Relay test system and device

Abstract

The invention discloses a relay test system and device, and the system comprises a power processing module, an energy-saving load driving module, an overload protection module, a hybrid load switching module, a multi-station test control module, a data collection and monitoring module, and a main control module. The power supply processing module is electrically connected with the energy-saving load driving module and the hybrid load switching module, and the energy-saving load driving module and the hybrid load switching module are electrically connected with the multi-station test control module. According to the invention, through the sectional current driving design of the energy-saving load driving module circuit, only the current effect is kept in the pull-in stage of the relay, the voltage is reduced to 12-24V, and the energy consumption in the test process is greatly reduced; and meanwhile, the duty ratio adjusting circuit can realize multi-coil interpenetration driving, so that the utilization rate of the equipment is further improved.

Description

Technical Field

[0001] This invention relates to the field of electrical equipment testing technology, specifically to a relay testing system and equipment. Background Technology

[0002] As a core switching element in electrical control systems, the performance stability and lifespan of relays directly affect the operational safety of the entire electrical system. Therefore, accurate and comprehensive electrical life testing of relays is crucial. Existing relay testing systems and equipment have several shortcomings in practical applications: First, poor energy efficiency. Existing testing systems experience both voltage and current effects during relay activation, resulting in significant energy loss. Long-term testing leads to substantial power waste and increased testing costs. Second, narrow load adaptability. Most testing equipment only supports a single type of load (such as resistive loads), failing to meet the testing needs of mixed load scenarios that relays may encounter in actual operation. Furthermore, existing equipment struggles to handle both AC and DC testing environments, requiring multiple devices for separate testing, increasing equipment investment costs. Third, insufficient overload protection. Existing systems often employ simple overcurrent protection devices, unable to meet the testing requirements of high-power equipment driven by low-voltage power grids. This can easily lead to test interruptions due to excessive grid load, and even damage to testing equipment and samples. Fourth, low data monitoring accuracy. Existing monitoring devices struggle to capture current and voltage waveform data in real time during testing, compromising the integrity and accuracy of the test data and hindering comprehensive analysis of relay performance. Furthermore, most devices only support single-station testing, resulting in low testing efficiency and failing to meet the needs of batch testing.

[0003] Based on the shortcomings of the existing technology, there is an urgent need for a relay testing system and equipment that features energy saving, wide load adaptability, AC / DC testing capabilities, accurate overload protection, and real-time data monitoring. Summary of the Invention

[0004] The purpose of this invention is to provide a relay testing system and equipment to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a relay testing system and equipment, comprising a power processing module, an energy-saving load drive module, an overload protection module, a mixed load switching module, a multi-station test control module, a data acquisition and monitoring module, and a main control module. An external three-phase five-wire 400V AC power supply is connected to the power processing module. The power processing module is electrically connected to the energy-saving load drive module and the mixed load switching module, respectively. The energy-saving load drive module and the mixed load switching module are both electrically connected to the multi-station test control module. The multi-station test control module is electrically connected to the data acquisition and monitoring module. The data acquisition and monitoring module, the energy-saving load drive module, the mixed load switching module, and the overload protection module are all electrically connected to the main control module. The overload protection module is connected in series between the power processing module and each load and drive module. The power processing module includes a voltage conversion unit, a rectification unit, and a filtering unit. The voltage conversion unit uses a step-down transformer, the rectification unit uses a full-bridge rectifier circuit, and the filtering unit uses an LC filter circuit with a switching switch.

[0006] In the aforementioned relay testing system, the energy-saving load drive module includes a drive voltage regulation unit, a current control unit, and an energy-saving control unit. The drive voltage regulation unit adopts a PWM pulse width modulation circuit, the current control unit adopts a constant current source circuit, and the energy-saving control unit adopts a segmented current drive circuit and is equipped with a duty cycle adjustment circuit.

[0007] In the aforementioned relay testing system, the rectifier unit of the power processing module consists of a rectifier bridge composed of four high-power diodes of model 800V / 200A, with a freewheeling diode connected in parallel at the output of the rectifier bridge; the filter unit consists of capacitors C1-C4, an inductor, and a switching switch K4.0 / K4.5, with capacitors of model 1000pF / 500V, inductors of model 1mH / 200A, and a high-power IGBT selected as the switching switch; a voltage detection sensor is installed at the output of the filter unit.

[0008] In the aforementioned relay testing system, the drive voltage adjustment unit of the energy-saving load drive module adopts an SG3525 PWM controller, which, together with a MOSFET power transistor, forms a PWM pulse width modulation circuit to achieve continuous adjustment of the 0-60VDC drive voltage. The current control unit consists of an operational amplifier, a sampling resistor, and an adjustment transistor, achieving precise control of the 0-5A drive current with a control accuracy of up to 0.01A. The segmented current drive circuit of the energy-saving control unit controls the switching switch to open and close through the main control module, so that only the current effect is retained during the relay's energizing phase. The duty cycle adjustment circuit can achieve the interleaved drive of 2-3 coils with a duty cycle not exceeding 30%.

[0009] In the aforementioned relay testing system, the overload protection module includes an overcurrent protection unit, an overvoltage protection unit, and a short-circuit protection unit. The overcurrent protection unit uses a 200A / 500V fuse and a 300A / 5A current transformer, the overvoltage protection unit uses a varistor and a discharge tube, and the short-circuit protection unit uses a fast-response circuit breaker and a short-circuit detection circuit.

[0010] In the aforementioned relay testing system, the hybrid load switching module includes a load unit and a switching control unit. The load unit includes a resistive load group, an inductive load group, and a capacitive load group. The impedance adjustment range of the resistive load group is 0.1-8Ω, the inductive reactance adjustment range of the inductive load group is 0.1-15mH, and the capacitive reactance adjustment range of the capacitive load group is 100-20000μF. The switching control unit adopts an IGBT matrix and controls the load type switching through the main control module.

[0011] In the aforementioned relay testing system, the multi-station test control module includes three independent test station circuits and a station switching control circuit. Each test station is equipped with an independent drive interface, load interface, and detection interface. The station switching control circuit uses a CD4051 multiplexer, and the switching response time does not exceed 0.1ms.

[0012] In the aforementioned relay testing system, the data acquisition and monitoring module includes a voltage acquisition unit, a current acquisition unit, a waveform acquisition unit, and a data transmission unit. The voltage acquisition unit uses an LV28-P voltage sensor, the current acquisition unit uses a TA100-300A current transformer, the waveform acquisition unit uses an ADS1256 oscilloscope module, and the data transmission unit uses an RS485 communication circuit.

[0013] In the aforementioned relay testing system, the main control module includes an STM32F407 ARM controller, a 19-inch industrial display screen, and an audible and visual alarm circuit. The display screen is connected to the ARM controller via SPI communication, and the ARM controller has a built-in high-speed AD acquisition module.

[0014] A relay testing device further includes a cabinet, an operating table, and an explosion-proof test sample cabinet; the cabinet is divided into a power control cabinet and a load cabinet, and the cabinet is equipped with an aluminum profile door frame and a tempered glass safety door, which is opened and closed by a hydraulic cylinder; the operating table is customized according to the size of the test sample and integrates an industrial display screen, control buttons, and an oscilloscope; the explosion-proof test sample cabinet has an explosion-proof design and is used to place the relay sample to be tested.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention utilizes a segmented current drive design in the energy-saving load drive module circuit to ensure that only the current effect is retained during the relay's activation phase, reducing the voltage effect and significantly lowering energy consumption during testing. Simultaneously, the duty cycle adjustment circuit enables multi-coil interleaving drive, further improving energy utilization.

[0016] The overload protection module circuit of this invention integrates overcurrent, overvoltage, and short-circuit protection functions. Through the synergistic effect of components such as fuses, varistors, and fast-response circuit breakers, it can quickly respond to fault conditions, cut off the test circuit, effectively protect the test system and the relay under test, and improve the safety of the test process.

[0017] The hybrid load switching module circuit of this invention can achieve precise switching of resistive, inductive and capacitive loads, adapting to the testing requirements of different types of relays; the multi-station test control module circuit supports three-station interleaved testing, enabling simultaneous testing of multiple relays and improving testing efficiency.

[0018] The data acquisition and monitoring module of this invention integrates an oscilloscope module, which can capture test waveforms in real time and accurately acquire voltage and current data. The data acquisition accuracy is high, providing reliable data support for the accurate analysis of relay test parameters.

[0019] This invention achieves the driving of high-power test loads under low grid load by optimizing the power processing module circuit and using energy-saving drive technology, thereby reducing the impact of the test process on the grid and improving the applicability of the test system. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the operating console structure of the relay testing equipment of the present invention; Figure 2 This is a schematic diagram of the cabinet structure of the relay testing equipment of the present invention; Figure 3 This is a block diagram of the relay testing system module of the present invention; Figure 4 This is a schematic diagram of the power processing module structure of the present invention; Figure 5 This is a schematic diagram of the energy-saving load drive module structure of the present invention; Figure 6 This is a schematic diagram of the overload protection module structure of the present invention. Figure 7 This is a schematic diagram of the hybrid load switching module structure of the present invention; Figure 8 This is a schematic diagram of the multi-station test control module structure of the present invention; Figure 9 This is a schematic diagram of the data acquisition and monitoring module structure of the present invention; Figure 10 This is a schematic diagram of the main control module structure of the present invention.

[0021] In the diagram: 1. Power processing module; 101. Voltage conversion unit; 102. Rectifier unit; 103. Filtering unit; 2. Energy-saving load drive module; 201. Drive voltage regulation unit; 202. Current control unit; 203. Energy-saving control unit; 3. Overload protection module; 301. Overcurrent protection unit; 302. Overvoltage protection unit; 303. Short circuit protection unit; 4. Mixed load switching module; 401. Load unit; 402. Switching control unit; 5. Multi-station test control module; 501. Test station circuit; 502. Station switching control circuit; 6. Data acquisition and monitoring module; 601. Voltage acquisition unit; 602. Current acquisition unit; 603. Waveform acquisition unit; 604. Data transmission unit; 7. Main control module; 701. ARM controller; 702. Display screen; 703. Audible and visual alarm circuit; 8. Cabinet; 9. Operating console; 10. Explosion-proof cabinet for test samples; 11. Power control cabinet; 12. Load cabinet; 13. Tempered glass safety door; 14. Oscilloscope. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 Please see Figure 1-10 This invention provides a technical solution: a relay testing system, comprising a power processing module 1, an energy-saving load drive module 2, an overload protection module 3, a mixed load switching module 4, a multi-station test control module 5, a data acquisition and monitoring module 6, and a main control module 7. An external three-phase five-wire 380V AC power supply is connected to the power processing module 1. The power processing module 1 is electrically connected to the energy-saving load drive module 2 and the mixed load switching module 4, respectively. The energy-saving load drive module 2 and the mixed load switching module 4 are both electrically connected to the multi-station test control module 5. The multi-station test control module 5 is electrically connected to the data acquisition and monitoring module 6. The data acquisition and monitoring module 6, the energy-saving load drive module 2, the mixed load switching module 4, and the overload protection module 3 are all electrically connected to the main control module 7. The overload protection module 3 is connected in series between the power processing module 1 and each load and drive module. The power processing module 1 includes a voltage conversion unit 101, a rectification unit 102, and a filter unit 103. The voltage conversion unit 101 adopts a step-down transformer, the rectification unit 102 adopts a full-bridge rectifier circuit, and the filter unit 103 adopts an LC filter circuit and is equipped with a switching switch. The energy-saving load drive module 2 includes a drive voltage regulation unit 201, a current control unit 202, and an energy-saving control unit 203. The drive voltage regulation unit 201 adopts a PWM pulse width modulation circuit, the current control unit 202 adopts a constant current source circuit, and the energy-saving control unit 203 adopts a segmented current drive circuit and is equipped with a duty cycle adjustment circuit.

[0024] Furthermore, the rectifier unit 102 of the power processing module 1 consists of a rectifier bridge composed of four high-power diodes of model 800V / 200A, and a freewheeling diode is connected in parallel at the output of the rectifier bridge; the filter unit 103 consists of capacitors C1-C4, an inductor, and a switching switch K4.0 / K4.5. The capacitors are of model 1000pF / 500V, the inductors are of model 1mH / 200A, the switching switch is a high-power IGBT, and a voltage detection sensor is set at the output of the filter unit 103.

[0025] When an external three-phase five-wire 380V AC power supply is input to the power processing module 1, the step-down transformer of the voltage conversion unit 101 first reduces the 380V AC power to 110V. Subsequently, the full-bridge rectifier circuit of the rectifier unit 102 converts the stepped-down AC power into pulsating DC power. The freewheeling diode connected in parallel at the output of the rectifier bridge can effectively suppress reverse voltage surges and prevent the diode from being damaged due to reverse breakdown. In the filter unit 103, the LC filter circuit composed of capacitors C1-C4 and inductor INDUCTOR filters the pulsating DC power. The main control module 7 can adjust the topology of the filter circuit by switching switch K4.0 / K4.5 according to the test requirements. When the test scenario has high requirements for voltage stability, K4.0 is closed to connect capacitors C1-C2 in series with the inductor to enhance the filtering effect. When a fast response to voltage changes is required, K4.0 is opened and K4.5 is closed, leaving only C3-C4 connected in parallel for filtering to reduce filtering delay. The voltage detection sensor at the output of the filter unit 103 collects the output voltage data in real time and feeds the data back to the main control module 7.

[0026] Furthermore, the drive voltage adjustment unit 201 of the energy-saving load drive module 2 adopts an SG3525 PWM controller, which is combined with a MOSFET power transistor to form a PWM pulse width modulation circuit to achieve continuous adjustment of the 0-60VDC drive voltage; the current control unit 202 is composed of an operational amplifier, a sampling resistor and an adjustment transistor to achieve precise control of the 0-5A drive current, with a control accuracy of up to 0.01A; the segmented current drive circuit of the energy-saving control unit 203 controls the switching switch to be on and off through the main control module 7, so that only the current effect is retained during the relay energizing stage, and the duty cycle adjustment circuit can realize the interleaved drive of 2-3 coils with a duty cycle of no more than 30%.

[0027] When the energy-saving load drive module 2 is working, the SG3525 PWM controller of the drive voltage regulation unit 201 adjusts the conduction time of the MOSFET power transistor according to the drive voltage command issued by the main control module 7, realizing continuous adjustment of the 0-60VDC drive voltage. The operational amplifier of the current control unit 202 collects the voltage signal across the sampling resistor in real time, compares it with the preset current threshold, and dynamically adjusts the output current by adjusting the transistor to accurately control the drive current within the range of 0-5A, meeting the coil current requirements of different specifications of relays. The segmented current drive circuit of the energy-saving control unit 203 plays a key role in the relay energizing stage: after the main control module 7 detects the relay coil energizing signal, it immediately controls the switching switch to disconnect the voltage drive branch, retaining only the current drive branch, eliminating the voltage effect during the energizing process and reducing energy loss; at the same time, the duty cycle adjustment circuit sets the duty cycle to 30% according to the relay coil parameters to realize the interleaved drive of 2-3 coils.

[0028] Furthermore, the overload protection module 3 includes an overcurrent protection unit 301, an overvoltage protection unit 302, and a short-circuit protection unit 303. The overcurrent protection unit 301 uses a 200A / 500V fuse and a 300A / 5A current transformer. The overvoltage protection unit 302 uses a varistor and a discharge tube. The short-circuit protection unit 303 uses a fast-response relay and a short-circuit detection circuit.

[0029] The overload protection module 3 monitors the current and voltage signals between the power processing module 1 and each load and drive module in real time: the 300A / 5A current transformer of the overcurrent protection unit 201 converts the main circuit current into a detection current of less than 5A. If the detection current exceeds the preset threshold, the fuse will immediately blow and cut off the main circuit; the varistor of the overvoltage protection unit 202 will quickly conduct when the detected voltage exceeds 500V to discharge the overvoltage to the ground. The discharge tube serves as backup protection and will trigger protection when the varistor fails; the short circuit detection circuit of the short circuit protection unit 203 determines whether a short circuit has occurred by collecting the main circuit voltage signal.

[0030] Furthermore, the hybrid load switching module 4 includes a load unit 401 and a switching control unit 402. The load unit 401 includes a resistive load group, an inductive load group, and a capacitive load group. The impedance adjustment range of the resistive load group is 0.1-8Ω, the inductive reactance adjustment range of the inductive load group is 0.1-15mH, and the capacitive reactance adjustment range of the capacitive load group is 100-20000μF. The switching control unit 402 adopts a 322-E4 model relay matrix and controls the load type switching through the main control module 7.

[0031] The load unit 401 of the mixed load switching module 4 includes resistive load groups, inductive load groups, and capacitive load groups. The resistive load group consists of multiple 0.1Ω metal film resistors connected in series, and the impedance can be adjusted from 0.1 to 8Ω via a switching switch. The inductive load group consists of multiple 1mH inductors connected in parallel, with an adjustment range of 0.1-15mH. The capacitive load group consists of multiple 100μF capacitors connected in series, with an adjustment range of 100-20000μF. Under the control of the main control module 7, the 322-E4 model relay matrix of the switching control unit 402 can achieve rapid switching between different load types.

[0032] Furthermore, the multi-station test control module 5 includes three independent test station circuits 501 and a station switching control circuit 502. Each test station is equipped with an independent drive interface, load interface and detection interface. The station switching control circuit 502 uses a CD4051 multiplexer, and the switching response time does not exceed 0.01s.

[0033] The three independent test station circuits 501 of the multi-station test control module 5 are each equipped with a drive interface, a load interface, and a detection interface, and each station can be independently connected to the relay to be tested. Under the control of the main control module 7, the CD4051 multiplexer of the station switching control circuit 502 realizes rapid switching of test stations, with a switching response time of no more than 0.1ms.

[0034] Furthermore, the data acquisition and monitoring module 6 includes a voltage acquisition unit 601, a current acquisition unit 602, a waveform acquisition unit 603, and a data transmission unit 604. The voltage acquisition unit 601 uses an LV28-P voltage sensor, the current acquisition unit 602 uses a TA100-300A current transformer, the waveform acquisition unit 603 uses an ADS1256 oscilloscope module, and the data transmission unit 604 uses an RS485 communication circuit.

[0035] Furthermore, the main control module 7 includes an STM32F407 ARM controller 701, a 19-inch industrial display screen 702, and an audible and visual alarm circuit 703. The display screen 702 is connected to the ARM controller 701 via SPI communication, and the ARM controller 701 has a built-in high-speed AD acquisition module.

[0036] The voltage acquisition unit 601 of the data acquisition and monitoring module 6 uses an LV28-P voltage sensor to acquire voltage data of the test circuit in real time with an acquisition accuracy of up to 0.01V; the current acquisition unit 602 uses a TA100-300A current transformer with an acquisition range of 0-300A and an acquisition accuracy of up to 0.1A; the ADS1256 oscilloscope module of the waveform acquisition unit 603 can capture the current and voltage waveforms during the test in real time with a sampling rate of up to 100kHz. The waveform data is uploaded to the main control module 7 through the RS485 communication circuit of the data transmission unit 604. The main control module 7 stores the acquired data in the built-in memory and displays the voltage and current curves, waveforms, and test parameters in real time on the 19-inch industrial display screen 702. If abnormal data is detected, the audible and visual alarm circuit 703 immediately issues an audible and visual alarm signal to remind the operator to handle the situation in time.

[0037] A relay testing device further includes a cabinet 8, an operating table 9, and a test sample explosion-proof cabinet 10; the cabinet 8 is divided into a power control cabinet 11 and a load cabinet 12; the operating table 9 integrates an industrial display screen 702, control buttons, and an oscilloscope 14; the test sample explosion-proof cabinet 10 is equipped with a tempered glass safety door 13, which is opened and closed by a hydraulic cylinder, and the test sample explosion-proof cabinet 10 has an explosion-proof design for placing relay samples to be tested.

[0038] In operation, an external three-phase five-wire 400V AC power supply is connected to the power processing module. The voltage conversion unit's step-down transformer reduces the 380V AC to 100V, which is then converted to DC by the full-bridge rectifier circuit. The DC is then filtered by the LC filter circuit and switching switch of the filter unit, outputting a stable DC voltage to supply both the energy-saving load drive module and the hybrid load switching module. The energy-saving load drive module's drive voltage regulation unit outputs an adjustable pulse width drive signal via an SG3525 PWM controller. After amplification by a MOSFET power transistor, the constant current source circuit of the current control unit stabilizes the drive current within the set range. Simultaneously, the segmented current drive circuit of the energy-saving control unit cuts off the voltage effect loop during relay engagement, retaining only the current effect loop. A duty cycle adjustment circuit enables the interleaved drive of 2-3 coils, reducing energy consumption. The hybrid load switching module, according to the instructions of the main control module, switches to resistive, inductive, or capacitive loads via a 322-E4 relay matrix. The system provides the corresponding load for the relay under test. The CD4051 multiplexer of the multi-station test control module switches to the designated test station according to the settings, and connects the drive signal of the energy-saving load drive module and the load signal of the mixed load switching module to the relay under test. The LV28-P voltage sensor and TA100-300A current transformer of the data acquisition and monitoring module collect the voltage and current data of the relay under test, respectively. The ADS1256 oscilloscope module captures the waveform data and transmits it to the main control module at a rate of 9600bps via the RS485 communication circuit. After receiving the data, the STM32F407 ARM controller of the main control module displays the test parameters, data and waveforms in real time on the 19-inch industrial display screen. At the same time, it monitors the status of each module. If the overload protection module detects an overcurrent, overvoltage or short circuit fault, the fast-response relay immediately cuts off the test circuit. The ARM controller triggers the audible and visual alarm circuit to issue a warning. The entire system completes the automated testing of the relay through the coordinated work of each module.

[0039] Example 2 As another embodiment of the present invention, a relay testing system includes: a power input and transformer circuit module, wherein the power input and transformer circuit module is connected to 380V three-phase five-wire AC power, a 500A circuit breaker is connected in series as the main power protection switch, and a 6kW transformer is configured to convert 380V high-voltage AC power into multiple low-voltage AC power such as 24V and 20V. The power processing and distribution circuit module is connected to the output terminal of the power input and transformer circuit module. The power processing and distribution circuit module has a built-in rectifier bridge Bridge1 and filter capacitor C1. The rectifier bridge Bridge1 converts low-voltage AC power into DC power, and the filter capacitor C1 filters and regulates the DC power. The power processing and distribution circuit module outputs multiple sets of 24V DC power with different power, and series current limiting / voltage dividing resistors R1-R20 and switches K10 / K11 realize power adaptation and path switching. The load control and monitoring circuit module is connected to the output of the power processing and distribution circuit module. The load control and monitoring circuit module includes a 300A / 5A current transformer, a relay KA3 / KA5, a freewheeling diode DC24, and multiple forward and reverse control modules. The 300A / 5A current transformer is used to collect the loop current. The relay KA3 / KA5 is used to control the on / off state of the test loop. The freewheeling diode DC24 is used to prevent reverse voltage from damaging the components when the inductive load is de-energized. The forward and reverse control modules are connected to the relay under test through terminals A1 / B1 and A2 / B2. The main control circuit module is connected to the load control and monitoring circuit module. The main control circuit module adopts an Autotronic self-developed ARM controller, is connected to a 19-inch industrial display screen, and has built-in measurement and control software, which can realize test parameter setting, test process monitoring and alarm prompts.

[0040] In use, the relay achieves accurate testing through a closed-loop process of power conversion, load adaptation, real-time monitoring, and intelligent control. The specific process is as follows: The power input and transformer circuit module receives 380V three-phase five-wire AC power. After protection by a 500A circuit breaker, a 6kW transformer converts the high-voltage AC power into multiple low-voltage AC power levels (24V, 20V, etc.) to provide adaptation voltage for subsequent modules. The power processing and distribution circuit module converts the low-voltage AC power into DC power through a rectifier bridge, and then filters it through a filter capacitor to obtain a stable DC voltage. Combined with the adjustment of current-limiting / voltage-dividing resistors and switches, it outputs power at different power levels to the load control and monitoring circuit module. Then, the load control and monitoring circuit module... The system connects to the relay under test via the forward and reverse control module. The main control circuit module sends commands to close relays KA3 / KA5, connecting the test circuit. A 300A / 5A current transformer collects the circuit current data in real time, and an oscilloscope simultaneously captures the current and voltage waveforms. All data is transmitted to the main control module. Finally, the main control circuit module, based on an ARM controller and self-developed software, monitors the test parameters in real time. When overload or abnormal waveforms occur, it immediately controls the relays to disconnect the circuit and triggers an alarm. After the test is completed, a test report containing waveform data and fault records is automatically generated. The entire system, through modular design, achieves efficient power conversion and distribution, flexible load adaptation, precise monitoring and automated control of the testing process, solving problems such as high energy consumption, poor load adaptability, and low testing accuracy of traditional equipment.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A relay testing system, characterized in that: The system includes a power processing module (1), an energy-saving load drive module (2), an overload protection module (3), a mixed load switching module (4), a multi-station test control module (5), a data acquisition and monitoring module (6), and a main control module (7). An external three-phase five-wire 380V AC power supply is connected to the power processing module (1). The power processing module (1) is electrically connected to the energy-saving load drive module (2) and the mixed load switching module (4). The energy-saving load drive module (2) and the mixed load switching module (4) are both electrically connected to the multi-station test control module (5). The multi-station test control module (5) is electrically connected to the data acquisition and monitoring module (6). The data acquisition and monitoring module (6), the energy-saving load drive module (2), the mixed load switching module (4), and the overload protection module (3) are all electrically connected to the main control module (7). The overload protection module (3) is connected in series between the power processing module (1) and each load and drive module. The power processing module (1) includes a voltage conversion unit (101), a rectification unit (102) and a filtering unit (103). The voltage conversion unit (101) uses IGBTs to switch to a low-voltage power module. The rectification unit (102) uses a full-bridge rectifier circuit. The filtering unit (103) uses an LC filter circuit and is equipped with a switching switch.

2. The relay testing system according to claim 1, characterized in that: The energy-saving load drive module (2) includes a drive voltage regulation unit (201), a current control unit (202) and an energy-saving control unit (203). The drive voltage regulation unit (201) adopts a PWM pulse width modulation circuit, the current control unit (202) adopts a constant current source circuit, and the energy-saving control unit (203) adopts a segmented current drive circuit and is equipped with a duty cycle adjustment circuit.

3. The relay testing system according to claim 2, characterized in that: The rectifier unit (102) of the power processing module (1) consists of a rectifier bridge composed of four high-power diodes of 800V / 300A, and a freewheeling diode is connected in parallel at the output of the rectifier bridge; the filter unit (103) consists of capacitors C1-C4, an inductor INDUCTOR and a switching switch K4.0 / K4.5, the capacitors are of 1000pF / 500V, the inductors are of 1mH / 300A, the switching switch is a high-power IGBT, and a voltage detection sensor is set at the output of the filter unit (103).

4. A relay testing system according to claim 3, characterized in that: The drive voltage regulation unit (201) of the energy-saving load drive module (2) adopts the SG3525 PWM controller and is paired with MOSFET power transistors to form a PWM pulse width modulation circuit to realize continuous regulation of 0-60VDC drive voltage; the current control unit (202) is composed of an operational amplifier, a sampling resistor and an adjustment transistor to realize precise control of 0-5A drive current; the segmented current drive circuit of the energy-saving control unit (203) controls the switching switch to open and close through the main control module (7) so that only the current effect is retained during the relay energizing stage.

5. A relay testing system according to claim 4, characterized in that: The overload protection module (3) includes an overcurrent protection unit (301), an overvoltage protection unit (302), and a short circuit protection unit (303). The overcurrent protection unit (301) uses a 200A / 500V fuse and a 300A / 5A current transformer. The overvoltage protection unit (302) uses a varistor and a discharge tube. The short circuit protection unit (303) uses a fast-response circuit breaker and a short circuit detection circuit.

6. A relay testing system according to claim 5, characterized in that: The hybrid load switching module (4) includes a load unit (401) and a switching control unit (402). The load unit (401) includes a resistive load group, an inductive load group and a capacitive load group. The impedance adjustment range of the resistive load group is 0.1-8Ω, the inductive reactance adjustment range of the inductive load group is 0.1-15mH, and the capacitive reactance adjustment range of the capacitive load group is 100-20000μF. The switching control unit (402) adopts a 322-E4 model relay matrix and controls the load type switching through the main control module (7).

7. A relay testing system according to claim 6, characterized in that: The multi-station test control module (5) includes three independent test station circuits (501) and a station switching control circuit (502). Each test station is equipped with an independent drive interface, load interface and detection interface. The station switching control circuit (502) uses a CD4051 multiplexer and the switching response time does not exceed 0.1ms.

8. A relay testing system according to claim 7, characterized in that: The data acquisition and monitoring module (6) includes a voltage acquisition unit (601), a current acquisition unit (602), a waveform acquisition unit (603), and a data transmission unit (604). The voltage acquisition unit (601) uses an LV28-P voltage sensor, the current acquisition unit (602) uses a TA100-300A current transformer, the waveform acquisition unit (603) uses an ADS1256 oscilloscope module, and the data transmission unit (604) uses an RS485 communication circuit.

9. A relay testing system according to claim 1, characterized in that: The main control module (7) includes an STM32F407 ARM controller (701), a 19-inch industrial display screen (702), and an audible and visual alarm circuit (703). The display screen (702) is connected to the ARM controller (701) via SPI communication. The ARM controller (701) has a built-in high-speed AD acquisition module.

10. A relay testing device, characterized in that, The relay testing system according to any one of claims 1-9 further includes a cabinet (8), an operating table (9), and a test sample explosion-proof cabinet (10); the cabinet (8) is divided into a power control cabinet (11) and a load cabinet (12); the operating table (9) integrates an industrial display screen (702), control buttons, and an oscilloscope (14); the test sample explosion-proof cabinet (10) is equipped with a tempered glass safety door (13), the safety door (13) is opened and closed by a hydraulic cylinder, and the test sample explosion-proof cabinet (10) has an explosion-proof design for placing relay samples to be tested.

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