An ultrahigh voltage resistance detection device and operating method

Abstract

The application discloses a kind of ultrahigh voltage resistance detection device and operating method and operating method, it is related to high voltage resistance detection technical field, including detection cabinet, detection cabinet one side symmetry is equipped with protective door, mouse table is installed in detection cabinet middle part far from the side of protective door, central control screen is installed in detection cabinet close to mouse table top, control module is installed in detection cabinet close to central control screen side, power supply groove is evenly provided in detection cabinet, power supply box is slidably installed in power supply groove, power module is installed in power supply box, terminal wiring panel is evenly installed in detection cabinet close to power module top, and electronic switching mechanism can be programmed control power module series connection by means of power magnet, rack and pinion and other components.Compared with the existing manual switching wiring mode, no manual operation is required, the risk of electric shock in a high-voltage environment is avoided, and different voltage requirements can be quickly responded to, and more detection scenarios can be adapted.

Description

Technical Field

[0001] This invention relates to the field of high voltage resistance detection technology, specifically to an ultra-high voltage resistance detection device and its operating method. Background Technology

[0002] In fields such as power systems and new energy vehicles, the performance of ultra-high voltage resistors determines the safety and stability of equipment, making accurate testing crucial. Currently, the industry has higher requirements for testing voltage range (200V-3500V), accuracy (0.01% of rated voltage accuracy), and adaptability to multiple scenarios. However, existing devices are mostly designed with a single power module, and some multi-power devices require manual wiring switching. Furthermore, they require continuous personnel monitoring and recording, and rely on external equipment for heat dissipation of the power module, thus only meeting basic testing needs.

[0003] However, existing ultra-high voltage resistance testing devices still have significant shortcomings in practical applications. From an operational convenience perspective, manually switching power module wiring is not only time-consuming and labor-intensive, but also poses a risk of electric shock due to operational errors in high-voltage environments. Furthermore, manual data recording is prone to human error, reducing the reliability of test results. Regarding equipment flexibility and space utilization, most devices lack foldable storage structures, requiring significant space during testing and difficult to store efficiently when not in use, making them particularly unsuitable for space-constrained laboratories or on-site testing scenarios. In terms of power module operational stability, multiple power modules are prone to localized heat accumulation. Existing cooling solutions are mostly integrated cooling systems, unable to provide precise temperature control for individual modules, leading to excessive module temperature rise (some devices have temperature rises exceeding 25°C when a single module outputs 500V), thus affecting voltage output stability and power module lifespan. From a testing efficiency perspective, single-channel or fixed-channel modes are difficult to adapt to test objects with different voltage requirements, necessitating frequent replacement of testing devices or adjustments to hardware configurations, significantly extending the testing cycle and failing to meet the industrial demands for batch testing or rapid verification. These defects not only increase testing costs and operational difficulty, but may also pose hidden dangers to the safe operation of subsequent high-voltage equipment due to inaccurate testing data and equipment failures.

[0004] In summary, an ultra-high voltage resistance detection device and its operation method are proposed to solve the above problems. Summary of the Invention

[0005] In view of this, the technical problem to be solved by the present invention is to provide an ultra-high voltage resistance detection device and operating method to solve the problems that have occurred in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an ultra-high voltage resistance testing device, comprising a testing cabinet, wherein protective doors are symmetrically installed on one side of the testing cabinet, a mouse stand is installed in the middle of the testing cabinet away from the protective doors, a central control screen is installed above the testing cabinet near the mouse stand, a control module is installed on the side of the testing cabinet near the central control screen, power supply slots are evenly arranged in the testing cabinet, a power supply box is slidably installed in the power supply slot, a power supply module is installed in the power supply box, and terminal blocks are evenly installed above the power supply module in the testing cabinet. The ultra-high voltage resistance testing device further includes a convenient storage mechanism and an electronic switching mechanism.

[0007] The convenient storage mechanism is installed on the testing cabinet and is used for convenient monitoring.

[0008] The electronic switching mechanism is located in the middle of the side of the testing cabinet near the power supply box, and is used to control the connection between power modules.

[0009] Preferably, the convenient storage mechanism includes a folding rotating plate, a transmission rod fixedly installed in the middle of the folding rotating plate, first conical teeth fixedly installed on the outer surfaces of both ends of the transmission rod, the two ends of the transmission rod being rotatably mounted on the testing cabinet, the tooth surfaces of the first conical teeth meshing with second conical teeth, a square support plate fixedly installed in the middle of the second conical teeth, universal wheels installed on the side of the square support plate away from the second conical teeth, the two ends of the square support plate being rotatably mounted on the testing cabinet, and a servo drive motor installed at one end of the transmission rod, and the servo drive motor being installed in the testing cabinet.

[0010] Preferably, the electronic switching mechanism includes a power supply frame, which is fixedly installed on the power supply slot of the testing cabinet. An isolation plate is fixedly installed on the power supply frame. The isolation plate is made of insulating material and has heat dissipation slots. A heat sink is installed on the heat dissipation slots of the isolation plate. Positive and negative terminal blocks are fixedly installed in the power supply slot, and positive and negative terminal blocks are fixedly installed at the ends of the positive and negative terminal blocks away from the power supply slot, respectively. The positive and negative terminal blocks are fixedly installed in the isolation plate, and the positive and negative terminal blocks are installed corresponding to the positive and negative terminal blocks, respectively. N-shaped brackets are fixedly installed at both ends of the power supply frame. The N-shaped brackets are used to fix the bottom of the power supply slot of the testing cabinet.

[0011] Preferably, the electronic switching mechanism further includes electromagnets, which are uniformly mounted on an n-shaped bracket. An auxiliary spring is symmetrically fixedly mounted in the middle of each electromagnet. An n-cast iron is fixedly mounted at the end of the auxiliary spring away from the electromagnet. The bottom of the n-cast iron is slidably mounted on an isolation plate. A meshing rack is fixedly mounted on the side of the n-cast iron away from the auxiliary spring. A meshing gear meshes with the teeth on the lower surface of the meshing rack. A swing plate is fixedly mounted in the middle of the meshing gear. An auxiliary plate is rotatably mounted at both ends of the swing plate. A T-shaped terminal block is rotatably mounted at the end of the auxiliary plate away from the swing plate. The side of the T-shaped terminal block away from the positive terminal block is slidably mounted in a heat sink. The positive and negative terminal blocks each have a slot in their middle portions. The protruding portion in the middle of the T-shaped terminal block is the same size as the slots of the positive and negative terminal blocks.

[0012] Preferably, each power module is configured with 1-16 groups, with each group corresponding to one channel, and the maximum voltage input range is 0-5000 volts.

[0013] A method for detecting ultra-high voltage resistance includes:

[0014] S1, Equipment Preparation and System Initialization: This section focuses on the basic safeguards before device testing, including environmental compliance checks, hardware connection setup, and software and hardware system initialization, to ensure that the device has the basic conditions to start testing.

[0015] S2, Test Execution and Post-Testing: The entire test process and its conclusion, including test parameter setting, voltage output control, data acquisition and calculation, as well as equipment operation and maintenance after the test, to complete the impedance detection of the tested object and ensure the long-term availability of the device.

[0016] Preferably, the system initialization described in S1 includes:

[0017] Power module initialization: After the device is powered on, it automatically detects 7 power modules, including power frequency transformers, rectifier and filter components (such as EC1 / EC2 capacitors), and protection components such as RT1 thermistor. If a module fails, the host computer will prompt the fault and it needs to be repaired before continuing.

[0018] Software system initialization: Start the software and initialize the parameters of 7 channels (channel 1 is in default 200V / 500V mode, channels 2-7 are to be activated); initialize the 24-bit high-precision ADC sampling module and the power supply box 0ps resolution PWM execution module, establish communication between the MCU and each channel, and ensure that the voltage acquisition and PWM adjustment functions are normal.

[0019] Preferably, the test parameters are set according to the requirements of the tested object. The host computer selects an output range of 200V-3500V, and the system automatically activates the electronic switching mechanism to programmatically control the connection of the power module, corresponding to the power module and channel. The rated voltage accuracy is set to 0.01%, and an appropriate sampling interval and number of acquisitions are set. The MCU collects the channel output voltage during the test execution, compares it with the reference voltage, and adjusts the PWM duty cycle through the PI algorithm to control the BOOST circuit to stabilize the output voltage. A high-precision ammeter collects the weak current of the tested object (e.g., 0.03uA during a 3000V test), which is processed by the conditioning circuit and converted into a digital signal by the ADC. The MCU calculates the impedance according to R=U / I and performs statistical processing on multiple data to improve reliability.

[0020] Compared with the prior art, the ultra-high voltage resistance detection device and operating method provided by the present invention have the following beneficial effects:

[0021] 1. Integrated Operation Design: The device integrates the protective door, mouse console, central control screen, and control module into the testing cabinet, eliminating the need for separate operating platforms. The central control screen provides intuitive control over the testing process, while the control module coordinates equipment operation. Compared to existing devices where operating components are scattered and require frequent switching of operating positions, this significantly improves operational convenience and reduces operational errors.

[0022] 2. High-efficiency storage function: The convenient storage mechanism uses a servo-driven motor to drive the transmission rod, which, in conjunction with a bevel gear transmission, enables the folding rotating plate and the square support plate to move in tandem. During testing, it automatically expands the auxiliary operating space; when idle, it automatically folds up, solving the problems of existing devices lacking storage structure, occupying large spaces, and being unsuitable for small areas, thus improving space utilization.

[0023] 3. Flexible switching between multiple power supplies: The electronic switching mechanism, using components such as electromagnets and rack and pinion gears, can programmatically control the series connection of power modules. Compared to existing manual switching wiring methods, it eliminates the need for manual operation, avoids the risk of electric shock in high-voltage environments, and can quickly respond to different voltage requirements, adapting to more testing scenarios.

[0024] 4. Safety, Insulation, and Heat Dissipation: The isolation plate uses insulating materials to prevent leakage between power modules; heat dissipation slots are provided and heat sinks are installed, along with independent air-cooling channels and temperature-controlled fans to achieve precise heat dissipation. Existing devices mostly use overall heat dissipation, which is prone to local overheating. This solution can ensure that the temperature rise of a single module is ≤15℃, ensuring the stable operation of the power module.

[0025] 5. Modular and convenient maintenance: Seven power modules correspond to independent pull-out power boxes, all with uniform dimensions and modular mounting brackets. Existing devices often have fixed power modules, making disassembly difficult. This solution features a pull-out power box design, facilitating module inspection and replacement, reducing maintenance difficulty and time costs.

[0026] 6. Stable Wiring Connection: The T-shaped terminal block precisely matches the positive and negative terminal block slots, and the electromagnet controls the terminal block linkage to ensure a tight connection. Compared with existing wiring solutions that are prone to loosening and poor contact, this solution offers higher wiring stability, reduces test data errors caused by wiring issues, and improves test reliability. Attached Figure Description

[0027] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0028] Figure 2 This is an auxiliary schematic diagram of the three-dimensional structure of the present invention;

[0029] Figure 3 This is a schematic diagram showing the structural connection relationship of the convenient storage mechanism of the present invention in its unfolded state;

[0030] Figure 4 For the present invention Figure 1 Enlarged view of point A in the middle;

[0031] Figure 5 This is a schematic diagram of the structural connection relationship of the electronic switching mechanism of the present invention;

[0032] Figure 6 For the present invention Figure 5 Enlarged view at point B in the middle;

[0033] Figure 7 This is a schematic diagram of the structural connection relationship of the electronic switching mechanism of the present invention;

[0034] Figure 8 For the present invention Figure 7 Enlarged view at point C;

[0035] Figure 9 This is an auxiliary schematic diagram showing the structural connection relationship of the electronic switching mechanism of the present invention;

[0036] Figure 10 This is a schematic diagram of the measurement process of the test object in this invention;

[0037] Figure 11 This is a schematic diagram of the control process of the multi-channel power module of the present invention.

[0038] In the picture:

[0039] 1. Testing cabinet; 11. Protective door; 12. Mouse console; 13. Central control screen; 14. Control module; 15. Power supply box; 16. Power supply module; 17. Terminal block;

[0040] 2. Convenient storage mechanism; 21. Folding rotating plate; 22. Transmission rod; 23. First conical tooth; 24. Second conical tooth; 25. Square support plate; 26. Universal wheels;

[0041] 3. Electronic switching mechanism; 31. Power supply bracket; 32. Isolation plate; 33. Heat sink; 34. Positive terminal block; 35. Negative terminal block; 36. N-shaped bracket;

[0042] 4. Series connection assembly; 41. Electromagnet; 42. Cast iron; 43. Meshing rack; 44. Meshing gear; 45. Swing plate; 46. Auxiliary plate; 47. T-shaped terminal block; 48. Auxiliary spring. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0044] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0045] Example 1, please refer to Figures 1 to 11 As shown:

[0046] To address the problems mentioned in the technical solutions, this application provides an ultra-high voltage resistance testing device and its operating method, including a testing cabinet 1. A protective door 11 is symmetrically installed on one side of the testing cabinet 1. A mouse stand 12 is installed in the middle of the testing cabinet 1 away from the protective door 11. A central control screen 13 is installed above the mouse stand 12 in the testing cabinet 1. A control module 14 is installed on the side of the testing cabinet 1 near the central control screen 13. Power supply slots are evenly arranged in the testing cabinet 1. A power supply box 15 is slidably installed in the power supply slots. A power supply module 16 is installed in the power supply box 15. Terminal blocks 17 are evenly installed above the power supply module 16 in the testing cabinet 1. The device also includes a convenient storage mechanism 2 and an electronic switching mechanism 3.

[0047] The convenient storage mechanism 2 is installed on the testing cabinet 1 and is used for convenience monitoring.

[0048] The electronic switching mechanism 3 is located in the middle of the side of the test cabinet 1 near the power box 15. The electronic switching mechanism 3 is used to control the connection between power modules.

[0049] The power supply slot has positive and negative terminal slots at its bottom, which are plugged into and connected to the positive and negative terminals at the bottom of the power module 16. The positive and negative terminals in the power supply slot are also connected to the positive terminal block 34 and the negative terminal block 35, respectively. Each channel corresponds to a single power supply module. This solution allows for the addition of power supply modules according to specific measurement needs, thus adapting to different measurement requirements and increasing the flexibility of various measurement applications.

[0050] The rated output voltage of a single power module can be set according to requirements (e.g., 500V per module by default), and the basic test voltage range of the corresponding channel is 0-500V, which meets the requirements for medium and low voltage resistance testing (e.g., 200V-500V range).

[0051] With the help of electronic switching mechanism 3, the new channel and the original channel can be connected in series through programmable control to expand the total test voltage range. For example, by adding one 500V power supply module (corresponding to channel 8) and connecting it in series with the original two 500V modules (channels 1 and 2), the total output voltage can reach 1500V, which can meet the test requirements of 1000V-1500V range.

[0052] If a maximum test voltage of 5000V is required, it can be achieved by adding up to 10 500V power supply modules (corresponding to 10 channels), all of which are connected in series under the control of electronic switching mechanism 3, thus achieving 5000V high voltage output.

[0053] Specifically, a transmission rod 22 is fixedly installed in the middle of the folding plate 21. First conical teeth 23 are fixedly installed on the outer surfaces of both ends of the transmission rod 22. Both ends of the transmission rod 22 are rotatably mounted on the inspection cabinet 1. The tooth surfaces of the first conical teeth 23 mesh with second conical teeth 24. A square support plate 25 is fixedly installed in the middle of the second conical teeth 24. A caster wheel 26 is installed on the side of the square support plate 25 away from the second conical teeth 24. Both ends of the square support plate 25 are rotatably mounted on the inspection cabinet 1. A servo drive motor is installed at one end of the transmission rod 22, and the servo drive motor is installed in the inspection cabinet 1.

[0054] Among them, such as Figure 4 As shown, the servo drive motor is connected to the controller. When the device starts, the controller can start the servo motor. The rotation of the motor can cause the transmission rod 22 to rotate synchronously. The rotation of the transmission rod 22 can drive the folding rotating plate 21 to rotate synchronously. Through the meshing action of the first conical tooth 23 and the second conical tooth 24, when the folding rotating plate 21 rotates, it will drive the square support plate 25 to start rotating in the opposite direction at the same angle, that is, as shown. Figure 1 and Figure 3 As shown, this solution can automatically expand the convenient storage mechanism 2 during testing. In the case of existing technology, operators need to stand and constantly observe and test. This solution can reduce the hardship of standing by assisting the operators with the convenient storage mechanism 2. At the same time, the convenient storage mechanism 2 can be automatically folded by the system control after use, which not only reduces the operating space, but also facilitates the operation of the operators.

[0055] Specifically, the power supply frame 31 is fixedly installed on the power supply slot of the test cabinet 1. An isolation plate 32 is fixedly installed on the power supply frame 31. The isolation plate 32 is made of insulating material and has heat dissipation slots. A heat sink 33 is installed on the heat dissipation slots of the isolation plate 32. Positive and negative terminal blocks are fixedly installed in the power supply slot. Positive terminal block 34 and negative terminal block 35 are fixedly installed at the ends of the positive and negative terminal blocks away from the power supply slot, respectively. Positive terminal block 34 and negative terminal block 35 are fixedly installed in the isolation plate 32. Positive terminal block 34 and negative terminal block 35 are installed corresponding to the positive and negative terminal blocks, respectively. N-shaped brackets 36 are fixedly installed at both ends of the power supply frame 31. The N-shaped brackets 36 are used to fix the bottom of the power supply slot of the test cabinet 1.

[0056] like Figures 7 to 9 As shown, this solution uses seven power modules, each corresponding to an independent drawer-style power box 15. Each power box 15 has a uniform size and features modular mounting brackets inside the drawers. Pull-out installation is achieved via guide rails, facilitating module maintenance and replacement. The power box 15 frame is made of 6061 aluminum alloy, precision-machined using CNC to ensure dimensional accuracy. The frame is covered with a 1.5mm thick cold-rolled steel plate, coated with anti-static powder, achieving an impedance of 10^6-10^9Ω, balancing structural strength and electromagnetic shielding performance.

[0057] Meanwhile, this solution sets up an independent heat dissipation partition on the isolation plate 32, and each power supply box 15 units has an independent air-cooling channel on the back. An axial fan is installed in the channel with an air volume of 15 CFM and a speed of 2500 rpm. The fan speed is controlled by a closed loop through a temperature sensor PT100 with a measurement range of -50℃ to 200℃. When the module temperature exceeds 50℃, the frequency is automatically increased to ensure that the temperature rise of a single module is ≤15℃ when outputting 500V, thus avoiding overheating problems when multiple modules are connected in series.

[0058] Specifically, electromagnets 41 are evenly mounted on n-shaped brackets 36. Auxiliary springs 48 are symmetrically fixedly mounted in the middle of electromagnets 41. An n-cast iron 42 is fixedly mounted on the end of the auxiliary springs 48 away from electromagnets 41. The bottom of the n-cast iron 42 is slidably mounted on the isolation plate 32. A meshing rack 43 is fixedly mounted on the side of the n-cast iron 42 away from the auxiliary springs 48. A meshing gear 44 meshes with the teeth on the lower surface of the meshing rack 43. A swing plate 45 is fixedly mounted in the middle of the meshing gear 44. Auxiliary plates 46 are rotatably mounted on both ends of the swing plate 45. A T-shaped terminal block 47 is rotatably mounted on the end of the auxiliary plate 46 away from the swing plate 45. The side of the T-shaped terminal block 47 away from the positive terminal block 34 is slidably mounted in the radiator 33. The positive terminal block 34 and the negative terminal block 35 are respectively provided with slots in the middle. The protruding part in the middle of the T-shaped terminal block 47 is the same size as the slots of the positive terminal block 34 and the negative terminal block 35.

[0059] Each power supply box 15 contains positive and negative conductive copper pillars, 8mm in diameter and 20mm in length, along with positioning pins. When multiple modules need to be connected in series, such as module 1+2 in a 1000V configuration, a control signal is transmitted to the electromagnet 41. When the electromagnet 41 receives the electrical signal, a magnetic field is generated through its internal coil, magnetizing the electromagnet 41. This causes the electromagnet 41 to attract the n-cast iron 42, causing the n-cast iron 42 to begin moving to the right. Figure 8 As shown, at this time, the meshing of the rack 43 and the gear 44 will cause the gear 44 to start rotating clockwise. The clockwise rotation of the gear 44 will cause the swing plate 45 to press against the auxiliary plate 46. The pressing of the auxiliary plate 46 will cause the T-shaped terminal block 47 to slide to both sides of the isolation plate 32. Since the T-shaped terminal block 47 is symmetrically arranged on both sides of the positive terminal block 34 and the negative terminal block 35, when the T-shaped terminal block 47 moves to both sides, it will connect with the positive terminal block 34 or the negative terminal block 35 at both ends. Since the T-shaped terminal block 47 will connect the same polarity busbars of the two batteries after moving to one side, when the T-shaped terminal block 47 moves to both sides, it will connect the upper and lower power modules 16 in series. When different voltage output levels are required, the batteries of different modules can be connected in series by activating the electromagnet 41.

[0060] Example 2: The specific implementation method of this solution is as follows:

[0061] 1. Environmental compliance inspection;

[0062] The testing device was confirmed to be placed in an indoor environment with a pollution level of 2 and an altitude of less than 2000m. The ambient temperature was measured to be 23°C±5°C and the relative humidity was below 80%RH, with no condensation. This met the environmental requirements for the device's use.

[0063] Check that there are no strong electromagnetic interference sources around the testing area, such as high-power motors or high-frequency equipment, to avoid affecting the high-precision testing of the device; at the same time, clear away debris around the testing cabinet to leave enough space for subsequent operations, especially to ensure that the protective door 11 can be opened and closed smoothly.

[0064] II. Hardware Connection Setup;

[0065] Open the protective doors 11 on both sides of the test cabinet 1 and check whether the power boxes 15 in the power supply slot are all slidably installed in place. Ensure that each power box 15 is accurately inserted into the positive and negative slots at the bottom of the power supply slot, and that the power modules 16 in the power box 15 are not loose, leaking or otherwise abnormal.

[0066] Depending on the test object, such as the test interface type of the insulation components of the power system of an 800V high-voltage platform electric vehicle, select a suitable connecting cable and connect the positive and negative terminals of the test object to the terminal block 17 on the test cabinet 1, which is located near the power module 16. During the connection process, ensure that the cable joints are firm, free from oxidation, and that the polarity is not reversed.

[0067] Check the AC input interface at the rear of the testing cabinet 1. After confirming that the power cord is intact, connect it to an AC power supply rated at 220Vac, 100V~240V, and 50 / 60Hz. At the same time, check the EtherNET cable of the communication interface circuit to ensure that it is properly connected to the host computer and that data exchange is stable.

[0068] Three hardware and software system initializations;

[0069] Power module initialization: Press the main power switch on test cabinet 1 to power on the device. The system will automatically start testing 7 power modules 16, including power frequency transformers (T1, T6, T7), rectifier and filter components (EC1, EC2, EC11, EC12, EC13, EC14), and protection components (RT1, RT6, RT7 thermistors). Observe the power module 16 testing status displayed on the central control screen 13. If a power module, such as power module 1, shows a fault message, turn off the main power, open the power box 15 of the corresponding power slot, and check whether the power frequency transformer, rectifier and filter components, and protection components of that power module are damaged. Replace the damaged parts or the entire power module, then power on again and test until all power modules show normal operation.

[0070] Software system initialization: The software system of the detection device is started, and the initialization interface is displayed on the central control screen 13. The system automatically initializes the parameters of 7 channels. Channel 1 is set to 200V / 500V mode by default, and channels 2-7 are in a pending activation state. The 24-bit high-precision ADC sampling module and the 150ps resolution PWM execution module are initialized. The initialization status of the modules is checked on the central control screen 13 to ensure that there are no error messages. At the same time, the system automatically establishes communication connections between the MCU and each channel, and sends test commands through the central control screen 13 to verify whether the voltage acquisition function, such as acquiring the reference voltage of channel 1, and the PWM adjustment function, such as adjusting the PWM duty cycle of channel 1, are normal. If there are communication or functional abnormalities, check the relevant circuit wiring and software settings to troubleshoot.

[0071] II. Test Execution and Follow-up Processing;

[0072] The test parameters are set as follows: Based on the insulation performance evaluation requirements of the insulation components of the 800V high-voltage platform electric vehicle power system under test, the test voltage range is determined to be 800V. Since the device does not have a direct 800V output range, the closest 1000V range is selected, which can be fine-tuned later via software. The host computer interface on the central control screen 13 is used to select the 1000V output range. After receiving the 1000V range selection command, the system automatically activates the electronic switching mechanism 3. The electromagnet 41 in the electronic switching mechanism 3 receives the control signal, and its internal coil generates a magnetic field, attracting the cast iron 42 to move towards the electromagnet 41, compressing the auxiliary spring 48. The movement of cast iron 42 drives the meshing rack 43 to move synchronously. The meshing rack 43 meshes with the meshing gear 44, causing the meshing gear 44 to rotate clockwise, which in turn drives the swing plate 45 to rotate. The swing plate 45 pushes the T-shaped terminal block 47 to slide to both sides in the radiator 33 through the auxiliary plate 46. The protruding part in the middle of the T-shaped terminal block 47 is inserted into the slots of the positive terminal block 34 and the negative terminal block 35, realizing the series connection of power module 1 and power module 2, and correspondingly activating channel 1 and channel 2. The rated voltage accuracy is set to 0.01% on the central control screen 13. According to the detection requirements of the tested object and the signal stability, the sampling interval is set to 100ms and the number of samplings is set to 50, thus completing the test parameter setting.

[0073] Two-voltage output control;

[0074] The MCU acquires the output voltages of channels 1 and 2, and compares the acquired actual voltage values ​​with a 500V reference voltage (the 1000V range is composed of two 500V power supply modules connected in series). If the actual voltage is lower than 500V, the PWM duty cycle is increased using a PI algorithm; for example, the PWM1 duty cycle of channel 1 is adjusted from 0.2223 to 0.23, controlling the BOOST circuit to boost the output voltage. If the actual voltage is higher than 500V, the PWM duty cycle is decreased until the output voltages of channels 1 and 2 stabilize at 500V. At this point, the output voltage of the entire device stabilizes at 1000V. During the voltage output stabilization process, the output voltage curve displayed on the central control screen 13 is observed in real time to ensure that there are no significant voltage fluctuations. At the same time, the working status of power supply module 1 and power supply module 2 is observed through the indicator lights on the detection cabinet 1. If voltage instability or module abnormality occurs, the test is stopped immediately, and the connection status of the electronic switching mechanism 3 and the BOOST circuit are checked for normal operation.

[0075] Three data acquisition and calculation;

[0076] When a high-precision galvanometer collects a weak 1000V current from the tested object, if the impedance of the tested object is approximately 10^8Ω and the current is approximately 0.01uA, the collected current signal is amplified and filtered by a conditioning circuit before being transmitted to a 24-bit high-precision ADC sampling module. The ADC sampling module converts the analog current signal into a digital signal and transmits it to the MCU. The MCU calculates the impedance of the tested object according to the impedance calculation formula R=U / I, where U is the 1000V output voltage of the device and I is the current collected and processed by the high-precision galvanometer. The impedance data obtained from 50 collections are statistically processed, removing the maximum and minimum values ​​and then averaging the results to improve data reliability. The central control screen 13 displays the current value collected each time, the calculated impedance value, and the final average impedance value, and generates a data report. The report includes information such as test time, test voltage, number of samplings, impedance values ​​for each sampling, and average impedance value. Operators can view the report through the central control screen 13 or transmit the report to a host computer for storage via the Ethernet interface.

[0077] (iv) Equipment operation and maintenance after testing; After the test is completed, operate the stop test command on the central control screen 13. The system will first gradually reduce the output voltage to 0V, and then turn off the power supply of the electromagnet 41 in the electronic switching mechanism 3. The magnetic field of the electromagnet 41 will disappear, the auxiliary spring 48 will recover its deformation, and push the n-cast iron 42 to move in the opposite direction, driving the meshing rack 43, meshing gear 44, swing plate 45, auxiliary plate 46 and T-shaped terminal block 47 to reset, disconnect the series connection between power module 1 and power module 2, and all power modules will stop working. Close the software system of the testing device, disconnect the mains input power and Ethernet communication cable, unplug the connection cable between the tested object and the terminal block 17, organize the cable and store it in a suitable position in the testing cabinet 1. Open the protective door 11 of the testing cabinet 1, check whether the power modules, electronic switching mechanism 3, convenient storage mechanism 2 and other components are overheated or damaged, and clean the dust inside the testing cabinet 1. If the device runs for a long time during the test, wait for the device to cool down to room temperature before closing the protective door 11. The convenient storage mechanism 2's storage function is activated by sending a storage command via the central control screen 13. This starts the servo drive motor, rotating the transmission rod 22, which in turn rotates and folds the folding plate 21. Simultaneously, the first conical teeth 23 and second conical teeth 24 at both ends of the transmission rod 22 mesh, rotating the square support plate 25 and causing the casters 26 to retract, thus completing the storage of the device. Relevant test information, such as test time, tested object information, test parameters, test results, and equipment operating status, is recorded and stored in the equipment file for future retrieval and maintenance management. Furthermore, based on the device's one-year accuracy guarantee period and the adjusted one-year accuracy guarantee period, the next calibration and maintenance time is recorded to ensure the device maintains high-precision testing performance over the long term.

[0078] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0079] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An ultra-high voltage resistance testing device, comprising a testing cabinet (1), wherein protective doors (11) are symmetrically installed on one side of the testing cabinet (1), a mouse stand (12) is installed on the side of the testing cabinet (1) away from the protective doors (11), a central control screen (13) is installed above the testing cabinet (1) near the mouse stand (12), and a control module (14) is installed on the side of the testing cabinet (1) near the central control screen (13), characterized in that, The testing cabinet (1) is evenly provided with power supply slots, and a power supply box (15) is slidably installed in the power supply slots. A power supply module (16) is installed in the power supply box (15). Terminal block (17) is evenly installed above the power supply module (16) in the testing cabinet (1). The ultra-high voltage resistance testing device also includes a convenient storage mechanism (2) and an electronic switching mechanism (3). The convenient storage mechanism (2) is installed on the testing cabinet (1), and the convenient storage mechanism (2) is used for convenient measurement and monitoring; The electronic switching mechanism (3) is located in the middle of the side of the test cabinet (1) near the power supply box (15). The electronic switching mechanism (3) is used for rapid switching between electronic circuits. The electronic switching mechanism (3) further includes a series assembly (4), which includes an electromagnet (41). The electromagnets (41) are evenly mounted on an n-shaped bracket (36). An auxiliary spring (48) is symmetrically fixedly mounted in the middle of the electromagnet (41). An n-cast iron (42) is fixedly mounted on the end of the auxiliary spring (48) away from the electromagnet (41). The bottom of the n-cast iron (42) is slidably mounted on an isolation plate (32). A meshing rack (43) is fixedly mounted on the side of the n-cast iron (42) away from the auxiliary spring (48). The teeth on the lower surface of the meshing rack (43) are... A meshing gear (44) is engaged, and a swing plate (45) is fixedly installed in the middle of the meshing gear (44). An auxiliary plate (46) is rotatably installed at both ends of the swing plate (45). A T-shaped terminal block (47) is rotatably installed at the end of the auxiliary plate (46) away from the swing plate (45). The side of the T-shaped terminal block (47) away from the positive terminal block (34) is slidably installed in the radiator (33). The positive terminal block (34) and the negative terminal block (35) are respectively provided with slots in the middle. The protruding part in the middle of the T-shaped terminal block (47) is the same size as the slots of the positive terminal block (34) and the negative terminal block (35).

2. The ultra-high voltage resistance detection device according to claim 1, characterized in that: The convenient storage mechanism (2) includes a folding turntable (21), a transmission rod (22) is fixedly installed in the middle of the folding turntable (21), a first conical tooth (23) is fixedly installed on the outer surface of both ends of the transmission rod (22), the two ends of the transmission rod (22) are rotatably installed on the testing cabinet (1), the tooth surface of the first conical tooth (23) meshes with a second conical tooth (24), a square support plate (25) is fixedly installed in the middle of the second conical tooth (24), a universal wheel (26) is installed on the side of the square support plate (25) away from the second conical tooth (24), the two ends of the square support plate (25) are rotatably installed on the testing cabinet (1), a servo drive motor is installed at one end of the transmission rod (22), and the servo drive motor is installed in the testing cabinet (1).

3. The ultra-high voltage resistance detection device according to claim 1, characterized in that: The electronic switching mechanism (3) includes a power supply frame (31), which is fixedly installed on the power supply slot of the test cabinet (1). An isolation plate (32) is fixedly installed on the power supply frame (31). The isolation plate (32) is made of insulating material and has a heat dissipation slot. A heat sink (33) is installed on the heat dissipation slot of the isolation plate (32). Positive and negative terminal blocks are fixedly installed in the power supply slot. Positive terminal block (34) and negative terminal block (35) are fixedly installed at the ends of the positive and negative terminal blocks away from the power supply slot. Positive terminal block (34) and negative terminal block (35) are fixedly installed in the isolation plate (32). Positive terminal block (34) and negative terminal block (35) are respectively installed corresponding to the positive and negative terminal blocks. An n-shaped bracket (36) is fixedly installed at both ends of the power supply frame (31). The n-shaped bracket (36) is used for fixing the bottom of the power supply slot of the test cabinet (1).

4. An ultra-high voltage resistance detection operation method, applicable to the ultra-high voltage resistance detection device according to any one of claims 1-3, characterized in that, include: S1, Equipment Preparation and System Initialization: This section focuses on the basic safeguards before device testing, including environmental compliance checks, hardware connection setup, and software and hardware system initialization, to ensure that the device has the basic conditions to start testing. S2, Test Execution and Post-Testing: The entire test process and its conclusion, including test parameter setting, voltage output control, data acquisition and calculation, as well as equipment operation and maintenance after the test, to complete the impedance detection of the tested object and ensure the long-term availability of the device.

5. The ultra-high voltage resistance detection operation method according to claim 4, characterized in that: The system initialization described in S1 includes: Power module initialization: After the device is powered on, it automatically detects the multi-channel power module containing power frequency transformers, rectifier filters, and protection components. If a module fails, the host computer will prompt the fault and it needs to be repaired before continuing. Software system initialization: Start the software, initialize the multi-channel parameters, channel 1 defaults to 200V / 500V mode, channels 2-7 are to be activated; initialize the 24-bit high-precision ADC sampling module and the 150ps resolution PWM execution module, establish communication between the MCU and each channel, and ensure that the voltage acquisition and PWM adjustment functions are normal from 0-500V.

6. The ultra-high voltage resistance detection operation method according to claim 5, characterized in that: The test parameters are set according to the needs of the test subject. The system automatically activates the electronic switching mechanism (3) to connect the power module (16) in a programmed manner, corresponding to the power module and the channel.

7. The ultra-high voltage resistance detection method according to claim 6, characterized in that: The electronic switching mechanism (3) is set with a rated voltage accuracy of 0.01% and a suitable sampling interval and number of acquisitions. The output voltage of the MCU acquisition channel is tested and compared with the reference voltage. The PWM duty cycle is adjusted by the PI algorithm to control the BOOST circuit to output a stable voltage.

8. The ultra-high voltage resistance detection method according to claim 7, characterized in that: The electronic switching mechanism (3) is equipped with a high-precision ammeter to collect the weak current of the measured object. After being processed by the conditioning circuit, it is converted into a digital signal by the ADC. The MCU calculates the impedance according to R=U / I and performs multiple data statistical processing to improve reliability.

9. The ultra-high voltage resistance detection operation method according to claim 5, characterized in that: The power module (16) is set to 1-16 groups per unit, and each group corresponds to one channel, with a maximum voltage input range of 0-5000 volts.

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