Ice water impact control method and system for direct current converter

Abstract

The invention discloses an ice water impact control method and system for a DC converter, and relates to the technical field of DC converter detection, and the method comprises the steps: collecting the first state data of a to-be-detected DC converter; determining a sample operation state according to the first state data; if the sample operation state is ready, controlling a main power supply to supply power to the to-be-tested DC converter; controlling an incubator and an electronic load to carry out load processing on the to-be-tested direct-current converter, so that the to-be-tested direct-current converter sequentially goes through a no-load working stage and a full-load working stage at a target temperature; after the full-load working stage is finished, an execution mechanism is controlled to perform water spraying impact treatment on the to-be-tested direct-current converter; monitoring operation data of the DC converter to be measured, wherein the operation data comprises second state data and external measurement data; and performing security protection processing according to the operation data. According to the invention, ice water impact control is realized, and accuracy and efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of direct current converter detection, and in particular to a direct current converter ice water impact control method and system. BACKGROUND

[0002] As a power electronic device, the direct current converter plays an important role in the field of electric vehicles and other fields, and its performance and reliability directly affect the normal operation of the vehicle. In order to verify the performance of the direct current converter in harsh environments, strict ice water impact tests need to be carried out. This test simulates the situation that the direct current converter is suddenly impacted by cold water under high temperature working condition when the vehicle is in extreme conditions such as wading or rainy and snowy weather. The existing method mainly relies on manual operation, however, the whole test process is time-consuming, and the operator needs to frequently control the sample state and switch the device function, which is labor-intensive and low in efficiency. At the same time, manual operation cannot guarantee accurate time control, resulting in inconsistent test results. Moreover, the operator can only observe the sample through the readings of the external power supply and load, and it is difficult to real-time understand the key state of the direct current converter inside, so it is difficult to find abnormalities in time, and the detection accuracy is low.

[0003] In summary, the technical problems in the related art need to be improved. SUMMARY

[0004] The main purpose of the embodiments of the present application is to provide a direct current converter ice water impact control method and system, which realizes ice water impact control and improves accuracy and efficiency.

[0005] In one aspect, the present application provides a direct current converter ice water impact control method, comprising the following steps: Collecting first state data of a direct current converter to be tested; According to the first state data, determining the sample running state; If the sample running state is ready, controlling the main power supply to supply power to the direct current converter to be tested; Controlling the temperature box and the electronic load to perform load processing on the direct current converter to be tested, so that the direct current converter to be tested experiences the no-load working phase and the full-load working phase at the target temperature in turn; After the full-load working phase ends, controlling the actuator to perform water impact processing on the direct current converter to be tested; Monitoring the running data of the direct current converter to be tested, the running data including second state data and external measurement data; According to the running data, performing safety protection processing.

[0006] In another aspect, the present application provides a direct current converter ice water impact control system, comprising: A data acquisition module is configured to acquire first state data of the DC converter to be tested. A sample state determination module is configured to determine a sample running state according to the first state data. A main power supply control module is configured to control a main power supply to supply power to the DC converter to be tested if the sample running state is ready. A load control module is configured to control a temperature box and an electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested undergoes an idle load working phase and a full load working phase in turn at a target temperature. A water spray impact driving module is configured to control an actuator to perform water spray impact processing on the DC converter to be tested after the full load working phase ends. An operation data monitoring module is configured to monitor operation data of the DC converter to be tested, the operation data including second state data and external measurement data. A safety protection module is configured to perform safety protection processing according to the operation data.

[0007] The embodiments of the present application have at least the following beneficial effects: The embodiments of the present application first acquire first state data of the DC converter to be tested, then determine a sample running state according to the first state data, control a main power supply to supply power to the DC converter to be tested if the sample running state is ready, control a temperature box and an electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested undergoes an idle load working phase and a full load working phase in turn at a target temperature, control an actuator to perform water spray impact processing on the DC converter to be tested after the full load working phase ends, and finally monitor operation data of the DC converter to be tested and perform safety protection processing, thereby realizing ice water impact control and improving accuracy and efficiency.

[0008] Other features and advantages of the present application will be further described in the following description, and in part will become apparent to those skilled in the art from the following description, or will be learned by practice of the present application. The objects and other advantages of the present application can be achieved and obtained by the structure particularly pointed out in the description and the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0009] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiment description will be briefly introduced.

[0010] Figure 1 A flow chart of a DC converter ice water impact control method according to an embodiment of the present application; Figure 2 A structure schematic diagram of a DC converter ice water impact control system according to an embodiment of the present application. DETAILED DESCRIPTION

[0011] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in combination with the drawings and examples.

[0012] In related art, a DC converter is a common power electronic device, for example, in an electric vehicle, it may be responsible for converting the power of a high-voltage battery into a lower voltage for use by the vehicle's electronic systems. Its performance and reliability are crucial for the normal operation of the vehicle. According to industry standards, DC converters need to undergo rigorous ice water impact tests. This test simulates the situation that the vehicle may encounter in harsh environments, such as wading or rainy and snowy weather, that is, sudden cold water impact under high temperature working condition, to verify its performance and reliability under extreme conditions. The test usually involves placing the sample in a specific position and spraying water impact on it through a nozzle.

[0013] The test conditions usually include: the sample is kept at 105 degrees Celsius for 30 minutes, 0-4 degrees Celsius tap water and dust mixture are used for 3 seconds of water impact, the water flow is 3-4 liters per second, the distance from the nozzle to the sample is 300-350 millimeters. The whole test needs to be carried out for 100 cycles, each cycle contains 15 minutes of no-load work and 15 minutes of full-load work, and 3 seconds of ice water impact after 30 minutes.

[0014] The traditional ice water impact test method usually relies on manual operation. This manual test has many problems: (1) long test time and large labor input: the whole test process is more than 50 hours, that is, 30 minutes multiplied by 100 cycles, and the operator needs to frequently control the sample state, switch the device function. (2) Inaccurate time control: manual operation cannot guarantee accurate time control, such as the on-off timing of KL15 and KL30f auxiliary power supply, and the timing of the main power supply access, which may cause inconsistency of test results. (3) Lack of real-time understanding of the internal state of the sample: the operator can only observe the sample through the readings of the external power supply and load, and cannot know the internal key states such as internal temperature, working mode, output voltage and current, and fault diagnosis information. This means that when an abnormality is found, the sample may have been damaged. (4) Poor operation consistency: manual operation cannot guarantee the absolute consistency of each instruction issuance and state confirmation, which affects the reliability and comparability of test results. (5) Potential risk of sample damage: when the sample is working with large current, water impact is performed, which may cause damage to the sample or failure of the test if not properly controlled.

[0015] To overcome these challenges, the present application proposes a DC converter ice water impact control method and system, aiming to realize high-precision, high-reproducibility, safe and reliable DC converter ice water impact test. The system can use the upper computer software as the "central commander", integrate CAN communication, multi-power cooperative control, high-precision time reference scheduling, hardware timing and multi-source information closed-loop safety protection technology, to ensure the accuracy, consistency and safety of the test process, and provide deep data analysis and traceability capability. In the long-period, multi-cycle ice water impact test scenario of the DC converter, multiple test equipment (such as power supply, load, oven, water spraying device) are controlled with high precision, while the internal state of the sample under test is monitored in real time and closed-loop protection is performed, to ensure the automation, high-reproducibility, safety and data traceability of the test process, thereby solving the challenges faced by the DC converter in the ice water impact test for waterproof performance in the process of research and development verification test and production line offline product verification test.

[0016] The embodiments of the present application will be specifically explained below in combination with the drawings: Figure 1 is an optional flowchart of a DC converter ice water impact control method provided by the embodiments of the present application, Figure 1 The method in can include but is not limited to steps S101 to S107.

[0017] Step S101, collect first state data of the DC converter to be tested; Step S102, determine the sample running state according to the first state data; Step S103, if the sample running state is ready, control the main power supply to supply power to the DC converter to be tested; Step S104, control the oven and electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested experiences the no-load working phase and the full-load working phase at the target temperature in turn; Step S105, after the full-load working phase ends, control the actuator to perform water impact processing on the DC converter to be tested; Step S106, monitor the running data of the DC converter to be tested, including the second state data and the external measurement data; Step S107, perform safety protection processing according to the running data.

[0018] The steps S101 to S107 shown in the embodiments of the present application realize ice water impact control, and improve accuracy and efficiency.

[0019] In some embodiments, steps S101-S107, first state data of the DC converter under test can be collected first. For example, the power input voltage, current, device connection state, and other information of the DC converter under test can be obtained through a sensor module. These data can be manually input or automatically read through a communication interface with the DC converter under test. Then, according to the first state data, the sample running state is determined, a series of judgment rules can be set, if all necessary parameters meet the preset "ready" condition, the sample running state is determined as "ready". Otherwise, troubleshooting or operator confirmation can be required. If the sample running state is ready, the main power supply is controlled to supply power to the DC converter under test. For example, the on-off of the main power supply can be controlled through a relay or a solid-state switch to ensure that the power supply is performed after the sample is ready to avoid misoperation. It can be understood that the sample running state refers to the specific working state of the DC converter under test determined according to the first state data, such as "ready", "running", "fault", etc.

[0020] The temperature box and the electronic load are further controlled to perform load processing on the DC converter under test, so that the DC converter under test experiences the no-load working phase and the full-load working phase in turn at the target temperature. For example, the temperature box can be set to 105 degrees Celsius and maintained for 30 minutes. The electronic load applies no load or a very small load in the no-load working phase and applies rated load or near rated load in the full-load working phase according to the preset test curve. It can be understood that the temperature box is used to provide and maintain the target temperature environment required by the DC converter under test during the test. The electronic load is used to simulate the load condition of the DC converter under test in actual application to realize the no-load and full-load working phases. The actuator refers to a mechanical device used to perform water spray impact processing, such as a water spray nozzle, a water pump, and a control valve.

[0021] After the full-load working phase ends, the actuator is controlled to perform water spray impact processing on the DC converter under test. For example, the actuator can include a nozzle, a water pump, and a solenoid valve. After the full-load working phase ends, the control system can issue an instruction to start the water pump and open the solenoid valve to spray 0-4 degrees Celsius tap water and dust mixture at a flow rate of 3-4 liters per second to the DC converter under test for 3 seconds.

[0022] Finally, the operation data of the to-be-tested DC converter is monitored, and safety protection processing is performed according to the operation data, wherein the operation data includes the second state data and the external measurement data. Exemplarily, the second state data such as internal temperature, output voltage, output current, working mode and the like of the to-be-tested DC converter can be acquired in real time through a built-in sensor or an external probe, while the external measurement data such as environmental temperature, humidity, water flow and the like is monitored. These data can be digitized through a data acquisition card and transmitted to a control system for processing. A series of safety thresholds and protection logic are set. When any parameter in the operation data exceeds the safety threshold, the system can automatically trigger an alarm, shutdown protection or adjust the test parameters to prevent equipment damage or test failure. It can be understood that the operation data is the data about the working condition of the to-be-tested DC converter collected in real time during the test, including the second state data (such as internal temperature, voltage, current, working mode, fault code and the like) and the external measurement data (such as environmental temperature, humidity, water flow and the like).

[0023] The embodiment ensures that the test is performed under the condition that the equipment is ready, avoids test interruption or error caused by unprepared equipment, by collecting the first state data of the to-be-tested DC converter and determining the sample operation state. When the sample operation state is ready, the main power supply is precisely controlled to supply power, ensuring the consistency of the starting condition of the test. Then, the automated control of the oven and the electronic load enables the to-be-tested DC converter to be subjected to precise load processing at the target temperature according to the preset idle load and full load working stages. This not only eliminates the time error of manual operation, ensures the standardization of each test cycle, but also improves the repeatability of the test results. After the full load working stage ends, the actuator performs water impact processing on the DC converter. This process also achieves automation and precise control, avoiding the problem of inaccurate or inconsistent impact caused by manual operation, thereby reducing the risk of sample damage. Finally, by monitoring the operation data of the to-be-tested DC converter in real time, the tester can comprehensively understand the working condition of the internal and external DC converter. This is in sharp contrast to the traditional method which can only observe through external power supply and load readings. Real-time data monitoring enables the system to discover abnormalities in time and perform safety protection processing when necessary, so that measures can be taken immediately when abnormalities occur, effectively avoiding sample damage and improving control accuracy and test safety.

[0024] By the above technical solutions, the embodiment introduces automatic control, precise timing management, and real-time data monitoring and safety protection mechanism, significantly improving the efficiency, accuracy, reliability, and safety of the ice water impact test. Compared with the traditional manual operation method, the embodiment can greatly reduce the labor input, reduce the cost, shorten the test period, improve the efficiency, ensure the consistency and comparability of the test results, and improve the accuracy, providing a more advanced and reliable solution for performance verification of the DC converter.

[0025] In some embodiments, in step S105, the control of the actuator to perform water impact treatment on the DC converter to be tested can include but is not limited to the following steps: Before water impact, according to the preset time, control the electromagnetic valve to be powered on; Monitor the first current value flowing through the electromagnetic valve coil within the preset time; Numerically integrate the first current value to calculate the initial electromagnetic energy obtained by the electromagnetic valve coil as a standard energy value; When water impact is performed, monitor the current current value flowing through the electromagnetic valve coil; Numerically integrate the current current value to calculate the current electromagnetic energy obtained by the electromagnetic valve coil; If the current electromagnetic energy is greater than the standard energy value, control the electromagnetic valve to be powered off and stop water impact.

[0026] In some embodiments, if the water impact treatment lacks fine control, it may cause the water impact time to be too long, the water volume to be too large, and thus cause unnecessary damage to the DC converter or affect the accuracy of the test results. To this end, the application further optimizes the water impact treatment by monitoring the electromagnetic energy of the electromagnetic valve coil to achieve precise control and safety protection of the water impact process.

[0027] To this end, before water impact, according to the preset time, control the electromagnetic valve to be powered on, aiming to obtain the electrical characteristic reference of the electromagnetic valve coil in the normal working state before the actual water impact starts. The preset time refers to the length of time sufficient to obtain a stable current value under the stable power-on state of the electromagnetic valve. At the same time, the first current value flowing through the electromagnetic valve coil within the preset time is monitored. The first current value reflects the current response of the electromagnetic valve coil under normal power-on state.

[0028] Then, the first current value is numerically integrated to calculate the initial electromagnetic energy obtained by the electromagnetic valve coil as a standard energy value. The initial electromagnetic energy is set as the standard energy value as a reference benchmark for the energy state of the electromagnetic valve coil in the subsequent water impact process. When water impact is performed, the current current value flowing through the electromagnetic valve coil is monitored. The current current value reflects the real-time working state of the electromagnetic valve in the actual water impact process.

[0029] The current current value is then numerically integrated to calculate the current electromagnetic energy obtained by the electromagnetic valve coil. In this way, by comparing the real-time calculated current electromagnetic energy with the pre-determined standard energy value, it can be determined whether the electromagnetic valve is operating abnormally. If the current electromagnetic energy is greater than the standard energy value, it indicates that the electromagnetic valve may have abnormal energization, sticking or other faults, and the electromagnetic valve can be controlled to be de-energized and the water impact stopped to prevent excessive water impact or equipment damage caused by abnormal operation of the electromagnetic valve.

[0030] The present embodiment effectively solves the problem of lack of fine control in the basic scheme by introducing an electromagnetic energy monitoring mechanism for the electromagnetic valve coil. Specifically, before the water impact starts, the initial electromagnetic energy reference of the electromagnetic valve coil, i.e. the standard energy value, is established by pre-energizing and monitoring the first current value. This standard energy value represents the energy consumption characteristics of the electromagnetic valve under normal operating conditions. During the actual water impact process, the system continuously monitors the current current value of the electromagnetic valve coil and calculates its current electromagnetic energy in real time. By comparing the current electromagnetic energy with the standard energy value, if the current electromagnetic energy exceeds the standard energy value, it indicates that the electromagnetic valve may be in an abnormal operating state, such as continuous energization of the coil, sticking of the valve, etc. At this time, the system can respond in time to control the electromagnetic valve to be de-energized and the water impact to be stopped. This real-time monitoring and comparison mechanism allows the water impact process to be accurately controlled, avoiding excessive water impact caused by abnormal electromagnetic valves, thereby effectively protecting the DC converter under test.

[0031] To more clearly illustrate the technical solution, specific examples are used in the following explanation. Assume that before the ice water impact test of the DC converter is performed, the electromagnetic valve is controlled to be energized for 100 milliseconds in order to establish the normal operating reference of the electromagnetic valve. During this pre-set time, the system monitors the first current value flowing through the electromagnetic valve coil and numerically integrates it to calculate the initial electromagnetic energy of 50 joules, which is set as the standard energy value. During the subsequent actual water impact process, the system continuously monitors the current current value flowing through the electromagnetic valve coil. For example, at a certain time during the water impact, the system monitors the current current value and numerically integrates it to calculate the current electromagnetic energy of 60 joules. Since 60 joules is greater than the pre-set standard energy value of 50 joules, the system immediately determines that the electromagnetic valve may have abnormalities, such as continuous energization of the coil for too long or short circuit, etc., and immediately controls the electromagnetic valve to be de-energized and the water impact to be stopped. In this way, even if the electromagnetic valve fails during the test, the water impact can be interrupted in time, effectively preventing the DC converter under test from being damaged by excessive water impact, ensuring the safety of the test process and the integrity of the equipment.

[0032] By the technical solution, the electromagnetic energy of the electromagnetic valve coil is monitored in real time and compared with the standard energy value, so that the abnormal working state of the electromagnetic valve can be found and corrected in time, and potential damage to the DC converter caused by too long water spraying time or too large water volume is effectively avoided. This not only improves the safety of the test process, but also ensures the accuracy and consistency of the test results, thereby significantly improving the reliability of the ice water impact test.

[0033] In some embodiments, in step S106, monitoring the operation data of the to-be-tested DC converter can include, but is not limited to, the following steps: Step S201, acquiring signals of the to-be-tested DC converter through a sensing module to obtain analog signals; Step S202, removing electromagnetic interference from the analog signals through a high-frequency common-mode rejection filter; Step S203, determining adaptive notch filter parameters according to the vibration state of the test bench; Step S204, filtering frequency noise from the analog signals after electromagnetic interference removal through an adaptive notch filter according to the adaptive notch filter parameters; Step S205, amplifying the analog signals after frequency noise filtering through a differential amplifier to obtain operation data.

[0034] In some embodiments, since the DC converter works in an ice water impact test environment, it may face complex electromagnetic environment and mechanical vibration, resulting in a large amount of high-frequency common-mode interference and mechanical noise of specific frequency in the directly collected operation data. If these noises are not effectively filtered, the accuracy and reliability of the operation data will be seriously affected, which may lead to misjudgment or omission of subsequent safety protection processing, and the safety of the to-be-tested DC converter cannot be effectively guaranteed in time.

[0035] Therefore, the sensing module can be used to acquire signals of the to-be-tested DC converter to obtain analog signals. The sensing module is a device for converting physical quantities (such as voltage, current, temperature, vibration, etc.) of the to-be-tested DC converter in the running process into electrical signals. Specifically, the sensing module can include a voltage sensor, a current sensor, a temperature sensor, or an acceleration sensor, etc., and its purpose is to obtain real-time operation state information of the to-be-tested DC converter in the ice water impact test process. The obtained analog signals are original and unprocessed electrical signals, which contain real operation information of the to-be-tested DC converter and environmental noise.

[0036] Then the analog signal is subjected to electromagnetic interference removal through a high-frequency common-mode suppression filter, aiming to filter out high-frequency common-mode noise in the analog signal caused by power lines, switching power supplies or external electromagnetic fields. The filter can be composed of common-mode choke coils, common-mode capacitors and other elements, and its purpose is to effectively reduce the impact of electromagnetic interference on signal quality before the signal enters the subsequent processing stage, thereby improving the signal-to-noise ratio of the signal.

[0037] According to the vibration state of the test bench, the adaptive notch filter parameters are determined. The vibration state of the test bench refers to the vibration condition of the test equipment or environment caused by mechanical movement, impact and other factors. This vibration state can be monitored in real time by additional vibration sensors. According to the monitored vibration frequency and intensity, the adaptive notch filter parameters such as notch center frequency, bandwidth and depth can be dynamically determined, aiming to accurately match and filter out specific frequency noise caused by mechanical vibration.

[0038] Finally, according to the adaptive notch filter parameters, the frequency noise of the analog signal after electromagnetic interference removal is filtered through the adaptive notch filter. The adaptive notch filter is a filter that can dynamically adjust its filtering parameters according to the characteristics of the input signal or external control signals. The analog signal processed by the high-frequency common-mode suppression filter can be further filtered for frequency noise according to the predetermined adaptive notch filter parameters. Its purpose is to specifically eliminate narrowband frequency noise caused by test bench vibration and avoid unnecessary attenuation of useful signals. At the same time, the analog signal after frequency noise filtering is amplified by a differential amplifier to obtain the operating data. The differential amplifier can effectively suppress common-mode noise and amplify differential-mode signals, thereby further improving the signal-to-noise ratio and measurement accuracy of the signal. The amplified signal is the operating data, which has higher accuracy and reliability and can be used for subsequent safety protection processing.

[0039] The embodiment effectively solves the problem of inaccurate operation data caused by electromagnetic interference and mechanical vibration in the traditional monitoring method through a multi-stage signal processing mechanism. First, the sensor module is responsible for converting the physical state of the DC converter under test into an original analog signal. Then, the high-frequency common-mode rejection filter specifically removes high-frequency common-mode interference caused by the power supply or the environment, ensuring the preliminary purity of the signal. Given that the vibration of the test bench may introduce noise at a specific frequency, the embodiment dynamically determines the parameters of the adaptive notch filter by monitoring the vibration state of the test bench in real time, so that the adaptive notch filter can accurately filter out these narrowband frequency noises, avoiding excessive filtering or insufficient filtering caused by fixed parameter filters. Finally, the differential amplifier amplifies the signal after two stages of noise filtering, not only improving the signal strength, but also further suppressing the residual common-mode noise, thereby obtaining high-precision and high-reliability operation data. This phased and targeted noise suppression strategy enables accurate DC converter operation data to be obtained even in a complex test environment.

[0040] To more clearly illustrate the technical solutions, specific examples are used in the following explanation. Assume that when an ice water impact test is performed on a DC converter for an electric vehicle, multiple sensors are installed on the test bench, including voltage sensors and current sensors for measuring output voltage and current, and acceleration sensors for monitoring the vibration of the test bench. When the DC converter experiences a full load working phase at a target temperature and then undergoes water spray impact processing, the voltage sensors and current sensors continuously collect analog signals of their output voltage and current. Due to high-frequency switching actions inside the DC converter and electromagnetic radiation of external power lines, these analog signals contain significant high-frequency common-mode interference. At this time, the high-frequency common-mode rejection filter will first process these analog signals to remove most of the high-frequency common-mode noise. At the same time, the acceleration sensor will monitor the vibration of the test bench in real time, for example, finding that the test bench will produce a stable 50Hz or 60Hz mechanical vibration frequency when sprayed with water. According to this vibration frequency, the system dynamically adjusts the parameters of the adaptive notch filter, so that its center frequency is accurately locked at 50Hz or 60Hz, and the analog signals processed by the high-frequency common-mode rejection filter are filtered for frequency noise, thereby eliminating specific frequency noise introduced by mechanical vibration. Finally, the analog signals filtered by two stages of noise are sent to the differential amplifier for amplification to improve the amplitude and signal-to-noise ratio of the signal, and finally output as high-precision, noise-free operation data for analysis by the safety protection module. In this way, even in a harsh ice water impact test environment, accurate and reliable DC converter operation data can be obtained.

[0041] By the technical scheme, the high-frequency common-mode interference and frequency noise caused by the test bench vibration are effectively removed, and the signal is amplified with high quality by introducing the high-frequency common-mode interference filter, the adaptive notch filter and the differential amplifier. This ensures that the obtained operation data can truly reflect the working state of the to-be-tested direct current converter, avoids misjudgment or missed judgment caused by noise interference, thereby providing a solid data foundation for subsequent safety protection processing, and greatly improves the safety and efficiency of the test process.

[0042] In some embodiments, in step S202, the electromagnetic interference removal on the analog signal by the high-frequency common-mode interference filter can include but is not limited to the following steps: Step S301, scanning the high-frequency common-mode interference spectrum of the to-be-tested direct current converter under different working states to obtain the interference frequency range and intensity distribution; Step S302, determining a first adjustment parameter according to the interference frequency range and intensity distribution, the first adjustment parameter being used to match the cutoff frequency and the attenuation slope of the high-frequency common-mode interference filter with the current interference spectrum characteristics; Step S303, monitoring the working state and environmental temperature change of the to-be-tested direct current converter; Step S304, determining a second adjustment parameter according to the working state and environmental temperature change, the second adjustment parameter being used to adapt to the changing interference spectrum; Step S305, adjusting the parameters of the high-frequency common-mode interference filter according to the first adjustment parameter and the second adjustment parameter; Step S306, removing the electromagnetic interference on the analog signal by the high-frequency common-mode interference filter with the adjusted parameters.

[0043] In some embodiments, since the working state and environmental temperature of the to-be-tested direct current converter can change, the high-frequency common-mode interference spectrum characteristics generated thereby also change. If the high-frequency common-mode interference filter adopts fixed parameters, it can not effectively adapt to these dynamic changes, thereby resulting in poor electromagnetic interference removal effect, and even possibly over-attenuating effective signals or failing to sufficiently suppress interference, affecting the accuracy of subsequent operation data.

[0044] Therefore, the high-frequency common-mode interference spectrum of the to-be-tested direct current converter under different working states can be scanned first to obtain the interference frequency range and intensity distribution, aiming to comprehensively understand the interference characteristics thereof under various typical operating conditions. The frequency range and intensity distribution of the interference can be obtained by scanning, thereby providing basic data for subsequent filter parameter setting.

[0045] Then, according to the interference frequency range and intensity distribution, a first adjustment parameter is determined, wherein the first adjustment parameter is used to match the cutoff frequency and attenuation slope of the high-frequency common-mode rejection filter with the current interference spectral characteristics. The first adjustment parameter can be determined based on the interference spectral characteristics obtained by the initial scanning, and the purpose is to enable the cutoff frequency and attenuation slope of the high-frequency common-mode rejection filter to preliminarily match the current interference spectral characteristics, thereby achieving effective suppression of known interference.

[0046] In order to cope with dynamic changes in actual operation, the working state and environmental temperature change of the to-be-tested DC converter can be monitored. The working state can include load size, input voltage, output current, etc., and the environmental temperature change refers to the fluctuation of the surrounding environmental temperature. These factors can all affect the electromagnetic interference spectrum generated by the DC converter. Then, according to the working state and environmental temperature change, a second adjustment parameter is determined, which is used to adapt to the changing interference spectrum, and the purpose is to enable the high-frequency common-mode rejection filter to adapt to the changing interference spectrum. For example, when the working state or the environmental temperature changes significantly, the interference spectrum can drift or change in intensity.

[0047] Finally, according to the first adjustment parameter and the second adjustment parameter, the high-frequency common-mode rejection filter is adjusted in parameters to maintain the best suppression effect. The first adjustment parameter provides baseline matching, and the second adjustment parameter provides dynamic adaptability. And through the high-frequency common-mode rejection filter after parameter adjustment, the electromagnetic interference of the analog signal is removed, ensuring that high-quality analog signals can be obtained under various working conditions and environmental conditions.

[0048] The embodiment introduces a dynamic parameter adjustment mechanism to solve the problem of poor electromagnetic interference removal effect of the fixed parameter high-frequency common-mode rejection filter when the DC converter is in different working states and the environmental temperature changes. Specifically, first, the frequency range and intensity distribution of the interference are obtained by scanning the high-frequency common-mode interference spectrum under different working states, which provides a comprehensive basis for the initial setting of the filter parameters. On this basis, the first adjustment parameter is determined according to the interference frequency range and intensity distribution, so that the cutoff frequency and attenuation slope of the high-frequency common-mode rejection filter can be preliminarily matched with the current interference spectrum characteristics, thereby realizing efficient electromagnetic interference suppression in static or known working conditions. In order to cope with the dynamic changes in actual operation, the embodiment can real-time perceive the external factors that may cause the interference spectrum to change by continuously monitoring the working state and environmental temperature changes of the DC converter to be tested. Based on these monitoring data, the second adjustment parameter is determined, which is specifically used to compensate for the interference spectrum drift or intensity fluctuation caused by the changes in working state and environmental temperature. Thus, by combining the first adjustment parameter and the second adjustment parameter, the high-frequency common-mode rejection filter is comprehensively adjusted, so that the filter can dynamically adapt to the changing interference spectrum and always maintain the best filtering performance. This adaptive adjustment mechanism ensures that even in a complex and dynamically changing operating environment, electromagnetic interference in the analog signal can be effectively removed, thereby providing a pure and reliable signal source for subsequent frequency noise filtering and operation data analysis.

[0049] To make the technical solution clearer, specific examples are used for explanation below. Assume that the working state of the DC converter to be tested is switched from no-load to full-load during the ice water impact test, and the temperature of the test environment may also fluctuate within a certain range. During the no-load working phase, the high-frequency common-mode interference frequency spectrum generated by the DC converter may be concentrated in a certain frequency range, while during the full-load working phase, the center frequency of the spectrum may shift and the intensity may increase. At the same time, the increase or decrease of the environmental temperature may also cause slight changes in the interference frequency spectrum. The high-frequency common-mode interference frequency spectrum of the DC converter in typical working states such as no-load and full-load can be scanned first to obtain the interference frequency range and intensity distribution in these states. Based on the scanning results, a set of initial first adjustment parameters are determined, so that the high-frequency common-mode suppression filter can effectively suppress these typical interference frequency spectrums. During the actual test process, the system continuously monitors the working state parameters of the DC converter such as the load current, input voltage, and the environmental temperature in the oven. When it is detected that the load is switched from no-load to full-load or the environmental temperature changes significantly, the system dynamically calculates the second adjustment parameters according to these change trends and the preset mapping relationship. For example, if the increase of the load causes the interference frequency spectrum to drift towards high frequency, the second adjustment parameters will correspondingly adjust the cutoff frequency of the filter so that it moves towards high frequency. Subsequently, the system will combine the first adjustment parameters and the second adjustment parameters to perform real-time parameter adjustment on the high-frequency common-mode suppression filter. In this way, no matter what working state the DC converter is in or how the environmental temperature changes, the high-frequency common-mode suppression filter can adaptively adjust its performance to always maintain the best suppression effect on the current electromagnetic interference, thereby ensuring that the monitored analog signals are always pure and reliable.

[0050] Through the above technical solution, the embodiment can effectively cope with the dynamic interference frequency spectrum generated by the DC converter under different working states and environmental temperature changes, avoiding the problems of insufficient interference suppression or excessive attenuation of effective signals caused by mismatched filter parameters. Thus, it ensures that the analog signals collected from the sensing module can maintain higher signal integrity and signal-to-noise ratio after the electromagnetic interference is removed, providing a more reliable basis for subsequent frequency noise filtering and operation data monitoring, thereby improving the accuracy and safety of the entire DC converter ice water impact control method.

[0051] In some embodiments, in step S304, determining the second adjustment parameters according to the working state and the environmental temperature change can include but is not limited to the following steps: Taking the interference frequency range and intensity distribution as the effective signal baseline; Monitoring the signal frequency spectrum output by the high-frequency common-mode suppression filter; Comparing the signal frequency spectrum with the effective signal baseline to obtain a comparison result; If the comparison result is that the attenuation is lower than the threshold value, the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change of the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode rejection filter in the interference frequency range meets the preset attenuation requirement. If the comparison result is that the attenuation is lower than the threshold value, the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change of the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode rejection filter in the interference frequency range meets the preset attenuation requirement.

[0052] In some embodiments, since the high-frequency common-mode rejection filter parameter is adjusted only by relying on the change of the working state and the ambient temperature, it can not be accurately ensured that it is always in the best working state. Especially when the interference frequency spectrum dynamically changes or the performance of the filter itself slightly drifts, it can cause the filtering effect to be too strong or insufficient, thereby affecting the accuracy of the running data. Therefore, the interference frequency range and intensity distribution can be taken as an effective signal baseline first. Under the normal working state of the to-be-tested direct current converter, the interference frequency range and intensity distribution obtained by scanning the high-frequency common-mode interference frequency spectrum are regarded as a reference standard. The baseline represents the suppression effect that the high-frequency common-mode rejection filter should achieve under ideal or expected working conditions.

[0053] Then, the signal spectrum output by the high-frequency common-mode rejection filter is monitored. Exemplarily, the frequency spectrum characteristics of the analog signal processed by the filter can be obtained in real time, so as to evaluate the actual working effect of the filter. The signal spectrum is compared with the effective signal baseline to obtain a comparison result. The output signal spectrum monitored in real time and the preset effective signal baseline can be compared through an algorithm or a preset rule to determine whether the attenuation performance of the filter meets the expectation. If the comparison result is that the attenuation exceeds the threshold value, the second adjustment parameter is determined according to the preset attenuation range, the working state and the change of the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode rejection filter is maintained within the preset attenuation range. If the comparison result is that the attenuation is lower than the threshold value, the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change of the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode rejection filter in the interference frequency range meets the preset attenuation requirement.

[0054] The embodiment realizes closed-loop feedback control of the filter performance by introducing a real-time monitoring and baseline comparison mechanism for the output signal spectrum of the high-frequency common-mode rejection filter. When the comparison result shows that the attenuation exceeds the threshold, it indicates that the filter may have excessively suppressed the effective signal. In this case, the system adjusts the second adjustment parameter, such as appropriately relaxing the cutoff frequency or reducing the attenuation slope of the filter, according to the preset attenuation range, the current working state, and the change in ambient temperature, to avoid excessive filtering and ensure the integrity of the useful signal. Conversely, if the comparison result shows that the attenuation is lower than the threshold, it indicates that the filter is not sufficient to suppress the interference signal. In this case, the system adjusts the second adjustment parameter, such as tightening the cutoff frequency or increasing the attenuation slope of the filter, according to the preset attenuation requirement, the current working state, and the change in ambient temperature, to enhance the suppression of the interference and ensure that the filtering effect meets the requirements. In this way, the high-frequency common-mode rejection filter can adaptively adjust according to the actual interference and its own performance, thereby maintaining the best filtering effect.

[0055] To more clearly illustrate the technical solutions, specific examples are used in the following explanation. Assume that during the ice water impact test of the to-be-tested DC converter, the high-frequency common-mode interference spectrum under different working states is first obtained by scanning and is taken as the effective signal baseline. During the test, the system continuously monitors the signal spectrum output by the high-frequency common-mode rejection filter. For example, if the monitoring result shows that the attenuation amplitude of the output signal spectrum in a certain key frequency range is much higher than the preset threshold, it may mean that the filter has unnecessarily suppressed the useful signal in the frequency range. In this case, the system dynamically adjusts the second adjustment parameter, such as the cutoff frequency or Q value of the filter, according to the preset attenuation range (for example, the attenuation amplitude should be between -20 dB and -30 dB), the current working state (such as the full-load working stage), and the ambient temperature (such as -20℃), so that the attenuation amplitude of the output signal falls to about -25 dB, thereby avoiding excessive filtering. Conversely, if the monitoring result shows that the attenuation amplitude of the output signal spectrum in the interference frequency range is lower than the preset requirement (for example, it should be attenuated by at least -40 dB, but it is actually attenuated by only -30 dB), the system adjusts the second adjustment parameter, such as further reducing the cutoff frequency or increasing the attenuation slope, according to the preset attenuation requirement, the current working state, and the ambient temperature, to enhance the suppression of the interference signal and ensure that the purity of the output signal meets the needs of subsequent data analysis.

[0056] By the technical solution, the embodiment can realize more refined and adaptive parameter adjustment, effectively avoiding the problems of excessive filtering or insufficient filtering. This not only improves the accuracy and efficiency of electromagnetic interference removal, ensures the quality of the analog signal, but also enables subsequent frequency noise filtering and signal amplification to be based on purer signals, thereby significantly improving the reliability and accuracy of operation data monitoring. The embodiment enhances the robustness and adaptability of the system under complex and variable working conditions, and provides more reliable data support for ice water impact control of the direct current converter.

[0057] In some embodiments, in step S107, performing safety protection processing according to the operation data can include but is not limited to the following steps: According to the operation data, transient fluctuation identification is performed to obtain a transient fluctuation identification result; If the transient fluctuation identification result is that there is a transient fluctuation, a delay time period is determined; After the delay time period, device safety analysis is performed according to the operation data to obtain a device safety analysis result; If the device safety analysis result is that the safety threshold is exceeded, a shutdown protection operation is performed on the direct current converter to be tested.

[0058] In some embodiments, due to the drastic changes in the external environment, the operation data may appear transient fluctuations. If safety judgment is directly based on these transient fluctuations, it may lead to system misjudgment as a fault and trigger unnecessary shutdown protection, thereby affecting the continuity and efficiency of the test. Therefore, transient fluctuation identification can be performed according to the operation data to obtain a transient fluctuation identification result. For example, real-time analysis can be performed on the monitored operation data to distinguish between short-term, non-persistent fluctuations caused by external interference (such as ice water impact) and actual device failure. This can be achieved through various signal processing techniques, for example, a high-pass filter can be used to filter out low-frequency stable signals and only retain high-frequency transient components; or a dynamic threshold can be set, when the data exceeds the threshold in a very short time but then quickly recovers, it is identified as a transient fluctuation. The purpose is to avoid misjudging short-term, harmless fluctuations as faults.

[0059] If the transient fluctuation identification result is that there is a transient fluctuation, a delay time period is determined. The delay time period can be a preset fixed duration, for example, hundreds of milliseconds to several seconds, or it can be adaptively adjusted according to the characteristics of the transient fluctuation (such as duration, amplitude). The purpose is to provide a buffer and self-recovery time for the device, wait for the transient fluctuation to subside, so that subsequent device safety analysis can be based on more stable and more real data.

[0060] After the delay period, a safety analysis is performed on the equipment based on the operational data to obtain the results. The current operational data can be compared with preset safety thresholds, or trend analysis can be performed to determine if there are any persistent anomalies in the equipment. The purpose is to provide a final, reliable assessment of the equipment's safety after eliminating transient interference. If the equipment safety analysis result shows that the safety threshold is exceeded, it indicates that the equipment does indeed have a persistent safety risk, and a shutdown protection operation can be performed on the DC-DC converter under test. This operation typically involves cutting off the main power supply to the DC-DC converter to prevent further damage to the equipment or other safety accidents.

[0061] This embodiment introduces a transient fluctuation identification mechanism to effectively distinguish between brief, non-continuous fluctuations caused by external disturbances such as ice water impacts and actual equipment failures. By setting a delay period after identifying a transient fluctuation, hasty safety judgments can be avoided before the equipment has stabilized or the fluctuations have subsided. After the delay period, the operating data is analyzed again for equipment safety. The data at this time is more stable and can more accurately reflect the true operating status of the equipment. Therefore, misjudgments caused by transient fluctuations can be avoided, ensuring that shutdown protection operations are only performed when it is confirmed that the equipment actually poses a risk exceeding the safety threshold, thereby improving the accuracy and reliability of safety protection.

[0062] To illustrate this technical solution more clearly, a specific example is used below. Suppose that during a water-cooled DC-DC converter under test, due to the impact of the water flow or a sudden temperature change, its output voltage or current experiences a spike or drop within a very short time, but then quickly returns to normal. This transient fluctuation can be identified based on the operating data. Due to the presence of this transient fluctuation, the system determines a delay period, for example, 500 milliseconds. During this delay, the system continues monitoring. After the transient fluctuation subsides, and the delay period ends, the operating data is analyzed again for equipment safety. If the equipment operating data has returned to the normal range, the equipment safety analysis result will not exceed the safety threshold, thus avoiding unnecessary shutdown protection. Conversely, if the equipment is still in an abnormal state after the delay, a shutdown protection operation will be executed, ensuring the true safety of the equipment.

[0063] Through the above technical solution, this embodiment introduces a delay mechanism to provide the system with buffering and self-recovery time, reducing unnecessary downtime protection and thus improving testing efficiency and equipment availability. At the same time, it makes the testing process more stable and reliable while ensuring equipment safety.

[0064] In some embodiments, step S107, based on the operating data, performs security protection processing, which may include, but is not limited to, the following steps: Calculate the rate of change of parameters based on the operational data; If the parameter change rate is greater than the preset change rate threshold, a safety alarm is triggered. After triggering the safety alarm, an alarm event log is recorded and the data sampling frequency is adjusted.

[0065] In some embodiments, since only basic safety protection processing is performed, subtle but potentially abnormal trends that may occur in the DC converter under test during the ice water impact test may not be discovered in a timely manner, which may result in a lack of early warning before failure occurs, affecting the reliability of the test and the safety of the equipment. Therefore, the parameter change rate can be calculated according to the operating data. For example, the change trend of the operating data over time can be quantified. For example, the difference method, the moving average method or a more complex statistical regression method can be used to calculate the change amplitude or rate of the parameter between consecutive sampling points. The purpose is to capture the dynamic change of the parameter, rather than just focusing on the instantaneous value, in order to identify potential abnormal trends.

[0066] If the parameter change rate is greater than the preset change rate threshold, a safety alarm is triggered. The preset change rate threshold is set in advance according to the design specifications of the DC converter under test, historical test data, industry standards and safety requirements. This threshold represents the maximum allowable change rate of the parameter under normal operating conditions. If the calculated parameter change rate is greater than the preset change rate threshold, it indicates that the parameter change is abnormal, which may indicate that the equipment is about to fail or is already in an unstable state. At this time, a safety alarm is triggered, such as through an audible and visual signal, an interface prompt or a remote notification, to remind the operator to pay attention.

[0067] After triggering the safety alarm, an alarm event log is recorded and the data sampling frequency is adjusted. The alarm event log can include the time of the alarm, the specific abnormal parameter, the parameter change rate, the operating data snapshot at the time and other related system state information. The purpose of recording the alarm event log is to provide detailed data support for subsequent fault diagnosis, cause analysis and improvement. At the same time, the data sampling frequency can be adjusted, for example, from the regular mode to the high frequency mode. The purpose of adjusting the data sampling frequency is to be able to collect data more densely and finely when an abnormality occurs, so as to capture more detailed information, which helps to more accurately analyze the evolution process of the fault and locate the cause of the fault, and provides a more sufficient data basis for taking further protection measures or intervention.

[0068] The embodiment realizes dynamic evaluation of the operating state of the DC converter by introducing the calculation and monitoring of the parameter change rate. The traditional safety protection may mainly rely on threshold judgment of the absolute value of the parameter, and the protection is triggered when the parameter exceeds a certain fixed range. However, in the severe test environment such as ice water impact, the rapid change of the parameter is often a precursor of failure, but the absolute value may not have reached the traditional threshold. By calculating the parameter change rate, the early, subtle but critical change trend can be captured. Once the parameter change rate exceeds the preset threshold, it indicates that the system may have an anomaly, so that the safety alarm can be triggered in time to provide an early warning for the operator. The sensitivity to the change trend enables the system to intervene before or at the early stage of failure, avoiding damage to the equipment or test failure due to delayed response. In addition, after the alarm is triggered, detailed event logs are recorded and the data sampling frequency is increased, which can provide more abundant and fine data for subsequent failure analysis, further improving the accuracy and efficiency of failure diagnosis.

[0069] To more clearly illustrate the technical solution, specific examples are used in the following explanation. Assume that during the full load working phase of the ice water impact test of the DC converter, the system continuously monitors its output voltage and output current. Under normal circumstances, the change rate of the output voltage should be maintained at a low level. For example, the preset change rate threshold is set to 0.1V per second. If at a certain time point, the system detects that the output voltage has dropped from 24.0V to 23.5V within 100 milliseconds, the change rate is (24.0-23.5)V / 0.1s = 5V / s. Since 5V / s is much greater than the preset threshold of 0.1V / s, the system will immediately trigger a safety alarm, such as emitting a beeping sound and displaying a warning message of “abnormal fluctuation of output voltage”. At the same time, the system will automatically record this alarm event, including the time of occurrence, the voltage change rate, the load condition at that time, etc., and increase the data sampling frequency of the output voltage and current from 100 times per second to 1000 times per second, in order to record the subsequent voltage and current changes in more detail, providing more fine data support for technicians to analyze the cause of the voltage drop. In this way, even if the output voltage has not dropped below the traditional “under-voltage protection” threshold, the system can discover and warn potential failure in time through the abnormal change rate, thereby avoiding more serious equipment damage.

[0070] By the above technical solution, the embodiment can more sensitively capture subtle fluctuations and abnormal trends of the equipment running state by monitoring the parameter change rate, thereby triggering an alarm before or at the early stage of failure, significantly improving the timeliness and effectiveness of safety protection. In addition, the mechanism of automatically recording event logs and adjusting the data sampling frequency after the alarm is triggered provides valuable data support for in-depth analysis and diagnosis of faults, helps to quickly locate problems and take corrective measures, and thus improves the reliability of testing, the safety of equipment, and the efficiency of fault diagnosis.

[0071] In some embodiments, in step S107, the safety protection processing according to the running data can include but is not limited to the following steps: Step S401, monitoring the working state and environmental temperature of the to-be-tested DC converter; Step S402, data aggregation on the working state, environmental temperature and running data to obtain aggregated data; Step S403, statistical feature calculation on the aggregated data to obtain statistical feature data; Step S404, fault identification processing according to the statistical feature data.

[0072] In some embodiments, since safety protection processing is only based on single or limited running data, it may not be able to comprehensively capture complex fault modes that may occur in the ice water impact test of the to-be-tested DC converter. For example, some faults may be caused by abnormal combinations of working state and environmental temperature, and if these information is not fully integrated and analyzed, it may lead to insufficient accuracy of fault identification or not timely response. Therefore, the working state and environmental temperature of the to-be-tested DC converter can be monitored first. For example, various sensors integrated in the test system can be used to obtain real-time key running parameters inside the to-be-tested DC converter, such as its internal temperature, voltage, current, power output, etc., and external conditions of the test environment, such as environmental temperature, humidity, air pressure, etc. These data are continuously collected to provide comprehensive context information.

[0073] Then, the working state, environmental temperature and running data are aggregated to obtain aggregated data. The monitored working state data, environmental temperature data and running data (including second state data and external measurement data) can be integrated. This aggregation operation aims to collect scattered, multi-source heterogeneous data together to form a unified, more informative comprehensive data set. The aggregation method can include time synchronization, data association, format unification, etc., and its purpose is to provide a complete data view for subsequent analysis.

[0074] The statistical feature data is obtained by performing statistical feature calculation on the aggregated data. Various statistical methods can be applied to the aggregated data to extract the inherent rules and features. For example, the mean, variance, standard deviation, maximum value, minimum value, change rate, trend, correlation, and other statistical quantities of the data can be calculated. These statistical features can effectively summarize the distribution, fluctuation, and evolution trend of the data, thereby transforming the original, high-dimensional data into more refined and easier-to-analyze feature representations.

[0075] Finally, according to the statistical feature data, a fault recognition process is performed. The calculated statistical feature data can be used in combination with a pre-set fault model, threshold, or machine learning algorithm to determine whether the DC converter under test has an anomaly or a fault. For example, the current statistical feature data can be compared with baseline statistical features in a normal operating state. If it exceeds the pre-set normal fluctuation range or meets a specific abnormal pattern, it is identified as a fault. The purpose is to improve the accuracy and sensitivity of fault recognition through comprehensive analysis of multi-dimensional information.

[0076] The embodiment can more comprehensively and deeply understand the operating condition of the equipment by aggregating the operating state, environmental temperature, and operating data of the DC converter under test in multiple dimensions and performing statistical feature calculation based thereon. The embodiment can capture the correlation between different data sources and the overall dynamic change trend of the data. For example, when the equipment is in a specific operating state and environmental temperature, the statistical features of its operating data deviate slightly but continuously. This anomaly may be ignored in single data monitoring, but it can be effectively identified after aggregation and statistical analysis. The fusion and advanced analysis of multi-source data enable the system to identify more complex and hidden fault patterns, thereby overcoming the limitations that may exist when relying solely on original operating data for safety protection.

[0077] To illustrate the technical solution more clearly, specific examples are used for explanation below. Assume that during the ice water impact test of the DC converter, the system continuously monitors the internal core temperature of the DC converter under test 100 (as working state data) and the environmental humidity in the test box (as environmental temperature data), as well as the output voltage and current of the DC converter (as running data). These data are collected in real time and time-stamped for alignment, forming aggregated data. Subsequently, statistical feature calculation of the aggregated data is performed in a sliding window, for example, the mean, standard deviation of the output voltage, and the change rate of the core temperature and environmental humidity. If it is found that the standard deviation of the output voltage continuously increases in a certain time period, while the core temperature and environmental humidity also show an abnormal rising trend, even if a single indicator has not reached the hard threshold, through comprehensive analysis of these statistical features, the system can identify early signs of potential faults such as overheating or internal short circuit of the device. For example, when the standard deviation of the output voltage exceeds 1.5 times the normal fluctuation range, and the core temperature change rate exceeds 0.5℃ / s for 3 consecutive sampling periods, the system will trigger a safety alarm and further perform fault identification processing, so as to take protective measures before the fault worsens.

[0078] Through the above technical solution, the working state and environmental temperature of the DC converter under test are included in the consideration range of safety protection, and are aggregated and analyzed with the running data, which significantly improves the accuracy and robustness of fault identification. The present embodiment can detect potential device anomalies or faults earlier and more accurately, effectively avoiding false positives or false negatives due to incomplete information. Thus, more reliable and comprehensive safety protection can be provided for the ice water impact test of the DC converter, ensuring the stability of the test process and the safety of the device, and thus improving the test efficiency and data reliability.

[0079] In some embodiments, in step S404, the fault identification processing according to the statistical feature data can include but is not limited to the following steps: obtaining the current working phase of the DC converter under test; extracting statistical feature baseline data and identification rules corresponding to the current working phase; identifying the normal fluctuation range of the current working phase according to the statistical feature baseline data and the identification rules; if the statistical feature data exceeds the normal fluctuation range, triggering a safety alarm.

[0080] In some embodiments, due to the different working stages (e.g. no-load, light-load, full-load, etc.) of the DC converter, the normal operation data fluctuation range and fault characteristics may have significant differences. If a single, universal fault identification rule is used, it may lead to false positives or false negatives, reducing the accuracy and reliability of fault identification. To this end, the current working stage of the DC converter to be tested can be obtained first. For example, the working mode or load condition of the DC converter can be monitored in real time, such as by detecting output current, voltage or power parameters, to determine whether it is in a no-load, light-load, full-load or other specific working state. The working stage can be classified based on pre-set thresholds or machine learning models.

[0081] Then the statistical feature baseline data and identification rules corresponding to the current working stage are extracted. A large number of tests and data analysis can be performed in advance on the normal operation data of the DC converter under different working stages to establish statistical feature baseline data (such as mean, variance, peak, etc.) and corresponding fault identification rules specific to each working stage. These baseline data and rules are stored in the system for real-time monitoring.

[0082] According to the statistical feature baseline data and identification rules, the normal fluctuation range of the current working stage is identified. The statistical feature data obtained in real time can be compared with the baseline data corresponding to the current working stage, and combined with the identification rules to determine the reasonable fluctuation range of each parameter under the current working stage. For example, in the no-load stage, the voltage fluctuation range may be small, while in the full-load stage, the current fluctuation range may be large. If the statistical feature data exceeds the normal fluctuation range, a safety alarm is triggered to notify the operator in time or to take further safety measures automatically.

[0083] The current working stage is obtained in this embodiment, and the system can dynamically call the baseline data and identification rules that best match the stage, so that fault identification is no longer a universal judgment of fixed thresholds, but a precise analysis based on the current actual operating conditions. Therefore, abnormal fluctuations can be more accurately identified, avoiding the situation where normal fluctuations are misjudged as faults in some working stages, or faults are not reported in other working stages due to unobvious fault characteristics.

[0084] To more clearly illustrate the technical solutions, specific examples are used in the following explanations. Assume that the DC converter to be tested switches from an idle state to a full load state during an ice water impact test. In the idle state, the system obtains the current working state as "idle" and extracts the statistical feature baseline data and identification rules of the "idle state" stored in advance. For example, in the idle state, the normal fluctuation range of the output voltage can be set as ±0.5 V. When the statistical feature data monitored by the system (for example, the mean value of the real-time output voltage) exceeds this ±0.5 V range, a safety alarm is triggered. Subsequently, when the DC converter switches to the full load working state, the system re-obtains the current working state as "full load" and extracts the statistical feature baseline data and identification rules of the "full load state". In the full load state, due to the large load change, the normal fluctuation range of the output current can be set as ±5 A. At this time, the system compares the real-time monitored statistical feature data (for example, the variance of the real-time output current) with the baseline data and identification rules of the "full load state". If it is found that the current variance significantly exceeds the ±5 A range, a safety alarm is triggered. In this way, the system can dynamically adjust the fault identification criteria according to the specific working state of the DC converter, thereby achieving more accurate and reliable fault identification.

[0085] Through the above technical solutions, the embodiment can significantly improve the accuracy and reliability of DC converter fault identification. By customizing fault identification for different working states, the system can better adapt to the complex and variable working environment of the DC converter, effectively reducing the false positive rate and the false negative rate. This adaptive fault identification mechanism based on the working state makes the safety protection processing more intelligent and refined, thereby prolonging the service life of the equipment and ensuring the stability and safety of the system operation.

[0086] The beneficial effects of implementing the embodiment of the present application include that the embodiment of the present application first collects first state data of the DC converter to be tested, then determines a sample running state according to the first state data, controls a main power supply to supply power to the DC converter to be tested if the sample running state is ready, controls a temperature box and an electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested experiences an idle working state and a full load working state in turn at a target temperature, controls an execution mechanism to perform water impact processing on the DC converter to be tested after the full load working state ends, and finally monitors running data of the DC converter to be tested to perform safety protection processing, thereby realizing ice water impact control and improving accuracy and efficiency.

[0087] As shown in Figure 2 The embodiment of the present application also provides a DC converter ice water impact control system, which comprises: A data acquisition module 501 is configured to acquire first state data of the DC converter to be tested. The sample state determination module 502 is configured to determine a sample running state according to the first state data. The main power supply control module 503 is configured to control the main power supply to supply power to the DC converter to be tested if the sample running state is ready. The load control module 504 is configured to control the oven and the electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested undergoes the no-load working phase and the full-load working phase in turn at the target temperature. The water jet impact driving module 505 is configured to control the actuator to perform water jet impact processing on the DC converter to be tested after the full-load working phase ends. The running data monitoring module 506 is configured to monitor running data of the DC converter to be tested, the running data including the second state data and external measurement data. The safety protection module 507 is configured to perform safety protection processing according to the running data.

[0088] The contents in the method embodiments are applicable to the system embodiments, the system embodiments specifically implement the same functions as the method embodiments, and achieve the same beneficial effects as the method embodiments.

[0089] The embodiments described in the embodiments of the present application are for more clearly illustrating the technical solutions of the embodiments of the present application, and do not constitute a limitation on the technical solutions provided by the embodiments of the present application. It can be known by those skilled in the art that, with the evolution of technology and the appearance of new application scenarios, the technical solutions provided by the embodiments of the present application are also applicable to similar technical problems.

Claims

1. A method for controlling water chiller impact on a DC converter, the method comprising: The method comprises the following steps: Collecting first state data of a to-be-tested direct current converter; Determining a sample running state according to the first state data; If the sample running state is ready, controlling a main power supply to supply power to the to-be-tested direct current converter; Controlling a temperature box and an electronic load to perform load processing on the to-be-tested direct current converter, so that the to-be-tested direct current converter sequentially experiences an idle load working stage and a full load working stage at a target temperature; After the full load working stage ends, controlling an actuator to perform water spray impact processing on the to-be-tested direct current converter; Monitoring running data of the to-be-tested direct current converter, the running data comprising second state data and external measurement data; According to the running data, performing safety protection processing.

2. The method of claim 1, wherein, The method of controlling the actuator to perform water spray impact processing on the to-be-tested direct current converter comprises the following steps: Before performing water spray impact, controlling an electromagnetic valve to be powered on according to a preset time; Monitoring a first current value flowing through the electromagnetic valve coil within the preset time; Numerically integrating the first current value to calculate an initial electromagnetic energy obtained by the electromagnetic valve coil as a standard energy value; When performing water spray impact, monitoring a current current value flowing through the electromagnetic valve coil; Numerically integrating the current current value to calculate a current electromagnetic energy obtained by the electromagnetic valve coil; If the current electromagnetic energy is greater than the standard energy value, controlling the electromagnetic valve to be powered off and stopping water spray impact.

3. The method of claim 1, wherein, The method of monitoring the running data of the to-be-tested direct current converter comprises the following steps: Collecting signals of the to-be-tested direct current converter through a sensing module to obtain analog signals; Removing electromagnetic interference from the analog signals through a high-frequency common-mode suppression filter; According to a vibration state of a test bench, determining adaptive notch filter parameters; According to the adaptive notch filter parameters, filtering frequency noise from the analog signals after removing electromagnetic interference through an adaptive notch filter; Amplifying the analog signals after filtering frequency noise through a differential amplifier to obtain the running data.

4. The method of claim 3, wherein, The method of removing electromagnetic interference from the analog signals through a high-frequency common-mode suppression filter comprises the following steps: Scanning high-frequency common-mode interference frequency spectrum of the to-be-tested direct current converter under different working states to obtain an interference frequency range and an intensity distribution; According to the interference frequency range and the intensity distribution, determining first adjustment parameters, which are used to match the cut-off frequency and the attenuation slope of the high-frequency common-mode suppression filter with the current interference frequency spectrum characteristics; Monitoring working states of the to-be-tested direct current converter and environmental temperature changes; According to the working states and the environmental temperature changes, determining second adjustment parameters, which are used to adapt to changing interference frequency spectrum; According to the first adjustment parameters and the second adjustment parameters, adjusting parameters of the high-frequency common-mode suppression filter; Removing electromagnetic interference from the analog signals through the high-frequency common-mode suppression filter after parameter adjustment.

5. The method of claim 4, wherein, The method of determining second adjustment parameters according to the working states and the environmental temperature changes comprises the following steps: Taking the interference frequency range and the intensity distribution as an effective signal baseline; monitor a signal spectrum of an output of the high-frequency common-mode rejection filter; compare the signal spectrum with the effective signal baseline to obtain a comparison result; if the comparison result is that the attenuation exceeds a threshold, determine the second adjustment parameter according to a preset attenuation range, the working state, and the ambient temperature change, so that an attenuation amplitude of an output signal of the high-frequency common-mode rejection filter is maintained within the preset attenuation range; if the comparison result is that the attenuation is lower than the threshold, determine the second adjustment parameter according to a preset attenuation requirement, the working state, and the ambient temperature change, so that an attenuation amplitude of the output signal of the high-frequency common-mode rejection filter within the interference frequency range meets the preset attenuation requirement.

6. The method of claim 1, wherein, The safety protection processing according to the operation data includes: performing transient fluctuation identification according to the operation data to obtain a transient fluctuation identification result; if the transient fluctuation identification result is that there is a transient fluctuation, determining a delay time period; after the delay time period, performing device safety analysis according to the operation data to obtain a device safety analysis result; if the device safety analysis result is that a safety threshold is exceeded, performing a shutdown protection operation on the to-be-tested direct current converter.

7. The method of claim 1, wherein, The safety protection processing according to the operation data includes: calculating a parameter change rate according to the operation data; if the parameter change rate is greater than a preset change rate threshold, triggering a safety alarm; after triggering the safety alarm, recording an alarm event log and adjusting a data sampling frequency.

8. The method of claim 1, wherein, The safety protection processing according to the operation data includes: monitoring a working state and an ambient temperature of the to-be-tested direct current converter; performing data aggregation on the working state, the ambient temperature, and the operation data to obtain aggregated data; performing statistical feature calculation on the aggregated data to obtain statistical feature data; performing fault identification processing according to the statistical feature data.

9. The method of claim 8, wherein, The fault identification processing according to the statistical feature data includes: obtaining a current working phase of the to-be-tested direct current converter; extracting statistical feature baseline data and identification rules corresponding to the current working phase; identifying a normal fluctuation range of the current working phase according to the statistical feature baseline data and the identification rules; if the statistical feature data exceeds the normal fluctuation range, triggering a safety alarm.

10. A direct current converter water impulse control system, characterized in that It includes: a data acquisition module configured to acquire first state data of a to-be-tested direct current converter; a sample state determination module configured to determine a sample operation state according to the first state data; a main power supply control module configured to control a main power supply to supply power to the to-be-tested direct current converter if the sample operation state is ready; a load control module configured to control a temperature box and an electronic load to perform load processing on the to-be-tested direct current converter, so that the to-be-tested direct current converter undergoes an unloaded working phase and a full-load working phase in turn at a target temperature; a water jet impact driving module configured to control an actuator to perform water jet impact processing on the to-be-tested direct current converter after the full-load working phase ends. The operation data monitoring module is configured to monitor operation data of the to-be-tested direct current converter, and the operation data comprises second state data and external measurement data. The security protection module is configured to perform security protection processing according to the operation data.

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