Relay on-off performance detection device

Abstract

The invention relates to a relay on-off performance detection device. The device comprises a PLC control module; the power supply module outputs a power supply and is used for supplying power to the PLC control module; the resistance measurement module is in communication connection with the PLC control module, the power supply supplies power to the resistance measurement module, the resistance measurement module is provided with a plurality of groups of resistance measurement ends, and a first measurement end and a second measurement end in one group of resistance measurement ends are connected to one end and the other end of one contact of a relay to be measured respectively; and the PLC control module controls to enter a resistance measurement mode. According to the invention, the on-off performance of the relay can be detected based on multiple dimensions of the single absolute value and mean square error of the contact resistance, the stability and reliability of the contact are comprehensively judged, and the actual working state of the relay is accurately reflected.

Description

Technical Field

[0001] The invention relates to the technical field of electrical engineering, and in particular to a relay on-off performance detection device. Background Art

[0002] In power systems and automation control systems, relays are an important electrical component whose performance is directly related to the reliability of the entire system. After long-term operation, the contact resistance of relays may increase due to oxidation and wear of the contacts, affecting the on-off performance and thus the normal operation of the system.

[0003] Traditionally, relay performance testing mainly relies on detecting the single absolute value of the contact resistance of the contacts to evaluate the on-off performance of the relay. However, the contact resistance of the contacts may be affected by many factors (such as contact pressure, temperature changes, etc.) in actual applications. It is difficult to fully reflect the true performance of the relay by simply relying on the single absolute value of the contact resistance. Therefore, a solution is needed that can comprehensively and reliably detect the on-off performance of the relay. Summary of the invention

[0004] In response to the problems pointed out in the background technology, the present invention provides a relay on-off performance detection device, which can detect the on-off performance of the relay based on the single absolute value and mean square error of the contact resistance in multiple dimensions, comprehensively judge the stability and reliability of the contacts, and accurately reflect the actual working state of the relay.

[0005] In order to solve the above technical problems, the present invention proposes the following technical solutions: The present application provides a relay on-off performance detection device, comprising: PLC control module; A power supply module, which outputs a power supply for supplying power to the PLC control module; A resistance measuring module is communicatively connected with the PLC control module and powered by the power supply. The resistance measuring module has multiple groups of resistance measuring terminals, wherein a first measuring terminal and a second measuring terminal in a group of resistance measuring terminals are respectively connected to one end and the other end of a contact of a relay to be measured. The PLC control module controls to enter a resistance measuring mode, and the resistance measuring mode includes the following: S11: Initialize the number of tests n; S12: Controlling the resistance measurement module to be powered; S13: Controlling the relay to be tested to lose power, and the resistance measuring module measures the contact resistance value of each normally closed contact of the relay to be tested; S14: controlling the relay to be tested to be powered, and the resistance measuring module measuring the contact resistance of each normally open contact of the relay to be tested; S15: Determine whether the contact resistance of any contact among all the contacts is within the corresponding preset range. If so, n=n+1 and proceed to S16; otherwise, proceed to S19; S16: Determine whether n reaches the preset number N, if yes, proceed to S17, otherwise, return to S13; S17: Calculate the mean square error of the contact resistance corresponding to any contact point; S18: Determine whether any mean square error is within the corresponding preset variance range. If so, determine that the switching performance of the relay to be tested is fault-free. If not, proceed to S19; S19: Determine whether the on-off performance of the relay to be tested has a fault.

[0006] In some embodiments of the present application, the detection device includes: A working relay, whose coil is powered by the PLC control module, all contacts of the relay to be tested are connected in parallel to multiple ports of the PLC control module, and the normally open contact of the working relay is connected to the power supply line through which the power supply supplies power to all contacts; Before entering the resistance measurement mode, the relay to be tested is first subjected to a power-on qualification test, the power-on qualification test comprising: S21: Initialize the number of power-on cycles m; S22: Control the relay to be tested and the working relay to be energized; S23: When the PLC control module does not receive a signal at the port corresponding to the normally open contact, the PLC control module outputs a signal indicating that the corresponding normally open contact is abnormal, otherwise, the PLC control module outputs a signal indicating that the corresponding normally open contact is normal; S24: switching and controlling the relay to be tested to lose power; S25: When the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the PLC control module outputs a signal indicating that the corresponding normally closed contact is abnormal; otherwise, the PLC control module outputs a signal indicating that the corresponding normally closed contact is normal; S26: m=m+1; S27: Determine whether m reaches the preset number of power-on cycles M, if so, proceed to S28, otherwise, return to S22; S28: If the PLC control module outputs a signal indicating that the corresponding normally closed contact or the corresponding normally open contact is abnormal, it means that the relay to be tested is not energized properly. Otherwise, it means that the relay to be tested is energized properly, and then enters the resistance measurement mode.

[0007] In some embodiments of the present application, the detection device includes: A display screen, on which a first display unit is configured; During the power-on qualified test, when the relay to be tested is powered on and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or when the relay to be tested is powered off and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the first display unit displays.

[0008] In some embodiments of the present application, the first display unit is an alarm number display box; Before the power-on qualified test is performed, the alarm number displayed in the alarm number display box is zero; During the power-on qualified test, when the relay to be tested is energized and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or when the relay to be tested is de-energized and the PLC control module does not receive a signal at the port corresponding to the normally open contact, the number of alarms increases by 1.

[0009] In some embodiments of the present application, the first display unit is an alarm light configured on the display screen for indicating each contact of the relay to be tested; During the power-on qualified test, when the relay to be tested is powered and the PLC control module does not receive a signal at the port corresponding to the normally open contact, the alarm light corresponding to the normally open contact issues an alarm indication; During the power-on qualified test, when the relay to be tested loses power and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the alarm light corresponding to the normally closed contact issues an alarm indication.

[0010] In some embodiments of the present application, the detection device further includes: An alarm prompt unit, which is connected to a port of the PLC control module and is powered by the PLC control module; During the power-on qualified test, if the relay to be tested is powered on and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or if the relay to be tested is powered off and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the alarm prompt unit issues an alarm prompt; During the resistance measurement mode, when it is determined that the on-off performance of the relay to be measured has a fault, the PLC control module controls the alarm prompt unit to issue an alarm prompt.

[0011] In some embodiments of the present application, the detection device includes: A display screen, on which a second display unit is configured; During the power-on qualified test, when the relay to be tested is energized and the PLC control module receives a signal at the port corresponding to the normally open contact, or when the relay to be tested is de-energized and the PLC control module receives a signal at the port corresponding to the normally open contact, the second display unit displays.

[0012] In some embodiments of the present application, the detection device further includes: The display screen is installed on the side panel of the cabinet, the PLC control module, the power supply module and the resistance measurement module are all installed in the cabinet, and the relay seat for installing the relay to be tested is installed on the table panel of the cabinet.

[0013] In some embodiments of the present application, the detection device further includes: A plurality of indicator lights, each indicator light being connected to a port of the PLC control module and powered by the PLC control module, and the number of the indicator lights being the same as the number of all contacts of the relay to be tested; During the resistance measurement mode, when the contact resistance of a corresponding contact exceeds a corresponding preset range, the PLC control module controls the indicator light corresponding to the contact to light up.

[0014] In some embodiments of the present application, the detection device further includes: A communication relay is connected to the port of the PLC control module and is controlled by the power supply of the PLC control module. The normally open contact of the communication relay is connected to the power supply line for the power supply to supply power to the resistance measurement module.

[0015] Compared with the prior art, the advantages and beneficial effects of the present invention are: (1) First, the contact resistance of a single contact is used for judgment. When the contact resistance of a single contact meets the corresponding preset range, the mean square error corresponding to the contact resistance of the contact is detected. The on-off performance of the relay to be tested is measured by the two fault detection dimensions of a single resistance value and its mean square error, which accurately reflects the actual working state of the relay and avoids the problem of misjudgment caused by the use of simple judgment logic.

[0016] (2) The preset range and preset variance range of the resistance of a single contact can be determined through dynamic threshold adjustment, which can adapt to slight changes in relay performance under different working conditions, thereby avoiding misjudgment without reducing sensitivity. This intelligent and flexible threshold setting method enhances the applicability of the detection device and can adapt to more complex industrial environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, a brief introduction is given below to the drawings required for use in the embodiments of the present invention or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0018] Figure 1 It is a flow chart of the relay on-off performance detection device of the present invention when performing resistance measurement mode; Figure 2 The electrical principle diagram of the relay on-off performance detection device of the present invention; Figure 3 A three-dimensional diagram of a relay on-off performance detection device according to the present invention; Figure 4 It is a side view of the relay on-off performance detection device of the present invention; Figure 5 For along Figure 4 Sectional view in the AA direction; Figure 6 This is a flow chart of the relay on-off performance detection device of the present invention when performing a power-on qualified test; Reference numerals: 100, cabinet; 110, right side panel; 120, left side panel; 130, top side panel; 140, front lower side panel; 140', front upper side panel; 150, rear side panel; 160, table panel; 170, indicator light; 180, protective cover; 190, relay socket to be tested; 200, PLC control module; 300, power module; 400, resistance measurement module; 500, display screen; 600, switch; KA, relay to be tested; KA1, working relay; KA2, communication relay. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0020] In the description of the present application, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0021] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise specified, "plurality" means two or more.

[0022] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" 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 it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0023] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0024] The disclosure below provides many different embodiments or examples to realize different structures of the present invention. In order to simplify the disclosure of the present invention, the parts and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present invention. In addition, the present invention can repeat reference numbers and / or reference letters in different examples, and this repetition is for the purpose of simplicity and clarity, which itself does not indicate the relationship between the various embodiments and / or settings discussed. In addition, the present invention provides various specific examples of processes and materials, but those of ordinary skill in the art can be aware of the application of other processes and / or the use of other materials.

[0025] In order to flexibly and reliably detect the on-off performance of the relay, see Figures 1 to 6 The present application relates to a relay on-off performance detection device, which includes a PLC control module 200, a power supply module 300 and a resistance measurement module 400.

[0026] The PLC control module 200 serves as a data processing center, which is powered by the power module 300 and communicates with the resistance measurement module 400 .

[0027] The resistance measuring module 400 is also powered by the power supply module 300 and has multiple groups of resistance measuring terminals, one group of resistance measuring terminals includes a first measuring terminal and a second measuring terminal, and the number of the multiple groups of resistance measuring terminals is greater than or equal to the number of all contacts of the relay to be tested, so that the resistance measuring module 400 can meet the requirements of detecting the contact resistance of multiple contacts of the relay KA to be tested and judging the on-off performance of the contacts.

[0028] See also Figure 2 , which shows that the relay to be tested has four normally closed contacts OS1 / OS2 / OS3 / OS4 and four normally open contacts OC1 / OC2 / OC3 / OC4, and the resistance measurement module 400 has eight groups of resistance measurement terminals: R1+ / R1-, R2+ / R2-, R3+ / R3-, R4+ / R4-, R5+ / R5-, R6+ / R6-, R7+ / R7- and R8+ / R8-.

[0029] For example, a group of resistance measuring terminals includes a first measuring terminal R1+ and a second measuring terminal R1-, which are used to detect the resistance value of the contact resistance of the normally open contact OC1; a group of resistance measuring terminals includes a first measuring terminal R2+ and a second measuring terminal R2-, which are used to detect the resistance value of the contact resistance of the normally open contact OC2, and so on.

[0030] When the resistance measuring module 400 is powered on, the first measuring end is connected to one end of a closed contact (e.g., a normally open contact or a normally closed contact) and the second measuring end is connected to the other end of the closed contact. At this time, the resistance measuring module 400 can measure the contact resistance of the closed contact through the first measuring end and the second measuring end.

[0031] In some embodiments of the present application, for the convenience of detection, see Figures 1 to 3 The detection device has a cabinet 100, and the bottom of the cabinet 100 has movable wheels to facilitate the movement of the detection device during detection. The PLC control module 200, the power module 300 and the resistance measurement module 400 are all arranged in the cabinet 100.

[0032] The cabinet body 100 is formed by a frame and a plurality of side panels, the side panels including a left side panel 120, a right side panel 110, a rear side panel 150, a front lower side panel 140, a front upper side panel 140', a top side panel 130 and a table panel 160, wherein the table panel 160 is laterally docked between the front upper side panel 140' and the front lower side panel 140 along the front-to-back direction of the cabinet body 100.

[0033] In order to facilitate the detection of the contacts of the relay KA, a relay seat 190 for mounting the relay KA is provided on the table panel 160, and a flippable protective cover 180 can be provided thereon, and the protective cover 180 can be provided as a transparent plastic cover.

[0034] In some embodiments of the present application, see Figure 2 The power module 300 is an AC220V to DC24V module, and an AC circuit breaker is connected between the AC220V and the input end of the power module 300 as an AC main switch Q1, and a DC circuit breaker is connected at the output end of the power module 300 as a DC main switch Q2.

[0035] The power supply module 300 can supply power to the PLC control module 200 and the resistance measurement module 400 only when both the AC main switch Q1 and the DC main switch Q2 are closed.

[0036] The AC main switch Q1 and the DC main switch Q2 are arranged on the front upper side plate 140' of the cabinet 100 (see Figure 3 The middle front upper side plate 140' is shown in a dotted box) for easy user operation.

[0037] The PLC control module 200 controls the entry into the resistance measurement mode to detect the contact resistance value of the contact points of the relay KA to be measured.

[0038] As follows, it will be combined Figure 1 and Figure 2 , the process of resistance measurement mode is explained.

[0039] S11: Initialize the number of tests n.

[0040] First, initialize the number of tests n=0.

[0041] S12: Control the resistance measurement module 400 to be powered.

[0042] When the resistance measurement module 400 is used, the resistance measurement module 400 is controlled to be powered on, and when the resistance measurement module 400 is not used, the resistance measurement module 400 is controlled not to be powered on, so as to ensure the measurement accuracy of the resistance measurement module 400 .

[0043] In some embodiments of the present application, whether the resistance measurement module 400 is powered on is controlled by the normally open contact KA2 of the communication relay KA2.

[0044] In some embodiments of the present application, the relay to be tested KA and the communication relay KA2 are both connected to corresponding ports of the PLC control module 200, and are controlled by the PLC control module 200 to control the energization / de-energization of the coil of the relay to be tested KA and the energization / de-energization of the coil of the communication relay KA2.

[0045] When the PLC control module 200 controls the coil of the communication relay KA2 to be energized, the direct current DC24V powers the coil, otherwise, the coil is not powered.

[0046] In some embodiments of the present application, other control switches may be used to replace the normally open contact of the communication relay KA2 to control the power on or off of the resistance measurement module 400.

[0047] In some embodiments of the present application, the resistance measurement module 400 uses eight resistance measurement modules, and the resistance range is 0.02MΩ~1MΩ.

[0048] As described above, the eight-resistance measurement module has eight groups of resistance measurement terminals: R1+ / R1-, R2+ / R2-, R3+ / R3-, R4+ / R4-, R5+ / R5-, R6+ / R6-, R7+ / R7- and R8+ / R8-.

[0049] The relay to be tested has four normally closed contacts OS1 / OS2 / OS3 / OS4 and four normally open contacts OC1 / OC2 / OC3 / OC4, so each group of resistance measuring terminals is used to measure the contact resistance value of a corresponding contact.

[0050] See also Figure 2 , R1+ / R1- are respectively connected to the two ends of OC1, R2+ / R2- are respectively connected to the two ends of OC2, R3+ / R3- are respectively connected to the two ends of OC3, R4+ / R4- are respectively connected to the two ends of OC4, R5+ / R5- are respectively connected to the two ends of OS1, R6+ / R6- are respectively connected to the two ends of OS2, R7+ / R7- are respectively connected to the two ends of OS3, and R8+ / R8- are respectively connected to the two ends of OS4.

[0051] S13: Control the relay KA to be tested to lose power, and the resistance measurement module 400 measures the contact resistance of each normally closed contact of the relay KA to be tested.

[0052] First, the PLC control module 200 keeps the relay KA to be tested de-energized. At this time, the four normally open contacts OC1 / OC2 / OC3 / OC4 of the relay KA to be tested are all open, and the four normally closed contacts OS1 / OS2 / OS3 / OS4 of the relay KA to be tested are all closed. At this time, R5+ / R5- detects the resistance value R55 of the contact resistance of the normally closed contact OS1, R6+ / R6- detects the resistance value R66 of the contact resistance of the normally closed contact OS2, R7+ / R7- detects the resistance value R77 of the contact resistance of the normally closed contact OS3, and R8+ / R8- detects the resistance value R88 of the contact resistance of the normally closed contact OS4.

[0053] In some embodiments of the present application, the resistance measurement module 400 also communicates with the PLC control module 200, so the measured resistance values ​​R55, R66, R77 and R88 can be communicated to the PLC control module 200 for processing.

[0054] In the present application, the detection device also includes a switch 600 (see Figure 5 ), which is used to communicate and connect the PLC control module 200 and the resistance measurement module 400.

[0055] The PLC control module 200 has a first network port (not shown), which is connected to the network port of the switch 600; the switch 600 also has a communication port (such as an RS485 port, not shown), which is communicatively connected to the communication port (such as an RS485 port) of the resistance measurement module 400.

[0056] The switch 600 is also powered by a DC 24V power supply output by the power module 300 .

[0057] S14: the relay KA to be tested is controlled to be energized, and the resistance measurement module 400 measures the contact resistance of each normally open contact of the relay KA to be tested.

[0058] The PLC control module 200 keeps the relay KA to be tested energized. At this time, the four normally open contacts OC1 / OC2 / OC3 / OC4 of the relay KA to be tested are all closed, and the four normally closed contacts OS1 / OS2 / OS3 / OS4 of the relay KA to be tested are all open. At this time, R1+ / R1- detects the resistance value R11 of the contact resistance of the normally closed contact OC1, R2+ / R2- detects the resistance value R22 of the contact resistance of the normally closed contact OC2, R3+ / R3- detects the resistance value R33 of the contact resistance of the normally closed contact OC3, and R4+ / R4- detects the resistance value R44 of the contact resistance of the normally closed contact OC4.

[0059] The resistance measurement module 400 may communicate the measured resistance values ​​R11 , R22 , R33 , and R44 to the PLC control module 200 for processing via the switch 600 .

[0060] S15: Determine whether the contact resistance of any contact among all contacts is within the corresponding preset range. If so, n=n+1 and proceed to S16; otherwise, proceed to S19.

[0061] In order to determine the contact on-off performance of the contactor KA to be tested, a corresponding preset range is set for the contact resistance of each contact, and the preset range corresponding to each contact may be the same or different.

[0062] After the PLC control module 200 receives R11, R22, R33, R44, R55, R66, R77 and R88, it will determine whether there is a contact resistance value exceeding the corresponding preset range based on the corresponding preset range.

[0063] When it is determined that the contact resistance of the corresponding contact exceeds the corresponding preset range, it indicates that the contact is severely oxidized, and it is determined that the switching performance of the relay KA to be tested has a fault.

[0064] When it is determined that the contact resistance of the corresponding contacts does not exceed the corresponding preset range, in order to reliably and accurately determine the actual working state of the relay KA to be tested, the mean square error calculation is introduced for the contact resistance of each contact, and the stability of the contact is evaluated by the discrete degree of multiple resistance measurements. On the basis of maintaining high-precision measurement, the stability and reliability of the contact can be judged more comprehensively and flexibly.

[0065] After using a single resistance value for comparison and then measuring it with the mean square error, we can determine problems such as random fluctuations or poor stability caused by poor contact. With a more detailed fault analysis perspective, we can discover potential relay faults and greatly improve the reliability and accuracy of detection.

[0066] Therefore, in order to satisfy the requirement that the resistance values ​​of the contact resistances of the contacts do not exceed the corresponding preset range, it is necessary to return to measure the resistance value of the contact resistance of each contact for multiple times, and therefore, the number of tests is increased by 1.

[0067] S16: Determine whether n reaches the preset number of times N, if so, proceed to S17, otherwise, return to S13.

[0068] In some embodiments of the present application, the preset number N is preset and can be set according to test requirements.

[0069] If the number of tests reaches N, it means that the upper limit of the number of tests is reached, and the process enters S17 to calculate the mean square error of the contact resistance of each contact point.

[0070] If the number of tests has not reached N, it is necessary to return to S13 to cyclically control the coil of the relay KA to be tested to de-energize / energize to obtain R11, R22, R33, R44, R55, R66, R77 and R88.

[0071] S17: Calculate the mean square error corresponding to the contact resistance of any contact point.

[0072] In S16 as described above, the resistance values ​​R11, R22, R33, R44, R55, R66, R77 and R88 of each contact point are obtained each time in N times. Therefore, the PLC control module 200 uses the mean square error formula to obtain the mean square error corresponding to the contact resistance of each contact point to measure the volatility of the contact point within N times.

[0073] For example, after N times, the mean square errors corresponding to the normally open contacts OC1 / OC2 / OC3 / OC4 and the four normally closed contacts OS1 / OS2 / OS3 / OS4 are S1, S2, S3, S4, S5, S6, S7 and S8 respectively.

[0074] S18: Determine whether any mean square error is within the corresponding preset variance range. If so, determine that the switching performance of the relay KA to be tested is not faulty. If not, proceed to S19.

[0075] In order to determine the contact on-off performance of the contactor KA to be tested, a corresponding preset variance range is set for the contact resistance of each contact, and the preset variance range corresponding to each contact may be the same or different.

[0076] After the PLC control module 200 receives S1, S2, S3, S4, S5, S6, S7 and S8, it determines whether the mean square error value corresponding to the contact is within the corresponding preset variance range according to the corresponding preset variance range.

[0077] If so, it means that the contact of the relay KA to be tested is stable and there is no random fluctuation caused by poor contact, and it is determined that the on-off performance of the relay KA to be tested is fault-free.

[0078] S19: Determine whether there is a fault in the on-off performance of the relay KA to be tested.

[0079] If at least one mean square error exceeds the corresponding preset variance range, it indicates that there is a random fluctuation caused by unstable contact or poor contact, and it is determined that the switching performance of the relay KA to be tested has a fault. At this time, it is necessary to intervene in the fault inspection of the relay KA to be tested.

[0080] As mentioned above, by combining the two fault dimension analyses of single resistance comparison and mean square error comparison, the on-off performance of the relay KA to be tested can be comprehensively and reliably determined.

[0081] The preset range and preset variance range as described above can be adjusted dynamically to adapt to slight changes in relay performance under different working conditions, thereby avoiding misjudgment without reducing detection sensitivity. This intelligent and flexible adjustment method makes the device more adaptable and able to adapt to more complex industrial environments.

[0082] In some embodiments of the present application, in order to achieve reliable use of the detection device, see Figure 2 An emergency stop button SB0, a start button SB1, a stop button SB2 and a reset button SB3 connected to the PLC control module 200 are also provided.

[0083] When the start button SB1 is pressed, the detection device starts working; when the stop button SB2 is pressed, the detection device stops working; when the emergency stop button SB0 is pressed, the detection device is stopped urgently; when the reset button SB3 is pressed, the detection device is reset.

[0084] See also Figure 3 As shown in the dotted line frame, the emergency stop button SB0, the start button SB1, the stop button SB2 and the reset button SB3 may be arranged on the front upper side plate 140' of the cabinet 100 to facilitate user operation.

[0085] In order to detect the on / off status of each contact of the relay KA to be tested, in some embodiments of the present application, the detection device also includes a plurality of indicator lights 170, each indicator light 170 is connected to a port of the PLC control module 200 and is powered by the PLC control module 200, and the number of the indicator lights 170 is the same as the number of all contacts of the relay KA to be tested.

[0086] That is, see Figure 2 When the relay KA to be tested has eight contacts OC1, OC2, OC3, OC4, OS1, OS2, OS3 and OS4, eight indicator lights HL1, HL2, HL3, HL4, HL5, HL6, HL7 and HL8 are also set.

[0087] For example, when the contact resistance of contact OC1 exceeds the corresponding preset range, or its mean square deviation exceeds the corresponding preset variance range, indicator light HL1 lights up to indicate; when the contact resistance of contact OC2 exceeds the corresponding preset range, or its mean square deviation exceeds the corresponding preset variance range, indicator light HL2 lights up to indicate.

[0088] In some embodiments of the present application, eight indicator lights HL1, HL2, HL3, HL4, HL5, HL6, HL7 and HL8 may be arranged on the front upper side plate 140' of the cabinet 100 (see Figure 3 The indicator light 170 shown in the figure is convenient for the user to observe.

[0089] In some embodiments of the present application, in order to conveniently remind the user that the relay KA to be tested has a switching performance failure, the detection device also includes an alarm prompt unit.

[0090] The alarm prompt unit may be a buzzer or a sound broadcast unit.

[0091] In this application, see Figure 2 The alarm prompt unit is a buzzer BUZ.

[0092] The buzzer BUZ is connected to a port of the PLC control module 200 and is controlled by the PLC control module 200 for power supply.

[0093] When the on-off performance of the relay KA to be tested fails, the buzzer BUZ will emit a buzzing sound.

[0094] In some embodiments of the present application, see Figure 3 The buzzer BUZ can be arranged on the front upper side plate 140' of the cabinet 100 for the convenience of users to check.

[0095] In some embodiments of the present application, a display screen 500 may be provided. The display screen 500 may be a touch display screen 500, on which the number of tests, the resistance value of the contact resistance of each contact point during each measurement, etc. may be displayed.

[0096] See also Figure 3 The display screen 500 can be arranged on the front upper side plate 140 ′ of the cabinet 100 for user viewing convenience.

[0097] Relays will become old after running for a long time, so the power-on test of the relays will be screened. For example, on the railway, the contact resistance of some old relays of railway components will increase after running for a certain period of time. Continuing to use may cause false contact. Therefore, these old components need to be screened out and not used. Therefore, before the resistance measurement mode, the relay to be tested needs to be tested for power-on qualification.

[0098] After the power-on qualification test, enter the resistance measurement mode.

[0099] In some embodiments of the present application, see Figure 2 The detection device is also provided with a working relay KA1, the coil of which is connected to the port of the PLC control module 200 and is controlled by the PLC control module 200 for power supply.

[0100] The normally open contact of the working relay KA1 is connected to a power supply line through which the power supply output by the power module 300 supplies power to all contacts.

[0101] See also Figure 2One end of the normally open contact of the working relay KA1 is connected to the positive end of the power supply, and the other end of the normally open contact is connected to one end of all the contacts, and the other ends of all the contacts are connected to the corresponding ends of the PLC control module 200.

[0102] As follows, see Figure 2 and Figure 6 , the process of conducting a power-on qualification test on the relay KA to be tested is described as follows.

[0103] S21: Initialize the number of power-on cycles m.

[0104] First, initialize the number of power-on cycles m=0.

[0105] S22: Control the relay to be tested KA and the working relay KA1 to be energized.

[0106] When the PLC control module 200 controls the working relay KA1 to be energized, the normally open contact of the working relay KA1 is closed. At this time, the power supply provides power to all contact switches.

[0107] A plurality of display lights (not shown) may be configured on the display screen 500 , and the number of the plurality of display lights is equal to the number of all contacts of the relay KA to be tested.

[0108] When the AC main switch Q1 is turned on, the power module 300 is powered on and the power indicator light HL0 is lit.

[0109] When the DC main switch Q2 is turned on, the PLC control module 200 and the display screen 500 are powered and enter the standby state.

[0110] Press the start button SB1, the program runs, and the PLC control module 200 controls the relay to be tested KA and the working relay KA1 to be energized.

[0111] The normally open contacts of the working relay KA1 are closed, supplying power to the contacts of the relay to be tested KA.

[0112] S23: When the PLC control module 200 does not receive a signal at the port corresponding to the normally open contact, it outputs a signal indicating that the corresponding normally open contact is abnormal, otherwise it outputs a signal indicating that the corresponding normally open contact is normal.

[0113] When both the working relay KA1 and the relay KA to be tested are energized, the normally open contact of the relay KA to be tested is closed. If there is no problem with the normally open contact of the relay KA to be tested, the PLC control module 200 will output a normal signal corresponding to the normally open contact, otherwise it will output an abnormal signal.

[0114] In some embodiments of the present application, a second display unit (not shown) is configured on the display screen 500 .

[0115] The second display unit may be a plurality of display lights, the number of which is equal to the number of all contacts of the relay KA to be tested.

[0116] For example, when the number of contacts of the relay KA to be tested is eight, the number of the plurality of display lights is also eight.

[0117] During the power-on qualified test, the relay KA to be tested is energized and the PLC control module 200 receives a signal at the port corresponding to the normally open contact, indicating that the normally open contact is normal during this test, and the display light corresponding to the normally open contact is on, otherwise it is not on.

[0118] During the power-on qualified test, when the relay KA to be tested loses power and the PLC control module 200 receives a signal at the port corresponding to the normally closed contact, it means that the normally closed contact is normal during this test, and the display light corresponding to the normally closed contact lights up, otherwise it will not light up.

[0119] S24: Switching control makes the relay KA to be tested lose power.

[0120] After the relay KA to be tested is energized in S23, the relay KA to be tested may be controlled to be de-energized after a certain time (for example, 3 seconds).

[0121] At this time, the normally open contact of the relay KA to be tested is disconnected, the corresponding display light goes out, and the normally closed contact is closed.

[0122] S25: When the PLC control module 200 does not receive a signal at the port corresponding to the normally closed contact, it outputs a signal indicating that the corresponding normally closed contact is abnormal; otherwise, it outputs a signal indicating that the corresponding normally closed contact is normal.

[0123] When the relay KA to be tested loses power, the normally closed contact of the relay KA to be tested closes. If there is no problem with the normally closed contact of the relay KA to be tested, the PLC control module 200 will output a signal corresponding to the normal normally closed contact, otherwise it will output an abnormal signal.

[0124] When the corresponding normally closed contact is normal, the corresponding display light configured on the display screen 500 lights up, otherwise it does not light up.

[0125] In S23 and S25 as described above, the display lights corresponding to the contacts configured on the display screen 500 can be set to be linked with the indicator lights HL1, HL2, HL3, HL4, HL5, HL6, HL7 and HL8 respectively.

[0126] That is, during the power-on qualified test, for example, when a display light on the display screen 500 corresponding to the contact OC1 is lit, the indicator light HL1 corresponding to the contact OC1 is also lit.

[0127] In this way, the user can not only learn the power-on test status of the relay from the state of the external indicator light 170 , but also learn the power-on test status of the relay by watching the display light on the display screen 500 .

[0128] S26:m=m+1.

[0129] In order to screen the number of times the relay is energized and qualified, it is necessary to return to perform power-on detection on each contact multiple times, so the number of power-on times is increased by 1.

[0130] S27: Determine whether m reaches the preset number of power-on cycles M. If so, proceed to S28; otherwise, return to S22.

[0131] In some embodiments of the present application, the preset number M of power-on cycles is preset and can be set according to test requirements.

[0132] If the number of power-on times reaches M, it means that the upper limit of the number of power-on times has been reached, and the process enters S28.

[0133] If the number of power-on times has not reached M, it is necessary to return to S22 to cyclically control the coil of the relay KA to be tested to be energized / de-energized.

[0134] S28: If the PLC control module 200 outputs a signal indicating that the corresponding normally closed contact or the corresponding normally open contact is abnormal, it means that the relay KA to be tested is not energized properly. Otherwise, it means that the relay KA to be tested is energized properly, and then enters the resistance measurement mode.

[0135] In some embodiments of the present application, a first display unit (not shown) is configured on the display screen 500 .

[0136] During the power-on qualified test, when (the working relay KA1 is energized) the relay KA to be tested is energized and the PLC control module 200 does not receive a signal at the port corresponding to the normally open contact, or when the relay KA to be tested is de-energized and the PLC control module 200 does not receive a signal at the port corresponding to the normally closed contact, the first display unit displays.

[0137] In some embodiments of the present application, the first display unit is an alarm number display box configured on the display screen 500.

[0138] Before the power-on qualification test is performed, the alarm count displayed in the alarm count display box is zero.

[0139] During the power-on qualified test, when the relay KA to be tested is energized and the PLC control module 200 does not receive a signal at the port corresponding to the normally open contact, or when the relay KA to be tested is de-energized and the PLC control module 200 does not receive a signal at the port corresponding to the normally open contact, the number of alarms increases by 1.

[0140] After the power-on qualified test is completed, the number of alarms displayed on the display screen 500 can be used as a detection result of whether the relay to be tested is available.

[0141] The first display unit may also be an alarm lamp (not shown) configured on the display screen 500 for indicating each contact of the relay KA to be tested.

[0142] When the relay KA to be tested has eight contacts, the number of the warning lights is also eight.

[0143] During the power-on qualified test, when the relay KA to be tested is energized and the PLC control module 200 does not receive a signal at the port corresponding to the normally open contact, the alarm light corresponding to the normally open contact sends out an alarm indication.

[0144] During the power-on qualified test, when the relay KA to be tested loses power and the PLC control module 200 does not receive a signal at the port corresponding to the normally closed contact, the alarm light corresponding to the normally closed contact gives an alarm indication.

[0145] In the case where the buzzer BUZ is provided as described above, during the power-on qualified test, the indication status of the alarm prompt unit (eg, buzzer) and each alarm lamp may be linked.

[0146] That is, when the alarm light gives an alarm indication, the buzzer BUZ will also give an alarm prompt, reminding that the relay KA under test that is currently undergoing a power-on test has failed the power-on test. In this way, the user can not only learn the power-on test status of the relay from the alarm prompt signal output by the external buzzer BUZ, but also learn the power-on test status of the relay by watching the alarm light on the display screen 500.

[0147] See also Figure 3 The buzzer BUZ as described above is also disposed on the front upper side plate 140' of the cabinet 100 to facilitate user observation.

[0148] The detection device involved in the present application adopts an integrated design, integrating the human-computer interaction design of the power module 300, the PLC control module 200, the switch 600, the resistance measurement module 400, the alarm system and the display screen 500, so as to facilitate user use.

[0149] The display screen 500 provides functions such as real-time data display, historical data query, alarm record viewing, preset range and preset variance range, and detection process control. Users can easily complete various operations and obtain detailed measurement reports. The interface design is designed to optimize user experience and improve operational efficiency.

[0150] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A relay on-off performance detection device, characterized in that: include: PLC control module; A power supply module, which outputs a power supply for supplying power to the PLC control module; A resistance measuring module is communicatively connected with the PLC control module and powered by the power supply. The resistance measuring module has multiple groups of resistance measuring terminals, wherein a first measuring terminal and a second measuring terminal in a group of resistance measuring terminals are respectively connected to one end and the other end of a contact of a relay to be measured. The PLC control module controls to enter a resistance measuring mode, and the resistance measuring mode includes the following: S11: Initialize the number of tests n; S12: Controlling the resistance measurement module to be powered; S13: Controlling the relay to be tested to lose power, and the resistance measuring module measures the contact resistance value of each normally closed contact of the relay to be tested; S14: controlling the relay to be tested to be powered, and the resistance measuring module measuring the contact resistance of each normally open contact of the relay to be tested; S15: Determine whether the contact resistance of any contact among all the contacts is within the corresponding preset range. If so, n=n+1 and proceed to S16; otherwise, proceed to S19; S16: Determine whether n reaches the preset number N, if yes, proceed to S17, otherwise, return to S13; S17: Calculate the mean square error of the contact resistance corresponding to any contact point; S18: Determine whether any mean square error is within the corresponding preset variance range. If so, determine that the switching performance of the relay to be tested is fault-free. If not, proceed to S19; S19: Determine whether the on-off performance of the relay to be tested has a fault.

2. The relay on-off performance detection device according to claim 1, characterized in that: The detection device comprises: A working relay, which is powered by the PLC control module, all contacts of the relay to be tested are connected in parallel to multiple ports of the PLC control module, and the normally open contact of the working relay is connected to the power supply line through which the power supply supplies power to all contacts; Before entering the resistance measurement mode, the relay to be tested is first subjected to a power-on qualification test, the power-on qualification test comprising: S21: Initialize the number of power-on cycles m; S22: Control the relay to be tested and the working relay to be energized; S23: When the PLC control module does not receive a signal at the port corresponding to the normally open contact, the PLC control module outputs a signal indicating that the corresponding normally open contact is abnormal, otherwise, the PLC control module outputs a signal indicating that the corresponding normally open contact is normal; S24: switching and controlling the relay to be tested to lose power; S25: When the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the PLC control module outputs a signal indicating that the corresponding normally closed contact is abnormal; otherwise, the PLC control module outputs a signal indicating that the corresponding normally closed contact is normal; S26: m=m+1; S27: Determine whether m reaches the preset number of power-on cycles M, if so, proceed to S28, otherwise, return to S22; S28: If the PLC control module outputs a signal indicating that the corresponding normally closed contact or the corresponding normally open contact is abnormal, it means that the relay to be tested is not energized properly. Otherwise, it means that the relay to be tested is energized properly, and then enters the resistance measurement mode.

3. The relay on-off performance detection device according to claim 2, characterized in that: The detection device comprises: A display screen, on which a first display unit is configured; During the power-on qualified test, when the relay to be tested is powered on and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or when the relay to be tested is powered off and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the first display unit displays.

4. The relay on-off performance detection device according to claim 3, characterized in that: The first display unit is an alarm number display box; Before the power-on qualified test is performed, the alarm number displayed in the alarm number display box is zero; During the power-on qualified test, when the relay to be tested is energized and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or when the relay to be tested is de-energized and the PLC control module does not receive a signal at the port corresponding to the normally open contact, the number of alarms increases by 1.

5. The relay on-off performance detection device according to claim 3, characterized in that: The first display unit is an alarm light configured on the display screen for indicating each contact of the relay to be tested; During the power-on qualified test, when the relay to be tested is powered and the PLC control module does not receive a signal at the port corresponding to the normally open contact, the alarm light corresponding to the normally open contact issues an alarm indication; During the power-on qualified test, when the relay to be tested loses power and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the alarm light corresponding to the normally closed contact issues an alarm indication.

6. The relay on-off performance detection device according to claim 2, characterized in that: The detection device also includes: An alarm prompt unit, which is connected to a port of the PLC control module and is powered by the PLC control module; During the power-on qualified test, if the relay to be tested is powered on and the PLC control module does not receive a signal at the port corresponding to the normally open contact, or if the relay to be tested is powered off and the PLC control module does not receive a signal at the port corresponding to the normally closed contact, the alarm prompt unit issues an alarm prompt; During the resistance measurement mode, when it is determined that the on-off performance of the relay to be measured has a fault, the PLC control module controls the alarm prompt unit to issue an alarm prompt.

7. The relay on-off performance detection device according to claim 2, characterized in that: The detection device comprises: A display screen, on which a second display unit is configured; During the power-on qualified test, when the relay to be tested is energized and the PLC control module receives a signal at the port corresponding to the normally open contact, or when the relay to be tested is de-energized and the PLC control module receives a signal at the port corresponding to the normally open contact, the second display unit displays.

8. The relay on-off performance detection device according to claim 3 or 7, characterized in that: The detection device also includes: The display screen is installed on the side panel of the cabinet, the PLC control module, the power supply module and the resistance measurement module are all installed in the cabinet, and the relay seat for installing the relay to be tested is installed on the table panel of the cabinet.

9. The relay on-off performance detection device according to claim 1, characterized in that: The detection device also includes: A plurality of indicator lights, each indicator light being connected to a port of the PLC control module and powered by the PLC control module, and the number of the indicator lights being the same as the number of all contacts of the relay to be tested; During the resistance measurement mode, when the contact resistance of the corresponding contact exceeds the corresponding preset range, or the mean square error of the corresponding contact exceeds the corresponding preset variance range, the PLC control module controls the indicator light corresponding to the contact to light up.

10. The relay on-off performance detection device according to claim 1, characterized in that: The detection device also includes: A communication relay is connected to the port of the PLC control module and is controlled by the power supply of the PLC control module. The normally open contact of the communication relay is connected to the power supply line for the power supply to supply power to the resistance measurement module.

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