New energy automobile connector fault test system

Abstract

The invention relates to the technical field of connector fault testing, and discloses a new energy automobile connector fault testing system, which comprises a data acquisition module, a data processing module and a fault testing module, the signal processing module is used for preprocessing and filtering the collected data, removing noise interference and improving data quality; the fault detection module is used for carrying out fault identification on the processed data based on a preset fault criterion; the environment simulation module is used for simulating temperature, humidity and vibration conditions of the connector in an actual working environment and evaluating performance of the connector under different working conditions; and the mechanical performance testing module is used for testing the mechanical performance of plugging times, impact resistance and vibration resistance of the connector. The invention provides a new energy automobile connector fault test system, and solves the problem that a traditional fault test method always focuses on detection of a single parameter and ignores comprehensive performance evaluation of a connector under a complex working condition.

Description

Technical Field

[0001] The present invention relates to the technical field of connector fault testing, and in particular to a new energy vehicle connector fault testing system. Background Art

[0002] As the future trend of the automotive industry, new energy vehicles are centered on the application of high-voltage power batteries and related systems. These systems are connected through complex electronic and electrical architectures. As a key component of signal transmission, the performance and reliability of connectors directly affect the operation safety of the entire vehicle. New energy vehicle connectors can be divided into high-voltage connectors and low-voltage connectors according to voltage levels. High-voltage connectors are mainly used in power batteries and drive motors, while low-voltage connectors are mainly used in body control systems. In the production process, fault testing of new energy vehicle connectors is crucial;

[0003] However, the connectors in the prior art have many deficiencies when performing fault testing:

[0004] 1. Traditional fault testing methods often focus on the detection of a single parameter, such as insulation resistance and contact resistance, and ignore the comprehensive performance evaluation of the connector under complex working conditions;

[0005] 2. Most of the testing methods are manual or semi-automatic, with low testing efficiency and easily affected by human factors, resulting in inconsistent test results.

[0006] In order to solve the above problems, this application proposes a new energy vehicle connector fault testing system. Summary of the invention

[0007] Based on the technical problems existing in the background technology, the present invention proposes a new energy vehicle connector fault testing system.

[0008] The present invention proposes a new energy vehicle connector fault testing system, comprising:

[0009] Data acquisition module: responsible for collecting various parameters of the connector;

[0010] Signal processing module: pre-process and filter the collected data to remove noise interference and improve data quality;

[0011] Fault detection module: Based on the preset fault criteria, fault identification is performed on the processed data;

[0012] Environmental simulation module: simulates the temperature, humidity, and vibration conditions of the connector in the actual working environment, and evaluates the performance of the connector under different working conditions;

[0013] Mechanical performance test module: Test the mechanical performance of the connector, such as the number of plug-in and pull-out times, impact resistance, and vibration resistance;

[0014] Electrical performance test module: Test the electrical performance of the connector including insulation resistance, contact resistance and withstand voltage;

[0015] Control module: responsible for the operation control of the entire test system, including the management of the test process, the setting of test parameters, and the storage and analysis of test results;

[0016] Human-computer interaction module: provides a user interface to facilitate user operations and result viewing;

[0017] The data acquisition module is connected to the signal processing module, the signal processing module is connected to the fault detection module, the environmental simulation module is connected to the mechanical performance test module and the electrical performance test module respectively, and the control module is connected to each module respectively.

[0018] Preferably, the data acquisition module includes:

[0019] Sensor unit: including voltage sensor, current sensor, temperature sensor and insulation resistance sensor, used to directly measure various parameters of the connector;

[0020] Data acquisition interface unit: responsible for converting the analog signals collected by the sensor into digital signals, and performing preliminary signal conditioning and amplification for subsequent processing;

[0021] Data cache unit: used to temporarily store the collected data in order to maintain the integrity and continuity of the data before the signal processing module can process it in time.

[0022] Preferably, the signal processing module includes:

[0023] Filtering unit: Use digital filtering algorithms, such as low-pass filtering, high-pass filtering, and band-pass filtering, to filter the collected signals, remove noise and interference components, and improve signal quality;

[0024] Spectrum analysis unit: Use Fourier transform digital signal processing technology to perform spectrum analysis on the filtered signal, extract the frequency components and characteristic parameters of the signal, and provide strong support for fault detection;

[0025] Data preprocessing unit: perform normalization, detrending and smoothing preprocessing operations on the signal to improve the accuracy and stability of the algorithm.

[0026] Preferably, the fault detection module includes:

[0027] Feature extraction unit: extracts fault-related feature parameters from the processed data, such as waveform features, spectrum features, and statistical features, for subsequent fault classification and identification;

[0028] Machine learning algorithm unit: contains the implementation code and model parameters of support vector machine (SVM) and neural network machine learning algorithms. This unit uses the extracted feature parameters to classify and identify fault modes and output fault detection results.

[0029] Fault criterion library: stores preset fault criteria and thresholds for comparison with the test results to determine whether the connector has a fault and the type of fault.

[0030] Preferably, the environmental simulation module includes:

[0031] Environmental control unit: responsible for setting and adjusting the environmental parameters of temperature, humidity and vibration in the environmental test chamber to simulate the conditions of the connector in the actual working environment;

[0032] Environmental monitoring unit: real-time monitoring of environmental parameters in the environmental test chamber to ensure the accuracy and stability of environmental conditions and avoid deviations in test results;

[0033] Safety protection unit: During the environmental simulation process, the temperature and humidity parameters in the test chamber are monitored to prevent equipment damage or safety accidents caused by exceeding the set range.

[0034] Preferably, the mechanical properties testing module comprises:

[0035] Mechanical testing equipment unit: including plug-in test machine and vibration test bench, which are used to simulate the plug-in, impact and vibration mechanical stress scenarios of connectors;

[0036] Test execution unit: controls the operation of mechanical test equipment and performs mechanical performance tests on connectors according to preset test plans;

[0037] Data recording unit: records various data during the test, such as plug-in and pull-out times, impact strength, and vibration frequency, for subsequent performance evaluation and fault analysis.

[0038] Preferably, the electrical performance test module includes:

[0039] Electrical test instrument unit: including special test instruments such as insulation resistance tester and withstand voltage tester, used to measure the electrical performance parameters of the connector such as insulation resistance, contact resistance and withstand voltage strength;

[0040] Test circuit unit: design and build test circuits, connect connectors to the test system, and ensure the accuracy and safety of electrical performance testing;

[0041] Data analysis unit: Process and analyze the data output by the test instrument, calculate the electrical performance parameters, and evaluate the electrical performance of the connector.

[0042] Preferably, the control module includes:

[0043] Central processing unit: As the core of the control module, it is responsible for the operation control and data processing of the entire test system;

[0044] Test process management unit: manage the execution order and steps of the test process according to the preset test plan to ensure the standardization and efficiency of the test process;

[0045] Test parameter setting unit: allows the user to input test parameters such as test time, test voltage, and test frequency through the human-computer interaction module, and pass these parameters to each test module;

[0046] Data storage and analysis unit: responsible for the storage, organization and analysis of test results, generating test reports, and providing users with intuitive test result display and performance evaluation.

[0047] Preferably, the human-computer interaction module includes:

[0048] User interface unit: provides a friendly user interface, including a touch screen or PC software interface, for displaying test parameters, test status and test results;

[0049] Input unit: including keyboard, mouse, and touch screen input devices, allowing users to input test parameters and instructions;

[0050] Output unit: including display screen and printer equipment, used to display test results and test reports, and support printing and saving of results;

[0051] Help and Documentation Unit: Provides user manuals, operation guides and help documents to help users quickly get started and solve problems.

[0052] The above technical solution of the present invention has the following beneficial technical effects:

[0053] 1. This system integrates multiple modules including data acquisition, signal processing, fault detection, environmental simulation, mechanical performance test, electrical performance test, control and human-computer interaction to achieve comprehensive and accurate fault testing of new energy vehicle connectors. It can simulate the actual working environment and mechanical stress and evaluate the performance of connectors under different working conditions.

[0054] 2. At the same time, the use of intelligent algorithms for fault identification improves the accuracy and efficiency of the test. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 This is a module block diagram of a new energy vehicle connector fault testing system proposed by the present invention. DETAILED DESCRIPTION

[0056] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. It should be understood that these descriptions are only exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, the description of well-known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present invention.

[0057] like Figure 1 As shown, a new energy vehicle connector fault testing system proposed by the present invention comprises:

[0058] Data acquisition module: responsible for collecting various parameters of the connector;

[0059] Signal processing module: pre-process and filter the collected data to remove noise interference and improve data quality;

[0060] Fault detection module: Based on the preset fault criteria, fault identification is performed on the processed data;

[0061] Environmental simulation module: simulates the temperature, humidity, and vibration conditions of the connector in the actual working environment, and evaluates the performance of the connector under different working conditions;

[0062] Mechanical performance test module: Test the mechanical performance of the connector, such as the number of plug-in and pull-out times, impact resistance, and vibration resistance;

[0063] Electrical performance test module: Test the electrical performance of the connector including insulation resistance, contact resistance and withstand voltage;

[0064] Control module: responsible for the operation control of the entire test system, including the management of the test process, the setting of test parameters, and the storage and analysis of test results;

[0065] Human-computer interaction module: provides a user interface to facilitate user operations and result viewing;

[0066] The data acquisition module is connected to the signal processing module, the signal processing module is connected to the fault detection module, the environmental simulation module is connected to the mechanical performance test module and the electrical performance test module respectively, and the control module is connected to each module respectively.

[0067] It should be noted that: the data acquisition module is directly connected to the connector, collects voltage, current, temperature, and insulation resistance parameters in real time through sensors, and transmits the collected data to the signal processing module;

[0068] The signal processing module receives the raw data from the data acquisition module, performs preprocessing and filtering operations, removes noise interference, and then passes the processed data to the fault detection module for further analysis;

[0069] The fault detection module uses the data provided by the signal processing module to identify faults based on machine learning algorithms and feeds the detection results back to the control module;

[0070] The environmental simulation module operates independently, but the control module controls the setting of its environmental parameters, such as temperature, humidity, and vibration, to simulate the actual working conditions of the connector, and provides the data in the simulated environment to the data acquisition module, or directly uses it in the testing of the electrical performance test module and the mechanical performance test module;

[0071] The mechanical performance test module and the electrical performance test module receive the test instructions from the control module respectively, perform the corresponding test tasks, such as plug-in test, vibration test, insulation resistance test, and feed back the test results to the control module for recording and analysis;

[0072] As the core of the system, the control module not only manages the test process and sets test parameters, but also coordinates the data interaction between modules, stores the test results in internal or external memory, and displays them to users through the human-computer interaction module;

[0073] The human-computer interaction module is connected to the control module, receives the test parameters and instructions input by the user, and displays the test results and status information to realize the interaction between the user and the test system.

[0074] In a specific embodiment, the data acquisition module includes:

[0075] Sensor unit: including voltage sensor, current sensor, temperature sensor and insulation resistance sensor, used to directly measure various parameters of the connector;

[0076] Data acquisition interface unit: responsible for converting the analog signals collected by the sensor into digital signals, and performing preliminary signal conditioning and amplification for subsequent processing;

[0077] Data cache unit: used to temporarily store the collected data in order to maintain the integrity and continuity of the data before the signal processing module can process it in time.

[0078] In a specific embodiment, the signal processing module includes:

[0079] Filtering unit: Use digital filtering algorithms, such as low-pass filtering, high-pass filtering, and band-pass filtering, to filter the collected signals, remove noise and interference components, and improve signal quality;

[0080] Spectrum analysis unit: Use Fourier transform digital signal processing technology to perform spectrum analysis on the filtered signal, extract the frequency components and characteristic parameters of the signal, and provide strong support for fault detection;

[0081] Data preprocessing unit: perform normalization, detrending and smoothing preprocessing operations on the signal to improve the accuracy and stability of the algorithm.

[0082] It should be noted that the fast Fourier transform performs spectrum analysis on the signal, and the formula is as follows:

[0083]

[0084] Among them, X[k] is the transformed frequency domain signal, x[n] is the time domain signal, N is the signal length, and k is the frequency domain index.

[0085] In a specific embodiment, the fault detection module includes:

[0086] Feature extraction unit: extracts fault-related feature parameters from the processed data, such as waveform features, spectrum features, and statistical features, for subsequent fault classification and identification;

[0087] Machine learning algorithm unit: contains the implementation code and model parameters of support vector machine (SVM) and neural network machine learning algorithms. This unit uses the extracted feature parameters to classify and identify fault modes and output fault detection results.

[0088] Fault criterion library: stores preset fault criteria and thresholds for comparison with the test results to determine whether the connector has a fault and the type of fault.

[0089] It should be noted that the SVM classifier is used for fault identification, and its decision function is:

[0090] f(x)=\text{sign}(\sum_{i=1}^{l}\alpha_i y_i K(x_i,x)+b)\]where \(x\) is the sample to be classified, \(x_i\) is the support vector, \(y_i\) is the corresponding category label, \(\alpha_i\) is the Lagrange multiplier, \(K(x_i,x)\) is the kernel function, and \(b\) is the bias term.

[0091] In a specific embodiment, the environment simulation module includes:

[0092] Environmental control unit: responsible for setting and adjusting the environmental parameters of temperature, humidity and vibration in the environmental test chamber to simulate the conditions of the connector in the actual working environment;

[0093] Environmental monitoring unit: real-time monitoring of environmental parameters in the environmental test chamber to ensure the accuracy and stability of environmental conditions and avoid deviations in test results;

[0094] Safety protection unit: During the environmental simulation process, the temperature and humidity parameters in the test chamber are monitored to prevent equipment damage or safety accidents caused by exceeding the set range.

[0095] In a specific embodiment, the mechanical performance test module includes:

[0096] Mechanical testing equipment unit: including plug-in test machine and vibration test bench, which are used to simulate the plug-in, impact and vibration mechanical stress scenarios of connectors;

[0097] Test execution unit: controls the operation of mechanical test equipment and performs mechanical performance tests on connectors according to preset test plans;

[0098] Data recording unit: records various data during the test, such as plug-in and pull-out times, impact strength, and vibration frequency, for subsequent performance evaluation and fault analysis.

[0099] In a specific embodiment, the electrical performance test module includes:

[0100] Electrical test instrument unit: including special test instruments such as insulation resistance tester and withstand voltage tester, used to measure the electrical performance parameters of the connector such as insulation resistance, contact resistance and withstand voltage strength;

[0101] Test circuit unit: design and build test circuits, connect connectors to the test system, and ensure the accuracy and safety of electrical performance testing;

[0102] Data analysis unit: Process and analyze the data output by the test instrument, calculate the electrical performance parameters, and evaluate the electrical performance of the connector.

[0103] In a specific embodiment, the control module includes:

[0104] Central processing unit: As the core of the control module, it is responsible for the operation control and data processing of the entire test system;

[0105] Test process management unit: manage the execution order and steps of the test process according to the preset test plan to ensure the standardization and efficiency of the test process;

[0106] Test parameter setting unit: allows the user to input test parameters such as test time, test voltage, and test frequency through the human-computer interaction module, and pass these parameters to each test module;

[0107] Data storage and analysis unit: responsible for the storage, organization and analysis of test results, generating test reports, and providing users with intuitive test result display and performance evaluation.

[0108] In a specific embodiment, the human-computer interaction module includes:

[0109] User interface unit: provides a friendly user interface, including a touch screen or PC software interface, for displaying test parameters, test status and test results;

[0110] Input unit: including keyboard, mouse, and touch screen input devices, allowing users to input test parameters and instructions;

[0111] Output unit: including display screen and printer equipment, used to display test results and test reports, and support printing and saving of results;

[0112] Help and Documentation Unit: Provides user manuals, operation guides and help documents to help users quickly get started and solve problems.

[0113] Working principle of this system: The data acquisition module serves as the perception front end of the entire test system. It is responsible for real-time and accurate collection of key parameters of the connector, such as physical dimensions and electrical signals, to provide basic data for subsequent analysis. Subsequently, these raw data are sent to the signal processing module, which performs preprocessing and filtering operations to effectively remove noise interference, improve data purity and reliability, and lay a solid foundation for subsequent analysis. At the same time, the environmental simulation module constructs a test environment to simulate the extreme working conditions of temperature changes, humidity fluctuations and vibration shocks that the connector may encounter in actual applications, so as to comprehensively evaluate the performance stability and durability of the connector under different working environments. The mechanical performance test module quantitatively evaluates the plug-in life, impact resistance and vibration resistance of the connector by simulating plug-in operations, applying impact loads and vibration tests. The electrical performance test module verifies the safety and efficiency of the connector in the electrical system by measuring the key parameters of insulation resistance, contact resistance and withstand voltage, and ensures the accuracy and stability of signal transmission. The control module, as the hub of the entire test system, is responsible for coordinating the operations between modules and realizing the automated management of the test process, including flexible setting of test parameters, real-time monitoring of the test process, and automatic storage and analysis of test results, which greatly improves the test efficiency and accuracy. Finally, the human-computer interaction module uses an intuitive and friendly user interface as a bridge to connect the test system and the user, which not only simplifies the complex operation process, but also allows the user to easily view the test results and analyze data trends, providing strong support for the design optimization and quality control of connectors.

[0114] It should be understood that the above specific embodiments of the present invention are only used to illustrate or explain the principles of the present invention, and do not constitute a limitation of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc. made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention. In addition, the appended claims of the present invention are intended to cover all changes and modifications that fall within the scope and boundaries of the appended claims, or the equivalent forms of such scope and boundaries.

Claims

1. A new energy vehicle connector fault testing system, characterized in that: include: Data acquisition module: responsible for collecting various parameters of the connector; Signal processing module: pre-process and filter the collected data to remove noise interference and improve data quality; Fault detection module: Based on the preset fault criteria, fault identification is performed on the processed data; Environmental simulation module: simulates the temperature, humidity, and vibration conditions of the connector in the actual working environment, and evaluates the performance of the connector under different working conditions; Mechanical performance test module: Test the mechanical performance of the connector, such as the number of plug-in and pull-out times, impact resistance, and vibration resistance; Electrical performance test module: Test the electrical performance of the connector including insulation resistance, contact resistance and withstand voltage; Control module: responsible for the operation control of the entire test system, including the management of the test process, the setting of test parameters, and the storage and analysis of test results; Human-computer interaction module: provides a user interface to facilitate user operations and result viewing; The data acquisition module is connected to the signal processing module, the signal processing module is connected to the fault detection module, the environmental simulation module is connected to the mechanical performance test module and the electrical performance test module respectively, and the control module is connected to each module respectively.

2. A new energy vehicle connector fault testing system according to claim 1, characterized in that: The data acquisition module comprises: Sensor unit: including voltage sensor, current sensor, temperature sensor and insulation resistance sensor, used to directly measure various parameters of the connector; Data acquisition interface unit: responsible for converting the analog signals collected by the sensor into digital signals, and performing preliminary signal conditioning and amplification for subsequent processing; Data cache unit: used to temporarily store the collected data in order to maintain the integrity and continuity of the data before the signal processing module can process it in time.

3. A new energy vehicle connector fault testing system according to claim 2, characterized in that: The signal processing module comprises: Filtering unit: Use digital filtering algorithms, such as low-pass filtering, high-pass filtering, and band-pass filtering, to filter the collected signals, remove noise and interference components, and improve signal quality; Spectrum analysis unit: Use Fourier transform digital signal processing technology to perform spectrum analysis on the filtered signal, extract the frequency components and characteristic parameters of the signal, and provide strong support for fault detection; Data preprocessing unit: perform normalization, detrending and smoothing preprocessing operations on the signal to improve the accuracy and stability of the algorithm.

4. A new energy vehicle connector fault testing system according to claim 3, characterized in that: The fault detection module comprises: Feature extraction unit: extracts fault-related feature parameters from the processed data, such as waveform features, spectrum features, and statistical features, for subsequent fault classification and identification; Machine learning algorithm unit: contains the implementation code and model parameters of support vector machine (SVM) and neural network machine learning algorithms. This unit uses the extracted feature parameters to classify and identify fault modes and output fault detection results. Fault criterion library: stores preset fault criteria and thresholds for comparison with the test results to determine whether the connector has a fault and the type of fault.

5. A new energy vehicle connector fault testing system according to claim 4, characterized in that: The environmental simulation module comprises: Environmental control unit: responsible for setting and adjusting the environmental parameters of temperature, humidity and vibration in the environmental test chamber to simulate the conditions of the connector in the actual working environment; Environmental monitoring unit: real-time monitoring of environmental parameters in the environmental test chamber to ensure the accuracy and stability of environmental conditions and avoid deviations in test results; Safety protection unit: During the environmental simulation process, the temperature and humidity parameters in the test chamber are monitored to prevent equipment damage or safety accidents caused by exceeding the set range.

6. A new energy vehicle connector fault testing system according to claim 5, characterized in that: The mechanical properties testing module includes: Mechanical testing equipment unit: including plug-in test machine and vibration test bench, which are used to simulate the plug-in, impact and vibration mechanical stress scenarios of connectors; Test execution unit: controls the operation of mechanical test equipment and performs mechanical performance tests on connectors according to preset test plans; Data recording unit: records various data during the test, such as plug-in and pull-out times, impact strength, and vibration frequency, for subsequent performance evaluation and fault analysis.

7. A new energy vehicle connector fault testing system according to claim 6, characterized in that: The electrical performance test module includes: Electrical test instrument unit: including special test instruments such as insulation resistance tester and withstand voltage tester, used to measure the electrical performance parameters of the connector such as insulation resistance, contact resistance and withstand voltage strength; Test circuit unit: design and build test circuits, connect connectors to the test system, and ensure the accuracy and safety of electrical performance testing; Data analysis unit: Process and analyze the data output by the test instrument, calculate the electrical performance parameters, and evaluate the electrical performance of the connector.

8. A new energy vehicle connector fault testing system according to claim 7, characterized in that: The control module comprises: Central processing unit: As the core of the control module, it is responsible for the operation control and data processing of the entire test system; Test process management unit: manage the execution order and steps of the test process according to the preset test plan to ensure the standardization and efficiency of the test process; Test parameter setting unit: allows the user to input test parameters such as test time, test voltage, and test frequency through the human-computer interaction module, and pass these parameters to each test module; Data storage and analysis unit: responsible for the storage, organization and analysis of test results, generating test reports, and providing users with intuitive test result display and performance evaluation.

9. A new energy vehicle connector fault testing system according to claim 8, characterized in that: The human-computer interaction module comprises: User interface unit: provides a friendly user interface, including a touch screen or PC software interface, for displaying test parameters, test status and test results; Input unit: including keyboard, mouse, and touch screen input devices, allowing users to input test parameters and instructions; Output unit: including display screen and printer equipment, used to display test results and test reports, and support printing and saving of results; Help and Documentation Unit: Provides user manuals, operation guides and help documents to help users quickly get started and solve problems.

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