Intelligent detection device and test method for power-on aging of multi-path cascade coil assembly

Abstract

The invention discloses a multipath cascade coil assembly power-on aging intelligent detection device and a test method, relates to the technical field of hydraulic servo valve detection, adopts a cascade expansion mode, and can meet the requirement of the actual production coil aging number according to the number of field actual aging coil loads and the number of cascade splicing coil aging test boards. Through matched testing software, the actual current magnitude and the aging time duration of a coil assembly needing to be aged are independently set, the actual coil current value and the coil resistance value in the aging process are monitored in real time, the abnormal coil assembly is subjected to color distinguishing alarm management, and the fault time and state are recorded; and the actual production process requirements of the field coil assembly can be well met, and the convenience and operability are greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of hydraulic servo valve detection, and more particularly to an intelligent detection device and a test method for energized aging of a multi-channel cascade coil assembly. Background Art

[0002] At present, the coil assembly is an important component of the torque motor of the electro-hydraulic servo valve. Whether its function is normal or not determines whether the electro-hydraulic servo valve can work normally. Enameled wire is the main component of the coil assembly. When the enameled wire is wound into a coil, there is a probability that the pinhole section will fit with the thinner part of the paint film. If it works in a high temperature environment and continuously powered on, the paint film will fall off, causing a short circuit, open circuit or a decrease in resistance, affecting the normal use of the electro-hydraulic servo valve.

[0003] After the servo valve coil assembly is processed and produced, the performance of the enameled wire can be improved by loading the coil assembly with a certain amount of current and a certain length of time, and the enameled wire coils with defects can be screened and removed. According to the above process route, the coil assembly power-on aging process uses a traditional analog current amplifier and has been applied in small-batch production of coil assemblies. However, the traditional analog current control device is used, and the current setting is cumbersome. It is impossible to monitor the coil current of each channel in real time, record process fault data, and is inconvenient for centralized data management. Workers need to spend a lot of time to operate.

[0004] Therefore, how to provide an intelligent detection device that can improve operability and convenience while meeting the actual production coil aging quantity requirements is an urgent problem that technicians in this field need to solve. Summary of the invention

[0005] In view of this, the present invention provides an intelligent detection device and test method for power-on aging of a multi-channel cascaded coil assembly, so as to improve the performance of the coil assembly in the mass production process, screen out the coil assembly with enameled wire defects, ensure the quality and pass rate of the coil assembly, and avoid quality problems during subsequent product assembly and customer on-site use.

[0006] In order to achieve the above object, the present invention adopts the following technical solution:

[0007] A multi-channel cascade coil assembly power-on aging intelligent detection device, the detection device is composed of several test devices, and a single test bench includes: a test bench panel, wiring alligator clips, a coil assembly fixed armature, a 4-channel 485 CNC constant current source module, an adjustable DC regulated power supply, a USB to 485 hub, an industrial control computer; 485 communication interface A, 485 communication interface B, power interface A, power interface B;

[0008] The test bench panel includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by fixed wiring alligator clips and coil assembly fixed armatures;

[0009] One end of the wiring alligator clip is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature;

[0010] The adjustable DC regulated power supply is connected to the power interface A to provide a DC regulated power supply to a single test bench, and respectively supplies power to the 4-channel 485 numerical control constant current source modules. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port of the next-level test bench;

[0011] The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the 485 communication interface B is connected to the 4-channel 485 numerical control constant current source module.

[0012] Optionally, the test bench panel includes 20 coil assembly aging channels, which are arranged in 5 rows and 4 columns and are uniformly numbered 1-20.

[0013] Optionally, the industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data cable and USB to 485 hub module. The 8 independent 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in parallel.

[0014] Optionally, the 4-channel 485 digital control constant current source module includes an ARM main control microcontroller, a digital-to-analog conversion module, an analog-to-digital conversion module, a power supply regulator, a constant current source drive module, a tested load module, and a 10-current sampling module; the ARM main control microcontroller is respectively connected to the digital-to-analog conversion module, the analog-to-digital conversion module, and the power supply regulator; the analog-to-digital conversion module, the constant current source drive module, the current sampling module, the tested load module, and the power supply regulator are connected in sequence.

[0015] Optionally, the ARM master microcontroller also includes a 485 transceiver interface and a USB transceiver interface.

[0016] Optionally, the ARM master microcontroller also includes a fault indicator light connected to the I / O interface.

[0017] A method for testing a multi-channel cascade coil assembly power-on aging intelligent detection device comprises the following steps:

[0018] Step 1: Select a single test bench panel. The panel has 20 coil assembly aging channels, which are arranged in 5 rows and 4 columns and numbered 1-20. A wiring alligator clip 2 and a coil assembly fixed armature are fixed around each coil to facilitate installation and testing. One end of the wiring alligator clip is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature to simulate the load.

[0019] Step 2: The adjustable DC regulated power supply provides a DC regulated power supply between 12V and 20V to a single test bench through the power interface A, and supplies power to the 4-channel 485 CNC constant current source modules respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port of the next test bench;

[0020] Step 3: The industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data cable and USB to 485 hub module. The 8-channel 485 communication interface communicates with the 4-channel 485 CNC constant current source module in each separate test bench in parallel;

[0021] Step 4: The 4-channel 485 CNC constant current source module is developed and designed using an embedded ARM single-chip microcomputer to complete data processing. The peripheral uses a 16-bit high-precision DAC8830 chip to control current output, and a 24-bit high-precision ADS1256IDB chip to complete the current data feedback collection task. The standard MODBUS protocol and 485 interface are used to complete data communication transmission;

[0022] Step 5: The industrial control computer and test software centrally manage the 4-channel 485 CNC constant current source module and communicate data transmission; this includes real-time monitoring and recording of process data, as well as color-coded alarm management for abnormal current after a coil component fails;

[0023] Step 6: When the coil assembly begins to age, first turn on the DC power supply to power each 4-channel 485 CNC constant current source module circuit board, and at the same time open the test software on the industrial control computer to establish software communication; after the communication is established, set the rated current value through the software according to the current specification of the aging coil, click [Current Monitoring] to display the current monitoring interface, click [Read], and the interface begins to display the actual current value and actual resistance value read; according to the actual test requirements, install and fix the coils on the No. 1-8 coil aging test boards respectively, and observe the computer current control monitoring interface. If there is no problem with the coil installation, the computer monitoring screen will display the actual current and resistance value and the table color will be green, indicating that the coil is installed normally; if the table is displayed in red, it means that the coil is not installed correctly or there is a problem, reinstall it or find the problem and deal with it.

[0024] It can be known from the above technical scheme that, compared with the prior art, the present invention discloses a multi-channel cascade coil assembly power-on aging intelligent detection device and test method, which adopts a cascade expansion method, and can cascade the number of coil aging test boards according to the number of coil loads that are actually aged on site, so as to meet the actual production coil aging quantity requirements. Through the supporting test software, the actual current size and aging time length of the coil assembly that needs to be aged are independently set, and the actual coil current value and coil resistance value during the aging process are monitored in real time. The abnormal coil assembly is managed by color differentiation alarm, and the fault time and status are recorded, which can better meet the actual production process requirements of the coil assembly on site, and its convenience and operability are greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0026] Figure 1 This is a principle block diagram of the intelligent detection device for aging of coil components provided by the present invention;

[0027] Figure 2 A schematic diagram of the structure of a single test bench for a coil assembly provided by the present invention, wherein Figure a is a front view and Figure b is a bottom view;

[0028] Figure 3 This is a schematic diagram of the structure provided by the present invention, and a functional block diagram of a single module of a 4-channel 485 numerically controlled constant current source;

[0029] Among them, 1-test bench panel; 2-wiring alligator clip; 3-coil assembly fixing armature. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] The embodiment of the present invention discloses an intelligent detection device for aging of a multi-channel cascade coil assembly. The intelligent detection device for aging of a multi-channel cascade coil assembly is developed and designed based on the actual process requirements of coil production and the convenience of actual operation and management. The principle block diagram of the detection device is shown in FIG. Figure 1 As shown, the schematic diagram of a single test bench is as follows Figure 2 As shown, Figure a is the front view and Figure b is the bottom view. A single test bench consists of a test bench panel 1, 20 wiring alligator clips 2, 20 coil assembly fixed armatures 3, 5 4-channel 485 CNC constant current source modules, 1 high-precision adjustable DC regulated power supply, 1 power interface A input, 1 USB to 485 hub, 1 industrial control computer and 1 set of test software; 1 485 communication interface A input terminal, 1 power cascade output interface B, and 1 485 cascade output communication interface B.

[0032] The test bench panel 1 includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by a fixed wiring alligator clip 2 and a coil assembly fixed armature 3;

[0033] One end of the wiring alligator clip 2 is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature 3;

[0034] A high-precision adjustable DC regulated power supply is connected to the power interface A to provide a DC regulated power supply to a single test bench, and to supply power to the 4-channel 485 numerical control constant current source modules respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port of the next-level test bench.

[0035] The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the 485 communication interface B is connected to the 4-channel 485 numerical control constant current source module.

[0036] In a specific embodiment, the test bench panel 1 includes 20 coil assembly aging channels arranged in 5 rows and 4 columns and numbered uniformly from 1 to 20.

[0037] In a specific embodiment, the industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data cable and USB to 485 hub module. The 8 independent 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in parallel.

[0038] In a specific embodiment, Figure 3As shown, the 4-channel 485 digital control constant current source module includes an ARM main control microcontroller, a digital-to-analog conversion module, an analog-to-digital conversion module, a power regulator, a constant current source drive module, a tested load module, and a current sampling module; the ARM main control microcontroller is connected to the digital-to-analog conversion module, the analog-to-digital conversion module, and the power regulator respectively; the analog-to-digital conversion module, the constant current source drive module, the current sampling module, the tested load module, and the power regulator are connected in sequence.

[0039] In a specific embodiment, the ARM master microcontroller also includes a 485 transceiver interface and a USB transceiver interface.

[0040] In a specific embodiment, the ARM main control microcontroller also includes a fault indicator light connected to the I / O interface.

[0041] A method for testing a multi-channel cascade coil assembly power-on aging intelligent detection device comprises the following steps:

[0042] Step 1: Select a single test bench panel 1, such as Figure 2 As shown in the center front view, the panel has a total of 20 coil assembly aging channels, arranged in 5 rows and 4 columns, and numbered uniformly from 1 to 20; a wiring alligator clip 2 and a coil assembly fixed armature 3 are fixed around each coil to facilitate installation and testing; one end of the wiring alligator clip 2 is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature 3 to simulate the load;

[0043] Step 2: The high-precision adjustable DC regulated power supply provides a DC regulated power supply between 12 and 20 V to a single test bench through the power interface A, and supplies power to five 4-channel 485 CNC constant current source modules respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port of the next test bench;

[0044] Step 3: The industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data cable and USB to 485 hub module. The 8-way 485 communication interface uses parallel communication to complete communication with the 4-channel 485 CNC constant current source module in each individual test bench; the 8-way 485 communication uses parallel communication, and its communication rate is greatly improved. Theoretically, one 485 interface can establish communication with 255 4-channel 485 CNC constant current source modules. Each 4-channel 485 CNC constant current source module can control 4 coils, which is equivalent to one 485 module can control 1020 coil components. The 8-way 485 interface can simultaneously realize the aging task of 8160 coil components; because the design principle adopts modular splicing design, different current paths can be spliced ​​according to customer requirements, and maintenance is extremely convenient.

[0045] Step 4: The 4-channel 485 CNC constant current source module is the core of the detection device. Its principle block diagram is as follows: Figure 3 As shown in the figure, it adopts embedded ARM single-chip microcomputer to complete data processing, and uses 16-bit high-precision DAC8830 chip to control current output, 24-bit high-precision ADS1256IDB chip to complete current data feedback acquisition task, and uses standard MODBUS protocol and 485 interface to complete data communication transmission. The module has the characteristics of high current control accuracy, stable data transmission, and convenient computer management.

[0046] Step 5: The industrial control computer and test software centrally manage the 4-channel 485 CNC constant current source module and interconnect data transmission, realize the setting of different types of current specifications, setting of working load power-on time, real-time monitoring and recording of process data such as the current and coil resistance of each group of coils, and perform color-differentiated alarm management for abnormal current after a coil failure.

[0047] Step 6: When the coil assembly begins to age, first turn on the DC power supply to power each 485 module constant current source circuit board, and at the same time open the test software on the industrial control computer to establish software communication; after the communication is established, set the rated current value through the software according to the current specification of the aging coil, click [Current Monitoring] to display the current monitoring interface, click [Read], and the interface begins to display the actual current value and actual resistance value read; according to the actual test requirements, install and fix the coils on the coil aging test boards No. 1-8 respectively, and observe the computer current control monitoring interface. If there is no problem with the coil installation, the computer monitoring screen will display the actual current and resistance value and the table color will be green, indicating that the coil is installed normally; if the table is displayed in red, it means that the coil is not installed correctly or there is a problem, reinstall it or find the problem and deal with it.

[0048] Starting from January 1, 2024, the coil assemblies in the production process will be subjected to aging screening tests using the self-developed multi-channel cascade coil assembly power-on aging intelligent detection device. The test device is composed of 8 independent test aging boards, which can meet the test of 160 coil assemblies at the same time each time. According to the process requirements, each batch needs to be given a rated current of the coil assembly for 48 hours of continuous aging time. As of May 30, 2024, a total of 8,000 coil assembly aging screening tests with different current specifications have been completed, and a total of 10 problematic coil assemblies have been screened out. Facts have proved that the detection device effectively prevents problematic coils from flowing into the production site, being installed in the torque motor and delivered to the customer site with the servo valve product, causing failures.

[0049] The multi-channel cascade coil assembly power-on aging intelligent detection device adopts a multi-channel cascade splicing method, combined with a digital software management system, and can simultaneously meet the task of aging up to 8160 coil assemblies. The current control management system can accurately output any current value in the range of 0-200mA according to the current value set by the host computer software. It has the characteristics of convenient current setting, high current output control accuracy, wide adjustable range, good stability, and easy operation. In addition to the coil assembly aging test, it can also be suitable for various applications that require constant current, such as small DC motor drive, light-emitting secondary tube testing, etc.

[0050] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0051] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An intelligent detection device for aging of multi-channel cascaded coil components, characterized in that: The detection device is composed of several test devices. A single test bench includes: test bench panel, wiring alligator clips, coil assembly fixed armature, 4-channel 485 CNC constant current source module, adjustable DC regulated power supply, USB to 485 hub, industrial control computer; 485 communication interface A, 485 communication interface B, power interface A, power interface B; The test bench panel includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by fixed wiring alligator clips and coil assembly fixed armatures; One end of the wiring alligator clip is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature; The adjustable DC regulated power supply is connected to the power interface A to provide a DC regulated power supply to a single test bench, and respectively supplies power to the 4-channel 485 numerical control constant current source modules. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port A of the next-level test bench; The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the 485 communication interface A is connected to the 4-channel 485 numerical control constant current source module.

2. The intelligent detection device for power-on aging of multi-channel cascaded coil assemblies according to claim 1, characterized in that: The test bench panel includes 20 coil assembly aging channels, which are arranged in 5 rows and 4 columns and are uniformly numbered 1-20.

3. The intelligent detection device for power-on aging of multi-channel cascaded coil components according to claim 1, characterized in that: The industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data line and USB to 485 hub module. The 8 independent 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in parallel.

4. The intelligent detection device for power-on aging of multi-channel cascaded coil assemblies according to claim 1, characterized in that: The 4-channel 485 digital control constant current source module includes an ARM main control microcontroller, a digital-to-analog conversion module, an analog-to-digital conversion module, a power supply regulator, a constant current source drive module, a tested load module, and a current sampling module; the ARM main control microcontroller is respectively connected to the digital-to-analog conversion module, the analog-to-digital conversion module, and the power supply regulator; the analog-to-digital conversion module, the constant current source drive module, the current sampling module, the tested load module, and the power supply regulator are connected in sequence.

5. The intelligent detection device for power-on aging of multi-channel cascaded coil components according to claim 4, characterized in that: The ARM master single chip microcomputer also includes a 485 transceiver interface and a USB transceiver interface.

6. The intelligent detection device for power-on aging of multi-channel cascaded coil assemblies according to claim 4, characterized in that: The ARM main control single chip computer also includes a fault indicator light connected to the I / O interface.

7. A test method for a multi-channel cascade coil assembly power-on aging intelligent detection device, characterized in that: The following steps are involved: Step 1: Select a single test bench panel. The panel has 20 coil assembly aging channels, which are arranged in 5 rows and 4 columns and numbered 1-20. A wiring alligator clip 2 and a coil assembly fixed armature are fixed around each coil to facilitate installation and testing. One end of the wiring alligator clip is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature to simulate the load. Step 2: The adjustable DC regulated power supply provides a DC regulated power supply between 12V and 20V to a single test bench through the power interface A, and supplies power to the 4-channel 485 CNC constant current source modules respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded and output from the power interface B to the power input port of the next test bench; Step 3: The industrial control computer converts the computer USB communication signal into 8 independent 485 communication interfaces through the computer USB interface, data cable and USB to 485 hub module. The 8-channel 485 communication interface communicates with the 4-channel 485 CNC constant current source module in each separate test bench in parallel; Step 4: The 4-channel 485 CNC constant current source module is developed and designed using an embedded ARM single-chip microcomputer to complete data processing. The peripheral uses a 16-bit high-precision DAC8830 chip to control current output, and a 24-bit high-precision ADS1256IDB chip to complete the current data feedback collection task. The standard MODBUS protocol and 485 interface are used to complete data communication transmission; Step 5: The industrial control computer and test software centrally manage the 4-channel 485 CNC constant current source module and communicate data transmission; These include real-time monitoring and recording of process data, as well as color-coded alarm management for abnormal current after a coil component failure; Step 6: When the coil assembly begins to age, first turn on the DC power supply to power each 4-channel 485 CNC constant current source module circuit board, and at the same time open the test software on the industrial control computer to establish software communication; after the communication is established, set the rated current value through the software according to the current specification of the aging coil, click [Current Monitoring] to display the current monitoring interface, click [Read], and the interface begins to display the actual current value and actual resistance value read; according to the actual test requirements, install and fix the coils on the No. 1-8 coil aging test boards respectively, and observe the computer current control monitoring interface. If there is no problem with the coil installation, the computer monitoring screen will display the actual current and resistance value and the table color will be green, indicating that the coil is installed normally; if the table is displayed in red, it means that the coil is not installed correctly or there is a problem, reinstall it or find the problem and deal with it.

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