Power adapter physical mating test mechanism and method

Abstract

The present application relates to power adapter production technical field, especially a kind of power adapter physical interfacing test mechanism and method, including placement assembly, test fixture, test docking assembly and test host, the test fixture is arranged on placement assembly, the test fixture is used for power adapter fixed, the power interface of the power adapter is towards test docking assembly, the end of the power adapter and power interface is away from and is provided with output connector, the side of the test fixture is provided with output interface, the output interface is used to connect output connector, the side of the test fixture towards test docking assembly is provided with output test interface, and the output test interface is electrically connected with output interface.The present application is by being provided with placement assembly, test fixture, test docking assembly and test host, forms an efficient test system.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power adapter production, in particular to a power adapter physical docking test mechanism and method. BACKGROUND

[0002] The power adapter, also known as an external power supply, is a small portable electronic device and electronic appliance power supply voltage conversion device. It is widely used in mobile phones, LCD screens, computer notebooks and other small electronic devices, and is also commonly used in security cameras, TV set-top boxes, wireless routers, light bars, massage instruments and other devices. The basic working principle of the power adapter is to convert AC input into DC output, which is usually composed of a shell, a transformer, an inductor, a capacitor, a control IC, a PCB and other components.

[0003] The power adapter needs to be tested during production. The test process requires physical docking of the power interface for conduction testing. The existing docking process is operated manually, which is low in testing efficiency and high in labor cost. Therefore, the existing power adapter production test needs to be redesigned. SUMMARY

[0004] To solve the above problems, the present application sets up a placing assembly, a test fixture, a test docking assembly and a test host to form a high-efficiency test system for power adapter physical docking test mechanism and method.

[0005] The technical solution adopted by the present application is: a power adapter physical docking test mechanism, comprising a placing assembly, a test fixture, a test docking assembly and a test host, the test fixture is arranged on the placing assembly, the test fixture is used for fixing the power adapter, the power interface of the power adapter faces the test docking assembly, one end of the power adapter away from the power interface is provided with an output connector, one side of the test fixture is provided with an output interface, the output interface is used for connecting the output connector, one side of the test fixture facing the test docking assembly is provided with an output test interface, and the output test interface is electrically connected with the output interface; at least two power terminals are arranged on the power interface, the test docking assembly comprises a supporting frame, a docking drive module, a power connection module, an output docking module and a test adjustment module, the supporting frame is located on one side of the placing assembly, the docking drive module is arranged on the supporting frame, and the docking drive module is used to drive the power connection module and the output docking module to move relatively towards the test fixture; the power connection module comprises a power clamping terminal and a clamping drive element, the clamping drive element is used to drive the power clamping terminal to clamp and contact the power terminal for conduction; the output docking module is used to connect the output test interface; the power connection module and the output docking module are both electrically connected with the test adjustment module, and the test adjustment module is electrically connected with the test host.

[0006] Further improvement of the above scheme is that the placing assembly comprises a conveying module and a positioning module, the positioning module is used for positioning the test fixture on the conveying module, and one side of the conveying module is provided with a pay-off groove for accommodating the connecting line of the connector.

[0007] Further improvement of the above scheme is that one side of the conveying module is provided with a plurality of test stations, each test station is provided with a test docking assembly and a test host; and each test station is provided with a positioning module for positioning the test fixture.

[0008] Further improvement of the above scheme is that the conveying module is provided with two groups of conveying supports, the two groups of conveying supports are oppositely provided with conveying positioning grooves, the test fixture is provided with a conveying positioning seat, the conveying positioning seat is arranged on the conveying positioning groove and is conveyed along the conveying positioning groove under the action of the conveying module.

[0009] Further improvement of the above scheme is that the positioning module is provided with two groups, the two groups of positioning modules are oppositely arranged on two sides of the test station, the positioning module is provided with a positioning lifting cylinder, a positioning driving cylinder and a positioning T-shaped block, the conveying positioning seat is provided with a T-shaped clamping groove, the positioning lifting cylinder and the positioning driving cylinder are matched to drive the positioning T-shaped block to be matched to the T-shaped clamping groove, so as to position the test fixture in the conveying direction of the conveying module, and then the positioning lifting cylinder drives the positioning T-shaped block to be pulled down, so as to drive the test fixture to move downward, so that the two sides of the test fixture abut against the surface of the conveying support, so as to position the test fixture in the Z-axis direction of the conveying module.

[0010] Further improvement of the above scheme is that the conveying positioning seat is provided with a reinforcing block, the T-shaped clamping groove is arranged on the reinforcing block, the reinforcing block is machined from SKD11 and has a quenched hardness of 55-60HRC; a guide slope is arranged at the notch of the T-shaped clamping groove, the positioning T-shaped block is provided with a matching slope, and the matching slope is used to match the guide slope, so that the positioning T-shaped block is accurately connected with the T-shaped clamping groove, and the test fixture is positioned in the Y-axis direction of the conveying module.

[0011] Further improvement of the above scheme is that the test fixture is provided with a placing groove, a positioning surface is arranged on the wall surface of the placing groove, the positioning surface is used for positioning the end surface of the power adapter, and the power interface is located on the upper side of the positioning surface; and the test docking assembly is parallel to the positioning surface.

[0012] Further improvement of the above-mentioned solution is that the docking drive module comprises a docking drive cylinder, a docking L-shaped frame and a docking mounting frame, the docking drive cylinder is arranged on the support frame, the docking L-shaped frame is arranged on the driving end of the docking drive cylinder, and the docking mounting frame is arranged on the docking L-shaped frame, and the power supply docking module and the output docking module are arranged on the two sides of the docking mounting frame.

[0013] Further improvement of the above-mentioned solution is that the power supply clamping terminal is provided with a plurality of power supply clamping terminals arranged on the docking mounting frame; the power supply clamping terminal comprises a mounting end, an elastic end and a clamping part, the clamping part is provided with a clamping groove, the groove opening of the clamping groove is provided with a clamping guide inclined surface, the elastic end is provided with an elastic inclined surface, and the mounting end is arranged on the docking mounting frame; the clamping drive element is used to drive the elastic end to drive the clamping part to open and close, so as to contact or loosen the power supply terminal.

[0014] Further improvement of the above-mentioned solution is that the clamping drive element comprises a clamping drive cylinder and an opening clamping plate, the clamping drive cylinder is used to drive the opening clamping plate to reciprocate on the elastic end, the opening clamping plate is provided with an opening clamping groove corresponding to the elastic inclined surface, and the elastic end is driven to move through the opening clamping groove to drive the clamping part to open and close.

[0015] Further improvement of the above-mentioned solution is that the output docking module comprises a docking connecting plate, a docking connector and a floating guide sleeve, the floating guide sleeve is arranged on the docking connecting plate, the docking connector is arranged on the floating guide sleeve, the docking connecting plate is provided with a docking mounting hole, one end of the docking connector passes through the docking mounting hole, and a gap is left between the docking mounting hole and the docking connector; the floating guide sleeve is provided with a floating spring, and one end of the floating spring abuts against the docking connector.

[0016] A power adapter physical docking test method comprises the power adapter physical docking test mechanism, and the method comprises the following steps:

[0017] Step S1, jig positioning stage

[0018] The test jig is transmitted to the test station along the conveying module;

[0019] The test jig is constrained in X / Y / Z axial direction by the three-dimensional positioning mechanism, which specifically comprises:

[0020] a) drive the positioning T-shaped block to be clamped into the T-shaped clamping groove of the reinforcing block along the conveying direction;

[0021] b) realize vertical positioning by pulling down through the lifting cylinder;

[0022] c) complete horizontal positioning by means of the interaction of the guide inclined surface and the matching inclined surface;

[0023] Step S2, Electrical Connection Stage

[0024] The drive docking module brings the test docking components close to the test fixture and executes synchronously:

[0025] a) The clamping drive cylinder controls the opening of the clamping plate to squeeze the elastic inclined surface of the elastic end, causing the clamping groove of the power clamping terminal to close and clamp the power terminal.

[0026] b) Automatic alignment of power terminals is achieved using a clamping guide ramp;

[0027] c) The spring compensation mechanism of the floating guide sleeve ensures reliable contact between the output docking module and the output test interface;

[0028] Step S3, Test Execution Phase

[0029] The following testing process is performed by testing and adjusting the module:

[0030] a) Apply a test voltage signal to the power supply module;

[0031] b) Real-time detection of current fluctuation parameters of the output docking module;

[0032] c) Synchronously collect the contact impedance of the power supply terminals and the conduction status of the output interface;

[0033] d) The collected data is transmitted to the test host for the following analysis: the actual output parameters are compared with the preset threshold range to determine whether the contact state meets the dynamic stability requirements, and a test report containing voltage fluctuation spectrum is generated.

[0034] Step S4, Reset Phase

[0035] Execute after the test is complete:

[0036] a) Release the clamping state of the power supply clamping terminal;

[0037] b) Drive the test docking component back to its initial position;

[0038] c) Release the three-dimensional positioning constraints of the test fixture;

[0039] d) Transfer the test fixture to the next workstation.

[0040] The beneficial effects of this invention are:

[0041] Compared to existing power adapter testing methods, this invention, in terms of structural design, forms a highly efficient testing system by incorporating a placement component, a test fixture, a test docking component, and a test host. The placement component ensures that the test fixture is positioned correctly. The test fixture not only securely holds the power adapter but also precisely aligns the power adapter's power interface with the test docking component. Simultaneously, an output connector is located on the end facing away from the power interface and connected to it via the output interface. This ensures clear and orderly connections during the power adapter testing process, reducing testing errors that may result from messy wiring.

[0042] The test docking assembly achieves a high degree of automation and precision. The support frame serves as the structural support for the entire assembly. The docking drive module moves the power connection module and the output docking module relative to the test fixture, ensuring they accurately reach their designated positions and dock with the corresponding interfaces of the power adapter, thus improving the success rate and accuracy of the docking. The test adjustment module establishes the electrical connection between the power connection module and the output docking module, enabling them to work collaboratively. It also connects to the test host, accurately transmitting test data. The test host can analyze and judge the received data, thereby achieving precise testing of various performance indicators of the power adapter. This highly integrated design significantly improves testing efficiency, reduces errors that may arise from manual intervention, and makes the test results more accurate and reliable.

[0043] This invention also boasts compatibility; specifically, the power interface is equipped with at least two power terminals, enabling the testing mechanism to adapt to power adapters of different specifications, thus exhibiting broad applicability. Whether it's a small electronic device power adapter or a large device power adapter, it can be effectively tested on this testing mechanism, meeting diverse testing needs in the market. Through its rational structural design, precise driving mechanism, stable electrical connection, and excellent compatibility, this invention achieves efficient and accurate physical connection testing of power adapters, providing highly efficient testing and production for power adapter quality inspection and performance optimization.

[0044] A physical docking test method for power adapters employs a three-dimensional positioning mechanism to precisely constrain the test fixture along the X, Y, and Z axes. Driving a positioning T-block along the conveying direction to engage with the T-slot of a reinforcing block effectively limits the fixture's displacement in the conveying direction, ensuring its positional accuracy. A lifting cylinder pulls down to achieve vertical positioning, preventing the fixture from swaying or shifting vertically. Lateral positioning is achieved through the interaction of a guide ramp and a mating ramp, further improving the fixture's horizontal positioning accuracy. This three-dimensional positioning method significantly enhances the stability and accuracy of the test fixture's positioning, providing a reliable foundation for subsequent electrical docking and testing. During the electrical docking phase, multiple actions work in tandem. The clamping drive cylinder controls the opening of the clamping plate to squeeze the elastic inclined surface of the elastic end, causing the clamping groove of the power clamping terminal to close and clamp the power terminal, ensuring a tight connection between the power terminal and the test component. The clamping guide inclined surface realizes automatic centering of the power terminal, improving the efficiency and accuracy of docking. The spring compensation mechanism of the floating guide sleeve ensures reliable contact between the output docking module and the output test interface, effectively avoiding problems such as poor contact and ensuring the stability of electrical signal transmission. During the test execution phase, the test adjustment module performs multi-parameter detection according to the set process and transmits the collected data to the test host for in-depth analysis. It can detect current fluctuation parameters in real time, collect power terminal contact impedance and output interface conduction status, and compare the actual output parameters with the preset threshold range to generate a test report including voltage fluctuation spectrum. It can not only comprehensively and accurately evaluate the performance of the power adapter, but also promptly detect potential problems and ensure product quality. During the reset phase, each action is executed in an orderly manner, quickly releasing the docking state and releasing the fixture constraints, and transferring the test fixture to the next station, realizing an efficient cycle of the test process and improving the overall test efficiency. Attached Figure Description

[0045] Figure 1 This is a three-dimensional schematic diagram of the physical docking test mechanism for the power adapter of the present invention;

[0046] Figure 2 for Figure 1 A three-dimensional schematic diagram of the physical docking test mechanism for power adapters from another perspective;

[0047] Figure 3 for Figure 1 A partial structural diagram of the physical docking test mechanism for the power adapter;

[0048] Figure 4 for Figure 1 A schematic diagram of the placement components of the power adapter physical docking test mechanism;

[0049] Figure 5 for Figure 1 A flowchart illustrating the positioning module of the physical docking test mechanism for power adapters;

[0050] Figure 6 for Figure 1 A schematic diagram of the test docking components of the power adapter physical docking test mechanism;

[0051] Figure 7 for Figure 6 A structural schematic diagram of the test docking component from another perspective;

[0052] Figure 8 for Figure 7 Enlarged diagram of point A in the diagram;

[0053] Figure 9 for Figure 6 A schematic diagram of the structure of the docking connector for the test docking components;

[0054] Figure 10 This is a flowchart illustrating the physical connection test method for the power adapter of the present invention.

[0055] Explanation of reference numerals in the attached drawings: Placement component 1, Conveying module 11, Conveying bracket 111, Conveying positioning groove 112, Positioning module 12, Positioning lifting cylinder 121, Positioning drive cylinder 122, Positioning T-block 123, Cable placement groove 13, Test fixture 2, Output interface 21, Output test interface 22, Conveying positioning seat 23, T-slot 231, Reinforcing block 232, Placement groove 24, Test docking component 3, Support frame 31, Dock driving module 32, Dock driving cylinder 321, Dock L-shaped frame 322, Dock mounting frame 323, Power connection module 33, Power clamp Terminal 331, mounting end 3311, elastic end 3312, clamping part 3313, clamping groove 3314, clamping guide slope 3315, elastic slope 3316, clamping drive element 332, clamping drive cylinder 3321, clamping plate 3322, clamping groove 3323, output docking module 34, docking connection plate 341, docking mounting hole 3411, docking connector 342, floating guide sleeve 343, floating spring 3431, test adjustment module 35, test host 4, power adapter 5, power interface 51, power terminal 511, output connector 52. Detailed Implementation

[0056] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0057] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0058] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-10 As shown, in one embodiment of the present invention, a power adapter physical docking test mechanism is provided, including a placement component 1, a test fixture 2, a test docking component 3, and a test host 4. The test fixture 2 is disposed on the placement component 1 and is used to fix the power adapter 5. The power interface 51 of the power adapter 5 faces the test docking component 3. An output connector 52 is provided at the end of the power adapter 5 opposite to the power interface 51. An output interface 21 is provided on one side of the test fixture 2 and is used to connect to the output connector 52. An output test interface 22 is provided on the side of the test fixture 2 facing the test docking component 3 and is electrically connected to the output interface 21. At least two power terminals 511 are provided on the power interface 51. Component 3 includes a support frame 31, a docking drive module 32, a power connection module 33, an output docking module 34, and a test adjustment module 35. The support frame 31 is located on one side of the placement component 1. The docking drive module 32 is mounted on the support frame 31 and is used to drive the power connection module 33 and the output docking module 34 to move relative to each other toward the test fixture 2. The power connection module 33 includes a power clamping terminal 331 and a clamping drive element 332. The clamping drive element 332 is used to drive the power clamping terminal 331 to clamp and make conductive contact with the power terminal 511. The output docking module 34 is used to connect to the output test interface 22. Both the power connection module 33 and the output docking module 34 are electrically connected to the test adjustment module 35, and the test adjustment module 35 is electrically connected to the test host 4. In terms of structural design, this invention constructs an efficient test system by cleverly arranging the placement component 1, the test fixture 2, the test docking component 3, and the test host 4. The placement component 1 ensures that the test fixture 2 is in the correct position. The test fixture 2 not only securely holds the power adapter 5, but also precisely aligns the power interface 51 of the power adapter 5 with the test docking component 3. At the same time, an output connector 52 is provided on the end away from the power interface 51, and is connected to it through the output interface 21. This makes the connection of the power adapter 5 clear and orderly during the test, reducing the test errors that may be caused by messy wiring.

[0059] The test docking assembly 3 achieves a high degree of automation and precision. The support frame 31 serves as the supporting structure for the entire docking assembly. The docking drive module 32 drives the power connection module 33 and the output docking module 34 to move relative to the test fixture 2, ensuring that the power connection module 33 and the output docking module 34 accurately reach their designated positions and dock with the corresponding interfaces of the power adapter 5, thus improving the docking success rate and test accuracy. The test adjustment module 35 establishes the electrical connection between the power connection module 33 and the output docking module 34, enabling the two modules to work collaboratively. It also connects electrically to the test host 4, accurately transmitting test data to the test host 4. The test host 4 can analyze and judge the received data, thereby achieving precise testing of various performance indicators of the power adapter 5. Through highly integrated design, testing efficiency is greatly improved, errors that may be caused by manual intervention are reduced, and test results are more accurate and reliable.

[0060] This invention also boasts compatibility; specifically, the power interface 51 is equipped with at least two power terminals 511, enabling the testing mechanism to adapt to power adapters 5 of different specifications for testing, thus possessing wide applicability. Whether it's a small electronic device power adapter 5 or a large device power adapter 5, it can be effectively tested on this testing mechanism, meeting diverse testing needs in the market. Through its rational structural design, precise driving mechanism, stable electrical connection, and excellent compatibility, this invention achieves efficient and accurate physical connection testing of the power adapter 5, providing highly efficient testing and production for the quality inspection and performance optimization of the power adapter 5.

[0061] See Figures 3-5As shown, the placement component 1 includes a conveying module 11 and a positioning module 12. The positioning module 12 is used to position the test fixture 2 on the conveying module 11. A wire feeding groove 13 is provided on one side of the conveying module 11 for storing the connecting wire of the output connector 52. Specifically, multiple test stations are provided on one side of the conveying module 11, each test station corresponding to a test docking component 3 and a test host 4. Each test station is equipped with a positioning module 12 to position the test fixture 2. In this embodiment, the coordinated arrangement of the conveying module 11 and the positioning module 12 improves the accuracy and stability of the test. The positioning module 12 can accurately position the test fixture 2 on the conveying module 11, ensuring that the test fixture 2 is in the correct position, so that the test docking component 3 and the power adapter 5 can achieve precise docking, effectively reducing the test error caused by position deviation and improving the reliability of the test results. The cable tray 13 is designed to neatly organize the connector cables, preventing them from becoming tangled and messy. This not only makes the testing environment cleaner and more organized but also facilitates operator work, reducing malfunctions caused by messy cables and improving testing efficiency. The multiple testing stations enable parallel testing of the power adapters 5. Each testing station corresponds to an independent testing docking component 3 and a testing host 4, allowing for simultaneous testing of multiple power adapters 5. This significantly shortens the testing cycle, improves testing efficiency, and meets the rapid testing needs of large-scale production.

[0062] See Figure 5As shown, the conveying module 11 is provided with two sets of conveying brackets 111, and the two sets of conveying brackets 111 are arranged opposite each other with conveying positioning grooves 112. The test fixture 2 is provided with a conveying positioning seat 23, which is set on the conveying positioning groove 112 and is transported along the conveying positioning groove 112 under the action of the conveying module 11. Specifically, the positioning module 12 is provided with two sets, which are arranged opposite each other on both sides of the test station. The positioning module 12 is provided with a positioning lifting cylinder 121 and a positioning drive cylinder 122. The system includes a positioning T-block 123. The conveying positioning seat 23 has a T-shaped slot 231. The positioning lifting cylinder 121 and positioning driving cylinder 122 work together to drive the positioning T-block 123 into the T-shaped slot 231, positioning the test fixture 2 in the conveying direction of the conveying module 11. Then, the positioning lifting cylinder 121 drives the positioning T-block 123 downwards, moving the test fixture 2 downwards so that both sides of the test fixture 2 abut against the surface of the conveying bracket 111, positioning the test fixture 2 in the Z-axis direction of the conveying module 11. In this embodiment, the two sets of conveying brackets 111 of the conveying module 11 are provided with conveying positioning grooves 112 opposite to each other. Combined with the conveying positioning seat 23 of the test fixture 2, this ensures accurate positioning and stable transmission of the test fixture 2 during the conveying process. This allows the test fixture 2 to move smoothly along the conveying positioning grooves 112, greatly improving the accuracy and consistency of the test fixture 2's transmission, reducing offset and shaking during transmission, and providing a reliable foundation for subsequent testing. Two sets of positioning modules 12, positioned opposite each other on both sides of the test station, achieve precise positioning of the test fixture 2 in the conveying direction through the cooperation of the positioning lifting cylinder 121, the positioning drive cylinder 122, and the positioning T-block 123 with the T-slot 231 on the conveying positioning seat 23. This ensures the accuracy of the test fixture 2's position each time it arrives at the test station, allowing control over the positional accuracy of the physical docking test. The positioning lifting cylinder 121 drives the positioning T-block 123 to pull down, causing the test fixture 2 to move downwards, so that its two sides abut against the surface of the conveying bracket 111, completing the positioning in the Z-axis direction. This ensures the omnidirectional precise fixation of the test fixture 2 in space, avoiding test errors caused by positional deviations, effectively improving the accuracy and reliability of the physical docking test of the power adapter 5, and enhancing the overall working efficiency and test quality of the testing mechanism.

[0063] A reinforcing block 232 is provided on the conveying positioning seat 23. A T-shaped slot 231 is disposed on the reinforcing block 232. The reinforcing block 232 is formed by SKD11 machining and hardened to a hardness of 55-60 HRC. A guide slope is provided at the opening of the T-shaped slot 231, and a mating slope is provided on the positioning T-block 123. The mating slope is used to engage with the guide slope, so that the positioning T-block 123 and the T-shaped slot 231 are precisely aligned, positioning the test fixture 2 in the Y-axis direction of the conveying module 11. In this embodiment, the reinforcing block 232 on the conveying positioning seat 23 is machined by SKD11 and hardened to a hardness of 55-60 HRC, greatly improving the wear resistance and strength of the reinforcing block 232. This ensures that during long-term testing, the reinforcing block 232 can stably support the test fixture 2 without being damaged or deformed due to frequent friction and vibration, thus guaranteeing the stability and reliability of the entire testing process. The guide slope at the opening of the T-slot 231 cooperates with the mating slope of the positioning T-block 123, achieving precise positioning of the test fixture 2 in the Y-axis direction of the conveying module 11. This effectively reduces positioning errors and improves test accuracy. In the physical docking test of the power adapter 5, precise positioning is crucial to ensuring the authenticity and validity of the test results. Any slight positioning deviation can lead to inaccurate test data and affect the judgment of product performance.

[0064] The test fixture 2 is provided with a placement slot 24, and the wall of the placement slot 24 is provided with a positioning surface. The positioning surface is used to position the end face of the power adapter 5, and the power interface 51 is located on the upper side of the positioning surface; the test docking assembly 3 is parallel to the positioning surface. In this embodiment, the positioning surface on the wall of the placement slot 24 can accurately position the end face of the power adapter 5. This ensures that the position of the power adapter 5 is highly consistent and accurate each time it is placed in the placement slot 24, greatly improving the repeatability and reliability of the test. Because the end face of the power adapter 5 is accurately defined, the subsequent test docking assembly 3 can dock with the power adapter 5 in a stable and accurate manner, reducing problems such as poor contact and unstable test data caused by positional deviation. The power interface 51 is located on the upper side of the positioning surface, which facilitates the docking operation between the test docking assembly 3 and the power interface 51, making the docking process smoother and reducing possible obstacles and interference during docking.

[0065] See Figure 8As shown, the docking drive module 32 includes a docking drive cylinder 321, a docking L-shaped frame 322, and a docking mounting frame 323. The docking drive cylinder 321 is mounted on the support frame 31, the docking L-shaped frame 322 is mounted on the drive end of the docking drive cylinder 321, and the docking mounting frame 323 is mounted on the docking L-shaped frame 322. The power connection module 33 and the output docking module 34 are respectively mounted on both sides of the docking mounting frame 323. In this embodiment, the docking drive cylinder 321, mounted on the support frame 31, can precisely control the magnitude and stroke of the output driving force according to the test requirements, ensuring a stable and reliable docking process and effectively avoiding docking failure or damage to the test sample due to unstable driving force. The docking L-shaped frame 322 is connected to the drive end of the docking drive cylinder 321, realizing the conversion and transmission of power. The linear driving force of the cylinder is converted into spatial motion suitable for docking operations, and a stable support structure is provided for the docking mounting bracket 323, ensuring the positional accuracy of the mounting bracket during movement, so that the power connection module 33 and the output docking module 34 can be accurately aligned during docking.

[0066] Multiple power clamping terminals 331 are provided and mounted on a docking mounting bracket 323. Each power clamping terminal 331 includes a mounting end 3311, an elastic end 3312, and a clamping part 3313. The clamping part 3313 is provided with a clamping groove 3314, and a clamping guide slope 3315 is provided at the opening of the groove. The elastic end 3312 is provided with an elastic slope 3316. The mounting end 3311 is mounted on the docking mounting bracket 323. The clamping drive element 332 is used to drive the elastic end 3312 to cause the clamping part 3313 to open and close, so as to contact or release the power terminal 511. In this embodiment, the arrangement of multiple power clamping terminals 331 can adapt to the testing of power adapters 5 with different specifications and quantity requirements, greatly improving the versatility and applicability of the testing mechanism and meeting diverse testing needs. The power clamping terminal 331, via the clamping guide slope 3315 at the opening of the clamping groove 3314 of the clamping part 3313, can accurately guide the power terminal 511 smoothly into the clamping groove 3314 during the power adapter 5 docking test, effectively reducing the docking difficulty and improving the success rate and efficiency of docking. The elastic slope 3316 of the elastic end 3312, in conjunction with the clamping drive element 332, allows the elastic end 3312 to drive the clamping part 3313 to open and close more smoothly and stably when driven, ensuring the reliability of the clamping action. The mounting end 3311 is firmly set on the docking mounting bracket 323, ensuring the stability of the entire power clamping terminal 331 during the test and reducing test errors caused by factors such as shaking. The clamping drive element 332 drives the elastic end 3312 to drive the clamping part 3313 to open and close in order to contact or release the power terminal 511, realizing a fast, convenient and accurate clamping and releasing operation of the power terminal 511.

[0067] See Figures 8-9As shown, the clamping drive element 332 includes a clamping drive cylinder 3321 and an opening clamping plate 3322. The clamping drive cylinder 3321 is used to drive the opening clamping plate 3322 to reciprocate on the elastic end 3312. The opening clamping plate 3322 is provided with an opening groove 3323 corresponding to the elastic inclined surface 3316. The opening groove 3323 drives the elastic end 3312 to move, thereby driving the clamping part 3313 to open and close. Specifically, the output docking module 34 includes a docking connection plate 341, a docking connector 342, and a floating guide sleeve 343. The floating guide sleeve 343 is disposed on the docking connection plate 341, and the docking connector 342 is disposed on the floating guide sleeve 343. The docking connection plate 341 is provided with a docking mounting hole 3411, and one end of the docking connector 342 passes through the docking mounting hole 3411, leaving a gap between the docking mounting hole 3411 and the docking connector 342. The floating guide sleeve 343 is provided with a floating spring 3431, and one end of the floating spring 3431 abuts against the docking connector 342. In this embodiment, the clamping drive element 332 clamps the power adapter 5 more precisely. The clamping drive cylinder 3321 drives the opening clamping plate 3322 to reciprocate on the elastic end 3312. The engagement of the opening clamping groove 3323 and the elastic inclined surface 3316 drives the elastic end 3312 to move, thereby opening and closing the clamping part 3313. This ensures reliable clamping of power adapters 5 of different specifications, adapts to various testing requirements, and effectively improves the versatility and compatibility of the testing mechanism. The mating mounting hole 3411 on the mating connecting plate 341 facilitates the installation of the entire module, ensuring the stability and accuracy of the installation. The mating connector 342 passes through the mating mounting hole 3411 with a gap between them. Combined with the floating spring 3431 on the floating guide sleeve 343, this provides a certain degree of floating performance during the mating process. One end of the floating spring 3431 abuts against the mating connector 342, effectively buffering the connection during mating and preventing damage to the power adapter 5 or the testing mechanism due to rigid mating. This improves the stability and safety of the mating process and ensures the accuracy and reliability of the test data.

[0068] See Figures 1-10 As shown, a physical connection test method for a power adapter includes the physical connection test mechanism for the power adapter 5, and the method includes the following steps:

[0069] Step S1, Fixture Positioning Stage

[0070] The test fixture 2 is transferred to the test station along the conveyor module 11;

[0071] The X / Y / Z axial constraints of the test fixture 2 are implemented by a three-dimensional positioning mechanism, specifically including: a) driving the positioning T-block 123 to snap into the T-slot 231 of the reinforcing block 232 along the conveying direction; b) achieving vertical positioning by pulling down the lifting cylinder; c) completing lateral positioning by the interaction of the guide slope and the mating slope.

[0072] Step S2, Electrical Connection Stage

[0073] The drive docking module 32 brings the test docking assembly 3 close to the test fixture 2 and performs the following synchronous actions: a) the clamping drive cylinder 3321 controls the opening clamping plate 3322 to squeeze the elastic inclined surface 3316 of the elastic end 3312, causing the clamping groove 3314 of the power clamping terminal 331 to close and clamp the power terminal 511; b) the clamping guide inclined surface 3315 is used to achieve automatic centering of the power terminal 511; c) the spring compensation mechanism of the floating guide sleeve 343 ensures reliable contact between the output docking module 34 and the output test interface 22.

[0074] Step S3, Test Execution Phase

[0075] The following testing process is performed by the test adjustment module 35: a) Apply a test voltage signal to the power connection module 33; b) Detect the current fluctuation parameters of the output connection module 34 in real time; c) Synchronously collect the contact impedance of the power terminal 511 and the conduction status of the output interface 21; d) Transmit the collected data to the test host 4 for the following analysis: compare the actual output parameters with the preset threshold range, determine whether the contact status meets the dynamic stability requirements, and generate a test report containing a voltage fluctuation spectrum.

[0076] Step S4, Reset Phase

[0077] After the test is completed, perform the following: a) release the clamping state of the power clamping terminal 331; b) drive the test docking assembly 3 back to the initial position; c) release the three-dimensional positioning constraints of the test fixture 2; d) transfer the test fixture 2 to the next station.

[0078] This embodiment employs a three-dimensional positioning mechanism to precisely constrain the test fixture 2 along the X, Y, and Z axes. Driving the positioning T-block along the conveying direction to engage with the T-slot of the reinforcing block 232 effectively limits the fixture's displacement in the conveying direction, ensuring its positional accuracy. The lifting cylinder pulls down to achieve vertical positioning, preventing the fixture from swaying or shifting vertically. Lateral positioning is achieved through the interaction of the guide ramp and the mating ramp, further improving the fixture's horizontal positioning accuracy. This three-dimensional positioning method significantly improves the stability and accuracy of the test fixture 2's positioning, providing a reliable foundation for subsequent electrical connection and testing. During the electrical connection phase, multiple actions work in concert. The clamping drive cylinder 3321 controls the opening clamping plate 3322 to press the elastic inclined surface 3316 of the elastic end 3312, causing the clamping groove 3314 of the power clamping terminal 331 to close and clamp the power terminal 511, ensuring a tight connection between the power terminal 511 and the test component. The clamping guide inclined surface 3315 realizes the automatic alignment of the power terminal 511, improving the efficiency and accuracy of docking. The spring compensation mechanism of the floating guide sleeve 343 ensures reliable contact between the output docking module 34 and the output test interface 22, effectively avoiding problems such as poor contact and ensuring the stability of electrical signal transmission. During the test execution phase, the test adjustment module 35 performs multi-parameter detection according to the set process and transmits the collected data to the test host 4 for in-depth analysis. It can detect current fluctuation parameters in real time, collect the contact impedance of the power terminal 511 and the conduction status of the output interface 21, and compare the actual output parameters with the preset threshold range to generate a test report including voltage fluctuation spectrum. It can not only comprehensively and accurately evaluate the performance of the power adapter 5, but also promptly detect potential problems and ensure product quality. During the reset phase, each action is executed in an orderly manner, quickly releasing the docking state and fixture constraints, and transferring test fixture 2 to the next workstation, thus realizing an efficient cycle of the testing process and improving overall testing efficiency.

[0079] In step S3 of this embodiment, a multi-level detection mechanism is constructed by testing host 4:

[0080] First detection layer: Sends a pulse test signal upon initial power-on to detect the transient response of power terminal 511;

[0081] Second detection layer: During the steady-state test phase, a stepped load current is applied to monitor the voltage drop curve of the output interface 21;

[0082] The third detection layer simulates abnormal operating conditions to trigger protection mechanism tests, and records response time and protection accuracy.

[0083] Dynamic stability requirements include:

[0084] a) Voltage fluctuations during the 10-second steady-state test shall not exceed ±1%;

[0085] b) Recovery time during load surges is less than 50ms;

[0086] c) The contact temperature rise is controlled within the range of ambient temperature +15℃;

[0087] d) Signal-to-noise ratio better than 60dB.

[0088] In step S2 of this embodiment, the elastic compensation mechanism specifically includes: when the docking connector 342 contacts the output test interface 22:

[0089] a) The axial clearance of the floating guide sleeve 343 is used to compensate for the docking deviation;

[0090] b) Utilize floating spring 3431 to absorb the impact energy during docking;

[0091] c) Automatically adjusts the docking angle when in inclined contact;

[0092] d) Monitor the floating displacement in real time and feed it back to the test host 4.

[0093] The above method also includes an exception handling process:

[0094] When contact resistance exceeding the limit is detected, execute:

[0095] a) Trigger a high-frequency vibration cleaning process on the clamping terminals;

[0096] b) Reapply clamping pressure and repeat the test;

[0097] c) Products that fail three retests are marked as defective.

[0098] d) Automatically generate microscopic images of the contact surface for defect analysis.

[0099] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A power adapter physical mating test mechanism, characterized in that: The utility model provides a test device, including placing component, test fixture, test docking assembly and test host computer, the test fixture sets up on placing component, the test fixture is used for power adapter fixed, the power interface of power adapter faces test docking assembly, the one end of power adapter is provided with output connector with power interface, one side of test fixture is provided with output interface, output interface is used for connecting output connector, one side of test fixture faces test docking assembly and is provided with output test interface, output test interface is electrically connected with output interface; The power interface is provided with at least two power terminals, the test docking assembly includes a support frame, a docking drive module, a power connection module, an output docking module, and a test adjustment module, the support frame is located on one side of the placing component, the docking drive module is arranged on the support frame, and the docking drive module is used to drive the power connection module and the output docking module to move relatively towards the test fixture; The power connection module includes a power clamping terminal and a clamping drive element, the clamping drive element is used to drive the power clamping terminal to clamp and contact the power terminal; the output docking module is used to connect the output test interface; The power connection module and the output docking module are electrically connected with the test adjustment module, and the test adjustment module is electrically connected with the test host computer; The placing component includes a conveying module and a positioning module, the positioning module is used to position the test fixture on the conveying module, one side of the conveying module is provided with a wire slot for accommodating the connecting line of the output connector; One side of the conveying module is provided with a plurality of test stations, each test station corresponds to a test docking assembly and a test host computer; a positioning module is arranged on each test station to position the test fixture; The conveying module is provided with two groups of conveying supports, the two groups of conveying supports are oppositely provided with conveying positioning grooves, the test fixture is provided with a conveying positioning seat, the conveying positioning seat is arranged on the conveying positioning groove and is conveyed along the conveying positioning groove under the action of the conveying module; The positioning module is provided with two groups, the two groups of positioning modules are oppositely arranged on two sides of the test station, the positioning module is provided with a positioning lifting cylinder, a positioning drive cylinder, and a positioning T-shaped block, the conveying positioning seat is provided with a T-shaped clamping groove, the positioning lifting cylinder and the positioning drive cylinder cooperate to drive the positioning T-shaped block to fit in the T-shaped clamping groove to position the test fixture in the conveying direction of the conveying module, then the positioning lifting cylinder drives the positioning T-shaped block to pull down, drives the test fixture to move downward, so that the two sides of the test fixture abut against the surface of the conveying support to position the test fixture in the Z-axis direction of the conveying module.

2. The power adapter physical mating test mechanism of claim 1, wherein: The conveying positioning seat is provided with a reinforcing block, the T-shaped clamping groove is arranged on the reinforcing block, the reinforcing block is processed from SKD11 and has a quenched hardness of 55-60HRC; a guide slope is arranged at the notch of the T-shaped clamping groove, the positioning T-shaped block is provided with a matching slope, the matching slope is used to match the guide slope to accurately connect the positioning T-shaped block with the T-shaped clamping groove and position the test fixture in the Y-axis direction of the conveying module.

3. The power adapter physical mating test mechanism of claim 2, wherein: The test fixture is provided with a placing groove, a wall surface of the placing groove is provided with a positioning surface for positioning an end surface of the power adapter, and the power interface is located on the upper side of the positioning surface; the test docking assembly is parallel to the positioning surface.

4. The power adapter physical mating test mechanism of claim 3, wherein: The docking drive module includes a docking drive cylinder, a docking L-shaped frame, and a docking mounting frame. The docking drive cylinder is arranged on the support frame. The docking L-shaped frame is arranged on the driving end of the docking drive cylinder. The docking mounting frame is arranged on the docking L-shaped frame. The power connection module and the output docking module are respectively arranged on both sides of the docking mounting frame.

5. The power adapter physical mating test mechanism of claim 4, wherein: The power clamping terminal is provided with a plurality of power clamping terminals arranged on the docking mounting frame. The power clamping terminal includes a mounting end, an elastic end, and a clamping part. The clamping part is provided with a clamping groove. The slot opening of the clamping groove is provided with a clamping guide inclined surface. The elastic end is provided with an elastic inclined surface. The mounting end is arranged on the docking mounting frame. The clamping drive element is used to drive the elastic end to drive the clamping part to open and close to contact or loosen the power terminal.

6. The power adapter physical mating test mechanism of claim 5, wherein: The clamping drive element includes a clamping drive cylinder and an opening clamp plate. The clamping drive cylinder is used to drive the opening clamp plate to reciprocate on the elastic end. The opening clamp plate is provided with an opening clamp groove corresponding to the elastic inclined surface. The opening clamp groove drives the elastic end to move to drive the clamping part to open and close.

7. The power adapter physical mating test mechanism of claim 6, wherein: The output docking module includes a docking connecting plate, a docking connector, and a floating guide sleeve. The floating guide sleeve is arranged on the docking connecting plate. The docking connector is arranged on the floating guide sleeve. The docking connecting plate is provided with a docking mounting hole. One end of the docking connector passes through the docking mounting hole. A gap is left between the docking mounting hole and the docking connector. The floating guide sleeve is provided with a floating spring. One end of the floating spring abuts against the docking connector.

8. A method of physical mating test for a power adapter, the method comprising: The power adapter physical docking test mechanism of claim 7 is implemented. The method includes the following steps: Step S1, fixture positioning stage The test fixture is transmitted to the test station along the conveying module; The test fixture is constrained in X / Y / Z axial direction by the three-dimensional positioning mechanism, which specifically includes: a) driving the positioning T-shaped block to be clamped into the T-shaped clamping groove of the reinforcing block along the conveying direction; b) achieving vertical positioning by pulling down through the lifting cylinder; c) completing horizontal positioning by the interaction of the guide inclined surface and the matching inclined surface; Step S2, electrical docking stage The docking drive module is driven to make the test docking assembly approach the test fixture, and the following is performed synchronously: a) controlling the opening clamp plate to press the elastic inclined surface of the elastic end through the clamping drive cylinder, so as to make the clamping groove of the power clamping terminal close to clamp the power terminal; b) realizing automatic centering of the power terminal by using the clamping guide inclined surface; c) ensuring reliable contact of the output docking module and the output test interface by the spring compensation mechanism of the floating guide sleeve; Step S3, test execution stage The following detection process is performed by the test adjustment module: a) applying a test voltage signal to the power connection module; b) detecting the current fluctuation parameter of the output docking module in real time; c) synchronously collecting the contact impedance of the power terminal and the on-state of the output interface; d) The collected data is transmitted to the test host for analysis, including comparing the actual output parameters with the preset threshold range, determining whether the contact state meets the dynamic stability requirement, and generating a test report containing the voltage fluctuation map; Step S4, reset phase After the test is completed, the following operations are performed: a) The clamping state of the power supply clamping terminal is released; b) The test docking assembly is driven to return to the initial position; c) The three-dimensional positioning constraint of the test fixture is released; d) The test fixture is transported to the next station.

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