Automatic test method and system for relay

Abstract

The invention relates to the technical field of electrical element testing, and provides an automatic relay testing method and system, and the method comprises the steps: obtaining at least one electrical characteristic parameter of a to-be-tested relay; matching the at least one electrical characteristic parameter with pre-stored characteristic information corresponding to a plurality of relay models to obtain the model of the to-be-tested relay; calling corresponding test configuration parameters according to the model of the to-be-tested relay; and controlling the electrical performance test of the to-be-tested relay according to the test configuration parameters. According to the invention, full automation and intelligentization of the relay test process are realized, and the test precision, consistency and efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of electrical component testing technology, and in particular to an automated testing method and system for relays. Background Technology

[0002] As a core execution and protection component in electrical control systems, the reliability of relays directly affects the safe and stable operation of the entire system in fields such as rail transit and industrial automation. During the manufacturing, manufacturing, and maintenance of relays, parameters such as coil resistance, pull-in and release characteristics need to be tested.

[0003] Currently, common relay testing methods mainly rely on manual operation or semi-automatic instruments. A typical testing process includes: operators manually measuring the coil and contact resistance using a multimeter or dedicated resistance meter; manually applying voltage to the coil via an external adjustable power supply and recording the relay's engagement and disengagement actions visually or using a simple timer; and using instruments with fixed test modes to test specific parameters individually. These traditional methods have significant drawbacks: First, they are highly dependent on manual operation; differences in experience and judgment standards among operators lead to inconsistent and unreliable test results. Second, the testing process is cumbersome, requiring repeated wiring, setting, and recording for different parameters, resulting in low efficiency and a high risk of errors. Third, the model identification process is weak, relying mainly on operators manually searching and selecting corresponding test parameters based on the relay's nameplate. When the model identification is unclear or similar models exist, parameter settings are easily incorrect, affecting test accuracy and potentially damaging the relay or testing equipment due to overvoltage or overcurrent. Furthermore, some existing automated testing equipment typically only tests fixed models, lacking the ability to automatically identify and adaptively test multiple relay models, resulting in insufficient flexibility and intelligence. Summary of the Invention

[0004] This invention provides an automated relay testing method and system, which realizes full automation and intelligence in the relay testing process, improves testing accuracy, consistency and efficiency, and is suitable for relay production lines, maintenance lines and other occasions that require relay testing.

[0005] In a first aspect, the present invention provides an automated testing method for relays, comprising: Obtain at least one electrical characteristic parameter of the relay under test; The at least one electrical characteristic parameter is matched with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay under test; The corresponding test configuration parameters are called according to the model of the relay under test; The electrical performance test of the relay under test is controlled according to the test configuration parameters.

[0006] In some embodiments, the at least one electrical characteristic parameter includes the DC resistance value of the coil of the relay under test, and matching the at least one electrical characteristic parameter with characteristic information corresponding to a plurality of pre-stored relay models includes: The DC resistance value of the coil is compared with the preset resistance characteristic range corresponding to multiple pre-stored relay models.

[0007] In some embodiments, the DC resistance value of the coil is compared with a preset resistance characteristic range corresponding to a plurality of pre-stored relay models to obtain the model of the relay under test, including: If the DC resistance value of the coil falls within the preset resistance characteristic range corresponding to a relay model, then the relay model is determined to be the model of the relay under test. If the DC resistance value of the coil falls within the preset resistance characteristic range corresponding to multiple relay models, then additional electrical characteristic parameters are obtained, and the model of the relay under test is obtained based on the DC resistance value of the coil and the additional electrical characteristic parameters.

[0008] In some embodiments, obtaining additional electrical characteristic parameters includes: A preset test voltage is applied to the relay under test, and the dynamic electrical parameters of the relay under test are obtained as the additional electrical characteristic parameters; wherein, the dynamic electrical parameters include at least one of pull-in voltage, release voltage, pull-in time, and release time.

[0009] In some embodiments, after matching the at least one electrical characteristic parameter with the characteristic information corresponding to a plurality of pre-stored relay models, the method further includes: When it is determined that the relay under test cannot match the feature information corresponding to all pre-stored relay models, the at least one electrical feature parameter and the model information manually entered by the user are used to form new model feature storage data.

[0010] In some embodiments, before controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: The contacts of the relay under test are electrically cleaned.

[0011] In some embodiments, after controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: Based on the electrical performance test data of the relay under test and the independent judgment thresholds for different types of contacts, the test results of the main contacts and sub-contacts of the relay under test are judged respectively.

[0012] In some embodiments, after controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: The system generates a test report containing the test data and judgment results of the relay under test, as well as a traceability identifier associated with the test report.

[0013] Secondly, the present invention also provides an automated relay testing method system, comprising: An electrical characteristic measurement module is used to measure at least one electrical characteristic parameter of the relay under test; The relay adapter interface module is electrically connected to the electrical characteristic measurement module and is used to provide multiple physical interfaces to adapt to the electrical pins of different types of relays under test. The test execution module is electrically connected to the relay adapter interface module and is used to perform electrical performance tests on the relay under test according to the test configuration parameters. The main control unit is electrically connected to the electrical characteristic measurement module, the relay adapter interface module, and the test execution module, respectively, and is used to execute the relay automated test method as described above.

[0014] In some embodiments, the test execution module includes: An adjustable power supply module is used to apply a test voltage to the relay under test according to the test configuration parameters; The status acquisition module is used to monitor the status changes of the relay contacts under test, and to acquire at least one of the following parameters based on the status changes: pull-in time, release time, pull-in voltage, and release voltage.

[0015] This invention achieves a fully automated process encompassing feature acquisition, model identification, parameter retrieval, and automatic testing. It completely transforms the current situation where relay testing relies on manual model identification and parameter setting. By making model identification the initial key step in the automated process and directly driving the subsequent retrieval of test parameters and the execution of test actions, it achieves end-to-end intelligent operation from relay connection to test completion. This fundamentally eliminates the risk of test errors caused by incorrect manual model selection, significantly improving the reliability and consistency of the testing process. Simultaneously, the automated process replaces cumbersome manual operations, significantly improving testing efficiency, making it particularly suitable for scenarios such as batch testing on production lines or rapid screening at maintenance stations. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating an automated relay testing method provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of a specific process for an automated relay testing method provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of an automated relay testing system provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the physical structure of the electronic device provided in an embodiment of the present invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0019] With the rapid development of rail transit, industrial automation, and electrical control systems, relays, as the most commonly used electrical actuators and protection components in electrical control systems, directly affect the safety and reliability of the entire system due to their performance stability and testing accuracy. During manufacturing and maintenance, relays require testing of parameters such as coil resistance, pull-in and release characteristics to evaluate their operating sensitivity, response time, and electrical performance.

[0020] Currently, relay testing still relies primarily on manual or semi-automatic methods. Common testing methods include: manually measuring coil and contact resistance using a multimeter or specialized instrument; manually applying voltage via an external power supply and observing the relay's engagement and disengagement actions; and using constant voltage testing instruments to test the engagement voltage, disengagement voltage, and engagement time. These traditional testing methods generally suffer from the following problems: First, they are highly dependent on manual operation, as different testers have different operating methods and judgment standards, leading to poor stability of test results. Second, the testing process is cumbersome, requiring separate wiring, voltage application, and recording for each parameter test, resulting in low efficiency and a high risk of errors. Third, the identification process relies on experience; currently, manual selection of test configurations is often based on the relay's appearance, model number, or nameplate information. If the models are similar or the markings are unclear, incorrect matching can easily occur, affecting test accuracy. Furthermore, some existing automated testing equipment can typically only test fixed models and struggles to automatically identify parameter differences between different types of relays.

[0021] To address the aforementioned problems, this invention proposes a measurement method based on automated relay identification. This method identifies the relay coil resistance characteristics, automatically matches the relay model, and combines four-wire resistance testing and adjustable power supply module control to achieve fully automated testing and data recording of key performance parameters such as relay engagement, release, and resistance. This significantly improves relay testing efficiency and accuracy, reduces manual intervention, and enables adaptive identification and testing control of multiple relay models, possessing broad engineering application value.

[0022] Figure 1 This is a flowchart illustrating an automated relay testing method provided in an embodiment of the present invention. The automated relay testing method can be executed by the automated relay testing system provided in this embodiment of the present invention, which can be implemented using software and / or hardware. Figure 1 As shown, automated relay testing includes the following steps: S101. Obtain at least one electrical characteristic parameter of the relay under test.

[0023] Specifically, electrical characteristic parameters refer to measurable physical quantities that characterize the electrical properties of a relay, such as the DC resistance, operating voltage, and operating time of the relay coil under test. The core process of automated relay testing methods begins with obtaining at least one electrical characteristic parameter of the relay under test, which serves as the basis for subsequent model identification.

[0024] For example, a relay adapter interface module can provide a variety of physical interfaces to adapt to the electrical pins of different types of relays under test. The relay adapter interface module can be a relay socket interface. Various types of relay socket interfaces can be configured on the test bench. Users can select and insert the corresponding relay socket interface according to the electrical pin type of the relay under test.

[0025] S102. Match at least one electrical characteristic parameter with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay to be tested.

[0026] Specifically, after acquiring at least one electrical characteristic parameter of the relay under test, the system matches this parameter with a pre-established database containing characteristic information corresponding to multiple known relay models. Through comparison, the system can determine which model in the database best matches the characteristics of the current relay under test, thus identifying the specific model of the relay under test.

[0027] In some embodiments, at least one electrical characteristic parameter includes the DC resistance value of the coil of the relay under test. Matching at least one electrical characteristic parameter with characteristic information corresponding to a plurality of pre-stored relay models includes: comparing the DC resistance value of the coil with a preset resistance characteristic range corresponding to a plurality of pre-stored relay models.

[0028] Specifically, the coil DC resistance value refers to the resistance value exhibited by the relay coil winding under DC current. The preset resistance characteristic range refers to the nominal value of the coil DC resistance and its allowable error range for a specific relay model. This range is pre-determined and stored in a database as a characteristic identifier of that model.

[0029] When the relay under test is connected to the testing system, the system first uses an ohmmeter or a four-wire resistance measurement circuit to accurately measure the DC resistance value across its coil. Then, the system compares the measured coil DC resistance value with the preset resistance characteristic ranges of all relay models stored in the database. This comparison process checks which model's preset resistance range the coil DC resistance value falls within. Through this range matching, the system can initially identify or directly determine the model of the relay under test.

[0030] Therefore, this invention uses the coil DC resistance value as an identification feature, which has the advantages of simple implementation, fast measurement, low cost, and high reliability. Coil resistance is a fundamental parameter of relays and is easy to measure accurately. Setting different resistance characteristic ranges for different models forms an effective distinguishing identifier, providing a highly feasible automatic identification method. This effectively distinguishes numerous relay models with significant differences in coil resistance values, providing a solid and easily implementable technical foundation for basic-level automated identification. It should be noted that the electrical characteristic parameter can be not only the coil DC resistance value of the relay under test, but also the normally open contact resistance value or normally closed contact resistance value. A four-wire measurement method can be used to perform high-precision testing of the coil DC resistance value, open contact resistance value, or normally closed contact resistance value of the relay under test, monitoring the contact on / off state in real time. Temperature and humidity sensors can also synchronously and automatically record the temperature, humidity, and other environmental information of the environment in which the relay under test is located. Correspondingly, the database of the test system can store the electrical characteristic parameters of multiple relay models, including coil resistance range, rated voltage, pull-in voltage, release voltage, time delay parameters, and environmental correction coefficients.

[0031] In some embodiments, the coil DC resistance value is compared with a preset resistance characteristic range corresponding to a plurality of pre-stored relay models to obtain the model of the relay under test, including: if the coil DC resistance value falls within the preset resistance characteristic range corresponding to a relay model, then the relay model is determined to be the model of the relay under test; if the coil DC resistance value falls within the preset resistance characteristic range corresponding to a plurality of relay models, then additional electrical characteristic parameters are obtained, and the model of the relay under test is obtained based on the coil DC resistance value and the additional electrical characteristic parameters.

[0032] Specifically, additional electrical characteristic parameters refer to electrical parameters other than the coil DC resistance value that can be used to distinguish relay models. After performing the aforementioned resistance comparison process, the system enters a judgment branch. In the first case, if the measured coil DC resistance value falls within the preset resistance characteristic range corresponding to only one relay model, and has no overlap with the ranges of all other models, the system can clearly determine that the relay under test is that model, and the identification process ends. In the second case, if the measured resistance value falls within the preset resistance characteristic range of two or more relay models simultaneously, that is, the resistance ranges of multiple models overlap, then a unique determination cannot be made based solely on the resistance value. At this time, the system will initiate an enhanced identification process, namely, acquiring additional electrical characteristic parameters. The system will measure one or more other electrical characteristic parameters, and then combine the initially measured coil DC resistance value with the newly acquired additional electrical characteristic parameters to form a richer set of feature vectors, which are then compared with the comprehensive feature information of several candidate models in the database. Through the common constraints of multi-dimensional features, the system can filter out the uniquely matching model from multiple candidate models, thereby completing accurate identification.

[0033] Therefore, the embodiments of the present invention significantly improve the robustness and accuracy of the automatic identification system, comprehensively consider the practical problem that different models of relays may have overlapping coil resistance ranges in real-world applications, and provide an intelligent solution. By introducing a strategy of conditional judgment and multi-feature fusion, the system can automatically activate a more complex identification mechanism when the simple feature resolution is insufficient, ensuring that even under difficult conditions of overlapping features, accurate and unique model determination can be ultimately achieved, avoiding identification failures or misidentifications, and greatly enhancing the reliability of the entire automated testing process.

[0034] In some embodiments, obtaining additional electrical characteristic parameters includes: controlling the application of a preset test voltage to the relay under test, and obtaining the dynamic electrical parameters of the relay under test as additional electrical characteristic parameters; wherein, the dynamic electrical parameters include at least one of pull-in voltage, release voltage, pull-in time, and release time.

[0035] Specifically, the preset test voltage refers to one or more pre-set safe voltage values ​​applied during the model identification phase to stimulate and measure the dynamic characteristics of the relay. The purpose of the preset test voltage is to induce a measurable action in the relay, rather than to perform a formal specification test. Dynamic electrical parameters refer to the parameters exhibited by the relay under voltage excitation that are related to the time or voltage change process; they reflect the relay's combined electromagnetic and mechanical characteristics.

[0036] When the system enters the enhanced identification process due to overlapping resistance values, the adjustable power supply module can be controlled to apply one or more preset test voltages to the coil of the relay under test. The preset test voltages need to be carefully selected; for example, they could be a common safety value lower than the rated voltage of all candidate models, or a threshold voltage that ensures at least some candidate models will activate. During the application of the preset test voltages, the system monitors changes in the coil current or contact state of the relay under test in real time using a high-speed sampling circuit or voltage comparator. For example, the system can slowly scan the voltage onto the relay under test, recording the instantaneous voltage value when the relay's contact state changes, such as the voltage value at the moment the normally open contact closes, as the pull-in voltage; or it can apply a step voltage to the relay under test, recording the time difference from the application of the step voltage to the activation of the relay's contacts using a timing circuit, as the pull-in time. Similarly, the release voltage and release time can be acquired. These dynamic parameters measured during the testing process are the additional electrical characteristic parameters used for auxiliary identification.

[0037] Therefore, the dynamic electrical parameters utilized in this embodiment of the invention differ in nature from the static coil resistance parameters. They reflect the comprehensive performance of the relay's magnetic circuit, spring mechanism, etc., and often possess unique characteristics for different models. By applying a safe test voltage to excite and measure these parameters, a highly discriminative identification dimension is added to the system, enabling it to effectively distinguish relay models with similar static resistance but different dynamic performance, further improving identification accuracy. For example, the system can also assign different confidence weights to different acquired electrical characteristic parameters and comprehensively calculate the matching degree with each pre-stored model.

[0038] In some embodiments, after matching at least one electrical characteristic parameter with the characteristic information corresponding to multiple pre-stored relay models, the method further includes: when it is determined that the relay under test cannot match the characteristic information corresponding to all pre-stored relay models, forming new model characteristic storage data by combining at least one electrical characteristic parameter and the model information manually input by the user.

[0039] Specifically, model feature storage data refers to data records formed by associating the feature information of a new relay model, such as electrical characteristic parameters, with its model name, to expand the system's identification database. During the automatic matching process, if the system finds after traversing the database that none of the electrical characteristic parameters of the relay under test, including any potentially acquired additional parameters, can successfully match any pre-stored model feature information (i.e., identification fails), the system will determine that the relay under test is an unknown model. At this point, the system will not terminate the process but will enter learning mode, temporarily saving all currently measured electrical characteristic parameters, such as coil resistance and dynamically acquired parameters. Simultaneously, the system will prompt the operator to manually input the correct model name of the relay through the human-machine interface. After the operator inputs the name, the system automatically binds the previously saved set of electrical characteristic parameters with the manually entered model name, forming a new model feature storage data entry, and permanently adds it to the system's feature information database.

[0040] Therefore, this invention breaks the limitation that automated testing systems can only recognize preset fixed models. When faced with new models or models not included in the database, the system does not need to wait for software upgrades or professional reprogramming. On-site operators can complete the instant expansion of the model library through simple measurement input operations, which greatly extends the service life of the system, broadens its application scope, and significantly reduces the later maintenance and update costs.

[0041] S103. Call the corresponding test configuration parameters according to the model of the relay under test.

[0042] Specifically, test configuration parameters refer to a set of control instructions and judgment criteria pre-set to complete a full performance test of a specific model of relay. These may include, but are not limited to, test voltage values, current limits, test procedure sequences, threshold values ​​for the acceptable range of parameters for each test item, test channels, and contact types such as normally open, normally closed, main contacts, and sub-contacts. Once the model is determined, the system automatically retrieves a complete set of test configuration parameters uniquely associated with that model from the database.

[0043] S104. Control the electrical performance test of the relay under test according to the test configuration parameters.

[0044] Specifically, electrical performance testing refers to a series of standard tests performed to evaluate whether a relay meets its design specifications. These tests may include coil resistance testing, contact resistance testing, and pull-in and release characteristic testing. Finally, based on the retrieved test configuration parameters, the system automatically controls the test hardware, such as the adjustable power supply module, electrical characteristic measurement module, and status acquisition module, to perform comprehensive electrical performance testing of the relay under test according to predetermined steps and conditions, without requiring manual intervention in parameter setting and process control.

[0045] For example, once the model is determined, the system can control the adjustable power supply module to apply a test voltage to the relay under test according to the test configuration parameters, and control the status acquisition module to monitor the state changes of the relay under test contacts, and obtain at least one parameter among the pull-in time, release time, pull-in voltage, and release voltage based on the state changes. Specifically, the pull-in time of the relay under test can be obtained by recording the coil pull-in moment, and then the output power can be disconnected and the disconnection moment recorded to obtain the release time of the relay under test. By controlling the output voltage of the adjustable power supply module to slowly rise until the relay under test pulls in, the pull-in voltage value of the relay under test is recorded, and then the output voltage is slowly decreased until the relay under test disconnects, and the disconnection voltage value of the relay under test is recorded. In addition, the test bench can also be equipped with an external test interface to support the connection of other electrical components, such as contactors, time relays, etc., and perform automatic identification and performance testing through the same test control process. For time relays, the system can detect the delay characteristics of the time relay through time control logic and generate a delay response curve.

[0046] Therefore, this invention achieves a fully automated process encompassing feature acquisition, model identification, parameter retrieval, and automatic testing. This completely changes the current situation where relay testing relies on manual model identification and parameter setting. By making model identification the initial key step in the automated process and directly driving the subsequent retrieval of test parameters and the execution of test actions, it achieves end-to-end intelligentization from relay connection to test completion. This fundamentally eliminates the risk of test errors caused by incorrect manual model selection, significantly improving the reliability and consistency of the testing process. Simultaneously, the automated process replaces cumbersome manual operation steps, significantly improving testing efficiency, and is particularly suitable for scenarios such as batch testing on production lines or rapid screening at maintenance stations.

[0047] In some embodiments, before controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes controlling the contacts of the relay under test to be electrically cleaned.

[0048] Specifically, electrical cleaning refers to the process of removing microscopic oxide layers, sulfide layers, or organic contaminants from the surface of the relay under test (TUT) contacts by applying a brief, high-current pulse to them. This process utilizes the thermal effect of the current and the ablation effect of the electric arc to restore the metal contact surface. Before the formal electrical performance test begins according to the test configuration parameters, the main control unit controls the electrical cleaning module, such as a transformer, to perform this operation. The main control unit issues a command to the electrical cleaning module to apply a pulse current much higher than the normal operating current to the TUT contacts (such as normally open and normally closed contacts) within a very short time. The powerful instantaneous current flows through the contact surface of the TUT contacts, generating high temperatures sufficient to vaporize or destroy the surface insulating film, exposing a clean metal substrate and thus improving its conductivity.

[0049] Therefore, this invention introduces an electrical cleaning step. For testing, the contact surfaces of relays or externally connected contactors that have been stored or used for a long time may have increased contact resistance due to oxidation. Direct testing may not reflect their true performance potential and could lead to misjudgments. Electrical cleaning restores the ideal contact state of the contacts, making subsequent performance tests, especially contact resistance tests, more accurate and reliable. For the relay products themselves, this step can serve as an aging screening or performance activation process, eliminating inferior products that cannot withstand the cleaning current due to defects in contact materials or processes, while improving the initial contact performance of qualified products and enhancing the overall quality level of the products leaving the factory.

[0050] In some embodiments, after controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: determining the test results of the main contacts and sub-contacts of the relay under test according to the electrical performance test data of the relay under test and the independent judgment thresholds for different types of contacts.

[0051] Specifically, the independent judgment threshold refers to the parameter limit value set separately for contacts with different functions inside the relay, such as main contacts and sub-contacts, to determine whether their test results are qualified. For example, the upper limit of the allowable contact resistance of the main contact is 50 milliohms, while the upper limit of the allowable contact resistance of the sub-contact used for signal transmission may be 100 milliohms. Different test thresholds and judgment ranges can be set for different contact types to achieve differentiated detection.

[0052] After completing the electrical performance test and acquiring all test data, the system enters the result judgment stage. The system first retrieves the independent judgment thresholds corresponding to the current test model from the database. These thresholds vary depending on the contact type. For example, for main contacts used to switch high-power loads, the requirements for switching capacity and contact resistance are more stringent, so their resistance pass threshold is set lower; while for sub-contacts used for control circuits or signal indications, the requirements are relatively lenient, and the threshold can be set higher. The system compares the tested main contact resistance value with the main contact judgment threshold, and compares the tested sub-contact resistance value with the sub-contact judgment threshold. The judgment process is completely independent and does not interfere with each other. Finally, the system generates a refined judgment conclusion, such as main contact qualified, sub-contact 1 qualified, and sub-contact 2 unqualified.

[0053] Therefore, this invention enables refined management and differentiated evaluation of test results, reflecting the true quality status of relays more scientifically and accurately. Traditional testing often applies the same standard to all contacts, which may lead to overly lenient requirements for main contacts or overly stringent requirements for sub-contacts. This invention sets independent judgment thresholds for different types of contacts, ensuring that the judgment standard matches the actual functional requirements of the contacts. This avoids misjudging relays with substandard contact performance as qualified, improving product reliability; it also reduces the possibility of misjudging relays with good overall performance as scrapped due to minor deviations in some contact parameters, reducing production losses and improving the rationality of quality control.

[0054] In some embodiments, after controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: controlling the generation of a test report containing the test data and judgment results of the relay under test, and a traceability identifier associated with the test report.

[0055] Specifically, a test report refers to a complete record, generated in the form of a structured document or electronic file, summarizing all process data and results of this test. A traceability identifier refers to a unique identifier associated with the test report, facilitating rapid retrieval, such as a QR code or barcode. After all testing and judgment steps are completed, the main control unit controls the report generation module to automatically compile all relevant information, including the model of the relay under test, test number, ambient temperature and humidity, measured values ​​of electrical characteristic parameters, and the pass / fail conclusions for each contact based on independent judgment. Electrical characteristic parameters may include coil resistance, contact resistance, pull-in and release voltages, and time, etc. The system formats this information into a complete test report according to a preset template. Simultaneously, the system generates a unique traceability identifier for this test, which is logically bound to this test report. The report can be displayed on a screen, stored in a data storage module, or printed on paper via a connected module such as a QR code printing module. The QR code is printed on a label and affixed to the relay under test or its packaging.

[0056] Therefore, this invention achieves automation, digitization, and traceability of test data management. Automated report generation replaces manual transcription, ensuring 100% accuracy and uniform format of data records, eliminating typos, and greatly improving data management efficiency. A unique traceability identifier linked to the test report enables rapid and convenient association between test data and physical products. Simply scanning a QR code allows retrieval of the relay's complete test report from the database, achieving traceability of quality data throughout the product's entire lifecycle.

[0057] Figure 2 This is a schematic flowchart illustrating a relay automated testing method provided in an embodiment of the present invention. The relay automated testing method specifically includes the following steps: S201, Begin.

[0058] S202, Insert the relay.

[0059] S203, Automatic Model Identification.

[0060] S204, Electrical cleaning.

[0061] S205, Resistance detection.

[0062] S206, Adsorption / Release Test.

[0063] S207. Determine if the test is qualified. If yes, proceed to S208; if no, proceed to S210.

[0064] S208, Print QR code.

[0065] S209, Storage Integration and Report Generation.

[0066] S210, retest, up to three times.

[0067] S211, End.

[0068] In summary, this invention, through integrated design, achieves a unified operation of automatic relay identification, automatic parameter setting, high-current cleaning, functional testing, and report generation, significantly improving testing efficiency and accuracy. It demonstrates a clear advantage over traditional solutions in terms of integration and automation. Specifically, it achieves intelligent operation of relay testing through an automated integrated system. First, it achieves automated identification, automatically recognizing different types of relays without manual intervention. It supports extended relay models, ensuring test compatibility and flexibility. Second, it achieves automated testing, automatically setting test parameters based on the identification results, including release voltage, release time, and test mode. It performs relay functional tests, such as fully automated detection of normally open and normally closed contacts, improving testing efficiency and accuracy. Third, it achieves automatic recording, with test data collected, stored, and test reports generated in real time. It supports QR code printing for data traceability and information management. Thus, automatic identification, automatic testing, and automatic recording are organically combined to achieve integrated operation.

[0069] This invention also provides an automated relay testing system. Figure 3 This is a schematic diagram of the structure of an automated relay testing system provided in an embodiment of the present invention. Figure 3As shown, the automated relay testing system includes an electrical characteristic measurement module 301, a relay adapter interface module 302, a test execution module, and a main control unit 303. The electrical characteristic measurement module 301 is used to measure at least one electrical characteristic parameter of the relay under test. The relay adapter interface module 302 is electrically connected to the electrical characteristic measurement module 301 and is used to provide multiple physical interfaces to adapt to the electrical pins of different types of relays under test. The test execution module is electrically connected to the relay adapter interface module 302 and is used to perform electrical performance tests on the relay under test according to the test configuration parameters. The main control unit 303 is electrically connected to the electrical characteristic measurement module 301, the relay adapter interface module 302, and the test execution module, respectively, and is used to execute the automated relay testing method described in the above embodiment.

[0070] Specifically, the relay adapter interface module 302 refers to a hardware module that provides various physical sockets or connectors to be compatible with relays, contactors, etc., with different pin counts, arrangements, and sizes. The electrical characteristic measurement module 301 refers to a collection of measuring instruments or circuit units used to measure various electrical parameters of the relay, such as resistance, voltage, and time. The test execution module refers to a hardware functional unit that executes specific test actions according to instructions, such as applying voltage, switching current, and switching test paths. The main control unit 303 refers to the core processing and control component of the system, which can be an industrial computer, microcontroller, etc., responsible for running control software, processing data, and coordinating the work of various modules. Additionally, corresponding to the industrial computer, a main control board responsible for logic control and a test board for connecting the relay adapter interface module 302 for switch control can also be set up.

[0071] The relay adapter interface module 302 provides diverse physical interfaces, such as 8-pin, 11-pin, and 14-pin sockets. Users insert the relay under test into the corresponding interface to complete the physical connection. The electrical characteristic measurement module 301 is internally connected to the relay adapter interface module 302 and can accurately measure various electrical characteristic parameters of the relay under test under the command of the main control unit 303, and upload the measurement data. For example, it can be a resistance detection module. The test execution module is connected to the relay adapter interface module 302 and includes functions such as power output, load control, and signal switching. It can execute specific pressure application, testing, and measurement actions according to the test configuration parameters issued by the main control unit 303.

[0072] The main control unit 303 is connected to all the above modules via an electrical bus. Its control software executes the automated relay testing method described in the above embodiments: receiving data from the electrical characteristic measurement module 301 and performing model matching; retrieving parameters from internal storage based on the matching results; converting the parameters into control commands and sending them to the test execution module; and finally collecting test data and generating a report. Under the centralized scheduling of the main control unit 303, all modules work collaboratively to achieve full automation of the entire process, including automatic identification, automatic testing, data processing, and report output.

[0073] For example, the system may also include a user interface module 306, an electrical cleaning module 307, a QR code printing module 308, a data storage module 309, a report generation module 310, and an anomaly handling module, etc., to achieve fully automated operation from relay identification, parameter setting, application of test voltage and release time, high-current cleaning, functional testing, to data acquisition and report generation. The system supports automatic identification and manual expansion of multiple relay models, test parameters can be automatically set according to the relay type, test data is acquired in real time and reports are generated, and QR code printing is supported for information traceability. Compared with existing alternatives, such as manual identification or template identification, the present invention has significant advantages in terms of automation, testing efficiency, accuracy, and data management, and does not require modification of the relays, making it suitable for multi-model, highly repeatable, and highly reliable relay testing applications.

[0074] In some embodiments, the test execution module includes an adjustable power supply module 304 and a status acquisition module 305. The adjustable power supply module 304 is used to apply a test voltage to the relay under test according to the test configuration parameters. The status acquisition module 305 is used to monitor the status changes of the contacts of the relay under test and acquire at least one parameter among the pull-in time, release time, pull-in voltage and release voltage according to the status changes.

[0075] Specifically, the adjustable power supply module 304 refers to a power supply device whose output voltage, current, waveform, and timing can all be precisely set and controlled via digital commands. The status acquisition module 305 refers to a circuit unit used to monitor changes in signals such as the on / off status of relay contacts and coil voltage and current in real time, and may include components such as opto-isolators, comparators, analog-to-digital converters, and timing circuits.

[0076] The adjustable power supply module 304 receives instructions from the main control unit 303, which include requirements for voltage, current, rise or fall time, and duration in the test configuration parameters. Based on these instructions, the adjustable power supply module 304 precisely generates the required test voltage signal and applies it to the corresponding coil terminal of the relay adapter interface module 302. The status acquisition module 305 continuously monitors the signal lines leading from the relay adapter interface module 302 that reflect the relay contact status. When the adjustable power supply module 304 applies voltage, causing the relay to operate, its contact status changes, such as a normally open contact changing from open to closed. The status acquisition module 305 can capture the instantaneous state transition at high speed. Using an internal precision clock, it can record the time difference from the initial voltage application to contact operation, i.e., the pull-in time. By measuring the actual voltage across the coil at the instant the contact operates, the pull-in voltage can be obtained; similarly, the release time and release voltage can be acquired. These acquired dynamic parameters are uploaded to the main control unit 303 in real time for processing and recording.

[0077] Therefore, this embodiment of the invention achieves precise control and measurement of the dynamic testing process. The adjustable power supply module 304 ensures the precise controllability of the excitation signal, and the status acquisition module 305 ensures the precise capture of the response signal. The combination of the two makes the measured dynamic parameters have extremely high accuracy and reliability.

[0078] In summary, this invention solves the problems of manual model selection, cumbersome testing procedures, and low accuracy in existing relay testing. It automatically identifies the relay model by measuring the relay coil resistance and, combined with four-wire resistance testing and adjustable power supply control, achieves automatic testing of normally open, normally closed, and coil resistances. Simultaneously, it accurately measures the relay's pull-in and release voltages and times. Compared to traditional manual testing methods, it automatically identifies the relay model without manual judgment; the testing process is fully automated, simple to operate, and highly efficient; it uses a four-wire measurement method for high testing accuracy; it automatically records test data for easy traceability and analysis; it supports automatic identification of multiple relay models and bases; it supports manually adding new model parameters, and the system can self-learn and expand; it has a high-current cleaning function to improve contact performance; it can be expanded to test contactors and time relays; it automatically generates test reports and QR code traceability labels; and it supports segmented determination of normally open / normally closed / main / sub-contacts, resulting in high testing accuracy.

[0079] Figure 4 This is a schematic diagram of the physical structure of the electronic device provided in an embodiment of the present invention. For example... Figure 4As shown, the electronic device may include: a processor 401, a communications interface 402, a memory 403, and a communication bus 404. The processor 401, communications interface 402, and memory 403 communicate with each other via the communication bus 404. The processor 401 can call logic instructions from the memory 403 to execute an automated relay testing method, including: Obtain at least one electrical characteristic parameter of the relay under test; At least one electrical characteristic parameter is matched with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay under test; The corresponding test configuration parameters are retrieved based on the model of the relay under test; The electrical performance test of the relay under test is controlled according to the test configuration parameters.

[0080] Furthermore, the logical instructions in the aforementioned memory 403 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0081] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer is able to perform the above-mentioned automated relay testing method, including: Obtain at least one electrical characteristic parameter of the relay under test; At least one electrical characteristic parameter is matched with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay under test; The corresponding test configuration parameters are retrieved based on the model of the relay under test; The electrical performance test of the relay under test is controlled according to the test configuration parameters.

[0082] In another aspect, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, is implemented to perform the above-described automated relay testing method, including: Obtain at least one electrical characteristic parameter of the relay under test; At least one electrical characteristic parameter is matched with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay under test; The corresponding test configuration parameters are retrieved based on the model of the relay under test; The electrical performance test of the relay under test is controlled according to the test configuration parameters.

[0083] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0084] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., including several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods of various embodiments or some parts of embodiments.

[0085] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automated testing method for relays, characterized in that, include: Obtain at least one electrical characteristic parameter of the relay under test; The at least one electrical characteristic parameter is matched with the characteristic information corresponding to multiple pre-stored relay models to obtain the model of the relay under test; The corresponding test configuration parameters are called according to the model of the relay under test; The electrical performance test of the relay under test is controlled according to the test configuration parameters.

2. The automated relay testing method according to claim 1, characterized in that, The at least one electrical characteristic parameter includes the DC resistance value of the coil of the relay under test. Matching the at least one electrical characteristic parameter with pre-stored characteristic information corresponding to multiple relay models includes: The DC resistance value of the coil is compared with the preset resistance characteristic range corresponding to multiple pre-stored relay models.

3. The automated relay testing method according to claim 2, characterized in that, The DC resistance value of the coil is compared with a preset resistance characteristic range corresponding to multiple pre-stored relay models to obtain the model of the relay under test, including: If the DC resistance value of the coil falls within the preset resistance characteristic range corresponding to a relay model, then the relay model is determined to be the model of the relay under test. If the DC resistance value of the coil falls within the preset resistance characteristic range corresponding to multiple relay models, then additional electrical characteristic parameters are obtained, and the model of the relay under test is obtained based on the DC resistance value of the coil and the additional electrical characteristic parameters.

4. The automated relay testing method according to claim 3, characterized in that, Obtain additional electrical characteristic parameters, including: A preset test voltage is applied to the relay under test, and the dynamic electrical parameters of the relay under test are obtained as the additional electrical characteristic parameters; wherein, the dynamic electrical parameters include at least one of pull-in voltage, release voltage, pull-in time, and release time.

5. The automated relay testing method according to claim 1, characterized in that, After matching the at least one electrical characteristic parameter with the characteristic information corresponding to multiple pre-stored relay models, the method further includes: When it is determined that the relay under test cannot match the feature information corresponding to all pre-stored relay models, the at least one electrical feature parameter and the model information manually entered by the user are used to form new model feature storage data.

6. The automated relay testing method according to any one of claims 1-5, characterized in that, Before controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: The contacts of the relay under test are electrically cleaned.

7. The automated relay testing method according to any one of claims 1-5, characterized in that, After controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: Based on the electrical performance test data of the relay under test and the independent judgment thresholds for different types of contacts, the test results of the main contacts and sub-contacts of the relay under test are judged respectively.

8. The automated relay testing method according to any one of claims 1-5, characterized in that, After controlling the electrical performance test of the relay under test according to the test configuration parameters, the method further includes: The system generates a test report containing the test data and judgment results of the relay under test, as well as a traceability identifier associated with the test report.

9. An automated relay testing system, characterized in that, include: An electrical characteristic measurement module is used to measure at least one electrical characteristic parameter of the relay under test; The relay adapter interface module is electrically connected to the electrical characteristic measurement module and is used to provide multiple physical interfaces to adapt to the electrical pins of different types of relays under test. The test execution module is electrically connected to the relay adapter interface module and is used to perform electrical performance tests on the relay under test according to the test configuration parameters. The main control unit is electrically connected to the electrical characteristic measurement module, the relay adapter interface module, and the test execution module, respectively, and is used to execute the relay automated test method as described in any one of claims 1-8.

10. The automated relay testing system according to claim 9, characterized in that, The test execution module includes: An adjustable power supply module is used to apply a test voltage to the relay under test according to the test configuration parameters; The status acquisition module is used to monitor the status changes of the relay contacts under test, and to acquire at least one of the following parameters based on the status changes: pull-in time, release time, pull-in voltage, and release voltage.

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