A dc converter water surge control method and system

Abstract

The application discloses a kind of DC converter ice water impact control method and system, it is related to DC converter detection technical field, method includes: the first state data of the DC converter to be measured is collected;According to the first state data, determine sample operating state;If the sample operating state is ready, then control mains power supply to the DC converter to be measured is powered;Control oven and electronic load to the DC converter to be measured is load processing, so that the DC converter to be measured is at target temperature in turn experiences idle operation phase and full load operation phase;After the full load operation phase ends, control actuator to the DC converter to be measured is water impact processing is executed;Monitoring the operating data of the DC converter to be measured, the operating data includes second state data and external measurement data;According to the operating data, carry out safety protection processing.The application realizes ice water impact control, improves accuracy and efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of direct current converter detection, and particularly relates 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 the like, 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. The 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] To sum up, 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:

[0006] Collecting first state data of a direct current converter to be tested;

[0007] Determining a sample running state according to the first state data;

[0008] If the sample running state is ready, controlling a main power supply to supply power to the direct current converter to be tested;

[0009] Controlling a temperature box and an electronic load to perform load processing on the direct current converter to be tested, so that the direct current converter to be tested experiences an idle working phase and a full load working phase in turn at a target temperature;

[0010] After the full load working phase ends, controlling an execution mechanism to perform water impact processing on the direct current converter to be tested;

[0011] Monitoring running data of the direct current converter to be tested, the running data including second state data and external measurement data;

[0012] According to the operation data, safety protection processing is performed.

[0013] In another aspect, the embodiment of the present application provides a direct current converter ice water impact control system, comprising:

[0014] A data acquisition module is configured to acquire first state data of a to-be-tested direct current converter.

[0015] A sample state determination module is configured to determine a sample operation state according to the first state data.

[0016] A main power supply control module is 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.

[0017] A load control module is 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 sequentially experiences an idle load working phase and a full load working phase at a target temperature.

[0018] A water spray impact driving module is configured to control an actuator to perform water spray impact processing on the to-be-tested direct current converter after the full load working phase ends.

[0019] An operation data monitoring module is configured to monitor operation data of the to-be-tested direct current converter, wherein the operation data comprises second state data and external measurement data.

[0020] A safety protection module is configured to perform safety protection processing according to the operation data.

[0021] The embodiment of the present application has at least the following beneficial effects: the embodiment of the present application first acquires first state data of a to-be-tested direct current converter, then determines a sample operation state according to the first state data, controls a main power supply to supply power to the to-be-tested direct current converter if the sample operation state is ready, controls 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 phase and a full load working phase at a target temperature, controls an actuator to perform water spray impact processing on the to-be-tested direct current converter after the full load working phase ends, and finally monitors operation data of the to-be-tested direct current converter and performs safety protection processing, so as to realize ice water impact control and improve accuracy and efficiency.

[0022] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent to those skilled in the art from the following description, or can be learned by practice of the present application. The objects and other advantages of the present application can be achieved and obtained by means of the structures particularly pointed out in the description and the appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to make the technical solutions in the embodiments of the present application clearer, the drawings needed in the embodiment description will be briefly introduced.

[0024] Figure 1 The flow chart of the ice water impact control method of the DC converter in the embodiment of the present application;

[0025] Figure 2 The structural schematic diagram of the ice water impact control system of the DC converter in the embodiment of the present application. DETAILED DESCRIPTION

[0026] In order to make the technical solutions in the embodiments of the present application clearer, the drawings needed in the embodiment description will be briefly introduced.

[0027] In the 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, a 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.

[0028] 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 / 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.

[0029] Traditional ice water impact test methods usually rely on manual operation. Such manual testing has many problems: (1) long test time and large labor input: the entire test process takes more than 50 hours, i.e. 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 the KL15 and KL30f auxiliary power supply, and the timing of the main power supply connection, which may cause inconsistency of the 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 state 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, thereby affecting the reliability and comparability of the test results. (5) Potential risk of sample damage: when the prototype is working with a large current, water impact is performed, and if not properly controlled, it may cause damage to the prototype or test failure.

[0030] To overcome these challenges, the present application proposes a direct current converter ice water impact control method and system, aiming to realize high-precision, high-reproducibility, safe and reliable direct current converter ice water impact test. The system can use the upper computer software as the "central commander", integrate CAN communication, multi-power collaborative control, high-precision time reference scheduling, hardware timing and multi-source information closed-loop safety protection technologies, to ensure the accuracy, consistency and safety of the test process, and provide deep data analysis and traceability capabilities. In the long-period, multi-cycle ice water impact test scenario of the direct current converter, multiple test devices (such as power supply, load, temperature box, 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 ice water impact test for waterproof performance in the process of research and development verification test and production line product verification test of the direct current converter.

[0031] The embodiments of the present application will be specifically explained in combination with the drawings:

[0032] Figure 1 is an optional flowchart of a direct current converter ice water impact control method provided by an embodiment of the present application, Figure 1 The method in can include but is not limited to steps S101 to S107.

[0033] Step S101, collecting first state data of the direct current converter to be tested;

[0034] Step S102, determining the sample running state according to the first state data;

[0035] Step S103, if the sample running state is ready, controlling the main power supply to supply power to the DC converter under test;

[0036] Step S104, controlling the oven and the electronic load to perform load processing on the DC converter under test, so that the DC converter under test sequentially experiences the no-load working phase and the full-load working phase at the target temperature;

[0037] Step S105, after the full-load working phase ends, controlling the actuator to perform water spray impact processing on the DC converter under test;

[0038] Step S106, monitoring the running data of the DC converter under test, the running data including the second state data and the external measurement data;

[0039] Step S107, performing safety protection processing according to the running data.

[0040] The steps S101 to S107 shown in the embodiments of the present application realize ice water impact control, and improve accuracy and efficiency.

[0041] In some embodiments, steps S101-S107 can first collect the first state data of the DC converter under test. 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, the sample running state is determined according to the first state data. A series of judgment rules can be set, and if all necessary parameters meet the preset "ready" condition, the sample running state is determined as "ready". Otherwise, troubleshooting or operator confirmation may 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, a relay or solid-state switch can be used to control the on-off of the main power supply, to ensure that the power supply is performed after the sample is ready, and 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.

[0042] The temperature chamber and electronic load are controlled to perform load processing on the DC converter under test, so that the DC converter under test experiences an idle working phase and a full load working phase at a target temperature in turn. For example, the temperature chamber can be set to 105 degrees Celsius and maintained for 30 minutes. The electronic load does not apply load or applies minimal load in the idle working phase and applies rated load or close to rated load in the full load working phase according to a preset test curve. It can be understood that the temperature chamber is used to provide and maintain the target temperature environment required by the DC converter under test during the test process. The electronic load is used to simulate the load condition of the DC converter under test in actual application to realize the idle working phase and the full load working phase. 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.

[0043] 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.

[0044] Finally, the running data of the DC converter under test is monitored, and safety protection processing is performed according to the running data, wherein the running data includes second state data and external measurement data. For example, the second state data of the DC converter under test, such as internal temperature, output voltage, output current, working mode, etc., can be obtained in real time through built-in sensors or external probes, while the external measurement data, such as environmental temperature, humidity, water flow, etc., is monitored. These data can be digitized through a data acquisition card and transmitted to the control system for processing. A series of safety thresholds and protection logic are set. When any parameter in the running 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 running data is the data collected in real time during the test process about the working condition of the DC converter under test, including second state data (such as internal temperature, voltage, current, working mode, fault code, etc.) and external measurement data (such as environmental temperature, humidity, water flow, etc.).

[0045] The first state data of the to-be-tested DC converter is collected and the sample running state is determined to ensure that the test is performed under the condition that the device is ready, and to avoid test interruption or errors caused by the device not being ready. When the sample running state is ready, the main power supply is precisely controlled to supply power, ensuring the consistency of the starting conditions of the test. Then, the automated control of the temperature box and the electronic load enables the to-be-tested DC converter to perform precise load processing at the target temperature according to the preset idle and full load working stages. This not only eliminates the time error of manual operation and 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 is also automated and precisely controlled, avoiding the problem of inaccurate or inconsistent impact caused by manual operation, thereby reducing the risk of sample damage. Finally, by monitoring the running data of the to-be-tested DC converter in real time, the tester can fully understand the internal and external working conditions of the 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 detect abnormalities in a timely manner and perform safety protection processing when necessary, thereby taking immediate action when an abnormality occurs, effectively avoiding sample damage and improving control accuracy and test safety.

[0046] Through the above technical solutions, the embodiment introduces automated control, precise timing management, and real-time data monitoring and safety protection mechanisms, significantly improving the efficiency, accuracy, reliability, and safety of the ice water impact test. Compared with the traditional manual operation method, the embodiment can significantly reduce labor input, reduce costs, shorten test cycle, improve efficiency, ensure the consistency and comparability of test results, and improve accuracy, providing a more advanced and reliable solution for performance verification of DC converters.

[0047] In some embodiments, in step S105, controlling the actuator to perform water impact processing on the to-be-tested DC converter can include, but is not limited to, the following steps:

[0048] Before performing water impact, according to the preset time, control the solenoid valve to be energized;

[0049] Monitor the first current value flowing through the solenoid valve coil within the preset time;

[0050] Numerically integrate the first current value to calculate the initial electromagnetic energy obtained by the solenoid valve coil as a standard energy value;

[0051] When performing water impact, monitor the current current value flowing through the solenoid valve coil;

[0052] Numerically integrate the current current value to calculate the current electromagnetic energy obtained by the solenoid valve coil;

[0053] If the current electromagnetic energy is greater than the standard energy value, the electromagnetic valve is controlled to be powered off and the water impact is stopped.

[0054] In some embodiments, if the water impact process 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 direct current converter or affect the accuracy of the test results. To this end, the application further optimizes the water impact process by monitoring the electromagnetic energy of the electromagnetic valve coil to achieve precise control and safety protection of the water impact process.

[0055] To this end, the electromagnetic valve can be powered on according to the preset time before the water impact is performed, 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 a 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.

[0056] Then, the first current value is numerically integrated to calculate the initial electromagnetic energy obtained by the electromagnetic valve coil as the 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 the 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.

[0057] The current current value is then numerically integrated to calculate the current electromagnetic energy obtained by the electromagnetic valve coil. Thus, by comparing the real-time calculated current electromagnetic energy with the pre-determined standard energy value, it can be determined whether the working state of the electromagnetic valve is abnormal. If the current electromagnetic energy is greater than the standard energy value, it indicates that the electromagnetic valve may have abnormal power-on, sticking or other faults, and the electromagnetic valve can be controlled to be powered off and the water impact is stopped to prevent excessive water impact or equipment damage caused by abnormal working of the electromagnetic valve.

[0058] The embodiment introduces an electromagnetic energy monitoring mechanism for the electromagnetic valve coil to effectively solve the problem of lack of fine control in the water impact process in the basic scheme. Specifically, before the water impact starts, the initial electromagnetic energy reference of the electromagnetic valve coil is established by presetting the power-on and monitoring the first current value, i.e., the standard energy value. The standard energy value represents the energy consumption characteristics of the electromagnetic valve in the normal working state. During the actual water impact process, the system continuously monitors the current current value of the electromagnetic valve coil and calculates the current electromagnetic energy in real time. By comparing the current electromagnetic energy with the standard energy value, once the current electromagnetic energy exceeds the standard energy value, it indicates that the electromagnetic valve may be in an abnormal working state, such as continuous power-on of the coil, valve jam, etc. At this time, the system can respond in time to control the electromagnetic valve to be powered off and stop the water impact. This real-time monitoring and comparison mechanism enables the water impact process to be accurately controlled, avoiding excessive water impact caused by electromagnetic valve abnormalities, thereby effectively protecting the DC converter under test.

[0059] 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 powered on for 100 milliseconds in order to establish the normal working reference of the electromagnetic valve. During this preset time, the system monitors the first current value flowing through the electromagnetic valve coil and integrates the value 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 moment during the water impact, the system monitors the current current value and integrates the value to calculate the current electromagnetic energy of 60 joules. Since 60 joules is greater than the preset standard energy value of 50 joules, the system immediately determines that the electromagnetic valve may have an abnormality, such as a too long continuous power-on time of the coil or a short circuit, etc., thereby immediately controlling the electromagnetic valve to be powered off and stopping the water impact. 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.

[0060] Through the above technical solution, the embodiment can timely discover and correct the abnormal working state of the electromagnetic valve by monitoring the electromagnetic energy of the electromagnetic valve coil in real time and comparing it with the standard energy value, effectively avoiding potential damage to the DC converter caused by too long water impact time or too large water volume. 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.

[0061] In some embodiments, in step S106, monitoring the operation data of the DC converter under test can include but is not limited to the following steps:

[0062] Step S201, signal acquisition of the to-be-tested direct current converter is performed through a sensing module to obtain an analog signal;

[0063] Step S202, electromagnetic interference removal is performed on the analog signal through a high-frequency common-mode suppression filter;

[0064] Step S203, adaptive notch filter parameters are determined according to the vibration state of the test bench;

[0065] Step S204, frequency noise filtering is performed on the analog signal after the electromagnetic interference removal through an adaptive notch filter according to the adaptive notch filter parameters;

[0066] Step S205, the analog signal after the frequency noise filtering is amplified through a differential amplifier to obtain operation data.

[0067] In some embodiments, since the direct current converter works in an ice water impact test environment, it may face a complex electromagnetic environment and mechanical vibration, resulting in a large amount of high-frequency common-mode interference and specific frequency mechanical noise 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 missed judgment of the subsequent safety protection processing, and the safety of the to-be-tested direct current converter cannot be effectively guaranteed in time.

[0068] Therefore, signal acquisition of the to-be-tested direct current converter can be performed through a sensing module to obtain an analog signal. The sensing module refers to a device for converting physical quantities (such as voltage, current, temperature, vibration, etc.) of the to-be-tested direct current converter in the running process into an electrical signal. 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 direct current converter in the ice water impact test process. The obtained analog signal is an original, unprocessed electrical signal, which contains the real operation information of the to-be-tested direct current converter and environmental noise.

[0069] Then, electromagnetic interference removal is performed on the analog signal through a high-frequency common-mode suppression filter, aiming to filter out high-frequency common-mode noise 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 influence of electromagnetic interference on signal quality before the signal enters the subsequent processing stage, and to improve the signal-to-noise ratio of the signal.

[0070] 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 of the test equipment or environment caused by mechanical movement, impact and other factors. The 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, with the purpose of accurately matching and filtering out specific frequency noise caused by mechanical vibration.

[0071] Finally, according to the adaptive notch filter parameters, the frequency noise of the analog signal after electromagnetic interference removal is filtered by 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 signal. According to the predetermined adaptive notch filter parameters, the analog signal processed by the high-frequency common-mode rejection filter can be further filtered for frequency noise. The 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.

[0072] The multi-stage signal processing mechanism of the embodiment effectively solves the problem of inaccurate operating data caused by electromagnetic interference and mechanical vibration in traditional monitoring methods. 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 to ensure the initial purity of the signal. In view of the fact that the vibration of the test bench may introduce specific frequency noise, the embodiment dynamically determines the adaptive notch filter parameters 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 the excessive filtering or insufficient filtering that may be caused by fixed parameter filters. Finally, the differential amplifier amplifies the signal after two-stage noise filtering, not only improving the signal strength, but also further suppressing the residual common-mode noise, thereby obtaining high-precision and high-reliability operating data. This phased and targeted noise suppression strategy enables accurate DC converter operating data to be obtained even in complex test environments.

[0073] To make the technical solution clearer, specific examples are used for explanation below. Assume that when a DC converter for an electric vehicle is subjected to a water-ice impact test, a plurality of sensors are installed on a test bench, including voltage sensors and current sensors for measuring output voltage and current, and an acceleration sensor for monitoring the vibration of the test bench. When the DC converter is subjected to a full-load working phase at a target temperature and then subjected to a water-ice impact process, the voltage sensors and the current sensors continuously collect analog signals of the output voltage and current of the DC converter. Due to high-frequency switching actions inside the DC converter and electromagnetic radiation of external power supply lines, the analog signals contain significant high-frequency common-mode interference. At this time, the high-frequency common-mode suppression filter first processes the analog signals to remove most of the high-frequency common-mode noise. At the same time, the acceleration sensor monitors the vibration of the test bench in real time, for example, it is found that the test bench produces a stable 50Hz or 60Hz mechanical vibration frequency when subjected to water-ice impact. According to the vibration frequency, the system dynamically adjusts the parameters of the adaptive notch filter, so that the center frequency of the adaptive notch filter is accurately locked at 50Hz or 60Hz, and the analog signals processed by the high-frequency common-mode suppression filter are filtered in frequency to eliminate the noise of a specific frequency introduced by mechanical vibration. Finally, the analog signals filtered by the two levels of noise are sent to the differential amplifier for amplification to improve the amplitude and signal-to-noise ratio of the signals, and finally output as high-precision, noise-free operation data for analysis by the safety protection module. In this way, even in a harsh water-ice impact test environment, accurate and reliable operation data of the DC converter can be obtained.

[0074] Through the above technical solution, by introducing the high-frequency common-mode suppression filter, the adaptive notch filter, and the differential amplifier, the high-frequency common-mode interference and the frequency noise caused by the vibration of the test bench are effectively removed, and the signals are amplified with high quality. This ensures that the obtained operation data can truly reflect the working state of the DC converter under test, avoids false positives or false negatives caused by noise interference, thereby providing a solid data foundation for subsequent safety protection processing, and greatly improving the safety and efficiency of the test process.

[0075] In some embodiments, in step S202, the electromagnetic interference removal of the analog signal by the high-frequency common-mode suppression filter can include but is not limited to the following steps:

[0076] Step S301, scanning the high-frequency common-mode interference spectrum of the DC converter under test under different working states to obtain an interference frequency range and an intensity distribution;

[0077] Step S302, determining a first adjustment parameter according to the interference frequency range and the intensity distribution, the first adjustment parameter being used to match the cutoff frequency and the attenuation slope of the high-frequency common-mode suppression filter to the current interference spectrum characteristics.

[0078] Step S303, monitoring the working state of the DC converter to be tested and the change of ambient temperature;

[0079] Step S304, determining a second adjustment parameter according to the working state and the change of ambient temperature, the second adjustment parameter being used to adapt to the changing interference spectrum;

[0080] Step S305, adjusting the high-frequency common-mode suppression filter according to the first adjustment parameter and the second adjustment parameter;

[0081] Step S306, removing electromagnetic interference from the analog signal through the high-frequency common-mode suppression filter after parameter adjustment.

[0082] In some embodiments, since the working state of the DC converter to be tested and the ambient temperature may change, the high-frequency common-mode interference spectrum generated thereby also changes accordingly. If the high-frequency common-mode suppression filter adopts fixed parameters, it may not be able to effectively adapt to these dynamic changes, resulting in poor electromagnetic interference removal effect, and even excessive attenuation of effective signals or failure to fully suppress interference, affecting the accuracy of subsequent operation data.

[0083] Therefore, the high-frequency common-mode interference spectrum of the DC converter to be tested under different working states can be scanned first to obtain the interference frequency range and intensity distribution, aiming to fully understand the interference characteristics of the DC converter under various typical operating conditions. Through scanning, the frequency range and intensity distribution of the interference can be obtained to provide basic data for subsequent filter parameter setting.

[0084] 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 suppression filter with the current interference spectrum characteristics. The first adjustment parameter can be determined based on the interference spectrum characteristics obtained by initial scanning, and the purpose is to make the cutoff frequency and attenuation slope of the high-frequency common-mode suppression filter preliminarily match the current interference spectrum characteristics, so as to effectively suppress the known interference.

[0085] In order to cope with dynamic changes in actual operation, the working state of the DC converter to be tested and the change of ambient temperature can be monitored. The working state can include load size, input voltage, output current, etc., and the change of ambient temperature refers to the fluctuation of the surrounding environment temperature. These factors can all affect the electromagnetic interference spectrum generated by the DC converter. Then, according to the working state and the change of ambient temperature, a second adjustment parameter is determined, the second adjustment parameter being used to adapt to the changing interference spectrum, and the purpose is to make the high-frequency common-mode suppression filter adapt to the changing interference spectrum. For example, when the working state or the ambient temperature changes significantly, the interference spectrum may drift or change in intensity.

[0086] Finally, according to the first adjustment parameter and the second adjustment parameter, the high-frequency common-mode rejection filter is adjusted to maintain the best suppression effect. The first adjustment parameter provides baseline matching, while the second adjustment parameter provides dynamic adaptability. The electromagnetic interference of the analog signal is removed by the high-frequency common-mode rejection filter after parameter adjustment, ensuring that high-quality analog signals can be obtained under various working conditions and environmental conditions.

[0087] 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 achieving 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 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 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 complex and dynamically changing operating environments, 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.

[0088] 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.

[0089] 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 problem 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.

[0090] 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:

[0091] Taking the interference frequency range and intensity distribution as the effective signal baseline;

[0092] Monitoring the signal frequency spectrum output by the high-frequency common-mode suppression filter;

[0093] The signal spectrum is compared with the effective signal baseline to obtain a comparison result;

[0094] If the comparison result is that the attenuation exceeds the threshold, the second adjustment parameter is determined according to the preset attenuation range, the working state and the change in the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode suppression filter is maintained within the preset attenuation range.

[0095] If the comparison result is that the attenuation is lower than the threshold, the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change in the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode suppression filter within the interference frequency range meets the preset attenuation requirement.

[0096] In some embodiments, since the high-frequency common-mode suppression filter parameter is adjusted only by relying on the change in 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 the effective signal baseline first. The interference frequency range and intensity distribution obtained by scanning the high-frequency common-mode interference frequency spectrum under the normal working state of the to-be-tested direct current converter are regarded as a reference standard. The baseline represents the suppression effect that the high-frequency common-mode suppression filter should achieve under ideal or expected working conditions.

[0097] Then, the signal spectrum output by the high-frequency common-mode suppression filter is monitored. Exemplarily, the frequency spectrum characteristics of the analog signal processed by the filter can be acquired 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 can be compared with the preset effective signal baseline by an algorithm or a preset rule, to judge whether the attenuation performance of the filter meets the expectation. If the comparison result is that the attenuation exceeds the threshold, the second adjustment parameter is determined according to the preset attenuation range, the working state and the change in the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode suppression filter is maintained within the preset attenuation range. If the comparison result is that the attenuation is lower than the threshold, the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change in the ambient temperature, so that the attenuation amplitude of the output signal of the high-frequency common-mode suppression filter within the interference frequency range meets the preset attenuation requirement.

[0098] 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.

[0099] 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 actually only attenuated by -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.

[0100] 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 a purer signal, 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.

[0101] 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:

[0102] According to the operation data, transient fluctuation identification is performed to obtain a transient fluctuation identification result.

[0103] If the transient fluctuation identification result is that there is a transient fluctuation, a delay time period is determined.

[0104] After the delay time period, device safety analysis is performed according to the operation data to obtain a device safety analysis result.

[0105] 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.

[0106] 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, according to the operation data, transient fluctuation identification can be performed 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 by setting a dynamic threshold, 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.

[0107] 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.

[0108] After the delay period, a device safety analysis is performed according to the running data, and a device safety analysis result is obtained. The current running data can be compared with a preset safety threshold, or a trend analysis can be performed to determine whether the device has a persistent abnormality. The purpose is to finally and reliably evaluate the safety of the device after transient disturbances are ruled out. If the device safety analysis result exceeds the safety threshold, it indicates that the device indeed has a persistent safety risk, and a shutdown protection operation can be performed on the DC converter under test. The operation usually includes cutting off the power supply of the DC converter by the main power supply to prevent further damage to the device or cause other safety accidents.

[0109] By introducing the transient fluctuation identification mechanism, the embodiment can effectively distinguish between short-term, non-persistent fluctuations caused by external disturbances such as ice water impact and actual device failures. By setting a delay period after identifying transient fluctuations, hasty safety judgments can be avoided when the device has not stabilized or the fluctuations have not subsided. After the delay period, the running data is analyzed again for device safety, and the data at this time is more stable and can more accurately reflect the true running state of the device. In this way, false positives caused by transient fluctuations can be avoided, and the shutdown protection operation is only performed when it is confirmed that the device indeed has a risk of exceeding the safety threshold, thereby improving the accuracy and reliability of safety protection.

[0110] To more clearly illustrate the technical solution, specific examples are used in the following explanation. Suppose that during the ice water impact treatment process, the output voltage or current of the DC converter under test has a sharp peak or drop in a very short time due to water flow impact or temperature sudden change, but then quickly recovers to normal. It can be identified from the running data that this is a transient fluctuation. Due to the transient fluctuation, the system determines a delay period of, for example, 500 milliseconds. During this delay period, the system continues to monitor, and after the transient fluctuation subsides, the running data is analyzed again for device safety after the delay period ends. At this time, if the device running data has returned to the normal range, the device safety analysis result will not exceed the safety threshold, thereby avoiding unnecessary shutdown protection. Conversely, if the device is still in an abnormal state after the delay, the shutdown protection operation is performed to ensure the real safety of the device.

[0111] Through the above technical solution, the embodiment introduces a delay mechanism to provide the system with a buffer and self-recovery time, reduces unnecessary shutdown protection, and thus improves test efficiency and device availability. At the same time, under the premise of ensuring device safety, the test process is more stable and reliable.

[0112] In some embodiments, in step S107, performing safety protection processing according to the running data can include, but is not limited to, the following steps:

[0113] According to the operation data, the parameter change rate is calculated;

[0114] If the parameter change rate is greater than the preset change rate threshold, a safety alarm is triggered;

[0115] After triggering the safety alarm, an alarm event log is recorded and the data sampling frequency is adjusted.

[0116] 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, according to the operation data, the parameter change rate can be calculated, and the change trend of the operation data over time can be quantified, for example. 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, so as to identify potential abnormal trends.

[0117] 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 specification of the DC converter under test, historical test data, industry standards and safety requirements. This threshold represents the maximum change rate of the parameter allowed under normal working 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, for example, through an audible and visual signal, an interface prompt or a remote notification, to remind the operator to pay attention.

[0118] 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 when the alarm occurs, the specific abnormal parameter, the parameter change rate, the snapshot of the operation data at that 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.

[0119] 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 abnormalities, so that the safety alarm can be triggered in time to provide 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.

[0120] To make the technical solution clearer, specific examples are used for explanation below. Assuming 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 occurrence time, voltage change rate, 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, so as to record the subsequent voltage and current changes in more detail, providing more fine data support for technicians to analyze the cause of 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.

[0121] By the technical solution, the parameter change rate is monitored, subtle fluctuations and abnormal trends of the equipment operation state can be captured more sensitively, and an alarm is triggered before or at the early stage of a fault, so that timeliness and effectiveness of safety protection are significantly improved. 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 reliability of testing, safety of equipment, and efficiency of fault diagnosis.

[0122] In some embodiments, in step S107, the safety protection processing according to the operation data can include but is not limited to the following steps:

[0123] Step S401, monitoring the working state and the environmental temperature of the to-be-tested direct current converter;

[0124] Step S402, data aggregation is performed on the working state, the environmental temperature and the operation data to obtain aggregated data;

[0125] Step S403, statistical feature calculation is performed on the aggregated data to obtain statistical feature data;

[0126] Step S404, fault identification processing is performed according to the statistical feature data.

[0127] In some embodiments, since safety protection processing is performed only according to single or limited operation data, complex fault modes that can occur in the to-be-tested direct current converter during the ice water impact test can not be fully captured. For example, some faults can be caused by abnormal combination of the working state and the environmental temperature, and if these information is not fully integrated and analyzed, the accuracy of fault identification can be insufficient or the response can not be timely. Therefore, the working state and the environmental temperature of the to-be-tested direct current converter can be monitored first. For example, various sensors integrated in the test system can be used to obtain key operation parameters inside the to-be-tested direct current converter in real time, such as internal temperature, voltage, current, power output, 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.

[0128] Then, data aggregation is performed on the working state, the environmental temperature and the operation data to obtain aggregated data. The monitored working state data, the environmental temperature data and the operation data (including the second state data and the external measurement data) can be integrated. The aggregation operation aims to collect scattered, multi-source heterogeneous data together to form a unified, more informative comprehensive data set. The aggregation mode can include time synchronization, data association, format unification, etc., and the purpose is to provide a complete data view for subsequent analysis.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] To illustrate the technical solution more clearly, specific examples are used for explanation below. Assume that during the ice water impact test of a direct current converter, the system continuously monitors the internal core temperature of the direct current converter 100 under test (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 direct current 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 value, 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.

[0133] Through the above technical solution, the working state and environmental temperature of the direct current 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 direct current converter, ensuring the stability of the test process and the safety of the device, and thus improving the test efficiency and data reliability.

[0134] In some embodiments, in step S404, performing fault identification processing according to the statistical feature data can include but is not limited to the following steps:

[0135] Obtaining the current working phase of the direct current converter under test;

[0136] Extracting statistical feature baseline data and identification rules corresponding to the current working phase;

[0137] Identifying the normal fluctuation range of the current working phase according to the statistical feature baseline data and identification rules;

[0138] If the statistical feature data exceeds the normal fluctuation range, a safety alarm is triggered.

[0139] 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 result in 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.

[0140] Then the statistical characteristic 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 characteristic 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.

[0141] According to the statistical characteristic baseline data and identification rules, the normal fluctuation range of the current working stage is identified. The statistical characteristic 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 characteristic data exceeds the normal fluctuation range, a safety alarm is triggered to notify the operator in time or to automatically take further safety measures.

[0142] 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.

[0143] To more clearly illustrate the technical solutions, specific examples are used in the following explanation. 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 ±0.5V. When the statistical feature data monitored by the system (for example, the mean value of the real-time output voltage) exceeds this ±0.5V 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 ±5A. 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 ±5A 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, so as to achieve more accurate and reliable fault identification.

[0144] 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 false negative rate. This adaptive fault identification mechanism based on 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.

[0145] The beneficial effects of implementing the embodiment of the application include that the embodiment of the 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 undergoes 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.

[0146] As shown in Figure 2 The embodiment of the application also provides a DC converter ice water impact control system, which comprises:

[0147] The data acquisition module 501 is configured to acquire first state data of the DC converter to be tested.

[0148] The sample state determination module 502 is configured to determine a sample running state according to the first state data.

[0149] 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.

[0150] The load control module 504 is configured to control the temperature box and the electronic load to perform load processing on the DC converter to be tested, so that the DC converter to be tested sequentially experiences the no-load working phase and the full-load working phase at the target temperature.

[0151] 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.

[0152] The running data monitoring module 506 is configured to monitor running data of the DC converter to be tested, the running data including second state data and external measurement data.

[0153] The safety protection module 507 is configured to perform safety protection processing according to the running data.

[0154] The contents in the method embodiments are all 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.

[0155] The embodiments described in the embodiments of the present application are used to more clearly illustrate 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 chilled water impact in a DC-DC converter, characterized in that, Includes the following steps: Acquire the first state data of the DC-DC converter under test; Based on the first status data, determine the sample's operating status; If the sample is in a ready operating state, the main power supply is controlled to supply power to the DC-DC converter under test. The temperature chamber and electronic load are controlled to apply load to the DC-DC converter under test, so that the DC-DC converter under test experiences an unloaded operation stage and a full-load operation stage at the target temperature in sequence. After the full-load operation phase ends, the control actuator performs a water jet impact treatment on the DC-DC converter under test. Monitor the operating data of the DC-DC converter under test, including second status data and external measurement data; Based on the aforementioned operational data, security protection measures will be implemented. The monitoring of the operating data of the DC-DC converter under test includes: The DC-DC converter under test is used to acquire signals through a sensing module to obtain analog signals; Electromagnetic interference is removed from the analog signal using a high-frequency common-mode rejection filter. Determine the parameters of the adaptive notch filter based on the vibration state of the test bench; Based on the adaptive notch filter parameters, frequency noise is filtered out from the analog signal after electromagnetic interference removal using the adaptive notch filter. The operating data is obtained by amplifying the analog signal after frequency noise filtering using a differential amplifier; The process of removing electromagnetic interference from the analog signal using a high-frequency common-mode rejection filter includes: The high-frequency common-mode interference spectrum of the DC-DC converter under test under different operating conditions is scanned to obtain the interference frequency range and intensity distribution. Based on the interference frequency range and the intensity distribution, a first adjustment parameter is determined. 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 spectrum characteristics. Monitor the operating status and ambient temperature changes of the DC-DC converter under test; Based on the operating state and the change in ambient temperature, a second adjustment parameter is determined, which is used to adapt to the changing interference spectrum. The parameters of the high-frequency common-mode rejection filter are adjusted according to the first adjustment parameter and the second adjustment parameter; Electromagnetic interference is removed from the analog signal using a high-frequency common-mode rejection filter with adjusted parameters.

2. The method according to claim 1, characterized in that, The control actuator performs water jet impact treatment on the DC-DC converter under test, including: Before the water jet impact is performed, the solenoid valve is energized according to a preset time. Monitor the first current value flowing through the solenoid valve coil within a preset time; The first current value is numerically integrated to calculate the initial electromagnetic energy obtained by the solenoid valve coil as the standard energy value. During water jet impact, monitor the current value flowing through the solenoid valve coil; The current current value is numerically integrated to calculate the current electromagnetic energy obtained by the solenoid valve coil; If the current electromagnetic energy is greater than the standard energy value, the solenoid valve is de-energized and the water jet impact is stopped.

3. The method according to claim 1, characterized in that, The step of determining the second adjustment parameter based on the working state and the change in ambient temperature includes: The interference frequency range and the intensity distribution are used as the effective signal baseline; Monitor the signal spectrum output of the high-frequency common-mode rejection filter; The signal spectrum is compared with the effective signal baseline to obtain the comparison result; If the comparison result is that the attenuation exceeds the threshold, then the second adjustment parameter is determined according to the preset attenuation range, the working state and the change in 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, then the second adjustment parameter is determined according to the preset attenuation requirement, the working state and the change in 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.

4. The method according to claim 1, characterized in that, The security protection process based on the operational data includes: Based on the operational data, transient fluctuation identification is performed to obtain transient fluctuation identification results; If the transient fluctuation identification result indicates the presence of transient fluctuations, then the delay time period is determined; After the aforementioned delay period, based on the operational data, a device safety analysis is performed to obtain the device safety analysis results. If the safety analysis result of the device exceeds the safety threshold, a shutdown protection operation is performed on the DC-DC converter under test.

5. The method according to claim 1, characterized in that, The security protection process based on the operational data includes: Calculate the parameter change rate based on the operational data; If the rate of change of the parameter is greater than a preset rate of change threshold, a safety alarm will be triggered; After a security alert is triggered, the alert event log is recorded and the data sampling frequency is adjusted.

6. The method according to claim 1, characterized in that, The security protection process based on the operational data includes: Monitor the operating status and ambient temperature of the DC-DC converter under test; The working status, the ambient temperature, and the operating data are aggregated to obtain aggregated data. Statistical feature calculations are performed on the aggregated data to obtain statistical feature data; Based on the statistical feature data, fault identification processing is performed.

7. The method according to claim 6, characterized in that, The fault identification process based on the statistical feature data includes: Obtain the current operating stage of the DC-DC converter under test; Extract the statistical feature baseline data and identification rules corresponding to the current working stage; Based on the statistical characteristic baseline data and the identification rules, identify the normal fluctuation range of the current working stage; If the statistical characteristic data exceeds the normal fluctuation range, a security alarm will be triggered.

8. A DC-DC converter chilled water impact control system, characterized in that, include: The data acquisition module is used to acquire the first state data of the DC-DC converter under test. The sample status determination module is used to determine the sample operating status based on the first status data. The main power control module is used to control the main power supply to supply power to the DC-DC converter under test if the sample is in a ready operating state. The load control module is used to control the temperature chamber and electronic load to perform load processing on the DC-DC converter under test, so that the DC-DC converter under test sequentially experiences the no-load operation stage and the full-load operation stage at the target temperature. The water jet impact drive module is used to control the actuator to perform water jet impact treatment on the DC converter under test after the full-load working stage ends. The operation data monitoring module is used to monitor the operation data of the DC-DC converter under test, including second status data and external measurement data. It is also used to acquire signals from the DC-DC converter under test through a sensing module to obtain analog signals; Electromagnetic interference is removed from the analog signal using a high-frequency common-mode rejection filter. Determine the parameters of the adaptive notch filter based on the vibration state of the test bench; Based on the adaptive notch filter parameters, frequency noise is filtered out from the analog signal after electromagnetic interference removal using the adaptive notch filter. The operating data is obtained by amplifying the analog signal after frequency noise filtering using a differential amplifier; It is also used to scan the high-frequency common-mode interference spectrum of the DC-DC converter under test under different operating conditions to obtain the interference frequency range and intensity distribution; Based on the interference frequency range and the intensity distribution, a first adjustment parameter is determined. 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 spectrum characteristics. Monitor the operating status and ambient temperature changes of the DC-DC converter under test; Based on the operating state and the change in ambient temperature, a second adjustment parameter is determined, which is used to adapt to the changing interference spectrum. The parameters of the high-frequency common-mode rejection filter are adjusted according to the first adjustment parameter and the second adjustment parameter; Electromagnetic interference is removed from the analog signal using a high-frequency common-mode rejection filter with adjusted parameters. The security protection module is used to perform security protection processing based on the operational data.

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