Relay multi-parameter automatic detection system

Abstract

The invention relates to the technical field of relay multi-parameter automatic detection systems, particularly discloses a relay multi-parameter automatic detection system, and aims to solve the problems that traditional detection equipment is insufficient in relay transient signal capturing capability, low in parameter measurement reliability and poor in universality. The system comprises a relay clamping device, a multi-channel signal excitation unit, a high-precision sensing acquisition unit, a time sequence synchronous control unit, a data processing analysis unit and a man-machine interaction terminal, a pull-in and release process is simulated through a programmable excitation signal, multiple paths of electrical response signals of a contact and a coil are synchronously acquired at a high speed, and key parameters such as contact resistance, pull-in / release voltage and time delay are calculated based on sequential logic verification; the clamping device adopts a replaceable interface module to adapt to various relay models, and the system supports remote communication and automatic generation of a test report. According to the invention, high-precision, high-efficiency and high-reliability relay multi-parameter automatic detection can be realized, and the harsh requirements of intelligent manufacturing on online detection of electronic components are met.

Description

Technical Field

[0001] This application belongs to the field of automatic testing and inspection technology of electrical components, specifically relating to an automated multi-parameter testing system for relays. Background Technology

[0002] With the rapid development of the power electronics industry, relays, as core components for circuit control and protection, directly affect the operational safety of power systems and various electronic devices due to their stability and reliability. Traditional quality testing methods have gradually evolved from manual testing of single parameters to integrated and intelligent approaches, aiming to ensure the accuracy of component operation in complex electromagnetic environments through high-precision parameter analysis. Especially in high-reliability applications such as aerospace, automatic control, and rail transportation, relays must withstand extremely high operating frequencies and environmental stresses. This makes comprehensive and real-time evaluation of multiple relay performance indicators a crucial link in ensuring the safe operation of the industrial chain.

[0003] Among these technologies, automated multi-parameter testing of relays serves as a crucial means to improve product qualification rates and R&D verification efficiency. It primarily achieves simultaneous acquisition of key indicators such as contact resistance, coil pull-in voltage, release voltage, and operating time by integrating high-precision sampling modules and automated control logic. The core of this technology lies in constructing a test environment capable of simulating actual operating conditions. By digitally processing the electrical signals collected by sensors, it enables a quantitative evaluation of the relay's overall performance without manual intervention.

[0004] However, existing detection systems often face a bottleneck in balancing sampling accuracy and detection rate, making it easy to overlook minute transient electrical fluctuations when processing large-scale samples. Simultaneously, traditional equipment lacks the ability to analyze the temporal correlations between different physical quantities, making it difficult to capture the dynamic characteristic evolution of relays during the engagement and disengagement processes, resulting in detection results that do not fully reflect the actual wear state of components. Furthermore, the automation level of existing systems is still limited to the repetitive execution of single processes, lacking deep integration and logical verification capabilities for multi-source heterogeneous detection data, making them highly susceptible to misjudgments or omissions when faced with non-standard signal feedback.

[0005] Therefore, an automated multi-parameter detection system for relays is desired. Summary of the Invention

[0006] The purpose of this invention is to provide an automated multi-parameter detection system for relays, which can effectively solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] An automated multi-parameter relay detection system includes a relay clamping device, a multi-channel signal excitation unit, a high-precision sensing and acquisition unit, a timing synchronization control unit, a data processing and analysis unit, and a human-machine interface terminal, wherein:

[0009] The relay clamping device is configured to electrically connect and physically fix the relay under test, ensuring that the contacts and coil terminals maintain stable and reliable electrical contact with the external test circuit during the test.

[0010] The multi-channel signal excitation unit is configured to apply programmable voltage or current excitation signals to the coil of the relay under test, and can dynamically adjust the excitation amplitude, rise slope and duration to simulate the pull-in and release process under different operating conditions.

[0011] The high-precision sensing and acquisition unit is configured to synchronously acquire multiple electrical response signals of the relay under test under excitation, including the voltage drop across the contacts, the current flowing through the contacts, the voltage across the coil, and the current in the coil circuit, and convert the acquired analog signals into digital signals for output.

[0012] The timing synchronization control unit is configured to coordinate the working timing of the multi-channel signal excitation unit and the high-precision sensing acquisition unit, ensuring that the application time of the excitation signal is strictly aligned with the sampling window of the sensing signal, and completing the complete waveform capture of the pull-in and release processes within a single test cycle.

[0013] The data processing and analysis unit is configured to receive digital signals output by the high-precision sensing and acquisition unit, calculate contact resistance, coil pull-in voltage, release voltage, pull-in time, release time and bounce time based on preset logic rules, and perform logical verification on the timing correlation between each parameter to identify abnormal signal patterns.

[0014] The human-computer interaction terminal is configured to receive test configuration commands input by the user, display real-time test waveforms, parameter calculation results and system diagnostic information, and support the automatic generation and export of test reports.

[0015] Preferably, the high-precision sensing and acquisition unit includes independent voltage sampling sub-channels and current sampling sub-channels. Each sub-channel is equipped with an isolation amplifier circuit and an analog-to-digital converter. Its sampling frequency is higher than the time resolution requirement of the relay action transient process to ensure complete capture of microsecond-level electrical fluctuations.

[0016] Furthermore, the multi-channel signal excitation unit has bidirectional programmable capability, enabling it to sequentially execute pull-in and release excitations in a single test process, and insert a steady-state holding phase of predetermined time between the two excitations to simulate the typical working cycle of a relay in practical applications.

[0017] Furthermore, the data processing and analysis unit has a built-in parameter validity judgment module. This module evaluates the reliability of the calculated contact resistance value based on the logical consistency between the contact closure state and the coil excitation state. When it detects that the contact is not fully closed or there is abnormal jitter, it automatically marks the measurement result as invalid data.

[0018] Preferably, the relay clamping device adopts a replaceable interface module design, which can adapt to relay models with different packaging forms and pin layouts, and ensures that the contact pressure is within a specific range through a spring loading mechanism to eliminate measurement errors caused by poor contact.

[0019] Furthermore, the timing synchronization control unit integrates a highly stable clock source with clock jitter below a preset threshold, ensuring that the relative deviation of the sampling time of each channel remains within the allowable error band in multiple consecutive batches of testing, thereby guaranteeing the comparability of test data across batches.

[0020] Furthermore, the human-computer interaction terminal supports a remote communication interface, enabling it to upload test data to a cloud server and receive batch test task instructions from the upper-level management system, thereby achieving centralized scheduling of the testing process and traceability management of quality data.

[0021] In summary, this application includes the following beneficial technical effects:

[0022] The automated multi-parameter relay testing system provided by this invention achieves synchronous, high-speed, and high-fidelity acquisition of key electrical parameters of relays through the collaborative work of a high-precision sensing and acquisition unit and a timing synchronization control unit, effectively overcoming the shortcomings of traditional testing equipment in capturing transient signals. The system's built-in data processing and analysis unit can not only accurately calculate various static and dynamic performance indicators, but also perform cross-validation based on the timing logic relationship between multiple parameters, significantly improving the reliability and anti-interference capability of the test results. The modular design of the relay clamping device and the programmable characteristics of the multi-channel signal excitation unit enable the system to flexibly adapt to the testing needs of various relay models, greatly improving testing efficiency and equipment versatility. In addition, the integration of human-machine interface terminal and remote communication functions provides a technical foundation for the automated archiving, remote monitoring, and quality closed-loop management of test data, meeting the stringent requirements of modern intelligent manufacturing for online testing of high-reliability electronic components. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall technical solution architecture;

[0024] Figure 2 This is a schematic diagram of the core principle framework of signal excitation and sensing acquisition based on time-synchronous control;

[0025] Figure 3 A logical flowchart illustrating the process of multi-parameter calculation and time-series correlation verification for the data processing and analysis unit. Detailed Implementation

[0026] Example 1

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0028] An automated multi-parameter detection system for relays includes a relay clamping device, a multi-channel signal excitation unit, a high-precision sensing and acquisition unit, a timing synchronization control unit, a data processing and analysis unit, and a human-machine interaction terminal.

[0029] The relay clamping device is used for physical positioning and electrical connection of the relay under test. It integrates multiple sets of flexible contact electrodes and an automated clamping mechanism. It is configured to clamp the pins of the relay under test onto the corresponding electrical contacts through mechanical actuators after receiving a test command. This ensures that the contacts and coil terminals maintain a stable contact resistance of less than milliohms under a current load of several amperes, thereby providing a zero-interference physical interface environment for subsequent electrical performance parameter measurements.

[0030] The multi-channel signal excitation unit is used to provide controlled energy input to the controlled terminal of the relay under test. Its core consists of a programmable linear DC power supply, a pulse width modulation waveform generation circuit, and a high linearity power amplifier. The unit is configured to generate voltage or current waveforms with adjustable amplitude, polarity, rise slope, and pulse width according to the excitation profile parameters issued by the data processing and analysis unit. Its output dynamic range covers the complete operating conditions from extremely weak signals to overload excitation, and can accurately simulate the dynamic process of relay engagement and disengagement in various harsh industrial environments.

[0031] The high-precision sensing and acquisition unit is used to monitor and record the full electrical characteristics of the relay under test in real time under excitation. It includes multiple parallel voltage sampling links and current sampling links. Each sampling link is independently equipped with a differential isolation amplifier with high common-mode rejection ratio, a low-pass anti-aliasing filter, and a high-speed, high-bit analog-to-digital conversion circuit. The unit is configured to synchronously digitize the contact voltage drop, contact current, coil voltage, and coil current at a sampling rate at the megahertz level, ensuring the faithful reproduction of the microsecond-level electrical jumps and mechanical jitter waveforms that occur at the moment of relay action.

[0032] The timing synchronization control unit is used to construct the global reference time axis of the entire detection system. It integrates a temperature-controlled crystal oscillator as a high-stability clock source and uses a precision timer / counter in a field-programmable gate array to achieve microsecond-level scheduling of the action timing of each unit. This unit is configured to ensure that the signal triggering time of the multi-channel signal excitation unit and the sampling start time of the high-precision sensing acquisition unit are strictly aligned at the sub-microsecond level on the time axis, thereby ensuring that the captured pull-in waveform and release waveform have extremely high timing consistency, providing an accurate time reference for subsequent parameter extraction.

[0033] The data processing and analysis unit is used to perform real-time calculations and in-depth analysis on massive digital waveform streams. It is equipped with a high-performance multi-core processing chip and a dedicated digital signal processing algorithm library. This unit is configured to identify key feature points of relay operation from the raw sampled data, automatically calculate core indicators such as contact resistance, pull-in voltage, release voltage, pull-in time, release time and bounce time according to preset logic definitions, and perform multi-dimensional timing logic verification. By comparing the order of current jump and voltage drop, it identifies false contact or external interference signals in the test process.

[0034] The human-machine interface terminal is used to provide user operation interface and visual presentation of test results. It is built on industrial touch screen or remote workstation and has a built-in graphical configuration interface, real-time waveform monitor and historical database query system. This unit is configured to receive user-defined test logic and pass / fail criteria, display the distribution trend of various parameters in real time, and automatically generate a quality inspection report that meets industry standards through the built-in report engine after the test is completed.

[0035] The high-precision sensing and acquisition unit includes independent voltage and current sampling sub-channels. Each sampling sub-channel is designed with independent analog and digital ground planes, and complete signal decoupling between channels is achieved through electromagnetic isolation technology. The isolation amplifier circuit uses a high-linearity opto-isolator or magnetic isolation amplifier, and its bandwidth is set sufficient to cover all high-frequency harmonic components generated by relay contact bounce. The sampling frequency of the analog-to-digital converter is set to be greater than or equal to 1 MHz, enabling the system to have a time resolution better than 1 microsecond for the transient process of relay operation. This hardware architecture ensures effective suppression of crosstalk noise from the high-current coil drive circuit when measuring extremely low contact resistance.

[0036] Furthermore, the multi-channel signal excitation unit possesses bidirectional programmable control capabilities. Its internal polarity switching matrix can automatically adjust the excitation direction at both ends of the coil according to test requirements, thereby evaluating the impact of residual magnetism on relay performance. In a single test process, the unit is configured to sequentially execute four stages: activation excitation, steady-state holding, excitation release, and static observation. A predetermined steady-state holding stage is dynamically inserted between two excitations. The duration of this stage can be precisely set at the millisecond level according to the relay's thermal balance requirements, thus realistically simulating the temperature rise and magnetic circuit evolution process of the relay in actual industrial control cycles.

[0037] Furthermore, the data processing and analysis unit incorporates a parameter validity judgment module, which is configured to execute an evaluation algorithm based on logical consistency. Specifically, this module determines whether the current measurement value is within a reasonable physical state space by real-time monitoring the correlation between the amplitude change of the coil excitation signal and the contact conduction state. When it is detected that the coil has been given sufficient pull-in voltage but the contact circuit current still fluctuates violently, or when the contact fails to open within a preset window after the coil is de-energized, the module automatically triggers abnormal diagnosis logic. If it is detected that the contact is not fully closed due to mechanical wear or foreign object interference, the module will automatically mark the contact resistance value obtained in this measurement as invalid data and send an alarm signal to the human-machine interface terminal to prevent erroneous data from entering the final quality analysis model.

[0038] Preferably, the relay clamping device adopts a replaceable interface module design. Its base is equipped with a universal signal transmission busbar and positioning slots. Different interface modules are configured to adapt to relay models with different package types, pin layouts, and pin materials. The interface module integrates a spring-loaded mechanism. This mechanism utilizes feedback control from a precision pressure sensor to ensure that the contact pressure applied by each test probe to the relay pin is within an optimized, specific range. This specific range is set to be sufficient to pierce the oxide layer on the pin surface to ensure electrical contact, while avoiding excessive mechanical stress that could cause pin deformation, thereby eliminating random measurement errors introduced by inconsistent contact conditions at the source.

[0039] Furthermore, the timing synchronization control unit integrates a highly stable clock source with a frequency stability better than one part per million, and clock jitter is strictly controlled within ten nanoseconds, far below the preset system error threshold. This high-precision clock architecture ensures that during continuous, long-term reliability testing across multiple batches, the sampling phase difference between each acquisition channel remains within the minimum allowable error range. This makes the test data acquired across batches highly comparable in the time domain, providing solid raw data support for analyzing the degradation trend of relay performance with increasing number of operations using big data methods.

[0040] Furthermore, the human-machine interface terminal supports standardized remote communication interfaces, such as industrial Ethernet interfaces, RS485 interfaces, or wireless LAN modules, enabling real-time synchronization of locally generated detailed test data to a remote cloud server. The terminal is also configured to receive batch test task instructions from the upper-level quality management system, achieving automated distribution of the testing process and flexible scheduling of production. Through cloud storage and computing resources, the system can aggregate data from multiple testing devices distributed across different production lines, using statistical process control algorithms to identify systematic deviations in the manufacturing process, thereby achieving lifecycle management and traceability control of relay product quality.

[0041] Within the internal logic of the data processing and analysis unit, the calculation process for contact resistance is broken down into multiple stages. First, the system selects a sliding window of a predetermined length to capture data within the stable range after the contacts are fully closed. Then, within the sliding window, the arithmetic mean is calculated for the voltage drop sample sequence across the contacts and the current sample sequence flowing through the contacts, respectively, to obtain the average voltage drop and average current values. Finally, the average voltage drop is divided by the average current value to obtain the final contact resistance measurement. This window-averaging algorithm effectively filters out random impulse noise interference in small-signal measurements, significantly improving the repeatability accuracy of resistance detection.

[0042] For detecting pull-in and release voltages, the multi-channel signal excitation unit is configured to perform a ramp scan mode. In the pull-in test, the coil voltage rises smoothly from zero at a preset step slope. The data processing and analysis unit monitors the current changes in the contact circuit in real time. When a sudden change in contact current from zero to a preset closing threshold is detected, the instantaneous value of the coil voltage at this moment is recorded and defined as the pull-in voltage. Similarly, in the release test, the coil voltage gradually decreases from its rated operating value. When the contact current drops to a preset opening threshold, the recorded coil voltage value is the release voltage. The entire scanning process is precisely controlled by a timing synchronization control unit to ensure the smoothness of the voltage gradient and sufficient sampling point density.

[0043] For extracting time parameters, the data processing and analysis unit is configured to utilize timestamp comparison technology. The pull-in time is defined as the time difference between the initial moment when the coil excitation signal jumps to its rated value and the moment when the contacts first achieve stable electrical contact. The release time corresponds to the time difference between the moment the coil power is cut off and the moment the contacts completely disconnect. Extracting the bounce time is more complex. The system needs to rapidly capture the voltage waveform at the instant of contact action, identify a series of pulse jitters caused by mechanical elastic collisions, and calculate the total duration from the first contact to the disappearance of the last pulse. This process requires the high-precision sensing and acquisition unit to have extremely high transient response capabilities, and the data processing and analysis unit to have accurate pulse edge detection algorithms.

[0044] To cope with electromagnetic interference in complex industrial environments, the system employs multi-level shielding measures in its physical structure. The entire system casing is made of highly conductive metal material, forming a complete Faraday cage structure. Signal transmission between functional units uses shielded twisted-pair cables, coupled with a specially designed common-mode choke filter. Particularly for the preamplifier circuit used in weak signal sampling, the system adopts a deeply symmetrical circuit layout. Through physical impedance matching and balancing design, induced interference voltages cancel each other out at the differential input terminals. These targeted engineering designs ensure that the system maintains extremely high signal-to-noise ratio and measurement accuracy even in strong electromagnetic environments (such as high-power motor operation sites).

[0045] Example 2

[0046] Based on the relay multi-parameter automated detection system described in Embodiment 1, this embodiment provides a variant of the distributed cluster architecture for mass production lines, which focuses on maximizing detection throughput and system redundancy.

[0047] In this distributed architecture, the system is divided into a central management node and multiple independent test terminals. Each test terminal includes a complete relay clamping device, a multi-channel signal excitation unit, and a high-precision sensing and acquisition unit. The central management node integrates an enhanced data processing and analysis unit and a human-machine interface terminal.

[0048] Specifically, the test terminal integrates a high-performance embedded control core, capable of independently applying excitation and capturing data for a single relay according to a preset test template. Each terminal is equipped with a local high-speed cache to temporarily store the large amount of raw waveform data generated at high sampling frequencies. After a single test cycle, the test terminal asynchronously uploads the pre-compressed and feature-extracted dataset to the central management node via a high-speed backplane bus or industrial Ethernet. This design effectively distributes the data acquisition load, enabling the system to support hundreds or thousands of test sites operating simultaneously, greatly improving production efficiency.

[0049] In terms of hardware implementation, the relay clamping device in this embodiment incorporates a pneumatic assist mechanism and a vision alignment module. The vision alignment module, comprising a miniature camera and an image processing chip, is configured to automatically identify the geometric center deviation and deformation degree of the pins before the relay enters the detection position. If the identified deviation exceeds the mechanical tolerance of the interface module, the system automatically drives a pneumatic translation stage to perform micron-level coordinate compensation, ensuring that the probe accurately hits the pin center. This non-contact pre-alignment mechanism significantly reduces probe wear and prevents damage to the relay structure caused by forced clamping.

[0050] The multi-channel signal excitation unit features a modular redundancy design within a distributed architecture. Each test channel is equipped with independent overcurrent protection and overheat monitoring circuits. When a channel detects a load short circuit or an abnormal excitation source output, its internal hardware circuit breaker will cut off the output within nanoseconds and report the fault status to the central management node without affecting the normal operation of other channels. Furthermore, the excitation unit incorporates a load characteristic adaptive function, capable of evaluating the impedance characteristics of the tested coil in real time by sending weak probe pulses and dynamically adjusting the PID parameters of the feedback loop accordingly. This ensures that the rise time and overshoot of the excitation waveform are always under optimal control, unaffected by individual relay differences.

[0051] The timing synchronization control unit employs a synchronization scheme based on a precise time protocol in cluster mode. The central management node acts as the master clock source, sending synchronization messages to all test terminals via the network. Each terminal's internal local clock, based on the timestamp information carried in the message, uses phase-locked loop technology to achieve precise locking with the master clock. This method eliminates signal transmission delay differences caused by inconsistent physical cable lengths, allowing waveform data across test points to be mapped to a unified timeline. This has significant engineering implications for analyzing common defects introduced by different processes on the production line; for example, by comparing test results from different locations, periodic vibration sources or power fluctuation interference in the production environment can be quickly located.

[0052] At the data processing level, the data processing and analysis unit introduces a parallel streaming processing architecture. It can not only perform basic parameter calculations but also utilize machine learning models to perform cluster analysis on massive amounts of historical test data. This model is configured to automatically identify potential defective product distribution trends in the production line using multi-dimensional electrical parameters as input features. For example, when the system detects that the pull-in voltage of a batch of relays shows a slow increase and increasing dispersion, it can issue a warning about potential tension control instability issues in the coil winding process. This shift from single-device detection to system-level process quality prediction is the core improvement of this embodiment compared to the basic embodiment.

[0053] The human-machine interface terminal transforms into a multi-level monitoring mode under a distributed architecture. In addition to the on-site industrial tablet PCs, the system also provides remote dashboards based on web technology. Quality engineers can access real-time inspection dynamics of factories nationwide or even globally through any terminal device connected to the enterprise intranet. The dashboards not only display real-time pass rates and fault distribution but also support in-depth backtracking of specific abnormal waveforms. By interactively zooming and measuring the original acquired waveforms in a browser, engineers can perform fault mechanism analysis as if they were in front of an oscilloscope on-site, significantly reducing the cost of remote maintenance and technical support.

[0054] For extreme testing environments, such as high and low temperature screening or damp heat testing, the relay clamping device in this embodiment uses high-temperature resistant Teflon material and gold-plated contacts. Electrical connections are sealed and moisture-proofed to prevent condensation-induced degradation of insulation performance. The front-end conditioning circuit of the high-precision sensing acquisition unit employs temperature drift compensation technology. By arranging multiple temperature sensors on the circuit board, the zero-point offset and gain factor of the operational amplifier are dynamically adjusted to ensure that the absolute measurement error of voltage and current remains within 0.05% across the entire temperature range from -40°C to +125°C.

[0055] Furthermore, this embodiment adds a high-frequency bounce analysis module to address the dynamic characteristics of the relay. This module, an extension of the data processing and analysis unit, is specifically designed to analyze the mechanical energy storage and dissipation logic of the contacts during operation. It can precisely pinpoint the moment of each contact micro-separation by calculating the second derivative of the current waveform. Utilizing the principle of energy equivalence, this module calculates the arc energy dissipation during the bounce process and assesses the degree of contact surface ablation accordingly. This function has crucial reference value for relay selection and lifespan prediction in high-frequency switching applications.

[0056] Example 3

[0057] An automated multi-parameter testing system for relays, based on Embodiment 1 or Embodiment 2, further enhances the system's flexibility in meeting heterogeneous testing requirements and its accuracy in capturing minute signal distortions. It is particularly suitable for research institutes to evaluate the research and development characteristics of novel electromagnetic or solid-state relays.

[0058] In this embodiment, the relay clamping device integrates an adaptive torque feedback control system. In addition to conventional electrical connections, the device is equipped with multiple highly sensitive miniature acoustic emission sensors and a triaxial vibration accelerometer. These sensors are configured to capture the mechanical acoustic waves and vibration signals generated when the moving iron core inside the relay strikes the stationary iron core. The data processing and analysis unit receives these non-electrical signals and performs time-domain fusion analysis with the electrical signals. By calculating the time delay between the electrical signal transition and the acoustic emission peak, the system can accurately reconstruct the mechanical motion history of the relay's internal mechanism, thereby detecting hidden mechanical defects such as excessive assembly clearances or fatigue of the return spring in internal parts without disassembling the housing.

[0059] In this embodiment, the multi-channel signal excitation unit is upgraded to an arbitrary waveform synthesis architecture. It is no longer limited to traditional DC step signals but can generate analog power fluctuation signals such as sinusoidal superimposed pulses, white noise background excitation, or specific frequency components based on complex scripts designed by the user through a human-machine interface terminal. The unit is internally equipped with a high-resolution digital-to-analog converter and a wideband power drive stage, capable of reproducing various power quality problems that may occur in actual power grids with extremely high fidelity. This capability allows the system to test the robustness of relays in environments containing high-order harmonics, transient surges, or voltage dips, providing direct evidence for improving the anti-interference capability of power protection devices.

[0060] To address the need for higher-dimensional signal capture, the high-precision sensing and acquisition unit in this embodiment employs multi-range automatic switching technology. Each sampling channel contains multiple amplifier branches with different gain coefficients connected in parallel. During testing, the system automatically switches to the most suitable range branch within nanoseconds based on the instantaneous intensity of the input signal via a high-speed analog switch. For example, when measuring the large current at the moment of contact closure, the system switches to a large range to prevent signal saturation; while when measuring the weak voltage drop after stable closure, the system automatically switches to a small range to obtain a higher signal-to-noise ratio. This dynamic range expansion capability enables the system to simultaneously perform high-current surge withstand analysis and high-precision measurement of milliohm-level contact resistance in a single test cycle, achieving an effective dynamic range exceeding 120 dB.

[0061] The timing synchronization control unit in Embodiment 3 introduces an external reference source locking function. It supports receiving second pulse synchronization signals from the Global Positioning System (GPS) or my country's BeiDou Navigation Satellite System, or receiving a frequency reference from a laboratory master clock via fiber optic connection. Through this external time synchronization mechanism, multiple geographically dispersed detection systems can achieve absolute time alignment across the entire network. This is crucial for studying the coordinated operation timing of multiple relay protection devices within large substations under wide-area faults, providing the most authentic timestamp evidence for optimizing the power grid fault isolation logic.

[0062] In terms of in-depth data mining, the data processing and analysis unit integrates a nonlinear dynamics analysis module based on phase space reconstruction. For complex stochastic processes like relay contact bounce, this module maps the collected voltage samples to a high-dimensional phase space. By calculating dynamic parameters such as correlation dimension and Lyapunov exponent, it quantitatively assesses the complexity and stability of the mechanical system. Furthermore, this unit is equipped with a frequency response function extraction function, capable of calculating the dynamic transfer function of the relay under coil excitation through cross-spectral density calculations of the excitation and response signals. By observing the position and bandwidth changes of the resonance peaks in the transfer function, the system can sensitively detect the initiation of microcracks on the contact spring surface or the weakening of connection strength, achieving a technological leap from fault detection to health early warning.

[0063] In this embodiment, the human-computer interaction terminal is equipped with enhanced simulation assistance capabilities. It features a built-in 3D virtual laboratory interface, utilizing digital twin technology to map the various electrical and mechanical parameters obtained from testing into a high-precision relay physical model in real time. Users can not only view 2D waveforms on the terminal but also observe the movement trajectory of the virtual iron core, the spatial distribution of the magnetic field strength, and the evolution of hot spots on the contact surface through 3D animation. This intuitive interaction method greatly facilitates researchers' understanding of the inherent coupling logic between physical parameters and electrical performance indicators, significantly shortening the iteration cycle of new products.

[0064] To ensure the security and integrity of the testing data, this embodiment incorporates a blockchain-based evidence storage mechanism. Each key piece of test data, system log, and calibration record undergoes encrypted hashing upon generation, forming a timestamped data block. These data blocks are backed up through consensus across multiple nodes within the cluster, ensuring the original testing data remains tamper-proof. This provides legally binding technical evidence in high-reliability application scenarios such as product quality disputes, major accident investigations, or military equipment acceptance.

[0065] The system also includes an automated self-calibration and health monitoring subsystem. This subsystem contains a high-level built-in standard source and a precision reference resistor. Before each formal test, the system automatically switches to calibration mode, automatically compensating for system drift caused by ambient temperature and component aging through cyclic measurements of the built-in standard components. If the system detects that the measurement deviation of a certain sampling channel exceeds the factory-preset warning value and cannot be corrected by the algorithm, it will automatically lock the channel and display a maintenance reminder on the human-machine interface. This self-correction capability greatly reduces the risk of misjudgment and ensures the authority of the test data.

[0066] Furthermore, to meet the needs of mixed testing of multiple relay models, the relay clamping device also incorporates QR code recognition and intelligent sorting logic. When the operator places the relay to be tested in the feeding area, the system automatically reads the unique identification code on its casing and retrieves the corresponding test parameter set, pin definition diagram, and pass / fail threshold from the cloud database. After the test is completed, the system control actuator automatically classifies the relays into different material boxes such as qualified, needing repair, and scrapped based on the test results. The entire process requires no manual intervention in setting test parameters, achieving truly "foolproof" fully automated testing.

[0067] Furthermore, the data processing and analysis unit supports detailed modeling of contact arc characteristics. By performing high-speed analysis of the voltage spike slope generated at the moment of contact disconnection, the duration of arc ignition, and the dielectric recovery voltage after arc extinction, the system can evaluate the relay's arc-extinguishing capability under specific inductive loads. This refined characterization of the extremely high-frequency, random process of arcing helps users rationally configure external absorption circuits based on the inductive reactance distribution of the actual application circuit, thereby effectively extending the electrical life of the relay.

[0068] Finally, this system adopts a modular, pluggable, plug-in architecture at the software level. Data processing algorithms, hardware drivers, and report templates can all be upgraded via online updates. This forward-looking software design allows the system to continuously evolve with the development of relay technology. For example, when solid-state relays become mainstream in the future, only the corresponding multi-range current sampling module and leakage current analysis plug-in need to be updated to achieve in-depth testing of semiconductor switch characteristics on the same hardware platform, greatly protecting the user's equipment investment value.

[0069] The above embodiments can be flexibly combined according to the needs of actual application scenarios. For example, the infrastructure in Embodiment 1 can be combined with the distributed management capabilities in Embodiment 2, or the high-precision analysis algorithm in Embodiment 3 can be integrated into the hardware platform of Embodiment 1.

[0070] The automated multi-parameter relay testing system provided by this invention achieves synchronous, high-speed, and high-fidelity acquisition of key electrical parameters of relays through the collaborative work of a high-precision sensing and acquisition unit and a timing synchronization control unit, effectively overcoming the shortcomings of traditional testing equipment in capturing transient signals. The system's built-in data processing and analysis unit can not only accurately calculate various static and dynamic performance indicators, but also perform cross-validation based on the timing logic relationship between multiple parameters, significantly improving the reliability and anti-interference capability of the test results. The modular design of the relay clamping device and the programmable characteristics of the multi-channel signal excitation unit enable the system to flexibly adapt to the testing needs of various relay models, greatly improving testing efficiency and equipment versatility. In addition, the integration of human-machine interaction terminal and remote communication functions provides a technical foundation for realizing automated archiving, remote monitoring, and closed-loop quality management of test data, meeting the stringent requirements of modern intelligent manufacturing for online testing of high-reliability electronic components.

[0071] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-parameter automated detection system for relays, characterized in that, include: The relay clamping device is configured to electrically connect and physically fix the relay under test, ensuring that the contacts and coil terminals maintain stable and reliable electrical contact with the external test circuit during the test. The multi-channel signal excitation unit is configured to apply a programmable excitation signal to the coil of the relay under test, and dynamically adjust the excitation amplitude, rise edge slope and duration to simulate the pull-in and release process under different operating conditions. A high-precision sensing and acquisition unit is configured to synchronously acquire multiple electrical response signals of the relay under test under excitation, and convert the acquired analog signals into digital signals for output. The timing synchronization control unit is configured to coordinate the working timing of the multi-channel signal excitation unit and the high-precision sensing acquisition unit, ensuring that the application time of the excitation signal is aligned with the sampling window of the sensing signal. The data processing and analysis unit is configured to receive digital signals, calculate contact resistance, coil pull-in voltage, release voltage, pull-in time, release time and bounce-back time, and perform logical verification on the timing correlation between parameters. The human-computer interaction terminal is configured to receive test configuration commands and display real-time test waveforms, parameter calculation results, and system diagnostic information.

2. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The high-precision sensing and acquisition unit includes multiple independent voltage sampling sub-channels and current sampling sub-channels. Each sampling sub-channel is independently equipped with a differential isolation amplifier with a high common-mode rejection ratio, a low-pass anti-aliasing filter, and a high-speed analog-to-digital converter circuit. The isolation amplifier circuit uses a high-linearity opto-isolator or magnetic isolation amplifier, and its bandwidth is configured to cover all high-frequency harmonic components generated by relay contact bounce. The sampling frequency of the analog-to-digital converter is configured to be greater than or equal to one megahertz, so that the system's time resolution for the transient process of relay operation is better than one microsecond. Each sampling sub-channel is equipped with independent analog ground and digital ground planes, and the signal decoupling between channels is achieved through electromagnetic isolation technology, which is configured to suppress crosstalk noise from the coil drive circuit when measuring low contact resistance.

3. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The multi-channel signal excitation unit includes a programmable linear DC power supply, a pulse width modulation waveform generation circuit, a high linearity power amplifier, and a polarity switching matrix. The multi-channel signal excitation unit has bidirectional programmable control capability. The polarity switching matrix is ​​configured to switch the excitation direction at both ends of the coil according to test requirements to evaluate the impact of residual magnetism on relay performance. In a single test cycle, the multi-channel signal excitation unit is configured to sequentially execute four stages: activation excitation, steady-state holding, release excitation, and static observation, with a predetermined steady-state holding stage dynamically inserted between two excitations. The duration of the steady-state holding stage is configured to be set in milliseconds according to the relay's thermal balance requirements, simulating the temperature rise and magnetic circuit evolution process of the relay in actual industrial control cycles.

4. The automatic multi-parameter detection system for relays according to claim 1, characterized in that: The relay clamping device includes a base and a replaceable interface module mounted on the base. The base is equipped with a universal signal transmission busbar and a positioning slot. The replaceable interface module is configured to adapt to relay models with different package types, pin layouts, and pin materials. The replaceable interface module integrates multiple sets of flexible contact electrodes, an automated clamping mechanism, and a spring loading mechanism. The spring loading mechanism utilizes feedback control from a precision pressure sensor to ensure that the contact pressure applied by each test probe to the relay pin is within a preset pressure range. This pressure range is configured to pierce the oxide layer on the pin surface and prevent mechanical deformation of the pin. The relay clamping device is also connected to a vision alignment module, which is configured to automatically identify the geometric center deviation of the pin and drive a pneumatic translation stage for coordinate compensation.

5. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The timing synchronization control unit includes a cryogenic crystal oscillator, a field-programmable gate array (FPGA), and a precision timer / counter. The cryogenic crystal oscillator serves as a high-stability clock source, with frequency stability better than one part per million and clock jitter limited to within ten nanoseconds. The precision timer / counter is configured to achieve microsecond-level scheduling of the timing of each unit's actions, ensuring sub-microsecond alignment between the signal triggering time of the multi-channel signal excitation unit and the sampling start time of the high-precision sensing acquisition unit on the time axis. The timing synchronization control unit also features an external reference source locking interface, supporting the reception of second-pulse synchronization signals from the Global Positioning System (GPS) or the BeiDou Navigation Satellite System (BDS), enabling absolute time alignment across the entire network for multiple geographically dispersed detection systems through an external time synchronization mechanism.

6. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The data processing and analysis unit is configured to execute contact resistance calculation logic based on a sliding window. Within the stable range after the contact is fully closed, the data processing and analysis unit selects a sliding window of a predetermined length for data extraction. Within the sliding window, it performs an arithmetic mean operation on the voltage drop sample sequence at both ends of the contact and the current sample sequence flowing through the contact, respectively, to obtain the average voltage drop and average current values. The average voltage drop is divided by the average current value to obtain the contact resistance measurement value. For the detection of pull-in and release voltages, the data processing and analysis unit configures the multi-channel signal excitation unit to execute a ramp scan mode. During the process of the coil voltage changing at a preset step slope, it monitors the current change in the contact circuit in real time. When the contact current reaches a preset closing threshold or opening threshold, it records the instantaneous coil voltage value at this time and defines it as the pull-in voltage and release voltage, respectively.

7. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The data processing and analysis unit has a built-in parameter validity judgment module, which is configured to execute an evaluation algorithm based on logical consistency. The parameter validity judgment module determines whether the current measurement value is within the physical state space by real-time monitoring the correlation between the amplitude change of the coil excitation signal and the contact conduction state. When it is detected that the coil has been applied with sufficient pull-in voltage but the contact circuit current fluctuates violently, or the contact fails to open within a preset window after the coil is de-energized, the abnormal diagnosis logic is automatically triggered. If the contact is detected to be incompletely closed due to mechanical wear or foreign object interference, the parameter validity judgment module is configured to automatically mark the contact resistance value obtained in this measurement as invalid data and send an alarm signal to the human-machine interaction terminal; the data processing and analysis unit is also configured with a timestamp comparison module, which extracts the pull-in time, release time and bounce time by calculating the time difference between the coil excitation signal jump time and the contact action time.

8. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The human-machine interface terminal is equipped with an industrial Ethernet interface, RS485 interface, or wireless LAN module, configured to synchronize locally generated test data to a remote cloud server in real time. The terminal is also configured to receive batch test task instructions from the upper-level quality management system, enabling automated distribution of the testing process. The system is further connected to a blockchain storage module, where each piece of test data, system log, and calibration record is encrypted and hashed after generation, forming a timestamped data block. Consensus backup is performed across multiple nodes within the cluster to ensure the original test data is tamper-proof. The terminal also features a 3D virtual laboratory interface, using digital twin technology to map the electrical and mechanical parameters obtained from the tests to a relay physical model in real time, and to display the iron core's movement trajectory and magnetic field spatial distribution through animation.

9. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The data processing and analysis unit also includes a nonlinear dynamics analysis module, a frequency response function extraction module, and a high-frequency bounce analysis module. The nonlinear dynamics analysis module is configured to map voltage sample values ​​into a high-dimensional phase space and quantitatively evaluate the stability of the mechanical system by calculating the correlation dimension and Lyapunov exponent. The frequency response function extraction module is configured to calculate the dynamic transfer function of the relay under coil excitation by performing cross-spectral density calculations on the excitation signal and the response signal, and to identify microcracks in the contact spring by monitoring the position and bandwidth changes of the resonance peak in the transfer function. The high-frequency bounce analysis module is configured to perform second-order derivative calculations on the current waveform at the moment of contact action to locate the moment of contact micro-separation, and to calculate the arc energy dissipation during the bounce process using the energy equivalence principle to evaluate the degree of ablation on the contact surface.

10. The automated multi-parameter detection system for relays according to claim 1, characterized in that: The system employs multi-level shielding in its physical structure. The system shell is made of a Faraday cage structure using highly conductive metal material. Signal transmission between functional units uses shielded twisted-pair cables and a common-mode choke filter. The front-end conditioning circuit of the high-precision sensing and acquisition unit uses temperature drift compensation technology, dynamically adjusting the zero-point offset and gain factor of the operational amplifier by arranging multiple temperature sensors on the circuit board. The system is also equipped with a self-calibration and health monitoring subsystem. This subsystem includes a built-in standard source and a precision reference resistor, configured to switch to calibration mode before each test. It automatically compensates for system drift caused by ambient temperature and device aging through cyclic measurements of the built-in standard components. When the measurement deviation of a sampling channel exceeds a preset warning value and cannot be compensated by the algorithm, the system automatically locks the channel and displays a maintenance reminder on the human-machine interface.

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