Multifunctional automatic aging system and method thereof

Abstract

The invention discloses a multifunctional automatic aging system and method, and the system comprises a multi-parameter measurement module, an integrated oscilloscope, a universal meter and a temperature sensor, and is used for measuring the output voltage ripple, the output voltage value, the output current value and the surface temperature of an aging module in real time; the data comparison and judgment unit is used for automatically comparing the real-time measurement data of the multi-parameter measurement module with a preset standard value, recording unqualified data and identifying the corresponding aging module; the abnormity monitoring and processing unit is used for monitoring over-temperature, over-current and overload abnormal states in the aging process in real time, triggering alarm and executing preset processing operation; the database module is used for storing all test data and supporting production process tracking and problem tracing based on the stored data; the report generation module is used for automatically screening test data according to customer requirements and generating a standardized test report; and the control software unit is provided with modules for setting aging time, selecting models of products to be tested, configuring test functions, reporting templates and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of aging testing of electronic products, and particularly to a multifunctional aging system based on automatic control and its implementation method for solving problems such as low efficiency, high error operation rate, and complex data processing in traditional manual aging testing. Background Art

[0002] Currently, in the common production process of electronic products, aging testing is a key link to ensure product reliability. Traditional aging testing mainly relies on manual operation, and it has at least the following defects:

[0003] Low efficiency: The aging time and test indicators of different products vary greatly, requiring full-time 24-hour on-site monitoring by dedicated personnel, which is time-consuming and laborious.

[0004] Risk of misoperation: Manual data recording is prone to errors, and frequent adjustment of equipment is required when switching test items, resulting in deviation of test results.

[0005] Lag in data processing: Test data needs to be manually sorted and analyzed, and the report generation cycle is long, making it difficult to meet the requirements of rapid production.

[0006] Safety hazards: Abnormalities such as overheating and overcurrent may occur during the aging process, and there is a risk of response delay in manual monitoring.

[0007] In addition, in the prior art, some automated aging equipment only realizes a single function (such as temperature monitoring), lacking the capabilities of multi-parameter integration, dynamic adjustment, and intelligent data processing, and cannot meet the comprehensive aging requirements of complex products. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide a multifunctional automated aging system and method. A multifunctional automated aging system and its method.

[0009] Its main inventive purposes are as follows:

[0010] 1. Realize the automatic and precise control of the entire process of aging testing. Users can flexibly set the aging time, test items, and qualified judgment indicators according to the product characteristics, and the system automatically completes the aging inspection, reducing manual intervention and improving the test accuracy.

[0011] 2. Build a powerful data processing and management system. The system automatically records the aging test data and uploads it to the database, automatically screens out unqualified products, and can also automatically generate and print test reports according to the diverse needs of customers, improving the data processing efficiency and the pertinence of the reports.

[0012] 3. Build a complete monitoring and automatic processing mechanism to monitor abnormal conditions such as overheating, overloading, and overcurrent in real time during the aging process. Once an abnormality is detected, immediately 1. issue an alarm and automatically take countermeasures to effectively avoid the risk of human misoperation and comprehensively improve the efficiency and quality of the aging test.

[0013] To solve the above technical problems, the present application provides the following technical solutions:

[0014] A multifunctional automated aging system of the present invention includes:

[0015] A multi-parameter measurement module, integrating an oscilloscope, a multimeter, and a temperature sensor, is used to measure the output voltage ripple, output voltage value, output current value, and surface temperature of the aging module in real time;

[0016] A data comparison and determination unit is used to automatically compare the real-time measurement data of the multi-parameter measurement module with preset standard values, record unqualified data, and identify the corresponding aging module;

[0017] An abnormal monitoring and processing unit is used to monitor over-temperature, over-current, and overloading abnormal states in real time during the aging process, trigger an alarm, and execute preset processing operations;

[0018] A database module is used to store all test data and support production process tracking and problem tracing based on the stored data;

[0019] A report generation module automatically filters test data according to customer requirements and generates a standardized test report;

[0020] A control software unit is provided with modules for setting the aging time, selecting the model of the product to be tested, configuring test functions, and report templates.

[0021] The present invention also provides a multifunctional automated aging method, which includes the following steps:

[0022] S1: Set the aging time, select the model of the product to be tested, and configure test functions through the control software;

[0023] S2: Start the multi-parameter measurement module to obtain the output voltage ripple, output voltage value, output current value, and surface temperature data of the aging module in real time;

[0024] S3: Automatically compare the measurement data with preset standard values. If the data is abnormal, record the unqualified data and identify the corresponding module;

[0025] S4: Monitor over-temperature, over-current, and overloading abnormal states during the aging process, trigger an alarm, and execute preset processing operations;

[0026] S5: Encrypt and store the test data in the database and associate it with the production batch information;

[0027] S6: Automatically generate a test report containing the filtered data and visualization charts according to customer requirements.

[0028] Among them,

[0029] The temperature sensor is a DLJC-W03 type temperature sensor, configured to measure the surface temperature of the aging module at multiple points.

[0030] The control software unit further includes:

[0031] An aging time segmented setting module to support dynamic adjustment of aging parameters at different stages;

[0032] A test function selection module to automatically match preset test indicators according to the product model.

[0033] The processing operations performed by the abnormal monitoring and processing unit include: cutting off the power supply of the abnormal module, starting the heat dissipation device, or sending a remote alarm signal.

[0034] The database module supports encrypted data storage and interfaces with the enterprise production management system to realize the associated traceability of aging data and production batch information.

[0035] Preferably:

[0036] In step S1, the aging time supports segmented setting, and different stages correspond to different dynamic adjustment strategies for test parameters.

[0037] In step S4, the preset processing operations include cutting off the power supply of the abnormal module, starting the heat dissipation device, or sending an alarm signal to a specified terminal.

[0038] In step S5, the database interacts with the production management system in real time, and associates the aging data with the product batch, production time, and operator information through data tags.

[0039] In step S6, the test report supports the addition of custom fields and generates charts including data trend charts, exception statistical tables, and pass rate analysis according to customer requirements.

[0040] Compared with the prior art, a multi-functional automatic aging system of the present invention has at least the following beneficial effects:

[0041] 1. The invention of a multi-functional automatic aging system improves the test accuracy and consistency: This multi-functional automatic aging system realizes a high degree of automation of aging tests, reduces manual intervention, effectively avoids human misoperations, and significantly improves the test accuracy and consistency. Compared with traditional manual tests, the test accuracy rate has increased from 80% to over 98%.

[0042] 2. Improve testing efficiency and shorten production cycle: The automated testing process and fast data processing capabilities have significantly improved the efficiency of aging testing. Taking this test as an example, it took 5 days to manually test 100 power modules in the past, while this system only takes 1 day, greatly shortening the testing cycle, improving production efficiency, and meeting the production needs of enterprises.

[0043] 3. Enhance quality control and ensure product stability: The system strictly conducts tests according to preset standards, avoiding the problem of inconsistent manual testing standards, and ensuring the stability and consistency of product quality. By real-time monitoring and automatically processing abnormal situations, the risk of equipment and product damage is effectively reduced, and product quality is improved.

[0044] 4. Improve data management and support production optimization: Test data is automatically saved to the database and stored and managed in categories, facilitating querying, statistics, and analysis. By mining and analyzing historical data, the root cause of product quality problems can be quickly traced, providing support for product quality improvement and production process optimization.

[0045] The following further explains a multi-functional automated aging system and its method of the present invention in conjunction with the accompanying drawings. Description of the Drawings

[0046] Figure 1 It is a schematic structural diagram of a multi-functional automated aging system of the present invention.

[0047] (It is recommended to supplement the software interface screenshot and mark the functions of each functional area and operation button to help understand the software operation process; or the software algorithm flowchart, hardware circuit diagram, etc.) Detailed Embodiment

[0048] As Figure 1 shown, the multi-functional automated aging system of the present invention includes a hardware module and a software control platform, and realizes automated testing through the following core components:

[0049] Control software: Provides functions such as aging parameter setting (time, test items, report template), device control instruction issuance, and data integration.

[0050] Multi-parameter measurement module: Integrates an oscilloscope (measures output voltage ripple), a multimeter (measures voltage / current values), and a DLJC-W03 temperature sensor (multi-point monitors the surface temperature of the module).

[0051] Data comparison and determination unit: Based on preset standard values, it determines in real time whether the data is qualified and marks abnormal modules.

[0052] Abnormal monitoring and processing unit: Triggers an alarm for abnormal states such as over-temperature, over-current, and over-load, and performs operations such as power cut-off and heat dissipation start.

[0053] Database module: Stores complete test data, supports encrypted storage and data interaction with the enterprise production management system (MES).

[0054] Report generation module: Automatically generates test reports containing data charts, anomaly statistics, and pass rate analysis according to customer requirements.

[0055] The hardware components mainly include a computer, KCKZ-24 module, oscilloscope, multimeter, DLC-W03 measurement module, and printer. Each output of the aging module is connected to the KCKZ-24 module. The KCKZ-24 module serves as a connection hub and is responsible for receiving and transmitting signals from the aging module. The DLC-W03 measurement module and the computer use 485 communication to transmit data, ensuring stable and reliable data transmission.

[0056] The software control unit: Develops specialized control software, which is installed in the computer to achieve unified management and control of hardware devices. The computer uses the control software to control the KCKZ-24 module to conduct a comprehensive measurement of all aging modules every two hours. During the measurement, the control software sends instructions to the oscilloscope, multimeter, and DLC-W03 measurement module respectively, controls the oscilloscope to measure the output voltage ripple value of the current path of the KCKZ-24, controls the multimeter to measure the current output voltage value, and controls the DLC-W03 measurement module to measure the output current value of the current path and the surface temperature value of the aging module. The software compares the measured data with the preset standard values in real time, records the data in detail, separately records the unqualified values, clearly marks the unqualified modules, and finally prints the test report according to the preset requirements of the customer.

[0057] In addition, software function expansion can be carried out: Enrich the functions of the control software, enabling users to flexibly set the aging time on the software interface, select the corresponding aging product model according to the product characteristics (the test functions and indicators of different models are different), freely choose the required test functions, and also customize the report template. The software monitors abnormal values such as overload, overcurrent, and over-temperature during the aging process in real time. Once an anomaly is detected, it automatically takes measures such as cutting off the power supply of the abnormal module and issuing an alarm prompt. The measured data is saved to the database for comprehensive traceability of the product production process and in-depth analysis of the root causes of product quality problems.

[0058] The method of the present invention includes the following steps:

[0059] 1. Test parameter setting step: The user inputs the aging time and selects the aging product model on the control software interface. The software automatically loads the corresponding default test functions and standard values according to the selected model. The user can also manually adjust the test function options according to actual needs.

[0060] 2. Loop measurement steps: The computer sends measurement instructions to the KCKZ-24 module at set time intervals (such as every two hours) through the control software. The KCKZ-24 module switches the test circuits in sequence. Each time a circuit is switched to, the control software synchronously sends measurement instructions to the oscilloscope, multimeter, and DLC-W03 measurement module. Each measurement module collects the voltage ripple value, voltage value, current value, and temperature value of the current circuit and transmits the data back to the computer.

[0061] 3. Data processing and judgment steps: After receiving the measurement data, the control software compares it with the standard value according to the preset algorithm. If the data is within the standard range, it is marked as qualified; if it exceeds the standard range, the unqualified data and the corresponding aging module number are recorded, and at the same time, the exception handling program is started.

[0062] 4. Exception handling steps: For over-temperature exceptions, the control software first reduces the load power of the corresponding aging module. If the temperature does not return to normal within the preset time, the power supply of the module is cut off; for overload and over-current exceptions, the power supply of the corresponding module is immediately cut off, and detailed information such as the time and type of the exception occurrence is recorded.

[0063] 5. Report generation and printing steps: After the aging test is completed, the control software extracts the test data from the database according to the report template selected by the user, generates a test report containing the test data of each aging module and the qualified judgment result, and sends it to the printer for printing output.

[0064] Steps for further implementing function plugin expansion: The software design adopts a plugin architecture, supporting the access of function plugins developed by third parties. When new test functions are needed, developers develop plugins according to the interface specifications provided by the software, install the plugins to the specified directory, and the control software automatically detects and loads the new plugins when starting up, realizing the rapid expansion of test functions.

[0065] Steps for further implementing custom report template expansion: Users can customize the layout, font, chart style, etc. of the report through the template editing tool built into the software. After editing, the template is saved to the database and can be directly selected for use when generating reports next time, meeting the personalized needs of different customers for report formats.

[0066] Steps for further implementing remote monitoring function expansion: Integrate a remote communication module in the software to achieve the access and control of remote devices through an Internet connection. Authorized users can remotely log in to the system through the web page or mobile application, view the running status and measurement data of the aging test in real time, and remotely send control instructions such as starting and stopping the test, adjusting test parameters, etc., to achieve remote monitoring and management.

[0067] Among them, in the data processing and judgment step, the software uses a sliding window algorithm to analyze the measurement data in real time. When multiple consecutive data points show an abnormal trend, a warning message is sent in advance, even if the data has not exceeded the standard value.

[0068] After the report generation and printing step, a data backup and traceability step may also be included: the control software backs up all the data of this test to an external storage device and creates an index in the database, so as to quickly query and trace the test data according to information such as product batch and test time in the future, providing data support for product quality analysis and production process improvement.

[0069] In a specific embodiment, the control software adopts a hierarchical architecture design, including a presentation layer, a business logic layer, a data access layer, and a hardware driver layer; the presentation layer is used to interact with users and provide an operation interface; the business logic layer is responsible for processing core business rules such as test process control, data processing and analysis; the data access layer is used to implement data storage, reading and management; the hardware driver layer is used to encapsulate operation instructions for the hardware device to ensure stable communication between the software and the hardware.

[0070] Its system hardware configuration

[0071] Control terminal: Industrial computer (pre-installed with control software), supporting RS485 and Ethernet communications.

[0072] Measuring equipment:

[0073] Oscilloscope: Bandwidth ≥ 100MHz, sampling rate 1GS / s.

[0074] Multimeter: Six and a half digits of precision, supporting multi-channel scanning.

[0075] DLJC-W03 temperature sensor: Temperature measurement range -20°C to 150°C, accuracy ±0.5°C.

[0076] Actuator: KCKZ-24 module (24-channel relay control), used to turn on and off the power of the aging module.

[0077] The control software includes:

[0078] 1. A test task management module, used to create, edit, schedule, pause, resume and terminate aging test tasks, and monitor the task progress in real time during the task execution;

[0079] 2. A data acquisition and processing module, which synchronously acquires data from multiple data sources using a multi-threaded or asynchronous communication mechanism, performs real-time verification, trend analysis, and correlation analysis on the acquired data, and stores the data classified by task number, timestamp, and test item;

[0080] 3. Abnormal handling and alarm module, which classifies and identifies abnormal situations such as over-temperature, overload, over-current, and communication failures during the aging process, establishes a multi-level alarm mechanism, and records abnormal information in detail;

[0081] 4. Report generation and export module, which provides multiple report templates for selection, supports custom modification of templates, uses data visualization means to display test data, and can export reports in formats such as PDF, Word, and Excel.

[0082] The control software introduces machine learning and artificial intelligence algorithms, uses clustering analysis algorithms to classify product performance data, and uses prediction model algorithms to predict the aging performance and reliability of new products; adopts data fusion and calibration algorithms to process data collected by different measuring devices; encrypts and stores sensitive data during transmission, and strictly controls user data access permissions.

[0083] The control software has a user authentication and authorization mechanism, uses user names, passwords, and verification codes for user identity verification, and assigns different operation permissions according to user roles and responsibilities; the control software establishes a system log recording mechanism to record, back up, and review user operation behaviors; and the control software is equipped with an automatic update mechanism to regularly push updated versions and perform maintenance and optimization.

[0084] The pseudo-code of its data comparison algorithm is as follows:

[0085] Copy

[0086] IF measured value > upper limit of standard value OR measured value < lower limit of standard value THEN

[0087] Record abnormal data and identify the module number

[0088] Trigger the abnormal handling program

[0089] ELSE

[0090] Store the data in the database and mark it as qualified

[0091] END IF

[0092] Customization of report templates

[0093] Users can select report templates through the control software, add enterprise LOGOs, customize fields (such as customer names, special test requirements), and insert visual elements such as data trend charts and bar charts.

[0094] The present invention has strong industrial applicability and can be widely applied to the production line aging tests of power modules, communication devices, automotive electronics, etc. It is compatible with multiple product models and has high scalability and adaptability.

[0095] The embodiments described above are only descriptions of the preferred embodiments of the present invention and do not limit the scope of the present invention. Without departing from the spirit of the present invention's design, 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 multifunctional automated aging system, characterized in that Comprising: A multi-parameter measurement module, integrating an oscilloscope, a multimeter and a temperature sensor, for real-time measurement of the output voltage ripple, output voltage value, output current value and surface temperature of the aging module; A data comparison and determination unit, for automatically comparing the real-time measurement data of the multi-parameter measurement module with preset standard values, recording unqualified data and identifying the corresponding aging module; An abnormal monitoring and processing unit, for real-time monitoring of over-temperature, over-current and over-load abnormal states during the aging process, triggering an alarm and performing preset processing operations; A database module, for storing all test data, and supporting production process tracking and problem tracing based on the stored data; A report generation module, for automatically screening test data according to customer requirements and generating a standardized test report; A control software unit, provided with modules for setting the aging time, selecting the model of the product to be tested, configuring test functions and report templates, etc.

2. The multifunctional automatic aging system according to claim 1, wherein, The temperature sensor is a DLJC-W03 type temperature sensor, configured for multi-point measurement of the surface temperature of the aging module.

3. The multifunctional automatic aging system according to claim 1, characterized in that The control software unit further includes: An aging time segmented setting module, to support dynamic adjustment of aging parameters in different stages; A test function selection module, to automatically match preset test indicators according to the product model.

4. A multi-functional automated aging system according to claim 1, wherein The processing operations performed by the abnormal monitoring and processing unit include: cutting off the power supply of the abnormal module, starting the heat dissipation device or sending a remote alarm signal.

5. A multifunctional automated aging system according to claim 1, characterized in that, The database module supports encrypted storage of data, and is docked with the enterprise production management system to realize the associated traceability of aging data and production batch information.

6. A multi-functional automated aging method, characterized in that, Including the following steps: S1: Set the aging time, select the model of the product to be tested and configure the test function through the control software; S2: Start the multi-parameter measurement module, and obtain in real time the output voltage ripple, output voltage value, output current value and surface temperature data of the aging module; S3: Automatically compare the measurement data with preset standard values, and if the data is abnormal, record the unqualified data and identify the corresponding module; S4: Monitor over-temperature, over-current and over-load abnormal states during the aging process, trigger an alarm and perform preset processing operations; S5: Encrypt and store the test data in the database, and associate the production batch information; S6: Automatically generate a test report containing screened data and visualization charts according to customer requirements.

7. The method according to claim 6, wherein: In step S1, the aging time supports segmented setting, and different stages correspond to different dynamic adjustment strategies of test parameters.

8. The method according to claim 6, wherein: In step S4, the preset processing operations include cutting off the power supply of the abnormal module, starting the heat dissipation device or sending an alarm signal to a specified terminal.

9. The method according to claim 6, wherein: In step S5, the database interacts with the production management system in real time, and associates aging data with product batches, production times and operator information through data tags.

10. The method according to claim 6, wherein: In step S6, the test report supports the addition of custom fields and generates charts including data trend charts, exception statistics tables, and pass rate analyses according to customer requirements.

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