A coil performance tester

Abstract

The application relates to the technical field of detection, in particular to a coil performance testing machine which comprises a frame assembly, a work station bottom plate, a jig mounting block, a probe assembly and an airtight assembly, a clamp base is fixedly installed on the jig mounting block, L-shaped fixing plates are fixedly installed on the two sides of the clamp base, pneumatic clamps are fixedly installed on the upper sides of the L-shaped fixing plates, flexible clamping plates are fixedly installed at the output ends of the pneumatic clamps, and coils are fixedly installed on the clamp base. The elastic supporting blocks are self-adaptive to the sizes of different specifications of coils, the two sides of the pneumatic clamps drive the flexible clamping plates to realize quick clamping and fixing of the coils, when testing, the probe assembly drives the contact probes to be in contact with the plastic-coated electrodes in the grooves, and the finished product coils can be directly detected; for the unfinished product coils, the positive and negative electrodes of the coils can be connected through the connecting posts and the standby electrodes are enabled to complete the test, the jig replacement frequency is effectively reduced, the testing demand of small batches and multiple varieties can be quickly adapted, and the coil production efficiency is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of testing technology, and in particular to a coil performance testing machine. Background Technology

[0002] As a core component for energy conversion, signal transmission, and electromagnetic control, coils are widely used in key electrical products such as relays, motors, transformers, and sensors in fields such as industrial automation control, new energy vehicle power systems, smart grid power transmission and distribution equipment, and precision electronic instruments. Their core performance parameters, such as DC resistance, inductance, insulation strength, and inter-turn short-circuit state, directly reflect the coil's conductivity, magnetic field energy storage capacity, safety insulation level, and structural integrity. Therefore, it is crucial to conduct comprehensive and accurate performance parameter testing and quality screening of coils during the manufacturing process to ensure the stability of the product during long-term operation.

[0003] Traditional coil performance testing methods mainly rely on manual operation of benchtop instruments (such as LCR bridges, withstand voltage testers, insulation resistance meters, etc.) to complete parameter measurements. The testing process requires multiple steps, including manually clamping the coil, manually connecting the test circuit, setting instrument parameters, and recording data. Due to the differences in winding structures of different models and sizes of coils, it is necessary to change to a matching special test fixture during testing. This process involves complex operations such as disassembling the old fixture, mechanically installing the new fixture, calibrating the positioning reference, and adjusting electrical parameters. A single fixture change typically takes 5-30 minutes. This testing mode, which relies on manual intervention, not only suffers from low operational efficiency but also struggles to meet the flexible production needs of modern manufacturing industries, which require "small batches, multiple varieties, and short lead times." Especially in scenarios with frequent product changes, frequent fixture changes can lead to excessive downtime on the production line, severely restricting capacity expansion and production rhythm optimization.

[0004] Therefore, it is urgent to improve the coil performance testing machine to solve the above-mentioned problems. Summary of the Invention

[0005] The purpose of this invention is to provide a coil performance testing machine. This machine uses an elastic support block to adapt to the size of coils of different specifications. Pneumatic clamps on both sides drive flexible clamping plates to quickly clamp and fix the coils. During testing, the probe assembly drives the probes to contact the plastic-coated electrodes in the grooves, allowing direct testing of finished coils. For non-finished coils, the positive and negative terminals can be connected via terminals, and a spare electrode can be used to complete the test. This effectively reduces the frequency of fixture changes, quickly adapts to the testing needs of small batches and multiple varieties, and significantly improves coil production efficiency.

[0006] To achieve the above objectives, the main technical solutions adopted by the present invention include: A coil performance testing machine includes a frame assembly and a workstation base plate fixedly mounted on the frame assembly. A fixture mounting block is fixedly mounted on the workstation base plate. A probe assembly is fixedly mounted on the front end of the fixture mounting block, and an airtight assembly is fixedly mounted on the rear end of the fixture mounting block. A clamp base is fixedly mounted on the fixture mounting block. L-shaped fixing plates are fixedly mounted on both sides of the clamp base. A pneumatic clamp is fixedly mounted on the upper side of the L-shaped fixing plate. A flexible clamp is fixedly mounted on the output end of the pneumatic clamp. A coil is fixedly mounted on the clamp base, and the flexible clamp corresponds to the coil. An elastic support block is vertically slidably disposed on the inner bottom side of the fixture base. The upper end of the elastic support block contacts the bottom side of the coil. A groove is formed on the fixture mounting block corresponding to the position of the probe assembly. A plastic-coated electrode is fixedly disposed on one end of the coil corresponding to the probe assembly. The plastic-coated electrode corresponds to the groove. Two sets of conductive probes are fixedly installed on the probe assembly. The conductive probes correspond to the plastic-coated electrode. An electrode guide groove is formed on the fixture mounting block. A spare electrode is fixedly installed inside the electrode guide groove. A terminal is fixedly installed at the root of the spare electrode. The positive and negative terminals of the coil power supply are electrically connected to the terminal through wires.

[0007] Preferably, a plurality of workstation partitions are fixedly installed on the upper end of the workstation base plate, and the fixture mounting block is fixedly disposed between two of the workstation partitions.

[0008] Preferably, an insulation withstand voltage tester is fixedly installed on the bottom side of the frame assembly, and a protective plate is fixedly installed on the outside of the insulation withstand voltage tester.

[0009] Preferably, a control panel assembly is fixedly installed on the upper side of the frame assembly. The control panel assembly includes a control system and a human-machine interaction system. The control system includes a main control unit, a signal switching system, and a power supply system. The human-machine interaction system includes test process editing software, a human-machine interface, and a data management system. A reflection sensor is fixedly installed on the side of the fixture mounting block. The reflection sensor processes and transmits information through an I / O module.

[0010] Preferably, an alarm light is fixedly installed on the top of the frame assembly, the alarm light is electrically connected to the control panel assembly through a wire, the two sets of conduction probes are connected in parallel to the positive and negative terminals of the power system through wires, and the pneumatic clamp is electrically connected to the power system through a wire.

[0011] Preferably, a feeding box is provided on the bottom side of the frame assembly, and a storage box is placed inside the feeding box. The storage box is used to place the coils that fail the test, and a through-beam sensor is fixedly installed inside the storage box.

[0012] Preferably, two vertically distributed cooling fans are fixedly installed on one side of the frame assembly, and two ventilation windows are opened on the side of the frame assembly away from the cooling fans, with the cooling fans corresponding to the ventilation windows.

[0013] Preferably, a probe mounting block is fixedly mounted on the upper end of the probe assembly by bolts, and the probe mounting block has a mounting groove corresponding to the conductive probe, and the conductive probe is disposed inside the mounting groove.

[0014] Preferably, a stamp driving assembly is fixedly installed on the side of the fixture mounting block away from the reflection sensor, and a stainless steel stamp is fixedly connected to the output end of the stamp driving assembly, the stainless steel stamp corresponding to the coil.

[0015] Preferably, a limiting cylinder is fixedly installed on one side of the airtight component, and a sealing limiting plate is fixedly installed at the output end of the limiting cylinder. The sealing limiting plate extends to the upper side of the fixture base, and a limiting plate groove is fixedly installed at the corresponding position of the workstation base plate. The sealing limiting plate is slidably disposed inside the limiting plate groove.

[0016] This invention has at least the following beneficial effects: 1. This invention uses an elastic support block to adapt to the size of coils of different specifications. The pneumatic clamps on both sides drive the flexible clamping plate to quickly clamp and fix the coil. During testing, the probe assembly drives the probe to contact the plastic-coated electrode in the groove, which can directly test the finished coil. For non-finished coils, the positive and negative terminals of the coil can be connected through the terminal block and the spare electrode can be used to complete the test. This effectively reduces the frequency of fixture replacement, can quickly adapt to the testing needs of small batches and multiple varieties, and significantly improves the coil production efficiency.

[0017] 2. This invention can store test data in a database, generate SPC statistical charts, support data traceability and report export. The reflective sensor mounted on the side of the fixture mounting block serves as a position detection element, working in conjunction with the I / O module to process digital signals, enabling real-time monitoring of the coil's presence and positioning status. Two sets of conduction probes are connected in parallel to the positive and negative terminals of the power system via wires, forming a detection circuit. When the probes have poor contact with the coil electrodes, an abnormal circuit current will trigger an alarm light to flash. The pneumatic clamp is connected to the power system via independent wires, forming a drive circuit. This ensures that the clamping action is not affected by the detection circuit, checking both the continuity of the circuit and ensuring the flexible clamp is firmly held. If the coil power supply is not properly connected, the alarm light will illuminate to alert the operator, thus not affecting the normal operation of the clamp while allowing for immediate detection of installation problems. Attached Figure Description

[0018] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 The overall elevation view provided for this invention; Figure 2 The structural diagram of the workstation base plate provided by this invention; Figure 3 Provided by the present invention Figure 2 Top view diagram; Figure 4 Provided by the present invention Figure 3 Enlarged view of point A in the middle; Figure 5 This is a schematic diagram of the probe assembly provided by the present invention; Figure 6 This is an exploded schematic diagram of the coil and pneumatic clamp provided by the present invention; Figure 7 This is a cross-sectional schematic diagram provided for the present invention; Figure 8 This is a schematic diagram of the system J structure provided by the present invention.

[0019] In the diagram, 1. Frame assembly; 2. Station base plate; 3. Fixture mounting block; 301. Groove; 302. Electrode guide groove; 303. Spare electrode; 304. Terminal block; 4. Probe assembly; 401. Conductive probe; 402. Probe mounting block; 403. Mounting groove; 5. Airtight assembly; 6. Fixture base; 601. Elastic support block; 7. L-shaped fixing plate; 8. Pneumatic fixture; 9. Flexible clamping plate; 10. Coil; 11. 12. Plastic-coated electrode; 13. Workstation partition; 14. Insulation withstand voltage tester; 15. Protective plate; 16. Control panel assembly; 17. Reflection sensor; 18. Alarm light; 19. Feeding box; 10. Storage box; 11. Through-beam sensor; 12. Cooling fan; 13. Ventilation window; 14. Stamp drive assembly; 15. Stainless steel stamp; 26. Limit cylinder; 27. Sealing limit plate; 28. Limit plate groove. Detailed Implementation

[0020] The following will describe in detail the implementation of this application with reference to the accompanying drawings and embodiments, so that the implementation process of how this application uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0021] like Figures 1-8As shown, the coil performance testing machine provided in this embodiment includes a frame assembly 1 and a workstation base plate 2 fixedly mounted on the frame assembly 1. The frame assembly 1 serves as the basic structure of the equipment, providing overall rigid support and bearing various functional modules. The workstation base plate 2 is used to realize the mechanical connection between the fixture system and the frame, ensuring the stability of the testing platform. A fixture mounting block 3 is fixedly mounted on the workstation base plate 2, which serves as the core functional carrier integrating probes, fixtures, and electrode systems. A probe assembly 4 is fixedly mounted at the front end, responsible for contact detection of coil electrical parameters. An airtight assembly 5 is fixedly mounted at the rear end, providing sealed protection for the testing environment and pneumatic driving power. A fixture base 6 is fixedly mounted on the fixture mounting block 3. Pneumatic clamps 8 are mounted on both sides of the base via L-shaped fixing plates 7. The flexible clamping plate 9 at the drive output end of the clamps achieves adaptive clamping of the coil 10, avoiding damage to the coil surface through flexible contact. An elastic support block 601 on the inner bottom side of the fixture base 6 compensates for height differences between different coils 10 through vertical sliding, ensuring a uniform positioning reference for the coils 10. A groove 301 is provided on the fixture mounting block 3 corresponding to the probe assembly 4, forming a guiding fit with the plastic-coated electrode 11 at the end of the coil 10. Two sets of conductive electrodes on the probe assembly 4 are connected. The probe 401 can accurately contact the plastic-coated electrode 11 to achieve electrical connection. For the testing needs of non-finished coils, the fixture mounting block 3 has a spare electrode 303 built in through the electrode guide groove 302. The terminal 304 at its root can be directly connected to the positive and negative poles of the coil 10, forming a dual-mode test interface that is compatible with the testing of coils 10 at different production stages. The probe assembly 4 has a probe mounting block 402 fixedly mounted on its upper end by bolts. The probe mounting block 402 has a mounting groove 403 corresponding to the conductive probe 401. The conductive probe 401 is set inside the mounting groove 403. The upper end of the workstation base plate 2 is fixedly equipped with three workstation partitions 12, and the fixture mounting block 3 is fixedly set between two adjacent workstation partitions 12. The two workstations can be tested simultaneously. The elastic support block 601 adapts to the size of coils of different specifications. The pneumatic clamps 8 on both sides drive the flexible clamping plate 9 to quickly clamp and fix the coil 10. During testing, the probe assembly 4 drives the probe 401 to contact the plastic-coated electrode 11 in the groove 301, which can directly test the finished coil 10. For non-finished coils 10, the positive and negative terminals of the coil 10 can be connected through the terminal block 304 and the spare electrode 303 can be used to complete the test. This effectively reduces the frequency of fixture replacement, can quickly adapt to the testing needs of small batches and multiple varieties, and significantly improves the production efficiency of coils 10. At the same time, such as Figures 1-8As shown, an insulation withstand voltage tester 13 is fixedly installed on the bottom side of the frame assembly 1, and a protective plate 131 is added to its outer side to ensure the safety of high-voltage testing. The upper side of the frame assembly 1 integrates a control panel assembly 14, which serves as the "nerve center" and "brain" of the equipment. This assembly includes an electrical measurement and control system and a software human-machine interaction system, which is responsible for executing specific test tasks and intelligent operation. The core of the electrical measurement and control system includes a main control unit, which adopts a high-performance PLC, runs the test software, and coordinates the work of each subsystem. The measuring instrument module integrates an LCR measuring instrument / impedance analyzer, an insulation withstand voltage tester 13, an insulation resistance tester, an inter-turn insulation tester, and a DC resistance tester. The signal switching system realizes the rapid switching between the measuring instrument and the coil terminal through a relay matrix or solid-state switch, which determines the test efficiency and degree of automation. The power supply system is equipped with a switching power supply, a linear power supply, and a noise filter to provide stable power to the control module, sensors, pneumatic components, and the coil under test. The software and human-machine interaction system, as the "soul" of the equipment, includes test process editing software, industrial touch screen human-machine interface and data management system. It can store test data to the database, generate SPC statistical charts, support data traceability and report export. The reflection sensor 141 mounted on the side of the fixture mounting block 3 serves as a position detection element. It works with the I / O module to process digital signals and realize real-time monitoring of the presence and positioning status of the coil. To intuitively monitor the power connection status of the non-finished coil 10 and promptly detect installation problems, the equipment is designed with a visual alarm and intelligent detection circuit system: like Figures 1-8 As shown, a three-color alarm light 15 is installed on the top of the frame component 1. This alarm light is electrically connected to the main control unit of the control panel component 14 via a wire, and can provide real-time feedback on the power connection status. The circuit connection adopts a dual-loop design: two sets of conduction probes 401 are connected in parallel to the positive and negative terminals of the power system via wires to form a detection loop. When the probes have poor contact with the coil electrodes, the abnormal loop current will trigger the alarm light 15 to flash. The pneumatic clamp 8 is connected to the power system via an independent wire to form a drive loop, ensuring that the clamping action is not affected by the detection circuit. It can check whether the circuit is continuous and ensure that the flexible clamp 9 is clamped tightly through the drive loop. Once the coil power is not properly connected, the alarm light 15 will light up to remind the operator, which will not affect the normal operation of the clamp and can detect the installation problem at the first time.

[0022] Furthermore, such as Figure 7As shown, a feeding box 16 is provided on the bottom side of the frame assembly 1 as a fast processing channel for defective products. Inside the box is a pull-out storage box 161, which is specifically used to classify and store the coils 10 that fail the test. The storage box 161 integrates a through-beam sensor 162, which can monitor the material height inside the box in real time. When the preset capacity is reached, an alarm is automatically triggered to prevent overflow. Two cooling fans 17 are installed on one side of the frame assembly 1, and two ventilation windows 18 are opened on the other side to form a forced convection cooling system. The cooling fans 17 actively draw in external cold air, which flows through the electrical component area and then exhausts hot air through the ventilation windows 18, effectively controlling the internal temperature of the equipment and ensuring the stability and service life of the precision measuring instrument. At the same time, such as Figure 2 and Figure 3 As shown, a stamp driving assembly 19 is fixedly installed on the side of the fixture mounting block 3 away from the reflection sensor 141. As a product marking execution unit, it marks the surface of the qualified coil 10 by pneumatically or electrically driving the stainless steel stamp 191 at the output end, realizing product quality traceability. A limit cylinder 20 is integrated on one side of the airtight assembly 5. It drives the sealing limit plate 201 to slide laterally along the limit plate slide groove 202 on the station base plate 2. When the sealing limit plate 201 extends to the upper side of the fixture base 6, it can cooperate with the airtight assembly 5 to form a closed test chamber, while limiting the displacement of the coil during the air pressure test, ensuring the accuracy of the airtightness test data.

[0023] like Figures 1-8 As shown in the figure, the principle of the coil performance testing machine provided in this embodiment is as follows: In use, two workstations can be tested simultaneously. The elastic support block 601 adapts to the size of coils of different specifications. The pneumatic clamps 8 on both sides drive the flexible clamping plate 9 to quickly clamp and fix the coil 10. During testing, the probe assembly 4 drives the probe 401 to contact the plastic-coated electrode 11 in the groove 301, which can directly test the finished coil 10. For non-finished coils 10, the positive and negative terminals of the coil 10 can be connected through the terminal block 304 and the spare electrode 303 can be used to complete the test. When the probe and the coil electrode have poor contact, the abnormal circuit current will trigger the alarm light 15 to flash. The pneumatic clamp 8 is connected to the power system through an independent wire to form a drive circuit, ensuring that the clamping action is not affected by the detection circuit. Once the coil power supply is not properly connected, the alarm light 15 will light up to remind the operator and can detect the installation problem at the first time.

[0024] If certain terms are used in the specification and claims to refer to specific components, those skilled in the art will understand that hardware manufacturers may use different names to refer to the same component. This specification and claims do not distinguish components based on differences in name, but rather on differences in function. The term "comprising" as used throughout the specification and claims is an open-ended term and should be interpreted as "comprising but not limited to." "Approximately" means that within an acceptable margin of error, those skilled in the art can solve the technical problem and substantially achieve the technical effect within a certain margin of error.

[0025] It should be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a product or system comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a product or system. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the product or system that includes that element.

[0026] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A coil performance testing machine, comprising a frame assembly (1) and a workstation base plate (2) fixedly disposed on the frame assembly (1), characterized in that: A fixture mounting block (3) is fixedly installed on the workstation base plate (2). A probe assembly (4) is fixedly installed at the front end of the fixture mounting block (3). An airtight assembly (5) is fixedly installed at the rear end of the fixture mounting block (3). A clamp base (6) is fixedly installed on the fixture mounting block (3). L-shaped fixing plates (7) are fixedly installed on both sides of the clamp base (6). A pneumatic clamp (8) is fixedly installed on the upper side of the L-shaped fixing plate (7). A flexible clamp (9) is fixedly installed at the output end of the pneumatic clamp (8). A coil (10) is fixedly installed on the clamp base (6). The flexible clamp (9) corresponds to the coil (10). An elastic support block (601) is vertically slidably arranged on the inner bottom side of the fixture base (6). The upper end of the elastic support block (601) is in contact with the bottom side of the coil (10). The fixture mounting block (3) has a groove (301) corresponding to the position of the probe assembly (4). A plastic-coated electrode (11) is fixedly arranged at one end of the coil (10) corresponding to the probe assembly (4). The plastic-coated electrode (11) corresponds to the groove (301). Two sets of conductive probes (401) are fixedly installed on the probe assembly (4). The conductive probes (401) correspond to the plastic-coated electrode (11). An electrode guide groove (302) is opened on the fixture mounting block (3). A spare electrode (303) is fixedly installed inside the electrode guide groove (302). A terminal block (304) is fixedly installed at the root of the spare electrode (303). The positive and negative terminals of the power supply of the coil (10) are electrically connected to the terminal block (304) through wires.

2. The coil performance testing machine according to claim 1, characterized in that: Several workstation partitions (12) are fixedly installed on the upper end of the workstation base plate (2), and the fixture mounting block (3) is fixedly set between two of the workstation partitions (12).

3. The coil performance testing machine according to claim 1, characterized in that: An insulation withstand voltage tester (13) is fixedly installed on the bottom side of the frame assembly (1), and a protective plate (131) is fixedly installed on the outside of the insulation withstand voltage tester (13).

4. A coil performance testing machine according to claim 1, characterized in that: The upper side of the frame component (1) is fixedly mounted with a control panel component (14). The control panel component (14) includes a control system and a human-machine interaction system. The control system includes a main control unit, a signal switching system and a power system. The human-machine interaction system includes test process editing software, a human-machine interface and a data management system. The side of the fixture mounting block (3) is fixedly mounted with a reflection sensor (141). The reflection sensor (141) processes and transmits information through an I / O module.

5. A coil performance testing machine according to claim 4, characterized in that: An alarm light (15) is fixedly installed on the top of the frame assembly (1). The alarm light (15) is electrically connected to the control panel assembly (14) through a wire. Two sets of conduction probes (401) are connected in parallel to the positive and negative poles of the power system through wires. The pneumatic clamp (8) is electrically connected to the power system through a wire.

6. A coil performance testing machine according to claim 1, characterized in that: The bottom side of the frame assembly (1) is provided with a feeding box (16), and a storage box (161) is placed inside the feeding box (16). The storage box (161) is used to place the coil (10) that fails the test. A through-beam sensor (162) is fixedly installed inside the storage box (161).

7. A coil performance testing machine according to claim 1, characterized in that: Two vertically distributed cooling fans (17) are fixedly installed on one side of the frame assembly (1). Two ventilation windows (18) are opened on the side of the frame assembly (1) away from the cooling fans (17). The cooling fans (17) correspond to the ventilation windows (18).

8. A coil performance testing machine according to claim 1, characterized in that: The probe assembly (4) is fixedly mounted with a probe mounting block (402) by bolts. The probe mounting block (402) has a mounting groove (403) corresponding to the conductive probe (401). The conductive probe (401) is disposed inside the mounting groove (403).

9. A coil performance testing machine according to claim 5, characterized in that: A stamp driving assembly (19) is fixedly installed on the side of the fixture mounting block (3) away from the reflection sensor (141). A stainless steel stamp (191) is fixedly connected to the output end of the stamp driving assembly (19). The stainless steel stamp (191) corresponds to the coil (10).

10. A coil performance testing machine according to claim 1, characterized in that: A limiting cylinder (20) is fixedly installed on one side of the airtight component (5). A sealing limiting plate (201) is fixedly installed at the output end of the limiting cylinder (20). The sealing limiting plate (201) extends to the upper side of the fixture base (6). A limiting plate groove (202) is fixedly installed at the corresponding position on the workstation base plate (2). The sealing limiting plate (201) is slidably disposed inside the limiting plate groove (202).

Images