Automobile connector durability test system

Abstract

An automobile connector durability test system specifically relates to the automobile connector durability test field, and comprises a data acquisition module, a parameter calculation module and a test execution module, the data acquisition module is used to acquire real-time data including a current temperature value W, a current humidity value S, a current altitude value HB, a current plugging interval time H0 and a current current value D0 in real time, and the parameter calculation module is used to calculate the current temperature value W, the current humidity value S, the current altitude value HB, the current plugging interval time H0 and the current current value D0. The method comprises the following steps: extracting stored historical data including a temperature upper limit value Wmax and a temperature lower limit value Wmin from a data acquisition module, sequentially calculating and outputting a basic current adjustment coefficient K, a post-adjustment plugging interval time T and a post-adjustment current value D by utilizing a parameter calculation module, and testing the current value D by utilizing a test execution module. And performing parameter adjustment on the adjusted plugging interval time T and the adjusted current value D. According to the invention, multi-factor influence is comprehensively considered and self-adaptive real-time adjustment is realized, so that the accuracy and reliability of a test result are improved.

Description

Technical Field

[0001] The invention relates to the technical field of automobile connector durability testing, in particular to an automobile connector durability testing system. Background Art

[0002] As the automotive industry is booming, automotive connectors, as key components of the electrical system, play a decisive role in the safety and reliability of the vehicle. To ensure that automotive connectors can work stably under complex and changeable actual working conditions, they must be subjected to comprehensive and accurate durability tests.

[0003] However, in actual situations, rising temperatures will intensify the corrosion effect of humidity on connectors, and changes in altitude will also affect the heat dissipation and insulation performance of connectors. However, the existing test system is unable to comprehensively consider these factors, resulting in a large deviation between the test results and actual usage. In addition, when the temperature of the connector rises abnormally, the existing test system still maintains the original current and plug-in interval time, which may cause the connector to be damaged prematurely due to excessive testing, or fail to accurately detect potential problems due to insufficient testing. In addition, due to the failure to consider the combined impact of multiple factors and the lack of a real-time adjustment mechanism, the test results of the existing technology are difficult to accurately reflect the durability of the connector in actual use, which leads to connector failures during vehicle operation, thereby affecting the safety and reliability of the vehicle, increasing maintenance costs and user safety risks.

[0004] Therefore, those skilled in the art provide an automotive connector durability testing system to solve the problems raised in the above background technology. Summary of the invention

[0005] The technical problem solved by the present invention is to provide an automobile connector durability testing system to achieve comprehensive consideration of multiple factors, adaptive real-time adjustment, and improve the accuracy and reliability of test results.

[0006] To solve the above problems, the present invention provides the following technical solutions: An automotive connector durability test system includes a data acquisition module, a parameter calculation module, and a test execution module, wherein the parameter calculation module includes a basic adjustment basis providing unit, a plug-in time adjustment unit, and a current adjustment unit; The specific implementation steps are as follows: Step 1: Using the data acquisition module, real-time data including the current temperature value W, the current humidity value S, the current altitude value HB, the current plug-in interval time H0, and the current current value D0 are collected; Step 2: Extract the stored data including the upper temperature limit value W from the data acquisition module. max And the lower limit of temperature Wmin Historical data; Step 3: Based on the real-time data and historical data, the parameter calculation module is used to sequentially calculate the output basic current adjustment coefficient K, the adjusted plug-in interval time T, and the adjusted current value D; Step 4: Utilize the test execution module to perform parameter adjustment on the adjusted plug-in / plug-out interval time T and the adjusted current value D.

[0007] Further: the equipment used in the data acquisition module includes a temperature sensor, a humidity sensor, an altitude sensor, and a power supply device; The equipment used in the parameter calculation module includes a programmable controller; The devices used by the test execution module include computing devices.

[0008] Further: The calculation formula of the basic adjustment basis unit is as follows:

[0009] in: K is the basic current adjustment coefficient; W is the current temperature value; W max is the upper temperature limit, W max The settings are based on the actual application areas of automotive connectors, including commercial, industrial, and military applications. The specific settings are as follows: The temperature range of commercial vehicle connector applications is 0℃ to 70℃, so set W max =70; The temperature range of industrial automotive connector applications is -40°C to 85°C, so set W max =85; The temperature range of military automotive connector applications is 55°C to 125°C, so set W max =125; S is the current humidity value; HB is the current altitude; In the calculation of , for every 1% increase in humidity, the result of the basic current adjustment coefficient K will increase by 0.01.

[0010] Further: The calculation formula of the basic adjustment basis unit is as follows:

[0011] in: K is the basic current adjustment coefficient; W is the current temperature value; W max is the upper temperature limit, W maxThe settings are based on the actual application areas of automotive connectors, including commercial, industrial, and military applications. The specific settings are as follows: The temperature range of commercial vehicle connector applications is 0℃ to 70℃, so set W max =70; The temperature range of industrial automotive connector applications is -40°C to 85°C, so set W max =85; The temperature range of military automotive connector applications is 55°C to 125°C, so set W max =125; S is the current humidity value; HB is the current altitude; In the calculation of , for every 1% increase in humidity, the result of the basic current adjustment coefficient K will increase by 0.01.

[0012] Further: The calculation formula of the plug-in time adjustment unit is as follows:

[0013] in: T is the plug-in and pull-out interval time after adjustment; T0 is the current plug-in interval time; The calculation reflects the preliminary adjustment of the current plug-in interval time T0 according to the basic current adjustment coefficient K; In the calculation, for every 200% increase in humidity, the adjusted plug-in / plug-out interval time T increases by 1 time.

[0014] Further: the current temperature value W≤the upper temperature limit value W max In this case, the basic current adjustment coefficient K will be automatically set to 1.

[0015] Further: The calculation formula of the current adjustment unit is as follows:

[0016] in: D is the adjusted current value; D0 is the current value; The calculation of reflects the preliminary adjustment of the current value D0 according to the basic current adjustment coefficient K.

[0017] Further: the current temperature value W≤the upper temperature limit value W max When the temperature exceeds the lower limit, the calculation formula of the basic adjustment unit is adjusted as follows:

[0018] in: W min is the lower limit of temperature, and W min The specific settings are as follows: Commercial Vehicle Connector Set W min =0; Industrial Automotive Connector Set W min =-40; Military Automotive Connector Set W min =55.

[0019] The effects of the above solution are as follows: 1. The present invention comprehensively considers the influence of the current temperature value W, the current humidity value S, and the current altitude value HB on the basic current adjustment coefficient K by providing a basic adjustment basis unit, and thereby incorporates multiple physical factors into the calculation, which can more realistically simulate the durability of the automotive connector under complex actual working conditions, and make the test results more in line with the actual situation.

[0020] 2. The plug-in time adjustment unit and the current adjustment unit of the present invention adjust the adjusted plug-in interval time T and the adjusted current value D in real time according to the basic current adjustment coefficient K and the current humidity value S, the current plug-in interval time H0, and the current current value D0 parameters monitored in real time, so that the system can automatically calculate and adjust the test parameters according to the formula, thereby avoiding damage to the connector due to overheating during the test and more accurately detecting the durability of the connector under different working conditions.

[0021] 3. The three formulas of the present invention are interrelated to form a closed-loop adaptive adjustment system. The result of the basic adjustment basis unit affects the plug-in time adjustment unit and the current adjustment unit, and the result of the current adjustment unit affects the heating of the connector, thereby cyclically affecting the calculation of the basic adjustment basis unit. This real-time dynamic adjustment method can continuously optimize the test parameters according to the real-time status of the connector, making the test process closer to actual usage, thereby improving the accuracy and reliability of the test results. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a schematic diagram of the method flow of the automotive connector durability testing system; Figure 2 This is a schematic diagram of the overall structure of the automotive connector durability test system. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present invention will be clearly and completely introduced below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0024] For example, see Figure 1-2, an automobile connector durability test system, including a data acquisition module, a parameter calculation module, and a test execution module, characterized in that: the parameter calculation module includes a basic adjustment basis providing unit, a plug-in time adjustment unit, and a current adjustment unit; The specific implementation steps are as follows: Step 1: Use the data acquisition module to collect real-time data including the current temperature value W, the current humidity value S, the current altitude value HB, the current plug-in interval time H0, and the current current value D0; Step 2: Extract the stored temperature upper limit value W from the data acquisition module max And the lower limit of temperature W min Historical data; Step 3: Based on the real-time data and historical data, the parameter calculation module is used to calculate the output basic current adjustment coefficient K, the adjusted plug-in interval time T, and the adjusted current value D in sequence; Step 4: Using the test execution module, perform parameter adjustment on the adjusted plug-in interval time T and the adjusted current value D; The equipment used in the data acquisition module includes temperature sensors, humidity sensors, altitude sensors, and power supply equipment; The equipment used in the parameter calculation module includes a programmable controller; The devices used by the test execution module include computing devices.

[0025] In this embodiment, the temperature sensor is used to measure the temperature of the connector, the humidity sensor is used to measure the humidity of the test environment, the altitude sensor is used to obtain the altitude of the test site, the power supply device adjusts the output current according to the calculated adjusted current value D to provide the connector with the power required for the test, the programmable controller controls the plugging and unplugging interval time and the plugging and unplugging action, and the computer device is used to run the parameter calculation software and the data analysis software to achieve the overall control and data processing of the test system; The basic adjustment basis unit, the plug-in time adjustment unit, and the current adjustment unit provided in this embodiment are interrelated, and are combined with the data acquisition module, the parameter calculation module, and the test execution module to comprehensively consider multiple factors such as temperature, humidity, and altitude to achieve adaptive real-time adjustment of test parameters, form a closed-loop optimization system, make the test more in line with actual working conditions, and thereby improve the accuracy and reliability of the test results.

[0026] See also Figure 1-2 , the calculation formula for the basic adjustment unit is as follows:

[0027] in: K is the basic current adjustment coefficient; W is the current temperature value; W max is the upper temperature limit, W max The settings are based on the actual application areas of automotive connectors, including commercial, industrial, and military applications. The specific settings are as follows: The temperature range of commercial vehicle connector applications is 0℃ to 70℃, so set W max =70; The temperature range of industrial automotive connector applications is -40°C to 85°C, so set W max =85; The temperature range of military automotive connector applications is 55°C to 125°C, so set W max =125; S is the current humidity value; HB is the current altitude; In the calculation of, for every 1% increase in humidity, the result of the basic current adjustment coefficient K will increase by 0.01; Current temperature value W≤temperature upper limit value W max In this case, the basic current adjustment coefficient K will be automatically set to 1.

[0028] In the basic adjustment basis providing unit of this embodiment, firstly The calculation part is used to measure whether the current temperature value W of the connector exceeds the upper temperature limit W max The relative degree of The obtained temperature difference is divided by the upper temperature limit W max , and then get a relative ratio value, if The result of the calculation part is positive, indicating that the temperature is outside the normal range, and The larger the result of the calculation part, the more serious the excess, and the square root operation will make The growth rate of the result value of the calculation part slows down, making The results of the calculation part will not fluctuate drastically due to small changes in temperature; In the calculation part Convert the current humidity value S into a decimal form so that it can be multiplied with other items. Because the current humidity value S is given in percentage form, it can be divided by 100 to get a decimal between 0 and 1, which is convenient for reflecting the influence of humidity on the basic current adjustment coefficient K in the formula. If the humidity is higher, The larger the value of the calculation part, the larger the basic current adjustment coefficient K will be; In the calculation part It is to scale the current altitude value HB so that its influence in the formula matches other factors. The current altitude value HB is usually a large value. Dividing it by 10000 can scale it to a suitable range to avoid the altitude factor from having too great an influence in the coefficient calculation. The higher the altitude, The smaller the value of the calculation part, the smaller the basic current adjustment coefficient K will be; The basic adjustment basis unit comprehensively considers the impact of the current temperature value W, the current humidity value S, and the current altitude value HB on the durability test of the automotive connector. In actual automotive use scenarios, the connector will be affected by the interaction of multiple environmental factors. Specifically, high temperature will accelerate the aging of the internal materials of the connector, high humidity will increase the risk of corrosion, and high altitude will affect the heat dissipation and insulation performance. By integrating these factors into a formula to calculate the basic current adjustment coefficient K, it can more realistically simulate the working state of the connector under complex actual working conditions, so that the subsequent test parameter adjustment is more in line with the actual situation, thereby improving the accuracy and reliability of the test results; It is worth noting that the basic adjustment basis unit is provided by The calculation part quantifies the abnormal temperature rise. The square root operation can smooth the impact of the abnormal temperature rise, thereby avoiding the coefficient from growing too fast. However, when the temperature is within the normal range, that is, the current temperature value W ≤ the upper temperature limit W max When the basic current adjustment coefficient K is automatically set to 1, it means that there is no need to adjust the test parameters due to abnormal temperature increase, thereby ensuring the stability of the test system under normal conditions. In actual situations, when the current temperature value W ≤ the upper temperature limit value W max This means that under the current test conditions, the heating of the connector is in line with expectations, and there is no abnormal temperature increase due to excessive current, poor contact, or excessive external environment. At this time, the working state of the connector is relatively stable, and there is no additional potential risk to its performance and durability due to temperature issues.

[0029] See also Figure 1-2 , the calculation formula of the plug-in time adjustment unit is as follows:

[0030] in: T is the plug-in and pull-out interval time after adjustment; T0 is the current plug-in interval time; The calculation reflects the preliminary adjustment of the current plug-in interval time T0 according to the basic current adjustment coefficient K; In the calculation, for every 200% increase in humidity, the adjusted plug-in / plug-out interval time T increases by 1 time.

[0031] In the plug-in / plug-out time adjustment unit of this embodiment, first, The calculation part makes a preliminary adjustment to the current plug-in interval T0 according to the basic current adjustment coefficient K. The basic current adjustment coefficient K reflects the comprehensive impact of temperature, humidity and altitude on the test. Multiplying it with the current plug-in interval T0 can obtain the current plug-in interval T0 after considering these factors. In the calculation part , is to convert the current humidity value S into a decimal form, and reduce the weight of the influence of humidity on the plug-in interval time, where the decimal obtained by dividing by 200 is smaller than the decimal obtained by dividing by 100 in the basic adjustment basis unit, so that the influence of humidity on the plug-in interval time is relatively small. Although humidity will also have a certain impact on the plug-in interval, relatively speaking, the degree of this impact is not as direct and strong as the impact on the current. The increase in the current humidity value S will cause a slight change in the friction during the plug-in process, but it will not cause the connector performance to deteriorate and safety problems as quickly as the impact on the current. Therefore, when calculating the plug-in interval time, in order to avoid excessive adjustment of the plug-in interval time, the current humidity value S is divided by 200 to reduce the weight of the influence of humidity on the result, so that the adjustment of the plug-in interval time is smoother and more reasonable, thereby reflecting the impact of humidity on the adjusted plug-in interval time. When the humidity increases, the plug-in interval time increases accordingly; The plug-in time adjustment unit uses the basic current adjustment coefficient K calculated by the basic adjustment basis unit to make a preliminary adjustment to the current plug-in interval T0. This means that the adjustment of the plug-in interval is based on the combined influence of multiple factors such as temperature, humidity and altitude, so that the plug-in interval can better reflect the actual use of the connector in the current environment. Specifically, when the basic current adjustment coefficient K changes due to abnormally high temperature and increased humidity, the plug-in interval will change accordingly, thereby avoiding damage to the connector due to excessively frequent plug-in and unplugging in harsh environments.

[0032] See also Figure 1-2 , the calculation formula of the current adjustment unit is as follows:

[0033] in: D is the adjusted current value; D0 is the current value; The calculation of reflects the preliminary adjustment of the current value D0 according to the basic current adjustment coefficient K.

[0034] In the current adjustment unit of this embodiment, first, The calculation part makes a preliminary adjustment to the current current value D0 according to the basic current adjustment coefficient K, where the basic current adjustment coefficient K reflects the comprehensive impact of temperature, humidity and altitude on the test. Multiplying it with the current current value D0 can obtain the preliminary current after considering these factors, thereby providing a basis for the subsequent consideration of the impact of the change in the plug-in interval time on the current; In the calculation part It is used to calculate the ratio of the adjusted plug-in interval time T to the current plug-in interval time T0 to reflect the change of the plug-in interval time. If the ratio of the calculated part is greater than 1, it means that the plug-in interval time increases. If the ratio of the calculated part is less than 1, it means that the plug-in interval time is reduced. The calculation part is used as the basis for the subsequent square root operation to calculate the impact of the change in the plug-in interval time on the current. The square root operation in the calculation part will make the change in the value relatively small; The current adjustment unit adjusts the current plug-in interval T0 by combining the basic current adjustment coefficient K of the basic adjustment basis unit and the adjusted plug-in interval T adjusted by the plug-in time adjustment unit. This makes the final adjusted current value D comprehensively consider the influence of multiple factors such as temperature, humidity, altitude and plug-in interval. In addition, The calculation part smoothes the change ratio of the plug-in interval time, and the square root operation prevents the current adjustment from fluctuating violently due to a small change in the plug-in interval time, thereby ensuring the stability of the current during the test and avoiding additional damage to the connector due to current mutations. At the same time, it can more accurately simulate the current changes of the connector in actual use; During the actual test, if the connector is in a good environment with normal temperature, humidity and low altitude, the connector itself will be less affected by external factors. Properly increasing the calculated adjusted current value D can simulate the working state of the connector under some extreme and high-load conditions. By increasing the test current, the durability and stability of the connector under high current can be more comprehensively detected, and potential heating and poor contact problems can be found. Higher currents will cause the connector to generate more heat and accelerate the aging process of internal materials. This accelerated aging test under good environmental conditions can evaluate the long-term performance of the connector in a relatively short period of time, shorten the test cycle and improve the test efficiency. In addition, under normal temperature, humidity and low altitude, the performance of the connector itself is relatively stable, and the calculated adjusted current value D can be extended. The adjusted plug-in and unplug interval time T can reduce unnecessary wear, avoid test errors caused by excessive plug-in and unplugging, and more accurately evaluate the durability of the connector. If it is in a harsh environment with high temperature, high humidity and high altitude, the performance of the connector will be greatly affected. High temperature will cause the material to expand and accelerate aging. High humidity will also cause corrosion and reduced insulation performance. High altitude will affect heat dissipation and insulation. At this time, lowering the calculated adjusted current value D can reduce the heat generation of the connector, reduce the risk of damage to the connector due to the combined effect of environmental factors and high current, protect the connector from excessive damage during the test, and ensure that the test can proceed smoothly. In addition, by shortening the calculated adjusted plug-in and unplug interval time T, the rigor of the test can be improved, ensuring that the connector can still meet the durability requirements in harsh environments; The adjusted current value D calculated by the current adjustment unit will affect the heating of the connector, and then affect the current temperature value W of the connector detected next time, thereby cyclically affecting the calculation of the basic adjustment basis unit. This cyclic influence forms an adaptive closed-loop system, which enables the test system to dynamically adjust the test parameters according to the real-time status of the connector. When the adjusted current value D increases and causes the connector temperature to rise, the basic current adjustment coefficient K calculated by the basic adjustment basis unit will change accordingly, thereby affecting the calculation results of the plug-in time adjustment unit and the current adjustment unit, so that the test parameters are adjusted again to ensure that the test process always matches the actual status of the connector. Through this cyclic influence, the test system can respond to changes in the connector status in a timely manner, continuously optimize the test parameters, and make the test process closer to actual usage. This helps to more accurately detect the durability of the connector under different working conditions, discover potential problems in advance, and thus improve the accuracy and reliability of the test results.

[0035] For example 2, please refer to Figure 1-2 , current temperature value W≤temperature upper limit value W max When the temperature exceeds the lower limit, the basic adjustment unit is adjusted according to the calculation formula as follows:

[0036] in: W min is the lower limit of temperature, and W min The specific settings are as follows: Commercial Vehicle Connector Set W min =0; Industrial Automotive Connector Set W min =-40; Military Automotive Connector Set W min =55.

[0037] In this embodiment, generally speaking, the lower the temperature, The smaller the value of the result obtained in the calculation part, the negative impact of low temperature on the performance of the connector is reflected. Therefore, the test under the condition that the temperature is lower than the lower limit is realized, so that the test system can simulate the working state of the automotive connector under a wider range of actual working conditions, thereby improving the accuracy and reliability of the test results. In a low temperature environment, according to As well as the original calculation formulas of the plug-in and unplugging time adjustment unit and the current adjustment unit, to calculate and adjust the test parameters, including lowering the current and adjusting the plug-in and unplugging interval time, which can reduce the damage to the connector caused by low temperature and protect the connector from excessive damage during the test.

[0038] Although the present invention is disclosed as above, the present invention is not limited thereto. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the scope defined by the claims.

Claims

1. An automotive connector durability test system, comprising a data acquisition module, a parameter calculation module, and a test execution module, characterized in that: The parameter calculation module includes a basic adjustment basis providing unit, a plug-in time adjustment unit, and a current adjustment unit; The specific implementation steps are as follows: Step 1: Using the data acquisition module, real-time data including the current temperature value W, the current humidity value S, the current altitude value HB, the current plug-in interval time H0, and the current current value D0 are collected; Step 2: Extract the stored data including the upper temperature limit value W from the data acquisition module. max And the lower limit of temperature W min Historical data; Step 3: Based on the real-time data and historical data, the parameter calculation module is used to sequentially calculate the output basic current adjustment coefficient K, the adjusted plug-in interval time T, and the adjusted current value D; Step 4: Utilize the test execution module to perform parameter adjustment on the adjusted plug-in / plug-out interval time T and the adjusted current value D.

2. The automotive connector durability testing system according to claim 1, characterized in that: The equipment used in the data acquisition module includes temperature sensors, humidity sensors, altitude sensors, and power supply equipment; The equipment used in the parameter calculation module includes a programmable controller; The devices used by the test execution module include computing devices.

3. The automotive connector durability testing system according to claim 2, characterized in that: The calculation formula of the basic adjustment basis unit is as follows: ； in: K is the basic current adjustment coefficient; W is the current temperature value; W max is the upper temperature limit, W max The settings are based on the actual application areas of automotive connectors, including commercial, industrial, and military applications. The specific settings are as follows: The temperature range of commercial vehicle connector applications is 0℃ to 70℃, so set W max =70; The temperature range of industrial automotive connector applications is -40°C to 85°C, so set W max =85; The temperature range of military automotive connector applications is 55°C to 125°C, so set W max =125; S is the current humidity value; HB is the current altitude; In the calculation of , for every 1% increase in humidity, the result of the basic current adjustment coefficient K will increase by 0.

01.

4. The automotive connector durability testing system according to claim 3, characterized in that: The calculation formula of the plug-in time adjustment unit is as follows: ； in: T is the plug-in and pull-out interval time after adjustment; T0 is the current plug-in interval time; The calculation reflects the preliminary adjustment of the current plug-in interval time T0 according to the basic current adjustment coefficient K; In the calculation, for every 200% increase in humidity, the adjusted plug-in / plug-out interval time T increases by 1 time.

5. The automotive connector durability testing system according to claim 4, characterized in that: The current temperature value W≤the upper temperature limit value W max In this case, the basic current adjustment coefficient K will be automatically set to 1.

6. The automotive connector durability testing system according to claim 5, characterized in that: The calculation formula of the current adjustment unit is as follows: ； in: D is the adjusted current value; D0 is the current value; The calculation of reflects the preliminary adjustment of the current value D0 according to the basic current adjustment coefficient K.

7. The automotive connector durability testing system according to claim 5, characterized in that: The current temperature value W≤the upper temperature limit value W max When the temperature exceeds the lower limit, the calculation formula of the basic adjustment unit is adjusted as follows: ； in: W min is the lower limit of temperature, and W min The specific settings are as follows: Commercial Vehicle Connector Set W min =0; Industrial Automotive Connector Set W min =-40; Military Automotive Connector Set W min =55.

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