Converter power module comprehensive detection system for rail transit

Abstract

The invention discloses a comprehensive detection system for a converter power module for rail transit. The comprehensive detection system comprises a high-voltage direct-current power supply system, an inductive load, an automatic inductive gear switching system, a low-voltage logic test system, an energy feedback power supply system, a three-phase alternating-current power supply / low-voltage direct-current power supply system, a resistive load, an automatic resistive gear switching system and a measurement and control system, the output end of the high-voltage direct-current power supply system is connected with the input end of the first power module; the output end of the first power module is connected with an inductance load through an inductance gear automatic switching system; the output end of the three-phase alternating-current power supply / low-voltage direct-current power supply system is connected with the input end of the second power module; the output end of the second power module is connected with a resistive load through a resistance gear automatic switching system; the measurement and control system is connected with the first power module and the second power module; two ends of the energy feedback power supply system are respectively connected with the first power module and the power supply. The system has the advantages of good compatibility, low cost, rich test functions and the like.

Description

Technical Field

[0001] This invention relates to the field of rail transit technology, specifically to a comprehensive testing system for converter power modules used in rail transit. Background Technology

[0002] Currently, the market share of maintenance in the rail transit sector is gradually increasing. Locomotive C6 maintenance is transitioning from batch trial maintenance to routine maintenance, with an estimated average of 1,618 locomotives to be maintained annually. In the urban rail sector, domestically produced products will fully enter the overhaul / major overhaul cycle, with an annual growth rate of overhaul exceeding 30%. 2,768 trains in the urban rail sector are undergoing major overhaul. In accordance with the requirements of China State Railway Group and metro users to shorten maintenance cycles and reduce maintenance downtime, the maintenance of major components such as traction systems adopts a localized maintenance model. Due to the large number of converter module models and significant differences in testing for high-level maintenance of locomotives and urban rail, if each type of converter module requires the development of a new testing device according to the requirements of newly manufactured testing equipment, a new testing device needs to be developed for each converter module model. Currently, the types of converter modules under maintenance involve more than 10 models. Maintaining testing equipment using existing methods faces problems such as high initial investment, large equipment footprint, high maintenance costs, and long investment payback period.

[0003] Existing testing equipment primarily focuses on developing a separate testing system for each power module of locomotive main transformers, auxiliary transformers, and urban rail main transformers, as well as auxiliary transformers. There is a lack of comprehensive testing equipment compatible with multiple products. Therefore, research is being conducted on a comprehensive testing system for power modules of high-level maintenance converters in rail transit. This system will develop high- and low-voltage tests suitable for the main and auxiliary converter power modules of Harmony-type electric locomotives. This will enhance the compatibility of converter module testing equipment, improve the interoperability of power supplies and loads within the testing equipment, maximize equipment efficiency, reduce initial investment costs, and improve overall equipment performance. This will provide strong equipment and technical support for lean and professional maintenance in rail transit. Summary of the Invention

[0004] To address the technical problems existing in the prior art, this invention provides a comprehensive testing system for converter power modules used in rail transit that is highly compatible and low in cost.

[0005] To solve the above-mentioned technical problems, the technical solution proposed by this invention is as follows:

[0006] A comprehensive testing system for converter power modules used in rail transit includes a high-voltage DC power supply system, an inductive load, an automatic inductor range switching system, a low-voltage logic testing system, an energy feeder power supply system, a three-phase AC power supply / low-voltage DC power supply system, a resistive load, an automatic resistance range switching system, and a measurement and control system.

[0007] The input terminal of the high-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the first power module; the output terminal of the first power module is connected to the inductive load via the inductor range automatic switching system.

[0008] The input terminal of the three-phase AC power supply / low-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the second power module; the output terminal of the second power module is connected to the resistive load via the automatic resistance range switching system.

[0009] The measurement and control system is connected to the first power module and the second power module respectively;

[0010] The input terminal of the energy feeder system is connected to the input terminal of the first power module, and the output terminal is connected to the power supply.

[0011] Preferably, the high-voltage DC power supply system includes a high-voltage DC power supply and an automatic discharge circuit, with the output terminal of the high-voltage DC power supply connected to the automatic discharge circuit; the high-voltage DC power supply is used to provide test power for the high-voltage chopping test and power assessment test of the power module; during the chopping test, it supplies power to the power capacitor built into or external to the power module, charging the power capacitor to the rated operating voltage of the power module for subsequent tests; during the power assessment test, it provides power to the power module.

[0012] Preferably, the automatic discharge circuit is divided into a normally open energizing circuit and a normally closed discharge circuit. The normally open energizing circuit includes a normally open switch and a normally open energizing resistor R2 connected in series, and the normally closed discharge circuit includes a normally closed switch and a normally closed discharge resistor R1 connected in series.

[0013] The normally open energizing circuit is used to release the electrical energy of the capacitors in the test bench before and after each test. The normally open energizing resistor R2 is connected and disconnected using remote control. The normally closed discharge circuit is used when the equipment is in an abnormal state. When the test bench encounters a power failure during the test, the normally closed contactor returns to its initial normally closed state, and the normally closed discharge resistor is connected to the main circuit, thereby releasing the electrical energy of the capacitors in the test bench.

[0014] Preferably, the normally open energizing circuit and the normally closed discharging circuit are interlocked.

[0015] Preferably, the automatic resistance level switching system includes multiple automatic resistance level switching switches, one end of which is connected to each power element of the power module, and the other end is connected to an inductive load.

[0016] Preferably, the automatic resistance range switching switch is a contactor.

[0017] Preferably, the measurement and control system includes a host computer, a control module, a transmission control unit, a DC power supply, a multimeter, and an oscilloscope; the control module, the transmission control unit, the DC power supply, the multimeter, and the oscilloscope are all connected to the host computer.

[0018] Preferably, the DC power supply includes a DC 110V DC power supply and a DC 0-30V DC power supply; the DC 110V DC power supply is a programmable single-channel DC power supply that provides DC 110V DC power to the power module and has remote control capability; the DC 0-30V DC power supply is a programmable three-channel DC power supply, with channel CH1 providing DC 24V power to the pulse distribution board of the main transformer and auxiliary transformer modules, and channel CH2 providing DC 15V power to the main circuit DC input of the power module logic test.

[0019] Preferably, the inductive load is a reactor, and the reactor is set with multiple inductance values ​​to adapt to different types of power module test loads.

[0020] Preferably, the reactor is an air-core reactor.

[0021] Compared with the prior art, the advantages of the present invention are as follows:

[0022] The present invention provides a comprehensive testing system for high-level maintenance converter power modules in rail transit. Breaking away from existing single-test equipment and the "one product, one test equipment" approach, this system is compatible with testing functions for multiple types of converter power modules (such as traction converters, auxiliary converters, and chargers for locomotives, EMUs, and urban rail transit). It achieves shared and compatible testing systems for rail transit products across various fields, optimizes the overall performance of the testing process, reduces the total types of equipment required, lowers the initial investment cost, improves equipment utilization, and achieves the goal of comprehensive testing of various power modules at both high and low voltage levels.

[0023] The integrated testing system for power modules of converters used in high-level maintenance of rail transit in this invention can maximize equipment utilization efficiency, reduce initial equipment investment costs, and reduce the space occupied by multiple devices for multiple product development. It enables one device to inspect multiple products, improves overall equipment performance, and provides strong equipment and technical support for lean and professional maintenance of rail transit.

[0024] The present invention relates to a comprehensive testing system for power modules of converters used in high-level maintenance of rail transit. This system replaces the traditional pure inductive load used in power assessments with a power-feeding power source. The power module outputs electrical energy to charge and feed it back to the power source. Remote power supply only needs to compensate for system energy losses, effectively reducing energy consumption (currently, conventional power assessments use a pure inductor as the power module output load, where the power module outputs electrical energy to the inductive load to generate reactive power and ensures the power module's output current reaches its rated value, thus simulating the vehicle's operating conditions. However, conventional assessments using inductive loads suffer from drawbacks such as high heat loss, high noise, high vibration, and high energy consumption).

[0025] This invention discloses a comprehensive testing system for power modules of high-level maintenance converters in rail transit. This system can be used for a series of functional and performance tests on the power modules of traction converters, auxiliary converters, and chargers in locomotives, EMUs, and urban rail transit, including low-voltage logic, high-voltage chopping, and power assessment. These tests target the internal IGBTs, pulse distribution boards, driver boards, detection boards, and the entire power module. Attached Figure Description

[0026] Figure 1 This is a topology diagram of the maintenance system of the present invention in an embodiment.

[0027] Figure 2 This is a circuit diagram of the maintenance system of the present invention in an embodiment.

[0028] Figure 3 This is a circuit schematic diagram of the high-voltage DC power supply of the present invention in an embodiment.

[0029] Figure 4 This is a circuit diagram of the automatic discharge circuit of the present invention in an embodiment.

[0030] Figure 5 This is a circuit diagram of the output switching circuit of the present invention in an embodiment.

[0031] Figure 6 This is a circuit schematic diagram of the energy feeder power supply of the present invention in an embodiment.

[0032] Figure 7 This is a topology diagram of the measurement and control system of the present invention in an embodiment. Detailed Implementation

[0033] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0034] like Figures 1-2As shown in the figure, the comprehensive testing system for power modules of high-level maintenance converters in rail transit according to an embodiment of the present invention includes a high-voltage DC power supply system, an inductive load, an inductor range automatic switching system, a low-voltage logic test system, an energy feed power supply system, a three-phase AC power supply / low-voltage DC power supply system, a resistive load, a resistance range automatic switching system, and a measurement and control system.

[0035] The input terminal of the high-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the first power module; the output terminal of the first power module is connected to the inductive load via the inductor range automatic switching system.

[0036] The input terminal of the three-phase AC power supply / low-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the second power module; the output terminal of the second power module is connected to the resistive load via the automatic resistance range switching system.

[0037] The measurement and control system is connected to the first power module and the second power module respectively;

[0038] The input terminal of the power supply system is connected to the input terminal of the first power module, and the output terminal is connected to the power supply.

[0039] The high-voltage DC power supply system provides test power for the high-voltage chopper test and power assessment test of the power module. During the chopper test, it supplies power to the power module's built-in or external power capacitors, charging them to the power module's rated operating voltage for subsequent testing. During the power assessment test, it supplies power to the power module itself. The power supply also features an automatic discharge circuit at the rear end, suitable for various test conditions, ensuring the safety of test personnel.

[0040] Inductive Load and Automatic Inductor Range Switching System: The inductive load provides a chopper test load for the power module. Through mutual oscillation and discharge with the power module's built-in or external power capacitors, it tests the current withstand capability of the IGBTs within the power module. The automatic inductor range switching system uses multiple contactors for switching the power module wiring circuit, load range, and test mode (i.e., switching between low-voltage logic, high-voltage chopper, and power assessment test resources) to achieve automated testing. The system also includes measurement circuits for an oscilloscope, differential probe, current probe, high-voltage probe, and multimeter. The oscilloscope, differential probe, and current probe are used to detect the voltage and current waveforms during high-voltage testing, while the high-voltage probe and multimeter are used to monitor the effective voltage value of the DC power supply in real time during the test.

[0041] Low-voltage logic test system: This system provides test power supplies and signal detection circuits of various specifications for low-voltage logic testing of power modules.

[0042] Energy Feeding Power Supply System: This system serves as a traceable load for power assessment tests, feeding the power module test output energy to the high-voltage DC front end to achieve the recycling of test energy.

[0043] Three-phase AC power supply / low-voltage DC power supply system: This system provides AC 100~700V (rated voltage AC 380V) AC power and DC 0~155V DC power to the charger module to meet the power requirements of different charger module tests. A voltage sensor is installed at the power output terminal to monitor and control the power output parameters.

[0044] Resistive load and automatic resistance range switching system: The resistive load provides current testing load for the charger module. The automatic resistance range switching system controls the load to be applied, thereby controlling the output current of the charger module to meet the testing requirements of different products.

[0045] Measurement and control system: This system provides operation control and test data acquisition for the experiment. It mainly consists of a control unit, a DC110V control power supply, a DC 0~30V control power supply, a DC 15V / 24V logic test power supply, a DC±15V sensor power supply, an industrial computer, a PLC controller, and a signal conditioning board.

[0046] like Figure 3 As shown, the high-voltage DC power supply system includes a high-voltage DC power supply and an automatic discharge circuit, with the output terminal of the high-voltage DC power supply connected to the automatic discharge circuit. The high-voltage DC power supply consists of a high-power IGBT full-bridge inverter, a high-frequency transformer, and Schottky diodes forming the main circuit. A high-performance digital signal processing controller forms the core of the control system, which uses AC 380V power. The system can be remotely controlled and features interlocking, alarm, charging current limiting, and operational status monitoring functions.

[0047] The high-voltage DC power supply adopts a regulated and current-regulating switching power supply, meeting the test requirements of DC 0V~2000V for high-voltage testing. The main technical parameters are as follows: Specification: DC2000V1A; Input power: AC 220V, 50Hz; Output voltage: DC 0V~2000V continuously adjustable; Rated current: 1A; Voltage regulation accuracy: not less than 0.5%; Current regulation accuracy: not less than 0.5%; Communication: Ethernet; Function: Automatic switching between constant voltage and constant current.

[0048] like Figure 4 As shown, the automatic discharge circuit serves as a safety guarantee for this test bench, ensuring that residual voltage within the test bench can be stably released in the event of test completion, interruption, or other abnormal situations, thus protecting the personal safety of test personnel.

[0049] The automatic discharge circuit is divided into a normally open energizing circuit and a normally closed discharge circuit. The normally open energizing circuit includes a normally open switch and a normally open energizing resistor R2 connected in series, and the normally closed discharge circuit includes a normally closed switch and a normally closed discharge resistor R1 connected in series.

[0050] Normally open discharge is used to release the energy of the capacitors in the test bench before and after each test when the equipment is working normally. The connection and disconnection of the discharge resistor is controlled remotely and can be automated or manually controlled. Normally closed discharge is used when the equipment is in an abnormal state. When the test bench encounters a power failure during the test, the normally closed contactor returns to its initial normally closed state, and the normally closed discharge resistor is connected to the main circuit, thereby releasing the energy of the capacitors in the test bench.

[0051] Normally open and normally closed discharge are interlocked in the test bench's software and hardware control to prevent accidental switching during the test, which could lead to insufficient chopper voltage or equipment damage.

[0052] like Figure 5 As shown, since a power module typically contains eight IGBT devices, there are eight different wiring methods depending on the IGBT's position (upper or lower). Manual wiring is prone to errors, potentially causing damage to the power module, equipment, or even personal injury. By simplifying the test circuit, the automatic inductance range switching system during chopper testing requires seven contactors to switch the output wiring circuits of the eight IGBT devices in the power module, thus achieving automatic switching of the test circuit. Furthermore, considering the different test loads required for different power modules, 40uH, 280uH, and 320uH air-core reactors are selected as the main ranges, and switching contactors are configured to maximize the automation function.

[0053] Finally, since the low-voltage logic test and high-voltage chopper test of the power module are basically the same in terms of the wiring points, but the related devices of the low-voltage logic test cannot withstand the impact of the high-voltage test, in previous tests, there were also cases where the wires were not disconnected after the low-voltage test, resulting in damage to the devices during the high-voltage test. Therefore, a 7-pole double-throw switch was installed at the front end of the 7 line switching contactors to automatically switch the high and low voltage test circuits and enhance the reliability of the system.

[0054] Since different types of power modules use different IGBT devices, the rated current of the IGBTs also varies. To be compatible with the testing requirements of different current levels of all power modules, in addition to adjusting the on-time of the chopper test double pulse, a load with a wide range of adjustable inductance values ​​is also an important option.

[0055] Inductive loads are used as loads for chopper tests. During the chopper test, the switching on and off of the IGBT is controlled, thereby controlling the oscillation discharge time of the capacitor on the inductor. The inductor will directly bear the instantaneous high voltage and high current impact during the chopper test.

[0056] The reactor is equipped with 14 inductance values ​​to adapt to different types of power module test loads; an air-core reactor is selected to reduce the load size and accommodate different maintenance site hardware configurations. Vacuum impregnation technology is used to coat the insulating varnish to achieve instantaneous high-voltage withstand capability between turns. The air-core reactor has 14 taps ranging from 0μH to 500μH, uses a single-phase air-core inductor, has a rated operating voltage of DC 4000V, and a peak operating current of 4500A (150ms).

[0057] The high-voltage testing equipment mainly consists of an oscilloscope, a differential probe, a current probe, a high-voltage probe, and a multimeter. The oscilloscope, differential probe, and current probe are used to detect the chopper voltage and current waveforms, while the high-voltage probe and multimeter are used to monitor the effective voltage value of the high-voltage chopper DC power supply in real time.

[0058] During power module chopper testing, the IGBT turn-on time is 50–500 ms. This extremely short turn-on time means that traditional voltage and current sensors, signal conditioning boards, and analog acquisition systems cannot meet the requirements for fast and accurate data acquisition. Therefore, a digital oscilloscope is embedded in this test bench to directly utilize the oscilloscope's high-speed data signal acquisition capability. Combined with a high-voltage differential probe and a flexible current probe, this enables accurate acquisition of chopper data while enhancing the overall interchangeability of the test bench.

[0059] The oscilloscope acquires the waveform signals of chopping voltage and chopping current through differential probes and current probes, and acquires the low-voltage pulse waveform of the built-in DCU module through a passive probe.

[0060] The test bench is equipped with a benchtop multimeter and a high-voltage probe for DC circuit voltage detection in chopper tests. The low-voltage section is equipped with a benchtop multimeter for measuring resistance signals such as temperature relays in low-voltage logic tests.

[0061] The low-voltage logic test system is used for test operation control and test data acquisition. It mainly consists of a control unit, a DC 110V control power supply, a DC 0-30V control power supply, a DC 15V / 24V logic test power supply, a DC ±15V sensor power supply, an industrial computer, a PLC controller, and a signal conditioning board. Its main functions are as follows: providing DC 110V control power to the power module; providing DC 24V and DC 5V power to the power module; providing DC 15V or DC 24V power for charging the low-voltage logic test capacitors to the power module; providing logic and chopper pulse control signals to the power module through the control unit, with a pulse peak of DC 24V. Signal-related cables (including enable signals) are shielded, with the shielding layer connected to test ground at one end; detecting the resistance signal parameters of the power module's temperature relay using a multimeter, and switching the measurement circuit through the relay; detecting the capacitance value of the power module's supporting capacitor using a multimeter, and switching the measurement circuit through the relay; providing control commands to the power module; and detecting the DC voltage of the power module through the drive control unit. 24V fault signal voltage; the voltage of each relative DC 15V negative and DC 15V positive terminal of the power module output is detected by the PLC analog input module and voltage divider conditioning board (voltage divider ratio 1 / 3); the relative DC negative waveform is measured by oscilloscope and passive voltage probe, and the measurement circuit is switched by relay.

[0062] like Figure 6 As shown, the energy-feedback power supply system is a grid-feedback analog power supply used as a load device for power module testing and verification. It features energy feedback to the grid and outputs a sine wave. Its main functions are as follows: It can feed energy from the AC source input to the main circuit and back to the AC380V grid output; it employs PWM rectification technology, providing a high input power factor; it has high dynamic response; it provides real-time circuit monitoring, effectively protecting the equipment in fault conditions and possessing fault storage functionality; it requires high frequency stability and good continuity; and it has a LAN communication interface (ProfiNet or MODBUS). TCP / IP protocol); Protection modes: overvoltage, overcurrent, overload, short circuit, overtemperature, etc.; Provides readings such as RMS voltage, RMS current, active power, frequency, and power factor; Response time within 100ms for 100% load and unload; Timely triggering of protection to prevent equipment damage during overcurrent; Features load mode to simulate resistive-inductive loads with a power factor of 0.85±0.05; Automatic grid connection function; After both the main circuit input and output power supplies are connected, the power supply automatically achieves grid connection and operates according to the required power and power factor; In case of system failure or power failure on the main circuit output side (i.e., AC380V grid side), the main circuit voltage can be reduced to below 36V within 300s, and a fault signal is issued to control the external switch to trip.

[0063] Because the specifications of the charger cabinet vary greatly depending on the design of the traction system, the power supply voltage of the charger module ranges from AC 380V, AC 440V to AC 560V. Therefore, the three-phase AC power supply / low-voltage DC power supply system uses a three-phase adjustable voltage regulator to provide AC 100-700V (rated voltage AC 380V) AC power to the charger module to meet the power supply requirements of the charger module under different system operating conditions.

[0064] In addition to the main function of the charger module outputting DC 110V power, different models of chargers also have a power supply module that outputs DC 24V. The power supply is taken from the output of the charger module, and the power supply ripple is relatively large. Therefore, this type of power supply module is equipped with a DC 0~155V DC power supply to be compatible with the power demand of all power modules in the charger cabinet.

[0065] Configure a three-phase AC voltage regulator with continuously adjustable output from AC 100-700V. This regulator must be able to automatically adjust via control, with limit switches for the high and low limits. Specific parameters are as follows: Input voltage: AC380V±10%, 50Hz; Output voltage range: AC100~700V (rated voltage AC380V); Capacity: 80kVA. Configure an adjustable DC 24V power supply with Ethernet communication to provide input to the tested 24V converter module. Input voltage: AC380V±10%, 50Hz; Output voltage range: DC 0~155V, with communication control function for output voltage and current values, and communication feedback capability; Output current adjustment range: 0~45A; Rated power: 6kW; Accuracy: ≤0.05% of rated value (source effect), ≤0.05% of rated value (time drift).

[0066] The resistive load and automatic resistance level switching system is applicable to a range of power modules for converter products other than inverters, such as charger modules or DC24V module loads, with an input voltage of DC 24~110V. This system is configured with a Siemens 200Smart as a slave station to control the closing and opening of the contactor in this cabinet and to collect the temperature status of the contactor, cabinet door, and resistor cabinet. An AC220V cooling fan is configured for heat dissipation of the resistors in this cabinet. A PT100 is required at the hottest point in the resistor cabinet to collect the resistor cabinet temperature. During resistance testing, the temperature rise should not exceed 100°C. Voltage and current sensors and a pressure switch are configured, and their values ​​are sent to the PLC.

[0067] like Figure 7 As shown, in the measurement and control system, the host computer on the test bench is an Advantech industrial computer, connected to an Ethernet control module CDCU, drive control unit, DC power supply, multimeter, oscilloscope, and other equipment. The PLC master station is a single S7-1200 PLC, communicating with the 200Smart slave station via Ethernet.

[0068] The drive control unit adopts a CDCU, which has the advantages of high compatibility, high reliability, and high maintainability. It is used to control the drive circuit of the control module, and thus control the IGBT conduction of the module. The CDCU can output a DC 24V pulse waveform with adjustable pulse width and duty cycle. The maximum drive current does not exceed 100mA. The output pulse has a protection function. When the current is too large, it should be able to disconnect the output to ensure that the pulse chip is not burned out.

[0069] The DC power supply includes a DC 110V power supply and a DC 0-30V power supply. The DC 110V power supply is a programmable single-channel DC power supply, providing DC 110V power to the power modules and possessing remote control capabilities; its total power is 1.5kW, which can meet the power capacity requirements of all power modules. The DC 0-30V power supply is a programmable three-channel DC power supply. Channel CH1 provides DC 24V power to the pulse distribution board of the main and auxiliary transformer modules, and channel CH2 provides DC 15V power to the main circuit DC input for the power module logic test. Its output voltage is continuously adjustable from 0V to 32V for CH1 and CH2, and from 0V to 6V for CH3; rated current is 5A for CH1 and CH2, and 3A for CH3; voltage adjustment step size is ≤0.1V.

[0070] The present invention provides a comprehensive testing system for high-level maintenance converter power modules in rail transit. Breaking away from existing single-test equipment and the "one product, one test equipment" approach, this system is compatible with testing functions for multiple types of converter power modules (such as traction converters, auxiliary converters, and chargers for locomotives, EMUs, and urban rail transit). It achieves shared and compatible testing systems for rail transit products across various fields, optimizes the overall performance of the testing process, reduces the total types of equipment required, lowers the initial investment cost, improves equipment utilization, and achieves the goal of comprehensive testing of various power modules at both high and low voltage levels.

[0071] The integrated testing system for power modules of converters used in high-level maintenance of rail transit, as described in this invention, can maximize equipment utilization efficiency, reduce initial equipment investment costs, and reduce the space occupied by multiple devices for multiple product developments. It enables one device to inspect multiple products, thereby improving overall equipment performance and providing strong equipment and technical support for lean and professional maintenance of rail transit.

[0072] The present invention relates to a comprehensive testing system for power modules of converters used in high-level maintenance of rail transit. This system replaces the traditional pure inductive load used in power assessments with a power-feeding power source. The power module outputs electrical energy to charge and feed it back to the power source. Remote power supply only needs to compensate for system energy losses, effectively reducing energy consumption (currently, conventional power assessments use a pure inductor as the power module output load, where the power module outputs electrical energy to the inductive load to generate reactive power and ensures the power module's output current reaches its rated value, thus simulating the vehicle's operating conditions. However, conventional assessments using inductive loads suffer from drawbacks such as high heat loss, high noise, high vibration, and high energy consumption).

[0073] This invention discloses a comprehensive testing system for power modules of high-level maintenance converters in rail transit. This system can be used for a series of functional and performance tests on the power modules of traction converters, auxiliary converters, and chargers in locomotives, EMUs, and urban rail transit, including low-voltage logic, high-voltage chopping, and power assessment. These tests target the internal IGBTs, pulse distribution boards, driver boards, detection boards, and the entire power module.

[0074] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A comprehensive testing system for converter power modules used in rail transit, characterized in that, Including high-voltage DC power supply system, inductive load, inductor range automatic switching system, low-voltage logic test system, energy feed power supply system, three-phase AC power supply / low-voltage DC power supply system, resistive load, resistance range automatic switching system and measurement and control system; The input terminal of the high-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the first power module; the output terminal of the first power module is connected to the inductive load via the inductor range automatic switching system. The input terminal of the three-phase AC power supply / low-voltage DC power supply system is connected to the power supply, and the output terminal is connected to the input terminal of the second power module; the output terminal of the second power module is connected to the resistive load via the automatic resistance range switching system. The measurement and control system is connected to the first power module and the second power module respectively; The input terminal of the energy feeder system is connected to the input terminal of the first power module, and the output terminal is connected to the power supply.

2. The integrated testing system for converter power modules in rail transit according to claim 1, characterized in that, The high-voltage DC power supply system includes a high-voltage DC power supply and an automatic discharge circuit. The output terminal of the high-voltage DC power supply is connected to the automatic discharge circuit. The high-voltage DC power supply is used to provide test power for the high-voltage chopping test and power assessment test of the power module. During the chopping test, it supplies power to the power capacitor built into or external to the power module, charging the power capacitor to the rated operating voltage of the power module for subsequent tests. During the power assessment test, it provides power to the power module.

3. The integrated testing system for converter power modules in rail transit according to claim 2, characterized in that, The automatic discharge circuit is divided into a normally open energizing circuit and a normally closed discharge circuit. The normally open energizing circuit includes a normally open switch and a normally open energizing resistor R2 connected in series, and the normally closed discharge circuit includes a normally closed switch and a normally closed discharge resistor R1 connected in series. The normally open energizing circuit is used to release the electrical energy of the capacitors in the test bench before and after each test. The normally open energizing resistor R2 is connected and disconnected using remote control. The normally closed discharge circuit is used when the equipment is in an abnormal state. When the test bench encounters a power outage during the test, the normally closed contactor returns to its initial normally closed state, and the normally closed discharge resistor is connected to the main circuit, thereby releasing the electrical energy of the capacitors in the test bench.

4. The integrated testing system for converter power modules in rail transit according to claim 3, characterized in that, The normally open energizing circuit and the normally closed discharging circuit are interlocked.

5. The integrated testing system for converter power modules in rail transit according to any one of claims 1-4, characterized in that, The automatic resistance level switching system includes multiple automatic resistance level switching switches. One end of each automatic resistance level switching switch is connected to a power element of the power module, and the other end is connected to an inductive load.

6. The integrated testing system for converter power modules in rail transit according to claim 5, characterized in that, The automatic resistance range switching switch is a contactor.

7. The integrated testing system for converter power modules in rail transit according to any one of claims 1-4, characterized in that, The measurement and control system includes a host computer, a control module, a transmission control unit, a DC power supply, a multimeter, and an oscilloscope; the control module, the transmission control unit, the DC power supply, the multimeter, and the oscilloscope are all connected to the host computer.

8. The integrated testing system for converter power modules in rail transit according to claim 7, characterized in that, The DC power supply includes a DC 110V DC power supply and a DC 0-30V DC power supply; the DC 110V DC power supply is a programmable single-channel DC power supply that provides DC 110V DC power to the power module and has remote control capability; the DC 0-30V DC power supply is a programmable three-channel DC power supply, with channel CH1 providing DC 24V power to the pulse distribution board of the main transformer and auxiliary transformer modules, and channel CH2 providing DC 15V power to the main circuit DC input of the power module logic test.

9. The integrated testing system for converter power modules in rail transit according to any one of claims 1-4, characterized in that, The inductive load is a reactor, which is set with multiple inductance values ​​to adapt to different types of power module test loads.

10. The integrated testing system for converter power modules in rail transit according to claim 9, characterized in that, The reactor is an air-core reactor.

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