Electrical equipment multi-comprehensive reliability evaluation method and system based on application scene

Abstract

The invention provides an electrical equipment multi-comprehensive reliability evaluation method and system based on an application scene, and relates to the field of electrical equipment.The electrical equipment multi-comprehensive reliability evaluation system comprises a comprehensive experiment box, the comprehensive experiment box can contain a vacuum bin of tested electrical equipment, and the comprehensive experiment box is electrically connected with a load simulation system through a load and a power interface; and a humidity control system, a temperature control system, a vacuum degree control system, a salt mist control system, a raining control system, a sand wind control system, a corrosive gas control system, a gaseous grease control system and a batting control system are respectively connected through a plurality of special interfaces. The device is applied to electrical equipment testing in a complex environment, especially for the problems of salt mist, corrosion and the like, matching of conditions such as load abrupt change and the like and environmental adaptability can be simulated according to a scene, and the environmental adaptability and reliability of equipment are verified.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electrical equipment, and in particular to a multi-comprehensive reliability evaluation method and system for electrical equipment based on application scenarios. BACKGROUND

[0002] Electrical equipment is widely used in electrical, mechanical, power electronics, port, petrochemical, high altitude, high salt fog and other industrial scenes, and is an important industrial control device. In particular, in important fields such as ports and chemical industry, it usually faces problems such as high salt fog, high dust, high temperature and humidity, and in plateau areas, it also faces the problem of insulation performance in high altitude applications. The current test method is to carry out salt spray test, high temperature test, vacuum chamber test in sequence, and then carry out rated power operation test. However, after the equipment subjected to sequential tests is applied to the application scene, problems such as three-proofing paint peeling and insulation degradation may occur, causing equipment failure.

[0003] The main problems are:

[0004] 1. When the equipment is actually running in a high-salt-fog corrosion state, the line board generates high temperature through the rated current, and the chemical corrosive substances in the air are corroded under the action of high temperature, thereby causing the three-proofing paint to peel off.

[0005] 2. Chemical grease, textile lint and other substances enter the equipment along the air duct, affecting the insulation in a high-pressure environment. Laboratories usually do not conduct live operation when doing corrosion environment.

[0006] 3. The work load of port and other scenes is often mutated, and the impact on the equipment in the mutated state will also affect the reliability. Only by simulating the actual working environment can the reliability of the equipment and internal components be truly evaluated.

[0007] 4. The existing method cannot realize full-scene simulation of the actual working condition, so there is a hidden danger in reliability.

[0008] In order to solve the above problems, the present application proposes a multi-comprehensive reliability evaluation method based on application scenarios to realize the real evaluation of the reliability of electrical equipment. SUMMARY

[0009] The present application aims to overcome the shortcomings of the prior art and proposes a multi-comprehensive reliability evaluation method and system for electrical equipment based on application scenarios.

[0010] The purpose of the present application is to solve the problem of reliability evaluation of industrial electrical equipment, to study an evaluation method capable of simulating actual operation conditions and environmental factors, and to mainly include the functions of simulating equipment load curve, simulating environmental temperature and alternation, simulating environmental humidity and alternation, simulating environmental salt spray corrosion, simulating chemical oil, simulating dust, simulating lint, simulating wind sand, and simulating high-altitude scene comprehensive reliability test verification.

[0011] The purpose of the present application is achieved by the following technical means:

[0012] A multi-comprehensive reliability evaluation system for electrical equipment based on application scenarios, comprising a comprehensive test box capable of accommodating a vacuum chamber of a test electrical equipment, the comprehensive test box being electrically connected to a load simulation system through a load and power supply interface, and being further connected to a humidity control system, a temperature control system, a vacuum degree control system, a salt spray control system, a rain control system, a wind sand control system, a corrosive gas control system, a gaseous oil control system and a lint control system through a plurality of special interfaces.

[0013] Moreover, the load and power supply interface comprises a communication interface, a control power supply interface and a power part interface.

[0014] Moreover, the special interfaces comprise, in sequence, a spraying interface, a heater / cooler interface, a vacuum pumping interface, a salt spray spraying interface, a rain simulation spraying interface, a wind sand interface, a corrosive gas interface, a gaseous oil interface and a lint interface, and the special interfaces are all provided with check valves for one-way inlet.

[0015] Moreover,

[0016] The load simulation system allows the load to work according to the set load type and load working current according to the set curve, so as to realize the simulation of the actual running state;

[0017] The humidity control system controls the humidity to reach the set humidity by controlling the humidifier and dehumidifier in the comprehensive test box according to the set humidity, and the relative humidity range is 0-100%;

[0018] The temperature control system controls the temperature to reach the set temperature by controlling the heater and cooler in the comprehensive test box according to the set temperature, and the temperature range is-50℃-+80℃;

[0019] The vacuum degree control system controls the vacuum degree of the cavity by vacuum pumping according to the set vacuum degree, and the vacuum degree range is-32000Pa;

[0020] The salt spray control system atomizes the salt solution into fine droplets by a spraying tower or a nozzle according to the set salt spray type and concentration, and uniformly distributes the droplets in the environmental chamber, and simultaneously starts the temperature control and humidity control systems according to the salt spray type;

[0021] Rain control system, according to the set rain type, rainfall and temperature, using fan-shaped nozzle to simulate large-area rainfall, pinhole nozzle to simulate storm impact, according to the rain type to start temperature control, to realize the simulation of hot rain and cold rain;

[0022] Wind and sand control system, according to the set wind and sand flow rate, particle size and metal content, through the exhaust system to blow into the environment warehouse, using open loop control, without installing related sensors;

[0023] Corrosive gas control system, according to the set corrosive gas type and concentration, through the electrochemical sensor to collect the current concentration in the environment warehouse, using mass flow controller to accurately control the gas inlet rate, unit: mL / min or L / min, combined with the volume of the environment warehouse and the target concentration, to calculate the required gas amount, formula: concentration = gas inlet amount / (warehouse air volume + air inlet rate x time), if low concentration gas is required, it needs to be realized through the dilution system, the mixing accuracy needs to be ≤ ± 2%, or according to the test requirements;

[0024] Gaseous oil control system, according to the set oil concentration and type, through the atomization method to spray gaseous oil into the environment warehouse, the concentration control uses open loop control method, without installing related sensors;

[0025] Lint control system, according to the set lint type, content and lint diameter, through the vibration release device or air flow purge release device to blow the lint into the environment warehouse, using open loop control.

[0026] A multi-comprehensive reliability evaluation method of electrical equipment based on application scene, the steps are as follows:

[0027] S1 Before the experiment box works, the anticorrosion and oil stain materials in the box are arranged, the equipment is put into the experiment cabin, and the external wiring is done well;

[0028] S2 Collect the current waveform in the actual operation scene of the equipment, record the running data waveform curve, including the highest and lowest temperature, humidity alternation, salinity, oil stain, corrosive gas composition, dust and lint composition content, altitude, wind and sand speed and particle size;

[0029] S3 According to the on-site working conditions or according to the relevant test standards, the simulation values are input into the load simulation system, the vacuum degree system, the temperature control system, the humidity control system, the corrosive gas control system, the gaseous oil control system, the lint control system, the wind and sand control system, the salt mist control system and the rain control system are selectively started, and the specific parameters are set;

[0030] S4 Calculate the aging rate of the equipment according to the Arrhenius equation, the formula is:

[0031] k = A e ^ (-Ea / (RT)),

[0032] Wherein, k is the aging rate, Ea is the activation energy, T is the absolute temperature, R is the gas constant, A is the constant;

[0033] S5 according to the requirement of aging rate, set the environmental temperature, the upper limit of temperature should not exceed the material decomposition temperature of corrosive gas and gaseous oil;

[0034] S6 record the voltage, current and temperature signal during the operation of the equipment, after completing the test of set time, take the equipment out of the comprehensive test box, then take out the main components in the equipment, according to the corresponding national standard, carry out the electrical performance test, material insulation strength and conductivity test, determine its environmental comprehensive adaptability.

[0035] Moreover, in the S5, the test mode of the comprehensive test box comprises:

[0036] ① High altitude, high salt fog wind sand test, according to the altitude setting of the vacuum degree system, the vacuum degree meets the altitude requirement; according to the salt fog content, the salt fog content of the salt fog control system is set, which meets the salt fog requirement; according to the wind sand grade, the wind sand content and wind speed of the wind sand control system are set; according to the load working curve, the load simulation system is set, so that the measured equipment works in the required operating condition; according to the formula calculation of step S4, start the temperature control system, and start the accelerated aging test;

[0037] ② High corrosive, high gaseous oil test, according to the corrosive gas control system of corrosive gas component and content; according to the gaseous oil control system of gaseous oil component and content; according to the principle of corrosive substance accelerated aging, the environmental humidity and temperature are set to accelerate the aging corrosion effect, and the load simulation system is set according to the load working curve, so that the measured equipment works in the required operating condition;

[0038] ③ High complexity test, according to the lint control system of chemical fiber lint component, the lint is blown out according to the set air volume and the dryness of the lint is ensured, and the air duct needs to be aligned with the air inlet of the measured equipment; after reaching the set time, start the humidity control system and the temperature control system, and start the metal dust injection through the wind sand control system, and set the load simulation system according to the load working curve, so that the measured equipment works in the required operating condition.

[0039] Moreover, the main components in the equipment include: capacitor, reactor, circuit board, power unit, switch.

[0040] The advantages and positive effects of the present application are:

[0041] The application is applied to electrical equipment test in complex environment, and mainly solves the problem that the existing electrical equipment and actual working scene are not consistent, the test condition is single, and after the test is completed in the laboratory, the fault frequently occurs in the actual scene, especially for salt fog, corrosion and the like, the method accelerates the chemical reaction through heating and humidifying to realize simulation of the corrosion degree, and meanwhile, scene simulation load mutation and the like and environmental adaptability are cooperated to verify the environmental adaptability and reliability of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0042] In order to more clearly illustrate the technical solutions of the present application, the following will briefly introduce the drawings needed to be used in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without any creative effort.

[0043] Figure 1 It is the overall logical block diagram of the system. DETAILED DESCRIPTION

[0044] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the drawings. Although some embodiments of the present application are shown in the drawings, it should be understood that the present application can be realized in various forms, and should not be interpreted as being limited to the embodiments described herein, on the contrary, these embodiments are provided to make the present application more thorough and complete. It should be understood that the drawings and embodiments of the present application are only for illustrative purposes, and are not intended to limit the scope of protection of the present application.

[0045] It should be understood that each step described in the method embodiment of the present application can be executed in different order and / or in parallel. In addition, the method embodiment can include additional steps and / or omit the execution of the steps shown. The scope of the present application is not limited in this respect.

[0046] The main parts of the test evaluation system include but are not limited to the comprehensive test box, the vacuum degree control system, the temperature control system, the humidity control system, the corrosive gas control system, the gaseous oil control system, the lint control system, the wind sand control system, the salt fog control system, the rain control system, the load simulation system and the like. Among them, the nozzles of the corrosive gas control system, the gaseous oil control system, the lint control system, the wind sand control system and the salt fog control system are movable nozzles, which can be adjusted to the equipment air inlet or external terminal position. The rain control system is installed on the top of the comprehensive test box. The vacuum degree control system, the temperature control system and the humidity control system are installed on the side wall of the comprehensive test box.

[0047] An electrical equipment multi-comprehensive reliability evaluation system based on application scenarios, referring to the accompanying drawings Figure 1 The main module functions involved are as follows:

[0048] The comprehensive experiment box can accommodate the vacuum chamber of the test electrical equipment. The comprehensive experiment box is electrically connected to the load simulation system through the load and power supply interface, and is also connected to a humidity control system, a temperature control system, a vacuum degree control system, a salt spray control system, a rain simulation control system, a wind and sand control system, a corrosive gas control system, a gaseous oil control system, and a lint control system through multiple special interfaces.

[0049] The load and power supply interface includes a communication interface, a control power supply interface, a power part interface, and other electrical interfaces. The special interfaces include, in sequence, a spray interface, a heater / cooler interface, a vacuum extraction interface, a salt spray interface, a rain simulation spray interface, a wind and sand interface, a corrosive gas interface, a gaseous oil interface, and a lint interface. All the above special interfaces are provided with check valves and are one-way inlets. According to experimental needs, a water mist spray interface and a dust interface can also be provided for connecting corresponding scene simulation systems.

[0050] The load simulation system allows the load to work according to the set load type and load working current and in accordance with a set curve, thereby achieving simulation of the actual running state.

[0051] The humidity control system controls the humidity in the comprehensive experiment box to reach the set humidity by controlling the humidifier and dehumidifier in the comprehensive experiment box according to the set humidity. The relative humidity (PH) ranges from 0 to 100%.

[0052] The temperature control system controls the temperature in the comprehensive experiment box to reach the set temperature by controlling the heater and cooler in the comprehensive experiment box according to the set temperature. The temperature ranges from -50°C to +80°C.

[0053] The vacuum degree control system controls the vacuum degree of the cavity by vacuum extraction according to the set vacuum degree. The vacuum degree ranges from 32,000 Pa (negative pressure).

[0054] The salt spray control system atomizes the salt solution into fine droplets by a spray tower or a nozzle according to the set salt spray type and concentration, and uniformly distributes the droplets in the environment chamber. At the same time, the temperature control and humidity control systems are started according to the salt spray type.

[0055] The rain simulation control system simulates large-area rainfall and heavy rain impact by using a fan-shaped nozzle and a pinhole nozzle according to the set rain type, rainfall amount, and temperature. The temperature control is started according to the rain type to achieve simulation of hot rain and cold rain.

[0056] Wind sand control system, according to the set wind sand flow rate, particle size and metal content, through the exhaust system blowing into the environment warehouse, using open loop control, without installing related sensors.

[0057] Corrosive gas control system, according to the set corrosive gas species and concentration, through the electrochemical sensor to collect the current concentration in the environment warehouse, using mass flow controller (MFC) to accurately control the gas into the rate (unit: mL / min or L / min), combined with the volume of the environment warehouse and the target concentration, to calculate the required gas amount (formula: concentration = gas into the amount / (warehouse air volume + ventilation rate x time)). If low concentration gas (such as ppm level) is needed, it needs to be achieved through a dilution system (mixing high concentration gas with clean air in proportion), and the mixing accuracy needs to be ≤ ± 2% (or according to the test requirements).

[0058] Gaseous oil control system, according to the set oil concentration and species, through the atomization method to spray gaseous oil into the environment warehouse, and the concentration control adopts open loop control method without installing related sensors.

[0059] Lint control system, according to the set lint species, content and lint diameter, through the vibration release or airflow purge release method to blow lint into the environment warehouse, using open loop control without installing related sensors.

[0060] The working principle and steps of the above system are as follows:

[0061] S1 Before the comprehensive test box works, the materials for preventing corrosion and oil stains are arranged in the box, then the equipment is put into the test cabin and the external wiring is done.

[0062] S2 Collect the current waveform in the actual operation scene of the equipment, record the running data waveform curve, including the highest and lowest temperature, humidity alternation, salinity, oil stain, corrosive gas composition, dust and lint composition content, altitude, wind sand speed and particle size.

[0063] S3 According to the on-site working conditions or according to the relevant test standards, input the simulation values into the load simulation system, selectively start the vacuum degree system, temperature control system, humidity control system, corrosive gas control system, gaseous oil control system, lint control system, wind sand control system, salt spray control system and rain control system, and set specific parameters;

[0064] S4 According to the Arrhenius equation (Arrhenius Equation), the formula is: k = A e^{-Ea / (RT)}, where k is the aging rate, Ea is the activation energy, T is the absolute temperature, R is the gas constant, and A is the constant.

[0065] S5 Set the environmental temperature according to the requirement of aging rate. The upper limit of temperature should not exceed the material decomposition temperature of corrosive gas and gaseous grease.

[0066] The main test mode of the comprehensive test box is as follows:

[0067] ①High-altitude, high-salt fog and sand test (salt lake scene), set the vacuum degree of 2 vacuum systems according to the altitude requirement, set the salt fog content of 9 salt fog control systems according to the salt fog requirement, set the wind sand content and wind speed of 8 wind sand control systems according to the wind sand grade, set 11 load simulation systems according to the load working curve, and make the device under test work in the required operating condition. Start 3 temperature control systems according to the formula in step 4 to start the accelerated aging test.

[0068] ②High corrosiveness and high gaseous grease test (petrochemical scene), set 5 corrosive gas control systems according to the corrosive gas composition and content, set 6 gaseous grease control systems according to the gaseous grease composition and content, set the environmental humidity and temperature according to the corrosive substance accelerated aging principle to accelerate the aging corrosion effect. Set 11 load simulation systems according to the load working curve to make the device under test work in the required operating condition.

[0069] ③High complexity test (chemical fiber scene), set 7 lint control systems according to the chemical fiber lint composition, blow out the lint according to the set air volume and ensure the dryness of the lint, and the air duct needs to be aligned with the air inlet of the device under test; after reaching the set time, start 4 humidity control systems and 3 temperature control systems, and start the metal dust injection through 8 wind sand control systems. Set 11 load simulation systems according to the load working curve to make the device under test work in the required operating condition.

[0070] S6 Record the voltage, current and temperature signals during the operation of the device, take the device out of the comprehensive test box after completing the test of the set time, and clean the foreign matter in the box. Take out the main components in the device, including: capacitors, reactors, circuit boards, power units, switches, etc. Test the electrical performance, material insulation strength and electrical conductivity of each component according to the corresponding national standards to determine its environmental comprehensive adaptability.

[0071] Finally, it should be noted that the above-described embodiments are merely specific embodiments of the present application, which are used to illustrate the technical solutions of the present application, but not to limit the same. The protection scope of the present application is not limited thereto. Although the present application has been described in detail with reference to the foregoing embodiments, it should be understood by those skilled in the art that any person skilled in the art can still modify or easily think of changes to the technical solutions recorded in the foregoing embodiments, or make equivalent replacements to some of the technical features, within the technical scope disclosed by the present application. The modifications, changes or replacements do not cause the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A comprehensive reliability evaluation system for electrical equipment based on application scenarios, characterized in that, It includes a comprehensive experimental chamber, which is a vacuum chamber that can accommodate the electrical equipment under test. The comprehensive experimental chamber is electrically connected to the load simulation system through load and power interfaces. At the same time, it is also connected to the humidity control system, temperature control system, vacuum control system, salt spray control system, rain control system, wind and sand control system, corrosive gas control system, gaseous grease control system, and lint control system through multiple dedicated interfaces.

2. The comprehensive reliability evaluation system for electrical equipment based on application scenarios according to claim 1, characterized in that, The load and power interfaces include a communication interface, a control power interface, and a power section interface.

3. The comprehensive reliability evaluation system for electrical equipment based on application scenarios according to claim 1, characterized in that, The dedicated interfaces include, in sequence, a spray interface, a heater / cooler interface, a vacuum interface, a salt spray interface, a rainwater simulation spray interface, a sandstorm interface, a corrosive gas interface, a gas and grease interface, and a lint interface. Each of the dedicated interfaces is equipped with a check valve and is a one-way inlet.

4. The comprehensive reliability evaluation system for electrical equipment based on application scenarios according to claim 1, characterized in that, The load simulation system simulates the actual operating state by making the load work according to the set load type and load operating current and following a set curve. The humidity control system controls the humidity to reach the set humidity by controlling the humidifier and dehumidifier in the integrated experimental chamber, with a relative humidity range of 0 to 100%. The temperature control system controls the temperature to reach the set temperature by controlling the heater and cooler in the integrated test chamber, with a temperature range of -50℃ to +80℃. The vacuum control system controls the vacuum level of the cavity by evacuation according to the set vacuum level, with a vacuum range of negative pressure 32000Pa. The salt spray control system atomizes the salt solution into tiny droplets through a spray tower or nozzles, according to the set salt spray type and concentration, and evenly distributes them in the environmental chamber. At the same time, it activates the temperature and humidity control systems according to the salt spray type. The rain control system uses fan-shaped nozzles to simulate large-area rainfall and pinhole nozzles to simulate rainstorm impact, based on the set rain type, rainfall amount and temperature. It also activates temperature control according to the rain type to simulate hot rain and cold rain. The wind and sand control system blows sand into the environmental chamber through the exhaust system according to the set wind and sand flow rate, particle size and metal content. It adopts open-loop control and does not install related sensors. The corrosive gas control system collects the current concentration in the environmental chamber using an electrochemical sensor based on the set type and concentration of corrosive gas. A mass flow controller precisely controls the gas inlet rate, with units of mL / min or L / min. Combining the environmental chamber volume and target concentration, the required gas volume is calculated using the formula: Concentration = Gas inlet volume / (Air volume in chamber + Inlet rate × Time). If a low concentration of gas is required, it must be achieved through a dilution system, with a mixing accuracy of ≤±2%, or as required by the test. The gaseous grease control system sprays gaseous grease into the environmental chamber through atomization based on the set grease concentration and type. The concentration control adopts an open-loop control method and does not require the installation of related sensors. The lint control system, based on the set lint type, content, and diameter, blows lint into the environmental chamber via a vibration release device or an airflow purging release device, employing open-loop control.

5. A method for comprehensive reliability evaluation of electrical equipment based on application scenarios, characterized in that, The steps are as follows: Before operating the S1 integrated test chamber, anti-corrosion and anti-oil materials should be placed inside the chamber before placing the equipment into the test chamber and making the external wiring. S2 collects current waveforms in actual equipment operation scenarios and records operating data waveform curves, including the highest and lowest temperatures, humidity alternation, salinity, oil stains, corrosive gas composition, dust and lint content, altitude, wind and sand speed, and particle size. Based on the on-site working conditions or relevant testing standards, S3 inputs the simulated values ​​into the load simulation system, selectively activates the vacuum system, temperature control system, humidity control system, corrosive gas control system, gaseous grease control system, lint control system, wind and sand control system, salt spray control system, and rain control system, and sets specific parameters. S4 calculates the aging rate of the equipment based on the Arrhenius equation, using the following formula: k = A e^{-Ea / (RT)}, Where k is the aging rate, Ea is the activation energy, T is the absolute temperature, R is the gas constant, and A is a constant; S5 sets the ambient temperature according to the aging rate requirements. The upper limit of the temperature should not exceed the material decomposition temperature of corrosive gases and gaseous greases. S6 records signals such as voltage, current, and temperature during equipment operation. After completing the test for the set time, the equipment is removed from the integrated test box. Then, the main components inside the equipment are removed, and electrical performance, material insulation strength, and conductivity tests are performed on each main component according to the corresponding national standards to determine its comprehensive environmental adaptability.

6. The method for comprehensive reliability evaluation of electrical equipment based on application scenarios according to claim 5, characterized in that, In S5, the test modes of the integrated experimental chamber include: ① High-altitude, high-salt-spray, and sandstorm test: Set the vacuum level of the vacuum system according to the altitude to meet the altitude requirements; set the salt spray content of the salt spray control system according to the salt spray content to meet the salt spray requirements; set the sandstorm content and wind speed of the sandstorm control system according to the sandstorm level; set the load simulation system according to the load working curve to make the equipment under test work under the required operating conditions; start the accelerated aging test by starting the temperature control system and calculating according to the formula in step S4. ② For high-corrosiveness and high-gase testing, a corrosive gas control system is set up according to the corrosive gaseous components and content; a gaseous grease control system is set up according to the gaseous grease components and content; according to the principle of accelerated aging of corrosive substances, the ambient humidity and temperature are set up to accelerate the aging and corrosion effect; and a load simulation system is set up according to the load working curve to make the tested equipment work under the required operating conditions. ③ For highly complex tests, a lint control system is set up according to the composition of chemical fiber lint. Lint is blown out according to the set air volume and the dryness of the lint is ensured. The air duct must be aligned with the air inlet of the equipment under test. After the set time is reached, the humidity control system and temperature control system are activated, and the metal dust is injected through the wind and sand control system. The load simulation system is set according to the load working curve to make the equipment under test work under the required operating conditions.

7. The method for comprehensive reliability evaluation of electrical equipment based on application scenarios according to claim 5, characterized in that, The main components inside the equipment include: capacitors, reactors, circuit boards, power units, and switches.

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