Portable train relay general tester and test method

Abstract

The invention discloses a portable train relay general tester and a test method. The tester comprises a box body, a power line, a power switch, a USB interface, a touch screen, a direct current stabilized power supply, an SBG train relay socket, a first AMGS train relay socket, a second AMGS train relay socket, a PLC, an acquisition card, a data processing unit, a numerical control direct current power supply and a numerical control alternating current power supply. The method comprises the following steps: firstly, opening an equipment box body, connecting a power line with 220V alternating current, and turning on a power switch; then, a relay to be tested is inserted into a corresponding train relay socket, and a test interface of a corresponding model is entered; and finally, selecting test content on a test interface, and clicking a test button to test the contact resistance and electrical parameters of the train relay. The device has the advantages of being complete in function, convenient to carry, high in measurement precision and wide in application range.

Description

Technical Field

[0001] This invention relates to train relay testing equipment, and in particular to a portable universal tester and testing method for train relays. Background Technology

[0002] With the rapid development of my country's economy, the rail transit industry has achieved leapfrog development, and the operating speed of high-speed trains is constantly increasing. However, this also poses new requirements for train operation safety technology.

[0003] Train relays are special automatic switches with functions such as automatic control, safety protection, and circuit switching. They are an important component of the train's electrical system and a crucial element in ensuring safe train operation. To improve the reliability of train relays, relevant national technical specifications impose strict requirements on their performance indicators and test methods.

[0004] In applications such as high-speed trains, regular passenger trains, subway cars, and locomotives, train relays are used very frequently and often malfunction, requiring regular inspection, maintenance, and management according to prescribed procedures. However, existing inspection methods have several problems: relays must be disassembled from the car body to obtain them, and then transported to a fixed, large-scale tooling inspection station for testing; relay testing is only performed during advanced or major overhauls, leading to the inability to promptly address early-stage faults; and relays need to be disassembled at the depot and transported back and forth between the depot and the maintenance workshop, resulting in lengthy inspection times and low efficiency.

[0005] Therefore, there is an urgent need to invent a portable train relay tester to measure the contact resistance and electrical parameters of train relays, reduce the risks caused by train relay failures, and improve the safety of train operation. Summary of the Invention

[0006] The purpose of this invention is to provide a portable train relay tester and test method that is simple in structure, easy to carry, and capable of accurately measuring relay contact resistance and electrical parameters.

[0007] The technical solution to achieve the purpose of this invention is as follows: a portable universal tester for train relays, comprising a housing, a power cord, a power switch, a USB interface, a touch screen, a DC regulated power supply, an SBG train relay socket, a first AMGS train relay socket, a second AMGS train relay socket, a PLC, a data acquisition card, a data processing unit, a digitally controlled DC power supply, and a digitally controlled AC power supply.

[0008] The enclosure serves as a mounting frame for the entire device, housing each unit unit.

[0009] The power cord is used to provide power to the entire device;

[0010] The power switch is used to control the switching of the entire device.

[0011] The USB interface is used to export measurement data;

[0012] The touchscreen is used to provide an interactive interface between the user and the entire testing system;

[0013] The DC regulated power supply provides a stable current of 0.5A for the relay test current;

[0014] The SBG train relay socket, the first AMGS train relay socket, and the second AMGS train relay socket are used to insert SBG train relays and AMGS train relays for testing.

[0015] The PLC is used to control the coordinated operation of various unit devices in the system.

[0016] The acquisition card collects voltage data when measuring contact resistance and transmits the collected data to the data processing unit for real-time viewing of the detection results; when measuring the working value, release value, and reverse working value, it is used to collect the closing and releasing signals of the relay contacts.

[0017] The data processing unit is used to receive voltage data transmitted by the acquisition card, calculate the resistance value, and send it to the touch screen for display.

[0018] The digitally controlled DC power supply is used to provide an adjustable and stable DC voltage to the relay under test. During the test, the voltage can be automatically increased or decreased according to the instructions of the PLC to test the electrical parameters of the relay under DC power supply conditions.

[0019] The digitally controlled AC power supply is used to provide an adjustable and stable AC voltage to the relay under test. During the test, the voltage can be automatically increased or decreased according to the instructions of the PLC to test the electrical parameters of the relay under AC power supply conditions.

[0020] As a specific example, the enclosure has a split structure, with both the upper and lower parts being sealed. The upper part of the enclosure is equipped with a power cord, power switch, USB interface, and touch screen, while the lower part is equipped with a DC regulated power supply, SBG train relay socket, first AMGS train relay socket, and second AMGS train relay socket. Inside the enclosure, a PLC, acquisition card, data processing unit, CNC DC power supply, and CNC AC power supply are installed.

[0021] As a specific example, the data processing unit is connected to the PLC, data acquisition card, CNC DC power supply, and CNC AC power supply via communication lines, controlling the communication between the PLC, CNC DC power supply, and CNC AC power supply, and reading data from the data acquisition card.

[0022] As a specific example, the power switch, USB interface, touch screen, and DC regulated power supply are installed in the upper part of the enclosure, and the internal circuit components are connected by connectors and soldering.

[0023] As a specific example, the SBG train relay socket, the first AMGS train relay socket, and the second AMGS train relay socket are installed on the right side of the lower half of the housing and are fixed by aluminum plates and screws.

[0024] As a specific example, the data processing unit is equipped with testing software, the functions of which include:

[0025] (1) Test various indicators of the relay and provide a test report. The test report can be generated as a PDF file for easy saving and printing.

[0026] (2) Perform multiple tests on individual indicators of the relay and output a test report;

[0027] (3) Control each node of the relay to perform repeated actions;

[0028] (4) Compare the periodic performance degradation of the same relay and make preventive treatment recommendations;

[0029] (5) Simultaneously test the three types of relays: SBG train relay, first AMGS train relay, and second AMGS train relay, to reduce testing time;

[0030] (6) Based on the error of multiple test results of the same relay, determine whether the relay is abnormal, and use big data to determine the cause of the abnormality and give preventive handling suggestions;

[0031] (7) When testing the relay, output the name or employee number of the operator, and indicate the name and time of the tester in the test results, and generate a test label.

[0032] A universal test method for portable train relays includes the following steps:

[0033] Step 1: Open the equipment casing, connect the power cord to 220V AC power, and turn on the power switch;

[0034] Step 2: Insert the relay to be tested into the corresponding train relay socket and enter the test interface for the corresponding model;

[0035] Step 3: Select the test content on the test interface, click the test button, and perform the train relay contact resistance and electrical parameter test.

[0036] As a specific example, step 3, which involves selecting the test content on the test interface and clicking the test button to measure the contact resistance and electrical parameters of the train relay, is as follows:

[0037] Step 3.1: When testing the contact resistance, a 0.5A constant current source is used. The data acquisition card obtains the voltage data, and the communication line transmits the data to the data processing unit to calculate the resistance value and display it on the touch screen.

[0038] Step 3.2: When testing the working value and release value, the output voltage of the corresponding power supply is controlled in real time. After the relay reaches the magnetization value, it drops back down. The release value is obtained after the acquisition card acquires the release signal. After the voltage drops to 0 and rises again, the working value is obtained after the engagement signal is acquired.

[0039] Step 3.3: When testing the reverse working value, the forward power supply is increased to the magnetization value and then drops back to 0 voltage. The reverse power supply voltage is increased, and the pull-in signal is collected to obtain the reverse working value.

[0040] Step 3.4: When testing the coil resistance, if the coil resistance is greater than 5Ω, use the single-arm bridge measurement method.

[0041] Step 3.5: When testing the pull-in time and release time, apply voltage to the relay coil. The voltage is a step function that rises from zero to the coil's rated value. The time interval from the moment the voltage rises to the coil's rated value until the contact output circuit finally switches to zero is the relay's pull-in time. Apply voltage to the relay coil. The voltage is a step function that drops from the coil's rated value to zero. The time interval from the moment the voltage drops to zero until the contact output circuit finally switches to zero is the relay's release time.

[0042] As a specific example, the test relay's slow-pull time described in step 3.5 is as follows:

[0043] When testing the slow-pull time, record time t1 when the relay coil voltage reaches the rated value, and record time t2 when the contacts close. The value of t2-t1 is the slow-pull time of the relay.

[0044] As a specific example, the test relay's release time described in step 3.5 is as follows:

[0045] When testing the release time, record time t3 when the relay coil voltage becomes 0 and time t4 when the contact opens. The value of t4-t3 is the release time of the relay.

[0046] Compared with the prior art, the present invention has the following significant advantages: (1) By designing the relay test circuit, controlling the test process, collecting circuit data, and calculating the measurement results, the relay socket can simultaneously test three types of train relays: SBG train relay, first AMGS train relay, and second AMGS train relay; (2) It adopts a portable design, which is convenient for timely testing; (3) It can accurately measure the relay contact resistance and electrical parameters, realize the testing of a variety of commonly used parameters, has high measurement accuracy, and is widely applicable. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the structure of a portable universal tester for train relays according to the present invention.

[0048] Figure 2 This is a schematic diagram of the user interface of the portable train relay contact resistance and electrical parameter general testing software in an embodiment of the present invention.

[0049] Figure 3 This is a schematic diagram of the connection method of the DC relay measurement route in an embodiment of the present invention.

[0050] Figure 4 This is a schematic diagram of the connection method of the AC relay measurement circuit in an embodiment of the present invention.

[0051] Figure 5 This is a flowchart illustrating a universal testing method for portable train relays according to the present invention. Detailed Implementation

[0052] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0053] like Figure 1 As shown, the present invention provides a portable universal tester for train relays, comprising a housing 1, a power cord 2, a power switch 3, a USB interface 4, a touch screen 5, a DC regulated power supply 6, an SBG train relay socket 7, a first AMGS train relay socket 8, a second AMGS train relay socket 9, a PLC 10, a data acquisition card 11, a data processing unit 12, a digitally controlled DC power supply 13, and a digitally controlled AC power supply 14.

[0054] The housing 1 serves as a mounting frame for the entire device, and is used to install each unit device.

[0055] The power cord 2 is used to provide power to the entire device;

[0056] The power switch 3 is used to control the switching of the entire device.

[0057] The USB interface 4 is used to export measurement data;

[0058] The touchscreen 5 is used to provide an interactive interface between the user and the entire testing system;

[0059] The DC regulated power supply 6 provides a stable current of 0.5A for the relay test current;

[0060] The SBG train relay socket 7, the first AMGS train relay socket 8, and the second AMGS train relay socket 9 are used to insert SBG train relays and AMGS train relays for testing.

[0061] The PLC 10 is used to control the coordinated operation of various unit devices in the system;

[0062] The acquisition card 11 acquires voltage data when measuring contact resistance and transmits the acquired data to the data processing unit for real-time viewing of the detection results; when measuring working value, release value and reverse working value, it is used to acquire the closing and releasing signals of the relay contacts.

[0063] The data processing unit 12 is used to receive voltage data transmitted by the acquisition card, calculate the resistance value, and send it to the touch screen 5 for display.

[0064] The digitally controlled DC power supply 13 is used to provide an adjustable and stable DC voltage to the relay under test. During the test, the voltage can be automatically increased or decreased according to the instructions of PLC 10 to test the electrical parameters of the relay under DC power supply conditions.

[0065] The CNC AC power supply 14 is used to provide an adjustable and stable AC voltage to the relay under test. During the test, the voltage can be automatically increased or decreased according to the instructions of PLC 10 to test the electrical parameters of the relay under AC power supply conditions.

[0066] As a specific example, the enclosure 1 has a split structure, with the internal structure fixed by custom PVC plastic. Both the upper and lower parts of the enclosure 1 are sealed structures. The upper part of the enclosure 1 is equipped with a power cord 2, a power switch 3, a USB interface 4, and a touch screen 5. The lower part is equipped with a DC regulated power supply 6, an SBG train relay socket 7, a first AMGS train relay socket 8, and a second AMGS train relay socket 9. The enclosure 9 is equipped with a PLC 10, a data acquisition card 11, a data processing unit 12, a CNC DC power supply 13, and a CNC AC power supply 14.

[0067] As a specific example, the data processing unit 12 is connected to the PLC 10, the data acquisition card 11, the CNC DC power supply 13, and the CNC AC power supply 14 via a communication line, and controls the communication between the PLC 10, the CNC DC power supply 13, and the CNC AC power supply 14 to read the data in the data acquisition card 11.

[0068] As a specific example, the power switch 3, USB interface 4, touch screen 5, and DC regulated power supply 6 are installed in the upper part of the housing 1, and the internal circuit components are connected by connectors and soldering.

[0069] As a specific example, the SBG train relay socket 7, the first AMGS train relay socket 8, and the second AMGS train relay socket 9 are installed on the right side of the lower half of the housing 1 and are fixed by aluminum plates and screws.

[0070] As a specific example, such as Figure 2 As shown, the data processing unit 12 is equipped with testing software, the functions of which include:

[0071] (1) Test various indicators of the relay and provide a test report. The test report can be generated as a PDF file for easy saving and printing.

[0072] (2) Perform multiple tests on individual indicators of the relay and output a test report;

[0073] (3) Control each node of the relay to perform repeated actions;

[0074] (4) Compare the periodic performance degradation of the same relay and make preventive treatment recommendations;

[0075] (5) Simultaneously test the three types of relays: SBG train relay, first AMGS train relay, and second AMGS train relay, to reduce testing time;

[0076] (6) Based on the error of multiple test results of the same relay, determine whether the relay is abnormal, and use big data to determine the cause of the abnormality and give preventive handling suggestions;

[0077] (7) When testing the relay, output the name or employee number of the operator, and indicate the name and time of the tester in the test results, and generate a test label.

[0078] As a specific example, the portable train relay universal tester simultaneously detects multiple contact resistances and needs to acquire relay contact closing signals. Therefore, a measurement circuit that meets the requirements needs to be designed, with the connection method as follows: Figure 3 , Figure 4 As shown.

[0079] like Figure 5 As shown, a universal test method for portable train relays includes the following steps:

[0080] Step 1: Open the equipment box 1, connect the power cord 2 to 220V AC power, and turn on the power switch 3;

[0081] Step 2: Insert the relay to be tested into the corresponding train relay socket and enter the test interface for the corresponding model;

[0082] Step 3: Select the test content on the test interface, click the test button, and perform the train relay contact resistance and electrical parameter test.

[0083] As a specific example, step 3, which involves selecting the test content on the test interface and clicking the test button to measure the contact resistance and electrical parameters of the train relay, is as follows:

[0084] Step 3.1: When testing the contact resistance, the 0.5A constant current source is working, the acquisition card 11 obtains the voltage data, and the communication line transmits the data to the data processing unit 12 to calculate the resistance value and display it on the touch screen 5.

[0085] Step 3.2: When testing the working value and release value, the output voltage of the corresponding power supply is controlled in real time. After the relay reaches the magnetization value, it drops back down. After the acquisition card 11 acquires the release signal, the release value is obtained. After the voltage drops to 0 and rises again, the working value is obtained after the engagement signal is acquired.

[0086] Step 3.3: When testing the reverse working value, the forward power supply is increased to the magnetization value and then drops back to 0 voltage. The reverse power supply voltage is increased, and the pull-in signal is collected to obtain the reverse working value.

[0087] Step 3.4: When testing the coil resistance, if the coil resistance is greater than 5Ω, use the single-arm bridge measurement method.

[0088] Step 3.5: When testing the pull-in time and release time, apply voltage to the relay coil. The voltage is a step function that rises from zero to the coil's rated value. The time interval from the moment the voltage rises to the coil's rated value until the contact output circuit finally switches to zero is the relay's pull-in time. Apply voltage to the relay coil. The voltage is a step function that drops from the coil's rated value to zero. The time interval from the moment the voltage drops to zero until the contact output circuit finally switches to zero is the relay's release time.

[0089] As a specific example, the test relay's slow-pull time described in step 3.5 is as follows:

[0090] When testing the slow-pull time, record time t1 when the relay coil voltage reaches the rated value, and record time t2 when the contacts close. The value of t2-t1 is the slow-pull time of the relay.

[0091] As a specific example, the test relay's release time described in step 3.5 is as follows:

[0092] When testing the release time, record time t3 when the relay coil voltage becomes 0 and time t4 when the contact opens. The value of t4-t3 is the release time of the relay.

[0093] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A portable universal tester for train relays, characterized in that, Includes housing (1), power cord (2), power switch (3), USB interface (4), touch screen (5), DC regulated power supply (6), SBG train relay socket (7), first AMGS train relay socket (8), second AMGS train relay socket (9), PLC (10), data acquisition card (11), data processing unit (12), CNC DC power supply (13) and CNC AC power supply (14); The enclosure (1) is used to provide an installation frame for the entire device and to install each unit device; The power cord (2) is used to provide power to the entire device; The power switch (3) is used to control the switching of the entire device; The USB interface (4) is used to export measurement data; The touchscreen (5) is used to provide an interactive interface between the user and the entire testing system; The DC regulated power supply (6) provides a stable current of 0.5A for the relay test current; The SBG train relay socket (7), the first AMGS train relay socket (8), and the second AMGS train relay socket (9) are used to insert SBG train relays and AMGS train relays for testing; The PLC (10) is used to control the coordinated operation of each unit device in the system; The acquisition card (11) acquires voltage data when measuring contact resistance and transmits the acquired data to the data processing unit for real-time viewing of the detection results; when measuring working value, release value and reverse working value, it is used to acquire the closing and releasing signals of the relay contacts. The data processing unit (12) is used to receive voltage data transmitted by the acquisition card, calculate the resistance value and send it to the touch screen (5) for display; The digitally controlled DC power supply (13) is used to provide an adjustable and stable DC voltage to the relay under test. During the test, the voltage is automatically raised and lowered according to the instructions of the PLC (10) to test the electrical parameters of the relay under DC power supply conditions. The digital control AC power supply (14) is used to provide an adjustable and stable AC voltage to the relay under test. During the test, the voltage is automatically raised and lowered according to the instructions of the PLC (10) to test the electrical parameters of the relay under AC power supply conditions.

2. The portable universal tester for train relays according to claim 1, characterized in that, The enclosure (1) is a split structure. Both the upper and lower parts of the enclosure (1) are sealed structures. The upper part of the enclosure (1) is equipped with a power cord (2), a power switch (3), a USB interface (4), and a touch screen (5). The lower part is equipped with a DC regulated power supply (6), an SBG train relay socket (7), a first AMGS train relay socket (8), and a second AMGS train relay socket (9). The enclosure (9) is equipped with a PLC (10), a data acquisition card (11), a data processing unit (12), a digitally controlled DC power supply (13), and a digitally controlled AC power supply (14).

3. The portable train relay universal tester according to claim 1, characterized in that, The data processing unit (12) is connected to the PLC (10), data acquisition card (11), CNC DC power supply (13), and CNC AC power supply (14) via a communication line, controls the communication between the PLC (10), CNC DC power supply (13), and CNC AC power supply (14), and reads the data in the data acquisition card (11).

4. The portable train relay universal tester according to claim 1, characterized in that, The power switch (3), USB interface (4), touch screen (5), and DC regulated power supply (6) are installed in the upper part of the housing (1), and the internal circuit components are connected by connectors and welding.

5. The portable universal tester for train relays according to claim 1, characterized in that, The SBG train relay socket (7), the first AMGS train relay socket (8), and the second AMGS train relay socket (9) are installed on the right side of the lower half of the housing (1) and are fixed by aluminum plates and screws.

6. The portable universal tester for train relays according to claim 1, characterized in that, The data processing unit (12) is equipped with testing software, the functions of which include: (1) Test various indicators of the relay and provide a test report. The test report can be generated as a PDF file for easy saving and printing. (2) Perform multiple tests on individual indicators of the relay and output a test report; (3) Control each node of the relay to perform repeated actions; (4) Compare the periodic performance degradation of the same relay and make preventive treatment recommendations; (5) Simultaneously test the three types of relays: SBG train relay, first AMGS train relay, and second AMGS train relay, to reduce testing time; (6) Based on the error of multiple test results of the same relay, determine whether the relay is abnormal, and use big data to determine the cause of the abnormality and give preventive handling suggestions; (7) When testing the relay, output the name or employee number of the operator, and indicate the name and time of the tester in the test results, and generate a test label.

7. A universal test method for portable train relays, characterized in that, This method, based on the portable train relay universal tester according to any one of claims 1 to 6, specifically includes the following steps: Step 1: Open the equipment box (1), connect the power cord (2) to 220V AC power, and turn on the power switch (3); Step 2: Insert the relay to be tested into the corresponding train relay socket and enter the test interface for the corresponding model; Step 3: Select the test content on the test interface, click the test button, and perform the train relay contact resistance and electrical parameter test.

8. The universal test method for portable train relays according to claim 7, characterized in that, Step 3 involves selecting the test content on the test interface, clicking the test button, and measuring the contact resistance and electrical parameters of the train relay, as detailed below: Step 3.1: When testing the contact resistance, the 0.5A constant current source is working, the acquisition card (11) obtains the voltage data, and the communication line transmits the data to the data processing unit (12), calculates the resistance value and displays it on the touch screen (5); Step 3.2: When testing the working value and release value, the output voltage of the corresponding power supply is controlled in real time. After the relay reaches the magnetization value, it drops back. After the acquisition card (11) acquires the release signal, the release value is obtained. After the voltage drops to 0, it rises again. After the engagement signal is acquired, the working value is obtained. Step 3.3: When testing the reverse working value, the forward power supply is increased to the magnetization value and then drops back to 0 voltage. The reverse power supply voltage is increased, and the pull-in signal is collected to obtain the reverse working value. Step 3.4: When testing the coil resistance, if the coil resistance is greater than 5Ω, use the single-arm bridge measurement method. Step 3.5: When testing the pull-in time and release time, apply voltage to the relay coil. The voltage is a step function that rises from zero to the coil's rated value. The time interval from the moment the voltage rises to the coil's rated value until the contact output circuit finally switches to zero is the relay's pull-in time. Apply voltage to the relay coil. The voltage is a step function that drops from the coil's rated value to zero. The time interval from the moment the voltage drops to zero until the contact output circuit finally switches to zero is the relay's release time.

9. The universal test method for portable train relays according to claim 8, characterized in that, The specific details of the test relay's slow-acting time described in step 3.5 are as follows: When testing the slow-pull time, record time t1 when the relay coil voltage reaches the rated value and time t2 when the contacts close. The value of t2-t1 is the slow-pull time of the relay.

10. The universal test method for portable train relays according to claim 8, characterized in that, The test relay's release time described in step 3.5 is as follows: When testing the release time, record time t3 when the relay coil voltage becomes 0 and time t4 when the contact opens. The value of t4-t3 is the release time of the relay.

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