High-precision resistor with self-diagnosis function and detection method thereof

Abstract

The invention relates to the field of electronic components, in particular to a high-precision resistor with a self-diagnosis function and a detection method thereof, and the resistor comprises a resistor body, a signal acquisition module, a signal processing module, a storage module and a diagnosis module. The signal acquisition module acquires electric signals of the resistor and an external circuit, the signal processing module analyzes and processes the signals, the storage module stores normal data and a fault judgment threshold value, and the diagnosis module performs fault diagnosis and outputs a result. The detection method comprises the steps of initialization, signal acquisition, signal processing and fault diagnosis. According to the high-precision resistor, the problems that the self-diagnosis function of an existing high-precision resistor is limited in diagnosis range and is easily influenced by environmental factors to cause false alarm and missing alarm are solved, the diagnosis range is widened, the false alarm and missing alarm probability is reduced, and the reliability and stability of a circuit system are improved.

Description

Technical Field

[0001] The present invention relates to the field of electronic components, and particularly to a high-precision resistor with a self-diagnosis function and a detection method thereof. Background Art

[0002] In modern electronic devices, high-precision resistors are widely used in various circuits, and the stability and reliability of their performance play a crucial role in the normal operation of the entire circuit system. Although existing high-precision resistors have a self-diagnosis function, there are many problems.

[0003] Firstly, the diagnosis range is limited. The current self-diagnosis function mainly focuses on the performance changes of the resistor itself, and situations such as resistance value drift and overheating can be detected. However, in an actual complex circuit environment, simply detecting the resistor itself is far from enough. Poor connections in the external circuit are very common, such as loose solder joints and broken wires. These problems will seriously affect the normal operation of the circuit, but the existing self-diagnosis function of the resistor cannot detect them. In addition, the failure of other components, such as capacitor leakage and inductor short circuit, may also cause the entire circuit system to malfunction, and the existing self-diagnosis function also cannot detect the failures of these external components.

[0004] Secondly, the problems of false alarms and missed alarms are prominent. The self-diagnosis function is extremely vulnerable to environmental factors. Temperature, humidity, and electromagnetic interference can all cause deviations in the diagnosis results. Under extreme conditions of too high or too low temperature, the physical properties of the resistor may change to a certain extent, resulting in the self-diagnosis system misjudging that the resistance value has changed abnormally, thus generating false alarms. In an environment with high humidity, a thin water film may form on the surface of the resistor, affecting its electrical performance and also possibly causing false alarms. In addition, strong electromagnetic interference may interfere with the signal transmission and processing of the self-diagnosis system, resulting in missed alarms of some actual faults, allowing the circuit system to continue running with potential hazards, increasing the risk of system failures.

[0005] In summary, the problems existing in the self-diagnosis function of existing high-precision resistors severely limit their application in circuit systems with extremely high reliability requirements. There is an urgent need for a high-precision resistor with a self-diagnosis function and a detection method thereof that can overcome the above defects. Summary of the Invention

[0006] The purpose of the present invention is to provide a high-precision resistor with a self-diagnosis function and a detection method thereof, so as to solve the problems of limited diagnosis range and susceptibility to environmental factors resulting in false alarms and missed alarms in the self-diagnosis function of existing high-precision resistors.

[0007] The technical solution adopted by the present invention to solve its technical problems is: a high-precision resistor with a self-diagnosis function, including a resistor body, and further including a signal acquisition module for acquiring the electrical signals of the resistor itself and the external circuit; a signal processing module connected to the signal acquisition module for analyzing and processing the acquired electrical signals; a storage module for storing the electrical signal data in the normal working state and the fault judgment threshold; a diagnosis module for performing fault diagnosis based on the analysis result of the signal processing module and the data in the storage module, and outputting the diagnosis result.

[0008] Specifically, the signal acquisition module includes a high-precision voltage sensor, a current sensor, and a probe for detecting the voltage of the external circuit connection point.

[0009] Specifically, the signal processing module uses a Butterworth filter to filter the electrical signals and an operational amplifier to amplify the electrical signals.

[0010] Specifically, the storage module uses an EEPROM memory.

[0011] Specifically, the diagnosis module compares the resistance value calculated from the voltage and current at both ends of the resistor with the fault judgment threshold in the storage module to determine whether the resistor itself is faulty; and compares the voltage at the external circuit connection point with the fault judgment threshold in the storage module to determine whether the external circuit is faulty.

[0012] Specifically, the signal acquisition module further includes a temperature sensor and a humidity sensor for acquiring the ambient temperature and humidity around the resistor, and the signal processing module uses an adaptive filtering algorithm to automatically adjust the parameters of the filter according to the changes in the ambient temperature and humidity.

[0013] Specifically, the resistor further includes a communication interface for transmitting the diagnosis result to an external device.

[0014] Specifically, the resistor further includes a self-repairing and fine-tuning circuit for automatically adjusting the slight drift of the resistance value caused by reasons such as temperature changes.

[0015] A detection method for a high-precision resistor with a self-diagnosis function includes the following steps: S1. Initialization: Enter the electrical signal data in the normal working state into the storage module and set the fault judgment threshold; S2. Signal acquisition: The signal acquisition module acquires the electrical signals of the resistor itself and the external circuit in real time; S3. Signal processing: The signal processing module performs filtering, amplification and other processing on the acquired electrical signals, and compares and analyzes them with the normal data in the storage module; S4. Fault diagnosis: The diagnosis module determines whether it exceeds the fault judgment threshold according to the analysis result of the signal processing module. If it exceeds, it is determined as a fault, and the fault type and location are output.

[0016] Advantages of the present invention: (1) The high-precision resistor of the present invention can simultaneously detect its own performance and faults in the external circuit, greatly broadening the diagnosis scope and improving the reliability of the circuit system. By collecting the connection status of the external circuit and the electrical signals of other components through the signal acquisition module, problems such as poor connection and failure of other components can be detected in a timely manner, avoiding circuit faults caused by these problems.

[0017] (2) The signal processing module performs various processes on the collected electrical signals and combines the data in the storage module for comparative analysis, effectively reducing the influence of environmental factors on the diagnosis result and reducing the probability of false alarms and missed alarms. Through filtering processing, electromagnetic interference signals can be removed. By comparing with normal data, it can be more accurately determined whether the change in the resistance value is caused by an actual fault rather than a misjudgment caused by environmental factors. Description of the drawings

[0018] The present invention will be further described below in conjunction with the drawings and embodiments.

[0019] Figure 1 It is a flowchart of the detection method in the present invention. Detailed implementation manners

[0020] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific implementation manners.

[0021] As Figure 1 shown, for the high-precision resistor with self-diagnosis function described in the present invention, the resistor body: as the core component, is made of a special high-stability resistor material. This material has been carefully selected and processed, with extremely low temperature coefficient and good long-term stability, ensuring that its resistance value can be maintained within a high-precision range under various complex working environments. The metal foil resistor material is selected, which can control the drift of the resistance value to a very small extent in the temperature range of -55°C to 125°C, thus meeting the strict requirements of high-precision circuits for resistors.

[0022] The signal acquisition module: This is the key part for obtaining electrical signals and integrates a variety of high-performance sensors.

[0023] In order to accurately collect the electrical signals of the resistor itself, high-sensitivity voltage sensors and current sensors are equipped. The voltage sensor adopts the advanced Hall effect principle and can quickly and accurately measure the voltage signal across the resistor, with a measurement accuracy of up to 0.01%. The current sensor uses magnetic modulation technology to accurately detect the current passing through the resistor, and the resolution can reach the microamp level.

[0024] For the collection of electrical signals of the external circuit, special detection probes are set. These probes are made of special alloy materials and have good electrical conductivity and antioxidant properties. They can closely contact the connection points of the external circuit and stably collect electrical signals such as voltage and current, providing data support for comprehensively detecting the state of the external circuit.

[0025] Signal processing module: undertakes the important task of processing the collected electrical signals.

[0026] A high-performance digital signal processor (DSP) is used as the core processing unit, which has powerful computing capabilities and fast data processing speeds. First, the built-in digital filter is used to filter the electrical signals. The IIR (Infinite Impulse Response) filter is adopted, and by carefully designing the filter coefficients, the high-frequency noise, power frequency interference, and other stray signals in the electrical signals can be effectively removed, ensuring the accuracy of subsequent analysis.

[0027] For the amplification processing of the signals, a high-precision operational amplifier is used. According to the amplitude range of different electrical signals, the amplification factor of the operational amplifier is automatically adjusted to ensure that weak electrical signals can be amplified to an appropriate amplitude for subsequent analysis and comparison. At the same time, the amplified signals are also subjected to analog-to-digital conversion to convert the analog signals into digital signals for more accurate processing by the digital signal processor.

[0028] Storage module: A large-capacity and highly reliable flash memory is used to store various key data.

[0029] In the normal working state, the electrical signal data of the resistor itself and the external circuit are recorded in detail. These data include the voltage and current values at different working modes and different time points, as well as the corresponding environmental parameters (such as temperature, humidity, etc.). Through long-term data accumulation, a comprehensive normal working state database is constructed.

[0030] Store pre-set fault judgment thresholds. These thresholds are determined through a large number of experiments and practical application experiences. For possible faults of the resistor itself, such as resistance value drift, open circuit, short circuit, etc., and for possible problems in the external circuit, such as poor connection, component failure, etc., corresponding threshold ranges of parameters such as voltage, current, and resistance are set respectively. When the deviation between the actual resistance value of the resistor and the nominal resistance value exceeds ±0.05%, it is determined that there is a resistance value drift fault in the resistor itself; when the voltage fluctuation at the connection point of the external circuit exceeds ±10% of the normal range, it is judged that there may be a fault in the connection or other components.

[0031] Diagnosis module: Based on the analysis results of the signal processing module and the data in the storage module, perform intelligent fault diagnosis.

[0032] Apply advanced fault diagnosis algorithms to conduct a comprehensive and detailed comparative analysis of the processed electrical signal data with the stored normal data and fault judgment thresholds. Adopt a neural network-based fault diagnosis algorithm. Through the learning and training of a large number of fault samples, the diagnosis module can accurately identify various fault modes.

[0033] When it is detected that the electrical signal parameters exceed the fault judgment thresholds, it is quickly determined as a fault, and detailed fault type and location information are output through the built-in communication interface. The fault types include faults of the resistor itself (such as resistance value drift, overheating, open circuit, short circuit, etc.) and faults of the external circuit (such as loose connection points, wire breakage, other component failures, etc.). The fault location is accurate to the specific pins of the resistor, the connection points of the external circuit, or the positions of specific components.

[0034] Detection method Initialization: Before the resistor is put into use, conduct a comprehensive initialization setting.

[0035] Enter the electrical signal data in the normal working state that has passed strict testing and verification into the storage module through a special programming interface. These data include the accurate electrical signal parameters of the resistor under different working conditions (such as different power supply voltages, load currents, ambient temperatures, etc.), ensuring the establishment of a complete and reliable normal working state model.

[0036] According to the performance indicators of the resistor, the application scenario, and the requirements of the actual circuit, professional technicians set reasonable fault judgment thresholds. The setting of these thresholds needs to consider various factors. It is necessary to ensure that faults can be detected in a timely and accurate manner, and at the same time, avoid frequent false alarms due to overly sensitive thresholds. For high-precision measurement circuits, the fault judgment thresholds may be set more strictly; while for some circuits with higher requirements for stability but relatively lower requirements for precision, the thresholds can be appropriately relaxed.

[0037] Signal acquisition: During the operation of the resistor, the signal acquisition module is always in a real-time monitoring state.

[0038] According to the set sampling frequency, the voltage sensor and current sensor quickly and continuously acquire the voltage and current signals of the resistor itself. The sampling frequency is adjusted according to the actual application requirements. For electrical signals that change rapidly, such as signals in high-frequency circuits, the sampling frequency can be set to dozens of kilohertz or even higher; for signals that change relatively slowly, the sampling frequency can be appropriately reduced to save data processing resources.

[0039] At the same time, the detection probe also periodically acquires electrical signals at the connection points of the external circuit. The acquired parameters include not only voltage and current, but also other relevant electrical signals such as power factor and harmonic content can be acquired according to needs, so as to more comprehensively understand the working state of the external circuit. The acquired data is transmitted to the signal processing module in real time through the high-speed data bus to ensure the timeliness and integrity of the data.

[0040] Signal processing: After receiving the acquired electrical signals, the signal processing module immediately performs a series of processing operations.

[0041] First, the digital filter is used to filter the electrical signals. According to different interference sources and signal characteristics, the appropriate filter type and parameters are selected. For power frequency interference (50Hz or 60Hz), a notch filter is used for targeted filtering; for high-frequency noise, a low-pass filter is used for suppression. Through the filtering process, the quality of the electrical signals is effectively improved, and the influence of interference on subsequent analysis is reduced.

[0042] Next, the filtered signal is amplified. According to the amplitude of the signal, the amplification factor of the operational amplifier is automatically adjusted to make the amplitude of the signal within a suitable range for subsequent analog-to-digital conversion and digital signal processing. The amplified signal is converted into a digital signal by a high-precision analog-to-digital converter (ADC), and the digital signal processor further analyzes and processes it.

[0043] Finally, the processed electrical signal data is compared and analyzed in detail with the normal data in the storage module. By calculating various parameters of the electrical signal (such as average value, peak value, effective value, frequency, etc.) and comparing them with the corresponding parameters in the normal data, it is determined whether there are abnormal changes in the electrical signal. If the deviation of the average voltage value across the resistor exceeds a certain range compared with the normal data, or the effective value of the current shows abnormal fluctuations, it may indicate the existence of potential faults.

[0044] Fault diagnosis: The diagnosis module makes a final fault judgment and processing based on the analysis results of the signal processing module.

[0045] Using pre - set fault diagnosis rules and algorithms, comprehensively evaluate the analysis results. If the electrical signal parameters exceed the fault judgment threshold set in the storage module, the diagnosis module immediately determines that a fault has occurred.

[0046] According to the correlation between the specific parameters exceeding the threshold and the fault type, accurately judge the fault type. If the calculated value of the resistor's resistance exceeds the normal range, and the change trends of voltage and current conform to the characteristics of resistance drift, it is determined as a resistor resistance drift fault; if the voltage at the external circuit connection point suddenly drops to zero and the current also decreases significantly, it is judged as an open - circuit fault at the connection point.

[0047] After determining the fault type, accurately determine the fault location through the built - in positioning algorithm and relevant information. For faults within the resistor itself, it is possible to locate to a specific resistance wire or pin; for faults in the external circuit, it is possible to locate to the connection point, wire or specific component position. Finally, output the fault type and location information in a timely manner through the communication interface for maintenance personnel to quickly and accurately troubleshoot and repair the fault.

[0048] Embodiment 1 Resistor manufacturing: Select a highly stable resistor material to make the resistor body to ensure the resistance accuracy under normal working conditions. Integrate a signal acquisition module inside the resistor. This module uses high - precision voltage sensors and current sensors to collect the voltage signal across the resistor and the current signal passing through the resistor respectively. At the same time, the signal acquisition module is also provided with a probe for detecting the voltage at the external circuit connection point, which can collect the electrical signal at the external circuit connection point.

[0049] Signal processing module design: The signal processing module uses a high - performance microprocessor to process the electrical signals collected by the signal acquisition module. First, perform filtering on the electrical signals. Use a Butterworth filter, and its transfer function is: , where S k is the pole of the filter. Through this filter, high - frequency noise signals such as electromagnetic interference can be effectively removed. Then perform amplification on the signals. Use an operational amplifier to amplify the signals, and the amplification factor is adjusted according to actual requirements.

[0050] Storage module setting: The storage module uses an EEPROM memory to pre - store the voltage and current data of the resistor itself and the external circuit connection point under normal working conditions. At the same time, set the fault judgment threshold. When the deviation between the actual resistance value of the resistor and the nominal resistance value exceeds ±0.1%, it is determined as a fault within the resistor itself; when the deviation between the voltage at the external circuit connection point and the normal voltage exceeds ±5%, it is determined as a connection problem or a fault in other components.

[0051] Diagnostic module implementation: The diagnostic module compares and analyzes the signals processed by the signal processing module with the data in the storage module. If the resistance value calculated from the voltage and current across the resistor exceeds the fault judgment threshold, it is diagnosed as a fault of the resistor itself; if the voltage at the external circuit connection point exceeds the fault judgment threshold, further analysis is carried out to determine whether it is a poor connection or a fault of other components. If the resistance value at the connection point approaches infinity, it is judged that the connection is disconnected.

[0052] Embodiment 2 Optimize the signal acquisition module: Add temperature sensors and humidity sensors to the signal acquisition module to collect the ambient temperature and humidity around the resistor in real time. The ambient temperature and humidity data are also used as reference factors for diagnosis.

[0053] Improve the signal processing algorithm: In the signal processing module, adopt an adaptive filtering algorithm to automatically adjust the parameters of the filter according to the changes in ambient temperature and humidity. When the temperature rises, appropriately adjust the cut-off frequency of the filter to better remove the noise signals generated by temperature changes. At the same time, adopt a data fusion algorithm to fuse the electrical signals of the resistor itself, the electrical signals at the external circuit connection points, and the environmental parameter signals to improve the accuracy of diagnosis.

[0054] Improve the storage module: In the storage module, not only store the data in the normal working state and the fault judgment threshold, but also store the reference data under different environmental conditions. Store the range of electrical signals for the resistor to work normally under different temperature and humidity conditions.

[0055] Enhance the function of the diagnostic module: When the diagnostic module performs fault diagnosis, it comprehensively considers environmental factors. When a change in resistance value is detected, first judge whether the current ambient temperature and humidity are within the normal range. If the environment is abnormal, analyze according to the reference data under different environmental conditions stored to determine whether the change in resistance value is caused by environmental factors. If not, it is determined as a fault of the resistor itself.

[0056] Embodiment 3 Hardware upgrade: Select a resistor body with higher precision and lower temperature coefficient, which can maintain a stable resistance value within a wider temperature range. At the same time, upgrade the sensors in the signal acquisition module to improve its sampling accuracy and speed. Use a 16-bit high-precision A / D converter to sample the electrical signals to improve the resolution of signal acquisition.

[0057] Software optimization: Add a fault prediction function to the software of the signal processing module. Establish a performance degradation model of the resistor through the analysis of historical data. Adopt time series analysis methods to predict possible future faults according to the change trend of the resistance value of the resistor over a period of time. When the predicted fault probability exceeds a certain threshold, an early warning signal is sent in advance.

[0058] Communication function addition: Add a communication interface, such as an SPI interface or an I2C interface, to the resistor so that it can communicate with external devices. Transmit the diagnostic results to the host computer in real time through the communication interface for remote monitoring and management of the working status of the resistor.

[0059] Self-repair function design: For some minor faults, such as slight resistance drift caused by temperature changes, design a self-repair function. By integrating a trimming circuit inside the resistor, when the diagnostic module detects resistance drift, the trimming circuit is automatically adjusted to restore the resistance value to the normal range.

[0060] Example 4 System integration test: Integrate the fabricated high-precision resistor with self-diagnostic function into an actual circuit system for testing. Test the circuit system under different environmental conditions, such as high temperature (85 °C), low temperature (-40 °C), high humidity (95% RH), and strong electromagnetic interference environment.

[0061] Fault simulation test: Manually simulate the faults of the resistor itself, such as resistance drift and open circuit, as well as external circuit faults, such as poor connection and capacitor short circuit, and observe whether the self-diagnostic function of the resistor can accurately detect the faults and output the correct fault type and location. The test results are shown in the following table:

[0062] Long-term stability test: Continuously operate the resistor in a normal working environment and regularly detect whether its self-diagnostic function is normal. After testing, the self-diagnostic function of the resistor always remains stable without false alarms and missed alarms.

[0063] Comparison test: Compare the high-precision resistor of the present invention with a traditional high-precision resistor that only has its own performance detection function. Under the same complex circuit environment and fault simulation conditions, the traditional resistor can only detect its own faults and cannot detect external circuit faults, and there are more serious false alarms and missed alarms under the influence of environmental factors. While the resistor of the present invention can accurately detect the faults of itself and external circuits and is less affected by environmental factors, greatly improving the reliability and stability of the circuit system.

[0064] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and the descriptions in the specification only illustrate the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope claimed by the present invention. The scope claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. High-precision resistor with self-diagnosis function, characterized in that, include: Resistor body; A signal acquisition module, used to collect electrical signals from the resistor itself and external circuits; The signal processing module is connected to the signal acquisition module to analyze and process the collected electrical signals; A storage module, used to store electrical signal data and fault judgment thresholds under normal working conditions; The diagnosis module performs fault diagnosis based on the analysis results of the signal processing module and the data in the storage module, and outputs the diagnosis results.

2. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The signal acquisition module includes a high-precision voltage sensor, a current sensor, and a probe for detecting the voltage of an external circuit connection point.

3. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The signal processing module uses a Butterworth filter to filter the electrical signal and uses an operational amplifier to amplify the electrical signal.

4. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The storage module adopts EEPROM memory.

5. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The diagnostic module compares the resistance value calculated based on the voltage and current at both ends of the resistor with the fault judgment threshold in the storage module to determine whether the resistor itself is faulty; and compares the voltage at the external circuit connection point with the fault judgment threshold in the storage module to determine whether the external circuit is faulty.

6. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The signal acquisition module also includes a temperature sensor and a humidity sensor for acquiring the ambient temperature and humidity around the resistor.

7. The high-precision resistor with self-diagnosis function according to claim 6, characterized in that: The signal processing module adopts an adaptive filtering algorithm to automatically adjust the filter parameters according to changes in ambient temperature and humidity.

8. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The resistor also includes a communication interface for transmitting the diagnosis result to an external device.

9. The high-precision resistor with self-diagnosis function according to claim 1, characterized in that: The resistor also includes a self-repairing fine-tuning circuit for automatically adjusting a slight drift in resistance value caused by temperature changes and the like.

10. A method for detecting a high-precision resistor with a self-diagnosis function as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: S1. Initialization: record the electrical signal data under normal working conditions into the storage module and set the fault judgment threshold; S2. Signal acquisition: The signal acquisition module collects the electrical signals of the resistor itself and the external circuit in real time; S3. Signal processing: The signal processing module filters and amplifies the collected electrical signals, and compares and analyzes them with the normal data in the storage module; S4. Fault diagnosis: The diagnosis module determines whether the fault judgment threshold is exceeded based on the analysis results of the signal processing module. If exceeded, it is determined as a fault and the fault type and location are output.

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