Whole-set aging test system and method for resistance welding controller circuit board

Abstract

The invention relates to a resistance welding controller circuit board set aging test system and method, the system comprises a plant power distribution cabinet, a centralized control cabinet and a test area, the plant power distribution cabinet is connected with the centralized control cabinet, the centralized control cabinet is connected with the test area, and the plant power distribution cabinet comprises a molded case circuit breaker and an AC contactor. The input end of the molded case circuit breaker is connected with a three-phase alternating-current 380V power supply, the output end of the molded case circuit breaker is connected with the alternating-current contactor, and the output end of the alternating-current contactor is connected with the centralized control cabinet. The whole test system is monitored in real time by arranging various sensors, and various power-off protection mechanisms are designed, so that the power utilization safety is ensured; meanwhile, the working environment of the circuit board on a client site is fully simulated, so that the circuit board is subjected to a full aging test in the approximately real working environment, and the product performance is more stable; energy consumption can be saved, and production efficiency can be improved.

Description

Technical Field

[0001] The invention belongs to the technical field of resistance welding control, and in particular to a complete set of aging test system and method for a resistance welding controller circuit board. Background Art

[0002] With the rapid development of science and technology, the automotive manufacturing industry is also constantly innovating its technology. With the continuous improvement of intelligent demand, the functions of the resistance welding controller circuit board are becoming more and more powerful, the integration is getting higher and higher, and the circuits are becoming more complex. Therefore, the probability of circuit board failure increases. The circuit board is the core control unit in the resistance welding controller. The stability of the circuit board directly affects the overall performance and stability of the resistance welding controller. Damage to the circuit board may cause the controller to be paralyzed, causing property losses or safety hazards to users.

[0003] Circuit board aging test refers to running the circuit board or equipment for a long time under strictly controlled environmental conditions to simulate the actual working environment of the circuit board, so as to detect the reliability and stability of the circuit board. At present, most of the traditional aging test methods in this technical field are whole machine aging tests, which are accompanied by high-power load operation. Traditional aging tests have the following disadvantages:

[0004] 1. Load operation will cause a lot of energy consumption;

[0005] 2. The busbar carrying capacity of general plant planning cannot meet the simultaneous load aging test of multiple devices, and the detection efficiency is low;

[0006] 3. The circuit board cannot be fully aged, and the instability factors and hidden dangers cannot be exposed in advance;

[0007] 4. The traditional aging test system in this field uses a switching power supply module as the power supply for the circuit board under test. First, a large number of switching power supplies are integrated, which greatly increases the cost of the aging test system. Secondly, the circuit board under test cannot achieve the purpose of aging test under an ideal power supply environment. Summary of the invention

[0008] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide a complete aging test system and method for a resistance welding controller circuit board, which can save energy consumption and improve production efficiency.

[0009] The present invention solves the technical problem by adopting the following technical solutions:

[0010] A complete aging test system for a resistance welding controller circuit board comprises a plant distribution cabinet, a centralized control cabinet and a test area, wherein the plant distribution cabinet is connected to the centralized control cabinet, the centralized control cabinet is connected to the test area, the plant distribution cabinet comprises a molded case circuit breaker and an AC contactor, the input end of the molded case circuit breaker is connected to a 3-phase AC 380V power supply, the output end of the molded case circuit breaker is connected to the AC contactor, and the output end of the AC contactor is connected to the centralized control cabinet.

[0011] Moreover, the centralized control cabinet includes: a PC, a switch, a cabinet cooling fan, a PLC, a cabinet temperature and humidity sensor, a first intermediate relay, a second intermediate relay, a third intermediate relay, a fourth intermediate relay, a fifth intermediate relay, a test area working voltage detection module, a test area power supply cabinet and an AC contactor, wherein the PC is connected to the switch, the cabinet cooling fan is connected to the PLC through the fifth intermediate relay, the cabinet temperature and humidity sensor is connected to the PLC, the AC contactor is connected to the PLC through the first intermediate relay, the test area working voltage detection module is respectively connected to the PLC and the test area power supply cabinet, the PLC is connected to the humidifier and the hot air blower in the test area through the second intermediate relay and the third intermediate relay, the PLC is connected to the AC contactor through the fourth intermediate relay, and the test area power supply cabinet is connected to the AC contactor.

[0012] Moreover, the test area includes a humidifier, a hot air blower, a test area temperature and humidity sensor, a test area smoke alarm sensor, test one to four sub-areas, and corresponding IO-link modules, wherein the humidifier is connected to the second intermediate relay, the hot air blower is connected to the third intermediate relay, the test area temperature and humidity sensor and the test area smoke alarm sensor are connected to the PLC, and the AC contactor is respectively connected to the test one to four sub-areas and the corresponding IO-link modules.

[0013] A test method for a complete set of aging test system for a resistance welding controller circuit board comprises the following steps:

[0014] Step 1: Detect whether there is a manual emergency stop button signal input;

[0015] Step 2: Check whether there is smoke in the test area;

[0016] Step 3: Check whether the temperature inside the power supply cabinet in the test area is too high;

[0017] Step 4: Check whether the temperature inside the centralized control cabinet is too high;

[0018] Step 5: Test the circuit board in the test area.

[0019] Moreover, the specific implementation method of step 1 is: detect whether there is a manual emergency stop button signal input. If an emergency stop signal input is detected, immediately disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system, otherwise proceed to step 2.

[0020] Moreover, the specific implementation method of step 2 is: detect whether the smoke sensor in the test area has output. If there is output, immediately disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. If there is no output, it is normal and proceed to step 3.

[0021] Moreover, the specific implementation method of step 3 is: detect whether the temperature in the power supply cabinet of the test area is too high. If so, stop the test and count for 5 minutes. If the temperature cannot return to normal, disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. If the temperature returns to normal within 5 minutes, restart the test; otherwise, proceed to step 4.

[0022] Moreover, the specific implementation method of step 4 is: detect whether the temperature in the centralized control cabinet is too high. If so, turn on the cooling fan of the centralized control cabinet to dissipate heat and proceed to step 5; if not, do not turn on the cooling fan and proceed to step 5.

[0023] Moreover, the specific implementation method of step 5 is: detect whether the working voltage of the test area is normal. If so, start the test and start the timing until the set test time is reached and stop the test. If the working voltage is abnormal, the timing is paused and the test is stopped, and the test is restarted and the timing continues after the fault is cleared; if during the test, it is detected that the temperature and humidity in the test area do not reach the set value, turn on the hot air blower or humidifier, otherwise it will not be turned on; if a fault is detected in the circuit board under test during the test, the timing is paused and the test is stopped, and the test is restarted and the timing continues after the fault is cleared.

[0024] The advantages and positive effects of the present invention are:

[0025] The present invention includes a power distribution cabinet in a plant, a centralized control cabinet and a test area, wherein the power distribution cabinet in the plant is connected to the centralized control cabinet, the centralized control cabinet is connected to the test area, the power distribution cabinet in the plant includes a molded case circuit breaker and an AC contactor, the input end of the molded case circuit breaker is connected to a 3-phase AC 380V power supply, the output end of the molded case circuit breaker is connected to the AC contactor, and the output end of the AC contactor is connected to the centralized control cabinet. The present invention monitors the entire test system in real time by setting a variety of sensors, and designs a variety of power-off protection mechanisms to ensure electricity safety; at the same time, the working environment of the circuit board at the customer site is fully simulated, so that the circuit board is fully aged in a near-real working environment, so that the product performance is more stable; the present invention can save energy consumption and improve production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a system structure diagram of the present invention;

[0027] Figure 2 This is a schematic diagram of the test partition of the present invention;

[0028] Figure 3 This is a test flow chart of the present invention.

[0029] Description of labels:

[0030] 0-factory power distribution cabinet, 01-molded case circuit breaker, 02-AC contactor, 1-centralized control cabinet, 11-PLC, 12-industrial integrated machine, 13-test area power supply cabinet, 14-switch, 111-cabinet temperature sensor, multiple intermediate relays, 132-four AC contactors, 131-test area working voltage detection module, 15-cabinet cooling fan, 2-test area, 25-humidifier, 26-hot air blower, 27-test area temperature and humidity sensor, 28-test area smoke sensor, 211~241-four IO-link modules, 111-cabinet temperature sensor, 131-test area working voltage detection module, 27-test area temperature and humidity sensor, 28-test area smoke sensor. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below with reference to the accompanying drawings.

[0032] A complete aging test system for a resistance welding controller circuit board, such as Figure 1 As shown, it includes a factory power distribution cabinet, a centralized control cabinet and a test area, wherein the factory power distribution cabinet is connected to the centralized control cabinet, the centralized control cabinet is connected to the test area, the factory power distribution cabinet includes a molded case circuit breaker and an AC contactor, the input end of the molded case circuit breaker is connected to a 3-phase AC 380V power supply, the output end of the molded case circuit breaker is connected to the AC contactor, and the output end of the AC contactor is connected to the centralized control cabinet.

[0033] The centralized control cabinet includes: a PC, a switch, a cabinet cooling fan, a PLC, a cabinet temperature and humidity sensor, a first intermediate relay, a second intermediate relay, a third intermediate relay, a fourth intermediate relay, a fifth intermediate relay, a test area working voltage detection module, a test area power supply cabinet and an AC contactor, wherein the PC is connected to the switch, the cabinet cooling fan is connected to the PLC through the fifth intermediate relay, the cabinet temperature and humidity sensor is connected to the PLC, the AC contactor is connected to the PLC through the first intermediate relay, the test area working voltage detection module is respectively connected to the PLC and the test area power supply cabinet, the PLC is connected to the humidifier and the hot air blower in the test area through the second intermediate relay and the third intermediate relay, the PLC is connected to the AC contactor through the fourth intermediate relay, and the test area power supply cabinet is connected to the AC contactor.

[0034] like Figure 2 As shown, the test area includes a humidifier, a hot air blower, a test area temperature and humidity sensor, a test area smoke alarm sensor, test one to four sub-areas, and corresponding IO-link modules, wherein the humidifier is connected to the second intermediate relay, the hot air blower is connected to the third intermediate relay, the test area temperature and humidity sensor and the test area smoke alarm sensor are connected to the PLC, and the AC contactor is respectively connected to the test one to four sub-areas and the corresponding IO-link modules.

[0035] Cabinet 0 is a power distribution cabinet in a plant. The present invention mainly applies to 01 molded case circuit breaker and 02 AC contactor in cabinet 0. The lower port of 01 molded case circuit breaker is connected to the upper port of 02 AC contactor, and the lower port of 02 AC contactor is connected to the voltage input terminal of cabinet 1. Cabinet 0 provides a three-phase AC 380V working voltage for cabinet 1.

[0036] Cabinet 1 is a centralized control cabinet, with 12 industrial integrated machines installed on the door of the centralized control cabinet, 11-PLC, 13-test area power supply cabinet, 14-switch, 111-cabinet temperature sensor, multiple intermediate relays, 132-four AC contactors, 131-test area working voltage detection module, and 15-cabinet cooling fan installed on the top of the centralized control cabinet;

[0037] 2 test areas, the test area integrates 25-humidifier, 26-hot air blower, 27-test area temperature and humidity sensor, 28-test area smoke sensor, 211~241-four IO-link modules, and the test area is divided into 4 partitions, each partition can hold multiple circuit boards under test

[0038] 111- cabinet temperature sensor, 131- test area working voltage detection module, 27- test area temperature and humidity sensor, 28- test area smoke sensor alarm output mode is switch output, one of the output leads of each sensor is connected to the 24V in the centralized controller cabinet, and the other is connected to the 11- PLC digital input point;

[0039] 11-PLC controls the corresponding intermediate relays to turn on or off 15-cabinet cooling fan, 132-AC contactor, 25-humidifier, and 26-hot air blower;

[0040] 11-PLC starts and controls the tested circuit boards in the four test partitions and collects fault information through IO-link. The connection method is: the IO port of the tested circuit board is connected to the digital input port of the IO-link module, the Ethernet interface of the IO-link module is connected to the switch through a network cable, and the switch is connected to 11-PLC through a network cable.

[0041] 12-PC and switch are connected via network cable;

[0042] 13- The power supply cabinet in the test area has an input voltage of three-phase AC 380V, which is rectified to obtain the DC 500V voltage required by the test area.

[0043] A test method for a complete set of aging test system for a resistance welding controller circuit board, such as Figure 3 As shown, the following steps are included:

[0044] Step 1: Check whether there is a manual emergency stop button signal input.

[0045] The specific implementation method of step 1 is: detect whether there is a manual emergency stop button signal input. If an emergency stop signal input is detected, immediately disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. Otherwise, proceed to step 2.

[0046] Step 2: Check whether there is smoke in the test area.

[0047] The specific implementation method of step 2 is: detect whether the smoke sensor in the test area has output. If there is output, immediately disconnect the AC contactor of the distribution cabinet to power off the circuit board aging test system. If there is no output, it is normal and proceed to step 3.

[0048] Step 3: Check whether the temperature in the test area is too high.

[0049] The specific implementation method of step 3 is: check whether the temperature in the power supply cabinet of the test area is too high. If so, stop the test and count down for 5 minutes. If the temperature cannot return to normal, disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. If the temperature returns to normal within 5 minutes, restart the test; otherwise, proceed to step 4.

[0050] Step 4: Check whether the temperature inside the centralized control cabinet is too high.

[0051] The specific implementation method of step 4 is: detect whether the temperature in the centralized control cabinet is too high. If so, turn on the cooling fan of the centralized control cabinet to dissipate heat and proceed to step 5; if not, do not turn on the cooling fan and proceed to step 5.

[0052] Step 5: Test the circuit board in the test area.

[0053] The specific implementation method of step 5 is: check whether the working voltage of the test area is normal. If so, start the test and start the timing until the set test time is reached and stop the test. If the working voltage is abnormal, the timing is paused and the test is stopped. After the fault is cleared, the test is restarted and the timing continues. If during the test, it is detected that the temperature and humidity in the test area do not reach the set value, turn on the hot air blower or humidifier, otherwise it will not be turned on. If a fault is detected in the circuit board under test during the test, the timing is paused and the test is stopped. After the fault is cleared, the test is restarted and the timing continues.

[0054] It should be emphasized that the embodiments described in the present invention are illustrative rather than restrictive. Therefore, the present invention includes but is not limited to the embodiments described in the specific implementation manner. Any other implementation manners derived by those skilled in the art based on the technical solution of the present invention also fall within the scope of protection of the present invention.

Claims

1. A complete aging test system for a resistance welding controller circuit board, characterized in that: It includes a factory power distribution cabinet, a centralized control cabinet and a test area, wherein the factory power distribution cabinet is connected to the centralized control cabinet, which is connected to the test area; the factory power distribution cabinet includes a molded case circuit breaker and an AC contactor; the input end of the molded case circuit breaker is connected to a 3-phase AC 380V power supply; the output end of the molded case circuit breaker is connected to the AC contactor; and the output end of the AC contactor is connected to the centralized control cabinet.

2. A complete aging test system for a resistance welding controller circuit board according to claim 1, characterized in that: The centralized control cabinet includes: a PC, a switch, a cabinet cooling fan, a PLC, a cabinet temperature and humidity sensor, a first intermediate relay, a second intermediate relay, a third intermediate relay, a fourth intermediate relay, a fifth intermediate relay, a test area working voltage detection module, a test area power supply cabinet and an AC contactor, wherein the PC is connected to the switch, the cabinet cooling fan is connected to the PLC through the fifth intermediate relay, the cabinet temperature and humidity sensor is connected to the PLC, the AC contactor is connected to the PLC through the first intermediate relay, the test area working voltage detection module is respectively connected to the PLC and the test area power supply cabinet, the PLC is connected to the humidifier and the hot air blower in the test area through the second intermediate relay and the third intermediate relay, the PLC is connected to the AC contactor through the fourth intermediate relay, and the test area power supply cabinet is connected to the AC contactor.

3. A complete aging test system for a resistance welding controller circuit board according to claim 1, characterized in that: The test area includes a humidifier, a hot air blower, a test area temperature and humidity sensor, a test area smoke alarm sensor, test one to four sub-areas, and corresponding IO-link modules, wherein the humidifier is connected to the second intermediate relay, the hot air blower is connected to the third intermediate relay, the test area temperature and humidity sensor and the test area smoke alarm sensor are connected to the PLC, and the AC contactor is respectively connected to the test one to four sub-areas and the corresponding IO-link modules.

4. A test method for a complete aging test system for a resistance welding controller circuit board according to any one of claims 1 to 3, characterized in that: The following steps are involved: Step 1: Detect whether there is a manual emergency stop button signal input; Step 2: Check whether there is smoke in the test area; Step 3: Check whether the temperature inside the power supply cabinet in the test area is too high; Step 4: Check whether the temperature inside the centralized control cabinet is too high; Step 5: Test the circuit board in the test area.

5. The test method of a complete set of aging test system for a resistance welding controller circuit board according to claim 4, characterized in that: The specific implementation method of step 1 is: detect whether there is a manual emergency stop button signal input. If an emergency stop signal input is detected, immediately disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. Otherwise, proceed to step 2.

6. The test method of a complete set of aging test system for a resistance welding controller circuit board according to claim 4, characterized in that: The specific implementation method of step 2 is: detect whether the smoke sensor in the test area has output. If there is output, immediately disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. If there is no output, it is normal and proceed to step 3.

7. The testing method of a complete set of aging testing system for a resistance welding controller circuit board according to claim 4, characterized in that: The specific implementation method of step 3 is: check whether the temperature in the power supply cabinet of the test area is too high. If so, stop the test and count down for 5 minutes. If the temperature cannot return to normal, disconnect the AC contactor of the distribution cabinet to cut off the power of the circuit board aging test system. If the temperature returns to normal within 5 minutes, restart the test; otherwise, proceed to step 4.

8. The test method of a complete set of aging test system for a resistance welding controller circuit board according to claim 4, characterized in that: The specific implementation method of step 4 is: detect whether the temperature in the centralized control cabinet is too high. If so, do not turn on the fan for heat dissipation and proceed to step 5; if not, do not turn on the fan and proceed to step 5.

9. The test method of a complete set of aging test system for a resistance welding controller circuit board according to claim 4, characterized in that: The specific implementation method of step 5 is: check whether the working voltage of the test area is normal. If so, start the test and start the timing until the set test time is reached and stop the test. If the working voltage is abnormal, the timing is paused and the test is stopped. After the fault is cleared, the test is restarted and the timing continues. If during the test, it is detected that the temperature and humidity in the test area do not reach the set value, turn on the hot air blower or humidifier, otherwise it will not be turned on. If a fault is detected in the circuit board under test during the test, the timing is paused and the test is stopped. After the fault is cleared, the test is restarted and the timing continues.

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