PWM controller detection system and method

Abstract

The invention discloses a PWM controller detection system and method, and the system comprises a signal generation module, a data collection module, a communication module, a power module and an upper computer, the signal generation module is used for generating a plurality of standard test signals, the signals serve as excitation signals to be inputted to a detected PWM controller, the data collection module is used for being connected to the output end of the detected PWM controller, and the data collection module is used for being connected to the output end of the detected PWM controller. According to the invention, various signals output by the PWM controller are collected in real time, and the detection system has the following advantages: the detection system can generate various types of test signals and collect abundant parameters output by the PWM controller, so that the comprehensive performance detection of the PWM controller is realized, the defect of single function of a traditional detection method is overcome, and the detection efficiency is improved. Multiple instruments and equipment do not need to be manually operated, the detection efficiency is greatly improved, the detection time is shortened, and the accuracy of detection data is ensured through a high-speed data acquisition module and an accurate algorithm.

Description

Technical Field

[0001] The present invention relates to the technical field of circuit detection, and particularly relates to a PWM controller detection system and method. Background Art

[0002] PWM controllers are widely used in various electronic devices, such as motor drive, power management and other fields. The quality of its performance directly affects the stability and reliability of the entire system. During the production process, it is necessary to comprehensively detect the PWM controller to ensure that it meets the quality standards.

[0003] Traditional PWM controller detection methods have many deficiencies. On the one hand, the detection equipment has a single function and usually can only detect a few parameters of the PWM controller, and cannot perform a comprehensive performance evaluation on it. On the other hand, the detection process is cumbersome and requires manual operation of multiple instrument devices, which is not only inefficient but also prone to introducing human errors. In addition, the existing detection methods have weak diagnostic capabilities for some complex faults and are difficult to accurately and quickly locate the problem. With the continuous development of electronic technology, the performance requirements for PWM controllers are getting higher and higher, and the traditional detection systems and methods can no longer meet the needs of modern production and quality control. Therefore, there is an urgent need for a new type of PWM controller detection system and method to improve the detection efficiency and accuracy, enhance the fault diagnosis ability, so a PWM controller detection system and method are provided to solve the above problems. Summary of the Invention

[0004] To solve the problems raised in the above background art, the technical solution adopted by the present invention to solve the technical problems is: a PWM controller detection system, which includes: a signal generation module, a data acquisition module, a communication module, a power supply module and a host computer. The signal generation module is used to generate a variety of standard test signals, and the signals are input into the PWM controller to be tested as excitation signals. The data acquisition module is used to connect to the output end of the PWM controller to be tested and collect various signals output by the PWM controller in real time. The communication module is used to upload the data collected by the data acquisition module to the host computer for analysis and processing in real time, and at the same time receive the control instructions sent by the host computer to adjust the working parameters of the detection system. The power supply module is used to provide a stable power supply for the entire detection system and the PWM controller to be tested. The host computer is used to provide a human-computer interaction interface.

[0005] As a preferred technical solution of the present invention, the standard test signals include PWM signals with different frequencies, duty cycles and amplitudes, as well as analog input signals, sine waves and triangular waves.

[0006] As a preferred technical solution of the present invention, the waveform, frequency, duty cycle of the output signal of the PWM controller, and the amplitude and phase parameters of the analog output signal are accurately captured by the data acquisition module to capture the dynamic changes of the signal.

[0007] As a preferred technical solution of the present invention, the communication module adopts a variety of communication interfaces, USB, Ethernet, RS-485, to meet different application requirements.

[0008] As a preferred technical solution of the present invention, the user can set the detection parameters through the host computer, including the test signal type, frequency range, and duty cycle range. The host computer receives the data from the data acquisition module, analyzes and processes the data using a preset algorithm, determines whether the PWM controller is qualified, and generates a detailed detection report.

[0009] The detection method of the PWM controller detection system includes the following steps:

[0010] Step S1: First, turn on the power of the detection system, and the host computer performs initialization settings on the detection system, including parameter configuration of the communication module and initial parameter setting of the signal generation module. At the same time, the PWM controller to be tested is correctly connected to the corresponding interface of the detection system;

[0011] Step S2: The signal generation module generates a specific test signal according to the parameters set by the host computer and inputs it into the PWM controller to be tested;

[0012] Step S3: The data acquisition module real-time collects the output signal of the PWM controller to be tested. During the acquisition process, the sampling frequency and the number of sampling points are reasonably adjusted according to the characteristics of the signal and the requirements of the detection accuracy;

[0013] Step S4: The collected data is transmitted to the host computer through the communication module. The host computer analyzes the data using a preset algorithm, and according to the technical specifications of the PWM controller, determines whether each detection parameter is within the normal range. If the detection parameter exceeds the normal range, the fault type is further analyzed. By comparing the signal characteristics of the normal PWM controller and the signal characteristics of the faulty PWM controller, the fault diagnosis algorithm is used to locate the cause of the fault;

[0014] Step S5: According to the data analysis result, the host computer determines whether the PWM controller to be tested is qualified. If it is qualified, a qualified detection report is generated. If it is unqualified, an unqualified detection report containing detailed fault information is generated.

[0015] As a preferred technical solution of the present invention, in step S2, the type and parameters of the test signal are selected according to the specifications of the PWM controller and the test requirements. For the PWM controller used for motor drive, a PWM signal simulating the change of the motor load can be sent.

[0016] As a preferred technical solution of the present invention, in step S3, for high-frequency PWM signals, according to the characteristics of the signals and the requirements of detection accuracy, a relatively high sampling frequency is adopted to ensure that the collected signals are not distorted.

[0017] As a preferred technical solution of the present invention, in step S4, the technical specifications of the PWM controller check whether the frequency and duty cycle of the PWM output signal are consistent with the expected values, and locate the cause of the fault through a fault diagnosis algorithm, including power transistor damage and control chip failure.

[0018] As a preferred technical solution of the present invention, in step S5, the detection report can be saved as an electronic document for convenient query and management by users.

[0019] The present invention has the following advantages: The detection system of the present invention can generate various types of test signals and collect rich parameters output by the PWM controller, realizing the comprehensive performance detection of the PWM controller, overcoming the defect of the single function of traditional detection methods;

[0020] The entire detection process is automatically completed by the detection system without manual operation of multiple instrument devices, greatly improving the detection efficiency and reducing the detection time;

[0021] The high-speed data acquisition module and accurate algorithm ensure the accuracy of the detection data, avoid human errors, improve the reliability of the detection results, and through an advanced fault diagnosis algorithm, can accurately and quickly locate the cause of the fault of the PWM controller, providing strong support for maintenance and quality improvement. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of the PWM controller detection system according to a preferred embodiment of the present invention;

[0023] Figure 2 is a schematic diagram of the detection method of the PWM controller detection system according to a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0024] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention. In the following description, many specific details are set forth in order to fully understand the present invention. However, the present invention may be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited by the specific embodiments disclosed below.

[0025] To more clearly understand the above-mentioned objects, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0026] Please refer to Figure 1 and Figure 2 A PWM controller detection system of the present invention includes: a signal generation module, a data acquisition module, a communication module, a power supply module, and a host computer. The signal generation module is used to generate a variety of standard test signals, and the signals are input into the PWM controller to be tested as excitation signals. The data acquisition module is used to connect to the output end of the PWM controller to be tested and collect various signals output by the PWM controller in real time. The communication module is used to upload the data collected by the data acquisition module to the host computer for analysis and processing in real time, and at the same time receive the control instructions sent by the host computer to adjust the working parameters of the detection system. The power supply module is used to provide a stable power supply for the entire detection system and the PWM controller to be tested. The host computer is used to provide a human-computer interaction interface.

[0027] Among them, the standard test signals include PWM signals with different frequencies, duty cycles, and amplitudes, as well as analog input signals, sine waves, and triangular waves. The waveforms, frequencies, and duty cycles of the PWM controller output signals, as well as the amplitudes and phase parameters of the analog output signals, accurately capture the dynamic changes of the signals through the data acquisition module. The communication module uses a variety of communication interfaces, USB, Ethernet, RS-485, to meet different application requirements. Users can set detection parameters, test signal types, frequency ranges, and duty cycle ranges through the host computer. The host computer receives the data from the data acquisition module, analyzes and processes the data using a preset algorithm, determines whether the PWM controller is qualified, and generates a detailed detection report. Among them, the signal generation module can use a professional signal generator chip such as AD9833, and generate various required test signals through programming control. The data acquisition module selects a high-speed ADC (analog-to-digital converter) chip to achieve high-speed and high-precision acquisition of the PWM controller output signals. The communication module uses a CH340 chip to implement the USB communication function. The power supply module combines a linear regulated power supply and a switching power supply to provide a stable power supply for each part of the system. Connect each hardware module according to the designed circuit schematic diagram and perform necessary debugging to ensure the normal operation of the hardware system. The host computer develops host computer detection software using programming languages such as C# and LabVIEW. The software interface design should be simple and clear for easy user operation. Functions such as detection parameter setting, data reception and processing, result determination, and report generation are implemented in the software.

[0028] The detection method of the PWM controller detection system includes the following steps:

[0029] Initialization:

[0030] Step S1: First, turn on the power of the detection system. The host computer initializes the detection system, including parameter configuration of the communication module and initial parameter setting of the signal generation module. At the same time, correctly connect the PWM controller under test to the corresponding interface of the detection system;

[0031] Install the PWM controller under test on the test fixture of the detection system to ensure reliable connection. Turn on the power of the detection system, start the host computer detection software, and perform system initialization. Set the test signal parameters required for this detection in the host computer software. For example, select the PWM signal as the test signal, set its frequency to 50Hz, and the duty cycle changes from 0% to 100% in 10% steps.

[0032] Send the test signal:

[0033] Step S2: According to the parameters set by the host computer, the signal generation module generates a specific test signal and inputs it into the PWM controller under test; the type and parameters of the test signal are selected according to the specifications and test requirements of the PWM controller. For a PWM controller used for motor drive, a PWM signal simulating motor load changes can be sent; Detection process: Click the "Start Detection" button in the host computer software. The signal generation module generates a test signal according to the set parameters and inputs it into the PWM controller under test. The data acquisition module real - time collects the output signal of the PWM controller, and collects the signal data within a certain time at each duty cycle setting point. For example, collect the PWM signal data of 100 cycles. The collected data is transmitted to the host computer in real - time through the communication module.

[0034] Data acquisition:

[0035] Step S3: The data acquisition module real - time collects the output signal of the PWM controller under test. During the acquisition process, reasonably adjust the sampling frequency and the number of sampling points according to the characteristics of the signal and the detection accuracy requirements; for high - frequency PWM signals, a higher sampling frequency is adopted to ensure that the collected signal is not distorted according to the characteristics of the signal and the detection accuracy requirements;

[0036] Data analysis and processing

[0037] Step S4: The collected data is transmitted to the host computer through the communication module. The host computer analyzes the data using a preset algorithm, and based on the technical specifications of the PWM controller, determines whether each detected parameter is within the normal range. If the detected parameter exceeds the normal range, the fault type is further analyzed. By comparing the signal characteristics of a normal PWM controller and a faulty PWM controller, the fault diagnosis algorithm is used to locate the cause of the fault; the technical specifications of the PWM controller check whether the frequency and duty cycle of the PWM output signal are consistent with the expected values, and the fault diagnosis algorithm is used to locate the cause of the fault, including power transistor damage and control chip failure; data analysis and result determination: The host computer software analyzes and processes the received data. First, parameters such as the actual frequency and duty cycle of the collected PWM signal are calculated and compared with the set theoretical values. If the deviation between the actual parameter and the theoretical value is within the allowable range, the parameter is determined to be qualified; if the deviation exceeds the allowable range, the cause of the fault is further analyzed. For example, if the duty cycle deviation of the PWM signal is too large, by analyzing the signal waveform and the relevant circuit principle, it is judged that it may be a comparator fault or a feedback circuit problem inside the PWM controller. According to the analysis result, the host computer software determines whether the measured PWM controller is qualified and generates a test report. If it is qualified, the test report shows that all detected parameters are normal; if it is unqualified, the unqualified parameters and possible causes of the fault are listed in detail in the report.

[0038] Result determination and report generation:

[0039] Step S5: According to the data analysis result, the host computer determines whether the measured PWM controller is qualified. If it is qualified, a qualified test report is generated; if it is unqualified, an unqualified test report containing detailed fault information is generated; the test report can be saved as an electronic document for convenient user query and management; after the test is completed, the user can view the test report in the host computer software and save and manage the test data. The measured PWM controller is removed from the test fixture to prepare for the next test.

[0040] The above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

[0041] The foregoing has shown and described the basic principles, main features and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-mentioned exemplary embodiments, and without departing from the spirit or basic features of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention. Any reference signs in the claims should not be construed as limiting the claims involved.

[0042] Other parts not detailed in the present invention belong to the prior art and will not be elaborated herein.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A PWM controller detection system, characterized in that, Including: A signal generation module, a data acquisition module, a communication module, a power supply module, and a host computer. The signal generation module is used to generate various standard test signals, which are input as excitation signals to the PWM controller under test. The data acquisition module is used to connect to the output end of the PWM controller under test and collect various signals output by the PWM controller in real time. The communication module is used to upload the data collected by the data acquisition module to the host computer for analysis and processing in real time, and at the same time receive the control instructions sent by the host computer to adjust the working parameters of the detection system. The power supply module is used to provide stable power for the entire detection system and the PWM controller under test. The host computer is used to provide a human-computer interaction interface.

2. The PWM controller detection system according to claim 1, wherein, The standard test signals include PWM signals with different frequencies, duty cycles, and amplitudes, as well as analog input signals, sine waves, and triangular waves.

3. The PWM controller detection system according to claim 1, wherein The waveforms, frequencies, duty cycles of the output signals of the PWM controller, and the amplitudes and phase parameters of the analog output signals accurately capture the dynamic changes of the signals through the data acquisition module.

4. A PWM controller detection system according to claim 1, characterized in that, The communication module adopts multiple communication interfaces, USB, Ethernet, RS-485, to meet different application requirements.

5. The PWM controller detection system according to claim 1, wherein The user can set detection parameters through the host computer, such as the type of test signal, frequency range, and duty cycle range. The host computer receives the data from the data acquisition module, analyzes and processes the data using a preset algorithm, determines whether the PWM controller is qualified, and generates a detailed detection report.

6. The detection method of the PWM controller detection system according to any one of claims 1-5, characterized in that, Including the following steps: Step S1: First, turn on the power of the detection system. The host computer initializes the detection system, including parameter configuration of the communication module and initial parameter setting of the signal generation module. At the same time, correctly connect the PWM controller under test to the corresponding interface of the detection system. Step S2: Generate specific test signals according to the parameters set by the host computer through the signal generation module and input them to the PWM controller under test. Step S3: Real-time collect the output signals of the PWM controller under test through the data acquisition module. During the collection process, reasonably adjust the sampling frequency and the number of sampling points according to the characteristics of the signals and the requirements of detection accuracy. Step S4: The collected data is transmitted to the host computer through the communication module. The host computer analyzes the data using a preset algorithm, and according to the technical specifications of the PWM controller, determines whether each detection parameter is within the normal range. If the detection parameter exceeds the normal range, further analyze the type of fault, and by comparing the signal characteristics of the normal PWM controller and the signal characteristics of the faulty PWM controller, use the fault diagnosis algorithm to locate the cause of the fault. Step S5: According to the data analysis results, the host computer determines whether the PWM controller under test is qualified. If it is qualified, generate a qualified detection report. If it is unqualified, generate an unqualified detection report containing detailed fault information.

7. The detection method of a PWM controller detection system according to claim 6, characterized in that, In step S2, the type and parameters of the test signals are selected according to the specifications of the PWM controller and the test requirements. For the PWM controller used for motor drive, a PWM signal simulating the change of motor load can be sent.

8. The detection method of a PWM controller detection system according to claim 6, characterized in that, In step S3, for high-frequency PWM signals, according to the characteristics of the signals and the requirements of detection accuracy, a relatively high sampling frequency is adopted to ensure that the acquired signals are not distorted.

9. The detection method of a PWM controller detection system according to claim 6, characterized in that, In step S4, the technical specifications of the PWM controller check whether the frequency and duty cycle of the PWM output signal are consistent with the expected values, and locate the cause of the fault through a fault diagnosis algorithm, including power transistor damage and control chip failure.

10. The detection method of a PWM controller detection system according to claim 6, characterized in that, In step S5, the detection report can be saved as an electronic document for the convenience of users to query and manage.

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