Wide-voltage high-power intelligent resistive load test system

Abstract

The invention particularly relates to a wide-voltage high-power intelligent resistive load test system. The system comprises a data acquisition module; and the data analysis module is used for analyzing the load resistance temperature of each wire group to obtain a preliminary screening coefficient, presetting a preliminary screening coefficient threshold value, and analyzing the wire corresponding to the preliminary screening coefficient lower than the preliminary screening coefficient threshold value to obtain a wire body temperature coefficient and a joint temperature coefficient. According to the method, the complex form of the electric wire in practical application is considered, and the electric wire is subjected to grouping testing according to different forms of natural stretching, bending, winding, spiral curling and the like; the working state of the electric wire under the actual working conditions of narrow electric appliance interior, dense wiring environment and the like is truly restored; by monitoring the temperatures of the surfaces, joints and load resistors of the wires in different forms, the performance of the wires under actual heat dissipation conditions and heat distribution can be evaluated more comprehensively, the problem that a test result is disjointed from actual application is effectively avoided, and a reliable basis is provided for accurately evaluating the load capacity of the wires.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical testing, and particularly to a wide-voltage high-power intelligent resistive load testing system. Background Art

[0002] During the operation of electrical equipment and power transmission systems, as a key component for electrical energy transmission, the load capacity and reliability of wires are like the "lifeline" of the system, directly determining whether the entire system can operate safely and stably.

[0003] Currently, there are many limitations in traditional wire load testing methods that urgently need to be solved. The most prominent problem is that the testing scenarios are only limited to straight wires, which are very different from the actual laying shapes of wires under complex working conditions.

[0004] In real application scenarios, from the intricate wiring environment inside small appliances to the winding and spiral curling of wires in large power facilities due to space limitations or installation requirements, the laying shapes of wires vary greatly. These complex shapes will significantly change the heat dissipation conditions and heat distribution of wires. For example, in a small space, the heat dissipation area of wires is greatly reduced due to bending and winding, making it difficult for heat to dissipate effectively, and it is very easy to cause local overheating problems.

[0005] However, since traditional testing methods do not consider these actual working conditions, the test results are seriously disconnected from actual applications, and it is impossible to accurately evaluate the load capacity of wires in the actual working state, making it difficult to effectively ensure the stable operation of electrical equipment and power transmission systems. Therefore, a wide-voltage high-power intelligent resistive load testing system is needed to address the above-mentioned problems. Summary of the Invention

[0006] The purpose of the present invention is to provide a wide-voltage high-power intelligent resistive load testing system to solve the above problems.

[0007] To achieve the above purpose, the present invention adopts the following technical solutions:

[0008] A wide-voltage high-power intelligent resistive load testing system includes:

[0009] A data acquisition module: dividing the wires to be subjected to load testing into groups according to a preset quantity, and obtaining the temperatures of the surfaces, joints, and load resistances of each group of wires.

[0010] A data analysis module: analyzing the load resistance temperatures of each wire group to obtain a preliminary screening coefficient, presetting a preliminary screening coefficient threshold, and analyzing the wires corresponding to the preliminary screening coefficient lower than the preliminary screening coefficient threshold to obtain a wire body temperature coefficient and a joint temperature coefficient.

[0011] Comprehensive processing module: After comprehensively analyzing the wire temperature coefficient and the joint temperature coefficient, obtain the wire load evaluation coefficient and determine the load test result level of the wire.

[0012] Preferably, it further includes a power input and regulation module, specifically including: a wide-voltage input unit and a power matching unit;

[0013] Wide-voltage input unit:

[0014] Adapt to the test requirements of different voltage levels and support the access of grid power or DC power;

[0015] Components: power interface, voltage regulator:

[0016] Power matching unit:

[0017] Calculate and match the required load power according to the wire cross-sectional area and the rated current.

[0018] Preferably, it further includes an intelligent resistive load module, specifically including a load resistance unit and a load control unit;

[0019] Load resistance unit:

[0020] Simulate the actual resistive load and provide a stable resistance value and power consumption capacity;

[0021] Component type:

[0022] Wire-wound resistor, ceramic power resistor, resistor box Load control unit:

[0023] Automatically adjust the load resistance through an intelligent controller to achieve a constant current / constant power control mode;

[0024] Control mode: Constant current mode: Set the target current, and the controller automatically adjusts the resistance value to maintain the current stable; Constant power mode: Set the power value, and the controller calculates the resistance according to the real-time voltage.

[0025] Preferably, the data acquisition module specifically includes:

[0026] Group the wires to be subjected to the load test according to a preset quantity, and the shapes of each group of wires are different; the shapes of the wires include natural extension, bending, winding, and spiral curling;

[0027] Real-time monitor the temperatures of the wire surface, joints and load resistors, and at the same time monitor the electrical parameters of the circuit to verify whether the load operates according to the setting.

[0028] Preferably, the process of obtaining the preliminary screening coefficient includes:

[0029] A thermocouple is attached to the surface of the load resistor to obtain temperature data of each part of the load resistor at preset time intervals;

[0030] A resistance temperature threshold is preset, and the difference between the obtained load resistance temperature and the resistance temperature threshold is calculated to obtain a resistance temperature difference value; an allowable range of the resistance temperature difference value is preset, and a resistance temperature difference value that is not within the allowable range of the resistance temperature difference value is marked as a resistance temperature difference value;

[0031] The resistance temperature difference values corresponding to each part of the load resistor are counted in sequence, and the total number of resistance temperature difference values is divided by the total number of resistance temperature difference values to obtain the resistance temperature difference coefficient;

[0032] Obtain the temperature data of each part of the load resistor at the same time interval, arrange the temperature data in descending order according to the value, and extract the maximum temperature and minimum temperature corresponding to each part in turn;

[0033] The difference between the highest temperature of one part and the lowest temperature of another part between adjacent parts of the load resistor is calculated in sequence, and the difference between the lowest temperature of one part and the highest temperature of another part is calculated again, and the absolute values of the two adjacent temperature differences of the adjacent parts are taken, and the larger value is extracted and recorded as the adjacent temperature extreme difference;

[0034] Obtain all adjacent temperature extreme difference values in sequence and extract the largest adjacent temperature extreme difference value;

[0035] The preliminary screening coefficient is obtained by comprehensively analyzing the resistance temperature difference coefficient and the adjacent temperature extreme difference.

[0036] Preferably, the process of obtaining the line body temperature coefficient includes the following parts:

[0037] Based on the shape of the wires in each wire group, the wires in each wire group are divided into regions with preset sizes, and temperature data of each region is obtained at preset time intervals;

[0038] Preset the temperature threshold of the wire, subtract the temperature threshold from the temperature of each area, sort the obtained temperature differences in descending order, and remove values less than 0;

[0039] Preset an allowable fluctuation range for the temperature difference, record the temperature difference that is not within the allowable range as an abnormal temperature difference; and determine the maximum abnormal temperature difference and its corresponding area;

[0040] Sequentially obtain the maximum abnormal temperature difference value and the corresponding area corresponding to each wire in the same group of wires, determine the maximum number of times the maximum abnormal temperature difference values of each wire are in the same area, and mark the area as a marked area;

[0041] Obtain the center of the marked area and the distance from the center of the marked area to the nearest electrical wire joint, which is denoted as the marked length;

[0042] Obtain the maximum abnormal temperature difference value corresponding to each marked area and its corresponding duration, and multiply the duration corresponding to each maximum abnormal temperature difference value by the marked length to respectively obtain each marked quantization value;

[0043] Arrange each marked quantization value in descending order according to the numerical value. If the number of marked quantization values is even, then use the maximum marked quantization value and the minimum marked quantization value as the major semi-axis and minor semi-axis of the ellipse respectively to establish an ellipse model, calculate the area of the ellipse model, and calculate the average value of the areas of all ellipse models to obtain the wire body temperature coefficient;

[0044] If the number of marked quantization values is odd, then use the maximum marked quantization value and the minimum marked quantization value as the major semi-axis and minor semi-axis of the ellipse respectively to establish an ellipse model, calculate the area of the ellipse model, and sum up the areas of all ellipse models to obtain the total ellipse area;

[0045] And use the remaining marked quantization values as the two right-angled sides of a right triangle respectively, connect the remaining side to obtain a complete right triangle, and calculate the area of the right triangle;

[0046] Sum up the total ellipse area and the area of the right triangle and then divide by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; sequentially obtain the wire body temperature coefficients of each wire group.

[0047] Preferably, the obtaining process of the joint temperature coefficient includes the following parts:

[0048] Obtain the joint temperature at a preset time interval, a preset joint temperature threshold, subtract the joint temperature threshold from the obtained joint temperature to get the joint temperature difference value, arrange the joint temperature difference values in descending order according to the numerical value, and extract the three largest joint temperature difference values, which are respectively denoted as the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value;

[0049] Obtain the time points corresponding to the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value; and extract the time point corresponding to the maximum abnormal temperature difference value of the electrical wire;

[0050] Respectively calculate the time durations between the time points of the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value and the time point corresponding to the maximum abnormal temperature difference value of the electrical wire, which are denoted as the difference times;

[0051] Mark the largest difference time among the three obtained difference times as the joint temperature difference change value;

[0052] Obtain the time point corresponding to the first joint temperature difference value, and the time points of the normal joint temperatures detected before the first joint temperature difference value is reached in the time series, and obtain the elapsed time between the first joint temperature difference value and the time points of the previous normal joint temperatures;

[0053] Divide the first joint temperature difference value by the corresponding elapsed time to obtain the rate of change;

[0054] Perform a weighted calculation on the joint temperature difference change value and the rate of change to obtain the joint temperature coefficient.

[0055] Preferably, the comprehensive analysis of the wire body temperature coefficient and the joint temperature coefficient to obtain the wire load evaluation coefficient includes:

[0056] After normalizing the wire body temperature coefficient and the joint temperature coefficient, use the wire body temperature coefficient and the joint temperature coefficient as the radius and height of a circle respectively to establish a cone model, calculate the volume of the cone model, and denote it as the wire load evaluation coefficient.

[0057] Preferably, preset the value ranges of three groups of thresholds. The value range of each group of thresholds corresponds to a wire load test result level. Match the wire load evaluation coefficient with the value ranges of the three groups of thresholds to obtain the wire load test result level corresponding to the wire load evaluation coefficient. The wire load test result levels include qualified, unqualified, and excellent.

[0058] In summary, due to the adoption of the above technical solutions, the beneficial effects of the present invention are:

[0059] 1. By considering the complex shapes of wires in actual applications, the present invention groups and tests wires according to different shapes such as natural stretching, bending, winding, and spiral curling; truly restores the working states of wires under actual working conditions such as inside small electrical appliances and in a dense wiring environment; by monitoring the temperatures of the surfaces, joints, and load resistances of wires in different shapes, the performance of wires under actual heat dissipation conditions and heat distribution can be more comprehensively evaluated, effectively avoiding the problem of the disconnection between test results and actual applications, and providing a reliable basis for accurately evaluating the wire load capacity.

[0060] 2. By deeply analyzing the temperature of the load resistance, combining the resistance temperature difference rate and the adjacent temperature pole difference value to obtain a preliminary screening coefficient, identifying the abnormal temperature areas inside the resistance and the overall temperature distribution uniformity; analyzing to obtain the wire load evaluation coefficient and dividing the load test result levels; this multi-dimensional and quantitative analysis method can comprehensively and accurately evaluate the wire load performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] In the following description of exemplary embodiments with reference to the drawings, more details, features, and advantages of the present application are disclosed. In the drawings:

[0062] Figure 1 is the flowchart of the present invention; Detailed implementation manners

[0063] Several embodiments of the present application will be described in more detail below with reference to the accompanying drawings so that those skilled in the art can implement the present application. The present application can be embodied in many different forms and for many different purposes and should not be limited to the embodiments set forth herein. These embodiments are provided so that this application will be thorough and complete, and will fully convey the scope of the application to those skilled in the art. The embodiments do not limit the present application.

[0064] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and / or this specification, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0065] Please refer to Figure 1 As shown, the present invention provides a technical solution:

[0066] A wide-voltage high-power intelligent resistive load test system, comprising:

[0067] Power input and regulation module: Based on the voltage input requirements of different test scenarios, control the stable output of the power supply;

[0068] Specifically including: a wide-voltage input unit and a power matching unit;

[0069] Wide-voltage input unit:

[0070] Adapt to the test requirements of different voltage levels (such as DC 12V~1000V, AC 220V~690V), and support the access of grid power or DC power (such as battery, photovoltaic inverter);

[0071] Components: Power interface: Compatible with a variety of plugs / terminals (such as aviation plugs, busbars), and support high-current input (such as above 100A);

[0072] Voltage regulator:

[0073] DC scenario: Use a thyristor rectifier (SCR) or a DC-DC converter to achieve continuously adjustable voltage.

[0074] AC scenario: Adopt a voltage regulator (such as a contact voltage regulator, an induction voltage regulator) to adjust the output voltage to the target value;

[0075] Power matching unit:

[0076] Calculate and match the required load power according to the wire cross-sectional area and rated current ( ), ensure that the load resistor consumes the main power, and avoid overheating and out-of-control of the wire;

[0077] Intelligent resistive load module: Simulate the actual resistive load, provide a stable resistance value and power consumption capacity, and automatically adjust the load resistance through an intelligent controller;

[0078] Specifically include a load resistor unit and a load control unit;

[0079] Load resistor unit:

[0080] Simulate the actual resistive load and provide a stable resistance value and power consumption capacity;

[0081] Component type:

[0082] Wire-wound resistor: Suitable for high-power, low-frequency scenarios (such as above 10kW), high temperature resistant (up to 300°C), but with strong inductance effect (special design is required when cooperating with AC loads);

[0083] Ceramic power resistor: Good high-frequency characteristics, suitable for wide voltage scenarios (such as photovoltaic, electric vehicle high-voltage harness testing), high power density (such as 500W / unit);

[0084] Resistance box / cabinet: Composed of multiple groups of resistors in parallel / series, supporting range switching (such as adjustable from 0.1Ω to 100Ω through contactor or relay combination);

[0085] Load control unit:

[0086] Automatically adjust the load resistance through an intelligent controller to achieve constant current / constant power control mode;

[0087] Control mode: Constant current mode: Set the target current (such as 16A), and the controller automatically adjusts the resistance value to maintain a stable current ; Constant power mode: Set the power value (such as 3.5kW), and the controller calculates the resistance according to the real-time voltage ;

[0088] Core components: PLC or single-chip microcomputer controller: Receive instructions from the upper computer and output signals to control the relay / solid-state relay to switch the resistance gear; Current / voltage sensor: Real-time collect the loop current and voltage, and feedback to the controller to form a closed-loop control;

[0089] Data acquisition module: Divide the wires for load testing into groups according to the preset quantity, and obtain the temperatures of the surfaces, joints and load resistors of each group of wires;

[0090] Specifically, it includes:

[0091] Group the wires to be subjected to the load test according to a preset quantity, and the forms of each group of wires are different; the forms of the wires include natural extension, bending, winding, and spiral curling;

[0092] For example: in the actual application scenario, the wires are not always laid in an ideal straight form, but complex forms such as winding and spiral curling will appear, and these forms will significantly affect the heat dissipation conditions and heat distribution of the wires;

[0093] For example, in the narrow internal space of an electrical appliance or a dense wiring environment, the wires may be bent and wound due to installation requirements. At this time, its heat dissipation area is reduced, and the heat is difficult to dissipate, which is likely to cause local overheating;

[0094] The traditional method of only testing the wires in a straight form cannot truly reflect the performance of the wires under actual working conditions, and there is a problem that the test results are disconnected from the actual application;

[0095] Therefore, including the wire form as a test variable aims to more comprehensively and truly simulate the actual working state of the wires and provide a more reliable basis for evaluating the load capacity of the wires;

[0096] Real-time monitor the temperatures of the wire surface, joints, and load resistance, and at the same time monitor the electrical parameters of the circuit to verify whether the load operates according to the setting;

[0097] The electrical parameters include parameters such as the current, voltage, power, and resistance of the circuit;

[0098] The components include: Current Transformer (CT): Measures large currents (such as 50A - 1000A), with an accuracy of ±0.5%, and outputs 4 - 20mA or digital signals;

[0099] Voltage sensor: Isolation measures the input voltage, with an accuracy of ±0.5%, and supports DC / AC modes;

[0100] Power meter: Calculates active power and power factor (in AC scenarios), with an accuracy of ±0.2%;

[0101] Data analysis module: When the load operates according to the setting, analyze the load resistance temperatures of each wire group to obtain a preliminary screening coefficient, preset a preliminary screening coefficient threshold, and analyze the wires corresponding to the preliminary screening coefficient lower than the preliminary screening coefficient threshold to obtain the wire body temperature coefficient and joint temperature coefficient;

[0102] The process of obtaining the preliminary screening coefficient includes:

[0103] Paste thermocouples on the surface of the load resistance, and obtain the temperature data of each part of the load resistance at preset time intervals;

[0104] Preset a resistance temperature threshold, calculate the difference between the obtained load resistance temperature and the resistance temperature threshold to obtain a resistance temperature difference value; preset an allowable range for the resistance temperature difference value, and mark the resistance temperature difference values that are not within the allowable range of the resistance temperature difference value as resistance temperature difference outliers;

[0105] Successively count the number of resistance temperature difference outliers corresponding to each part of the load resistance, divide the total number of resistance temperature difference outliers by the total number of resistance temperature difference values after obtaining the total number of resistance temperature difference outliers to obtain a resistance temperature difference rate;

[0106] Obtain the temperature data of each part of the load resistance at the same time interval, arrange the temperature data in descending order according to the numerical value, and successively extract the highest temperature and the lowest temperature corresponding to each part;

[0107] Successively calculate the difference between the highest temperature of one part and the lowest temperature of another part between adjacent parts of the load resistance, and then calculate the difference between the lowest temperature of one part and the highest temperature of another part. Take the absolute value of the two adjacent temperature differences of the adjacent parts obtained, and extract the larger value among them and record it as the adjacent temperature extreme difference value;

[0108] Successively obtain all the adjacent temperature extreme difference values, and extract the largest adjacent temperature extreme difference value among them;

[0109] After comprehensively analyzing the resistance temperature difference rate and the adjacent temperature extreme difference value, obtain a preliminary screening coefficient;

[0110] Mark the resistance temperature difference rate and the adjacent temperature extreme difference value as 、 and then substitute them into the formula: ;

[0111] Obtain the preliminary screening coefficient ; where is the reference maximum adjacent temperature extreme difference value; a1 and a2 are the weight factors corresponding to the resistance temperature difference rate and the adjacent temperature extreme difference value respectively;

[0112] Real-time collect the multi-point temperature data of the load resistance through a thermocouple array, combine statistical analysis and temperature difference calculation to realize the quantitative evaluation of the thermal state of the resistance. The core objectives are:

[0113] Identify the abnormal temperature areas inside the resistance (such as local overheating or uneven heat dissipation);

[0114] Evaluate the uniformity of the overall temperature distribution of the resistance;

[0115] Combine the temperature difference rate and the temperature extreme difference value to establish a comprehensive evaluation index (preliminary screening coefficient) to judge whether the resistance is qualified or needs maintenance, so as to facilitate the subsequent analysis of the wire group corresponding to the qualified resistance to ensure the accuracy of the data;

[0116] The process of obtaining the line body temperature coefficient includes the following parts:

[0117] Based on the shape of the wires in each wire group, the wires in each wire group are divided into regions with preset sizes, and temperature data of each region is obtained at preset time intervals;

[0118] Preset the temperature threshold of the wire, subtract the temperature threshold from the temperature of each area, sort the obtained temperature differences in descending order, and remove values less than 0;

[0119] Preset an allowable fluctuation range for the temperature difference, record the temperature difference that is not within the allowable range as an abnormal temperature difference; and determine the maximum abnormal temperature difference and its corresponding area;

[0120] Sequentially obtain the maximum abnormal temperature difference value and the corresponding area corresponding to each wire in the same group of wires, determine the maximum number of times the maximum abnormal temperature difference values of each wire are in the same area, and mark the area as a marked area;

[0121] Obtain the center of the marked area and the distance from the center of the marked area to the nearest wire connector, which are recorded as the marked length;

[0122] Obtain the maximum abnormal temperature difference value and its corresponding duration corresponding to each marked area, and multiply the duration corresponding to each maximum abnormal temperature difference value by the marked length to obtain the quantitative value of each mark;

[0123] Arrange the labeled quantization values in descending order according to their numerical values. If the number of labeled quantization values is even, use the maximum labeled quantization value and the minimum labeled quantization value as the major and minor semi-axes of the ellipse, respectively, to establish an ellipse model, calculate the area of the ellipse model, and calculate the average of the areas of all ellipse models to obtain the line body temperature coefficient.

[0124] If the number of labeled quantization values is an odd number, the maximum labeled quantization value and the minimum labeled quantization value are used as the major and minor semi-axes of the ellipse respectively to establish an ellipse model, and the area of the ellipse model is calculated by summing the areas of all ellipse models to obtain the total ellipse area;

[0125] The remaining quantified values are used as the two right-angled sides of the right triangle, and the remaining side is connected to form a complete right triangle. The area of the right triangle is calculated.

[0126] The total area of the ellipse and the area of the right triangle are summed and then divided by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; the wire body temperature coefficient of each wire group is obtained in turn;

[0127] Quantify the comprehensive impact of temperature anomalies through the areas of ellipses and triangles. The larger the area, the more severe and unevenly distributed the temperature anomalies are;

[0128] Compare the wire body temperature coefficients of the four groups of wires, namely "natural stretch", "bend", "wrap", and "helical curl", to evaluate the impact of the shape on heat dissipation, so as to obtain the bearing capacity of the normal working shape of the wire under load;

[0129] The process of obtaining the joint temperature coefficient includes the following parts:

[0130] Obtain the joint temperature at a preset time interval, preset the joint temperature threshold, subtract the joint temperature threshold from the obtained joint temperature to get the joint temperature difference value, sort the joint temperature difference values in descending order according to the numerical size, and extract the largest three joint temperature difference values, which are respectively recorded as the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value;

[0131] Obtain the time points corresponding to the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value; and extract the time point corresponding to the maximum abnormal temperature difference value of the wire;

[0132] Calculate the time durations between the time points of the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value and the time point corresponding to the maximum abnormal temperature difference value of the wire, which are recorded as the difference times;

[0133] Mark the largest difference time among the three obtained difference times as the joint temperature difference change value;

[0134] Obtain the time point corresponding to the first joint temperature difference value, and the time point of the normal joint temperature detected before reaching the first joint temperature difference value in the time series, and obtain the crossing time between the first joint temperature difference value and the previous normal joint temperature time point;

[0135] Divide the first joint temperature difference value by the corresponding crossing time to get the change rate;

[0136] Perform a weighted calculation on the joint temperature difference change value and the change rate to obtain the joint temperature coefficient;

[0137] Including: preset the weight factors of the joint temperature difference change value and the change rate, and respectively perform a product calculation on the joint temperature difference change value and the change rate with their corresponding weight factors, and then sum to obtain the joint temperature coefficient;

[0138] Comprehensively evaluate the thermal performance of the joint through the combination of time difference analysis and temperature change rate analysis; its core idea is: when there are problems such as poor contact in the joint, it will not only cause the time of the temperature peak to lag behind the main body of the wire, but also make the temperature rise rate abnormal;

[0139] After normalizing the wire temperature coefficient and the joint temperature coefficient, the wire temperature coefficient and the joint temperature coefficient are respectively used as the radius and the height of a circle to establish a cone model, and the volume of the cone model is calculated and denoted as the wire load evaluation coefficient.

[0140] Comprehensive processing module: After comprehensively analyzing the wire temperature coefficient and the joint temperature coefficient, obtain the wire load evaluation coefficient and determine the wire load test result level.

[0141] Preset the value ranges of three groups of thresholds. Each value range of the thresholds corresponds to a wire load test result level. Match the wire load evaluation coefficient with the value ranges of the three groups of thresholds to obtain the wire load test result level corresponding to the wire load evaluation coefficient. The wire load test result levels include qualified, unqualified, and excellent.

[0142] The above formulas are all obtained by collecting a large amount of data for software simulation and selecting a formula close to the true value. The influence weight factors and specific coefficient values in the formula are set by those skilled in the art according to the actual situation and can be adjusted and modified subsequently.

[0143] The above description of the embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be obvious to those skilled in the art. The general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A wide-voltage high-power intelligent resistive load test system, characterized in that, Including: Data acquisition module: Group and divide the wires to be subjected to load testing according to a preset quantity, and obtain the temperatures of the surfaces, joints and load resistances of each group of wires. Data analysis module: Analyze the load resistance temperatures of each wire group to obtain a preliminary screening coefficient, preset a preliminary screening coefficient threshold, and analyze the wires corresponding to the preliminary screening coefficient lower than the preliminary screening coefficient threshold to obtain a wire body temperature coefficient and a joint temperature coefficient. Comprehensive processing module: Comprehensively analyze the wire body temperature coefficient and the joint temperature coefficient to obtain a wire load evaluation coefficient, and determine the load test result level of the wire.

2. The wide-voltage high-power intelligent resistive load test system according to claim 1, characterized in that It further includes a power input and regulation module, specifically including: a wide voltage input unit and a power matching unit. Wide voltage input unit: Adapt to the test requirements of different voltage levels, and support the access of grid power or DC power. Components: Power interface, voltage regulator Power matching unit: Calculate and match the required load power according to the wire cross-sectional area and rated current.

3. The wide-voltage high-power intelligent resistive load test system according to claim 2, characterized in that It further includes an intelligent resistive load module, specifically including a load resistance unit and a load control unit. Load resistance unit: Simulate an actual resistive load and provide a stable resistance value and power consumption capacity. Component type: Wire-wound resistor, ceramic power resistor, resistance box Load control unit: Automatically adjust the load resistance through an intelligent controller to achieve a constant current / constant power control mode. Control mode: Constant current mode: Set a target current, and the controller automatically adjusts the resistance value to maintain a stable current; Constant power mode: Set a power value, and the controller calculates the resistance according to the real-time voltage.

4. A wide-voltage high-power intelligent resistive load test system according to claim 1, characterized in that, Data acquisition module, specifically including: Group and divide the wires to be subjected to load testing according to a preset quantity, and the forms of each group of wires are different; The forms of the wires include natural extension, bending, winding, and spiral curling. Real-time monitor the temperatures of the wire surfaces, joints and load resistances, and at the same time monitor the electrical parameters of the circuit to verify whether the load operates according to the setting.

5. The wide-voltage high-power intelligent resistive load test system according to claim 4, wherein The process of obtaining the preliminary screening coefficient includes: Paste a thermocouple on the surface of the load resistance, and obtain the temperature data of each part of the load resistance at a preset time interval. Preset a resistance temperature threshold, calculate the difference between the obtained load resistance temperature and the resistance temperature threshold to obtain a resistance temperature difference value; Preset the allowable range of the resistance temperature difference value, and mark the resistance temperature difference value that is not within the allowable range of the resistance temperature difference value as a resistance temperature difference deviation value. Successively count the number of resistance temperature difference deviation values corresponding to each part of the load resistance to obtain the total number of resistance temperature difference deviation values, and then divide by the total number of resistance temperature difference values to obtain a resistance temperature difference rate. Obtain the temperature data of each part of the load resistance at the same time interval, arrange the temperature data in descending order according to the numerical value, and successively extract the highest temperature and the lowest temperature corresponding to each part. Successively calculate the difference between the highest temperature of one part and the lowest temperature of another part between adjacent parts of the load resistance, and then calculate the difference between the lowest temperature of one part and the highest temperature of another part, take the absolute value of the two adjacent temperature difference values of the adjacent parts, and extract the larger one as the adjacent temperature extreme difference value. Obtain all adjacent temperature extreme difference values in sequence and extract the largest adjacent temperature extreme difference value; The preliminary screening coefficient is obtained by comprehensively analyzing the resistance temperature difference coefficient and the adjacent temperature extreme difference.

6. The wide-voltage high-power intelligent resistive load test system according to claim 5, characterized in that The process of obtaining the line body temperature coefficient includes the following parts: Based on the shape of the wires in each wire group, the wires in each wire group are divided into regions with preset sizes, and temperature data of each region is obtained at preset time intervals; Preset the temperature threshold of the wire, subtract the temperature threshold from the temperature of each area, sort the obtained temperature differences in descending order, and remove values less than 0; The permissible fluctuation range of the temperature difference is preset, and the temperature difference that is not within the permissible range is recorded as an abnormal temperature difference; And determine the maximum abnormal temperature difference and its corresponding area; Sequentially obtain the maximum abnormal temperature difference value and the corresponding area corresponding to each wire in the same group of wires, determine the maximum number of times the maximum abnormal temperature difference values of each wire are in the same area, and mark the area as a marked area; Obtain the center of the marked area and the distance from the center of the marked area to the nearest wire connector, which are recorded as the marked length; Obtain the maximum abnormal temperature difference value and its corresponding duration corresponding to each marked area, and multiply the duration corresponding to each maximum abnormal temperature difference value by the marked length to obtain the quantitative value of each mark; Arrange the labeled quantization values in descending order according to their numerical values. If the number of labeled quantization values is even, use the maximum labeled quantization value and the minimum labeled quantization value as the major and minor semi-axes of the ellipse, respectively, to establish an ellipse model, calculate the area of the ellipse model, and calculate the average of the areas of all ellipse models to obtain the line body temperature coefficient. If the number of labeled quantization values is an odd number, the maximum labeled quantization value and the minimum labeled quantization value are used as the major and minor semi-axes of the ellipse respectively to establish an ellipse model, and the area of the ellipse model is calculated by summing the areas of all ellipse models to obtain the total ellipse area; The remaining quantified values are used as the two right-angled sides of the right triangle, and the remaining side is connected to form a complete right triangle. The area of the right triangle is calculated. The total ellipse area and the area of the right triangle are summed and then divided by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; the wire body temperature coefficient of each wire group is obtained in turn.

7. The wide-voltage high-power intelligent resistive load test system according to claim 6, wherein, The process of obtaining the joint temperature coefficient includes the following parts: Acquire the joint temperature at a preset time interval, preset a joint temperature threshold, subtract the joint temperature threshold from the acquired joint temperature to obtain a joint temperature difference value, arrange the joint temperature difference values in descending order according to their numerical values, and extract the three largest joint temperature difference values, which are recorded as the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value, respectively; Obtaining the time points corresponding to the first joint temperature difference value, the second joint temperature difference value, and the third joint temperature difference value; and extracting the time point corresponding to the maximum abnormal temperature difference value of the wire; Calculate the time between the time points of the first joint temperature difference, the second joint temperature difference, and the third joint temperature difference and the time point corresponding to the maximum abnormal temperature difference of the wire, and record it as the difference time; Mark the maximum difference time among the three obtained difference times as the joint temperature difference change value; Obtain the time point corresponding to the first joint temperature difference value and the time point of the normal joint temperature detected before reaching the first joint temperature difference value in the time series, and obtain the crossing time between the first joint temperature difference value and the time point of the previous normal joint temperature; Divide the first joint temperature difference value by the corresponding crossing time to obtain the change rate; Perform a weighted calculation on the joint temperature difference change value and the change rate to obtain the joint temperature coefficient.

8. The wide-voltage high-power intelligent resistive load test system according to claim 7, wherein, After comprehensively analyzing the wire body temperature coefficient and the joint temperature coefficient, obtain the wire load evaluation coefficient, including: After normalizing the wire body temperature coefficient and the joint temperature coefficient, use the wire body temperature coefficient and the joint temperature coefficient as the radius and height of a circle respectively to establish a cone model, calculate the volume of the cone model, and record it as the wire load evaluation coefficient.

9. The wide-voltage high-power intelligent resistive load test system according to claim 8, characterized in that Preset the value ranges of three groups of thresholds. Each value range of the thresholds corresponds to a wire load test result level. Match the wire load evaluation coefficient with the value ranges of the three groups of thresholds to obtain the wire load test result level corresponding to the wire load evaluation coefficient. The wire load test result levels include qualified, unqualified, and excellent.

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