Method for testing action power of intermediate relay

Abstract

The invention discloses an action power test method for an intermediate relay, which relates to the technical field of relay inspection, and comprises the following steps: collecting loop signals through a test port and an action feedback interface, and automatically judging the wiring compliance; receiving a direct current target test mode, an alternating current target test mode and an intermediate relay rated parameter instruction; according to the target test mode, the DC / AC switching module is controlled to switch, the function change-over switch is synchronously driven, the corresponding input and output switch is closed, the adjustable power supply is started, and AC / DC power supply interlocking control is executed; starting a voltage automatic adjusting strategy based on the rated parameters, gradually adjusting the output voltage and collecting voltage signals in real time; continuously collecting on-off signals, stopping voltage regulation after judging that the relay acts, and locking voltage and power signals at the moment of action; and calling an industrial standard parameter library for comparison, generating a comprehensive judgment result, and closing a corresponding power supply to complete the test. According to the method, automation and precision of the operation power test of the intermediate relay are realized, and the test efficiency and the result reliability are improved.

Description

Technical Field

[0001] This invention relates to the field of relay testing technology, and in particular to a method for testing the operating power of an intermediate relay. Background Technology

[0002] Intermediate relays are core components in power systems, enabling signal conversion, control command transmission, and logical judgment. They are widely used in the control circuits of power equipment such as substations and distribution systems, and their operating performance directly determines the operational stability and reliability of the power system. Therefore, accurate testing of key performance parameters such as the operating power of AC / DC intermediate relays is an important prerequisite for ensuring the safe and stable operation of the power system.

[0003] In existing technologies, the testing of the operating power of AC / DC intermediate relays suffers from technical problems such as poor test mode adaptability, asynchronous signal acquisition and action determination, and inability to effectively distinguish signal differences between AC and DC modes. These problems result in test results that cannot accurately reflect the actual operating performance of the relay. Furthermore, during signal acquisition, the determination of the operating state and the locking of parameters lack stable and precise logic control, which can easily lead to mismatches between test parameters and actual operating states. This affects the accuracy of the relay operating performance evaluation and fails to meet the high precision and high reliability requirements of power systems for relay testing. Summary of the Invention

[0004] To address the technical problems existing in the prior art, the present invention provides a method for testing the operating power of an intermediate relay.

[0005] The technical solution adopted in this invention is: a method for testing the operating power of an intermediate relay, comprising the following steps:

[0006] Step 1: Collect circuit signals through the test port and action feedback interface, and automatically determine the compliance of the wiring between the intermediate relay coil and the test port, and between the normally open contact of the intermediate relay and the action feedback interface;

[0007] Step 2: Receive the target test mode and intermediate relay rated parameter instructions, wherein the target test mode includes DC mode and AC mode;

[0008] Step 3: According to the target test mode, control the DC / AC switching module to switch to the corresponding test mode, switch the synchronous drive function switch to the position matching the target test mode, control the input and output switches of the corresponding mode to close, start the corresponding type of adjustable power supply, and execute AC / DC power supply interlock control at the same time.

[0009] Step 4: Based on the rated parameters of the intermediate relay, start the automatic voltage adjustment strategy, drive the voltage adjustment module to gradually adjust the output voltage, and collect and acquire the real-time voltage signal in real time;

[0010] Step 5: Continuously collect the on / off signal of the action feedback interface. When the on / off signal is detected to switch from the off state to the closed state, it is determined that the intermediate relay has completed the action, and the command is immediately output to stop the voltage regulation and lock the current real-time voltage signal and the corresponding power signal.

[0011] Step 6: Call the preset industry standard parameter library, extract the standard power threshold range and standard voltage threshold range corresponding to the rated parameters of the intermediate relay, compare the locked power signal with the standard power threshold range and the locked real-time voltage signal with the standard voltage threshold range respectively, and generate a comprehensive judgment result of the intermediate relay action parameters.

[0012] Step 7: Output the comprehensive judgment result, the locked power signal and the real-time voltage signal, and control the power module to shut down the corresponding type of adjustable power supply to complete the test.

[0013] The beneficial effects of this invention are: by dynamically monitoring and locking key parameters during signal acquisition, it is possible to effectively ensure that the acquired signal is consistent with the actual operating state of the relay, avoid the distortion of test results caused by signal acquisition deviation, and thus improve the accuracy of relay operation performance evaluation. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the method flow according to an embodiment of the present invention. Detailed Implementation

[0015] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0016] This embodiment provides a method for testing the operating power of AC / DC intermediate relays, which solves the technical problems in existing AC / DC intermediate relay operating power tests, such as asynchronous signal acquisition and action determination, and the inability of test results to accurately reflect the actual operating performance of the relay. Figure 1 As shown, it includes the following steps:

[0017] Step 1: Collect circuit signals through the test port and action feedback interface, and automatically determine the compliance of the wiring between the intermediate relay coil and the test port, and between the normally open contact of the intermediate relay and the action feedback interface;

[0018] It should be noted that the test port is used to connect the intermediate relay coil and collect relevant electrical signals from the coil circuit. The stability of its wiring to the intermediate relay coil directly affects the accuracy of signal acquisition. The action feedback interface is used to connect the normally open contacts of the intermediate relay and collect the on / off status signals of the contacts, providing feedback on the operating status of the intermediate relay. The circuit signal refers to the electrical signal in the coil circuit where the test port is located and the contact circuit where the action feedback interface is located, which reflects the wiring status, including the impedance signal of the coil circuit and the on / off status signal of the contact circuit. Wiring compliance refers to whether the wiring between the intermediate relay coil and the test port, and between the normally open contacts of the intermediate relay and the action feedback interface, is correct, whether the contact is good, and whether it meets the basic requirements for subsequent signal acquisition and testing.

[0019] Given that existing testing methods rely on manual inspection of wiring status, which is inefficient and prone to misjudgment due to human error, leading to abnormalities in subsequent testing processes; incorrect wiring or poor contact can cause signal distortion, resulting in deviations in subsequent action determination and parameter locking, failing to reflect the actual operating performance of the intermediate relay; and if wiring abnormalities are not promptly investigated, the electrical signal output by the testing equipment may not be transmitted normally to the intermediate relay, causing test failure. To solve these technical problems, in the specific implementation process, circuit signals are collected through the test port and action feedback interface to automatically determine the compliance of the wiring between the intermediate relay coil and the test port, and between the normally open contact of the intermediate relay and the action feedback interface.

[0020] Step 1.1: Acquire the impedance signal of the coil circuit through the test port, and acquire the on / off status signal of the contact circuit through the action feedback interface; during the acquisition process, maintain the stability of the acquisition circuit and avoid signal distortion caused by interference in the acquisition link.

[0021] Step 1.2: Compare the impedance signal of the coil circuit with the preset impedance threshold range, and compare the on / off state signal of the contact circuit with the preset initial state; whereby the preset impedance threshold range is preset according to the standard impedance range of different models of intermediate relay coils, and is adapted to the coil characteristics of most commonly used AC and DC intermediate relays; the preset initial state refers to the open state that its normally open contacts should be in when the intermediate relay is not activated, that is, the on / off state signal of the contact circuit is the open signal.

[0022] Step 1.3: When the impedance signal is within the preset impedance threshold range and the contact circuit on / off status signal meets the preset initial state, the wiring is deemed compliant and the test process proceeds to Step 2; otherwise, the wiring is deemed abnormal and an alarm signal is output, and the test process is paused until the staff has investigated and corrected the wiring problem, and then Step 1 is executed again.

[0023] For example, for a certain model of AC / DC intermediate relay, the standard impedance range of its coil is 100Ω-150Ω, and the preset impedance threshold range is set to 95Ω-155Ω, leaving a reasonable error range; the preset initial state is that the contact circuit on / off state signal is an open signal. The coil circuit impedance signal acquired through the test port is 120Ω, which is within the preset impedance threshold range; the contact circuit on / off state signal acquired through the action feedback interface is an open signal, which conforms to the preset initial state. Therefore, the wiring is deemed compliant, and the subsequent test steps are initiated. If the acquired coil circuit impedance signal is 80Ω, which exceeds the preset impedance threshold range, the wiring is deemed abnormal, and an alarm signal is output, prompting the staff to check whether the wiring between the coil and the test port is loose or reversed; if the acquired contact circuit on / off state signal is a closed signal (not conforming to the preset initial state), the wiring is deemed abnormal, prompting the staff to check whether the wiring between the normally open contact and the action feedback interface is short-circuited.

[0024] This step automates the determination of wiring compliance, eliminating the need for manual inspection of each wiring connection. This significantly reduces human intervention, improves the efficiency and accuracy of wiring determination, and avoids subsequent test anomalies caused by human error. By proactively identifying wiring errors and poor contact issues, it effectively prevents signal distortion caused by wiring problems, providing an accurate signal foundation for subsequent action determination and parameter locking. This also prevents test failures caused by the test equipment's inability to transmit signals normally, improving the smoothness of the test process. Furthermore, it avoids the risk of equipment damage caused by wiring errors in advance, ensuring the safety of the test equipment and intermediate relays, and reducing safety hazards during the test process.

[0025] Step 2: Receive the target test mode and intermediate relay rated parameter instructions, wherein the target test mode includes DC mode and AC mode.

[0026] It should be noted that the target test mode refers to two preset test modes based on the actual operating mode of the intermediate relay: DC mode and AC mode. The DC mode is used to test intermediate relays operating in a DC circuit, and the AC mode is used to test intermediate relays operating in an AC circuit. The intermediate relay rated parameter command refers to the command containing core parameters such as the rated voltage and rated current of the intermediate relay. These parameters are important bases for subsequent voltage adjustment and standard parameter comparison. Command reception can be achieved through the human-machine interaction module or external control equipment to ensure the accuracy and timeliness of command transmission.

[0027] Considering that existing testing methods have fixed test modes and can only test intermediate relays in a single operating mode (DC or AC), they cannot adapt to AC / DC intermediate relays with different operating modes, resulting in poor versatility. Furthermore, the lack of received intermediate relay rated parameters means that subsequent voltage adjustment and standard parameter comparison lack a basis, leading to a mismatch between voltage adjustment and the actual characteristics of the relay, and a discrepancy between the judgment standard and the relay's rated parameters. Consequently, the test results cannot reflect the actual operating performance of the relay. Additionally, errors such as formatting errors and missing parameters may occur during command transmission. If these are not verified in a timely manner, they can cause abnormalities in subsequent test procedures, such as mode switching errors and voltage adjustment deviations. To address these technical issues, the following measures are taken during the specific implementation process:

[0028] The test equipment receives user input or external control device commands regarding the target test mode and intermediate relay rated parameters via its human-machine interface module or communication interface. It then parses the received commands to extract the target test mode and intermediate relay rated parameters, such as rated voltage and rated current. The parsed commands are verified to ensure correct format and reasonable parameters. If a command is abnormal, such as an unclear mode, missing parameters, or parameters exceeding a reasonable range, a prompt signal is output, and the system waits for a new command. If the command is normal, the parsed parameters are transmitted to the subsequent control module, providing data support for mode switching in step 3 and voltage adjustment in step 4.

[0029] For example, the user inputs the target test mode as DC mode through the human-machine interface module, and simultaneously inputs the rated parameters of the intermediate relay as rated voltage 220V and rated current 0.5A. The testing equipment parses and verifies the received instructions. After confirming that the instructions are normal, it transmits the DC mode instruction and rated parameters to the control module. The control module then prepares for subsequent mode switching and voltage adjustment operations based on these parameters. If the user's input target test mode is not explicitly stated as DC or AC, the testing equipment outputs a prompt signal to remind the user to input the correct test mode. If the user inputs a rated voltage of 500V, which exceeds the reasonable rated voltage range of commonly used intermediate relays, the testing equipment outputs a prompt signal to remind the user to check the parameters and re-enter them.

[0030] This step can flexibly receive commands for both DC and AC target test modes, enabling the test method to adapt to AC / DC intermediate relays with different operating modes, significantly improving the versatility of the test method. Secondly, it receives the rated parameters of the intermediate relay, providing an accurate basis for subsequent voltage adjustment and standard parameter comparison, ensuring that the subsequent test process is accurately adapted to the actual characteristics of the intermediate relay, laying the foundation for the accuracy of the test results. In addition, this step parses and verifies the commands, promptly identifying problems such as command format errors, missing parameters, and abnormal parameters, avoiding deviations or interruptions in the subsequent test process due to command anomalies, and ensuring the smoothness of the test process.

[0031] Step 3: According to the target test mode, control the DC / AC switching module to switch to the corresponding test mode, switch the synchronous drive function switch to the position matching the target test mode, control the input and output switches of the corresponding mode to close, start the corresponding type of adjustable power supply, and execute AC / DC power supply interlock control at the same time.

[0032] It should be noted that the DC / AC switching module is used to switch between DC and AC test modes, and the type of output signal, such as DC or AC, can be adjusted according to control commands. The function switch is used in conjunction with the DC / AC switching module to switch the wiring positions of the test circuit, ensuring that the test circuit matches the test mode. The input / output switches are divided into DC input / output switches and AC input / output switches, which are used to control the on / off connection of the DC adjustable power supply and the AC adjustable power supply to the test circuit, respectively. The adjustable power supply includes both DC and AC adjustable power supplies, and the output voltage can be adjusted according to control commands to provide the working voltage required for the intermediate relay test. The AC / DC power supply interlock control refers to the logic control to ensure that the DC adjustable power supply and the AC adjustable power supply do not start or connect to the test circuit at the same time, avoiding safety hazards such as short circuits and equipment damage caused by the simultaneous operation of the two power supplies.

[0033] Considering that existing testing methods cannot achieve AC / DC test mode switching, or that mode switching and circuit range switching are not synchronized, resulting in a mismatch between the test signal type and the test circuit, the intermediate relay cannot be triggered to operate normally, leading to test failure; furthermore, the lack of interlocking control between AC and DC power supplies means that both power supplies may start simultaneously and be connected to the test circuit at the same time, causing a short circuit, damaging the test equipment and intermediate relays, posing a serious safety hazard; if the initial state of the input / output switches is not checked before power supply startup, and the switches are in the closed state, the power supply may directly output a high-voltage signal after startup, damaging the equipment or relays; failure to start the corresponding type of adjustable power supply in a timely manner after mode switching, or starting the wrong type of power supply, will prevent the test from being carried out normally; the lack of status monitoring during mode switching means that abnormal switching, such as module failure or incomplete range switching, cannot be detected in time, leading to distortion of subsequent test signals. To solve the above technical problems, the specific implementation process includes the following:

[0034] Step 3.1: Detect the current status of the DC input / output switch and the AC input / output switch. After confirming that both switches are in the open state, perform the subsequent mode switching operation to avoid safety hazards caused by abnormal initial state. If either switch is detected to be in the closed state, first output a command to control the switch to open, and then perform the subsequent operation.

[0035] Step 3.2: When the target test mode is DC mode, control the DC / AC switching module to switch to DC test mode, and switch the synchronous drive function switch to DC test position to ensure that the test circuit is compatible with DC signal; then, control the DC input / output switch to close, start the DC adjustable power supply, and lock the AC input / output switch to keep it in the open state to prevent the AC adjustable power supply from starting, thus completing the DC mode switching and power supply startup.

[0036] Step 3.3: When the target test mode is AC mode, control the DC / AC switching module to switch to AC test mode, and switch the synchronous drive function switch to AC test position to ensure that the test circuit is compatible with AC signal; then, control the AC input / output switch to close, start the AC adjustable power supply, and lock the DC input / output switch to keep it in the open state to prevent the DC adjustable power supply from starting, thus completing the AC mode switching and power supply startup.

[0037] Throughout the process, the status of AC / DC input / output switches, power-on status, and mode switching status are continuously monitored. If any abnormality occurs, such as the AC switch closing unexpectedly, mode switching failing, or power-on failure, an immediate command is output to shut down all power supplies and switches, stop the test, and output an alarm signal.

[0038] For example, when the target test mode is DC mode, the DC / AC switching module switches to DC mode, the function switch simultaneously switches to the DC position, controls the DC input / output switch to close, and starts the DC adjustable power supply. At this time, the AC input / output switch is locked and cannot be closed manually or automatically. If an operator mistakenly attempts to close the AC input / output switch, the switch cannot be closed due to the interlock control, and the test equipment outputs an alarm. When the target test mode switches to AC mode, the DC adjustable power supply is first turned off, the DC input / output switch is disconnected, then the DC / AC switching module switches to AC mode, the function switch switches to the AC position, the AC input / output switch is closed, the AC adjustable power supply is started, and the DC input / output switch is locked simultaneously. If the function switch is not switched to the corresponding position after the mode switch is detected, the power supply is immediately turned off, an alarm signal is output, and the test is paused.

[0039] This step enables precise and synchronous switching between DC and AC modes, ensuring complete matching of test modes, test circuits, and power supply types. This avoids test anomalies or failures caused by mode mismatches and guarantees the normal operation of intermediate relays. The execution of AC / DC power supply interlock control effectively avoids the risk of short circuits caused by simultaneous operation of the two power supplies, ensuring the safety of the test equipment and intermediate relays and improving the safety of the test process. Detecting the initial state of the switch before power-on prevents false high-voltage signal output caused by initial switch closure, further mitigating the risk of equipment damage. Real-time status monitoring during mode switching and power-on can promptly detect switching anomalies, power supply anomalies, and other issues, preventing signal distortion or test failures caused by anomalies in subsequent tests and improving the reliability of the test process.

[0040] Step 4: Based on the rated parameters of the intermediate relay, start the automatic voltage adjustment strategy, drive the voltage adjustment module to gradually adjust the output voltage, and collect and acquire the real-time voltage signal in real time; during the automatic voltage adjustment process, monitor the rate of change of the output voltage in real time, and when the rate of change exceeds the preset rate threshold, automatically adjust the driving parameters of the voltage adjustment module.

[0041] It should be noted that the automatic voltage regulation strategy refers to a logic scheme based on the preset rated parameters of the intermediate relay, used to control the voltage regulation module to gradually adjust the output voltage. This includes parameters such as the initial voltage regulation value, target adjustment range, and adjustment step size. The voltage regulation module receives control commands and adjusts the output voltage of the adjustable power supply, enabling continuous and precise adjustment. The real-time voltage signal refers to the actual value of the adjustable power supply output voltage acquired in real time during the voltage regulation process, used to provide feedback on the voltage regulation effect and subsequent parameter locking. The output voltage change rate refers to the amount of change in output voltage per unit time, reflecting the speed of voltage regulation. The preset rate threshold is preset based on the operating characteristics of the intermediate relay, used to limit the maximum change rate of voltage regulation and avoid voltage fluctuations caused by excessively rapid adjustment. The drive parameters are parameters used to control the operating state of the voltage regulation module; the voltage regulation rate can be changed by adjusting the drive parameters.

[0042] Considering that existing testing methods rely on manual operation for voltage adjustment, resulting in low accuracy and efficiency, and inconsistent adjustment methods among different operators leading to poor repeatability of test results; furthermore, the lack of consideration for intermediate relay rated parameters, such as starting value, target range, and step size, may result in situations where the starting voltage is too high, directly triggering the relay, or too low, failing to trigger the relay, or the target range not covering the critical operating voltage, making it impossible to lock in the true operating parameters; the absence of real-time voltage signal acquisition during voltage adjustment prevents feedback on the adjustment effect, potentially leading to voltage adjustment exceeding the target range and damaging the intermediate relay; and the lack of control over the voltage adjustment rate means that excessively fast adjustment causes output voltage fluctuations, affecting the accuracy of signal acquisition, while excessively slow adjustment significantly reduces testing efficiency. To address these technical issues, the specific implementation process includes the following:

[0043] Step 4.1: Determine the starting value and target adjustment range of the voltage regulation based on the rated parameters of the intermediate relay.

[0044] The initial value is usually set to 50%-60% of the rated voltage of the intermediate relay to ensure that the initial voltage is lower than the critical operating voltage of the intermediate relay and to avoid triggering the action directly due to an excessively high initial voltage. The target adjustment range is set to 50%-110% of the rated voltage of the intermediate relay to cover the possible critical operating voltage range of the intermediate relay and to ensure that the intermediate relay can be triggered.

[0045] Step 4.2: The drive voltage regulation module starts from the initial value and gradually increases the output voltage according to the preset step size; the preset step size is determined according to the rated parameters and operating characteristics of the intermediate relay to ensure the accuracy and efficiency of voltage regulation.

[0046] Step 4.3: During the voltage regulation process, the voltage signal is acquired in real time to ensure that the voltage signal changes continuously within the target regulation range; at the same time, the rate of change of the output voltage is calculated in real time and compared with the preset rate threshold.

[0047] Step 4.4: When the rate of change of the output voltage is detected to exceed the preset rate threshold, the driving parameters of the voltage regulation module are automatically adjusted to reduce the rate of voltage regulation, so that the rate of change of the output voltage returns to the preset rate threshold range; if the rate of change is lower than the preset rate threshold, the driving parameters can be adjusted appropriately to increase the regulation rate and balance regulation accuracy and efficiency.

[0048] For example, for an intermediate relay with a rated voltage of 220V, the initial voltage regulation value is set at 110V, the target regulation range is 110V-242V, and the preset step size is 5V; the preset rate threshold is 10V / s, meaning the voltage change per unit time should not exceed 10V. The voltage regulation module starts at 110V and gradually increases the output voltage in 5V steps, while simultaneously acquiring real-time voltage signals. If the voltage change rate is detected to reach 12V / s at a certain moment, exceeding the preset rate threshold, the driving parameters of the voltage regulation module are automatically adjusted, changing the adjustment step size to 3V to reduce the voltage change rate to 6V / s, ensuring a smooth output voltage change. If the voltage change rate drops to 5V / s, below the preset rate threshold, the adjustment step size is adjusted back to 5V to improve testing efficiency. If the real-time acquired voltage signal reaches 242V, the upper limit of the target range, and the relay still does not activate, voltage regulation is immediately stopped, an alarm signal is output, and the operator is prompted to check the relay status.

[0049] This step enables automatic adjustment of the output voltage without manual intervention, significantly improving the efficiency and accuracy of voltage regulation. It also avoids individual differences caused by manual adjustment and enhances the repeatability of test results. By combining the rated parameters of the intermediate relay to determine the adjustment parameters, it ensures that the starting voltage, target range, and step size are compatible with the actual characteristics of the relay. This avoids test anomalies caused by excessively high / low starting voltage or the target range not covering the critical operating voltage, and ensures that the relay can be triggered and the true parameters are locked.

[0050] By acquiring voltage signals in real time, the adjustment effect can be fed back in a timely manner, avoiding relay damage caused by voltage exceeding the target range. At the same time, it provides real-time voltage data for subsequent parameter locking. By monitoring the voltage change rate in real time and automatically adjusting the drive parameters, the output voltage changes smoothly, reducing the impact of voltage fluctuations on signal acquisition and action determination, while balancing test accuracy and efficiency.

[0051] Step 5: Continuously collect the on / off signal of the action feedback interface. When the on / off signal is detected to switch from the off state to the closed state, it is determined that the intermediate relay has completed the action. Immediately output a command to stop voltage regulation and lock the current real-time voltage signal and the corresponding power signal.

[0052] It should be noted that the preset sampling frequency refers to the frequency at which the processor collects the on / off signals of the action feedback interface. It is preset according to the mechanical action characteristics of the intermediate relay to ensure that the switching state of the on / off signal can be accurately captured. The on / off signal refers to the electrical signal collected by the action feedback interface that reflects the state of the normally open contact of the intermediate relay. When the contact is open, it is an open signal, and when the contact is closed, it is a closed signal.

[0053] The power acquisition module is used to acquire the output power of the adjustable power supply and obtain the power signal. Its acquisition frequency is synchronized with the voltage signal acquisition frequency to ensure the correspondence between the power signal and the voltage signal. The current power signal refers to the actual value of the output power of the adjustable power supply acquired by the power acquisition module at the moment the intermediate relay completes its action. It corresponds to the real-time voltage signal and is the core parameter reflecting the action performance of the intermediate relay. Parameter locking refers to fixing and storing the real-time voltage signal and power signal at the moment the intermediate relay operates to avoid parameter distortion caused by subsequent signal changes.

[0054] Given that existing testing methods rely on manual observation for action determination, resulting in low efficiency, high false positive rates, and an inability to capture the instantaneous action of the relay, relying solely on a single on / off signal switch for action determination, they are susceptible to transient electromagnetic interference, mistakenly identifying false closed signals as action signals, leading to distorted parameter locking. The mechanical rebound during relay operation causes the on / off signal to switch multiple times in a short period. If the processor's sampling frequency coincides with the rebound period, the locked action parameters are unstable values ​​during the rebound process, failing to reflect the relay's true operational performance. To address these technical issues, in the specific implementation process, the on / off signal of the action feedback interface is continuously acquired. When the on / off signal is detected to switch from an open state to a closed state, the intermediate relay is determined to have completed its action, and a command is immediately output to stop voltage regulation, locking the current real-time voltage signal and corresponding power signal, including the following:

[0055] Step 5.1: Continuously acquire the on / off signal of the action feedback interface at a preset sampling frequency. During the acquisition process, maintain the stability of the sampling link to avoid electromagnetic interference causing distortion of the on / off signal. At the same time, synchronously acquire the real-time voltage signal and power signal to ensure the synchronization of the three acquisition times.

[0056] Step 5.2: Perform real-time analysis on the acquired on / off signals and monitor the state changes of the on / off signals; when the on / off signal is in a closed state after a preset number of consecutive acquisitions, eliminate single signal interference, such as false closed signals caused by instantaneous electromagnetic interference, and confirm that the intermediate relay has completed its action; the preset number of acquisitions is determined based on the preset sampling frequency and the mechanical action characteristics of the intermediate relay to ensure that interference can be effectively eliminated without affecting the timeliness of the judgment.

[0057] Step 5.3: Upon confirming that the intermediate relay has completed its operation, immediately output a stop command to the voltage regulation module to control the voltage regulation module to stop voltage regulation and prevent the voltage from continuing to rise and causing parameter changes; at the same time, lock the current power signal through the power acquisition module and synchronously lock the real-time voltage signal at the corresponding moment, store the two parameters in the designated storage unit, and complete the parameter locking. During the locking process, it is forbidden to modify the parameters.

[0058] For example, the preset sampling frequency is 100Hz, meaning 100 on / off signals are collected per second, with a preset count of 3. The processor continuously collects the on / off signals of the action feedback interface at a frequency of 100Hz, while simultaneously collecting real-time voltage and power signals. When the on / off signal is found to be closed for 3 consecutive times (within 30ms), false signals caused by momentary electromagnetic interference are eliminated, confirming that the intermediate relay has completed its action. A stop command is immediately output to the voltage regulation module to stop voltage regulation, and the current real-time voltage signal (e.g., 154V) and the corresponding power signal (e.g., 5.2W) are locked and stored in the storage unit. Once locked, these parameters cannot be modified and are used for subsequent comparison and judgment. If the on / off signal returns to the open state after only one closed signal is collected, it is determined to be a false interference signal, the action is not confirmed, and signal collection continues.

[0059] This step enables automatic determination of the intermediate relay's operating state without manual observation, significantly improving the efficiency and accuracy of the action determination and avoiding misjudgments caused by manual observation. By continuously collecting the closing signal a preset number of times, false signals caused by instantaneous electromagnetic interference are effectively eliminated, preventing misjudgments of the operating state and ensuring the reliability of the action determination.

[0060] To address the issue of multiple switching of on / off signals within a short period due to relay mechanical rebound, a logic that continuously samples the closed signal a preset number of times filters out unstable switching signals during the rebound process. This ensures that the locked parameter is the true stable value at the moment of relay action, rather than the fluctuating value during the rebound process. This solves the technical problem of locking parameters as unstable values ​​when the sampling frequency coincides with the rebound period. Voltage regulation is stopped immediately after action determination to avoid parameter distortion caused by continued voltage increase, ensuring that the locked parameter is the true value at the moment of relay action. Simultaneous acquisition and locking of voltage and power signals ensure the correspondence of the two core parameters, enabling a comprehensive and accurate reflection of the intermediate relay's operating performance.

[0061] Step 6: Call the preset industry standard parameter library, extract the standard power threshold range and standard voltage threshold range corresponding to the rated parameters of the intermediate relay, compare the locked power signal with the standard power threshold range and the locked real-time voltage signal with the standard voltage threshold range respectively, and generate a comprehensive judgment result of the intermediate relay action parameters.

[0062] It should be noted that the preset industry standard parameter library refers to a database storing the threshold ranges of operating parameters for AC / DC intermediate relays of different models and rated parameters in relevant power industry standards. The standard parameters in the database can be updated according to the updates of industry standards. The standard power threshold range refers to the acceptable range of operating power for intermediate relays with corresponding rated parameters as specified in industry standards. The standard voltage threshold range refers to the acceptable range of operating voltage for intermediate relays with corresponding rated parameters as specified in industry standards. The comprehensive judgment result refers to the judgment conclusion generated by combining the locked power signal and voltage signal with the corresponding standard threshold range, reflecting whether the operating performance of the intermediate relay is qualified, including qualified and unqualified results.

[0063] Given that existing testing methods rely solely on a single parameter for judgment, the results are incomplete and fail to fully reflect the operational performance of intermediate relays. For example, if the power rating is acceptable but the voltage rating is unacceptable, the relay's actual operational performance still indicates a problem. Furthermore, the lack of labeling of unacceptable parameters and the difference exceeding thresholds hinders staff from quickly diagnosing performance issues, resulting in low post-testing maintenance efficiency. To address these technical problems, the comprehensive judgment result of intermediate relay operational parameters generated during implementation includes the following:

[0064] Step 6.1: From the preset industry standard parameter library, retrieve the corresponding standard power threshold range and standard voltage threshold range based on the intermediate relay rated parameters received in Step 2; during the retrieval process, confirm that the retrieved standard parameters are completely matched with the intermediate relay rated parameters and target test mode to avoid retrieval errors.

[0065] Step 6.2: Compare the power signal locked in Step 5 with the retrieved standard power threshold range, and at the same time compare the real-time voltage signal locked in Step 5 with the retrieved standard voltage threshold range; during the comparison process, accurately calculate the difference between the locked parameters and the standard threshold range, and record the comparison results.

[0066] Step 6.3: Based on the comparison results of the two parameters, generate a comprehensive judgment result; when the power signal is within the standard power threshold range and the real-time voltage signal is within the standard voltage threshold range, a qualified result is generated; when either the power signal exceeds the standard power threshold range or the real-time voltage signal exceeds the standard voltage threshold range, or both exist simultaneously, an unqualified result is generated, and the parameter type and specific difference exceeding the threshold are marked to facilitate the staff in troubleshooting the performance problems of the intermediate relay.

[0067] For example, the intermediate relay rated parameters received in step 2 are rated voltage 220V and rated current 0.5A. The corresponding standard power threshold range is 5W-7W and the standard voltage threshold range is 121V-154V, which are retrieved from the industry standard parameter library. The power signal locked in step 5 is 5.5W and the real-time voltage signal is 143V. The 5.5W is compared with the 5W-7W range to confirm that it is within the standard range. The 143V is compared with the 121V-154V range to confirm that it is within the standard range. Therefore, a qualified result is generated.

[0068] If the locked power signal is 4.8W, exceeding the lower limit of the standard power threshold by 0.2W, and the real-time voltage signal is 143V, which is within the standard range, then an unqualified result is generated, and it is noted that the power signal exceeds the lower limit of the threshold by 0.2W. If the locked power signal is 7.3W, exceeding the upper limit by 0.3W, and the voltage signal is 160V, exceeding the upper limit by 6V, then an unqualified result is generated, and it is noted that the power signal exceeds the upper limit by 0.3W and the voltage signal exceeds the upper limit by 6V.

[0069] This step retrieves industry standard parameters that match the rated parameters and test mode of the intermediate relay, ensuring that the judgment criteria meet the requirements of the power industry. This allows the judgment results to accurately reflect the actual operating performance of the intermediate relay and can be directly used for evaluating relay operating performance. By combining the two core parameters of power and voltage for comprehensive comparison, the one-sidedness of judgment based on a single parameter is avoided, making the judgment results more comprehensive and accurate. By marking the types of parameters that exceed the threshold and the specific differences, it is easy for staff to quickly locate the performance problems of the intermediate relay, such as insufficient power or excessive operating voltage, which greatly improves the efficiency of post-test maintenance.

[0070] Step 7: Output the comprehensive judgment result, the locked power signal and the real-time voltage signal, and control the power module to shut down the corresponding type of adjustable power supply to complete the test.

[0071] It should be noted that the display module is used to intuitively display test-related information, showing users information such as comprehensive judgment results and locked parameters for easy viewing; the storage module is used to store test data, ensuring its traceability; test data refers to various related data generated during the test, including target test mode, intermediate relay rated parameters, locked power signals, real-time voltage signals, comprehensive judgment results, and test timestamps; the timestamp records the time information of test completion, used to distinguish test data from different batches and times, facilitating subsequent traceability and management; the communication module is used to enable data transmission between the test equipment and external devices; the test report is a document generated based on the test data, reflecting the intermediate relay test status, including core information such as test parameters, comparison results, and comprehensive judgment conclusions; the power supply module is used to control the start and stop of the adjustable power supply, and can shut down the corresponding type of adjustable power supply according to control commands.

[0072] In the specific implementation process, the output of the comprehensive judgment result, the locked power signal, and the real-time voltage signal includes the following:

[0073] Step 7.1: The control display module outputs the comprehensive judgment result, the locked power signal and the real-time voltage signal. It can also output the target test mode and the rated parameters of the intermediate relay, so that users can intuitively view the test situation and test results and quickly understand the operating performance of the intermediate relay.

[0074] Step 7.2: Control the storage module to store test data. The test data includes the target test mode, rated parameters, locked power signal, real-time voltage signal, pass / fail judgment result and test timestamp. During the storage process, ensure the integrity and accuracy of the test data, avoid data loss or distortion, and classify and store the test data of different relays for easy subsequent query and traceability.

[0075] Step 7.3: Based on the preset output instructions, selectively generate test reports. The test reports integrate various core data and comparison results from the testing process to form standardized documents. The test reports and test data are transmitted to external devices through the communication module to facilitate subsequent data analysis and equipment maintenance. If no test report is generated or data is transmitted, the storage operation is completed directly.

[0076] Step 7.4: After the output and storage operations are completed, control the power supply module to shut down the corresponding type of adjustable power supply, i.e., the DC adjustable power supply or AC adjustable power supply started in step 3. At the same time, control the input and output switches of the corresponding mode to disconnect, stop the test process, ensure the safety of the test equipment and intermediate relays, and avoid energy waste and equipment damage caused by long-term power supply.

[0077] For example, after the test is completed, the display module shows the target test mode as DC mode, the intermediate relay rated voltage as 220V, the locking power as 5.5W, the locking voltage as 143V, and the overall judgment result as qualified. The storage module stores all the above information and adds a test timestamp, such as the test completion time. It also associates this data with the relay's number for easy retrieval later. According to the preset output command, a test report is generated, containing test parameters, signal acquisition status, parameter comparison results, and an overall judgment conclusion. The test report and test data are transmitted to the external operation and maintenance management system via the communication module. Subsequently, the adjustable DC power supply is turned off, and the DC input / output switch is disconnected, completing the entire test process. If data transmission is not required, only the display and storage operations are completed before turning off the power and disconnecting the switch; if a test report is not required, the data is directly stored and the power is turned off.

[0078] This step uses a display module to intuitively show test results and core parameters, making it easy for staff to quickly view them and improving the human-computer interaction experience and operational efficiency. Complete storage of test data with timestamps ensures data traceability, facilitating subsequent analysis, troubleshooting, archiving, and handover of test results. Categorized storage also enhances the standardization of data management. After testing, the adjustable power supply is promptly turned off and the switch disconnected, avoiding energy waste caused by prolonged power-on and mitigating the risks of damage and operational hazards associated with prolonged equipment operation, thus ensuring the safety of the test equipment and intermediate relays.

[0079] The embodiments described above are merely illustrative of specific implementations of the present invention, and while the descriptions are detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A method for testing the operating power of an intermediate relay, characterized in that, Includes the following steps: Step 1: Collect circuit signals through the test port and action feedback interface, and automatically determine the compliance of the wiring between the intermediate relay coil and the test port, and between the normally open contact of the intermediate relay and the action feedback interface; Step 2: Receive the target test mode and intermediate relay rated parameter instructions, wherein the target test mode includes DC mode and AC mode; Step 3: According to the target test mode, control the DC / AC switching module to switch to the corresponding test mode, switch the synchronous drive function switch to the position matching the target test mode, control the input and output switches of the corresponding mode to close, start the corresponding type of adjustable power supply, and execute AC / DC power supply interlock control at the same time. Step 4: Based on the rated parameters of the intermediate relay, start the automatic voltage adjustment strategy, drive the voltage adjustment module to gradually adjust the output voltage, and collect and acquire the real-time voltage signal in real time; Step 5: Continuously collect the on / off signal of the action feedback interface. When the on / off signal is detected to switch from the off state to the closed state, it is determined that the intermediate relay has completed the action, and the command is immediately output to stop the voltage regulation and lock the current real-time voltage signal and the corresponding power signal. Step 6: Call the preset industry standard parameter library, extract the standard power threshold range and standard voltage threshold range corresponding to the rated parameters of the intermediate relay, compare the locked power signal with the standard power threshold range and the locked real-time voltage signal with the standard voltage threshold range respectively, and generate a comprehensive judgment result of the intermediate relay action parameters. Step 7: Output the comprehensive judgment result, the locked power signal and the real-time voltage signal, and control the power module to shut down the corresponding type of adjustable power supply to complete the test.

2. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, In step 1, the circuit signal is acquired through the test port and the action feedback interface, and the wiring compliance of the intermediate relay coil and the test port, and the normally open contact of the intermediate relay and the action feedback interface is automatically determined, including the following: Step 1.1: Acquire the impedance signal of the coil circuit through the test port, and acquire the on / off status signal of the contact circuit through the action feedback interface; Step 1.2: Compare the impedance signal of the coil circuit with the preset impedance threshold range, and compare the on / off state signal of the contact circuit with the preset initial state; Step 1.3: When the impedance signal is within the preset impedance threshold range and the contact circuit on / off status signal meets the preset initial state, the wiring is deemed compliant; otherwise, the wiring is deemed abnormal and an alarm signal is output.

3. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, Step 3, executing the AC / DC power supply interlock control includes the following: Step 3.1: Detect the current status of the DC input / output switch and the AC input / output switch; Step 3.2: When the target test mode is DC mode, control the DC input / output switch to close, and at the same time lock the AC input / output switch to remain open; Step 3.3: When the target test mode is AC mode, control the AC input / output switch to close, and at the same time lock the DC input / output switch to remain open.

4. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, Step 4, initiating the automatic voltage regulation strategy includes the following: Step 4.1: Determine the starting value and target adjustment range of the voltage regulation based on the rated parameters of the intermediate relay; Step 4.2: The drive voltage regulation module gradually increases the output voltage from the initial value according to the preset step size; Step 4.3: During the voltage regulation process, the voltage signal is acquired in real time to ensure that the voltage signal changes continuously within the target regulation range.

5. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, In step 5, the on / off signal of the action feedback interface is continuously acquired. When the on / off signal is detected to switch from the off state to the closed state, it is determined that the intermediate relay has completed its action, and a command is immediately output to stop voltage regulation. The current real-time voltage signal and the corresponding power signal are locked, including the following: Step 5.1: Acquire the on / off signal of the action feedback interface at a preset sampling frequency; Step 5.2: When the on / off signal is detected as closed after a preset number of consecutive tests, eliminate signal interference and confirm that the intermediate relay has completed its operation; Step 5.3: Immediately output a stop command to the voltage regulation module, and at the same time lock the current power signal through the power acquisition module to ensure that the power signal is the parameter at the moment of the intermediate relay action.

6. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, In step 6, the comprehensive judgment result of the intermediate relay operation parameters includes the following: Step 6.1: Retrieve the standard power threshold range corresponding to the rated parameters of the intermediate relay from the industry standard parameter library; Step 6.2: Compare the locked power signal with the standard power threshold range; Step 6.3: When the locked power signal is within the standard power threshold range, generate a qualified result; when the locked power signal exceeds the standard power threshold range, generate an unqualified result and indicate the specific difference exceeding the threshold.

7. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, In step 7, the output of the comprehensive judgment result, the locked power signal, and the real-time voltage signal includes the following: Step 7.1: Control the display module to output the pass / fail judgment result, the locked power signal, and the real-time voltage signal; Step 7.2: Control the storage module to store test data, which includes target test mode, rated parameters, locked power signal, real-time voltage signal, pass / fail judgment result and test timestamp; Step 7.3: Based on the preset output instructions, selectively generate test reports and transmit them to external devices through the communication module.

8. The method for testing the operating power of an intermediate relay according to claim 1, characterized in that, In step 4, during the automatic voltage adjustment process, the rate of change of the output voltage is monitored in real time. When the rate of change exceeds the preset rate threshold, the driving parameters of the voltage adjustment module are automatically adjusted.

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