Carbon brush holder electrical performance detection equipment and detection method

Abstract

The invention discloses carbon brush holder electrical performance detection equipment and a detection method, and belongs to the field of carbon brush holder detection. Aiming at the industry blank that only basic physical indexes can be screened and the welding spot quality cannot be accurately judged in the existing carbon brush holder detection, the equipment takes a rack as a carrier, integrates a carbon brush holder positioning seat, an electrical property detection assembly and a PLC (Programmable Logic Controller) electric control system, and can be selectively provided with a pre-press mounting mechanism and a dotting mechanism. Through a constant voltage current measurement method, a magnetic switch cylinder drives a conductive block to be in short circuit connection with a probe, a servo motor drives a conductive press head to be in press connection with a positive electrode and a negative electrode to construct a detection loop, current data are collected at the precision of 0.01 A under the test voltage of 0.01-0.1 V, and the defects such as pseudo soldering and open circuit of a welding spot are accurately judged. The device is high in automation degree, improves the detection efficiency by more than 200% compared with manual detection, has a data tracing function, can fill the core performance detection blind area of the carbon brush holder, and is suitable for batch detection of the pump head carbon brush holder.

Description

Technical Field

[0001] This invention relates to an improvement in the field of carbon brush holder testing, and more particularly to an improvement in a carbon brush holder electrical performance testing device and testing method. Background Technology

[0002] Among the core components of the pump head, the carbon brush holder plays a crucial role in current conduction and commutation buffering. Its conductivity stability determines the pump head's operating efficiency, service life, and operational safety. The electrical performance of the carbon brush holder is one of the core criteria for evaluating product quality.

[0003] However, the current industry has significant shortcomings in the testing technology for the electrical performance of carbon brush holders. There is no dedicated testing solution that can cover the aforementioned core indicators, and related testing needs have long been in a technological vacuum. Existing technologies can only screen some basic indicators through traditional physical testing methods. Due to the lack of professional conductivity testing methods, it is impossible to determine whether there are problems such as missing welds at the carbon brush holder solder joints, resulting in serious blind spots in quality control.

[0004] There is a risk of misjudging products with substandard conductivity as qualified products. Once these substandard products enter the market, they can easily cause pump head malfunctions, which not only affect the user experience of end-user equipment but may also lead to safety hazards due to the malfunctions. This puts manufacturers under the dual pressure of reputational damage and increased after-sales costs.

[0005] Therefore, it is necessary to design a new type of specialized equipment for testing the electrical performance of carbon brush holders, filling the technological gap in the industry in the field of core performance testing of carbon brush holders and overcoming the limitations of existing testing methods. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a carbon brush holder electrical performance testing device and testing method based on voltage-current method.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A carbon brush holder electrical performance testing device includes a frame, characterized in that: the frame is provided with a carbon brush holder positioning seat, an electrical performance testing component, and an electrical control system; the carbon brush holder positioning seat has a slot, and a positioning sensor is installed in the slot; the electrical performance testing component includes a high-precision DC power supply, a conductive block, and a voltage probe; the conductive block is movable back and forth, and is equipped with a first power source with position feedback function; the conductive block is short-circuited with two probes of the carbon brush holder; the voltage probe is movable up and down, and is equipped with a second power source with position feedback function; the voltage probe is press-fitted with the positive and negative terminals of the carbon brush holder; the positioning sensor, electrical performance testing component, first power source, and second power source are all connected to the electrical control system.

[0008] The first power source is a magnetic switch cylinder.

[0009] The second power source is a servo motor.

[0010] The voltage conductor is connected to the pre-pressure cylinder, which is mounted on the lifting seat. The lifting seat is mounted on the guide rail, and the lifting seat is connected to the servo motor via a lead screw drive.

[0011] The electrical control system is a PLC, equipped with an MCGS interactive human-machine interface and a high-precision current sensor.

[0012] The electrical performance testing component has a test voltage range of 0.01~0.1V and a current adjustment accuracy of 0.01A.

[0013] The frame is also equipped with a pre-pressing mechanism, which includes a pressing head and a third power source with position feedback function. The pressing head is pressed into place with the carbon brush holder.

[0014] The frame is also equipped with a dotting mechanism, which corresponds to the carbon brush holder.

[0015] The conductive block includes a conductive body and two conductive rods, which are elastically extendable and retractable on the conductive body.

[0016] The testing method of the above-mentioned carbon brush holder electrical performance testing equipment is characterized by including the following steps: 1) Loading and positioning: The operator places the carbon brush holder to be tested into the slot of the carbon brush holder positioning seat, triggering the positioning sensor; the positioning sensor sends a "product in place" signal to the electronic control system, and the electronic control system then starts the testing process; 2) Probe short-circuiting: The electronic control system instructs the first power source to drive the conductive block forward, and the conductive block contacts and short-circuits the two probes of the carbon brush holder; after the first power source detects the "in position" signal, it feeds back to the electronic control system and proceeds to the next stage; 3) Circuit connection: The electronic control system controls the second power source to drive the voltage probe to press down. The voltage probe presses against the top of the carbon brush holder, so that the carbon brush holder, voltage probe, probe and conductive block form a complete circuit; at the same time, the second power source monitors the pressing displacement in real time. When the preset compression amount is reached, it sends a "pressurization complete" signal to the electronic control system. 4) Voltage and current detection: The electrical control system commands the electrical performance detection component to start, the high-precision DC power supply outputs the preset voltage, and at the same time the high-precision current sensor collects the loop current data in real time; the collected current data is transmitted to the electrical control system through the analog module and compared with the preset qualified threshold. 5) Result judgment and feedback: If the average current is within the threshold range, the electronic control system judges the product as "qualified", the human-machine interface displays a green "OK" mark, and the qualified indicator light illuminates at the same time; if the current value exceeds the threshold range, it is judged as "unqualified", the human-machine interface displays a red "NG" mark, the buzzer alarms at the same time, and the unqualified is recorded in the historical screen. 6) Reset: After the test results are fed back, the electrical control system controls the second power source to rise and the first power source to retreat, restoring the initial position; the operator removes the carbon brush holder that has been tested, and the equipment waits for the next feeding, completing one test cycle.

[0017] The beneficial effects of this invention are as follows: 1) It fills a technological gap in the industry and achieves quantitative testing of core indicators: breaking through the limitations of traditional physical testing that focuses on screening appearance and spring pressure, it is the first to achieve quantitative evaluation of the conductivity of carbon brush holders through the "constant pressure current measurement" method. It can directly determine whether the solder joints are faulty, open-circuited, or short-circuited by the current value, solving the problem of blind spots in quality control. 2) It has a high degree of automation, improving testing efficiency and consistency: through the coordinated control of PLC, servo motors, and high-precision sensors, the testing process is fully automated, improving efficiency by more than 200% compared to manual physical testing. At the same time, the testing parameters are uniformly set by the system, avoiding judgment errors caused by differences in manual operation. 3) It has strong traceability, facilitating problem tracing: the electrical control system automatically records the data of each carbon brush holder's electrical performance test, including testing time, voltage parameters, current parameters, and judgment results, supporting query and export through a human-machine interface. If quality problems occur later, the corresponding testing data can be traced through the product number to quickly locate the root cause of the problem. Attached Figure Description

[0018] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention.

[0020] Figure 2 For the present invention Figure 1 Enlarged view of part A. Detailed Implementation

[0021] The accompanying drawings illustrate the structure of the present invention, and further details will be described below in conjunction with the drawings. In this embodiment, see the attached drawings. Figure 1-2The carbon brush holder electrical performance testing equipment includes a frame 1, which includes a mounting platform. The frame 1 is equipped with a carbon brush holder positioning seat 2, an electrical performance testing component, and an electrical control system. The carbon brush holder positioning seat 2 has a slot containing a positioning sensor. The electrical performance testing component includes a high-precision DC power supply, a conductive block 3, and a voltage probe 4. The conductive block 3 is movable back and forth and is short-circuited with two probes of the carbon brush holder 12. The conductive block 3 is equipped with a first power source 5 with position feedback function, preferably a magnetic switch cylinder. The lower part of the carbon brush holder positioning seat 2 has an opening for the conductive block 3 to extend into. The voltage probe 4 is movable up and down and is press-fitted with the positive and negative terminals of the carbon brush holder 12. The voltage probe 4 is equipped with a second power source 6 with position feedback function, preferably a servo motor. The positioning sensor, electrical performance testing component, first power source 5, and second power source 6 are all connected to the electrical control system.

[0022] As a further improved specific implementation, the voltage conductor 4 is connected to the pre-pressure cylinder 7, the pre-pressure cylinder 7 is set on the lifting seat 8, the lifting seat 8 is set on the guide rail 9, and the lifting seat 8 is connected to the servo motor by a lead screw drive. The corresponding lifting seat 8 is provided with a lead screw nut. Through the buffer of the pre-pressure cylinder 7, direct pressing is avoided to prevent the carbon brush holder from breaking brittlely.

[0023] As a further improvement, the electrical performance testing component has a test voltage range of 0.01~0.1V and a current adjustment accuracy of 0.01A, which can accurately detect the current output under different conditions and determine whether the product is qualified.

[0024] As a further improvement, the electrical control system is a PLC, preferably a Keyence PLC from Japan, and is equipped with an MCGS interactive human-machine interface and a high-precision current sensor. Through closed-loop collaboration of "command decision-information interaction-signal feedback", the detection process is automated, standardized and traceable.

[0025] As a further improved specific implementation, the frame 1 is also provided with a pre-pressing mechanism 10. The pre-pressing mechanism includes a pressing head and a third power source with position feedback function. Preferably, the third power source is a magnetic switch cylinder. The pressing head cooperates with the carbon brush holder for pressing. The pressing head is used to pre-press the carbon brush holder. After confirming that the carbon brush holder is installed in place, a feedback signal is sent to the electronic control system, and then the probe short-circuiting stage is entered.

[0026] As a further improvement, the frame 1 is also provided with a dotting mechanism 11, which corresponds to the carbon brush holder 12. The dotting mechanism is an existing structure. After the carbon brush holder 12 is inspected, qualified products trigger the dotting mechanism to mark, and unqualified products can be marked with different marks or not marked, so as to avoid missed inspections and mixing.

[0027] As a further improved specific implementation, the conductive block 3 includes a conductive body 13 and two conductive rods. The two conductive rods 13 are elastically and telescopically mounted on the conductive body. Specifically, the two conductive rods 13 are arranged side by side and can be moved through the conductive body. Each of the two conductive rods 13 is fitted with a spring. The two conductive rods are used to short-circuit the two probes of the carbon brush holder, and have an elastic buffering function to avoid hard contact and damage to the probes.

[0028] The working principle of this invention is as follows: After the device is connected to an external power source, the carbon brush holder is placed in the slot of the carbon brush holder positioning seat. Then, the first power source 5 drives the conductive block 3 to make precise contact with the two probes of the carbon brush holder. Next, the second power source 6 drives the conductive head 4 to press and connect the positive and negative terminals of the carbon brush holder, establishing a complete current path. The system uses a high-precision current sensor to collect the current in the circuit in real time and analyzes it in conjunction with a preset qualified threshold. If the current meets the standard, it indicates that the spot weld connection of the workpiece is firm; if an abnormal current occurs, it is determined that there are defects such as incomplete welding. In essence, it verifies the electrical continuity of the spot weld by power-on detection, and indirectly achieves accurate judgment of welding quality through quantified electrical parameters.

[0029] Before starting the detection process, the pre-installation and parameter settings of this invention require two core preparatory steps: 1) Mechanical calibration: Determine the reference surface of the carbon brush holder positioning seat 2 and the installation position of the carbon brush holder 12, and ensure that after the carbon brush holder 12 is placed, the deviation between its probe center and the piston rod center of the magnetic switch cylinder used for shorting below does not exceed ±0.5mm; at the same time, adjust the initial height of the servo motor so that the compression amount of the carbon brush holder when pressing down is consistent with the actual compression amount during operation.

[0030] Electronic control parameter configuration: Input detection parameters through the MCGS human-machine interface, including customized DC power supply output voltage, current qualification threshold, magnetic switch cylinder holding time and servo motor pressing speed.

[0031] In this embodiment, the testing method of the carbon brush holder electrical performance testing equipment includes the following steps: 1) Loading and positioning: The operator places the carbon brush holder to be tested into the slot of the carbon brush holder positioning seat 2, triggering the positioning sensor; the positioning sensor sends a "product in place" signal to the electronic control system, and the electronic control system then starts the testing process; 2) Probe short-circuiting: The electronic control system instructs the first power source 5 to drive the conductive block 3 forward, and the conductive block 3 contacts and short-circuits the two probes of the carbon brush holder; after the first power source 5 detects the "in position" signal, it feeds back to the electronic control system and enters the next stage; 3) Circuit connection: The electronic control system controls the second power source 6 to drive the voltage conductor 4 to press down. The voltage conductor 4 presses down on the top of the carbon brush holder, so that the carbon brush holder, voltage conductor 4, probe and conductive block 3 form a complete circuit. At the same time, the second power source 6 monitors the pressing displacement in real time. When the preset compression amount is reached, it sends a "pressurization complete" signal to the electronic control system. 4) Voltage and current detection: The electrical control system commands the electrical performance detection component to start, the high-precision DC power supply outputs the preset voltage, and at the same time the high-precision current sensor collects the loop current data in real time; the collected current data is transmitted to the electrical control system through the analog module and compared with the preset qualified threshold. 5) Result judgment and feedback: If the average current is within the threshold range, the electronic control system judges the product as "qualified", the human-machine interface displays a green "OK" mark, and the qualified indicator light illuminates at the same time; if the current value exceeds the threshold range, it is judged as "unqualified", the human-machine interface displays a red "NG" mark, the buzzer alarms at the same time, and the unqualified is recorded in the historical screen. 6) Reset: After the test results are fed back, the electrical control system controls the second power source 6 to rise and the first power source 5 to retreat, restoring the initial position; the operator removes the carbon brush holder that has been tested, and the equipment waits for the next feeding, completing one test cycle.

[0032] In summary, the above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A carbon brush holder electrical performance testing device, comprising a frame, characterized in that: The frame is equipped with a carbon brush holder positioning seat, an electrical performance testing component, and an electronic control system. The carbon brush holder positioning seat has a slot containing a positioning sensor. The electrical performance testing component includes a high-precision DC power supply, a conductive block, and a voltage probe. The conductive block is movable back and forth and is equipped with a first power source with position feedback function. The conductive block is short-circuited with two probes of the carbon brush holder. The voltage probe is movable up and down and is equipped with a second power source with position feedback function. The voltage probe is press-fitted with the positive and negative terminals of the carbon brush holder. The positioning sensor, electrical performance testing component, first power source, and second power source are all connected to the electronic control system.

2. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The first power source is a magnetic switch cylinder.

3. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The second power source is a servo motor.

4. The carbon brush holder electrical performance testing equipment as described in claim 3, characterized in that: The voltage conductor is connected to the pre-pressure cylinder, which is mounted on the lifting seat. The lifting seat is mounted on the guide rail, and the lifting seat is connected to the servo motor via a lead screw drive.

5. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The electrical control system is a PLC, equipped with an MCGS interactive human-machine interface and a high-precision current sensor.

6. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The electrical performance testing component has a test voltage range of 0.01~0.1V and a current adjustment accuracy of 0.01A.

7. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The frame is also equipped with a pre-pressing mechanism, which includes a pressing head and a third power source with position feedback function. The pressing head is pressed into place with the carbon brush holder.

8. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The frame is also equipped with a dotting mechanism, which corresponds to the carbon brush holder.

9. The carbon brush holder electrical performance testing equipment as described in claim 1, characterized in that: The conductive block includes a conductive body and two conductive rods, which are elastically extendable and retractable on the conductive body.

10. The testing method of the carbon brush holder electrical performance testing equipment as described in any one of claims 1-8, characterized in that: Includes the following steps: Loading and positioning: The operator places the carbon brush holder to be tested into the slot of the carbon brush holder positioning seat, triggering the positioning sensor; the positioning sensor sends a "product in place" signal to the electronic control system, and the electronic control system then starts the testing process; Probe short-circuiting: The electronic control system instructs the first power source to drive the conductive block forward, and the conductive block contacts and short-circuits the two probes of the carbon brush holder; after the first power source detects the "in position" signal, it feeds back to the electronic control system and proceeds to the next stage; Circuit connection: The electronic control system controls the second power source to drive the voltage probe to press down. The voltage probe presses against the top of the carbon brush holder, so that the carbon brush holder, voltage probe, probe and conductive block form a complete circuit; at the same time, the second power source monitors the pressing displacement in real time. When the preset compression amount is reached, it sends a "pressurization complete" signal to the electronic control system. Voltage and current detection: The electrical control system commands the electrical performance detection component to start, the high-precision DC power supply outputs the preset voltage, and at the same time the high-precision current sensor collects the loop current data in real time; the collected current data is transmitted to the electrical control system through the analog module and compared with the preset qualified threshold. Result judgment and feedback: If the average current is within the threshold range, the electronic control system determines the product to be "qualified", the human-machine interface displays a green "OK" mark, and the qualified indicator light illuminates at the same time; if the current value exceeds the threshold range, it is determined to be "unqualified", the human-machine interface displays a red "NG" mark, the buzzer sounds an alarm, and the unqualified is recorded in the historical screen. Reset: After the test results are fed back, the electrical control system controls the second power source to rise and the first power source to retreat, restoring the initial position; the operator removes the carbon brush holder after testing, and the equipment waits for the next feeding, completing one testing cycle.

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