Test power supply device for controlling distribution box

Abstract

The invention relates to the field of electrical technology, in particular to a device for controlling a test power supply of a distribution box, which comprises a box body, a start button and a stop button ES arranged on the surface of the box body, and a main air switch Q1, an alternating current contactor KM, a DC24V power supply, a DC12V power supply and a current source arranged in the box body. A DC 24V voltage-stabilized source and a DC 12V voltage-stabilized source are designed, and the control requirements of fire-fighting circuit power sources, PLC circuit power sources and other circuit power sources are met. A path of AC 380V power supply and an adjustable 0-300A current source are integrated, so that on-line simulation of field equipment is realized, and various action monitoring indexes are tested.

Description

Technical Field

[0001] This invention relates to the field of electrical technology, specifically to a device for controlling the test power supply of a distribution box. Background Technology

[0002] The protection of equipment inside the distribution cabinet and the sensing and calculation of the execution program all rely on the voltage, current, and electrical quality of the feeder circuit as data. The terminal sampling of the smallest branches determines the accuracy and safe, reliable operation of the backend calculations, making data verification during factory testing particularly important. The test power supply is the foundation for stability and accuracy verification. The test power supply needs to provide multiple voltage levels to meet the requirements of various products under test, and the adjustable current source serves as a simulated load for test scenarios under different conditions. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention is based on collecting a large amount of factory and operational data from control panels, distinguishing between control and power sources, and comprehensively considering various product requirements to meet the power needs of one-time control testing, current testing, voltage monitoring, and module power supply calibration. A multi-output control distribution box test power supply device is designed according to these requirements, including one DC24V and one DC12V regulated power supply to meet the control requirements of power supplies for fire protection, PLC, and other circuits. Integrating one AC380V power supply and an adjustable 0-300A voltage and current source, it enables online simulation of field equipment and testing of various operational monitoring indicators.

[0004] The technical solution adopted by this invention to solve its technical problem is: A test power supply device for controlling a distribution box includes a box, a start button and a stop button ES disposed on the surface of the box, and a main circuit breaker Q1, an AC contactor KM, a DC24V power supply, a DC12V power supply, and a current source disposed inside the box. A three-phase four-wire power supply is introduced into the box and connected to the input terminal of the main circuit breaker Q1. The start button, stop button ES, and AC contactor KM constitute a control circuit connected between the A-phase power and the neutral wire of the output terminal of the main circuit breaker Q1. The start button and stop button are located within the control circuit. The coils of ES and AC contactor KM are connected in series. One set of normally open contacts of AC contactor KM is connected in parallel with the start button. The three sets of normally open contacts of AC contactor KM are connected in series with the A-phase, B-phase, and C-phase power output terminals of the main circuit breaker Q1, respectively. The input terminal of the DC24V power supply is connected to the A-phase power output terminal and the neutral wire of the main circuit breaker Q1. The input terminal of the DC12V power supply is connected to the B-phase power output terminal and the neutral wire of the main circuit breaker Q1. The input terminal of the current source is connected to the C-phase power output terminal and the neutral wire of the main circuit breaker Q1.

[0005] As a preferred embodiment, a further technical solution of the present invention is: Preferably, the current source includes a 0-250V voltage regulator module, a 0-300A current booster, and a feed current display module. The input terminal of the 0-250V voltage regulator module is connected to the output terminal of power supply Q1, and the output terminal is connected to the 0-300A current booster, which is used to control the current boosting effect by changing the output voltage amplitude. The input terminal of the 0-300A current booster is connected to the adjustable voltage of the 0-250V voltage regulator module, which is used to convert low-current AC power into 0-300A current to meet the test load simulation requirements. The feed current display module is connected to the current output terminal of the 0-300A current booster, which is used to display the output current value.

[0006] Preferably, the adjustment knob of the 0-250V voltage regulator module is located on the surface of the enclosure.

[0007] Preferably, the feed current display module is mounted on the surface of the enclosure.

[0008] Preferably, the surface of the enclosure is provided with a DC24V power switch, a DC12V power switch and a current source switch; the DC24V power switch is connected in series with the DC24V power input terminal, the DC12V power switch is connected in series with the DC12V power input terminal, and the current source switch is connected in series with the current source input terminal.

[0009] Preferably, the DC24V power switch, DC12V power switch, and current source switch are all illuminated switches.

[0010] Preferably, the surface of the enclosure is provided with an output power direct connector, a DC24V power direct connector, a DC12V power direct connector, a current source current output direct connector, and a current source current input direct connector; the output power direct connector is connected to the output terminal of the main circuit breaker Q1; the DC24V power direct connector is connected to the DC24V power output terminal; the DC12V power direct connector is connected to the DC12V power output terminal; the current source current output direct connector is connected to the current source current output terminal; and the current source current input direct connector is connected to the current source current input terminal.

[0011] Preferably, a three-phase voltmeter is also provided on the surface of the enclosure, and the three-phase voltmeter is connected to the output terminal of the main circuit breaker Q1.

[0012] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art: 1. The test data is intuitive and accurate. By using existing enterprise standards, the accuracy of the test power supply is regularly verified to ensure the accuracy of the data and the reliability of the operation of the products leaving the factory.

[0013] 2. The integrated design of multiple, diverse isolated sources meets the testing requirements of most factory-shipped products. It includes both current and voltage sources, enabling the calculation and verification of output power.

[0014] 3. Quick-connect output power supply design, both plug-in and direct connection can guarantee output, making factory testing simpler and faster.

[0015] 4. The feed source indicator design includes an indicator light for each individual source switch, effectively preventing incorrect selection of multiple voltage levels or forgetting to turn off the power after testing. Combined with appropriate operating procedures, this effectively avoids the dangers of negligence during and after testing.

[0016] 5. The digital power supply display is more intuitive and reliable, facilitating the verification of relevant test data. It effectively avoids visual errors. Furthermore, the overall display clearly shows which power source is off, providing a safety guarantee for both the operator and the tester. Attached Figure Description

[0017] Figure 1 This is a circuit diagram of the control power supply device for the distribution box in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the test power supply device for controlling the distribution box in an embodiment of the present invention.

[0018] Explanation of reference numerals in the attached diagram: 1. Housing; 2. Start button; 3. DC24V power supply; 4. DC12V power supply; 5. Current source; 6. Output current display module; 7. Adjustment knob; 8. DC24V power switch; 9. DC12V power switch; 10. Current source switch; 11. Output power connector; 12. DC24V power connector; 13. DC12V power connector; 14. Current source current output connector; 15. Current source current input connector; 16. Three-phase voltmeter; Stop button ES, main circuit breaker Q1, AC contactor KM. Detailed Implementation

[0019] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0020] like Figure 1 and Figure 2As shown in the figure, this embodiment provides a control device for a test power supply of a distribution box, including a box 1, a start button 2 and a stop button ES disposed on the surface of the box 1, and a main circuit breaker Q1, an AC contactor KM, a DC 24V power supply 3, a DC 12V power supply 4, and a current source 5 disposed inside the box; a three-phase four-wire power supply is introduced into the box 1 and connected to the input terminal of the main circuit breaker Q1; the start button 2, the stop button ES, and the AC contactor KM constitute a control circuit connected between the A-phase power and the neutral wire of the main circuit breaker Q1 power output terminal; the start button in the control circuit... Button 2, stop button ES, and the coil of AC contactor KM are connected in series. One set of normally open contacts of AC contactor KM is connected in parallel with start button 2. The three sets of normally open contacts of AC contactor KM are connected in series with the A-phase, B-phase, and C-phase power output terminals of main circuit breaker Q1, respectively. The input terminal of DC24V power supply 3 is connected to the A-phase power output terminal and the neutral wire of main circuit breaker Q1. The input terminal of DC12V power supply 4 is connected to the B-phase power output terminal and the neutral wire of main circuit breaker Q1. The input terminal of current source 5 is connected to the C-phase power output terminal and the neutral wire of main circuit breaker Q1.

[0021] In implementation, the current source 5 includes a 0-250V voltage regulator module, a 0-300A current booster, and a feed current display module 6. The input of the 0-250V voltage regulator module is connected to the output of power supply Q1, and the output is connected to the 0-300A current booster, which controls the current boosting effect by changing the output voltage amplitude. The input of the 0-300A current booster is connected to the adjustable voltage of the 0-250V voltage regulator module, which converts low-current AC power into 0-300A current to meet the test load simulation requirements. The feed current display module 6 is connected to the current output of the 0-300A current booster to display the output current value.

[0022] The adjustment knob 7 of the 0-250V voltage regulator module is located on the surface of the housing 1.

[0023] The feed current display module 6 is mounted on the surface of the housing 1.

[0024] The surface of the enclosure 1 is equipped with a DC24V power switch 8, a DC12V power switch 9, and a current source switch 10; the DC24V power switch 8 is connected in series to the input terminal of the DC24V power supply 3, the DC12V power switch 8 is connected in series to the input terminal of the DC12V power supply 4, and the current source switch 10 is connected in series to the input terminal of the current source 5.

[0025] The DC24V power switch 8, DC12V power switch 9, and current source switch 10 are all illuminated switches.

[0026] The surface of the enclosure 1 is provided with an output power direct connector 11, a DC24V power direct connector 12, a DC12V power direct connector 13, a current source current output direct connector 14, and a current source current input direct connector 15; the output power direct connector 11 is connected to the output terminal of the main circuit breaker Q1; the DC24V power direct connector 12 is connected to the output terminal of the DC24V power supply 3; the DC12V power direct connector 13 is connected to the output terminal of the DC12V power supply 4; the current source current output direct connector 14 is connected to the current output terminal of the current source 5; and the current source current input direct connector 15 is connected to the current input terminal of the current source 5.

[0027] The surface of the enclosure 1 is also equipped with a three-phase voltmeter 16, which is connected to the output terminal of the main circuit breaker Q1.

[0028] The DC12V circuit serves as the power supply for traditional fire protection, monitoring, and external plug-in equipment, forming a DC safety display and alarm system. It requires a certain power supply capacity and stable power quality. The requirements for the manufactured product lean towards testing the control source. The power module adopts a 10A high-capacity, high-cooling design, allowing for short-circuit operation and featuring self-recovery. Considering that the DC12V circuit is mostly used independently and for aesthetic reasons, it is placed on the left side of the test power supply above the ammeter, with sufficient external space to avoid interference from other circuits.

[0029] The DC24V output module is geared towards testing industrial control power supplies. In control cabinets, PLCs, digital modules, DC sensors, and external industrial control equipment mostly use DC24V control systems. Based on the principle of low-voltage control of high-voltage, it utilizes DC relays to control 220V or 380V circuits, thereby achieving low-voltage control of high-voltage and forming a complete control system. Its role varies significantly depending on the system. In PLC cabinets, it often serves as the power supply for PLCs, gateways, various communication modules, and sensors; in relay modules, it is primarily used as a control power supply.

[0030] The retained AC380V system was the primary power source for the original factory tests. It is an important test component after the insulation withstand voltage test. Since low-voltage cabinets often use a 380V system for main power supply, and the line voltage is often used for control or instrument power, this test serves two purposes: firstly, it allows for checking key areas for power supply defects through the official power supply line; secondly, it enables functional verification of the cabinet control system. It also fills in any gaps in the insulation test and checks the quality of components shipped from the factory. In 24V or other control voltage levels, it serves as the main circuit power supply, assessing the integrity of the cabinet components' operation.

[0031] The current source is designed to meet the requirements of capacity monitoring and protection function verification of the outgoing load during factory enclosure testing. It serves two purposes: firstly, by applying current through a primary circuit, it completely monitors the current loop, thereby determining the condition of relevant components or identifying open circuits, short circuits, or other issues. It also serves as the basis for current loop data calibration, achieving data consistency through data correction and power calculation, among other interlocking functions. Secondly, it works in conjunction with other device power supplies to simulate actual field operations, completing the operation check of the protection devices within the enclosure, such as overcurrent instantaneous tripping caused by thermal protection and overload protection. Example

[0032] Main circuit breaker: Schneider NSX series molded case circuit breaker (model NSX100NTM16D3P3D), rated current 16A, short circuit breaking capacity ≥6kA, quickly disconnects short circuit faults, and ensures the safety of the main circuit.

[0033] Output power connector: Phoenix Contact ST series direct-plug terminal block (model ST-4-QUATTRO) is used to achieve three-phase four-wire output with ABCN, contact resistance ≤0.5mΩ, avoiding heat generation under high current.

[0034] AC contactor: Siemens 3RT series (model 3RT6026-1AP00), rated current 25A, coil voltage AC220V, with self-locking auxiliary contacts, withstands the starting inrush current of the current booster.

[0035] Start button: Schneider XB2BA31C, self-resetting design, the contactor engages and locks when pressed.

[0036] Stop button: Schneider XB2BS542C, mushroom head structure, pressing it cuts off the power supply to the contactor coil to achieve emergency power cut-off.

[0037] DC12V power supply: Mean Well RQ-120D-12 power module, output current 10A, strong cooling design, supports short-time short circuit self-recovery, suitable for testing fire protection and monitoring equipment.

[0038] DC24V power supply: Mean Well HRP-300-24 power module, output current 12.5A, voltage accuracy ±1%, compatible with PLC, digital module, and DC sensor testing.

[0039] 0-250V Voltage Regulator Module: Omron G3PA-240B solid-state voltage regulator module, input AC220V, output 0-250V continuously adjustable, voltage regulation accuracy ≤±1%, providing adjustable input voltage for current boosters. 0-300A Booster: Ametek Sorensen SGX-300A-60V, input voltage 0-250VAC, output current 0-300A continuously adjustable, constant current stability ≤±0.3%, built-in power analyzer, supports synchronous monitoring of voltage, current and power; built-in thermal overload protection device, short-time overload capacity 120% (lasting 5 minutes), automatically cuts off output in case of short circuit, and self-recovers after fault clearance.

[0040] Feed current display module: Siemens 7KM2111-1BA00-3AA0, measurement range 0-400A, accuracy class 0.2, LCD digital display, supports 4-20mA signal output.

[0041] Three-phase voltmeter: Schneider PM5350 power parameter measuring instrument, measuring range 0-450V, displays AB, BC, CA line voltages, accuracy ±0.5%.

[0042] Current-through connector: Weidmüller A-Series (model A-600-95), rated current 600A, voltage rating 690V, direct-through spring-clamp design, tool-free wiring, and 80% improvement in insertion and removal efficiency.

[0043] Voltage direct-plug connector: Schneider ZB4BZ103, compatible with DC12V, DC24V, and AC380V outputs, with anti-misplugging structure to avoid reverse polarity connection.

[0044] During use, open the enclosure and connect the external three-phase four-wire 380V power supply to the input terminal of the main circuit breaker Q1. Close the main circuit breaker to close the enclosure. The AC220V auxiliary power supply of the feeder current display module is turned on. Press the start button, and the AC contactor KM will engage and lock itself. The main power supply will supply power to each power module and the voltage regulation module. The operator sets the output voltage using the adjustment knob on the voltage regulating module. The 0-250V voltage regulating module converts the AC220V auxiliary power supply into an adjustable AC voltage of 0-250V. This adjustable voltage is input to a 0-300A current booster, which internally uses a transformer to step up the voltage (or amplify the current). The principle is to convert the input low-current voltage signal into a large current: voltage and current are positively correlated (within the rated power range of the booster), that is, the higher the output voltage of the voltage regulating module, the larger the output current of the booster, and vice versa; the 0-300A booster current is output through the current source current output direct connector, and the generated large current is sent to the current loop of the distribution box cabinet under test, and then led back through the current source current input direct connector, forming a current closed loop path, ensuring that the output current completely flows back to the booster, avoiding voltage spikes or test failures caused by open circuits. The feed-out current display module collects the output current signal in real time and digitally displays the actual current value. Operators can fine-tune the voltage regulating module according to test requirements (such as rated load, overload test) to make the current reach the target value. Through the booster output current, it is possible to check for open circuits and short circuits in the line, and judge the condition of components. When the current is adjusted to overload / The short-circuit threshold can verify the reliability of thermal protection and overcurrent instantaneous trip protection devices; the three-phase voltmeter display monitors the stability of the main power supply voltage. If voltage fluctuations cause the current to deviate from the set value, it can be compensated and adjusted through the voltage regulation module to ensure the accuracy of the current output. After the test is completed, first adjust the voltage regulator module to 0V (to avoid sudden current changes), then press the stop button. The AC contactor will lose power, and the current booster will stop outputting.

[0045] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A control device for a test power supply of a distribution box, comprising a housing, characterized in that, It also includes a start button and a stop button ES installed on the surface of the enclosure, and a main circuit breaker Q1, an AC contactor KM, a DC24V power supply, a DC12V power supply, and a current source installed inside the enclosure. A three-phase four-wire power supply is introduced into the enclosure and connected to the input terminal of the main circuit breaker Q1. The start button, stop button ES, and AC contactor KM form a control circuit connected between phase A and the neutral wire of the main circuit breaker Q1 power output terminal. In the control circuit, the coils of the start button, stop button ES, and AC contactor KM are connected in series. One set of normally open contacts of the AC contactor KM is connected in parallel with the start button. The three sets of normally open contacts of the AC contactor KM are connected in series with phase A, phase B, and phase C of the main circuit breaker Q1 power output terminal, respectively. The input terminal of the DC24V power supply is connected to phase A and the neutral wire of the main circuit breaker Q1 power output terminal. The input terminal of the DC12V power supply is connected to phase B and the neutral wire of the main circuit breaker Q1 power output terminal. The input terminal of the current source is connected to phase C and the neutral wire of the main circuit breaker Q1 power output terminal.

2. The test power supply device for the control distribution box according to claim 1, characterized in that, The current source includes a 0-250V voltage regulator module, a 0-300A current booster, and a feed current display module. The input of the 0-250V voltage regulator module is connected to the output of power supply Q1, and its output is connected to the 0-300A current booster, which controls the current boosting effect by changing the output voltage amplitude. The input of the 0-300A current booster is connected to the adjustable voltage of the 0-250V voltage regulator module, which converts low-current AC power into 0-300A current to meet the requirements of test load simulation. The feed current display module is connected to the current output of the 0-300A current booster to display the output current value.

3. The test power supply device for the control distribution box according to claim 2, characterized in that, The adjustment knob of the 0-250V voltage regulator module is located on the surface of the enclosure.

4. The test power supply device for the control distribution box according to claim 2, characterized in that, The feed current display module is mounted on the surface of the enclosure.

5. The test power supply device for the control distribution box according to claim 1, characterized in that, The surface of the enclosure is equipped with a DC24V power switch, a DC12V power switch, and a current source switch; the DC24V power switch is connected in series with the DC24V power input terminal, the DC12V power switch is connected in series with the DC12V power input terminal, and the current source switch is connected in series with the current source input terminal.

6. The test power supply device for the control distribution box according to claim 5, characterized in that, The DC24V power switch, DC12V power switch, and current source switch all use illuminated switches.

7. The test power supply device for the control distribution box according to claim 1, characterized in that, The surface of the enclosure is equipped with output power direct-connect connectors, DC24V power direct-connect connectors, DC12V power direct-connect connectors, current source current output direct-connect connectors, and current source current input direct-connect connectors; the output power direct-connect connectors are connected to the output terminal of the main circuit breaker Q1; the DC24V power direct-connect connectors are connected to the DC24V power output terminal; and the DC12V power direct-connect connectors are connected to the DC12V power output terminal. The current source current output direct connector is connected to the current source current output terminal, and the current source current input direct connector is connected to the current source current input terminal.

8. The test power supply device for the control distribution box according to claim 1, characterized in that, The surface of the enclosure is also equipped with three voltmeters, which are connected to the output terminal of the main circuit breaker Q1.

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