Universal semi-automatic safety test machine

Abstract

The invention aims to provide the universal semi-automatic safety test machine which is compact in structure, wide in applicability, high in test efficiency, high in safety protection, fine in test data and visual in result. The device comprises a safety comprehensive test instrument, the safety comprehensive test instrument is in communication connection with an upper computer, the safety comprehensive test instrument is connected with a power switching box, a voltage dividing plate, a relay plate and a substrate, the upper computer is connected with the substrate, the substrate is connected with a motor module and a cylinder module, and the motor module is connected with the cylinder module. The motor module and the cylinder module are both in transmission connection with a tested product, and the voltage dividing plate and the relay plate are both connected with the tested product. The invention is applied to the technical field of detection systems.

Description

Technical Field

[0001] This invention relates to the technical field of testing systems, and in particular to a general-purpose semi-automatic safety testing machine. Background Technology

[0002] Safety testing machines are crucial quality control tools in the production of consumer electronics products. They are used to conduct electrical safety tests, such as grounding resistance and withstand voltage tests, to ensure that products meet safety standards. The development of safety testing machines has evolved from importation and assimilation to independent innovation: initially reliant on imports, it has now achieved self-sufficiency and perfection in technology, products, and the entire industry chain. Technology has also progressed from analog to digital and then to intelligent systems: this technological evolution has driven the development of equipment from single-function to multi-function devices.

[0003] In existing technologies, most products are tested directly using safety testing equipment, with manual plugging and unplugging of cables to perform DC, AC, GB, and other tests; the test results are then read directly from the safety testing equipment by a Mac mini. However, manual testing suffers from low safety levels, difficulty in viewing and comparing test data (which is not readily visualized), and low efficiency. For example, Chinese patent CN207991752U discloses a high-voltage wiring harness performance testing system. This system utilizes a microcomputer and programmable controller to control and select the control points of the high-voltage relays in the high-voltage acquisition and selection control circuits. Combined with a resistance tester, safety analyzer, and testing modules, it achieves high precision, accuracy, and reliability in high-voltage wiring harness testing, completing the testing of airtightness, continuity, resistance, withstand voltage, and insulation electrical performance in a single operation. However, this testing system also suffers from low safety levels, difficulty in viewing and comparing test data (which is not readily visualized), low efficiency, and limited applicability. Therefore, it is necessary to provide a universal semi-automatic safety testing machine that is compact, widely applicable, highly efficient, provides high safety protection, generates detailed test data, and visualizes the results. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a universal semi-automatic safety testing machine with compact structure, wide applicability, high testing efficiency, high safety protection, detailed test data, and visualized results.

[0005] The technical solution adopted in this invention is as follows: This invention includes a safety testing instrument, which is communicatively connected to a host computer. The safety testing instrument is connected to a power switching box, a voltage divider board, a relay board, and a base plate. The host computer is connected to the base plate, which is connected to a motor module and a cylinder module. Both the motor module and the cylinder module are connected to the product under test. The voltage divider board and the relay board are both connected to the product under test. The safety testing instrument is used for AC power testing, DC power testing, and impedance to ground testing. The power switching box performs mutual exclusion control on high-voltage DC and AC power. The voltage divider board converts the high voltage output by the safety testing instrument into a low voltage that the base plate can measure. The relay board is used to switch signals connected to the product under test and related to the safety testing instrument. The base plate is used to provide control and measurement of weak current signals.

[0006] As can be seen from the above solution, this application offers high testing efficiency, provides extremely high safety protection for the equipment itself, the environment, and personnel, and delivers detailed test data presented in a visual chart format. It protects operators from the risk of electric shock; the controller and DMM acquire data quickly and accurately, and generate real-time graphs based on the new data, making the data presentation more intuitive; it effectively replaces manual operation, achieving semi-automatic testing and improving efficiency; by detecting the cable connection status, it assists in determining the equipment status before HV testing, saving testing time; and it has wide applicability, suitable for testing consumer and enterprise-level products of different sizes and weights.

[0007] In a preferred embodiment, the general-purpose semi-automatic safety testing machine also includes a CGM board, which is connected to the safety testing instrument. The CGM board is used to measure whether the machine grounding and the factory grounding are good. If the contact is poor, the buzzer on the machine will continuously alarm and disconnect the 220V power supply of the safety testing instrument and the product under test.

[0008] In a preferred embodiment, the general-purpose semi-automatic safety testing machine further includes an interface plug box, through which the power switching box is connected to the product under test.

[0009] In a preferred embodiment, the substrate includes a control board and a digital multimeter module. The control board controls the motor module via UART and the cylinder module via I / O expansion. The digital multimeter module measures the voltage of AC and DC power and measures the impedance current to ground.

[0010] In a preferred embodiment, the substrate further includes an IV conversion circuit, which converts the 25A current relative to ground impedance into a corresponding voltage, and then switches it via a relay to finally supply the voltage measured by the digital multimeter module.

[0011] In a preferred embodiment, the general-purpose semi-automatic safety testing machine further includes an electrical power control circuit, which is connected to the CGM board and controls the 220V power supply of the safety testing instrument and the 220V power supply of the product under test.

[0012] In a preferred embodiment, the general-purpose semi-automatic safety testing machine further includes an electrical high-voltage enable control circuit, which is connected to the relay board. Attached Figure Description

[0013] Figure 1 This is a structural block diagram of the present invention; Figure 2 This is a schematic diagram of the present invention; Figure 3 This is the circuit schematic of the CGM board; Figure 4 This is the circuit diagram of the power switching box; Figure 5 This is the logic control circuit diagram of the relay board; Figure 6 This is the circuit diagram of the relay board; Figure 7 This is the circuit schematic of the CC_Source circuit. Figure 8 This is a circuit diagram of the IV conversion circuit and the digital multimeter module; Figure 9 This is the circuit schematic of the control board; Figure 10 This is the circuit diagram of the electrical power supply control loop; Figure 11 This is the circuit diagram of the high-voltage electrical enable control circuit. Figure 12 This is the circuit diagram of the grating control loop; Figure 13 This is a system test and calibration data sheet; Figure 14 This is a graph of data collected by the digital multimeter module. Detailed Implementation

[0014] like Figures 1 to 14As shown, in this embodiment, the present invention includes a safety testing instrument 1, which is communicatively connected to a host computer 2. The safety testing instrument 1 is connected to a power switching box 3, a voltage divider plate 4, a relay plate 5, and a base plate 6. The host computer 2 is connected to the base plate 6. The base plate 6 is connected to a motor module 7 and a cylinder module 8. Both the motor module 7 and the cylinder module 8 are connected to the product under test 9. The voltage divider plate 4 and the relay plate 5 are both connected to the product under test 9. The safety testing instrument 1 is used for AC power testing, DC power testing, and impedance to ground testing. The power switching box 3 performs mutual exclusion control on high-voltage DC and AC power. The voltage divider plate 4 converts the high voltage output by the safety testing instrument 1 into a low voltage that the base plate 6 can measure. The relay plate 5 is used to switch signals connected to the product under test 9 and related to the safety testing instrument 1. The base plate 6 is used to provide control and measurement of weak current signals.

[0015] The host computer 2 is the control center of the entire testing system. The host computer 2 sends instructions to the safety comprehensive tester 1 to determine the test mode. At the same time, the host computer 2 also sends instructions to the control board of the base plate 6 to switch the various test paths.

[0016] The safety testing instrument 1 is the core of the entire testing system. It generates DC HV 2130V or 4250V, AC 200V or 500V for high-voltage testing. At the same time, it also generates a 25A current source for GB testing. The safety testing instrument 1 is either Chroma 19032 or Chroma 19052. The power switching box 3 is used to switch between HV (200VAC / 500VAC / 2130VDC / 4250VDC) and AC220V power supplies, which is achieved by pushing and pulling the terminals of the cylinder module 8. This part is controlled by the relay board 5, realizing mutual exclusion control of the HV (200VAC / 500VAC / 2130VDC / 4250VDC) and AC220V power paths. The voltage divider 4 is used to convert the high voltage output by the safety test instrument 1 into a low voltage that can be measured by the digital multimeter module; based on the maximum output voltage of HV 4250V, a high voltage divider with a voltage division ratio of 1000:1 is set. The relay board 5 is used to switch signals connected to the product under test 9 and related to the safety test instrument 1, such as: the CC_Source circuit signal indicating whether the USBC connection with the product under test 9 is good; the voltage signal after passing through the voltage divider board 4; the I2C signal controlled by the EEPROM in the Power Cable and RTN cable; the VBUS voltage signal indicating whether the Spartan connection to the product is successful; and the decoder enables the mutual exclusion conduction of the above relays. The substrate 6 provides control and measurement of low-voltage signals. The control board 12 is the control core, and the digital multimeter module 13 is the measurement core. The control board 12 controls the motor module 7 via UART and the cylinder module 8 via I / O expansion. The digital multimeter module 13 measures AC / DC voltage and GB current. The motor module 7 and the cylinder module 8 are used to control the movement of the product under test 9 and to achieve compatibility with products of different sizes; the whole process achieves semi-automatic operation and testing.

[0017] like Figures 1 to 3 As shown, in this embodiment, the general-purpose semi-automatic safety testing machine also includes a CGM board 10. The CGM board 10 is connected to the safety comprehensive testing instrument 1. The CGM board 10 is used to measure whether the machine grounding and the factory grounding are good. If the contact is poor, the buzzer on the machine will continuously alarm and disconnect the 220V power supply to the safety comprehensive testing instrument 1 and the product under test 9. CGM refers to continuous grounding detection.

[0018] The CGM board 10 is used to measure whether the machine ground and the factory ground are good. If the contact is poor, that is, the impedance is greater than 3R, the buzzer on the machine will continuously alarm and disconnect the 220V power supply of the safety test instrument 1 and the product under test 9. Only when the contact is good will the 220V power supply of the safety test instrument 1 and the product under test 9 be normal. The CGM board 10 provides a 10mA constant current source between the machine ground and the factory ground. By measuring the voltage between the two grounds and amplifying it by 100 times, it is compared with a specific voltage, and the comparison is output in the form of IO high and low levels to determine the impedance between the machine ground and the factory ground.

[0019] like Figures 1 to 4As shown, in this embodiment, the general-purpose semi-automatic safety testing machine also includes an interface plug box 11, through which the power switching box 3 is connected to the product under test 9. The interface plug box 11 serves as a plug interface for connecting to the product under test 9, and is a box that implements isolation protection. Only banana plugs and USBA connectors can be connected to the panel. The power cable with the USBA connector contains an EEPROM that records and updates the number of cable insertions and removals. HV is connected to the high-voltage output terminal of the Chroma, L7 / N7 is connected to the 220V AC input of the machine, and DUT_L and DUT_N are connected to the DUT terminal. By controlling the IO, the cylinder is controlled, thereby enabling different terminals to conduct and achieving different circuit connections.

[0020] like Figures 1 to 9 As shown, in this embodiment, the substrate 6 includes a control board 12 and a digital multimeter module 13. The control board 12 controls the motor module 7 via UART and the cylinder module 8 via I / O expansion. The digital multimeter module 13 measures the voltage of AC and DC power, as well as the impedance current to ground. The control board 12 outputs UART data, which is converted to RS232 to control the motor controller. The I / O expansion chip on the substrate 6 outputs I / O signals, which are isolated and level-converted by a PS2805C-4 to become 24V I / O, thereby controlling the solenoid valve and the cylinder's movement. These two control methods are compatible with the control of both the motor and the cylinder, enabling motion control of products of different weights.

[0021] like Figure 8 As shown, in this embodiment, the substrate 6 further includes an IV conversion circuit, which converts the 25A current of the impedance to ground into a corresponding voltage, and then switches it through a relay to finally provide the digital multimeter module 13 with the measured voltage.

[0022] like Figure 10 As shown, in this embodiment, the general-purpose semi-automatic safety testing machine further includes an electrical power control circuit. This circuit is connected to the CGM board 10 and controls the 220V power supply to the safety testing instrument 1 and the 220V power supply to the product under test 9. The CGM board 10, E-STOP, and temperature sensor control the 220V power supply to the safety testing instrument 1 and the product, providing strong protection for system safety.

[0023] like Figures 1 to 2As shown, in this embodiment, the general-purpose semi-automatic safety testing machine also includes an electrical high-voltage enable control circuit, which is connected to the relay board 5. This is the enable PIN control circuit for the safety testing instrument 1. As can be seen, the safety testing instrument 1 only has the HV output condition when the Inter Lock relay and all safety door locks around the machine are engaged. This design ensures that all safety doors of the machine are fully closed during use, preventing accidental human contact and improving the protection level.

[0024] like Figure 5 and Figure 6 As shown, the decoder controls the switching of various signal relays. The high-voltage relay switches the voltage signal after HV voltage division, the CC Source impedance measurement signal, and the Chroma high-voltage output enable signal Inter_Lock. In addition, the relay also switches the I2C signal and the VBUS, CC, SBU, and USB signals of USBC.

[0025] like Figure 7 As shown, the substrate 6 includes a CC_Source circuit, which provides a 10mA constant current source for detecting whether the USBC interface is connected to the product and whether the connection is good.

[0026] like Figure 12 As shown, the general-purpose semi-automatic safety testing machine also includes a light grating control circuit. This design is for preventing hand pinching. When the front curtain of the machine is moving, if a person triggers the light grating, it will stop the movement of the motor or cylinder, thereby controlling the curtain to stop moving and achieving the purpose of protection.

[0027] Although the embodiments of the present invention are described with reference to actual solutions, they do not constitute a limitation on the meaning of the present invention. Modifications to the embodiments and combinations with other solutions based on this specification will be obvious to those skilled in the art.

Claims

1. A general-purpose semi-automatic safety testing machine, comprising a safety testing instrument (1), wherein the safety testing instrument (1) is communicatively connected to a host computer (2), characterized in that: The safety testing instrument (1) is connected to a power switching box (3), a voltage divider plate (4), a relay plate (5), and a base plate (6). The host computer (2) is connected to the base plate (6). The base plate (6) is connected to a motor module (7) and a cylinder module (8). The motor module (7) and the cylinder module (8) are both connected to the product under test (9). The voltage divider plate (4) and the relay plate (5) are both connected to the product under test (9). The safety testing instrument (1) is used for AC power testing, DC power testing, and impedance to ground testing. The power switching box (3) performs mutual exclusion control on high voltage DC and AC power. The voltage divider plate (4) converts the high voltage output by the safety testing instrument (1) into a low voltage that the base plate (6) can measure. The relay plate (5) is used to switch the signals connected to the product under test (9) and related to the safety testing instrument (1). The base plate (6) is used to provide control and measurement of weak electrical signals.

2. The general-purpose semi-automatic safety testing machine according to claim 1, characterized in that, The general-purpose semi-automatic safety testing machine also includes a CGM board (10), which is connected to the safety comprehensive tester (1). The CGM board (10) is used to measure whether the machine grounding and the factory grounding are good. If the contact is poor, the buzzer on the machine will continuously alarm and disconnect the 220V power supply of the safety comprehensive tester (1) and the product under test (9).

3. The general-purpose semi-automatic safety testing machine according to claim 1, characterized in that, The general-purpose semi-automatic safety testing machine also includes an interface plug box (11), and the power switching box (3) is connected to the product under test (9) via the interface plug box (11).

4. The universal semi-automatic safety testing machine according to claim 1, characterized in that, The base plate (6) includes a control board (12) and a digital multimeter module (13). The control board (12) controls the motor module (7) via UART and the cylinder module (8) via IO expansion. The digital multimeter module (13) measures the voltage of AC and DC power and measures the impedance current to ground.

5. The general-purpose semi-automatic safety testing machine according to claim 4, characterized in that, The substrate (6) also includes an IV conversion circuit, which converts the 25A current of the impedance to ground into a corresponding voltage, and then switches it through a relay to finally supply the digital multimeter module (13) to measure the voltage.

6. The general-purpose semi-automatic safety testing machine according to claim 2, characterized in that, The general-purpose semi-automatic safety testing machine also includes an electrical power control circuit, which is connected to the CGM board (10). The electrical power control circuit controls the 220V power supply of the safety comprehensive tester (1) and the 220V power supply of the product under test (9).

7. The general-purpose semi-automatic safety testing machine according to claim 1, characterized in that, The general-purpose semi-automatic safety testing machine also includes an electrical high-voltage enable control circuit, which is connected to the relay board (5).

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