and further verifying whether the function and performance of the power supply module test bench meet the requirements.

[0052] When the power supply module full-state simulation system is working, it performs the following functions through the JMD-37 electrical connector: 1) Obtain the power supply provided by the power supply module test bench, which is generally AC 176-253V variable or three-phase 380V, and some models use three-phase 99V; 2) Send the output power back to the test bench through the JMD-37 interface to consume the specified power; 3) Obtain the necessary input working status provided by the test bench, such as main / standby interlock input, module main / standby signal input, main / standby module switching input, main / supplementary power supply working indication input, and standby module power supply direct auxiliary point introduction, etc.; 4) Send the output status to the test bench through the JMD-37 interface, such as alarm, over-temperature, current sharing, main / standby interlock output, module main / standby signal output, main / standby module parallel output, main / standby module switching output, main / supplementary power supply working indication output, and standby module power supply direct auxiliary point lead-out, etc.

[0053] The power supply module full-state simulation system simulates the functions of all power supply modules through software and simulates all working states of all modules (including normal and various abnormal states) based on user operations. By checking whether the test results of the power supply module test bench can correctly reflect the state settings of the power supply module full-state simulation system, the functional and performance tests of the power supply module test bench can be completed.

[0054] Specifically, a full-state simulation system for a power supply module, such as... Figure 3 As shown, it includes a computer, a voltage input switching and monitoring unit, a status input switching and monitoring unit, a status output control switching and monitoring unit, a power output switching and control unit, and an adjustable AC / DC voltage supply unit.

[0055] The system comprises the following components: a voltage input switching and monitoring unit monitors the designated terminals of the JMD-37 interface, measures the current input voltage value, and sends the result to the computer; a status input switching and monitoring unit monitors the designated terminals of the JMD-37 interface and sends the result to the computer; a status output switching and control unit sets the module's status output according to the computer's instructions and sends it to the designated terminals of the JMD-37 interface; an adjustable AC / DC voltage supply unit provides different AC / DC voltage values ​​according to the computer's instructions and sends them to the power output switching and control unit; a power output switching and control unit sends the output voltage to the designated terminals of the JMD-37 interface according to the computer's instructions; and an industrial computer runs simulation system software, controlling other units according to the user's settings on the operating interface to simulate different modules and their various states.

[0056] Due to the wide variety of modules, their diverse functions and parameters, and the irregular use of input / output interfaces, a unified description is difficult. For convenience, this embodiment uses a relatively simple Z1 module from a certain company as an example to describe the full-state simulation principle of the system designed for the module. The Z1 module is a high-frequency DC module, using terminals 1, 2-7, and 8 of the JMD-37 as input LN, terminals 34, 36-35, and 37 as the positive and negative terminals of the DC output, terminals 14-15 as the input status, and terminals 17-18 as the alarm signal output.

[0057] The Z1 module has two states: normal and abnormal. Abnormal states can be further categorized into several types: input connection failure, output connection failure, input status failure, output status failure, input voltage range not meeting specifications, large output voltage error, and load capacity not meeting specifications. The system designed in this embodiment can simulate the module's normal state and one, several, or even all abnormal states through software settings.

[0058] The system can simulate the normal working state of the Z1 module by simultaneously performing the following operations under software control:

[0059] (1) Introduce the input voltage of terminals 1,2-7,8 ​​into the module;

[0060] (2) The module can work when there is input voltage at 1-7, 2-8, 1-8, and 2-7;

[0061] (3) When the input voltage of terminals 1,2-7,8 ​​varies between AC176-253V, the output of the module at terminals 34,35-36,37 is DC24V±3%.

[0062] (4) The DC24V voltage is sent out of the module through terminals 34, 35-36, and 37;

[0063] (5) When the status input terminals 14-15 are short-circuited, if the input meets the requirements, the output will be normal.

[0064] (6) When status input terminals 14-15 are open, there is no output at any time;

[0065] (7) When power is off, status outputs 17-18 are in an open circuit state;

[0066] (8) After power-on, status outputs 17-18 are in a short-circuit state.

[0067] (9) When the current output through terminals 34, 35-36, 37 varies within 0-85A, the output voltage varies within DC24V±3%.

[0068] By configuring the software to prevent the system from executing any one, two, three, ..., eight, or all of the above items, various fault states of the Z1 module can be simulated. Through software configuration, all states of the Z1 module can be simulated, achieving full-state simulation of the Z1 module.

[0069] For other modules, the requirements for normal operation are similar to those above and have been integrated into the software. Therefore, the system designed in this embodiment can realize full-state simulation of all modules.

[0070] Example 2

[0071] The testing method using the system provided in Example 1 includes the following steps:

[0072] The power supply module test bench is used to test different power supply modules one by one through a full-state simulation system. The modules are configured to operate in different states, and then the test bench is used to test the simulated modules. If, after statistical analysis, the test results consistently and accurately reflect the state of the simulated modules, the power supply module test bench is considered to be functioning correctly.

[0073] The following test procedure is given using the aforementioned Z1 DC output module under a certain set working state as an example.

[0074] Step 1: Set a certain state of module Z1 on the full-state simulation system of power supply module.

[0075] Selecting a Z1 DC output module from a specific manufacturer on the computer interface will automatically simulate the module's basic functions and characteristics. Then, following the prompts on the interface, you can set the module's voltage input, power output, input status, and output status.

[0076] Step 2: Connect the power supply module test bench to the power supply module full-state simulation system.

[0077] According to the prompts in the software interface, connect the DL37 interface of the power supply module test bench and the DL37 interface of the power supply module full-state simulation system using a dedicated cable.

[0078] Step 3: Use the power supply module test bench to test the simulated Z1 module.

[0079] Following the operating instructions from the power supply module test bench manufacturer, start the test bench to test the simulated module.

[0080] Step 4: Compare the test results of the test bench with the settings of the power supply module full-state test system, evaluate and record the function of the power supply module test bench.

[0081] Following the above process, all states of the module (including normal and various abnormal states) are traversed and tested one by one, thus completing the testing of one type of module. Then, by traversing all modules and based on the recorded state settings and test results from the test bench, an evaluation result of the test bench's performance can be given.

[0082] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0083] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0084] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0085] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0086] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made by those skilled in the art without creative effort within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A full-state simulation system for a power supply module, characterized in that, It includes a voltage input switching and monitoring unit, a status input switching and monitoring unit, a status output switching and control unit, a power output switching and control unit, an adjustable AC / DC voltage supply unit, and a processor, wherein: The voltage input switching and monitoring unit is used to detect the first set of terminals of the electrical connector connected to the test bench of the power supply panel module under test, obtain the current input voltage value, and transmit the result to the processor. The status input switching and monitoring unit is connected to the second set of terminals of the electrical connector, acquires status input, and transmits it to the processor; The status output switching and control unit is connected to the processor and sets the status output according to the processor's instructions to send it to the third set of terminals of the electrical connector. An adjustable AC / DC voltage supply unit is connected to the processor and adjusts the AC / DC voltage value according to the processor's instructions, then sends it to the power output switching and control unit. The power output switching and control unit is connected to the adjustable AC / DC voltage supply unit and is used to adjust the output voltage to be fed into the fourth set of terminals of the electrical connector. The processor is used to respond to simulation status commands, configure the status or value of the corresponding unit, change the corresponding unit to different states, and realize the full-state simulation of the system. The processor is configured to acquire the current input voltage value and status input, and compare them with the AC / DC voltage supply voltage and status output configured in the simulation to determine whether the function / performance of the power supply panel module test bench is normal.

2. The full-state simulation system for a power supply module as described in claim 1, characterized in that, The voltage input switching and monitoring unit obtains the power supply provided by the power supply panel module test bench under test.

3. The full-state simulation system for a power supply module as described in claim 1, characterized in that, The power output switching and control unit sends the output power back to the test bench of the power supply panel module under test through an electrical connector, consuming the specified power.

4. The full-state simulation system for a power supply module as described in claim 1, characterized in that, The status inputs include at least one of the following: master / slave interlock input, module master / slave signal input, master / slave module switching input, master / slave power supply working indication input, and backup module power supply direct auxiliary point input.

5. The full-state simulation system for a power supply module as described in claim 1, characterized in that, The status output includes at least one of the following: alarm information, over-temperature information, current sharing information, main / standby interlock output, module main / standby signal output, main / standby module parallel operation output, main / standby module switching output, main / supplementary power supply working indication output, and standby module power supply direct supply auxiliary point lead-out.

6. The full-state simulation system for a power supply module as described in claim 1, characterized in that, The processor is equipped with simulation software, which is used to receive user input and adjust the output of the state output switching and control unit and the adjustable AC / DC voltage supply unit according to the user input to realize state configuration.

7. The full-state simulation system for a power supply module as described in claim 6, characterized in that, The status configuration includes normal working status and abnormal working status configuration.

8. A method of operating the system based on any one of claims 1-7, characterized in that, Includes the following steps: The full-state simulation system of the power supply module and the test bench of the power supply module under test are connected using electrical connectors. The power supply module full-state simulation system is used to simulate different power supply modules one by one, and the simulated power supply modules are set to be in different working states. The test bench for the power supply module under test tests the working state of the simulated power supply module and analyzes the test results. If the test results of the test bench for the power supply module under test can correctly reflect the state of the simulated power supply module, then the test bench for the power supply module under test is considered to be functioning / performing normally.

9. The working method as described in claim 8, characterized in that, The process of simulating different power supply modules one by one using a full-state simulation system for power supply modules, and setting the simulated power supply modules to be in different working states, includes: Determine the model and parameters of the power supply module to be simulated; The power supply module full-state simulation system receives the determined power supply module model and parameters, as well as the configured voltage input, power output, input status, and output status. Based on the configured voltage input, power output, input state, and output state, the output of the state output switching and control unit and the adjustable AC / DC voltage supply unit are adjusted to achieve state adjustment; Based on the results obtained by the voltage input switching and monitoring unit and the status input switching and monitoring unit, determine whether they match the information after status adjustment. If they do, the test bench for the power supply panel module under test is functioning / performing normally under the current status. Change the configured voltage input, power output, input status, and output status, repeat the status adjustment and determination process until all statuses or target statuses of the power supply module to be simulated are traversed, and the test is completed.

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