High-voltage connector test method

Abstract

The invention discloses a high-voltage connector test method. The method comprises the following steps: initializing a system and configuring parameters; automatically executing a swing angle and return stroke test, and acquiring data and comparing the data with a preset threshold value; automatically executing a contact resistance test and judging; docking action performance testing under the set stroke and height difference is automatically executed, and action reliability is judged through position and conduction signals; and finally, automatically generating a report integrating all test data and results. According to the invention, the integration, automation and datamation of the test process are realized, the test efficiency, accuracy and consistency are obviously improved, and the labor intensity of workers is effectively reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of high-voltage electrical equipment detection, in particular to a test method for mechanical performance and electrical performance of a high-voltage connector. BACKGROUND

[0002] The high-voltage connector is a key component for connecting the high-voltage circuit of a locomotive, and its performance reliability is crucial. Currently, the test of the high-voltage connector usually relies on multiple independent devices and a large amount of manual operation to complete, such as using an angle ruler, a tape measure, a micro-ohmmeter, etc. to measure the swing angle, the return stroke, and the contact resistance, respectively. This discrete test method has the following problems: Low efficiency: each test item needs to re-set the equipment and tooling, and the test process is not coherent.

[0003] Large human error: the reading and recording both depend on manual operation, and the subjectivity is strong, so it is difficult to guarantee the accuracy and consistency of the data.

[0004] Low automation: it is unable to realize automatic criteria, data linkage, and report automatic generation, and the labor intensity is large.

[0005] Difficulty in comprehensive motion test: it is difficult to simulate and automatically judge the reliability of repeated docking actions under a specific distance and height difference.

[0006] Therefore, there is an urgent need for a highly integrated, automated, and data-based test method to comprehensively improve the test efficiency and quality of the high-voltage connector. SUMMARY

[0007] The technical problem to be solved by the present application is to provide a high-voltage connector test method, which can accurately measure the swing angle performance, the return stroke performance, the electrical conduction performance, and the docking action performance of the high-voltage connector, and can achieve the purposes of improving the test efficiency and reducing the labor intensity.

[0008] To solve the above technical problems, the technical solution of the present application is: a high-voltage connector test method, comprising the following steps: Step S1: system initialization and parameter configuration; Step S2: perform high-low swing angle test: fix the sensor test assembly and the reflector plate on the high-voltage connector support seat, manually up and down the high-voltage connector top rod to the limit position, and the test bench automatically records the maximum swing angle data; Step S3: left-right swing angle test: fix the sensor test assembly and the reflector plate on the high-voltage connector support seat, manually left and right the high-voltage connector top rod to the limit position, and the test bench automatically records the maximum swing angle data; Step S4: return stroke test: fix the sensor test assembly and the reflector plate on the high-voltage connector support seat, manually pull the high-voltage connector top rod back and forth, and the test bench automatically records the maximum and minimum return stroke values; Step S5: contact resistance test: remove the sensor test assembly, and butt the high-voltage connectors in manual mode; clamp the resistance tester output test clamp to the conductive rod end or the bus end, set the output current value and test time, start the test, and the equipment automatically records the contact resistance value after the test is completed; Step S6: butt action test: remove the sensor test assembly and remove the resistance tester test cable, and set the mode knob switch to automatic mode; connect a group of contacts to the two high-voltage connector bus output ends, and realize conduction when the high-voltage connectors are butted, so that the computer can judge whether the butt is successful; place the light sensors at a distance of 520 mm and 680 mm from the center of the stationary high-voltage connector, and the computer can judge whether the high-voltage connector center from 520 mm to 680 mm is butted normally, set the test number and test interval time, start the test, and the fixed end of the high-voltage connector is automatically started after being raised by 30 mm, and the requirement is that the center distance of the two high-voltage connectors after butt is between 520 mm and 680 mm without separation, and the test is automatically stopped after completion; Step S7: generate and save a test report integrating all test data and judgment results.

[0009] As an improvement, the sensor test assembly includes a three-dimensional electronic compass and a pull rope displacement sensor, and the sensor test assembly is transmitted to the upper computer in real time through an RS232 communication interface.

[0010] As an improvement, the sensor assembly is arranged on the lock at the end of the high-voltage connector, and the reflector plate is arranged on the cross head support seat of the high-voltage connector.

[0011] As an improvement, in step S6, the high-voltage connector A is butted with the high-voltage connector B, the high-voltage connector B is fixed, the high-voltage connector A is controlled by the cylinder, and the cylinder is controlled by the PLC integrated with a dynamic compensation algorithm.

[0012] The beneficial effects brought by the present application compared with the prior art are: By combining the data acquisition of various sensors (three-dimensional electronic compass, displacement sensor, resistance tester, position sensor, feedback contact) with the programmed control logic of the PLC, a complete and automated test process is defined. This method realizes the transition from single-point parameter measurement to comprehensive performance evaluation, significantly improves the test efficiency and data accuracy, reduces the labor cost and operation strength, and ensures the consistency and reliability of the high-voltage connector performance. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1Schematic diagram of the test bench.

[0014] Figure 2 This is a block diagram illustrating the working principle of the high-voltage connector test bench. Detailed Implementation

[0015] The present invention will now be further described with reference to the accompanying drawings.

[0016] like Figure 1 , 2 As shown, a high-voltage connector testing method relies on an integrated test bench, which includes a PLC, an industrial computer, various sensors, pneumatic actuators, and tooling. The tooling includes a fixed mounting base 21 and a movable mounting base 11, which can move relative to the fixed mounting base 21. During testing, high-voltage connector A is fixed on the movable mounting base 11, and high-voltage connector B is fixed on the fixed mounting base 21. The test bench's interface has four functional areas: Function Area 1: Test type selection area; Function Area 2: Status and data display area; Function Area 3: Model parameter display area; Function Area 4: Report information input and storage area.

[0017] The test method specifically includes the following steps: Step S1: System initialization and parameter configuration; The operator selects the model of the high-voltage connector under test through the test software on the industrial control computer, and the system automatically loads the corresponding performance qualification thresholds for that model (such as high and low swing angle ≥8.5°, contact resistance ≤850μΩ, etc.). Step S2: Fix the sensor test assembly 14 and reflector 15 on the high-voltage connector support. The sensor assembly 14 is located on the locking device 13 at the end of the high-voltage connector, and the reflector 15 is located on the crosshead support 12 of the high-voltage connector. The sensor test assembly 14 includes a three-dimensional electronic compass and a pull-string displacement sensor. The sensor test assembly transmits data to the host computer in real time through an RS232 communication interface. Step S3: Perform high and low swing angle test: According to the interface prompts, manually move the high voltage connector push rod 16 up and down to the limit position. The test bench will automatically record the maximum swing angle data. The up and down swing angle should not be less than 8.5°. Step S4: Left and right swing angle test: According to the interface prompts, manually move the high voltage connector push rod 16 to the limit position. The test bench will automatically record the maximum swing angle data. The left and right swing angle should not be less than 34°. Step S5: Return Test: According to the interface prompts, manually pull the high-voltage connector push rod 16 back and forth. The test bench will automatically record the maximum and minimum return values. The maximum return is required to be >240mm and the minimum return is required to be >210mm. Step S6: contact resistance test: remove the sensor test assembly, dock the high voltage connector in manual mode; clamp the resistance tester output test clip to the end of the conductive rod or busbar, set the output current value and test time respectively, start the test, and the equipment automatically records the contact resistance value after the test is completed; the equipment automatically records the contact resistance value after the test is completed, the contact resistance of the two busbar output ends is required to be not more than 850uΩ, and the contact resistance between the conductive rods is required to be not more than 650uΩ; it should be noted that: before starting the test, the test position, test current and test time need to be confirmed, and after confirmation, click "start test" to automatically fill in the contact resistance value box after the test is completed; Step S7: docking action test: remove the sensor test assembly, remove the resistance tester test cable, and set the mode knob switch to automatic mode; high voltage connector A and high voltage connector B are docked, high voltage connector B is fixed, high voltage connector A is controlled by the air cylinder, and the air cylinder is controlled by the PLC integrated with dynamic compensation algorithm; connect a group of contacts to the two high voltage connector busbar output ends, and realize conduction when the high voltage connectors are docked, so that the computer can judge whether the docking is successful; place the light sensor at a distance of 520mm and 680mm from the center of the stationary high voltage connector, and the computer can judge whether the high voltage connector center 520mm to 680mm is docked normally, set the test number and test interval time, and start the test after the high voltage connector fixed end is raised by 30mm, the two high voltage connector centers are required to be not separated within 520mm to 680mm after docking, and the test is automatically stopped after completion; Step S8: generate and save the test report integrating all test data and judgment results; the test report is automatically generated and contains the test piece model, original data of each test item, qualified judgment result and test time information.

Claims

1. A test method for high-voltage connectors, characterized in that, Includes the following steps: Step S1: System initialization and parameter configuration; Step S2: Perform high and low swing angle test: Fix the sensor test assembly and reflector on the high voltage connector support, manually move the high voltage connector top rod up and down to the limit position, and the test bench will automatically record the maximum swing angle data; Step S3: Left and right swing angle test: Fix the sensor test assembly and reflector on the high voltage connector support, manually move the high voltage connector top rod left and right to the limit position, and the test bench will automatically record the maximum swing angle data; Step S4: Return Test: Fix the sensor test assembly and reflector on the high-voltage connector support, manually pull the high-voltage connector top rod back and forth, and the test bench will automatically record the maximum and minimum return values; Step S5: Contact Resistance Test: Remove the sensor test assembly and connect the high voltage connector in manual mode; clip the output test clip of the resistance tester to the conductive rod end or bus end, set the output current value and test time respectively, and start the test. After the test is completed, the device will automatically record the contact resistance value. Step S6: Docking Action Test: Remove the sensor test assembly and the resistance tester test cable. Set the mode knob switch to automatic mode. Connect a set of contacts to the output terminals of the two high-voltage connector busbars. The high-voltage connectors will conduct when docked, and the computer will use this to determine if the docking is successful. Place optical sensors at distances of 520mm and 680mm from the center of the stationary high-voltage connectors. The computer will use this to determine if the docking between the centers of the high-voltage connectors at 520mm and 680mm is normal. After setting the number of tests and the test interval, start the test. The test will start automatically after the fixed end of the high-voltage connector is raised by 30mm. It is required that the center distance between the two high-voltage connectors does not separate between 520mm and 680mm after docking. The test will stop automatically after completion. Step S7: Generate and save a test report that integrates all test data and judgment results.

2. The high-voltage connector testing method according to claim 1, characterized in that: The sensor testing assembly includes a three-dimensional electronic compass and a drawstring displacement sensor. The sensor testing assembly transmits data to the host computer in real time via an RS232 communication interface.

3. The high-voltage connector testing method according to claim 1, characterized in that: The sensor assembly is mounted on the locking device at the end of the high-voltage connector, and the reflector is mounted on the crosshead support of the high-voltage connector.

4. The high-voltage connector testing method according to claim 1, characterized in that: In step S6, high-voltage connector A is connected to high-voltage connector B, high-voltage connector B is fixed, and high-voltage connector A is driven and controlled by a cylinder, which is controlled by a PLC with integrated dynamic compensation algorithm.

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