Automatic switching acquisition system based on program control resistance box

Abstract

The invention provides an automatic switching acquisition system based on a program control resistance box. The system comprises a program control resistance box which is used for providing multiple paths of programmable change resistance loads; the switching system is used for receiving a control instruction and automatically switching the output end of any product to be tested to be connected with the program control resistance box or a shared process motor; the power-on protection system is used for ensuring the power-on / power-off time sequence of the control power and the power power of the to-be-tested product and providing protection in case of abnormality; and the data acquisition system is used for directly acquiring voltage and current signals at the output end of the product to be tested and carrying out signal conditioning and conversion. According to the invention, the automation of the test process can be realized, the dependence on manpower is reduced, and a single process motor is allowed to serve the test of a plurality of driving products, so that the comprehensive cost is remarkably reduced, and the test throughput is improved.

Description

Technical Field

[0001] This invention belongs to the field of electronic information technology, and in particular to an automatic switching acquisition system based on a programmable resistor box. Background Technology

[0002] In the factory inspection of motor drive products, temperature cycling and aging tests must be performed according to standards. Existing technology typically uses ceramic resistors or process motors as loads, and the following procedures are completed manually: switching the drive product output to the resistor or motor, recording test data, and changing the test channel and load.

[0003] The existing technology has the following obvious drawbacks:

[0004] High labor costs: Operators need to be on duty in the test workshop in harsh environments such as high noise throughout the process to perform repetitive operations and record data, resulting in a large investment of manpower.

[0005] Low testing efficiency: Due to the reliance on manual switching and synchronization, the number of products that can be tested in a single parallel run is strictly limited in order to ensure the consistency of test conditions.

[0006] High equipment costs: To achieve simultaneous testing of multiple drive products, multiple expensive process motors are required, which leads to a sharp increase in the overall testing cost.

[0007] Therefore, there is an urgent need in this field for a test system that can achieve automated switching, data acquisition, and reduce device dependence. Summary of the Invention

[0008] The purpose of this invention is to address the problems of high labor and equipment costs, low testing efficiency, and insufficient automation in existing testing methods for drive products, and to provide an automatic switching acquisition system based on a programmable resistor box. Through the application of this invention, the testing process can be automated, reducing reliance on manpower and allowing a single process motor to serve the testing of multiple drive products, thereby significantly reducing overall costs and increasing testing throughput.

[0009] The technical solution to achieve the purpose of this invention is as follows: On the one hand, an automatic switching acquisition system based on a programmable resistor box is provided, the system including a programmable resistor box, a switching system, a power-on protection system and a data acquisition system;

[0010] The programmable resistor box is used to provide multiple programmable and variable resistance loads;

[0011] The switching system is used to receive control commands and automatically switch the output of any product under test to the connection of the programmable resistor box or a shared process motor.

[0012] The power-on protection system is used to ensure the power-on / power-off sequence of the control and power circuits of the product under test, and to provide protection in case of abnormalities.

[0013] The data acquisition system is used to directly acquire voltage and current signals at the output terminal of the product under test, and to perform signal conditioning and conversion.

[0014] Furthermore, the programmable resistor box has a built-in resistance adjustment network, which includes multiple resistors with different or the same resistance values ​​connected in series and a switch connected in parallel with each resistor. The target resistance value is obtained by controlling the closing and opening of the switch.

[0015] Furthermore, the switching system includes a front-end interface connected to the product under test, a bottom interface connected to the programmable resistor box, and a back-end interface connected to the process motor; it also includes a relay array that responds to external control signals and selectively connects corresponding paths according to preset logic.

[0016] Furthermore, the power-on protection system includes a logic interlock unit and a status monitoring unit; the logic interlock unit ensures, through hardware wiring, that the control power relay operates before the power power relay; the status monitoring unit collects the electrical parameters of the control and power circuits in real time, and cuts off the power supply when an abnormality is detected by the programmable logic controller.

[0017] Furthermore, the data acquisition system includes a voltage acquisition module and a current acquisition module, used to acquire the operating voltage and current of the product under test, respectively.

[0018] Furthermore, the data acquisition system also includes a signal conversion module and a data acquisition card. The signal conversion module is used to convert the signals acquired by the voltage acquisition module and the current acquisition module into standard voltage or current signals that can be recognized by the data acquisition card.

[0019] Furthermore, the signal conversion module converts the acquired signal into a standard voltage or current signal that can be recognized by the data acquisition card through a step-down circuit and a transimpedance amplifier circuit.

[0020] Furthermore, the signal conversion module includes:

[0021] The voltage conversion module divides the acquired voltage to 0-9.9V using a high-precision resistor, then isolates it using an isolation module before finally outputting it to the data acquisition card.

[0022] The current conversion module converts the acquired current from voltage to current through a cross-amplifier circuit, converting it to 0-9.9V. The current is then isolated by an isolation module before being output to the data acquisition card.

[0023] Furthermore, the control power and power power of the product under test are provided by a control DC power supply and a power DC power supply, respectively.

[0024] On the other hand, an automatic switching acquisition method is provided, the method comprising the following steps:

[0025] Set the test parameters;

[0026] The industrial control computer in the data acquisition system controls the environmental test chamber to start temperature change and sends instructions to the lower-level computer.

[0027] The power-on protection system sequentially activates the control DC power supply and the power DC power supply according to a safety sequence.

[0028] During the test, the switching system automatically switches the output of the specified product under test between "resistive load" and "motor load" according to the preset program;

[0029] The data acquisition system collects voltage and current data in real time on the side of the product under test, and sends the data to the data acquisition card after conditioning.

[0030] The industrial control computer host collects all data, monitors, records and judges it, and generates a report after the test.

[0031] Compared with the prior art, the significant advantages of this invention are:

[0032] (1) System integration innovation: For the first time, programmable resistors, multi-channel automatic switching, safety protection and high-precision acquisition are integrated into one system to build a complete automated testing system.

[0033] (2) Resource sharing innovation: Through specific switching logic and array design, the time-division multiplexing of a single process motor and programmable resistor box for multiple products under test is realized, which fundamentally reduces the number of motors required for testing.

[0034] (3) Significantly reduce equipment costs: By sharing a single process motor, the number of motors required in multi-channel testing is reduced, which directly reduces fixed asset investment.

[0035] (4) Effectively saves labor costs: The test process is automated, and operators do not need to be on duty for the whole process. They only need to complete the initial connection and parameter setting, which greatly reduces the labor input and labor intensity.

[0036] (5) Comprehensive improvement of test efficiency: Automated switching and data acquisition enable the number of products that can be tested in parallel in a single test to reach the physical limit of the environmental test chamber, and the test speed and data accuracy are both improved by orders of magnitude.

[0037] (6) Enhance system reliability and test accuracy: Hardware-level safety protection mechanisms prevent equipment damage caused by operational errors; near-end acquisition scheme ensures the authenticity and accuracy of test data.

[0038] The present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0039] Figure 1 This is a block diagram of the overall composition of an automatic switching acquisition system based on a programmable resistor box in one embodiment.

[0040] Figure 2 This is a schematic diagram of a single-channel resistor network of a programmable resistor box in one embodiment.

[0041] Figure 3 This is a logic diagram of a power-on protection circuit in one embodiment.

[0042] Figure 4 This is a schematic diagram of the exterior layout in one embodiment.

[0043] Figure 5 This is a hardware connection block diagram in one embodiment.

[0044] Figure 6 This is a schematic diagram of the switching board circuit in one embodiment.

[0045] Figure 7 This is a schematic diagram of the signal conversion module circuit in one embodiment. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0047] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0048] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0049] In one embodiment, combined Figure 1 An automatic switching and acquisition system based on a programmable resistor box is provided. The system includes a programmable resistor box, a switching system, a power-on protection system, and a data acquisition system.

[0050] The programmable resistor box is used to provide multiple programmable and variable resistance loads;

[0051] The switching system is used to receive control commands and automatically switch the output of any product under test to the connection of the programmable resistor box or a shared process motor.

[0052] The power-on protection system is used to ensure the power-on / power-off sequence of the control and power circuits of the product under test, and to provide protection in case of abnormalities.

[0053] The data acquisition system is used to directly acquire voltage and current signals at the output terminal of the product under test, and to perform signal conditioning and conversion.

[0054] Furthermore, in one embodiment, the programmable resistor box has a built-in resistance adjustment network. This network includes multiple resistors of different or the same resistance value connected in series and a switch connected in parallel with each resistor. The target resistance value is achieved by controlling the opening and closing of the switches. The principle is as follows: Figure 2 As shown.

[0055] Here, the target resistance value is determined by controlling the opening and closing of the switch.

[0056] It should be noted that the resistance range and step accuracy of the programmable resistor box can be expanded by adding or removing resistors.

[0057] Furthermore, in one embodiment, the switching system includes a front-end interface connected to the product under test, a bottom interface connected to the programmable resistor box, and a back-end interface connected to the process motor; it also includes a relay array that responds to external control signals and selectively connects corresponding paths according to preset logic (e.g., 01-resistor, 10-motor).

[0058] Preferably, in some embodiments, the switching system includes a programmable switching board and an adapter board. The programmable switching board includes several switching boards, each integrating several sets of relay arrays. These relay arrays correspond one-to-one with multiple products under test (DUTs). Each relay array / each DUT corresponds to multiple lower-level machine input mode controls, including test mode and aging mode. The adapter board is used to integrate and interface all interfaces on the switching boards with external interfaces. The adapter board contains high-quality, locking connectors that can be replaced according to the actual product interface and ensure reliability under repeated plugging / unplugging and vibration conditions.

[0059] The schematic diagram of each relay array is as follows: Figure 6 As shown, it includes a first switching array for switching the output of the product under test to a programmable resistor box, a second switching array and a third switching array for switching the output of the product under test to a motor;

[0060] The first switching array includes a first Schottky diode, a second Schottky diode, and a first relay. The first and second Schottky diodes are connected in parallel. The anodes of the first and second Schottky diodes are connected to pin 8 of the first relay and grounded. The cathodes of the first and second Schottky diodes are connected to pin 1 of the first relay and connected to the aging mode input signal. Pins 2 and 7 of the first relay are connected to the negative and positive terminals of the motor, respectively. Pins 4 and 5 of the first relay are connected to the negative and positive terminals of the resistor, respectively. Pins 3 and 6 of the first relay are connected to the negative and positive output terminals of the product under test, respectively.

[0061] The second switching array includes a third Schottky diode, a fourth Schottky diode, and a second relay. The third and fourth Schottky diodes are connected in parallel. The anodes of the third and fourth Schottky diodes are connected to pin 8 of the second relay and grounded. The cathodes of the third and fourth Schottky diodes are connected to pin 1 of the second relay and connected to the first test mode input signal. Pins 4 and 5 of the second relay are connected to the positive and negative terminals of the motor, respectively. Pins 3 and 6 of the first relay are connected to the positive terminal of the test driver output wiring (positive output terminal of the product under test) and the negative terminal of the test driver output wiring (negative output terminal of the product under test), respectively.

[0062] The third switching array includes a fifth Schottky diode, a sixth Schottky diode, a seventh Schottky diode, an eighth Schottky diode, a third relay, and a fourth relay. The fifth and sixth Schottky diodes are connected in parallel, with their anodes connected to pin 8 of the third relay and grounded. Their cathodes are connected to the second test mode input signal. Pins 4 and 5 of the third relay are connected to points 2 and 1 of the motor potentiometer, respectively, and pins 3 and 6 of the third relay are connected to the second and first potentiometer wiring, respectively. The seventh and eighth Schottky diodes are connected in parallel, with their anodes connected to pin 8 of the fourth relay and grounded. Their cathodes are connected to the second test mode input signal. Pin 5 of the fourth relay is connected to point 3 of the motor potentiometer, and pin 6 of the fourth relay is connected to the third potentiometer wiring.

[0063] By default, the test driver is connected to the motor. When the aging mode input is high, a resistor is connected for aging. When the test mode input is high, a servo motor and a potentiometer are connected for testing.

[0064] Here, the relay replacement position on the internal switching board of the switching system is replaced with an appropriate relay according to the actual switching function, thereby saving space and cost, while maximizing the switching reliability and improving the switching life; its internal adapter board modular design greatly improves the scalability and maintainability of the switching system and shortens the fault location time.

[0065] It should be noted that the control logic unit in the switching system can be either a standalone PLC or integrated on the I / O board of an industrial computer. While the latter may sacrifice some real-time performance, it can further reduce cost and size.

[0066] Furthermore, in one embodiment, the power-on protection system includes a logic interlock unit and a status monitoring unit; the logic interlock unit ensures, through hardware wiring, that the control power relay operates before the power power relay; the status monitoring unit collects electrical parameters of the control and power circuits in real time, and, through a programmable logic controller, cuts off the power supply when an anomaly is detected, as described in the following principle. Figure 3 As shown.

[0067] Furthermore, in one embodiment, the data acquisition system includes a voltage acquisition module and a current acquisition module, used to acquire the operating voltage and current of the product under test, respectively.

[0068] Preferably, in some embodiments, the data acquisition system further includes a signal conversion module and a data acquisition card, wherein the signal conversion module is used to convert the signals acquired by the voltage acquisition module and the current acquisition module into standard voltage or current signals that can be recognized by the data acquisition card.

[0069] Preferably, in some embodiments, the signal conversion module converts the acquired signal into a standard voltage or current signal that can be recognized by the data acquisition card through a step-down circuit and a transimpedance amplifier circuit.

[0070] Preferably, in some embodiments, the signal conversion module includes:

[0071] The voltage conversion module divides the acquired voltage to 0-9.9V using a high-precision resistor, then isolates it using an isolation module before finally outputting it to the data acquisition card.

[0072] Combination Figure 7 The voltage conversion module includes a first resistor R1, a second resistor R2, a third resistor R3, a fourth resistor R4, a first capacitor C1, a second capacitor C2, a third capacitor C3, and a first isolation module;

[0073] The SOUT+ pin of the first isolation module is grounded through the first resistor R1 and the first capacitor C1. The SOUT- pin of the first isolation module is grounded. The SIN- pin is connected to the negative terminal V- of the power or control voltage. A TVS and a second capacitor C2 are connected in parallel between the SIN- pin and the SIN+ pin. One end of the second capacitor C2 is connected to one end of the third resistor R3, and the other end is connected to one end of the second resistor R2. The other end of the second resistor R2 is connected to the other end of the third resistor R3 and one end of the fourth resistor R4. The other end of the fourth resistor R4 is connected to the positive terminal V+ of the power or control voltage. The PIN+ pin of the first isolation module is connected to the 24V voltage and one end of the third capacitor C3. The other end of the third capacitor C3 is connected to the PIN- pin and the data acquisition card.

[0074] The current conversion module converts the acquired current from voltage to current through a cross-amplifier circuit, converting it to 0-9.9V. The current is then isolated by an isolation module before being output to the data acquisition card.

[0075] Combination Figure 7The current conversion module includes a current sensor chip, capacitors C21 (21st), C22 (22nd), C23 (23rd), C24 (24th), and C25 (25th), a first voltage follower U1, a second voltage follower, resistors R5 (5th), R6 (6th), R7 (7th), R8 (8th), and R9 (9th). The two IP+ pins of the current sensor chip are connected to the positive current terminal I+ of the power or control circuit, and the two IP- pins are connected to the positive current terminal I- of the power or control circuit. The VCC pin of the current sensor chip is connected to 5V and grounded through capacitor C21 (21st). The VIOUT pin of the current sensor chip is connected in parallel with capacitor C25 (22nd). 22 and the twenty-fourth capacitor C24 are grounded and connected to the negative input terminal of the second voltage follower through the fifth resistor R5. The fifth resistor R5 and the negative input terminal of the second voltage follower are grounded through the eighth resistor R8 and the twenty-fifth capacitor C25 connected in parallel. The positive input terminal of the second voltage follower is connected to the output terminal of the first voltage follower U1 through the sixth resistor R6. The positive input terminal of the first voltage follower U1 is connected to its output terminal, and the negative input terminal of the first voltage follower U1 is connected to the reference ground. The positive input terminal of the second voltage follower and its output terminal are connected in parallel through the twenty-third capacitor C23 and the seventh resistor R7. The output terminal of the second voltage follower is connected to the data acquisition card through the ninth resistor R9 and grounded through the ninth resistor R9 and a capacitor in sequence.

[0076] Here, the data acquisition system has a large acquisition range and can be used for various product models. Each channel, including the acquisition channel, is isolated and protected against power failure, ensuring the reliability and accuracy of the acquisition system.

[0077] Preferably, in some embodiments, the control power and power power of the product under test are provided by a control DC power supply and a power DC power supply, respectively.

[0078] Preferably, in some embodiments, the overall distribution of the automatic switching acquisition system based on a programmable resistor box is as follows: Figure 4 As shown, the programmable resistor box is located on one side of the environmental test chamber, and the switching system is located inside the programmable resistor box; the control cabinet is located on the other side of the environmental test chamber, and the power-on protection system and data acquisition system are located inside the control cabinet.

[0079] The specific hardware connection principle of the system is as follows: Figure 5As shown, the control cabinet uses PCI bus technology. The data acquisition system includes an industrial PC host, which contains internal expansion slots for the PCI controller. Two 8-channel high-speed independent RS422 bus communication cards and one 4-channel high-speed independent RS422 bus communication card are inserted, forming a 20-channel data acquisition board used to receive data from the signal conversion module. Furthermore, the system retains expansion slots for future equipment upgrades. The industrial PC connects to external devices such as monitors, keyboards, and mice via standard cables.

[0080] Preferably, the environmental test chamber, power DC power supply, control DC power supply and other equipment communicate with the industrial control computer host through the LAN interface, receive control commands issued by the industrial control computer, and upload the collected equipment status parameter information.

[0081] Preferably, the product to be tested is placed in a high and low temperature test chamber and connected to a motor, control power supply, and DC power supply via cables; it communicates with the industrial control computer host via an RS422 bus.

[0082] Preferably, the programmable resistor box can autonomously adjust 20 resistors, allowing them to vary from 1 to 100Ω in 1Ω increments. A motor is integrated on its top for testing the performance of the product under test. The motor is connected to the programmable resistor box control circuit via a connector on the box. By switching the array, the output terminal of the product under test can be freely selected to be connected to either a resistor or a motor.

[0083] Preferably, the industrial control computer host sends commands via the PCI bus, communicates with the environmental test chamber via the LAN interface built into the industrial control computer host, communicates with the product under test via the RS422 bus, and communicates with the power supply and control power supply via the PLC; and selects the product under test connected to the motor.

[0084] It should be noted that the bus type and communication protocol of the industrial control computer host in this invention can be replaced as needed.

[0085] In one embodiment, an automatic switching acquisition method for the automatic switching acquisition system is provided, the method comprising the following steps:

[0086] Set the test parameters (such as temperature profile, resistance change sequence, test channels);

[0087] The industrial control computer in the data acquisition system controls the environmental test chamber to start temperature change and sends instructions to the lower-level computer.

[0088] The power-on protection system sequentially activates the control DC power supply and the power DC power supply according to a safety sequence.

[0089] During the test, the switching system automatically switches the output of the specified product under test between "resistive load" and "motor load" according to the preset program;

[0090] The data acquisition system collects voltage and current data in real time on the side of the product under test, and sends the data to the data acquisition card after conditioning.

[0091] The industrial control computer host collects all data, monitors, records and judges it, and generates a report after the test.

[0092] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention without departing from its spirit and scope should be included within the protection scope of the present invention.

Claims

1. An automatic switching acquisition system based on a programmed resistance box, characterized in that, The system comprises a programmable resistance box, a switching system, a power-on protection system and a data acquisition system. The programmable resistance box is used to provide multiple programmable variable resistance loads. The switching system is used to receive control instructions and automatically switch the output of any product under test to the programmable resistance box or a shared process motor. The power-on protection system is used to ensure the power-on / off timing of the control power and the power power of the product under test and provide protection in abnormal conditions. The data acquisition system is used to directly acquire voltage and current signals at the output of the product under test and perform signal conditioning and conversion.

2. The automatic switch and acquisition system based on the programmed resistance box according to claim 1, characterized in that, The programmable resistance box has a resistance value adjustment network comprising a plurality of series-connected resistors with different or same resistance values and a switch connected in parallel with each resistor, and the target resistance value is obtained by controlling the closing and opening of the switch.

3. The automatic switch and acquisition system based on the programmed resistance box of claim 1, wherein, The switching system comprises a front-end interface connected to the product under test, a bottom interface connected to the programmable resistance box, and a rear-end interface connected to the process motor, and further comprises a relay array that selectively connects corresponding paths according to preset logic in response to external control signals.

4. The automatically switched acquisition system based on a programmed resistance box according to claim 1, characterized in that, The power-on protection system comprises a logic interlocking unit and a state monitoring unit; the logic interlocking unit ensures that the control power relay operates before the power power relay through hardware connection; and the state monitoring unit acquires electrical parameters of the control and power circuits in real time and cuts off the power power supply when an abnormality is detected through the programmable logic controller.

5. The automatically switched acquisition system based on a programmed resistance box according to claim 1, characterized in that, The data acquisition system comprises a voltage acquisition module and a current acquisition module for acquiring the working voltage and current of the product under test, respectively.

6. The automatically switched acquisition system based on a programmed resistance box according to claim 5, characterized in that, The data acquisition system further comprises a signal conversion module and a data acquisition card, and the signal conversion module is used to convert the signals acquired by the voltage acquisition module and the current acquisition module into standard voltage or current signals recognizable by the data acquisition card.

7. The automatically switched acquisition system based on a programmed resistance box according to claim 6, characterized in that, The signal conversion module converts the acquired signals into standard voltage or current signals recognizable by the data acquisition card through a voltage reduction circuit and a transimpedance amplifier circuit.

8. The automatically switched acquisition system based on a programmed resistance box according to claim 7, characterized in that, The signal conversion module comprises: a voltage conversion module that divides the acquired voltage through a high-precision resistor, divides it to 0-9.9V, then isolates it through an isolation module, and finally outputs it to the data acquisition card; a current conversion module that converts the acquired current into voltage-current through a transimpedance amplifier circuit, converts it to 0-9.9V, then isolates it through an isolation module, and finally outputs it to the data acquisition card.

9. The automatically switched acquisition system based on a programmed resistance box according to claim 1, characterized in that, The control power and the power power of the product under test are provided by a control DC power supply and a power DC power supply, respectively.

10. An automatic switching acquisition method based on the system of claims 1 to 9, characterized in that, The method comprises the following steps: setting test parameters; the host computer of the data acquisition system controls the environmental test box to start temperature change and sends instructions to the lower computer; the power-on protection system turns on the control DC power supply and the power DC power supply in sequence according to the safety timing; during the test, the switching system automatically switches the output of the specified product under test between the "resistance load" and the "motor load" according to the preset program; the data acquisition system acquires voltage and current data in real time at the product under test side and sends them to the data acquisition card after conditioning; The industrial computer host computer collects all data, monitors, records and judges, and generates a report after the test is completed.

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