An intelligent resistive load test system

Abstract

The present invention is specifically an intelligent resistive load testing system, comprising: a data acquisition module; a data analysis module: analyzing the load resistance temperature 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 the wire body temperature coefficient and the joint temperature coefficient. In the present invention, considering the complex form of wires in actual applications, the wires are grouped and tested according to different forms such as natural stretching, bending, winding, and spiral curling; the working state of the wires under actual working conditions such as the inside of small electrical appliances and dense wiring environments is truly restored; by monitoring the temperature of the surface, joints and load resistors of wires of different forms, the performance of the wires under actual heat dissipation conditions and heat distribution can be more comprehensively evaluated, effectively avoiding the problem of disconnection between test results and actual applications, and providing a reliable basis for accurately evaluating the load capacity of wires.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical testing, and in particular to an intelligent resistive load testing system. Background Art

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

[0003] Currently, traditional wire load testing methods have many limitations that need to be addressed. The most prominent problem is that its testing scenario is limited to straight-line wires, which is very different from the laying form of wires under actual complex working conditions.

[0004] In real-world applications, wire layouts vary widely, from the complex wiring environments within small appliances to the tangled and spiraled configurations found in large power facilities due to space constraints or installation requirements. These complex configurations can significantly alter the heat dissipation conditions and distribution of the wires. For example, in confined spaces, the bending and tangling of wires significantly reduces the heat dissipation area, making it difficult to effectively dissipate heat and easily causing localized overheating.

[0005] However, traditional testing methods fail to consider these actual working conditions, resulting in a serious disconnect between test results and actual applications. These methods make it impossible to accurately assess the load capacity of wires under actual working conditions, making it difficult to effectively ensure the stable operation of electrical equipment and power transmission systems. Therefore, an intelligent resistive load testing system is needed to address the above-mentioned issues. Summary of the Invention

[0006] The purpose of the present invention is to provide an intelligent resistive load testing system in order to solve the above problems.

[0007] In order to achieve the above object, the present invention adopts the following technical solutions:

[0008] An intelligent resistive load testing system, comprising:

[0009] Data acquisition module: divides the wires to be loaded into groups according to the preset number, and obtains the temperature of the wire surface, joints and load resistors of each group;

[0010] Data analysis module: Analyzes the load resistance temperature of each wire group to obtain a preliminary screening coefficient, presets a preliminary screening coefficient threshold, and analyzes the wires corresponding to the preliminary screening coefficients lower than the preliminary screening coefficient threshold to obtain the wire body temperature coefficient and the joint temperature coefficient;

[0011] Comprehensive processing module: After comprehensive analysis of the wire body temperature coefficient and the connector temperature coefficient, the wire load evaluation coefficient is obtained and the load test result level of the wire is determined.

[0012] Preferably, the power supply input and regulation module is also included, specifically including: a wide voltage input unit and a power matching unit;

[0013] Wide voltage input unit: adapts to test requirements of different voltage levels and supports grid power or DC power access;

[0014] Power matching unit: Calculates and matches the required load power based on the wire cross-sectional area and rated current.

[0015] Preferably, the system further comprises an intelligent resistive load module, specifically comprising a load resistance unit and a load control unit;

[0016] Load resistance unit: simulates actual resistive load and provides stable resistance value and power consumption capability;

[0017] Load control unit: Automatically adjust the load resistance through the intelligent controller to achieve constant current / constant power control mode;

[0018] Control mode: Constant current mode: set the target current, the controller automatically adjusts the resistance value to maintain current stability; constant power mode: set the power value, the controller calculates the resistance based on the real-time voltage.

[0019] Preferably, the data acquisition module specifically includes:

[0020] The wires to be tested for load are divided into groups according to a preset number, and the shapes of the wires in each group are different; the shapes of the wires include natural stretching, bending, winding, and spiral curling;

[0021] Monitor the temperature of the wire surface, connectors, and load resistors in real time, while monitoring the electrical parameters of the circuit to verify whether the load is operating as set.

[0022] Preferably, the process of obtaining the preliminary screening coefficient includes:

[0023] 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;

[0024] 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;

[0025] 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;

[0026] 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;

[0027] 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, 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;

[0028] Obtain all adjacent temperature extreme difference values ​​in sequence and extract the largest adjacent temperature extreme difference value;

[0029] The preliminary screening coefficient is obtained by comprehensively analyzing the resistance temperature difference coefficient and the adjacent temperature extreme difference.

[0030] Preferably, the process of obtaining the line body temperature coefficient includes the following parts:

[0031] 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;

[0032] 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;

[0033] 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;

[0034] 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;

[0035] 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;

[0036] 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;

[0037] 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.

[0038] 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;

[0039] 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.

[0040] The total ellipse area and the area of ​​the right triangle are summed and divided by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; based on the above content, the wire body temperature coefficient of each wire group is obtained in turn.

[0041] Preferably, the process of obtaining the joint temperature coefficient includes the following parts:

[0042] 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;

[0043] 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;

[0044] 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;

[0045] The maximum difference time among the three obtained difference times is marked as the joint temperature difference change value;

[0046] Obtaining 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 obtaining the span time between the first joint temperature difference value and the previous normal joint temperature time point;

[0047] Divide the temperature difference of the first joint by the corresponding span time to obtain the rate of change;

[0048] The joint temperature coefficient is obtained by weighted calculation of the joint temperature difference change value and the change rate.

[0049] Preferably, the comprehensive analysis of the wire body temperature coefficient and the connector temperature coefficient to obtain the wire load evaluation coefficient includes:

[0050] After normalizing the wire body temperature coefficient and the joint temperature coefficient, the wire body temperature coefficient and the joint temperature coefficient are used as the radius and height of the circle respectively to establish a cone model, calculate the volume of the cone model, and record it as the wire load evaluation coefficient.

[0051] Preferably, the value ranges of the three groups of thresholds are preset, and the value range of each group of thresholds corresponds to the load test result level of a wire. The wire load evaluation coefficient is matched with the value ranges of the three groups of thresholds to obtain the load test result level of the wire corresponding to the wire load evaluation coefficient. The load test result levels of the wire include qualified, unqualified, and excellent.

[0052] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0053] 1. This invention considers the complex shapes of wires in actual applications and groups them for testing according to different shapes, such as natural stretching, bending, winding, and spiral curling. This truly reproduces the working state of wires under actual working conditions, such as inside small electrical appliances and in dense wiring environments. By monitoring the temperature of the surface, joints, and load resistors of wires in different shapes, it can more comprehensively evaluate the performance of wires under actual heat dissipation conditions and heat distribution, effectively avoiding the disconnection between test results and actual applications, and providing a reliable basis for accurately evaluating the load capacity of wires.

[0054] 2. The present invention conducts an in-depth analysis of the load resistor temperature, combines the resistor temperature difference coefficient and the adjacent temperature extreme difference to obtain a preliminary screening coefficient, identifies the abnormal temperature area inside the resistor and the uniformity of the overall temperature distribution; analyzes to obtain the wire load evaluation coefficient and classifies the load test results; this multi-dimensional, quantitative analysis method can comprehensively and accurately evaluate the wire load performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Further details, features and advantages of the present application are disclosed in the following description of exemplary embodiments in conjunction with the accompanying drawings, in which:

[0056] Figure 1 is a flow chart of the present invention; DETAILED DESCRIPTION

[0057] 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 described herein. These embodiments are provided to make the present application comprehensive and complete and to fully convey the scope of the present application to those skilled in the art. The embodiments do not limit the present application.

[0058] 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 consistent with their meaning in the relevant art and / or the context of this specification, and will not be interpreted in an idealized or overly formal sense unless expressly defined as such herein.

[0059] See also Figure 1 As shown, the present invention provides a technical solution:

[0060] An intelligent resistive load testing system, comprising:

[0061] Power input and regulation module: controls the stable output of power supply based on the voltage input requirements of different test scenarios;

[0062] Specifically including: wide voltage input unit and power matching unit;

[0063] Wide voltage input unit:

[0064] Adapts to test requirements of different voltage levels (such as DC 12V~1000V, AC 220V~690V), and supports access to grid power or DC power (such as batteries, photovoltaic inverters);

[0065] Components: Power interface: compatible with a variety of plugs / terminals (such as aviation plugs, copper busbars), supporting high current input (such as more than 100A);

[0066] Voltage Regulator:

[0067] DC scenario: Use a silicon-controlled rectifier (SCR) or DC-DC converter to achieve continuously adjustable voltage.

[0068] AC scenario: Use a voltage regulator (such as a contactor voltage regulator or inductive voltage regulator) to adjust the output voltage to the target value;

[0069] Power matching unit:

[0070] 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 to avoid overheating and runaway of the wire;

[0071] Intelligent resistive load module: simulates actual resistive load, provides stable resistance value and power consumption capability, and automatically adjusts the load resistance through an intelligent controller;

[0072] Specifically comprising a load resistance unit and a load control unit;

[0073] Load resistance unit:

[0074] Simulate actual resistive loads to provide stable resistance values ​​and power consumption capabilities;

[0075] Component Type:

[0076] Wirewound resistors: Suitable for high-power, low-frequency applications (e.g., above 10kW), high-temperature resistant (up to 300°C), but with a strong inductive effect (requiring special design for AC loads).

[0077] Ceramic power resistors: They have good high-frequency characteristics and are suitable for wide voltage scenarios (such as photovoltaic and electric vehicle high-voltage wiring harness testing). They also have high power density (e.g., 500W / piece).

[0078] Resistance box / cabinet: composed of multiple groups of resistors connected in parallel or series, supporting range switching (such as 0.1Ω~100Ω adjustable through contactor or relay combination);

[0079] Load control unit:

[0080] Automatically adjust the load resistance through the intelligent controller to achieve constant current / constant power control mode;

[0081] Control mode: Constant current mode: set the target current (such as 16A), the controller automatically adjusts the resistance value to maintain a stable current ; Constant power mode: set the power value (such as 3.5kW), the controller calculates the resistance according to the real-time voltage ;

[0082] Core components: PLC or single-chip microcomputer controller: receives commands from the host computer and outputs signals to control the relay / solid-state relay to switch the resistance gear; current / voltage sensor: collects loop current and voltage in real time and feeds them back to the controller to form closed-loop control;

[0083] Data acquisition module: divides the wires to be loaded into groups according to the preset number, and obtains the temperature of the wire surface, joints and load resistors of each group;

[0084] Specifically include:

[0085] The wires to be tested for load are divided into groups according to a preset number, and the shapes of the wires in each group are different; the shapes of the wires include natural stretching, bending, winding, and spiral curling;

[0086] For example, in actual application scenarios, wires are not always laid in an ideal straight line, but may appear in complex shapes such as entanglement and spiral curling, which will significantly affect the heat dissipation conditions and heat distribution of the wires.

[0087] For example, in a narrow space inside an appliance or in a dense wiring environment, wires may be bent or entangled due to installation requirements. This reduces the heat dissipation area and makes it difficult to dissipate heat, which can easily lead to local overheating.

[0088] The traditional method of testing only straight-line wires cannot truly reflect the performance of wires under actual working conditions, and there is a problem of disconnection between test results and actual applications;

[0089] Therefore, incorporating wire morphology into the test variables aims to more comprehensively and realistically simulate the actual working conditions of wires and provide a more reliable basis for evaluating the load capacity of wires;

[0090] Real-time monitoring of the temperature of the wire surface, connectors, and load resistors, while also monitoring the electrical parameters of the circuit to verify whether the load is operating as set;

[0091] Electrical parameters include circuit current, voltage, power, resistance and other parameters;

[0092] Components include: Current transformer (CT): measures large currents (e.g., 50A to 1000A) with an accuracy of ±0.5% and outputs 4-20mA or digital signals;

[0093] Voltage sensor: isolated measurement of input voltage, accuracy of ±0.5%, supports DC / AC mode;

[0094] Power meter: calculates active power and power factor (AC scenario), with an accuracy of ±0.2%;

[0095] Data analysis module: When the load is running according to the settings, the load resistance temperature of each wire group is analyzed to obtain the preliminary screening coefficient. The preliminary screening coefficient threshold is preset, and the wires corresponding to the preliminary screening coefficients lower than the preliminary screening coefficient threshold are analyzed to obtain the wire body temperature coefficient and the joint temperature coefficient;

[0096] The process of obtaining the preliminary screening coefficient includes:

[0097] 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;

[0098] 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;

[0099] 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;

[0100] 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;

[0101] 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, 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;

[0102] Obtain all adjacent temperature extreme difference values ​​in sequence and extract the largest adjacent temperature extreme difference value;

[0103] The preliminary screening coefficient is obtained by comprehensively analyzing the resistance temperature difference coefficient and the adjacent temperature extreme difference value;

[0104] The resistance temperature difference coefficient and the adjacent temperature extreme difference are marked as 、 The subsequent entry formula: ;

[0105] Get the preliminary screening coefficient ;in is the reference maximum adjacent temperature extreme difference; a1 and a2 are the weight factors corresponding to the resistance temperature difference rate and the adjacent temperature extreme difference respectively;

[0106] Thermocouple arrays are used to collect temperature data from multiple measurement points on the load resistor in real time. Combined with statistical analysis and temperature difference calculation, this allows for a quantitative assessment of the resistor's thermal state. The core objectives are:

[0107] Identify abnormal temperature areas inside the resistor (such as local overheating or uneven heat dissipation);

[0108] Evaluate the uniformity of the overall temperature distribution of the resistor;

[0109] Combined with the temperature difference coefficient and the temperature extreme difference, a comprehensive evaluation index (preliminary screening coefficient) is established to determine whether the resistor is qualified or requires maintenance. This allows for subsequent analysis of the wire groups corresponding to qualified resistors to ensure data accuracy.

[0110] The process of obtaining the line body temperature coefficient includes the following parts:

[0111] 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;

[0112] 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;

[0113] 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;

[0114] 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;

[0115] 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;

[0116] 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;

[0117] 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.

[0118] 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;

[0119] 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.

[0120] The total area of ​​the ellipse and the area of ​​the right triangle are summed and divided by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; based on the above content, the wire body temperature coefficient of each wire group is obtained in turn;

[0121] The comprehensive impact of temperature anomalies is quantified by the areas of ellipses and triangles, where larger areas indicate more severe temperature anomalies and more uneven distribution;

[0122] Comparing the wire body temperature coefficients of four groups of wires—naturally stretched, bent, wrapped, and spirally curled—to assess the impact of shape on heat dissipation and determine the load-bearing capacity of the wires in their normal operating configuration.

[0123] The process of obtaining the joint temperature coefficient includes the following parts:

[0124] 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;

[0125] 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;

[0126] 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;

[0127] The maximum difference time among the three obtained difference times is marked as the joint temperature difference change value;

[0128] Obtaining 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 obtaining the span time between the first joint temperature difference value and the previous normal joint temperature time point;

[0129] Divide the temperature difference of the first joint by the corresponding span time to obtain the rate of change;

[0130] The joint temperature coefficient is obtained by weighted calculation of the joint temperature difference change value and the change rate;

[0131] The method includes: presetting weight factors of the joint temperature difference change value and the change rate, multiplying the joint temperature difference change value and the change rate with their corresponding weight factors, and summing the sum to obtain the joint temperature coefficient;

[0132] The thermal performance of the connector is comprehensively evaluated by combining time difference analysis and temperature change rate analysis. The core idea is that when the connector has problems such as poor contact, not only will the temperature peak appear later than the wire body, but the temperature rise rate will also be abnormal.

[0133] After normalizing the wire body temperature coefficient and the joint temperature coefficient, the wire body temperature coefficient and the joint temperature coefficient are used as the radius and height of the circle respectively to establish a cone model, calculate the volume of the cone model, and record it as the wire load evaluation coefficient.

[0134] Comprehensive processing module: After comprehensive analysis of the wire body temperature coefficient and the connector temperature coefficient, the wire load evaluation coefficient is obtained and the load test result level of the wire is determined;

[0135] Three groups of threshold value ranges are preset, and the value range of each group of threshold values ​​corresponds to the load test result level of a wire. The wire load evaluation coefficient is matched with the value range of the three groups of threshold values ​​to obtain the load test result level of the wire corresponding to the wire load evaluation coefficient. The load test result levels of the wire include qualified, unqualified, and excellent.

[0136] The above formulas are obtained by collecting a large amount of data and performing software simulation, and a formula close to the actual value is selected. The influencing weight factors and specific coefficient values ​​in the formula are set by technical personnel in this field according to actual conditions, and can be adjusted and modified later.

[0137] The above description of the embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An intelligent resistive load testing system, characterized in that: include: Data acquisition module: divides the wires to be tested into groups according to the preset number and obtains the temperature of the wire surface, joints and load resistance of each group, including: The wires to be tested for load are divided into groups according to a preset number, and the shapes of the wires in each group are different; the shapes of the wires include natural stretching, bending, winding, and spiral curling; Real-time monitoring of the temperature of the wire surface, connectors, and load resistors, while also monitoring the electrical parameters of the circuit to verify whether the load is operating as set; Data analysis module: Analyzes the load resistance temperature of each wire group to obtain a preliminary screening coefficient, presets a preliminary screening coefficient threshold, and analyzes the wires corresponding to the preliminary screening coefficients lower than the preliminary screening coefficient threshold to obtain the wire body temperature coefficient and the joint temperature coefficient; The process of obtaining the preliminary screening coefficient includes: 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; 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; 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; 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; 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, 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; 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 value; Comprehensive processing module: After comprehensive analysis of the wire body temperature coefficient and the connector temperature coefficient, the wire load evaluation coefficient is obtained and the load test result level of the wire is determined.

2. The intelligent resistive load testing system according to claim 1, characterized in that: It also includes a power input and regulation module, specifically including: a wide voltage input unit and a power matching unit; Wide voltage input unit: adapts to test requirements of different voltage levels and supports grid power or DC power access; Power matching unit: Calculates and matches the required load power based on the wire cross-sectional area and rated current.

3. The intelligent resistive load testing system according to claim 2, characterized in that: Also included is an intelligent resistive load module, specifically including a load resistance unit and a load control unit; Load resistance unit: simulates actual resistive load and provides stable resistance value and power consumption capability; Load control unit: Automatically adjust the load resistance through the intelligent controller to achieve constant current / constant power control mode; Control mode: Constant current mode: set the target current, the controller automatically adjusts the resistance value to maintain current stability; constant power mode: set the power value, the controller calculates the resistance based on the real-time voltage.

4. The intelligent resistive load testing system according to claim 1, 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 marked 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 divided by the number of ellipse models and right triangles to obtain the wire body temperature coefficient; based on the above content, the wire body temperature coefficient of each wire group is obtained in turn.

5. The intelligent resistive load testing system according to claim 4, characterized in that: 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; The maximum difference time among the three obtained difference times is marked as the joint temperature difference change value; Obtaining 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 obtaining the span time between the first joint temperature difference value and the previous normal joint temperature time point; Divide the temperature difference of the first joint by the corresponding span time to obtain the rate of change; The joint temperature coefficient is obtained by weighted calculation of the joint temperature difference change value and the change rate.

6. The intelligent resistive load testing system according to claim 5, characterized in that: The wire load evaluation coefficient is obtained by comprehensively analyzing the wire body temperature coefficient and the connector temperature coefficient, including: After normalizing the wire body temperature coefficient and the joint temperature coefficient, the wire body temperature coefficient and the joint temperature coefficient are used as the radius and height of the circle respectively to establish a cone model, calculate the volume of the cone model, and record it as the wire load evaluation coefficient.

7. The intelligent resistive load testing system according to claim 6, characterized in that: Three groups of threshold value ranges are preset, and the value range of each group of threshold values ​​corresponds to the load test result level of a wire. The wire load evaluation coefficient is matched with the value range of the three groups of threshold values ​​to obtain the load test result level of the wire corresponding to the wire load evaluation coefficient. The load test result levels of the wire include qualified, unqualified, and excellent.

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