Silicon controlled rectifier power regulator

Abstract

The invention provides a silicon controlled rectifier power regulator, relates to the technical field of silicon controlled rectifiers, and solves the technical problem that a traditional silicon controlled rectifier power regulator cannot detect whether a load is connected with a wrong power supply line or not. The silicon controlled rectifier power regulator comprises four input terminals, six first zero-cross detection circuits, four input relays, at least one silicon controlled rectifier control module, at least one output relay, a second zero-cross detection circuit and a control unit. Through the structure, the plurality of first zero-cross detection circuits can send a plurality of first pulses to the control unit, and the second zero-cross detection circuit can send a second pulse to the control unit, so that the control unit can control the plurality of first pulses based on the respective first moments of all the first pulses and the second moments of the second pulses. And whether the load is connected to a wrong power supply line is accurately judged.

Description

Technical Field

[0001] This application relates to the field of thyristor technology, specifically to a thyristor power regulator. Background Technology

[0002] Thyristor power regulators are widely used in kilns, heat treatment furnaces, electric high-temperature furnaces, synthesis furnaces, lighting, electrochemical processing, new energy power generation, and motor speed control. Depending on the load and operating environment, different control modes can be selected, such as phase control, distributed zero-potential control, and time-proportional adjustable control, to meet diverse industrial needs. In the silicon wafer processing of the photovoltaic industry, precise temperature control of furnace tube heating is required. Using thyristor power regulators for furnace tube heating control is safer and more controllable than discrete solid-state relay control.

[0003] Traditional thyristor power conditioners typically employ a three-phase, three-input (powered by three phases) and three-output (connected to three loads) wiring configuration, or a single-phase, one-input (powered by one live wire) and one-output (connected to one load) wiring configuration. This wiring is relatively simple, resulting in a lower probability of wiring problems. However, multi-output thyristor power conditioners can simultaneously control multiple (e.g., dozens) heating loads in a photovoltaic thermal field. The complex and diverse operating environment of photovoltaic thermal fields, coupled with the numerous outputs of the thyristor power conditioner, makes on-site installation and commissioning very complex and prone to various problems, such as loads being connected to incorrect power lines. Traditional thyristor power conditioners usually only have simple internal self-testing mechanisms but lack detection for external load connections, thus failing to detect whether a load is connected to an incorrect power line. Summary of the Invention

[0004] To address the aforementioned technical problems, this application is proposed. Embodiments of this application provide a thyristor power regulator.

[0005] In a first aspect, one embodiment of this application provides a thyristor power regulator configured to supply power to at least one load, comprising: four input terminals electrically connected to four power supply lines, wherein three power supply lines are three phase lines with two different phases, and the other power supply line is a neutral line; six first zero-crossing detection circuits, each first zero-crossing detection circuit electrically connected to two input terminals, the first zero-crossing detection circuit being configured to generate a first pulse when a first AC voltage between the two input terminals connected to the first zero-crossing detection circuit reaches zero; four input relays electrically connected to the four input terminals; at least one thyristor control module, the at least one thyristor control module being configured one-to-one with at least one load, wherein for the corresponding thyristor control module and load, the thyristor control module is electrically connected to one of the three power supply lines with two different phases, and the load is electrically connected to the other of the three power supply lines with two different phases, or electrically connected to the neutral line; at least one output relay, configured one-to-one with at least one load, the output relay being electrically connected to the corresponding load; and a second zero-crossing detection circuit, and... All output relays and all input relays are electrically connected. The second zero-crossing detection circuit is configured to generate a second pulse when the second AC voltage between the input relay and the output relay connected to the second zero-crossing detection circuit reaches zero. The control unit, electrically connected to the first zero-crossing detection circuit, all input relays, all SCR control modules, all output relays, and the second zero-crossing detection circuit, is configured to control all input relays, all SCR control modules, and all output relays to be turned on or off. Furthermore, when one of the input relays is turned on, one of the output relays is turned on, and all SCR control modules are turned off, the control unit receives the first pulse generated by each of the first zero-crossing detection circuits and the second pulse generated by the second zero-crossing detection circuit. Based on the first moment of receiving each of the first pulses and the second moment of receiving the second pulses, the control unit determines a first detection result of the load connection to the power supply line. The first detection result includes whether the load is connected to an incorrect power supply line and / or the target power supply line to which the load is actually connected.

[0006] In some embodiments, the thyristor power regulator further includes: a DC power supply electrically connected to all input relays and configured to provide a DC voltage; a current sampling circuit electrically connected to the DC power supply and to all output relays; wherein the control unit is also electrically connected to the current sampling circuit, and in the case that one of the input relays is conducting, the output relay connected to the load electrically connected to the power supply line of the conducting input relay is conducting, and all thyristor control modules are disconnected, the current sampling circuit is configured to detect a first current value flowing through the load connected to the conducting output relay, and the control unit is configured to receive the first current value and determine a second detection result of the load connected to the conducting output relay based on a pre-stored DC voltage value, a pre-stored voltage calibration value, and the first current value, wherein the second detection result includes at least one of whether the load resistance is degraded, whether the load is not connected to the power supply line, whether the load has poor contact with the power supply line, and whether there is a short circuit between the load and the power supply line.

[0007] In some embodiments, the thyristor power regulator further includes: at least one voltage measurement module, each voltage measurement module being configured to correspond one-to-one with at least one load, the voltage measurement module being electrically connected to one of three power supply lines with different phases in each pair, and the voltage measurement module being electrically connected to the corresponding load, the power supply line connected to the voltage measurement module being the same as the power supply line connected to the thyristor control module corresponding to the load; a voltage sampling circuit, electrically connected to all output relays and all input relays; wherein, the control unit is also electrically connected to the voltage measurement module and the voltage sampling circuit, and when one of the input relays is turned on, one of the output relays is turned on, and all thyristor control modules are turned off, the voltage measurement module is configured to detect a first voltage value between the power supply line connected to the thyristor control module corresponding to the load connected to the turned-on output relay and the power supply line connected to the load connected to the turned-on output relay; the voltage sampling circuit is configured to detect a second voltage value between the power supply line connected to the input terminal of the turned-on input relay and the power supply line connected to the load connected to the turned-on output relay; the control unit is configured to receive the first voltage value and the second voltage value, and determine whether the internal circuit of the voltage sampling circuit is abnormal based on the first voltage value and the second voltage value.

[0008] In some embodiments, after all the thyristor control modules are disconnected, when the controller receives at least two first pulses, the control unit is further configured to: determine first phase sequence data based on pre-stored operating data, the first phase sequence data including the order and time interval of the zero-point times of at least two sets of AC currents formed by the two enabled power supply lines; and determine, based on the first moment of receiving at least two first pulses and the first phase sequence data, whether the enabled power supply lines are actually enabled, whether the disabled power supply lines are actually disabled, and whether the order and time interval of the zero-point times of at least two sets of AC currents formed by the two enabled power supply lines are abnormal.

[0009] In some embodiments, the control unit is further configured to receive a first voltage value for each thyristor control module, and determine, based on the first voltage value and a first preset voltage range, whether the power supply line connected to the thyristor control module is incorrect.

[0010] In some embodiments, the resistance value of the load is the rated resistance value; in the absence of calibration data stored in the control unit, the control unit is configured to read the pre-stored factory data configuration and perform factory testing on the thyristor power regulator based on the factory data configuration, wherein the calibration data is the data stored in the control unit after the thyristor power regulator has been factory tested.

[0011] In some embodiments, when all the thyristor control modules are disconnected, the control unit is configured to receive the first pulses generated by each of the first zero-crossing detection circuits, determine the second phase sequence data based on the factory data configuration, the second phase sequence data including the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines, and determine whether the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines are abnormal based on the first moment of all the first pulses and the second phase sequence data received.

[0012] In some embodiments, the thyristor power regulator further includes: at least one voltage measurement module, each voltage measurement module being configured to correspond one-to-one with at least one load; each voltage measurement module being electrically connected to one of three power supply lines with different phases; and the voltage measurement module being electrically connected to the corresponding load; the power supply line connected to the voltage measurement module is the same as the power supply line connected to the thyristor control module corresponding to the load; wherein, the control unit is also electrically connected to the voltage measurement module; when all thyristor control modules are disconnected, the voltage measurement module is configured to detect a first voltage value between the power supply line connected to the thyristor control module corresponding to the load connected to the conducting output relay and the power supply line connected to the load connected to the conducting output relay; the control unit is further configured to receive the first voltage value, and based on the first voltage value and a second preset voltage range, determine whether the power supply line connected to the thyristor control module is incorrect; and, if the power supply line connected to the thyristor control module is correct, determine voltage correction parameters for the voltage measurement module based on the first voltage value and the preset voltage value, wherein the preset voltage value is within the second preset voltage range, and the voltage correction parameters are used to calibrate the voltage value measured by the voltage measurement module.

[0013] In some embodiments, the thyristor control module includes: a current measurement module; wherein the control unit is electrically connected to the current measurement module, and when all thyristor control modules are disconnected, the current measurement module is configured to detect a second current value flowing through the load corresponding to the thyristor control module, the control unit is configured to receive the second current value, determine whether the thyristor control module is abnormal based on the second current value and a first preset current range, and, when the thyristor control module is normal, determine a first current calibration value of the current measurement module based on the second current value and the first preset current value, wherein the first preset current value is within a first preset current range, and the first current calibration value is used to perform zero-point drift calibration on the current measurement module.

[0014] In some embodiments, when all output relays are off and at least one of all SCR control modules is on, for the on-screen SCR control module, the current measurement module is configured to detect a third current value flowing through the load corresponding to the SCR control module; wherein, the control unit is further configured to: receive the third current value, determine whether the current measurement module is malfunctioning based on the third current value and a second preset current range; and, if the current measurement module is functioning normally, determine a second current calibration value for the current measurement module based on the third current value and the second preset current value, wherein the second preset current value is within the second preset current range, and the second current calibration value is used to calibrate the current gain coefficient of the current measurement module.

[0015] In some embodiments, the thyristor power regulator further includes: a voltage sampling circuit electrically connected to all output relays and all input relays; wherein the control unit is electrically connected to the voltage sampling circuit, and when one of the input relays is turned on, one of the output relays is turned on, and all thyristor control modules are turned off, the voltage sampling circuit is configured to detect a second voltage value between the power supply line connected to the input terminal of the turned-on input relay and the power supply line connected to the load of the turned-on output relay; the control unit is configured to receive the second voltage value and, based on the second voltage value and a third preset voltage range, determine whether the voltage sampling circuit is malfunctioning, or whether the turned-on output relay is connected to an incorrect load.

[0016] In some embodiments, when one of the input relays is turned on, one of the output relays is turned on, and all the thyristor control modules are turned off, the control unit is further configured to receive a first pulse generated by each of the first zero-crossing detection circuits and a second pulse generated by the second zero-crossing detection circuit, and determine whether the turned-on output relay is connected to an incorrect load based on a first time when all the first pulses are received and a second time when the second pulses are received.

[0017] In some embodiments, the load resistance is the rated resistance value. When one of all input relays is turned on, the output relay connected to the load connected to the power supply line electrically connected to the turned input relay is turned on, and all thyristor control modules are turned off, the current sampling circuit is configured to detect a fourth current value flowing through the load connected to the turned output relay. The control unit is configured to receive the fourth current value and determine a voltage calibration value based on the DC voltage, the fourth current value, and the rated resistance value.

[0018] The thyristor power regulator proposed in this application, by setting multiple input relays, can flexibly adjust the power supply line connected to the load, ensuring that the power supply line is consistent with the power supply line electrically connected to the thyristor control module corresponding to the load. By setting multiple output relays, the load to be tested can be flexibly selected. This allows for zero-crossing detection of multiple loads in the test path, eliminating the need for a separate second zero-crossing detection circuit for each load, significantly simplifying the thyristor power regulator circuitry and reducing costs. By setting multiple first zero-crossing detection circuits to send multiple first pulses to the control unit, and setting second zero-crossing detection circuits to send second pulses to the control unit, the control unit can accurately determine whether the load is connected to an incorrect power supply line based on the first moment of each first pulse and the second moment of each second pulse. Furthermore, it can identify the incorrect power supply line (i.e., the target power supply line) connected to the load, facilitating the reconnection of the load to the correct power supply line. Attached Figure Description

[0019] The above and other objects, features, and advantages of this application will become more apparent from the more detailed description of the embodiments of this application in conjunction with the accompanying drawings. The drawings are provided to further illustrate the embodiments of this application and form part of the specification. They are used together with the embodiments of this application to explain this application and do not constitute a limitation thereof. In the drawings, the same reference numerals generally represent the same components or steps.

[0020] Figure 1 The diagram shown is a schematic diagram of a thyristor power regulator provided in an exemplary embodiment of this application.

[0021] Figure 2 The diagram shown is a flowchart illustrating a factory testing method for a thyristor power regulator provided in an exemplary embodiment of this application.

[0022] Figure 3 The diagram shown is a flowchart illustrating a power-on self-test method for a thyristor power regulator provided in an exemplary embodiment of this application.

[0023] Figure label: 100. Thyristor power regulator; 101. Input terminal; 102. First zero-crossing detection circuit; 103. Input relay; 104. Thyristor control module; 105. Output relay; 106. Second zero-crossing detection circuit; 107. Control unit; 108. DC power supply; 109. Current sampling circuit; 110. Voltage sampling circuit; 200. Load. Detailed Implementation

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] Figure 1 The diagram shown is a schematic representation of a thyristor power regulator provided in an exemplary embodiment of this application. The diagram illustrates the connection relationships between the various modules within the thyristor power regulator 100. Figure 1 The diagram only shows the electrical connections between the control unit 107 and one input relay 103, one output relay 105, and one thyristor control module 104, but the control unit 107 is actually electrically connected to all the input relays 103, all the output relays 105, and all the thyristor control modules 104.

[0026] like Figure 1As shown, this application embodiment provides a thyristor power regulator 100 configured to supply power to at least one load 200 (such as a heater), including: four input terminals 101, six first zero-crossing detection circuits 102, four input relays 103, at least one thyristor control module 104, at least one output relay 105, a second zero-crossing detection circuit 106, and a control unit 107. The four input terminals 101 are electrically connected to four power supply lines, wherein three power supply lines are three phase lines with different phases in each pair, and the other power supply line is a neutral line. Each first zero-crossing detection circuit 102 is electrically connected to two input terminals 101, and the first zero-crossing detection circuit 102 is configured to generate a first pulse when a first AC voltage between the two input terminals 101 connected to the first zero-crossing detection circuit 102 reaches zero. The four input relays 103 are electrically connected to the four input terminals 101 respectively. At least one SCR control module 104 is configured to correspond one-to-one with at least one load 200. For each SCR control module 104 and load 200, the SCR control module 104 is electrically connected to one of the three power supply lines with different phases, and the load 200 is electrically connected to the other of the three power supply lines with different phases, or to the neutral line. At least one output relay 105 is configured to correspond one-to-one with at least one load 200, and the output relay 105 is electrically connected to the corresponding load 200. A second zero-crossing detection circuit 106 is electrically connected to all output relays 105 and all input relays 103. The second zero-crossing detection circuit 106 is configured to generate a second pulse when the second AC voltage between the input relay 103 and the output relay 105 that is connected to the second zero-crossing detection circuit 106 reaches zero. The control unit 107 is electrically connected to the first zero-crossing detection circuit 102, all input relays 103, all SCR control modules 104, all output relays 105, and the second zero-crossing detection circuit 106. It is configured to control all input relays 103, all SCR control modules 104, and all output relays 105 to be turned on or off. When one of the input relays 103 is turned on, one of the output relays 105 is turned on, and all SCR control modules 104 are turned off, it receives the first pulse generated by each of the first zero-crossing detection circuits 102 and the second pulse generated by the second zero-crossing detection circuit 106. Based on the first moment of receiving each of the first pulses and the second moment of receiving the second pulses, it determines the first detection result of the connection between the load 200 and the power supply line. The first detection result includes whether the load 200 is connected to the wrong power supply line and / or the target power supply line that the load 200 is actually connected to.

[0027] Specifically, the four input terminals 101 are L1 input terminal 101, L2 input terminal 101, L3 input terminal 101 and N input terminal 101. L1 input terminal 101 is electrically connected to the phase line L1, L2 input terminal 101 is electrically connected to the phase line L2, L3 input terminal 101 is electrically connected to the phase line L3, and N input terminal 101 is electrically connected to the neutral line N. Among them, L1, L2 and L3 are the three phase lines with different phases in the three-phase power supply.

[0028] Specifically, in the six first zero-crossing detection circuits 102, the two input terminals 101 electrically connected to each first zero-crossing detection circuit 102 are not completely the same as the two input terminals 101 electrically connected to the other first zero-crossing detection circuit 102 (that is, only one input terminal 101 is the same as the other two input terminals 101 electrically connected to each first zero-crossing detection circuit 102, or both input terminals 101 are different), so that the six first zero-crossing detection circuits 102 are electrically connected to L1 and N, L1 and L2, L2 and N, L2 and L3, L3 and N, and L3 and L1 respectively.

[0029] Specifically, the four input relays 103 are L1 input relay 103, L2 input relay 103, L3 input relay 103, and N input relay 103. During any test, at most one input relay 103 can be turned on at the same time.

[0030] For example, the thyristor control module 104 is electrically connected to the power supply line via an input copper busbar. The current required by the input terminal 101 is very small, so it does not need to be electrically connected to the power supply line via a copper busbar (copper busbars are typically used for high-current connections).

[0031] For example, the number of SCR control modules 104 is M+N+P, namely M L1 SCR control modules 104, N L2 SCR control modules 104, and P L3 SCR control modules 104. The L1 SCR control modules 104 are electrically connected to L1, the L2 SCR control modules 104 are electrically connected to L2, and the L3 SCR control modules 104 are electrically connected to L3. Correspondingly, the load 200 includes M L1 loads 200, N L2 loads 200, and P L3 loads 200. The L1 loads 200 are electrically connected to their corresponding L1 SCR control modules 104, the L2 loads 200 are electrically connected to their corresponding L2 SCR control modules 104, and the L3 loads 200 are electrically connected to their corresponding L3 SCR control modules 104. For the corresponding SCR control module 104 and load 200, the power supply line connected to the SCR control module 104 is different from the power supply line connected to the load 200. For example, if the SCR control module 104 is connected to L1, then the load 200 can only be connected to L2, L3 or the neutral line.

[0032] For example, there are M+N+P output relays 105, namely M L1 output relays 105, N L2 output relays 105 and P L3 output relays 105. The L1 output relays 105 are electrically connected to the corresponding L1 load 200, the L2 output relays 105 are electrically connected to the corresponding L2 load 200, and the L3 output relays 105 are electrically connected to the corresponding L3 load 200.

[0033] During any given test, at most one output relay 105 can be turned on simultaneously to test the branch containing one load 200. During tests with output relay 105 on, to avoid interfering with the test results and causing inaccurate results, the SCR control module 104 must be turned off. However, when the SCR power regulator 100 is performing heating control (at which point the SCR control module 104 is on), output relay 105 must be turned off.

[0034] For example, the control unit 107 is a microcontroller unit (MCU). Specifically, the control unit 107 can store data configuration, run the driver software of the first zero-crossing detection circuit 102, run the driver software of the second zero-crossing detection circuit 106, and run the driver software for turning the input relay 103 and the output relay 105 on or off, etc.

[0035] In practical applications, before testing whether the power supply line connected to a certain load 200 is faulty, it is necessary to ensure that all thyristor control modules 104 are disconnected to avoid affecting the test results. Furthermore, it is necessary to ensure that the input relay 103 connected to the input terminal 101 of the power supply line connected to the thyristor control module 104 corresponding to the load 200 is conductive, so that the power supply line connected to the thyristor control module 104 corresponding to the load 200 can still conduct with the load 200 and with the second zero-crossing detection circuit 106 during the test. Additionally, it is necessary to ensure that the output relay 105 corresponding to the load 200 is conductive, so that the second zero-crossing detection circuit 106 conducts with the load 200. This allows the first power supply line (the power supply line connected to the input terminal 101), input terminal 101, input relay 103, second zero-crossing detection circuit 106, output relay 105, load 200, and the second power supply line (the power supply line connected to the thyristor control module 104 corresponding to the load 200) to form a test path. When the voltage between the two power supply lines actually connected to the load 200 reaches zero, the second zero-crossing detection circuit 106 generates a second pulse. After the control unit 107 receives all the first pulses generated by the first zero-crossing detection circuit 102 and the second pulses generated by the second zero-crossing detection circuit 106, it can determine the first pulses that are the same at the first and second moments, and identify the two power supply lines connected to the first zero-crossing detection circuit 102 that generated the first pulse. These two power supply lines are the two power supply lines actually connected to the load 200, thereby determining whether the load 200 is connected to the wrong power supply line, and / or the target power supply line that the load 200 is actually connected to.

[0036] For example, load 200 of L1 should be electrically connected to L2, and load 200 of L1 is connected to L1 through the thyristor control module 104. During the test, L1 input relay 103 and L1 output relay 105 corresponding to load 200 of L1 are turned on. If the first pulse that is the same at the first moment and the second moment among all the first pulses received by control unit 107 is generated by the first zero-crossing detection circuit 102 connected to L1 and L3, it indicates that load 200 is connected to the wrong power supply line, and the target power supply line is L3.

[0037] In the above embodiments, by setting multiple input relays 103, the power supply line connected to the load 200 can be flexibly adjusted to match the power supply line electrically connected to the thyristor control module 104 corresponding to the load 200. By setting multiple output relays 105, the load 200 to be tested can be flexibly selected. This allows for zero-crossing detection of multiple loads 200 in the test path, based on only one second zero-crossing detection circuit 106, without requiring a separate second zero-crossing detection circuit 106 for each load 200. This greatly simplifies the wiring of the thyristor power regulator 100 and reduces costs. By setting multiple first zero-crossing detection circuits 102 to send multiple first pulses to the control unit 107, and setting a second zero-crossing detection circuit 106 to send second pulses to the control unit 107, the control unit 107 can accurately determine whether the load 200 is connected to the wrong power supply line based on the first time of each of the first pulses and the second time of the second pulse. Furthermore, it can also determine the wrong power supply line (i.e., the target power supply line) connected to the load 200, making it easier for staff to reconnect the wiring between the load 200 and the wrong power supply line, so that the load 200 is connected to the correct power supply line.

[0038] In addition, the combined use of input relay 103 and output relay 105, as well as the software configuration of control unit 103, enables the thyristor power regulator 100 to form various test environments for various tests (see the embodiments below for details).

[0039] In some embodiments, such as Figure 1 As shown, the thyristor power regulator 100 also includes a DC power supply 108 and a current sampling circuit 109. The DC power supply 108 is electrically connected to all input relays 103 and is configured to provide DC voltage. The current sampling circuit 109 is electrically connected to the DC power supply 108 and to all output relays 105.

[0040] The control unit 107 is also electrically connected to the current sampling circuit 109. When one of the input relays 103 is turned on, the output relay 105 connected to the load 200 connected to the power supply line of the turned input relay 103 is turned on, and all the thyristor control modules 104 are turned off, the current sampling circuit 109 is configured to detect a first current value flowing through the load 200 connected to the turned output relay 105. The control unit 107 is configured to receive the first current value and, based on a pre-stored DC voltage value, a pre-stored voltage calibration value, and the first current value, determine a second detection result of the load 200 connected to the turned output relay 105. The second detection result of the load 200 includes at least one of the following: whether the load 200 has deteriorated resistance, whether the load 200 is not connected to the power supply line, whether the load 200 has poor contact with the power supply line, and whether there is a short circuit between the load 200 and the power supply line.

[0041] For example, L1 input relay 103 is turned on, and L1 output relay 105 is turned on.

[0042] Specifically, the control unit 107 can obtain the actual voltage value by subtracting the voltage calibration value from the DC voltage value, and then divide the actual voltage value by the first current value to obtain the resistance value of the load 200. When the resistance value of the load 200 is not within the preset resistance value range, it is determined that the resistance of the load 200 has deteriorated (such as melting, short circuit, burnout, oxidation, etc., leading to an increase in resistance value); when the resistance value of the load 200 is infinite, it is determined that the load 200 is not connected to the conducting output relay 105; when the resistance value of the load 200 fluctuates frequently, it is determined that the load 200 has poor contact; when the resistance value of the load 200 is 0 ohms, it is determined that the load 200 is short-circuited.

[0043] Traditional thyristor power regulators cannot detect problems such as poor load wiring, deteriorated load resistance, load short circuits, or unconnected loads. However, in the above embodiment, since the power supply line connected to the conducting input relay 103 and the power supply line connected to the load 200 connected to the conducting output relay 105 are the same power supply line, the voltage applied to the load 200 from the same power supply line is 0. At this time, the DC voltage value of the DC power supply 108 is the total voltage value of the branch where the load 200 is located. By subtracting the voltage calibration value from the DC voltage value, the actual voltage value applied to the load 200 can be obtained. Dividing the actual voltage value by the first current value accurately yields the resistance value of the load 200. Actual testing shows that the resistance value of the load 200 detected by this method can reach an accuracy of 0.01 ohms and a resolution of 0.001 ohms. It can detect minute changes in the resistance value of the load 200, making load degradation analysis more accurate and effective, ensuring electrical safety and preventative maintenance. Furthermore, by detecting the resistance value of load 200, it is also possible to determine whether load 200 is not connected to the power supply line, whether load 200 has poor contact with the power supply line, or whether there is a short circuit between load 200 and the power supply line.

[0044] In some embodiments, the resistance of the load 200 is the rated resistance value. When one of all the input relays 103 is turned on, the output relay 105 connected to the load 200 via the power supply line connected to the turned input relay 103 is turned on, and all the SCR control modules 104 are turned off, the current sampling circuit 109 is configured to detect a fourth current value flowing through the load 200 connected to the turned output relay 105. The control unit 107 is configured to receive the fourth current value and determine a voltage calibration value based on the DC voltage, the fourth current value, and the rated resistance value.

[0045] The voltage calibration value mainly comes from the voltage drop of the current sampling circuit 109.

[0046] Specifically, the actual voltage value borne by the load 200 can be obtained by multiplying the fourth current value and the rated resistance value. Then, the voltage calibration value is obtained by subtracting the actual voltage value borne by the load 200 from the DC voltage value. After obtaining the voltage calibration value, when measuring the resistance value of the load 200, the control unit 107 can obtain the actual voltage value by subtracting the voltage calibration value from the DC voltage value, and then divide the actual voltage value by the first current value to obtain the resistance value of the load 200.

[0047] In the above embodiments, by using a load 200 with an accurate rated resistance value, the voltage calibration value can be accurately calculated based on the DC voltage, the fourth current value, and the rated resistance value, thereby enabling the control unit 107 to accurately determine the resistance value of the load 200 based on the DC voltage value, the voltage calibration value, and the first current value.

[0048] In some embodiments, the thyristor power regulator 100 further includes at least one voltage measurement module (not shown) and a voltage sampling circuit 110. The at least one voltage measurement module is configured to correspond one-to-one with at least one load 200. Each voltage measurement module is electrically connected to one of three power supply lines with different phases in each pair, and is also electrically connected to the corresponding load 200. The power supply line connected to the voltage measurement module is the same as the power supply line connected to the thyristor control module 104 corresponding to the load 200. The voltage sampling circuit 110 is electrically connected to all output relays 105 and all input relays 103.

[0049] For example, if the power supply line electrically connected to the voltage measurement module is L1, then the power supply line electrically connected to the thyristor control module 104 corresponding to the load 200 is also L1.

[0050] The control unit 107 is also electrically connected to the voltage measurement module and the voltage sampling circuit 110. When one of the input relays 103 is turned on, one of the output relays 105 is turned on, and all the thyristor control modules 104 are turned off, the voltage measurement module is configured to detect a first voltage value between the power supply line of the thyristor control module 104 connected to the load 200 connected to the turned-on output relay 105 and the power supply line of the load 200 connected to the turned-on output relay 105. The voltage sampling circuit 110 is configured to detect a second voltage value between the power supply line of the input terminal 101 connected to the turned-on input relay 103 and the power supply line of the load 200 connected to the turned-on output relay 105. The control unit 107 is configured to receive the first voltage value and the second voltage value, and determine whether the internal circuit of the voltage sampling circuit 110 is abnormal based on the first voltage value and the second voltage value.

[0051] Specifically, the voltage measurement module and the voltage sampling circuit 110 theoretically measure the voltage between the same two power supply lines, such as measuring the voltage between L1 and L2. Therefore, if the first voltage value is accurate, but the second voltage value is different, it indicates that the internal circuit of the voltage sampling circuit 110 is abnormal, such as some switches installed inside the voltage sampling circuit 110, and some of the switches are configured incorrectly.

[0052] In the above embodiment, by controlling the input relay 103 and the output relay 105, the voltage measurement module and the voltage sampling circuit 110 measure the voltage between the same two power supply lines, respectively obtaining the first voltage value and the second voltage value. By comparing whether the first voltage value and the second voltage value are the same, it is possible to accurately detect whether the wiring of the voltage sampling circuit 110 is abnormal.

[0053] In some embodiments, after all the thyristor control modules 104 are disconnected, when the controller receives at least two first pulses, the control unit 107 is further configured to: determine first phase sequence data based on pre-stored operating data configuration, the first phase sequence data including the order and time interval of the zero-point times of at least two sets of AC currents formed by the two enabled power supply lines; and determine, based on the first moment of receiving at least two first pulses and the first phase sequence data, whether the enabled power supply lines are actually enabled, whether the disabled power supply lines are actually disabled, and whether the order and time interval of the zero-point times of at least two sets of AC currents formed by the two enabled power supply lines are abnormal.

[0054] Specifically, the operating data configuration stores first phase sequence data, which includes the order and time interval of the zero-point times of at least two of the alternating currents formed by L1-N, L1-L2, L2-N, L2-L3, L3-N, and L3-L1. For example, the zero-point time of the alternating current formed by L1-N is time A, and the zero-point time of the alternating current formed by L1-L2 is time B.

[0055] Since the zero-point times and time intervals of the AC power generated by the activated power lines are within the first phase sequence data, while those of the AC power generated by the inactive power lines are not, if the first pulse corresponding to the AC power generated by the two activated power lines is not received, it indicates that at least one of the two activated power lines is actually not activated. If the first pulse corresponding to the AC power generated by the inactive power line is received, it indicates that the inactive power line is actually activated. Therefore, it can be determined whether the activated power lines are actually activated and whether the inactive power lines are actually not activated. By comparing the first moments of at least two first pulses with the first phase sequence data, it can be determined whether the zero-point times and time intervals of at least two sets of AC power generated by the two activated power lines are abnormal. If the zero-point times of at least two sets of AC power generated by the two activated power lines are abnormally ordered, then one of the two power lines corresponding to the abnormally ordered AC power has a power line with a wiring error between it and the corresponding input terminal 101. If the zero-point times and time intervals of at least two sets of AC power generated by the two activated power lines are abnormal, it indicates that the first phase sequence data is configured incorrectly.

[0056] In the above embodiments, based on the first phase sequence data and the first pulse, it is possible to accurately detect whether the enabled power supply line is actually enabled, whether the disabled power supply line is actually disabled, whether there is a wiring error between the power supply line and the input terminal 101, and whether the first phase sequence data is configured incorrectly.

[0057] In some embodiments, the control unit 107 is further configured to receive a first voltage value for each thyristor control module 104, and determine, based on the first voltage value and a first preset voltage range, whether the power supply line connected to the thyristor control module 104 is incorrect.

[0058] Specifically, if the first voltage value is not within the first preset voltage range, it indicates that the power supply line connected to the thyristor control module 104 is incorrect; if the first voltage value is within the first preset voltage range, it indicates that the power supply line connected to the thyristor control module 104 is correct.

[0059] For example, if the first voltage value is 380 V and the first preset voltage range is 210 V to 230 V, that is, the first voltage value is not within the first preset voltage range, it indicates that the power supply line connected to the thyristor control module 104 is incorrect.

[0060] In the above embodiments, by setting a first preset voltage range and detecting the first voltage value between the power supply line connected to the SCR control module 104 corresponding to the load 200 connected to the conducting output relay 105 and the power supply line connected to the load 200 connected to the conducting output relay 105, it is possible to accurately detect whether the power supply line connected to the SCR control module 104 is incorrect. Furthermore, combined with the method in the aforementioned embodiments for determining whether the load 200 is connected to the wrong power supply line through zero-crossing detection, it is possible to determine whether the AC current applied to the load 200 during the heating control process is correct from both the zero-crossing moment and voltage perspectives.

[0061] In some embodiments, the resistance value of the load 200 is the rated resistance value. When the control unit 107 does not store calibration data, the control unit 107 is configured to read pre-stored factory data configuration and perform factory testing on the thyristor power regulator 100 based on the factory data configuration, wherein the calibration data is the data stored in the control unit 107 after the thyristor power regulator 100 has undergone factory testing.

[0062] In the above embodiment, by using a load 200 with a resistance value equal to the rated resistance value, the fault factors of the load 200 itself can be eliminated, and on this basis, the internal faults of the thyristor power regulator 100 are mainly detected. If the control unit 107 does not store calibration data, it indicates that the thyristor power regulator 100 has not undergone factory testing, therefore, factory testing needs to be enabled.

[0063] In some embodiments, when all the thyristor control modules 104 are disconnected, the control unit 107 is configured to: receive the first pulses generated by each of the first zero-crossing detection circuits 102, determine the second phase sequence data based on the factory data configuration, the second phase sequence data including the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines, and determine whether the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines are abnormal based on the first moment of all the first pulses and the second phase sequence data received.

[0064] If the sequence of zero-point times of all the AC currents formed by the two power supply lines is abnormal, it indicates that there is an error in the internal wiring of the thyristor power regulator 100. If the time interval of the zero-point times of all the AC currents formed by the two power supply lines is abnormal, it indicates a hardware circuit failure of the thyristor power regulator 100, such as a chip failure or a thyristor failure.

[0065] In the above embodiments, this method can accurately detect whether there are errors in the internal wiring of the thyristor power regulator 100, and whether the hardware circuit of the thyristor power regulator 100 is faulty.

[0066] In some embodiments, the thyristor power regulator 100 further includes at least one voltage measurement module. The at least one voltage measurement module is configured to correspond one-to-one with at least one load 200. The voltage measurement module is electrically connected to one of three power supply lines with different phases in each pair, and the voltage measurement module is electrically connected to the corresponding load 200. The power supply line to which the voltage measurement module is electrically connected is the same as the power supply line to which the thyristor control module 104 corresponding to the load 200 is electrically connected.

[0067] The control unit 107 is also electrically connected to the voltage measurement module. When all the SCR control modules 104 are disconnected, the voltage measurement module is configured to detect a first voltage value between the power supply line of the SCR control module 104 connected to the load 200 connected to the conducting output relay 105 and the power supply line of the load 200 connected to the conducting output relay 105. The control unit 107 is also configured to receive the first voltage value and, based on the first voltage value and a second preset voltage range, determine whether the power supply line connected to the SCR control module 104 is incorrect. If the power supply line connected to the SCR control module 104 is correct, the control unit 107 determines the voltage correction parameters of the voltage measurement module based on the first voltage value and the preset voltage value. The preset voltage value is within the second preset voltage range, and the voltage correction parameters are used to calibrate the voltage value measured by the voltage measurement module.

[0068] Specifically, if the first voltage value is not within the second preset voltage range, it indicates that the power supply line connected to the SCR control module 104 is incorrect; if the first voltage value is within the second preset voltage range, it indicates that the power supply line connected to the SCR control module 104 is correct. Under the condition that the power supply line connected to the SCR control module 104 is correct, the voltage correction parameters of the voltage measurement module can be determined based on the first voltage value and the preset voltage value.

[0069] For example, if the first voltage value is 220 V and the second preset voltage range is 375 V to 385 V, it indicates that the power supply line connected to the thyristor control module 104 is incorrect.

[0070] For example, if the first voltage value is 377 V and the preset voltage value is 380 V, then it is necessary to determine the voltage correction parameters based on 377 V and 380 V.

[0071] In the above embodiments, based on the first voltage value and the second preset voltage range, it is possible to accurately determine whether the power supply line connected to the thyristor control module 104 is incorrect, and by determining the voltage correction parameters, the voltage value measured by the voltage measurement module with deviation can be calibrated, thereby enabling the voltage measurement module to accurately detect voltage.

[0072] In some embodiments, the thyristor control module 104 includes a current measurement module (not shown). The control unit 107 is electrically connected to the current measurement module. When all thyristor control modules 104 are disconnected, the current measurement module is configured to detect a second current value flowing through the load 200 corresponding to the thyristor control module 104. The control unit 107 is configured to receive the second current value, determine whether the thyristor control module 104 is malfunctioning based on the second current value and a first preset current range, and, if the thyristor control module 104 is functioning normally, determine a first current calibration value for the current measurement module based on the second current value and the first preset current value. The first preset current value is within a first preset current range, and the first current calibration value is used to perform zero-point drift calibration on the current measurement module.

[0073] The first preset current value is 0 A.

[0074] Specifically, with all the SCR control modules 104 disconnected, the second current value measured by the current measurement module should be 0 A. If the second current value is not within the first preset current range (i.e., not close to 0 A), it indicates that the SCR control module 104 is malfunctioning. If the second current value is within the first preset current range (i.e., close to 0 A), it indicates that the SCR control module 104 is functioning normally. If the second current value is different from the first preset current value, it indicates that the current measurement module has experienced zero-point drift. Therefore, it is necessary to determine the first current calibration value based on the second current value and the first preset current value to perform zero-point drift calibration on the current measurement module.

[0075] For example, if the second current value is 0.001A, then the first current calibration value is 0.001A, and the current value measured by the current measurement module after calibration should be reduced by 0.001A.

[0076] In the above embodiments, based on the second current value and the first preset current range, it is possible to accurately determine whether the thyristor control module 104 is abnormal, and by determining the first current calibration value, the current measurement module can be zero-point drift calibrated so that the current measurement module can accurately detect the current.

[0077] In some embodiments, when all output relays 105 are off and at least one of the SCR control modules 104 is on, for the on-screen SCR control module 104, the current measurement module is configured to detect a third current value flowing through the load 200 corresponding to the SCR control module 104. The control unit 107 is further configured to: receive the third current value; determine whether the current measurement module is malfunctioning based on the third current value and a second preset current range; and, if the current measurement module is functioning normally, determine a second current calibration value for the current measurement module based on the third current value and the second preset current value, wherein the second preset current value is within the second preset current range, and the second current calibration value is used to calibrate the current gain coefficient of the current measurement module.

[0078] Specifically, if the third current value is not within the second preset current range, the current measurement module is determined to be malfunctioning; if the third current value is within the second preset current range, the current measurement module is determined to be normal.

[0079] For example, if the third current value is 21.5 A and the second preset current value is 22 A, then the second current calibration value needs to be determined based on 21.5 A and 22 A.

[0080] In the above embodiments, the current measurement module can be accurately determined to be abnormal based on the third current value and the second preset current range. Furthermore, the current gain coefficient of the current measurement module can be calibrated using the second current calibration value, enabling the current measurement module to accurately detect the current.

[0081] In some embodiments, the thyristor power regulator 100 further includes a voltage sampling circuit 110, which is electrically connected to all output relays 105 and all input relays 103.

[0082] The control unit 107 is electrically connected to the voltage sampling circuit 110. When one of the input relays 103 is turned on, one of the output relays 105 is turned on, and all the thyristor control modules 104 are turned off, the voltage sampling circuit 110 is configured to detect a second voltage value between the power supply line connected to the input terminal 101 of the turned-on input relay 103 and the power supply line connected to the load 200 of the turned-on output relay 105. The control unit 107 is configured to receive the second voltage value and, based on the second voltage value and a third preset voltage range, determine whether the voltage sampling circuit 110 is abnormal, or whether the turned-on output relay 105 is connected to the wrong load 200.

[0083] Specifically, if the second voltage value is not within the third preset voltage range, it indicates that the voltage sampling circuit 110 is abnormal, or that the conducting output relay 105 is connected to the wrong load 200; if the second voltage value is within the third preset voltage range, it indicates that the voltage sampling circuit 110 is normal, and the conducting output relay 105 is connected to the correct load 200.

[0084] In the above embodiments, based on the second voltage value and the third preset voltage range, it is possible to accurately determine whether the voltage sampling circuit 110 is abnormal, or whether the conducting output relay 105 is connected to the wrong load 200.

[0085] In some embodiments, when one of the input relays 103 is turned on, one of the output relays 105 is turned on, and all the thyristor control modules 104 are turned off, the control unit 107 is further configured to: receive a first pulse generated by each of the first zero-crossing detection circuits and a second pulse generated by the second zero-crossing detection circuit, and determine whether the turned-on output relay 105 is connected to an incorrect load based on a first time when all the first pulses are received and a second time when the second pulses are received.

[0086] In the above embodiments, by comparing all the first moments and the second moment when the second pulse is received during factory testing, it is possible to accurately determine whether the conducting output relay 105 is connected to the correct load 200.

[0087] In some embodiments, the control unit 107 is also communicatively connected to an alarm device. In response to any of the abnormal situations tested in the foregoing embodiments, the control unit 107 can send the abnormal situation to the alarm device so that the alarm device can display the abnormal situation. And / or, the control unit 107 can also send to the alarm device whether the thyristor power regulator 100 is currently performing factory testing, power-on self-test, or related detection of the resistance value of the load 200.

[0088] The control unit 107 can send specific reasons for the abnormality to the alarm device, such as which load 200 is incorrectly connected to which power supply line, so that the staff can repair the abnormality.

[0089] For example, the alarm device may include a host computer, mobile phone, monitor, computer or other device with display function to display the cause of the abnormality. The alarm device may also include an audio playback device such as a speaker to play an audio of the cause of the abnormality. The alarm device may also include an indicator light, buzzer or other device to prompt the staff that the thyristor power regulator 100 has malfunctioned.

[0090] In the above embodiments, the alarm device can accurately inform the staff of the abnormal cause and detection status of the thyristor power regulator 100, which facilitates the staff to maintain and control the thyristor power regulator 100.

[0091] In practical applications, the thyristor power regulator 100 needs to undergo factory testing before being put into use, and then a power-on self-test is performed upon commissioning. The factory testing primarily checks whether the internal functional modules of the thyristor power regulator 100 are functioning correctly (especially the thyristor control module), whether the internal cables are properly connected, and whether they meet factory inspection standards. The power-on self-test mainly checks whether the external cables are properly connected and whether the load resistance is within the design requirements, thereby analyzing signs of heating system deterioration and facilitating preventative maintenance of the heating system.

[0092] The following sections describe the factory testing process and the power-on self-test process. For any parts not described in detail in the following examples, please refer to the content in the foregoing examples.

[0093] Figure 2 The diagram shown is a flowchart illustrating a factory testing method for a thyristor power regulator provided in an exemplary embodiment of this application.

[0094] like Figure 2 As shown in the figure, this application provides a factory testing method for a silicon controlled rectifier power regulator, including the following steps 301 to 329.

[0095] Step 301: Set up the test environment for factory testing, and use a three-phase four-wire regulated power supply to power the thyristor power regulator.

[0096] Step 301 includes electrically connecting both the output relay 103 and the thyristor control module 104 to the load 200 with a resistance value of the rated resistance value.

[0097] Step 302: The control unit disconnects all the thyristor control modules.

[0098] Step 303: Determine whether the control unit stores calibration data.

[0099] The calibration data is the data stored in the control unit after the silicon controlled rectifier power regulator 100 has undergone factory testing.

[0100] If the control unit 107 does not store calibration data, then proceed to step 304; if the control unit 107 stores calibration data, then proceed to step 329.

[0101] Step 304: The control unit reads the pre-stored factory data configuration.

[0102] For example, factory data configuration can be manually edited.

[0103] Step 305: Based on the first moment and second phase sequence data of all received first pulses, the control unit determines whether the sorting and time interval of the zero-point moments of all AC currents formed by the two power supply lines are abnormal.

[0104] If any of the zero-point times or time intervals of all the AC currents formed by the two power supply lines are abnormal, proceed to step 306; if the zero-point times and time intervals of all the AC currents formed by the two power supply lines are normal, proceed to step 307.

[0105] Step 306: The control unit records the sequence of zero-point moments of the AC current formed by the two power supply lines and any abnormalities in the time interval.

[0106] Step 307: The control unit receives the first voltage value measured by the voltage measurement module, and determines whether the power supply line connected to the thyristor control module is incorrect based on the first voltage value and the second preset voltage range.

[0107] If the power supply line connected to the thyristor control module 104 is incorrect, proceed to step 308; if the power supply line connected to the thyristor control module 104 is correct, proceed to step 309.

[0108] Step 308: The control unit records an error in the power supply line connected to the thyristor control module.

[0109] Step 309: The control unit determines the voltage correction parameters of the voltage measurement module based on the first voltage value and the preset voltage value.

[0110] For each voltage measurement module, the detection method shown in steps 307 to 309 needs to be executed for detection. Therefore, this part can be executed cyclically to detect each voltage measurement module.

[0111] Step 310: The control unit receives the second current value measured by the current measurement module, and determines whether the thyristor control module is abnormal based on the second current value and the first preset current range.

[0112] If the thyristor control module 104 is malfunctioning, proceed to step 311; if the thyristor control module 104 is functioning normally, proceed to step 312.

[0113] Step 311: The control unit records an abnormality in the thyristor control module.

[0114] Step 312: The control unit determines the first current calibration value of the current measurement module based on the second current value and the first preset current value.

[0115] For each current measurement module, the detection method shown in steps 310 to 312 needs to be executed. Therefore, this part can be executed cyclically to detect each current measurement module.

[0116] Step 313: The control unit controls one of the SCR control modules to conduct, receives the third current value detected by the current measurement module, and determines whether the current measurement module is abnormal based on the third current value and the second preset current range.

[0117] If the current measurement module malfunctions, proceed to step 314; if the current measurement module is functioning normally, proceed to step 315.

[0118] Step 314: The control unit records an abnormality in the current measurement module.

[0119] Step 315: The control unit determines the second current calibration value of the current measurement module based on the third current value and the second preset current value.

[0120] For each current measurement module, the detection method shown in steps 313 to 315 needs to be executed. Therefore, this part can be executed cyclically to detect each current measurement module.

[0121] Step 316: The thyristor control module that was turned on by the control unit is turned off.

[0122] Step 317: The control unit controls one of the input relays and one of the output relays to turn on.

[0123] Step 318: The control unit receives the second voltage value detected by the voltage sampling circuit, and based on the second voltage value and the third preset voltage range, determines whether the voltage sampling circuit is abnormal, or whether the conducting output relay is connected to the wrong load.

[0124] If the voltage sampling circuit is faulty, or if the connected output relay and the corresponding load are connected incorrectly, proceed to step 319; if the voltage sampling circuit is normal, and the connected output relay and the corresponding load are not connected incorrectly, proceed to step 320.

[0125] Step 319: Record an abnormality in the voltage sampling circuit, or an incorrect load connection between the conducting output relay and the circuit.

[0126] Step 320: The control unit determines whether the activated output relay is connected to the wrong load based on the first time of each of the first pulses received and the second time of the second pulses received.

[0127] If the conducting output relay is connected to the wrong load, proceed to step 321; if the conducting output relay is connected to the correct load, proceed to step 322.

[0128] Step 321: Record the connection between the conducting output relay and the incorrect load.

[0129] Step 322: The control unit controls the input relay that is turned on to turn off, and controls the output relay that is electrically connected to the load and electrically connected to the power supply line that is electrically connected to the input relay to turn on.

[0130] Step 323: The control unit receives the fourth current value detected by the current sampling circuit and determines the voltage calibration value based on the DC voltage, the fourth current value and the rated resistance value.

[0131] Step 324: The control unit controls the input relay and the output relay to disconnect.

[0132] Step 325: The control unit determines whether all output channels have been tested successfully.

[0133] If all output channels have been tested, proceed to step 326; if at least one output channel has not been tested, return to step 317.

[0134] Step 326: Determine if the control unit has recorded any abnormalities.

[0135] If the control unit records an abnormality, proceed to step 327; if the control unit does not record an abnormality, proceed to step 328.

[0136] Step 327: Determine that the factory test failed and output the detected abnormality to the alarm device.

[0137] Step 328: Confirm that the factory test has passed and store the calibration data.

[0138] Step 329: Confirm that the factory test has passed.

[0139] For example, the control unit 107 includes a data storage subunit (flash) in which calibration data, factory data configuration, and operating data configuration are all stored.

[0140] The factory testing method for the thyristor power regulator provided in this application embodiment calibrates the electrical measurement parameters, ensuring the measurement accuracy of the voltage and current measurement modules. Furthermore, the factory testing method for the thyristor power regulator provided in this application embodiment also ensures the correct wiring of key internal components of the thyristor power regulator 100, thereby guaranteeing product quality.

[0141] Figure 3 The diagram shown is a flowchart illustrating a power-on self-test method for a thyristor power regulator provided in an exemplary embodiment of this application.

[0142] like Figure 3 As shown in the figure, this application provides a power-on self-test method for a silicon controlled rectifier power regulator, including the following steps 401 to 420.

[0143] Step 401: The control unit disconnects all the thyristor control modules.

[0144] Step 402: The control unit reads the pre-stored operating data configuration.

[0145] For example, the runtime data configuration can be manually edited based on the electrical installation diagram.

[0146] Step 403: The control unit records the first moment of each of the first pulses received.

[0147] Step 404: The control unit determines the first phase sequence data based on the pre-stored operating data configuration.

[0148] Step 405: Based on the first moment and first phase sequence data of at least two first pulses received, the control unit determines whether the activated power supply line is actually activated, whether the inactive power supply line is actually inactive, and whether the order and time interval of the zero point moments of at least two sets of AC power formed by the two activated power supply lines are abnormal.

[0149] If the control unit 107 detects at least one abnormal situation in step 405, then step 406 is executed; if the control unit 107 does not detect any abnormal situation in step 405, then step 407 is executed.

[0150] Step 406: The control unit records the abnormal situation in step 405.

[0151] Step 407: For each thyristor control module, the control unit receives a first voltage value and, based on the first voltage value and a first preset voltage range, determines whether the power supply line connected to the thyristor control module is incorrect.

[0152] Since each thyristor control module 104 must be tested according to the testing methods shown in steps 407-408, if the power supply line connected to the thyristor control module 104 is incorrect, step 408 is executed. If the power supply line connected to the thyristor control module 104 is correct, and all thyristor control modules 104 have been tested according to the testing methods shown in steps 407-408, step 409 is executed. If the power supply line connected to the thyristor control module 104 is correct, and at least one thyristor control module 104 has not yet been tested according to the testing methods shown in steps 407-408, step 407 is executed again (not shown in the figure).

[0153] Step 408: The control unit records an error in the power supply line connected to the thyristor control module.

[0154] If all the thyristor control modules 104 have been tested according to the testing methods shown in steps 407 to 408, then step 409 is executed after step 408. If at least one thyristor control module 104 has not been tested according to the testing methods shown in steps 407 to 408, then step 407 is returned to be executed (not shown in the figure).

[0155] Step 409: The control unit controls one of the input relays and one of the output relays to turn on.

[0156] Step 410: The control unit is configured to receive a first voltage value detected by the voltage measurement module and a second voltage value detected by the voltage sampling circuit, and determine whether the internal circuitry of the voltage sampling circuit is abnormal based on the first voltage value and the second voltage value.

[0157] If the internal circuitry of the voltage sampling circuit is faulty, proceed to step 411; if the internal circuitry of the voltage sampling circuit is normal, proceed to step 412.

[0158] Step 411: The control unit records an internal circuit abnormality in the voltage sampling circuit.

[0159] Step 412: The control unit receives the first pulse generated by each of the first zero-crossing detection circuits and the second pulse generated by the second zero-crossing detection circuit, and determines whether the load is connected to the wrong power supply line based on the first time of receiving each of the first pulses and the second time of receiving the second pulse.

[0160] If load 200 is connected to the wrong power supply line, proceed to step 413; if the load is connected to the correct power supply line, proceed to step 414.

[0161] Step 413: The control unit records that the load is connected to the wrong power supply line, and the target power supply line that the load is actually connected to in the power supply line.

[0162] Step 414: The control unit controls the input relay that is turned on to turn off, and controls the output relay that is electrically connected to the load and the power supply line that is electrically connected to the input relay to turn on.

[0163] Step 415: The control unit receives the first current value detected by the current sampling circuit, and based on the pre-stored DC voltage value, the pre-stored voltage calibration value and the first current value, determines whether the load connected to the conducting output relay has deteriorated resistance, is not connected to the power supply line, has poor contact with the power supply line, or is short-circuited with the power supply line.

[0164] If the control unit 107 detects at least one of the following: load 200 has deteriorated resistance, is not connected to the power supply line, has poor contact with the power supply line, or has a short circuit with the power supply line, then step 416 is executed; if the control unit 107 detects that load 200 has not deteriorated resistance, is connected to the power supply line, has good contact with the power supply line, or has no short circuit with the power supply line, then step 417 is executed.

[0165] Step 416: The control unit records any abnormal load conditions.

[0166] Specifically, all abnormal conditions of the load 200 detected by the control unit 107 in step 415 are recorded.

[0167] Step 417: The control unit controls the input relays that are turned on to turn off and the output relays that are turned on to turn off.

[0168] Step 418: The control unit determines whether all output channels have been tested successfully.

[0169] The output channel is the branch where each load 200 is located.

[0170] If all output channels have been tested, proceed to step 419; if at least one output channel has not been tested, return to step 409.

[0171] Step 419: Determine if the control unit has recorded any abnormal conditions.

[0172] If the control unit records an abnormal situation, proceed to step 420; if the control unit does not record an abnormal situation, proceed to step 421.

[0173] Step 420: Determine that the power-on self-test fails and output the detected abnormality to the alarm device.

[0174] After executing step 420, the control unit 107 will disable the normal heating control program and wait for the staff to perform maintenance on the thyristor power regulator 100.

[0175] Step 421: Confirm that the power-on self-test has passed and enter the operation mode.

[0176] After entering the operating mode, the control unit 107 can accept the instructions of the temperature controller, thereby controlling the thyristor control module 104.

[0177] The power-on self-test method for the thyristor power regulator provided in this application ensures correct on-site installation of the product and avoids some accidents and safety incidents.

[0178] In addition, during process downtime, the resistance value of load 200 can be detected (i.e., steps 414 to 416). Due to the high accuracy of resistance detection, preventive maintenance of load 200 can be effectively carried out by analyzing the historical trend of the resistance value change of load 200.

[0179] The basic principles of this application have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this application are merely examples and not limitations, and should not be considered as essential features of each embodiment of this application. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the application to the necessity of employing the aforementioned specific details for implementation.

[0180] The block diagrams of devices, apparatuses, devices, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, devices, and systems can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the terms “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

[0181] It should also be noted that in the apparatus, equipment, and methods of this application, the components or steps can be disassembled and / or recombined. These disassemblies and / or recombinations should be considered as equivalent solutions of this application.

[0182] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use this application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of this application. Therefore, this application is not intended to be limited to the aspects shown herein, but rather to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0183] The above description has been given for purposes of illustration and description. Furthermore, this description is not intended to limit the embodiments of this application to the forms disclosed herein. Although numerous exemplary aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations thereof.

Claims

1. A silicon controlled power regulator, characterized by Configured to supply power to at least one load, including: The four input terminals are electrically connected to four power supply lines, three of which are phase lines with different phases in each pair, and the other power supply line is a neutral line. Six first zero-crossing detection circuits, each first zero-crossing detection circuit being electrically connected to two of the input terminals, the first zero-crossing detection circuit being configured to generate a first pulse when a first AC voltage between the two input terminals to which the first zero-crossing detection circuit is connected reaches zero; Four input relays are electrically connected to the four input terminals, respectively. At least one thyristor control module is provided, and at least one thyristor control module is configured to correspond one-to-one with at least one load. For the corresponding thyristor control module and the load, the thyristor control module is electrically connected to one of the three power supply lines with different phases, and the load is electrically connected to the other of the three power supply lines with different phases, or to the neutral line. At least one output relay is provided in one-to-one correspondence with at least one of the said loads, and the output relay is electrically connected to the corresponding said load; A second zero-crossing detection circuit is electrically connected to all of the output relays and all of the input relays. The second zero-crossing detection circuit is configured to generate a second pulse when a second AC voltage between the input relays that are connected to the second zero-crossing detection circuit and the output relays that are connected reaches zero. The control unit, electrically connected to the first zero-crossing detection circuit, all the input relays, all the SCR control modules, all the output relays, and the second zero-crossing detection circuit, is configured to control all the input relays, all the SCR control modules, and all the output relays to be turned on or off. Furthermore, when one of the input relays is turned on, one of the output relays is turned on, and all the SCR control modules are turned off, the control unit receives the first pulse generated by each of the first zero-crossing detection circuits and the second pulse generated by the second zero-crossing detection circuit. Based on the first moment of receiving each of the first pulses and the second moment of receiving the second pulse, the control unit determines a first detection result regarding the connection between the load and the power supply line. The first detection result includes whether the load is connected to an incorrect power supply line and / or whether the load is actually connected to the target power supply line.

2. The thyristor power regulator according to claim 1, characterized in that, Also includes: A DC power supply, electrically connected to all of the input relays, is configured to provide a DC voltage; The current sampling circuit is electrically connected to the DC power supply and to all of the output relays; The control unit is also electrically connected to the current sampling circuit. When one of the input relays is conducting, the output relay connected to the load via the power supply line connected to the conducting input relay is conducting, and all the SCR control modules are disconnected, the current sampling circuit is configured to detect a first current value flowing through the load connected to the conducting output relay. The control unit is configured to receive the first current value and, based on a pre-stored DC voltage value, a pre-stored voltage calibration value, and the first current value, determine a second detection result for the load connected to the conducting output relay. The second detection result includes at least one of the following: whether the load has degraded resistance, whether the load is not connected to the power supply line, whether the load has poor contact with the power supply line, and whether there is a short circuit between the load and the power supply line.

3. Thyristor power regulator according to claim 1 or 2, characterized in that, Also includes: At least one voltage measurement module is provided, and at least one voltage measurement module is configured to correspond one-to-one with at least one load. The voltage measurement module is electrically connected to one of the three power supply lines with different phases in pairs, and the voltage measurement module is electrically connected to the corresponding load. The power supply line to which the voltage measurement module is electrically connected is the same as the power supply line to which the corresponding thyristor control module of the load is electrically connected. The voltage sampling circuit is electrically connected to all of the output relays and all of the input relays; The control unit is also electrically connected to the voltage measurement module and the voltage sampling circuit. When one of the input relays is on, one of the output relays is on, and all the SCR control modules are off, the voltage measurement module is configured to detect a first voltage value between the power supply line connected to the SCR control module corresponding to the load connected to the on-state output relay and the power supply line connected to the load connected to the on-state output relay. The voltage sampling circuit is configured to detect a second voltage value between the power supply line connected to the input terminal of the on-state input relay and the power supply line connected to the load connected to the on-state output relay. The control unit is configured to receive the first voltage value and the second voltage value, and based on the first voltage value and the second voltage value, determine whether the internal circuitry of the voltage sampling circuit is abnormal.

4. The thyristor power regulator according to claim 1 or 2, characterized in that, After all the aforementioned SCR control modules are disconnected, and the controller receives at least two of the first pulses, the control unit is further configured to: Based on pre-stored operational data configuration, a first phase sequence data is determined, which includes the sorting and time interval of the zero-point moments of at least two sets of AC currents formed by the two enabled power supply lines; Based on the first moment and the first phase sequence data of receiving at least two first pulses, determine whether the activated power supply line is actually activated, whether the inactive power supply line is actually inactive, and whether the sorting and time interval of the zero point moments of at least two sets of AC power formed by the two activated power supply lines are abnormal.

5. The thyristor power regulator according to claim 3, characterized in that, The control unit is also configured to receive the first voltage value for each of the thyristor control modules, and based on the first voltage value and a first preset voltage range, determine whether the power supply line connected to the thyristor control module is incorrect.

6. The thyristor power regulator according to claim 1 or 2, characterized in that, The resistance value of the load is the rated resistance value; In the absence of calibration data stored in the control unit, the control unit is configured to read pre-stored factory data configuration and perform factory testing on the thyristor power regulator based on the factory data configuration, wherein the calibration data is the data stored in the control unit after the factory test of the thyristor power regulator.

7. The thyristor power regulator according to claim 6, characterized in that, With all the thyristor control modules disconnected, the control unit is configured to receive the first pulse generated by each of the first zero-crossing detection circuits, determine the second phase sequence data based on the factory data configuration, the second phase sequence data including the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines, and determine whether the order and time interval of the zero-crossing moments of all the AC currents formed by the two power supply lines are abnormal based on the first moment of all the received first pulses and the second phase sequence data.

8. The thyristor power regulator according to claim 6, characterized in that, Also includes: At least one voltage measurement module is provided, and at least one voltage measurement module is configured to correspond one-to-one with at least one load. The voltage measurement module is electrically connected to one of the three power supply lines with different phases in pairs, and the voltage measurement module is electrically connected to the corresponding load. The power supply line to which the voltage measurement module is electrically connected is the same as the power supply line to which the corresponding thyristor control module of the load is electrically connected. The control unit is also electrically connected to the voltage measurement module. When all the SCR control modules are disconnected, the voltage measurement module is configured to detect a first voltage value between the power supply line of the SCR control module connected to the load corresponding to the conducting output relay and the power supply line of the load connected to the conducting output relay. The control unit is also configured to receive the first voltage value and, based on the first voltage value and a second preset voltage range, determine whether the power supply line connected to the SCR control module is incorrect. If the power supply line connected to the SCR control module is correct, the control unit determines a voltage correction parameter for the voltage measurement module based on the first voltage value and the preset voltage value, wherein the preset voltage value is within the second preset voltage range, and the voltage correction parameter is used to calibrate the voltage value measured by the voltage measurement module.

9. The thyristor power regulator according to claim 6, characterized in that, The thyristor control module includes: Current measurement module; The control unit is electrically connected to the current measurement module. When all the SCR control modules are disconnected, the current measurement module is configured to detect a second current value flowing through the load corresponding to the SCR control module. The control unit is configured to receive the second current value, determine whether the SCR control module is abnormal based on the second current value and a first preset current range, and, if the SCR control module is normal, determine a first current calibration value of the current measurement module based on the second current value and the first preset current value. The first preset current value is within the first preset current range, and the first current calibration value is used to perform zero-point drift calibration on the current measurement module.

10. The thyristor power regulator according to claim 9, characterized in that, With all the output relays off and at least one of the SCR control modules on, the current measurement module is configured to detect a third current value flowing through the load corresponding to the on SCR control module for the on-state SCR control module. The control unit is further configured to: Receive the third current value, and based on the third current value and the second preset current range, determine whether the current measurement module is malfunctioning; When the current measurement module is functioning normally, a second current calibration value for the current measurement module is determined based on the third current value and the second preset current value, wherein the second preset current value is within the range of the second preset current, and the second current calibration value is used to calibrate the current gain coefficient of the current measurement module.

11. The thyristor power regulator according to claim 6, characterized in that, Also includes: The voltage sampling circuit is electrically connected to all of the output relays and all of the input relays; The control unit is electrically connected to the voltage sampling circuit. When one of the input relays is turned on, one of the output relays is turned on, and all the SCR control modules are turned off, the voltage sampling circuit is configured to detect a second voltage value between the power supply line connected to the input terminal of the turned-on input relay and the power supply line connected to the load of the turned-on output relay. The control unit is configured to receive the second voltage value and, based on the second voltage value and a third preset voltage range, determine whether the voltage sampling circuit is malfunctioning, or whether the turned-on output relay is connected to the wrong load.

12. The thyristor power regulator according to claim 6, characterized in that, In the event that one of the input relays is turned on, one of the output relays is turned on, and all the SCR control modules are turned off, the control unit is further configured to receive the first pulse generated by each of the first zero-crossing detection circuits and the second pulse generated by the second zero-crossing detection circuit, and determine whether the turned-on output relay is connected to the wrong load based on the first time of receiving each of the first pulses and the second time of receiving the second pulse.

13. The thyristor power regulator according to claim 2, characterized in that, The resistance of the load is the rated resistance value. When one of the input relays is turned on, the output relay connected to the load via the power supply line electrically connected to the turned input relay is turned on, and all the thyristor control modules are turned off, the current sampling circuit is configured to detect a fourth current value flowing through the load connected to the turned output relay. The control unit is configured to receive the fourth current value and determine the voltage calibration value based on the DC voltage, the fourth current value, and the rated resistance value.

Images