Multi-output intelligent automatic adjusting and detecting system

Abstract

The invention discloses a multi-output intelligent automatic adjusting and detecting system. The system comprises an integrated cabinet, a control host, an output control module, a multipath program control load and a software control module. The integrated cabinet adopts an anti-interference design and is internally provided with a plurality of test devices, so that electromagnetic interference is inhibited, and the test precision is guaranteed. And the output control module realizes sequential switching detection of multiple output channels through multiple relays. The program-controlled load can simulate actual working conditions and dynamically adjust load current. And the software control module automatically executes operations such as test equipment initialization, test process control, data acquisition and analysis, report generation and the like. Meanwhile, the system has modularized hardware layout and software configuration, and is high in compatibility and expandability. The test method based on the system can efficiently complete multi-path output test. In addition, the invention further provides a cabinet layout structure matched with the cabinet. The system greatly improves the testing efficiency and accuracy, reduces the cost, and has a wide application prospect in the field of electronic equipment testing.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic equipment testing, and in particular to a multi-channel output intelligent automatic debugging system for batch automatic testing of multi-channel output power modules. Background Art

[0002] As electronic devices develop towards multifunctionality and high integration, multi-output power modules are widely used in industrial control, communication equipment, new energy and other fields. However, the testing and inspection of such modules faces the following technical bottlenecks:

[0003] Low testing efficiency: Traditional testing requires building independent testing environments for each channel. The test cycle of a single module is as long as 1.5 hours, and batch operations are not possible.

[0004] Strong manual dependence: During the test process, test channels need to be switched manually and data needs to be recorded manually, which can easily introduce operational errors and lead to poor consistency in test results.

[0005] Serious interference between devices: When multiple devices are tested together, electromagnetic interference (such as ripple distortion and background noise superposition) causes measurement errors of key parameters (such as output voltage ripple), affecting test accuracy.

[0006] The testing process lacks standardization: Different products require customized testing processes, and the existing system is difficult to flexibly adapt to the testing requirements of multi-channel and multi-specification modules.

[0007] Therefore, it is urgent to develop an automated testing system with high integration, strong anti-interference ability, and support for multi-channel dynamic switching to solve the above technical pain points. Summary of the invention

[0008] The object of the present invention is to provide a multi-channel output intelligent automatic debugging system, in particular, an automatic testing system with high integration, strong anti-interference ability and support for multi-channel dynamic switching.

[0009] In order to solve the above technical problems, this application provides the following technical solutions:

[0010] A multi-channel output intelligent automatic debugging system, comprising:

[0011] Integrated cabinet, built-in test module placement platform, program-controlled load, output controller and multimeter;

[0012] Control host, connect program-controlled load, output control module (KCKZ-24), oscilloscope and multimeter through communication interface;

[0013] The output control module is used to switch multiple output channels and communicate with the control host via RS485;

[0014] The multi-channel programmable load is connected to the control host through RS232 and adjusts the load parameters according to instructions.

[0015] The software control module realizes functions of automated test process control, data acquisition and analysis, and report generation.

[0016] Preferably, the output control module includes multiple relays, and each channel independently controls the connection between the output end of the module under test and the test equipment (oscilloscope, multimeter) to realize multi-channel sequential switching detection.

[0017] Preferably, the cabinet adopts anti-interference design, including shielding layer layout, independent grounding and filter circuit, to suppress electromagnetic interference between devices and ensure the test accuracy of output voltage ripple.

[0018] Preferably, the software control module is used to automatically perform the following operations:

[0019] a. Initialize the test equipment and configure the test parameters;

[0020] b. Control the output controller to sequentially turn on the output channels one by one;

[0021] c. Perform electrical performance tests on each output in turn, including voltage accuracy, ripple and spike, output power, protection functions (overheat protection, reverse connection protection, overvoltage / overcurrent protection) and timing parameters (power supply delay, power-on sequence);

[0022] d. Real-time record the test data, automatically mark the unqualified items, and generate a test report.

[0023] Furthermore, it may further include: a display and a human-computer interaction interface displayed thereon, which are used to display the test progress, parameters and results and provide a manual intervention function; a push-pull drawer for placing the device under test. The multi-channel output intelligent automated inspection and adjustment system has a modular hardware layout, supports rapid disassembly, installation and expansion of the device; the software control module supports modular configuration, is compatible with modules under test with different output channels, and the test items, judgment criteria and report templates can be customized.

[0024] Among them, the programmable load is a multi-channel independent load, and each load is connected to the output end of the module under test, and the load current is dynamically adjusted by software to simulate the actual working conditions.

[0025] The present invention also provides a multi-channel output test method based on the system, which includes the following steps:

[0026] Connect the module under test to the system, and the software selects the test channels and parameters;

[0027] Control the output control module to sequentially turn on the specified channels, and the programmable load applies the corresponding load;

[0028] Collect voltage and ripple data through an oscilloscope and a multimeter, and analyze it in real time by software and compare it with the standard value;

[0029] After completing the test of the current channel, it automatically switches to the next channel and loops until the tests of all channels are completed.

[0030] Preferably, the test items include but are not limited to electrical performance indicators such as output voltage accuracy, ripple, overload protection, and short-circuit protection. The test results automatically generate a report and mark the abnormal items.

[0031] And a cabinet layout structure is provided, which is applicable to the system and includes a test equipment area, a load area, and a control area with a hierarchical layout. Each area is separated by a partition board to reduce signal crosstalk.

[0032] The multi-output intelligent automation testing and adjustment system of the present invention has at least the following beneficial effects:

[0033] Hardware integration and optimized layout: Enclose the test equipment in an anti-interference cabinet to reduce electromagnetic crosstalk.

[0034] Multi-channel automatic switching technology: Adopt a relay control module designed independently to realize the sequential switching of multi-output channels.

[0035] Full-process software control: Realize the automation of the test process through modular software, including load regulation, data acquisition, result analysis, and report generation.

[0036] Compatibility and scalability: Support the testing of modules with different output channels (such as 2 channels, 4 channels, 6 channels), and the test items and judgment criteria can be customized.

[0037] The multi-output intelligent automation testing and adjustment system of the present invention will be further described below with reference to the accompanying drawings. Description of the Drawings

[0038] Figure 1 It is a schematic structural diagram of the multi-output intelligent automation testing and adjustment system of the present invention;

[0039] Figure 2 It is a schematic diagram of the software control interface of the multi-output intelligent automation testing and adjustment system of the present invention;

[0040] Figure 3 It is a schematic diagram of the cabinet of the multi-output intelligent automation testing and adjustment system of the present invention;

[0041] Figure 4 It shows the layout of each module in the cabinet of the multi-output intelligent automation testing and adjustment system of the present invention, including the connection relationship of the KCKZ-24 relay module, the programmable load, the oscilloscope, the multimeter, and the control host;

[0042] Figure 5, is a schematic diagram of the KCKZ-24 module and application of the present invention. DETAILED DESCRIPTION

[0043] The core solution of the present invention includes two parts: hardware architecture and software control, as follows:

[0044] 1. Hardware Architecture

[0045] Cabinet integrated design

[0046] Structural composition: The interior of the cabinet is divided into test equipment area, load area and control area. Each area is separated by a metal isolation plate to reduce signal crosstalk.

[0047] Anti-interference measures:

[0048] It adopts a double-layer shielded cabinet structure, with the inner layer being galvanized steel plate and the outer layer covered with a conductive coating, and the grounding impedance is ≤0.1Ω.

[0049] An EMI filter is set at the power input to suppress high-frequency noise.

[0050] The signal line uses twisted-pair shielded wire, and the connector uses a metal shell shield.

[0051] Functional modules:

[0052] Platform for placing modules under test: equipped with standardized interfaces to support quick plugging and unplugging of modules under test.

[0053] Sliding drawer: built-in keyboard, mouse and spare tools for easy operation and maintenance.

[0054] LCD display: Displays test status and data in real time, with a resolution of 1920×1080.

[0055] The output control module (KCKZ-24) is a multi-channel switching module (relay module). Its function is to control the switching of multiple output channels to ensure independent testing of each channel.

[0056] Technical parameters:

[0057] Contains 24 relays, each with a rated current of 10A and a response time of ≤5ms.

[0058] The communication interface is RS485, supporting Modbus protocol, and the communication rate is 9600bps.

[0059] Working logic:

[0060] The software sends instructions to the KCKZ-24 module to turn on the specified channel relay and connect the current measured circuit to the oscilloscope and multimeter.

[0061] After completing the test, close the current channel, switch to the next channel in sequence, and loop until all channels are tested.

[0062] Programmable load module

[0063] Composition: 6 independent electronic loads, with a maximum power of 1500W for channels 1 and 2, and a current adjustment range of 0 - 240A; for channels 3, 4, 5, and 6, the maximum power is 200W, the current adjustment range is 0 - 20A, and the accuracy is ±0.1%.

[0064] Communication method: Connect to the control host through RS232, receive load parameter instructions, and feedback real-time current data.

[0065] Function: Simulate actual working conditions, dynamically adjust the load current, and test the performance of the module under different loads.

[0066] Data acquisition equipment

[0067] Oscilloscope: Sampling bandwidth of 200MHz, sampling rate of 1GS / s, communicate with the control host through the network port (TCP / IP protocol), and collect high-frequency signals such as ripples and spikes.

[0068] Multimeter: In a specific embodiment, a six-and-a-half-digit high-precision digital multimeter is used to transmit voltage and current data through the RS232 interface, with a measurement accuracy of ±0.01%.

[0069] Among them: DC voltage 200mV, 2, 20, 200, 1000V, ≤0.015% (indicated value) + 0.004% (range 200mV and 20V), 0.003% (range 2V, 200V, and 1000V); DC current: ranges 200μA, 2000μA, 20mA, 200mA, 2A, 10A, ≤0.03% (indicated value) + 0.008% (200mA range), ≤0.2% (indicated value) + 0.01% (10A range).

[0070] II. Software control module

[0071] System architecture

[0072] Main control program: Developed based on C++, using modular design, including device driver layer, logic control layer, and user interface layer.

[0073] Communication protocol: Supports multiple protocols such as RS232, RS485, TCP / IP, etc., to achieve seamless interaction with hardware devices.

[0074] Core functions

[0075] Automated test process:

[0076] Initialize the device: Automatically detect and configure the oscilloscope, multimeter, KCKZ-24 module, and programmable load.

[0077] Channel switching control: Turn on the relay channels in the preset order to ensure independent single-channel testing.

[0078] Load dynamic adjustment: Adjust the current of the programmable load according to the requirements of the test items to simulate different working states.

[0079] Data acquisition and analysis: Real-time obtain 20 parameters such as voltage, ripple, and overcurrent protection, and compare them with the preset thresholds.

[0080] Exception handling: When detecting out-of-standard data, automatically mark the abnormal items and record detailed logs.

[0081] Report generation module:

[0082] Supports custom report templates and automatically generates PDF reports containing test results, curve graphs, and recommended measures. The test report can include information segments such as overall report information, list of main detection devices, test results, and detection records.

[0083] Data storage: Save the test results in CSV format for easy subsequent traceability and analysis.

[0084] Compatibility design

[0085] Define the number of channels, test items, and judgment criteria of the module under test through a configuration file (XML format), and adapt to different products without modifying the code.

[0086] Provide API interfaces to support integration with third-party test management systems (such as MES, ERP).

[0087] Example 1:

[0088] As Figure 1 shown, the multi-output intelligent automation testing and adjustment system of the present invention. And Figure 5 is the schematic diagram of the KCKZ-24 module and its application of the present invention.

[0089] This specific embodiment is for the testing of a 6-channel output power module

[0090] Hardware connection

[0091] Fix the module under test on the cabinet platform, and connect the output end to the KCKZ-24 module through an aviation plug.

[0092] Connect the programmable load to the output end of the module through a copper bar, and connect the oscilloscope probe to the common test point of the relay.

[0093] Software configuration

[0094] Select the number of test channels (6 channels) on the control interface, set the load current range (0 - 10A), and import the judgment standard file (such as ripple ≤ 50mV).

[0095] Test execution. Its working test process is as follows:

[0096] The program-controlled software controls to simultaneously turn on 1 and 7 of KCKZ-24 through the RS485 communication method, and starts to test the electrical performance parameters of the first-channel output of the module under test. The program-controlled load applies a current of 5A, the oscilloscope collects the ripple data, and the multimeter records the voltage value;

[0097] After completing the test of the first channel, turn off 1 and 7 of KCKZ-24, and then turn on 2 and 8 to test the electrical performance parameters of the second-channel output of the module under test;

[0098] Turn off 2 and 8, turn on 3 and 9, and test the third channel. Turn off 3 and 9, turn on 4 and 10, and test the fourth channel. Turn off 4 and 10, turn on 5 and 11, and test the fifth channel. Turn off 5 and 11, turn on 6 and 12, and test the sixth channel. Loop until all 6 channels are completed. After the test is completed, turn off 6 and 12, and upload the test data to the database.

[0099] Result output

[0100] The system automatically generates a test report and completes the printing of the test report. It is prompted that the overload protection response time of the third channel exceeds the standard (measured 12ms, standard ≤ 10ms), and it is recommended to re-inspect.

[0101] Software control is implemented according to the technical conditions of the module under test and the communication protocols of the electronic load and the program-controlled power supply. Each electrical performance test has an error range. After the test captures the data, it is judged whether it is within the error range. If it is within the range, it passes; if it is not within the range, the data is captured for the second time and judged again. If it is still not within the range, this test fails, and the number of data capture times can be set.

[0102] Example 2: Test of the power supply module of a 4-channel communication device

[0103] Adaptive adjustment

[0104] Modify the configuration file, set the number of test channels to 4 channels, and adjust the upper limit of the load current to 8A.

[0105] Replace the interface adapter of the module under test to ensure physical connection compatibility.

[0106] Extended function test

[0107] Add a test item of "input inrush current", and verify the protection function of the module by simulating inrush current impact through software control of the program-controlled load.

[0108] This system has been applied to the power module production line. More than 5000 modules have been tested cumulatively. The fault detection rate has been increased to 98%, the production efficiency has been improved by 90%, the single-module test time has been shortened from 1.5 hours of traditional manual testing to 10 minutes, and continuous batch testing is supported. Precision guarantee: The anti-interference cabinet design enables the ripple test error to be ≤2mV, and the data consistency reaches 99.5%. High flexibility: It can be adapted to various output modules such as 2-way, 4-way, and 6-way. The test items and report templates can be customized as needed. Cost savings: Reduce manual intervention, reduce the test cost by about 70%, and avoid module damage caused by misoperation at the same time. In the future, it can be extended to multiple fields such as new energy vehicle electronic control systems and photovoltaic inverters, with broad market prospects.

[0109] The embodiments described above are only used to describe the preferred embodiments of the present invention, and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various deformations and improvements made by those of ordinary skill in the art to the technical solutions of the present invention shall fall within the protection scope determined by the claims of the present invention.

Claims

1. A multi-channel output intelligent automatic debugging system, characterized in that: include: Integrated cabinet, built-in test module placement platform, program-controlled load, output controller and multimeter; Control host, connect program-controlled load, output control module (KCKZ-24), oscilloscope and multimeter through communication interface; The output control module is used to switch multiple output channels and communicate with the control host via RS485; Multi-channel control load, connected to the control host via RS232, adjust load parameters according to instructions; The software control module realizes the functions of automated test process control, data collection and analysis, and report generation.

2. The multi-channel output intelligent automatic debugging system according to claim 1 is characterized in that: The output control module includes multiple relays, each of which independently controls the connection between the output end of the module under test and the test equipment, thereby realizing multiple sequential switching detection.

3. The multi-channel output intelligent automatic debugging system according to claim 2 is characterized in that: The cabinet adopts an anti-interference design, including a shielding layer layout, independent grounding and a filtering circuit, to suppress electromagnetic interference between devices and ensure the accuracy of output voltage ripple testing.

4. The multi-channel output intelligent automatic debugging system according to claim 2 is characterized in that: The software control module is used to automatically perform the following operations: a. Initialize the test equipment and configure the test parameters; b. Control the output controller to open the output channels one by one in sequence; c. Conduct electrical performance tests on each output in turn, including voltage accuracy, ripple and peak, output power, protection function and timing parameters; d. Record test data in real time, automatically mark unqualified items, and generate test reports.

5. The multi-channel output intelligent automatic debugging system according to claim 2, characterized in that: It also includes: a display and a human-computer interaction interface displayed thereon, which is used to display the test progress, parameters and results and provide a manual intervention function; a push-pull drawer, which is used to place the device under test.

6. The multi-channel output intelligent automatic debugging system according to claim 4, characterized in that: The multi-channel output intelligent automatic debugging system has a modular hardware layout and supports rapid disassembly and expansion of equipment; the software control module supports modular configuration and is compatible with tested modules with different output channels, and the test items, judgment criteria and report templates can be customized.

7. The multi-channel output intelligent automatic debugging system according to claim 4, characterized in that: The program-controlled load is a multi-channel independent load, each of which is connected to the output terminal of the module under test, and the load current is dynamically adjusted by software to simulate actual working conditions.

8. A multi-channel output testing method based on the system of claim 1, characterized in that: The following steps are involved: Connect the module under test to the system, and select the test paths and parameters through the software; The control output control module opens the designated channels in sequence, and the program-controlled load applies the corresponding load; The voltage and ripple data are collected by oscilloscope and multimeter, and the software is used for real-time analysis and comparison with standard values; After completing the test of the current channel, it will automatically switch to the next channel and cycle until all channel tests are completed.

9. The method according to claim 8, characterized in that The test items include but are not limited to electrical performance indicators such as output voltage accuracy, ripple, overload protection, and short-circuit protection. The test results automatically generate a report and mark abnormal items.

10. A cabinet layout structure, applicable to the system according to claim 1, characterized in that: It includes a layered layout of test equipment area, load area and control area. Each area is separated by an isolation board to reduce signal crosstalk.

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