Automatic line detection system and use method thereof

Abstract

The invention provides an automatic line detection system and a use method thereof. The automatic line detection system comprises a controller, a resistance tester, an inductance tester, an insulation impedance tester, a line switching module and a communication module, the resistance tester, the inductance tester and the insulation impedance tester are all connected with a circuit of the magnetic suspension centrifugal compressor to be tested through the circuit switching module, and the controller is in communication connection with the resistance tester, the inductance tester, the insulation impedance tester and the circuit switching module through the communication module; and the controller is used for controlling the line switching module to realize ordered switching of multiple test loops. According to the technical scheme, the automatic testing equipment is used for replacing a production line manual detection procedure, full-automatic collection, analysis and judgment of various key parameters of a compressor line are achieved through automatic butt joint of the equipment and the magnetic suspension centrifugal compressor, and the problems that manual detection is low in efficiency and high in error are fundamentally solved.

Description

Technical Field

[0001] This invention relates to the field of magnetic levitation centrifugal refrigeration compressor technology, and in particular to an automatic circuit detection system and its usage method. Background Technology

[0002] As the mass production scale of magnetic levitation centrifugal compressors expands, market and internal enterprise standards for quality control are rising, while the need to increase production is becoming increasingly urgent. As high-value industrial equipment, full inspection of magnetic levitation centrifugal compressors before shipment is a crucial step in ensuring product quality; however, existing inspection methods have significant bottlenecks. Currently, the testing process relies entirely on manual operation. Each machine requires a significant manpower investment to complete repetitive tasks such as cable connection, parameter reading, and data recording. Furthermore, the testing process demands extremely high precision, and manual operation is prone to errors and omissions due to fatigue and differences in experience, leading to defective products entering the market. To compensate for the shortcomings of manual testing, companies often need to assign multiple people to perform repeated tests, further increasing labor costs and testing cycles, severely hindering production line efficiency and capacity improvement.

[0003] Therefore, the industry urgently needs a continuous and stable automated testing solution to replace low-value repetitive manual processes and transfer human resources to high-value technology research and development and process optimization. This is not only the core need for enterprises to improve production capacity and product value, but also an important direction for promoting technological upgrading in the industry. Summary of the Invention

[0004] In view of this, the purpose of this invention is to provide an automatic circuit detection system and its usage method, which replaces the manual inspection process on the production line with automated testing equipment. By automatically docking the equipment with the magnetic levitation centrifugal compressor, the system can realize the fully automatic collection, analysis and judgment of various key parameters of the compressor circuit, fundamentally solving the problems of low efficiency and high error of manual inspection.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an automatic circuit detection system, comprising a controller (100), a resistance tester (110), an inductance tester (120), an insulation impedance tester (130), a circuit switching module (101), and a communication module; the resistance tester (110), the inductance tester (120), and the insulation impedance tester (130) are all connected to the circuit of the magnetic levitation centrifugal compressor (200) under test through the circuit switching module (101); the controller (100) establishes communication connections with the resistance tester (110), the inductance tester (120), the insulation impedance tester (130), and the circuit switching module (101) respectively through the communication module; the controller (100) is used to control the circuit switching module (101) to realize the orderly switching of multiple test circuits.

[0006] In a preferred embodiment, it also includes a control box test plug (150), a control box cable (160), an intermediate cable test plug (170), an intermediate cable (180), and a compressor test plug (190).

[0007] In a preferred embodiment, the line switching module (101) includes a resistance tester relay (111), an inductance tester relay (121), an insulation impedance tester relay (131), a control box plug test relay (151), a control box plug wiring sequence relay (171), an intermediate cable test relay (172), an intermediate cable connection relay (173), an intermediate cable wiring sequence relay (191), a compressor test relay (192), and a compressor connection relay (193); the controller (100) directly or indirectly controls the closing and opening of each relay to realize the connection and switching of the corresponding test circuit.

[0008] In a preferred embodiment, the resistance tester (110) is connected to the resistance tester relay (111); the inductance tester (120) is connected to the inductance tester relay (121); the insulation resistance tester (130) is connected to the insulation resistance tester relay (131); the control box test plug (150) is connected to the control box plug test relay (151); the intermediate cable test plug (170) is connected to the control box plug sequence relay (171), the intermediate cable test relay (172), and the intermediate cable connection relay (173); and the compressor test plug (190) is connected to the intermediate cable sequence relay (191), the compressor test relay (192), and the compressor connection relay (193).

[0009] In a preferred embodiment, the two ends of the control box cable (160) are respectively connected to the control box test plug (150) and the other end of the intermediate cable test plug (170); the two ends of the intermediate cable (180) are respectively connected to the other end of the intermediate cable test plug (170) and one end of the compressor test plug (190), the other end of the compressor test plug (190) is connected to the magnetic levitation centrifugal compressor (200), and one wire of the insulation resistance tester relay (131) is connected to the outer casing of the magnetic levitation centrifugal compressor (200).

[0010] In a preferred embodiment, after the test is started, the controller (100) controls the line switching module (101), and the line switching module (101) controls the resistance tester relay (111), the inductance tester relay (121), the insulation impedance tester relay (131), the control box plug test relay (151), the control box plug line sequence relay (171), the intermediate cable test relay (172), the intermediate cable connection relay (173), the intermediate cable line sequence relay (191), the compressor test relay (192), and the compressor connection relay (193) to close and open respectively. The controller (100) controls the resistance tester (110), the inductance tester (120), and the insulation impedance tester (130) to start the test of the magnetic levitation centrifugal compressor (200) respectively through the communication line (140).

[0011] In a preferred embodiment, when testing the resistance value of the radial power line of the magnetic bearing of the magnetic levitation centrifugal compressor (200), the radial power line path of the magnetic bearing in the resistance tester relay (111) and the compressor test relay (192) is closed. At this time, the positive and negative interfaces of the resistance tester (110) are connected to one of the radial power lines of the magnetic bearing of the magnetic levitation centrifugal compressor (200) through the test line. The resistance tester (110) switches the test mode and uses Ohm's law to calculate the total resistance value of the connecting cable, relay, test plug and radial power line of the magnetic bearing, and then obtains the resistance value of the radial power line of the magnetic bearing under test.

[0012] In a preferred embodiment, when testing the inductance value of the radial power line of the magnetic bearing of the magnetic levitation centrifugal compressor (200), the resistance tester relay (111) is disconnected, and then the radial power line path of the magnetic bearing in the inductance tester (120) and the compressor test relay (192) is closed. At this time, the two positive and two negative interfaces of the inductance tester (120) are connected to one of the radial power lines of the magnetic bearing through the test line. The inductance tester (120) switches to the test mode and calculates the inductance value of the radial power line of the magnetic bearing using the impedance balance principle of the four-wire bridge.

[0013] In a preferred embodiment, when testing the insulation impedance, the insulation impedance of each group of lines to the shell is tested separately. When testing the insulation value of the radial bearing power line to the shell, the insulation impedance tester relay (131) is closed. The insulation impedance test is only performed once after all the lines are connected. That is, the magnetic bearing radial power line path in the control box plug test relay (151), the magnetic bearing radial power line path in the intermediate cable connection relay (173), and the magnetic bearing radial power line path in the compressor connection relay (193) are closed. At this time, the positive terminal of the insulation impedance tester (130) has been connected to one of the magnetic bearing radial power lines through the test line, and the negative terminal of the insulation impedance tester (130) has been connected to the shell of the magnetic levitation centrifugal compressor (200) separately. The insulation impedance tester (130) is switched to the test mode, and a high voltage is applied to the positive terminal to test the negative terminal current. The insulation value of the radial bearing power line to the shell is calculated using Ohm's law.

[0014] This invention also provides a method for using an automatic line detection system. Based on the aforementioned automatic line detection system, when intermediate cable sequence verification is required before testing, the controller (100) controls the line switching module (101), the closed resistance tester relay (111), the control box plug test relay (151), and the control box plug sequence relay (171). The controller (100) controls the resistance tester (110) to read the resistance value to determine the line continuity. If the resistance value approaches zero, it indicates that the line sequence of this group of lines is correct, and the line sequence verification of a group of lines is completed. Repeat the above process to complete the line sequence verification of all lines; thus, the line sequence continuity verification of a group of lines can be completed. When testing the magnetic levitation centrifugal compressor (200) to determine whether the bearing coil and overall resistance value meet the design standards, the controller (100) controls the circuit switching module (101), the closed resistance tester relay (111), the control box plug test relay (151), the intermediate cable connection relay (173), and the compressor connection relay (193); the controller (100) controls the resistance tester (110) to read the resistance value data, compares the data with the preset standard value, and thus completes the single resistance value acquisition and preliminary judgment.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. Significantly improve production line efficiency: By replacing manual operation with automated testing, cumbersome steps such as manual wiring, reading, and recording are completely eliminated, significantly shortening the testing time of a single device, accelerating the testing process, effectively reducing production line waiting time, and driving production line capacity improvement.

[0016] 2. Ensure the stability of testing quality: Automated operation avoids false detection and missed detection caused by factors such as human fatigue and experience differences. The entire testing process is precisely controlled by the program, which greatly improves the repeatability and accuracy of data. At the same time, test data is automatically stored, which facilitates quality traceability and problem review and reduces the risk of unqualified products leaving the market.

[0017] 3. Reduce overall costs: On the one hand, it reduces the manpower required for repeated testing, thus lowering labor costs; on the other hand, it reduces maintenance and debugging time and material waste by quickly locating fault points, while shortening the employee training cycle and eliminating the need to train a large number of high-precision testing personnel, thereby further controlling production costs.

[0018] 4. Efficient and convenient troubleshooting: The innovative segmented testing and line sequence verification design not only eliminates connection errors at the source, but also quickly locates the fault by comparing segmented data, providing clear guidance for maintenance personnel, greatly shortening the fault handling time and improving the rework efficiency of the production line. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the main module composition of a preferred embodiment of the present invention; Figure 2 This is a simplified circuit design diagram of a preferred embodiment of the present invention; Label Explanation: 100. Controller; 101. Line switching module; 110. Resistance tester; 111. Resistance tester relay; 120. Inductance tester; 121. Inductance tester relay; 130. Insulation resistance tester; 131. Insulation resistance tester relay; 140. Communication line; 150. Control box test plug; 151. Control box plug test relay; 160. Control box cables; 170. Intermediate cable test plug; 171. Control box plug wiring sequence relay; 172. Intermediate cable test relay; 173. Intermediate cable connection relay; 180. Intermediate cable; 190. Compressor test plug; 191. Intermediate cable sequence relay; 192. Compressor test relay; 193. Compressor on relay; 200. Magnetic levitation centrifugal compressor. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0022] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this application; as used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise; furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0023] An automatic line detection system, reference Figure 1-2 This system adopts an integrated design approach, combining three core testing instruments—resistance tester 110, inductance tester 120, and insulation impedance tester 130—with controller 100, communication module, and line switching module 101 into a single integrated device (this solution focuses on electrical system design and does not include mechanical structures such as automatic connection mechanisms or equipment frames). Its core working mechanism involves the precise control of the line switching module to achieve orderly switching of multiple test circuits, enabling segmented testing of different parameters.

[0024] The specific workflow is as follows: The controller 100, as the core control unit, connects the target test lines one by one through the direct or indirect control line switching module 101, realizing the connection between the ports of each testing instrument and the corresponding lines of the tested magnetic levitation centrifugal compressor 200. Then, the controller 100 sends a start command to the testing instrument. After completing the parameter acquisition, the testing instrument feeds back the data to the controller 100 through the communication module, and the controller 100 completes the data storage and preliminary analysis.

[0025] This innovative solution proposes a "segmented testing" strategy, significantly improving detection accuracy and fault location efficiency. First, the wiring sequence of critical connections, such as intermediate cables, is verified to ensure correct connections before proceeding to subsequent parameter testing. Similarly, segmented testing is used for core parameters like resistance and inductance, collecting parameter values ​​for each cable segment after connection. This strategy not only effectively eliminates detection biases caused by incorrect connections but also allows for direct location of faulty cable segments through segmented data comparison, providing clear fault guidance for maintenance personnel.

[0026] like Figure 1The diagram shows the composition of the equipment modules. The controller 100 serves as the control core and establishes communication connections with the resistance tester 110, the inductance tester 120, the insulation impedance tester 130, and the line switching module 101. The line switching module 101 enables the connection with the magnetic levitation centrifugal compressor 200 to complete the testing process.

[0027] like Figure 2 The diagram shown is a circuit design schematic of this device. The 52 wires involved in the actual test have been simplified to 2 wires shown in the diagram (here, the part of the double-ended component near the control box test plug 150 is defined as the near end, and the part near the magnetic levitation centrifugal compressor 200 is defined as the far end). Before starting the test, it is necessary to ensure that all components are properly connected, that is, the control box test plug 150 is properly connected to the near end of the control box cable 160, the far end of the control box cable 160 is properly connected to the near end of the intermediate cable test plug 170, the far end of the intermediate cable test plug 170 is properly connected to the near end of the intermediate cable 180, the far end of the intermediate cable 180 is properly connected to the near end of the compressor test plug 190, the far end of the compressor test plug 190 is properly connected to the magnetic levitation centrifugal compressor 200, and one wire of the insulation resistance tester relay 131 is properly connected to the outer casing of the magnetic levitation centrifugal compressor 200.

[0028] After the test is started, the controller 100 controls the circuit switching module 101, which in turn controls the resistance tester relay 111, inductance tester relay 121, insulation resistance tester relay 131, control box plug tester relay 151, control box plug wiring sequence relay 171, intermediate cable tester relay 172, intermediate cable connection relay 173, intermediate cable wiring sequence relay 191, compressor tester relay 192, and compressor connection relay 193 to close and open respectively. The controller 100 then controls the resistance tester 110, inductance tester 120, and insulation resistance tester 130 to start testing the magnetic levitation centrifugal compressor 200 via the communication line 140.

[0029] When specifically testing the resistance value of the radial power line of the magnetic bearing in the magnetic levitation centrifugal compressor 200, the radial power line path of the magnetic bearing in the resistance tester relay 111 and the compressor test relay 192 is closed. At this time, the positive and negative interfaces of the resistance tester 110 are connected to one set of radial power lines of the magnetic bearing in the magnetic levitation centrifugal compressor 200 through the test line. The resistance tester 110 switches the test mode, and the total resistance value of the connecting cable, relay, test plug and radial power line of the magnetic bearing can be calculated using Ohm's law. Since the resistance of the connecting cable, relay and test plug is normally close to zero and much smaller than the resistance value of the bearing power line, the measured total resistance value can be regarded as the resistance value of the radial power line of the magnetic bearing being tested.

[0030] When testing the inductance value of the radial power line of the magnetic bearing in the magnetic levitation centrifugal compressor 200, the resistance tester relay 111 is disconnected, and then the radial power line path of the magnetic bearing in the inductance tester 120 and the compressor test relay 192 is closed. At this time, the two positive and two negative interfaces of the inductance tester 120 are connected to one of the radial power lines of the magnetic bearing through the test line. The inductance tester 120 switches to the test mode and uses the impedance balance principle of the four-wire bridge to calculate the inductance value of the radial power line of the magnetic bearing.

[0031] When testing the resistance values ​​of the axial power line, radial power line, axial sensor line, radial sensor line, motor line, and temperature line, disconnect the radial power line path of the magnetic bearing in the compressor test relay 192, and then close the other parts respectively. Repeat the above actions to test the resistance and inductance values ​​of each group respectively.

[0032] Following the above method, disconnect the compressor test relay 192, close the intermediate cable test relay 172 and the compressor on relay 193. Repeat the above steps to test the resistance and inductance values ​​of each group when the intermediate cable 180 is connected. Then disconnect the intermediate cable test relay 172, close the control box plug test relay 152 and the intermediate cable on relay 173. Repeat the above steps to test the resistance and inductance values ​​of each group when the control box cable 160 and the intermediate cable 180 are connected.

[0033] When testing insulation resistance, the insulation resistance of each group of lines to the casing is tested separately. When testing the insulation value of the radial bearing power line to the casing, the insulation resistance tester relay 131 is closed. To prevent damage to the lines and components from repeated high voltage applications, the insulation resistance test is only performed once after all lines are connected. Specifically, the magnetic bearing radial power line path in the control box plug test relay 151, the magnetic bearing radial power line path in the intermediate cable connection relay 173, and the magnetic bearing radial power line path in the compressor connection relay 193 are closed. At this time, the positive terminal of the insulation resistance tester 130 is connected to one of the magnetic bearing radial power lines through the test line, and the negative terminal of the insulation resistance tester 130 is connected separately to the casing of the magnetic levitation centrifugal compressor 200. The tester switches to the test mode, applies high voltage to the positive terminal to test the current at the negative terminal, and the insulation value of the radial bearing power line to the casing can be calculated using Ohm's law.

[0034] based on Figure 2 The circuit structure shown indicates that the typical application scenarios of this system in actual production are divided into two categories: line sequence verification and parameter testing.

[0035] Before testing, when verifying the wiring sequence of intermediate cables, controller 100 controls line switching module 101, closed-circuit resistance tester relay 111, control box plug test relay 151, and control box plug wiring sequence relay 171. Controller 100 controls resistance tester 110 to read resistance values ​​and determine the continuity of the lines. If the resistance value approaches zero, it indicates that the wiring sequence of this group is correct and the connection is reliable, completing the wiring sequence verification for one group. Repeat the above process to complete the wiring sequence verification for all lines. This completes the wiring continuity verification for one group of lines.

[0036] When testing the overall resistance value of the magnetic levitation centrifugal compressor, including the bearing coil, to determine whether it meets the design standards, the controller 100 controls the circuit switching module 101, the closed resistance tester relay 111, the control box plug test relay 151, the intermediate cable connection relay 173, the compressor connection relay 193, and the controller 100 controls the resistance tester 110 to read the resistance value data. By comparing this data with the preset standard value, a single resistance value acquisition and preliminary judgment can be completed.

Claims

1. An automatic line detection system, characterized in that, The system includes a controller (100), a resistance tester (110), an inductance tester (120), an insulation impedance tester (130), a line switching module (101), and a communication module. The resistance tester (110), the inductance tester (120), and the insulation impedance tester (130) are all connected to the circuit of the magnetic levitation centrifugal compressor (200) under test through the line switching module (101). The controller (100) establishes communication connections with the resistance tester (110), the inductance tester (120), the insulation impedance tester (130), and the line switching module (101) respectively through the communication module. The controller (100) is used to control the line switching module (101) to realize the orderly switching of multiple test circuits.

2. The automatic line detection system according to claim 1, characterized in that, It also includes a control box test plug (150), a control box cable (160), an intermediate cable test plug (170), an intermediate cable (180), and a compressor test plug (190).

3. The automatic line detection system according to claim 2, characterized in that, The line switching module (101) includes a resistance tester relay (111), an inductance tester relay (121), an insulation impedance tester relay (131), a control box plug test relay (151), a control box plug wiring sequence relay (171), an intermediate cable test relay (172), an intermediate cable connection relay (173), an intermediate cable wiring sequence relay (191), a compressor test relay (192), and a compressor connection relay (193). The controller (100) directly or indirectly controls the closing and opening of each relay to realize the connection and switching of the corresponding test circuit.

4. The automatic line detection system according to claim 3, characterized in that, The resistance tester (110) is connected to the resistance tester relay (111); the inductance tester (120) is connected to the inductance tester relay (121); the insulation impedance tester (130) is connected to the insulation impedance tester relay (131); the control box test plug (150) is connected to the control box plug test relay (151); the intermediate cable test plug (170) is connected to the control box plug sequence relay (171), the intermediate cable test relay (172), and the intermediate cable connection relay (173); the compressor test plug (190) is connected to the intermediate cable sequence relay (191), the compressor test relay (192), and the compressor connection relay (193).

5. The automatic line detection system according to claim 4, characterized in that, The two ends of the control box cable (160) are respectively connected to the control box test plug (150) and the other end of the intermediate cable test plug (170); the two ends of the intermediate cable (180) are respectively connected to the other end of the intermediate cable test plug (170) and one end of the compressor test plug (190), the other end of the compressor test plug (190) is connected to the magnetic levitation centrifugal compressor (200), and one wire of the insulation resistance tester relay (131) is connected to the outer shell of the magnetic levitation centrifugal compressor (200).

6. The automatic line detection system according to claim 5, characterized in that, After the test is started, the controller (100) controls the line switching module (101). The line switching module (101) controls the resistance tester relay (111), the inductance tester relay (121), the insulation impedance tester relay (131), the control box plug test relay (151), the control box plug line sequence relay (171), the intermediate cable test relay (172), the intermediate cable connection relay (173), the intermediate cable line sequence relay (191), the compressor test relay (192), and the compressor connection relay (193) to close and open respectively. The controller (100) controls the resistance tester (110), the inductance tester (120), and the insulation impedance tester (130) to start the test of the magnetic levitation centrifugal compressor (200) respectively through the communication line (140).

7. The automatic line detection system according to claim 6, characterized in that, When testing the resistance value of the radial power line of the magnetic bearing of the magnetic levitation centrifugal compressor (200), the magnetic bearing radial power line path in the resistance tester relay (111) and the compressor test relay (192) is closed. At this time, the positive and negative interfaces of the resistance tester (110) are connected to one of the magnetic bearing radial power lines of the magnetic levitation centrifugal compressor (200) through the test line. The resistance tester (110) switches the test mode and uses Ohm's law to calculate the total resistance value of the connecting cable, relay, test plug and magnetic bearing radial power line, and then obtains the resistance value of the tested magnetic bearing radial power line.

8. The automatic line detection system according to claim 6, characterized in that, When testing the inductance value of the radial power line of the magnetic bearing of the magnetic levitation centrifugal compressor (200), the resistance tester relay (111) is disconnected, and then the radial power line path of the magnetic bearing in the inductance tester (120) and the compressor test relay (192) is closed. At this time, the two positive and two negative interfaces of the inductance tester (120) are connected to one of the radial power lines of the magnetic bearing through the test line. The inductance tester (120) switches to the test mode and uses the impedance balance principle of the four-wire bridge to calculate the inductance value of the radial power line of the magnetic bearing.

9. The automatic line detection system according to claim 6, characterized in that, When testing the insulation impedance, the insulation impedance of each group of lines to the shell is tested separately. When testing the insulation value of the radial bearing power line to the shell, the insulation impedance tester relay (131) is closed. The insulation impedance test is only performed once after all the lines are connected. The magnetic bearing radial power line path in the control box plug test relay (151), the magnetic bearing radial power line path in the intermediate cable connection relay (173), and the magnetic bearing radial power line path in the compressor connection relay (193) are closed. At this time, the positive terminal of the insulation impedance tester (130) is connected to one of the magnetic bearing radial power lines through the test line, and the negative terminal of the insulation impedance tester (130) is connected to the shell of the magnetic levitation centrifugal compressor (200) separately. The insulation impedance tester (130) is switched to the test mode, and a high voltage is applied to the positive terminal to test the negative terminal current. The insulation value of the radial bearing power line to the shell is calculated using Ohm's law.

10. A method of using an automatic line detection system, characterized in that, An automatic line detection system based on any one of claims 1-9 above; when intermediate cable sequence verification is required before testing, the controller (100) controls the line switching module (101), the closed resistance tester relay (111), the control box plug test relay (151), and the control box plug sequence relay (171), and the controller (100) controls the resistance tester (110) to read the resistance value to determine the line conduction status. If the resistance value approaches zero, it indicates that the line sequence of the group is correct, and a line sequence verification is completed. Repeat the above process to complete the wiring sequence verification for all lines; This completes the continuity verification of a set of lines; When testing the magnetic levitation centrifugal compressor (200) to determine whether the bearing coil and overall resistance value meet the design standards, the controller (100) controls the circuit switching module (101), the closed resistance tester relay (111), the control box plug test relay (151), the intermediate cable connection relay (173), and the compressor connection relay (193); the controller (100) controls the resistance tester (110) to read the resistance value data, compares the data with the preset standard value, and thus completes the single resistance value acquisition and preliminary judgment.

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