Contact material electric ablation morphology in-situ extraction system and method

Abstract

The invention discloses a contact material electric ablation morphology in-situ extraction system and method, and belongs to the field of contact material electric performance testing and electric contact failure analysis. The device comprises a bottom plate, a Z-axis electric sliding table, a movable contact clamp, a movable contact, a spring, an X-axis electric sliding table, a Y-axis manual sliding table, a static contact clamp, a static contact, a reference ruler, an industrial camera used for shooting the movable contact, a three-dimensional shape measuring instrument used for shooting the movable contact, an industrial camera used for shooting the static contact and a three-dimensional shape measuring instrument used for shooting the static contact. The system comprises a displacement sensor, a power supply, a load, a control switch, an industrial control computer and a single-chip microcomputer. The invention aims to provide a contact material electric ablation morphology in-situ extraction system and a contact state in-situ evaluation method so as to realize in-situ extraction of surface morphology characteristics of a contact material in an electric life experiment process and evaluate a contact state corresponding to a pairing position in the experiment process according to the electric ablation morphology of the contact material.

Description

Technical Field

[0001] This invention relates to an in-situ extraction system and method for the electroablation morphology of contact materials, belonging to the field of electrical performance testing and electrical contact failure analysis of contact materials. Background Technology

[0002] Contact materials are the carriers within electrical switches that perform the functions of conducting and breaking current. The electrical properties of contact materials specifically refer to parameters that reflect their arc-breaking performance (including arc time and arc energy) and electrical contact performance (including contact resistance and contact temperature rise). The arc discharge generated during contact opening and closing will cause ablation on the surface, which in electrical life tests manifests as contact mass loss, material alloying, and morphological changes. This will cause the electrical contact performance to gradually degrade after each contact closure until failure. Furthermore, the surface morphology of the contact material and the state of the contact interface will also affect the arc-breaking behavior of the contact. It is evident that the cyclic arc discharge, electrical ablation, and electrical contact behavior occurring during electrical life tests are mutually influential. Therefore, studying the in-situ extraction of surface morphology characteristics of contact materials during electrical life tests, and then evaluating the contact state corresponding to the mating positions during the experiment based on the electrical ablation morphology, is of great value for the testing and evaluation of the electrical performance of contact materials.

[0003] The contact state evaluation of contact materials during electrical life testing needs to meet the following conditions: 1. It should be able to evaluate the contact state of the contact material in real time during electrical life testing with tens of thousands of contact actions, without removing the contacts from the experimental device; 2. It should be able to accurately reproduce the mating position of the contact material in the electrical life test and the contact state when closed; 3. It should be able to obtain key information about the contact interface at the microscale of the contact material, including the number of contact points, the location of the contact points, and the resulting contact area.

[0004] Currently, the main methods for evaluating the contact state of contact materials are as follows: Method 1: Using industrial CT to scan the contact in a closed state, directly obtaining the morphology of the contact interface of the contact material and extracting the electrical ablation characteristics of the contact material; Method 2: Given a contact force, test the contact resistance, and compare the contact resistance to reflect the contact area and contact state of the contact material; Method 3: The existing Chinese patent with publication number CN104061881B invented an optical device for observing and analyzing the contact area of ​​the contact and calculating the actual contact area, using a transparent flat plate material to replace a contact, simulating contact contact while capturing images of the contact material; Method 4: The existing Chinese patent with publication number CN111347187B invented an experimental device that can acquire the welding parameters of the contact material in real time during the contact electrical life test, using an industrial camera to capture images of the static contact in situ.

[0005] Of the aforementioned evaluation methods, Method 1 requires removing the contact material sample from the working environment, which cannot meet the evaluation requirements of the contact material's contact state in electrical life tests involving a large number of contact actions. Method 1 also cannot obtain the number, location, and contact area of ​​contact points at the microscopic scale, thus making it impossible to reasonably evaluate contact materials with similar or identical contact resistances. Method 3 uses a transparent plate to replace a single contact, and Method 4 can only photograph the static contact in situ; neither method can reproduce the true situation of the contact interface between the moving and static contacts, and therefore cannot evaluate the contact state of the contact material in electrical life tests. Therefore, current technologies cannot yet achieve in-situ evaluation of the contact material's morphological features and contact state during electrical life tests.

[0006] Therefore, there is an urgent need to propose an in-situ extraction system and method for the electroablation morphology of contact materials to solve the above-mentioned technical problems. Summary of the Invention

[0007] The purpose of this invention is to provide an in-situ extraction system for the electroablation morphology of contact materials and an in-situ evaluation method for the contact state, enabling the in-situ extraction of surface morphology features of contact materials during electrical lifetime experiments, and evaluating the contact state corresponding to the mating positions during the experiment based on their electroablation morphology. A brief overview of the invention is provided below to provide a basic understanding of certain aspects of the invention. It should be understood that this overview is not an exhaustive summary of the invention. It is not intended to identify key or essential parts of the invention, nor is it intended to limit the scope of the invention.

[0008] The technical solution of this invention:

[0009] Option 1: An in-situ extraction system for the electroablation morphology of contact materials, comprising a base plate, a Z-axis electric slide, a moving contact fixture, a moving contact, a spring, an X-axis electric slide, a Y-axis manual slide, a stationary contact fixture, a stationary contact, a reference ruler, an industrial camera for photographing the moving contact, a three-dimensional morphology measuring instrument for photographing the moving contact, an industrial camera for photographing the stationary contact, a three-dimensional morphology measuring instrument for photographing the stationary contact, a displacement sensor, a power supply, a load, a control switch, an industrial control computer, and a microcontroller;

[0010] An X-axis electric slide is mounted on the base plate. A Y-axis manual slide, an industrial camera for capturing moving contacts, and a three-dimensional shape measuring instrument for capturing moving contacts are mounted on the X-axis electric slide. A stationary contact is mounted on the Y-axis manual slide via a stationary contact clamp.

[0011] The base plate is also equipped with an industrial camera for capturing images of stationary contacts, a three-dimensional shape measuring instrument for capturing images of stationary contacts, and a displacement sensor.

[0012] A Z-axis electric slide is fixedly mounted on the base plate. The Z-axis electric slide has a moving contact mounted on it through a moving contact clamp. The moving contact clamp contains the spring inside, which is used to provide flexible contact for the contact to close.

[0013] The reference ruler is fixed on the base plate, located between the moving contact and the stationary contact, and its length direction is consistent with the movement direction of the X-axis electric slide.

[0014] The industrial control computer is electrically connected to the industrial camera used to capture moving contacts, the industrial camera used to capture stationary contacts, the three-dimensional topography measuring instrument used to capture moving contacts, and the three-dimensional topography measuring instrument used to capture stationary contacts, respectively, for controlling the acquisition and processing of image and point cloud data.

[0015] The microcontroller is electrically connected to the industrial control computer, the Z-axis electric slide, the X-axis electric slide, the displacement sensor, and the control switch, respectively.

[0016] The power supply, load, and control switch are connected in series to form a load circuit, and the two ends of the load circuit are electrically connected to the moving contact clamp and the stationary contact clamp, respectively.

[0017] Preferably, the direction parallel to the front plane of the reference ruler is defined as the XY plane, and the direction perpendicular to this plane and pointing away from the base plate is defined as the +Z direction. The reference ruler is made of transparent material, and the front side with the scale lines is parallel to the XY plane and oriented towards the +Z direction.

[0018] Preferably, both the industrial camera used to capture the moving contact and the three-dimensional shape measuring instrument used to capture the moving contact are fixed on the X-axis electric slide, and the shooting direction of both is perpendicular to the XY plane and oriented towards the -Z direction.

[0019] Preferably, both the industrial camera used to capture static contact points and the three-dimensional shape measuring instrument used to capture static contact points are fixed on the base plate, and the shooting direction of both is perpendicular to the XY plane and faces the +Z direction.

[0020] Preferably, both the three-dimensional topography measuring instrument used for capturing moving contacts and the three-dimensional topography measuring instrument used for capturing static contacts are snapshot-type three-dimensional topography measuring instruments.

[0021] Preferably, the X-axis electric slide moves in a direction parallel to the extension direction of the scale lines on the front of the reference ruler, and when the X-axis electric slide moves, it drives the Y-axis manual slide, the industrial camera for capturing the moving contact point, and the three-dimensional shape measuring instrument for capturing the moving contact point to move synchronously.

[0022] Preferably, both the moving contact clamp and the stationary contact clamp are conductive, and an electrical connection is formed when the moving contact and the stationary contact are closed.

[0023] Option 2, an in-situ extraction method for the electro-ablation morphology of contact materials, is based on the in-situ extraction system for the electro-ablation morphology of contact materials described in Option 1, and includes the following steps:

[0024] Step S1: Calibrate the industrial camera used to photograph moving contacts, the industrial camera used to photograph stationary contacts, the 3D topography measuring instrument used to photograph moving contacts, the 3D topography measuring instrument used to photograph stationary contacts, the X-axis electric slide, and the Z-axis electric slide, and establish a global coordinate system.

[0025] Step S2: Extract visual image data and three-dimensional point cloud data of the electrical ablation features of the moving and stationary contacts in situ.

[0026] Step S3: Restore the true spatial relationship between the moving contact and the stationary contact, and extract the electrical ablation characteristic parameters of the moving contact and the stationary contact.

[0027] Step S4: Establish a virtual contact between the moving contact and the stationary contact, and extract the characteristic parameters of the contact interface.

[0028] The present invention has the following beneficial effects:

[0029] This invention uses an industrial camera and a three-dimensional topography measuring instrument to observe the surface morphology of the contact material in the electrical lifetime experiment in situ via an X-axis electric slide, without removing the contact material from the experimental device.

[0030] This invention utilizes a reference ruler, combined with visual images captured by an industrial camera and three-dimensional point cloud data captured by a three-dimensional topography measuring instrument, to accurately restore the true positional relationship between moving and stationary contacts in an electrical life test, and to reconstruct the virtual contact when the contacts are closed.

[0031] This invention is based on virtual contact of contact materials, extracts key characteristic parameters of the contact material electroablation process, including the number of contact points, their location and the resulting contact area, as well as the amount of contact volume change and the shortest distance, and evaluates the contact state of the contact material and the morphological changes during the electroablation process from multiple dimensions.

[0032] In summary, this invention enables the extraction of morphological features of contact materials and in-situ evaluation of contact states in electrical life experiments. Attached Figure Description

[0033] Figure 1 A structural diagram of the in-situ extraction system for the electroablation morphology of contact materials for in-situ evaluation of contact state provided by the present invention;

[0034] Figure 2 This is a functional diagram of the data acquisition and communication module provided by the present invention;

[0035] Figure 3The diagram shows the positions of each component in the mechanical structure module and the data measurement module when the X-axis electric slide provided by the present invention is located at the camera observation position, the three-dimensional observation position and the contact point action position. In the figure, (a) is a visual image taken at the camera observation position, (b) is a visual image taken at the three-dimensional observation position and (c) is a visual image taken at the contact point action position.

[0036] Figure 4 This is a schematic diagram of the visual image captured by an industrial camera when the X-axis electric slide is located at the camera observation position. In the figure, (a) is a schematic diagram of the visual image of the moving contact, and (b) is a schematic diagram of the visual image of the stationary contact.

[0037] Figure 5 The figure shows a schematic diagram of a three-dimensional point cloud captured by a three-dimensional topography measuring instrument when the X-axis electric slide is located in a three-dimensional observation position. In the figure, (a) is a schematic diagram of the visual image of the moving contact point, and (b) is a schematic diagram of the visual image of the stationary contact point.

[0038] In the diagram: 1-Base plate, 2-Z-axis electric slide, 3-Moving contact fixture, 4-Moving contact, 5-Spring, 6-X-axis electric slide, 7-Y-axis manual slide, 8-Stabilized contact fixture, 9-Stabilized contact, 10-Reference ruler, 11-Industrial camera for photographing the moving contact, 12-3D topography measuring instrument for photographing the moving contact, 13-Industrial camera for photographing the stationary contact, 14-3D topography measuring instrument for photographing the stationary contact, 15-Displacement sensor, 16-Power supply, 17-Load, 18-Control switch, 19-Industrial control computer, 20-Microcontroller. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer, the invention is described below with reference to specific embodiments shown in the accompanying drawings. However, it should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0040] The connections mentioned in this invention are divided into fixed connections and detachable connections. Fixed connections (i.e., non-detachable connections) include, but are not limited to, conventional fixed connection methods such as folded connections, riveted connections, adhesive connections, and welded connections. Detachable connections include, but are not limited to, conventional disassembly methods such as threaded connections, snap-fit ​​connections, pin connections, and hinged connections. When a specific connection method is not explicitly defined, it is assumed that at least one existing connection method can always be found to achieve the function, and those skilled in the art can choose according to their needs. For example, a welded connection can be chosen for fixed connections, and a hinged connection can be chosen for detachable connections.

[0041] Specific implementation method one: Combining Figures 1-5 This embodiment describes an in-situ extraction system for the electroablation morphology of contact materials. The system includes a mechanical structure module, a data measurement module, a load circuit, and a data acquisition and communication module.

[0042] The mechanical structure module includes: base plate 1, Z-axis electric slide 2, moving contact fixture 3, moving contact 4, X-axis electric slide 6, Y-axis manual slide 7, stationary contact fixture 8, stationary contact 9, and reference ruler 10.

[0043] Furthermore, the X-axis electric slide 6 is composed of a ball screw and a stepper motor.

[0044] Define the direction parallel to the front plane of the reference ruler 10 as the XY plane, and the direction perpendicular to this plane and pointing away from the base plate 1 as the +Z direction.

[0045] Specifically, the base plate 1 is used to support the fixed components in the mechanical structure module; the Z-axis electric slide 2 is fixed on the base plate 1 and is used to drive the moving contact clamp 3 and the moving contact 4 to move linearly along the Z direction, simulating the contact closing and breaking action;

[0046] The moving contact clamp 3 is connected to the Z-axis electric slide 2 and is used to clamp the moving contact 4. It contains a spring 5. During the contact closure process, the spring 5 is compressed to provide flexible contact to the contact.

[0047] The X-axis electric slide 6 is fixed on the base plate 1, and its displacement direction is consistent with the X-axis direction. The stepper motor drives the roller screw to control the Y-axis manual slide 7 equipped with the stationary contact fixture 8 and stationary contact 9, the industrial camera 11 for photographing the moving contact, and the three-dimensional shape measuring instrument 12 for photographing the moving contact to move along the X-direction.

[0048] The Y-axis manual slide 7 is located on the X-axis electric slide 6 and is used to adjust the position of the stationary contact 9 in the Y direction; the stationary contact clamp 8 is connected to the Y-axis manual slide 7 and is used to clamp the stationary contact 9.

[0049] The reference ruler 10 is fixed on the base plate 1, located between the moving contact 4 and the stationary contact 9. Its length direction is consistent with the movement direction of the X-axis electric slide 6, and its calibrated X-direction range includes the movement range of the X-axis electric slide 6.

[0050] Furthermore, both the moving contact clamp 3 and the stationary contact clamp 8 are conductive, enabling electrical connection between the moving contact 4 and the stationary contact 9 when the contacts are closed.

[0051] The reference ruler 10 is made of transparent material, and the side of the reference ruler 10 with scale lines is defined as the front side, and the side opposite the front side is the back side. The front side of the reference ruler 10 is parallel to the XY plane and faces the +Z direction, with the edge of the side with the scale lines facing upward.

[0052] like Figure 1 As shown, the data measurement module in the in-situ extraction system for the electroablation morphology of contact materials provided by the present invention includes: an industrial camera 11 for capturing moving contacts, a three-dimensional morphology measuring instrument 12 for capturing moving contacts, an industrial camera 13 for capturing stationary contacts, a three-dimensional morphology measuring instrument 14 for capturing stationary contacts, and a displacement sensor 15.

[0053] Furthermore, both the industrial camera 11 for capturing moving contacts and the industrial camera 13 for capturing stationary contacts are preferably CCD cameras and equipped with telecentric lenses.

[0054] Both the 3D topography measuring instrument 12 for capturing moving contacts and the 3D topography measuring instrument 14 for capturing stationary contacts are preferably 3D snapshot sensors, which can obtain 3D point cloud data without motion scanning during shooting.

[0055] The displacement sensor 15 is preferably a point laser displacement sensor.

[0056] Specifically, the industrial camera 11 for capturing moving contacts and the three-dimensional shape measuring instrument 12 for capturing moving contacts are located on the X-axis electric slide 6, with the shooting direction perpendicular to the XY plane and facing the -Z direction; the industrial camera 13 for capturing stationary contacts and the three-dimensional shape measuring instrument 14 for capturing stationary contacts are fixed on the base plate 1, with the shooting direction perpendicular to the XY plane and facing the +Z direction; the displacement sensor 15 is fixed on the base plate 1.

[0057] Furthermore, the distance between the Z-axis of the industrial camera 13 used to photograph the static contact and the Z-axis of the three-dimensional topography measuring instrument 14 used to photograph the static contact, and the distance between the Z-axis of the industrial camera 11 used to photograph the moving contact and the Z-axis of the three-dimensional topography measuring instrument 12 used to photograph the moving contact, are both l1; the distance between the moving contact 4 and the Z-axis of the industrial camera 13 used to photograph the static contact, and the distance between the moving contact 9 and the Z-axis of the industrial camera 11 used to photograph the moving contact, are both l2. The industrial camera 11 used to photograph the moving contact 4 and the industrial camera 13 used to photograph the static contact 9 can be performed simultaneously, and the three-dimensional topography measuring instrument 12 used to photograph the moving contact 4 and the three-dimensional topography measuring instrument 14 used to photograph the static contact 9 can be performed simultaneously.

[0058] When the X-axis electric slide 6 moves in the X direction, the Y-axis manual slide 7, the industrial camera 11 for capturing moving contacts, and the three-dimensional shape measuring instrument 12 for capturing moving contacts on the X-axis electric slide 6 move synchronously in the X direction.

[0059] Furthermore, the resolution of the industrial camera in the XY plane is superior to that of the 3D topography measuring instrument in the XY plane. Therefore, in use, the coordinates of the 3D point cloud data captured by the 3D topography measuring instrument in the XY plane are registered based on the visual image data captured by the industrial camera.

[0060] The repeatability of the industrial camera and the 3D topography measuring instrument in the XY plane is better than the repeatability of the X-axis electric slide 6 in the X direction. Therefore, the X-axis electric slide 6 is calibrated by the industrial camera and the 3D topography measuring instrument during use.

[0061] The repeatability of the displacement sensor 15 is better than the repeatability of the Z-axis electric slide 2 in the Z direction. Therefore, the Z-axis electric slide 2 is calibrated by the displacement sensor 15 during use.

[0062] like Figure 1 As shown, the load circuit in the in-situ extraction system for the electroablation morphology of contact materials provided by the present invention includes: a power supply 16, a load 17 and a control switch 18, which are connected to the moving contact fixture 3 and the stationary contact fixture 8 to form a circuit.

[0063] Furthermore, the control switch 18 is preferably a solid-state relay, used to control the on / off state of the load circuit and to provide isolation protection for the load circuit.

[0064] like Figure 1 As shown, the acquisition and communication module in the in-situ extraction system for the electroablation morphology of contact materials provided by the present invention includes: an industrial control computer 19 and a microcontroller 20.

[0065] Figure 2 This is a functional diagram of the acquisition and communication module in the in-situ extraction system for the electroablation morphology of contact materials provided by this invention. Figure 2 As shown, the specific functions of the acquisition and communication module include:

[0066] The industrial control computer 19 records the position of the Z-axis electric slide 2; the industrial control computer 19 sets the speed and target position of the Z-axis electric slide 2 along the Z direction, and sends them to the Z-axis electric slide 2 by the microcontroller 20, controlling the Z-axis electric slide 2 to drive the moving contact clamp 3 and the moving contact 4 to move at the set speed and target position.

[0067] The industrial control computer 19 records the position of the X-axis electric slide 6; the industrial control computer 19 sets the speed, displacement or target position of the X-axis electric slide 6 along the X direction, and sends it to the X-axis electric slide 6 by the microcontroller 20, controlling the X-axis electric slide 6 to drive the Y-axis manual slide 7 equipped with the stationary contact fixture 8 and stationary contact 9, the industrial camera 11 for capturing the moving contact and the three-dimensional shape measuring instrument 12 for capturing the moving contact, to move synchronously according to the set translation speed, displacement or target position;

[0068] The industrial control computer 19 controls the industrial camera and the three-dimensional topography measuring instrument to capture images of the moving contact 4 and the stationary contact 9, and acquires and processes the captured visual images and three-dimensional point cloud data.

[0069] The industrial control computer 19 issues a displacement measurement command, which is sent by the microcontroller 20 to the displacement sensor 15 to control it to measure the displacement data of the moving contact 4. The microcontroller 20 collects the displacement data measured by the displacement sensor 15 and sends it back to the industrial control computer 19 for processing.

[0070] The industrial control computer 19 issues a turn-on command or a turn-off command, which is sent by the microcontroller 20 to the control switch 18 to control the on / off state of the load circuit.

[0071] Specific Implementation Method Two: Combining Figures 1-5 This embodiment describes an in-situ extraction method for the electro-ablation morphology of contact materials, based on the in-situ extraction system for the electro-ablation morphology of contact materials described in Embodiment 1. The method includes the following steps:

[0072] Step S1: Calibrate the industrial camera 11 for capturing moving contacts, the industrial camera 13 for capturing stationary contacts, the 3D topography measuring instrument 12 for capturing moving contacts, the 3D topography measuring instrument 14 for capturing stationary contacts, the X-axis electric slide 6, and the Z-axis electric slide 2, and establish a global coordinate system.

[0073] Step S2: Extract visual image data and three-dimensional point cloud data of the electrical ablation features of moving contact 4 and stationary contact 9 in situ.

[0074] Step S3: Restore the true spatial relationship between the moving contact 4 and the stationary contact 9, and extract the electrical ablation characteristic parameters of the moving contact 4 and the stationary contact 9.

[0075] Step S4: Establish a virtual contact between the moving contact 4 and the stationary contact 9, and extract the characteristic parameters of the contact interface.

[0076] The steps of the above method will be discussed in detail below:

[0077] Step S1 specifically includes:

[0078] Step S11: Using the reference ruler 10 as a reference, calibrate the industrial camera and the 3D topography measuring instrument, as follows:

[0079] Step S111: Use the checkerboard method to calibrate the internal parameters of the industrial camera (11) used to capture moving contacts and the industrial camera (13) used to capture stationary contacts; use the reference ruler 10 as a reference to calibrate the external parameters of the industrial cameras 11 and 13, so that the edge of the side with the scale line printed in the visual image of the reference ruler 10 is parallel to the X-axis, the scale line is parallel to the Y-axis, and the distance between adjacent scale lines in the visual image is equal to the measurement spacing of the reference ruler 10.

[0080] Step S112: Using the front side of the reference ruler 10 as a reference, calibrate the three-dimensional topography measuring instrument 12 used for capturing moving contact points so that the front side of the reference ruler 10 in the three-dimensional point cloud is parallel to the XY plane; using the back side of the reference ruler 10 as a reference, calibrate the three-dimensional topography measuring instrument 14 used for capturing static contact points so that the back side of the reference ruler 10 in the three-dimensional point cloud is parallel to the XY plane.

[0081] Step S12: Establish a global coordinate system, as follows:

[0082] Step S121: Define the upper end of the first long scale line from left to right in the front visual image of the reference ruler 10 taken when the X-axis electric slide 6 is located in the camera observation position as the origin of the coordinate system, and define the upper end of the first long scale line from left to right in the back visual image of the reference ruler 10 as the positioning point.

[0083] Based on the coordinate origin, a global coordinate system is established with the X direction being parallel to the edge of the reference ruler 10 containing the printed scale lines, the Y direction being parallel to the scale lines, and the Z direction being perpendicular to the front of the reference ruler 10.

[0084] Step S122: Obtain the scale values ​​x corresponding to the origin and positioning point on the reference ruler 10 by taking visual images of the front and back sides of the reference ruler 10 when the X-axis electric slide 6 is in the camera observation position. 00 and x 10 Calculate the coordinates x1 and y1 of the positioning point in the global coordinate system. The specific formula is as follows:

[0085]

[0086] Step S13: Obtain the X-coordinate (x) of the origin of the reference ruler 10 in the visual image data by taking visual images of the front and back sides of the reference ruler 10 when the X-axis electric slide 6 is located in the camera observation position. 01The industrial control computer 19 sets a displacement and controls the X-axis electric slide 6 to move a certain distance along the +X direction. The industrial camera 11, used to capture the moving contact, captures a visual image of the front of the reference ruler 10, obtaining a visual image of the front of the reference ruler 10 containing at least one long scale line. The upper end of the first long scale line from left to right is selected as reference point A, and the scale value x corresponding to reference point A on the reference ruler 10 is obtained. A0 and the X coordinate x in visual image data A1 According to x 01 x A0 x A1 Calculate the displacement x of the X-axis electric slide 6 in the global coordinate system; adjust the instructions of the industrial control computer 19 so that the input displacement is equal to the displacement x of the X-axis electric slide 6 in the global coordinate system. The specific formula for calculating x is as follows:

[0087]

[0088] Step S14: The industrial control computer 19 controls the X-axis electric slide 6 to move a certain distance along the X direction, so that the moving contact 4 will not contact the stationary contact 9, the industrial camera 11 for photographing the moving contact, and the three-dimensional shape measuring instrument 12 for photographing the moving contact during the movement along the Z direction; the industrial control computer 19 sets the target position for movement along the Z direction, controls the Z-axis electric slide 2 to move between different target positions, and uses the displacement sensor 15 to measure the displacement of the Z-axis electric slide 2 during the movement; the industrial control computer 19 adjusts the distance between any two target positions to be equal to the displacement of the Z-axis electric slide 2 between these two target positions measured by the displacement sensor 15.

[0089] In step S2, the in-situ extraction of visual image data and three-dimensional point cloud data of the electro-ablation morphology of the contact material specifically includes:

[0090] S21: Determine the camera observation position, the 3D observation position, and the contact point action position respectively, as follows:

[0091] Position 1: The industrial control computer 19 controls the X-axis electric slide 6 to move along the X direction and records the camera observation position of the X-axis electric slide 6, which is used to capture visual images of the moving contact 4 and the stationary contact 9 using industrial cameras 11 and 13 respectively.

[0092] Specifically, Figure 3 This is a schematic diagram of a visual image captured by an industrial camera when the X-axis electric slide 6 provided by the present invention is located at the camera observation position. Figure 3Figure a is a schematic diagram of the visual image captured by the industrial camera 11 used to capture the moving contact. When the X-axis electric slide 6 is in the camera observation position, the industrial camera 11 used to capture the moving contact shows a complete surface image of the moving contact 4 and an image of the front of the reference ruler 10 containing some scale lines. Figure 3 Figure b is a schematic diagram of the visual image captured by the industrial camera 13 used to capture the stationary contact. When the X-axis electric slide 6 is in the camera observation position, the industrial camera 13 used to capture the stationary contact shows a complete surface image of the stationary contact 9 and an image of the back of the reference ruler 10 containing some scale lines.

[0093] Position 2: The industrial control computer 19 controls the X-axis electric slide 6 to move along the -X direction and records a three-dimensional observation position of the X-axis electric slide 6, which is used to capture visual images of the moving contact 4 and the stationary contact 9 using the three-dimensional topography measuring instruments 12 and 14 respectively.

[0094] Specifically, Figure 4 This is a schematic diagram of a three-dimensional point cloud captured by a three-dimensional topography measuring instrument when the X-axis electric slide 6 provided by this invention is located in a three-dimensional observation position. Figure 4 Figure a in the figure is a schematic diagram of the three-dimensional point cloud captured by the three-dimensional topography measuring instrument 12 used to capture the moving contact. When the X-axis electric slide 6 is moved to the three-dimensional observation position, the three-dimensional topography measuring instrument 12 used to capture the moving contact can obtain complete three-dimensional point cloud data of the surface of the moving contact 4 and part of the three-dimensional point cloud data of the front of the reference ruler 10, and can capture the coordinate origin. Figure 4 Figure b shows a schematic diagram of the three-dimensional point cloud captured by the three-dimensional topography measuring instrument 14 used to capture the static contact. When the X-axis electric slide 6 moves to the three-dimensional observation position, the three-dimensional topography measuring instrument 14 used to capture the static contact can obtain complete three-dimensional point cloud data of the surface of the static contact 9 and partial three-dimensional point cloud data of the back of the reference ruler 10. For example, Figure 4 As shown in Figure b, since the 3D topography measuring instrument can only acquire the height data of the surface of the object being photographed, it cannot acquire the 3D point cloud data of the scale line of the reference ruler 10 when photographing the back of the reference ruler 10.

[0095] Position 3: The industrial control computer 19 controls the X-axis electric slide 6 to move along the -X direction to a certain position, so that when the Z-axis electric slide 2 drives the moving contact clamp 3 and the moving contact 4 to move linearly along the Z direction, the moving contact 4 and the stationary contact 9 can perform closing and opening actions. This position is recorded in the industrial control computer 19 as the contact action position.

[0096] Step S22: The slide controller 7, in conjunction with the X-axis electric slide 6, moves the contact to the action position. The Z-axis electric slide 2 controls the moving contact 4 to move along the Z direction to simulate the contact closing and opening action. The displacement sensor 15 measures the displacement Δd1 of the moving contact 4 during the contact closing process.

[0097] Step S23: The slide controller 7, in conjunction with the X-axis electric slide 6, moves the slide to the camera observation position, and the industrial camera 11 used to capture the moving contact simultaneously acquires visual image data of the surface of the moving contact 4 [X]. m10 Y m10 The visual image data of the front of the reference ruler 10 is obtained, and the coordinates x of the origin in the visual image data are extracted. 01 ,y 01 The industrial camera 13 used for capturing images of stationary contacts 9 is used to simultaneously acquire visual image data of the surface of the stationary contact 9. [X] s10 ,Y s10 The visual image data of the back of the reference ruler 10 is obtained, and the coordinates x of the positioning point in the visual image data are extracted. 11 ,y 11 .

[0098] Step S24: The X-axis electric slide 6 is moved to the three-dimensional observation position by the slide controller 7 in conjunction with the X-axis electric slide 6. The displacement of the X-axis electric slide 6 from the camera observation position to the three-dimensional observation position is 1x. The three-dimensional topography measuring instrument 12 used to photograph the moving contact point is used to simultaneously acquire the three-dimensional point cloud data [X] of the surface of the moving contact point 4. m20 Y m20 Z m20 [X] and the three-dimensional point cloud data of the front surface of the reference ruler 10, and extract the Z coordinate z1 of the front surface plane of the reference ruler 10 in the three-dimensional point cloud data; use the three-dimensional topography measuring instrument 14 for photographing the static contact to obtain the three-dimensional point cloud data of the surface of the static contact 9 [X] s20 Y s20 Z s20 The three-dimensional point cloud data of the back of the reference ruler 10 is obtained, and the Z coordinate z2 of the back plane of the reference ruler 10 in the three-dimensional point cloud data is extracted.

[0099] In step S3, the restoration of the true spatial relationship between the moving contact 4 and the stationary contact 9, and the extraction of contact electrical ablation characteristic parameters, specifically include:

[0100] Step S31: Based on the data [X] obtained in step S23 m10 Y m10 ]、x 01 , y 01 [X] s10 Y s10 ]、x11 , y 11 Calculate the coordinates of the moving contact 4 surface and the stationary contact 9 surface in the XY plane of the global coordinate system when the X-axis electric slide 6 is located at the camera observation position. m11 Y m11 ] and [X s11 Y s11 The visual image data of moving contact 4 and stationary contact 9 are transformed into the global coordinate system. The specific formula is as follows:

[0101]

[0102] Step S32: Using the SIFT algorithm, obtain the visual image [X] of the moving contact point 4. m11 Y m11 Based on ], the three-dimensional point cloud data matrix [X] of the moving contact point 4 is analyzed. m20 Y m20 Z m20 Perform registration to obtain the registration rotation matrix R. m And the registration translation matrix T m According to [X] m20 Y m20 Z m20 ]、R m T m And z1, the three-dimensional point cloud data set [X] of the moving contact 4 in the global coordinate system is calculated. m Y m Z m The 3D point cloud data of the moving contact point 4 is transformed into the global coordinate system. The specific formula is as follows:

[0103]

[0104] Step S33: Convert the 3D point cloud data of static contact point 9 to the global coordinate system, as follows:

[0105] Step S331: According to [X] s11 Y s11 ] and 1x, calculate the set of XY plane coordinate points [X] of the surface of the stationary contact 9 in the global coordinate system when the X-axis electric slide 6 is located at the three-dimensional observation position. s12 Y s12 The specific formula is as follows:

[0106]

[0107] Step S332: For [X] s20 Y s20 Zs20 Perform a coordinate rotation transformation, rotating the 3D point cloud of the surface of stationary contact 9 by 180° around the Y-axis to obtain the 3D point cloud data set of the surface of stationary contact 9 after coordinate rotation transformation [X]. s21 Y s21 Z s21 The specific formula is as follows:

[0108]

[0109]

[0110] Step S333: Using the SIFT algorithm, obtain the visual image [X] of the static touch point 9. s12 Y s12 Based on ], its three-dimensional point cloud data matrix [X s21 Y s21 Z s21 Perform registration to obtain the registration rotation matrix R. s And the registration translation matrix T s The three-dimensional point cloud data set [X] of static contact point 9 after registration was calculated. s22 Y s22 Z s22 The specific formula is as follows:

[0111]

[0112] Step S334: According to [X] s22 Y s22 Z s22 Based on the thickness h of z2 and the reference ruler 10, the three-dimensional point cloud data set of the stationary contact 9 in the global coordinate system when the X-axis electric slide 6 is in the contact action position is calculated. s Y s Z s The 3D point cloud data of static contact point 9 is transformed into the global coordinate system. The specific formula is as follows:

[0113]

[0114] Step S34: Obtain the height data matrix Z in the global coordinate system from steps S32 and S33. m x, y and Z s Given x and y, calculate the shortest distance G between moving contact 4 and stationary contact 9. The specific formula is as follows:

[0115]

[0116] Step S35: Repeat steps S22-S24 and S31-S33 to obtain the height data matrix Z of the moving contact 4 and the stationary contact 9 in the global coordinate system after the i-th closure and break. m_i x, y and Z s_i x, y, and the height data matrix Z in the global coordinate system after the j-th closed segmentation. m_j x, y and Z s_j Using x and y, and combining the resolutions Δx and Δy of the 3D topography measuring instrument in the X and Y directions, calculate the volume change ΔV of the moving contact 4 and the stationary contact 9 from the i-th closure to the j-th closure. m and ΔV s The specific formula is as follows:

[0117]

[0118] In step S4, establishing virtual contact between the moving contact 4 and the stationary contact 9 and extracting contact interface feature parameters specifically includes:

[0119] Step S41: Based on the three-dimensional point cloud data set of the moving contact 4 and the stationary contact 9 in the global coordinate system when the X-axis electric slide 6 is in the contact action position, calculated in step S3 [X m Y m Z m ] and [X s Y s Z s ], and the displacement Δd of the moving contact 4, calculate the three-dimensional point cloud data set [X] of the virtual contact between the moving contact 4 and the stationary contact 9 in the closed state. m Y m Z m ] and [X s Y s Z s The height data matrices of moving contact 4 and stationary contact 9 are respectively represented by Z. m x, y and Z s x, y. The specific formula is as follows:

[0120]

[0121] Wherein, the displacement Δd of the moving contact 4 can be set to the displacement Δd1 of the moving contact 4 during the contact closing process measured by the displacement sensor 15 in step S22, then [X] can be obtained. m Y m Z m ] and [X s Y s Zs ] represents the three-dimensional point cloud data set of the moving contact 4 and the stationary contact 9 in a stable closed state; furthermore, the contact situation when the stroke of the moving contact 4 is different can be simulated by changing the displacement Δd of the moving contact 4.

[0122] Step S42: According to Z m x, y and Z s x, y Extract the data point set {a} within the contact area between moving contact 4 and stationary contact 9 under the stable closed state of the contacts. k The specific formula is as follows:

[0123]

[0124] Step S43: Ignore the extension of the contact material in the XY plane after contact, according to {a k The number of data points in} |a k |And the resolutions Δx and Δy of the 3D topography measuring instrument in the X and Y directions, to calculate the true contact area S under the stable closed state of the contact point. i The specific formula is as follows:

[0125]

[0126] This invention addresses the need for reproducing and in-situ evaluating the contact state after electro-ablation of contact materials. It proposes an in-situ extraction system for the electro-ablation morphology of contact materials and an in-situ evaluation method for the contact state. Through this invention, visual images and three-dimensional point clouds of the electro-ablation characteristics of contact materials can be extracted in-situ during contact electrical life experiments. Based on the visual image data and three-dimensional point cloud data, the true spatial relationship between the moving contact 4 and the stationary contact 9 can be reconstructed, establishing a virtual contact in the closed state of the contacts. Electro-ablation characteristic parameters of the contact materials can then be extracted, thereby evaluating the contact state of the contact materials during the electro-ablation process. It should be noted that in the above embodiments, any non-contradictory technical solutions can be permuted and combined. Those skilled in the art can exhaust all possibilities based on the mathematical knowledge of permutations and combinations. Therefore, this invention will not describe each permuted and combined technical solution individually, but it should be understood that the permuted and combined technical solutions have been disclosed by this invention.

[0127] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A system for in-situ extraction of the electroablation morphology of contact materials, characterized in that: Includes base plate (1), Z-axis electric slide (2), moving contact fixture (3), moving contact (4), spring (5), X-axis electric slide (6), Y-axis manual slide (7), stationary contact fixture (8), stationary contact (9), reference ruler (10), industrial camera for photographing moving contact (11), three-dimensional shape measuring instrument for photographing moving contact (12), industrial camera for photographing stationary contact (13), three-dimensional shape measuring instrument for photographing stationary contact (14), displacement sensor (15), power supply (16), load (17), control switch (18), industrial control computer (19), and microcontroller (20); An X-axis electric slide (6) is mounted on the base plate (1). A Y-axis manual slide (7), an industrial camera (11) for photographing moving contacts, and a three-dimensional shape measuring instrument (12) for photographing moving contacts are mounted on the X-axis electric slide (6). A stationary contact (9) is mounted on the Y-axis manual slide (7) through a stationary contact clamp (8). An industrial camera (13) for photographing static contacts, a three-dimensional shape measuring instrument (14) for photographing static contacts, and a displacement sensor (15) are also installed on the base plate (1). A Z-axis electric slide (2) is fixedly installed on the base plate (1). The Z-axis electric slide (2) has a moving contact (4) installed on it through a moving contact clamp (3). The moving contact clamp (3) contains the spring (5) inside, which is used to provide flexible contact for the contact to close. The reference ruler (10) is fixed on the base plate (1) and located between the moving contact (4) and the stationary contact (9). Its length direction is consistent with the movement direction of the X-axis electric slide (6). The industrial control computer (19) is electrically connected to the industrial camera (11) used to capture moving contacts, the industrial camera (13) used to capture stationary contacts, the three-dimensional shape measuring instrument (12) used to capture moving contacts, and the three-dimensional shape measuring instrument (14) used to capture stationary contacts, and is used to control the acquisition and processing of image and point cloud data. The microcontroller (20) is electrically connected to the industrial control computer (19), the Z-axis electric slide (2), the X-axis electric slide (6), the displacement sensor (15), and the control switch (18), respectively. The power supply (16), load (17) and control switch (18) are connected in series to form a load circuit, and the two ends of the load circuit are electrically connected to the moving contact clamp (3) and the stationary contact clamp (8) respectively.

2. The in-situ extraction system for the electroablation morphology of contact materials according to claim 1, characterized in that: The direction parallel to the front plane of the reference ruler (10) is defined as the XY plane, and the direction perpendicular to the plane and pointing away from the base plate (1) is defined as the +Z direction. The reference ruler (10) is made of transparent material, and the front of the ruler with the scale lines is parallel to the XY plane and faces the +Z direction.

3. The in-situ extraction system for the electroablation morphology of contact materials according to claim 2, characterized in that: The industrial camera (11) used to capture the moving contact and the three-dimensional shape measuring instrument (12) used to capture the moving contact are both fixed on the X-axis electric slide (6), and the shooting direction of both is perpendicular to the XY plane and towards the -Z direction.

4. The in-situ extraction system for the electroablation morphology of contact materials according to claim 3, characterized in that: The industrial camera (13) used to photograph static contacts and the three-dimensional shape measuring instrument (14) used to photograph static contacts are both fixed on the base plate (1), and the shooting direction of both is perpendicular to the XY plane and towards the +Z direction.

5. The in-situ extraction system for the electroablation morphology of contact materials according to claim 4, characterized in that: Both the three-dimensional topography measuring instrument (12) used for photographing moving contacts and the three-dimensional topography measuring instrument (14) used for photographing static contacts are snapshot-type three-dimensional topography measuring instruments.

6. The in-situ extraction system for the electroablation morphology of contact materials according to claim 5, characterized in that: The X-axis electric slide (6) moves in a direction parallel to the extension direction of the scale line on the front of the reference ruler (10), and when the X-axis electric slide (6) moves, it drives the Y-axis manual slide (7), the industrial camera (11) for capturing the moving contact and the three-dimensional shape measuring instrument (12) for capturing the moving contact to move synchronously.

7. The in-situ extraction system for the electroablation morphology of contact materials according to claim 5, characterized in that: Both the moving contact clamp (3) and the stationary contact clamp (8) are conductive, and an electrical connection is formed when the moving contact (4) and the stationary contact (9) are closed.

8. A method for in-situ extraction of the electro-ablation morphology of contact materials, implemented based on the in-situ extraction system for the electro-ablation morphology of contact materials as described in any one of claims 2-7, characterized in that, Includes the following steps: Step S1: Calibrate the industrial camera (11) for capturing moving contacts, the industrial camera (13) for capturing stationary contacts, the three-dimensional topography measuring instrument (12) for capturing moving contacts, the three-dimensional topography measuring instrument (14) for capturing stationary contacts, the X-axis electric slide (6), and the Z-axis electric slide (2), and establish a global coordinate system. Step S2: Extract visual image data and three-dimensional point cloud data of the electroablation features of the moving contact (4) and the stationary contact (9) in situ. Step S3: Restore the true spatial position relationship between the moving contact (4) and the stationary contact (9), and extract the electrical ablation characteristic parameters of the moving contact (4) and the stationary contact (9). Step S4: Establish a virtual contact between the moving contact (4) and the stationary contact (9), and extract the characteristic parameters of the contact interface.

Images