A load simulation method for soft start test of a cabinet and device thereof

Abstract

The application relates to a load simulation method and device for soft start test of a cabinet, and relates to the technical field of industrial cabinets. The method comprises the following steps: collecting rated power, rated output voltage and resistance parameters in response to a connection signal; reading a resistance threshold value from the resistance parameters; determining an impedance demand value; determining a reminding parameter and a switch demand state if the impedance demand value is not greater than the resistance threshold value; collecting an actual switch state of an indicator light; starting the test when the actual switch state is consistent with the switch demand state; determining an adjustment demand value according to the impedance demand value and the resistance threshold value if the impedance demand value is greater than the resistance threshold value; determining a series connection parameter by combining the adjustment demand value and the resistance parameter; controlling a corresponding test resistance to be connected in series based on the series connection parameter, updating the resistance parameter by combining the test resistance connected in series, and determining the reminding parameter and the switch demand state by combining the resistance parameter. The application has the effect of adapting to the soft start test requirements of cabinets of different powers and different types.

Description

Technical Field

[0001] This invention relates to the field of industrial cabinet technology, and in particular to a load simulation method and apparatus for cabinet soft-start testing. Background Technology

[0002] The soft starter mounted on the industrial cabinet can smoothly adjust the starting current and voltage to prevent damage to internal components such as contactors and fuses caused by the instantaneous surge current generated when the equipment starts up, while protecting the power supply line and the safe and stable operation of the downstream load equipment.

[0003] Currently, industrial cabinets must undergo soft-start testing before leaving the factory, after maintenance, and during on-site operation and maintenance to verify the effectiveness, accuracy, and reliability of their soft-start function. This testing has become a core component of electrical equipment quality control and safety assurance.

[0004] However, traditional testing solutions often use a single fixed resistor as the load, which can only simulate specific impedance conditions and is difficult to adapt to the soft-start testing requirements of different power and different models of cabinets. Summary of the Invention

[0005] To meet the soft-start testing requirements of cabinets with different power ratings and models, this invention provides a load simulation method and apparatus for cabinet soft-start testing.

[0006] In a first aspect, the present invention provides a load simulation method for rack soft-start testing, which adopts the following technical solution: A load simulation method for rack soft-start testing includes: Step 1: In response to the connection signal, acquire the rated power, rated output voltage, and resistance parameters; Step 2: Read the resistance value with the largest value from the resistance parameters and define it as the resistance threshold; Step 3: Determine the impedance requirement based on the rated power and rated output voltage; Step 4: If the impedance requirement is not greater than the resistance threshold, then determine the reminder parameters and switch requirement status by combining the impedance requirement and resistance parameters; Step 5: Control the on / off state of the preset reminder light based on the reminder parameters, and at the same time collect the actual status of the switch; Step 6: When the actual state of the switch matches the required state, start the test; Step 7: If the impedance requirement is greater than the resistance threshold, then determine the adjustment requirement based on the impedance requirement and the resistance threshold. Step 8: Determine the series parameters by combining the adjustment requirements and resistance parameters; Step 9: Control the corresponding test resistors to be connected in series based on the series parameters, and update the resistance parameters based on the series test resistors, then jump to step 4.

[0007] By adopting the above technical solution, based on the comparison between impedance requirement value and resistance threshold, the parallel or series path is automatically determined. The test is started after ensuring that the switch status is consistent with the requirement by linking the reminder parameter with the indicator light. After series expansion, the resistance parameter is automatically updated and the determination is cyclically performed to adapt to the load requirement range of different cabinets.

[0008] Optional methods for determining reminder parameters include: Step 40: Read the resistor number and its corresponding resistance value from the resistance parameters; Step 41: Determine the parallel combination and its corresponding parallel impedance value based on the resistor number and its corresponding resistance value, and then determine the total current by combining the parallel impedance value and the rated output voltage; Step 42: Select parallel combinations whose total current is less than the rated current and define them as safe parallel combinations; Step 43: Calculate the impedance difference based on the parallel impedance value of the safe parallel combination and the impedance requirement value; Step 44: Select the safe parallel combination with the smallest impedance difference and define it as the preferred parallel combination; Step 45: Match the corresponding resistor numbers by selecting the best parallel combination and form the reminder parameters.

[0009] By adopting the above technical solution, all possible parallel combinations are generated based on resistor numbers and resistance values. The total current is calculated in combination with the rated output voltage. Safe parallel combinations with a total current less than the rated current are strictly screened. Then, the optimal combination is selected based on the principle of minimum impedance difference, ensuring that the load impedance is highly compatible with the required value and improving the accuracy of soft-start testing.

[0010] Optional, preferred methods for determining parallel combinations include: Step 440: Determine the first deviation threshold based on the rated current, rated output voltage, and resistance parameters; Step 441: Extract the impedance difference with the smallest value and define it as the initial screening impedance difference; Step 442: If the initial screening impedance difference is greater than the first deviation threshold, issue a warning; Step 443: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is unique, then the corresponding safe parallel combination is defined as the preferred parallel combination. Step 4440: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is not unique, then obtain the number of parallel connections from the safe parallel combinations corresponding to the initial screening impedance difference. Step 4441: Define the safe parallel combination with the smallest number of parallel connections as the preferred parallel combination.

[0011] By adopting the above technical solution, a first deviation threshold is introduced as a screening criterion. When the minimum impedance difference exceeds the threshold, an alert is issued. In the case where the impedance difference is unique, the preferred parallel combination is directly locked. In the case where the difference is not unique, the combination with the fewest parallel connections is selected first. This simplifies the circuit connection and reduces the error caused by contact resistance while ensuring matching accuracy.

[0012] Optionally, the method for determining the first deviation threshold includes: Step 4400: Obtain the volatility coefficient; Step 4401: Determine the current fluctuation value based on the rated current and fluctuation coefficient; Step 4402: Read the resistance value accuracy of the corresponding resistor number in the safe parallel combination from the resistor parameters; Step 4403: Calculate the average accuracy based on the accuracy of all read resistance values; Step 4404: Calculate the current fluctuation adaptation value by combining the rated output voltage, current fluctuation value and rated current; Step 4405: Calculate the resistance accuracy compensation value by multiplying the rated output voltage and the average accuracy value; Step 4406: Calculate the first deviation threshold by summing the current fluctuation adaptation value and the resistance accuracy compensation value.

[0013] By adopting the above technical solution, combining the rated current and fluctuation coefficient to determine the current fluctuation value, adapting to the current fluctuation characteristics of the equipment itself, calculating the average accuracy based on the actual resistance value accuracy of the resistor, compensating for the influence of the resistor's own error on the matching result, and obtaining the first deviation threshold as the dynamic value corresponding to the equipment parameters, the test accuracy is improved.

[0014] Optionally, methods for determining the series parameters include: Step 80: Obtain the maximum number of resistors from the resistor parameters; Step 81: Determine several resistance ranges based on the resistance threshold and the maximum resistance quantity; Step 82: Define the resistance range into which the impedance requirement value falls as the initial screening resistance range; Step 83: Determine the series impedance value and its corresponding initial screening series parameters by combining the initial screening resistance range and all resistance values; Step 84: Update the first deviation threshold based on the resistance accuracy of the resistor number corresponding to the initial screening series parameters and define it as the second deviation threshold; Step 85: Select the unique initial series parameter by using the series impedance value, impedance requirement value, and second deviation threshold, and define it as the series parameter.

[0015] By adopting the above technical solution, the resistance range is first divided based on the maximum number of resistors, the initial screening resistance range corresponding to the impedance requirement value is quickly determined, the screening range of series combination is narrowed, the second deviation threshold is updated in combination with the resistance value accuracy, and finally the unique series parameter that meets the deviation requirement is selected.

[0016] Optionally, methods for selecting a unique initial series parameter by using the series impedance value, impedance requirement value, and second deviation threshold include: Step 850: Calculate the absolute deviation value by subtracting the series impedance value from the impedance requirement value; Step 851: If the absolute deviation value is greater than the second deviation threshold, issue a reminder; Step 852: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is unique, then define the corresponding initial screening series parameters as series parameters. Step 8530: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is not unique, then compare the series impedance value corresponding to the absolute deviation value. Step 8531: Define the series parameters by selecting the initial series parameters with the largest series impedance value.

[0017] By adopting the above technical solution, the absolute deviation value is compared with the second deviation threshold. When the threshold is exceeded, an alert is issued. If the absolute deviation value is unique, the series parameters are locked directly. If the absolute deviation value is not unique, the combination with the largest series impedance is selected first to avoid the soft start test failing to meet the rated load conditions due to insufficient impedance.

[0018] Optionally, after starting the test, the following will be included: Step 60: Obtain the structure number, define the corresponding activated structure number as the target number, and define the structure number adjacent to the target number as the adjustment number; Step 61: Determine the wind force value based on the impedance requirement value; Step 62: Collect the actual status, required status, and sliding distance of the switch corresponding to the adjustment number; Step 63: If the actual state of the switch is inconsistent with the required state of the switch, activate the preset flow guiding structure corresponding to the adjustment number based on the wind force value and obtain distance data; Step 640: When the distance data is not less than the sliding distance, control the analog structure corresponding to the adjustment number to move based on the sliding distance; Step 6410: When the distance data is less than the sliding distance, obtain the impedance requirement value corresponding to the target number and collect the running time; Step 6411: Determine the correction factor based on the impedance requirement and running time; Step 6412: Calculate and correct the wind force value according to the correction factor; Step 6413: Control the operation of the guide structure corresponding to the corrected wind force value.

[0019] By adopting the above technical solution, the simulation structure is divided into numbered zones. The flow guiding structure of the adjacent simulation structure that is not running is activated and moved out as a whole to optimize the heat dissipation flow field, thereby improving the heat dissipation effect of the target number. In case of insufficient removal distance, the correction coefficient is calculated using the impedance requirement value of the target number and the running time to make the wind power adjustment adapt to the load heating state.

[0020] Optional methods for obtaining distance data include: Step 630: Collect the recoil pressure value and match the standard pressure value and distance limit according to the wind force value; Step 631: When the recoil pressure value is consistent with the standard pressure value, use the upper limit of the distance as the distance data; Step 632: When the back pressure value is inconsistent with the standard pressure value, calculate the pressure difference based on the back pressure value and the standard pressure value; Step 633: Obtain distance data based on pressure difference matching.

[0021] By adopting the above technical solution, distance data is indirectly derived from the pressure signal based on the comparison between the back pressure value and the standard pressure value. When the back pressure is consistent with the standard pressure, the upper limit of the distance is directly used. When they are inconsistent, the distance data is matched by the pressure difference to compensate for the error caused by airflow fluctuations or structural resistance.

[0022] Secondly, the present invention provides a load simulation device for rack soft-start testing, which adopts the following technical solution: A load simulation device for rack soft-start testing, controlled by any of the above-mentioned load simulation methods for rack soft-start testing, includes a frame and a simulation structure installed inside the frame for performing soft-start testing on the rack. The simulation structure includes a connection interface for electrical connection with the cabinet and multiple sets of resistor components for electrical connection with the cabinet. The resistor assembly includes a switching power supply for providing power, several test resistors for increasing load impedance, several control switches for controlling the on / off state of the test resistors, and several indicator lights corresponding to the on / off state of the control switches. The test resistors, control switches, and indicator lights are configured in a one-to-one correspondence.

[0023] By adopting the above technical solution, the test resistors, control switches and indicator lights in the resistor assembly correspond one-to-one. The on / off status of the switch can be observed intuitively through the indicator lights, which is convenient for manual verification and fault diagnosis. Multiple sets of resistor assemblies can be flexibly combined and connected to the circuit through the corresponding control switches to adapt to cabinet soft start tests with different power and impedance requirements.

[0024] Optionally, the bottom of the frame is also fixedly equipped with several omnidirectional casters for controlling movement and several handles for easy manual gripping; The simulation structure is provided in several parts, which are arranged in sequence and located inside the frame and detachably connected to the frame. The simulation structure also includes a housing for supporting the connection interface and the resistor assembly, and several cooling fans fixedly installed on the side wall of the housing. The cooling fans are used to dissipate heat from the resistor assembly.

[0025] By adopting the above technical solutions, the universal pulleys at the bottom of the frame work in conjunction with the handle to facilitate flexible movement of the device in the test site, reducing transportation costs. The simulation structure and the frame are detachably connected, which facilitates the maintenance, replacement or expansion of individual modules, and improves the service life of the equipment. The heat dissipation fan on the side wall of the outer shell is designed to dissipate heat from the resistor components in a targeted manner, so as to dissipate the heat generated by the test resistor during the test in a timely manner.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: Based on the comparison between impedance requirement and resistance threshold, the system automatically determines whether to use a parallel or series path. It then triggers the test by linking indicator lights with reminder parameters and ensuring that the switch status matches the requirements. After series expansion, the system automatically updates the resistance parameters and performs cyclic checks to adapt to the load requirements of different cabinets. The simulation structure is divided into numbered sections. The flow guiding structure of the adjacent simulation structure that is not running is activated and moved out as a whole to optimize the heat dissipation flow field, thereby improving the heat dissipation effect of the target number. In case of insufficient removal distance, the correction coefficient is calculated using the impedance requirement value of the target number and the running time to make the wind power adjustment adapt to the load heating state. The test resistors, control switches, and indicator lights in the resistor assembly correspond one-to-one. The indicator lights allow for intuitive observation of the switch's on / off status, facilitating manual verification and troubleshooting. Multiple sets of resistor assemblies can be flexibly combined and connected to the circuit via corresponding control switches to adapt to soft-start tests of cabinets with different power and impedance requirements. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the load simulation device for rack soft-start testing according to this application; Figure 2 This is a partial schematic diagram of a load simulation device for rack soft-start testing according to this application; Figure 3 This is a schematic diagram of the simulated structure of this application; Figure 4 yes Figure 3 Enlarged view of point A in the middle; Figure 5This is a flowchart of a load simulation method for rack soft-start testing according to this application.

[0028] The parts referred to by the numbers in the above attached diagrams are as follows: 1. Frame; 2. Analog structure; 21. Shell; 22. Connection interface; 23. Resistor assembly; 231. Switching power supply; 232. Test resistor; 233. Control switch; 234. Indicator light; 24. Cooling fan; 3. Universal caster; 4. Handle. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0030] This invention discloses a load simulation device for rack soft-start testing.

[0031] Reference Figure 1 A load simulation device for rack soft-start testing includes a frame 1, a plurality of simulation structures 2 installed inside the frame 1 for performing soft-start testing on the rack, a plurality of universal casters 3 fixedly installed at the bottom of the frame 1 for controlling movement, and a number of handles 4 for easy manual gripping.

[0032] Reference Figure 2 , Figure 3 and Figure 4 The simulation structure 2 includes a connection interface 22 for electrical connection with the cabinet under test and multiple sets of resistor components 23 for electrical connection with the cabinet under test.

[0033] The resistor assembly 23 includes a switching power supply 231 for providing a power source, two test resistors 232 for increasing the load impedance, two control switches 233 for controlling the on / off state of the test resistors 232, and two indicator lights 234 corresponding to the on / off state of the control switches 233. The test resistors 232, control switches 233 and indicator lights 234 are set in a one-to-one correspondence.

[0034] Multiple simulation structures 2 are provided, arranged in sequence and located inside the frame 1 and detachably connected to the frame 1. The simulation structure 2 also includes a housing 21 for supporting the connection interface 22 and the resistor assembly 23, and multiple cooling fans 24 fixedly installed on the side wall of the housing 21. The cooling fans 24 are used to dissipate heat from the resistor assembly 23.

[0035] Insert the plug of the cabinet under test into the connection interface 22. The switching power supply 231 provides power to the control switch 233. Start the control switch 233 to complete the electrical connection between the corresponding test resistor 232 and the cabinet under test. At this time, the indicator light 234 will be constantly lit to indicate the start of the test. The cabinet under test is then soft-started to begin testing. By turning different control switches 233 on and off, the corresponding test resistor 232 can be connected into the circuit of the cabinet under test to achieve impedance control, thereby adapting to the testing requirements of different cabinets under test.

[0036] Based on the same inventive concept, embodiments of the present invention provide a load simulation method for rack soft-start testing.

[0037] refer to Figure 5 A load simulation method for rack soft-start testing includes the following steps: Step 1: In response to the connection signal, acquire the rated power, rated output voltage and resistance parameters.

[0038] The connection signal refers to the trigger signal generated by the system after the cabinet under test and the analog structure 2 establish a valid electrical connection through the connection interface 22. It is automatically output by the system when it detects that the loop connection between the cabinet and the analog structure 2 is on.

[0039] Rated power refers to the maximum active power that the cabinet under test can output when it is working stably for a long time. It is obtained by scanning the QR code with product information affixed to the surface of the cabinet under test. The staff scans and enters the information into the system in advance.

[0040] Rated output voltage refers to the standard voltage value that the output terminal should provide when the cabinet under test is working stably for a long time. It is obtained by scanning the QR code with product information affixed to the surface of the cabinet under test. The staff scans and enters the information into the system in advance.

[0041] Resistance parameters refer to the set of core electrical properties of all test resistors 232 in simulation structure 2, including the unique resistor number, resistance value, and resistance accuracy of each test resistor 232. Each test resistor 232 is tested and numbered in advance by the staff, and the results are integrated to form resistance parameters and entered into the system.

[0042] Step 2: Read the resistance value with the largest value from the resistance parameters and define it as the resistance threshold.

[0043] The resistance threshold is the largest resistance value among all the individual test resistors 232 extracted from the resistance parameters. The maximum value is selected from all the individual test resistors 232 through comparison and selection, which is defined as the resistance threshold.

[0044] Since all the test resistors 232 are usually connected in parallel, the maximum resistance value of the entire analog structure 2 is the value of the largest single test resistor 232, which is used as the resistance threshold.

[0045] Step 3: Determine the impedance requirement based on the rated power and rated output voltage.

[0046] The impedance requirement value refers to the load matching requirement of the cabinet under test for soft start testing, calculated using a formula based on the rated power and rated output voltage. The formula is: R 需求 =U 2 / P, where R 需求 Here, U represents the impedance requirement, U represents the rated output voltage, and P represents the rated power.

[0047] Step 4: If the impedance requirement value is not greater than the resistance threshold, then determine the reminder parameters and switch requirement status by combining the impedance requirement value and the resistance parameters.

[0048] The impedance requirement is no greater than the resistance threshold. The test resistor 232, representing the maximum single resistance value, can provide an impedance no less than the target load without the need for series expansion, only parallel adjustment.

[0049] The reminder parameters refer to the structured parameters corresponding to the set of target access test resistors 232 that are compatible with the impedance matching requirements. They include the unique resistor number of all test resistors 232 in the set and the reminder light control logic. They are used to guide the operator to accurately complete the on / off operation of the control switch 233. The specific determination method will be disclosed in detail in subsequent steps and will not be elaborated here.

[0050] The switch demand state refers to the target on / off state that the control switch 233 corresponding to each test resistor 232 should be in in order to ensure that the actual impedance of the simulation structure 2 meets the impedance demand value. After determining the test resistors 232 that need to be connected to the parallel circuit, the target state of the control switch 233 corresponding to the test resistors 232 that need to be connected is set to "closed", and the target state of the control switches 233 corresponding to the other test resistors 232 is set to "open". This is organized into a set of correspondences between resistor numbers and target states of control switches 233, which is the switch demand state.

[0051] The method for determining the reminder parameters includes the following steps: Step 40: Read the resistor number and its corresponding resistance value of test resistor 232 from the resistor parameters.

[0052] The resistor number is a unique identifier assigned to distinguish multiple test resistors 232. It is pre-set and numbered by the staff and integrated into the resistor parameters, and can be directly read here.

[0053] The resistance value refers to the actual resistance value measured before testing each test resistor 232. This value is obtained by the staff through prior testing and integrated into the resistance parameters, and can be read directly here.

[0054] Step 41: Determine the parallel combination and its corresponding parallel impedance value based on the resistor number and its corresponding resistance value, and then determine the total current by combining the parallel impedance value and the rated output voltage.

[0055] A parallel combination refers to a set of resistors formed by connecting multiple test resistors 232 in parallel topology. It is used to achieve different load impedances. Based on the resistor number and resistance value in the resistor parameters, all possible parallel connection methods of one or more test resistors are enumerated to form all potential parallel combinations.

[0056] The parallel impedance value refers to the total impedance corresponding to each parallel combination, which is calculated according to the parallel circuit impedance formula.

[0057] Total current refers to the total current in the circuit when the output voltage is applied across the parallel connection. It is calculated by dividing the rated output voltage by the parallel impedance value based on Ohm's law.

[0058] Step 42: Select parallel combinations whose total current is less than the rated current and define them as safe parallel combinations.

[0059] A safe parallel combination refers to a parallel combination whose total current is less than the rated current of the cabinet under test, so as not to cause overcurrent damage to the cabinet. Calculate the total current of each parallel combination and compare it with the rated current. The parallel combination whose value is less than the rated current value is defined as a safe parallel combination.

[0060] Step 43: Calculate the impedance difference based on the parallel impedance value of the safe parallel combination and the impedance requirement value.

[0061] Impedance difference refers to the absolute difference between the parallel impedance value and the impedance requirement value of a safe parallel combination. It is obtained by subtracting the impedance requirement value from the parallel impedance value and then calculating the absolute value.

[0062] Step 44: Select the safe parallel combination with the smallest impedance difference and define it as the preferred parallel combination.

[0063] The preferred parallel combination refers to the unique combination selected from the safe parallel combinations whose parallel impedance value is closest to the impedance requirement value. In other words, the safe parallel combination with the smallest impedance difference is defined as the preferred parallel combination. The specific determination method will be disclosed in detail in subsequent steps and will not be elaborated here.

[0064] The method for determining the preferred parallel combination includes the following steps: Step 440: Determine the first deviation threshold based on the rated current, rated output voltage, and resistance parameters.

[0065] The first deviation threshold is the critical value for judging whether the impedance difference is acceptable. It is determined based on the rated current, rated output voltage and resistance parameters. The specific determination method will be disclosed in detail in subsequent steps and will not be repeated here.

[0066] The method for determining the first deviation threshold includes the following steps: Step 4400: Obtain the volatility coefficient.

[0067] The fluctuation coefficient is a parameter used to quantify the allowable current deviation ratio in the soft-start test of the cabinet under test. It is obtained by scanning the QR code with product information affixed to the surface of the cabinet under test. The staff scans and enters the information into the system in advance. In this embodiment, the fluctuation coefficient is 0.08.

[0068] Step 4401: Determine the current fluctuation value based on the rated current and the fluctuation coefficient.

[0069] The current fluctuation value refers to the maximum allowable current deviation during the cabinet soft-start test. It is calculated by multiplying the rated current and the fluctuation coefficient to ensure that the test current does not exceed the safe range.

[0070] Step 4402: Read the resistance value accuracy of the corresponding resistor number in the safe parallel combination from the resistance parameters.

[0071] Resistance accuracy refers to the percentage deviation between the actual resistance value and the nominal resistance value. It is obtained by the staff through prior testing and integrated into the resistance parameters, and can be read directly here.

[0072] Step 4403: Calculate the average accuracy based on the accuracy of all read resistance values.

[0073] Average accuracy refers to the average value of the accuracy of all resistors in a safe parallel combination, calculated by weighting the values ​​of all read resistance accuracy.

[0074] Step 4404: Calculate the current fluctuation adaptation value by combining the rated output voltage, current fluctuation value and rated current.

[0075] The current fluctuation tolerance value refers to the upper limit of the equivalent impedance deviation corresponding to the current fluctuation value. It is calculated using the formula: Current fluctuation tolerance value = U * I 允 / I 额 2 Where U is the rated output voltage, I 允 I represents the current fluctuation value. 额 This is the rated current.

[0076] Step 4405: Calculate the resistance accuracy compensation value by multiplying the rated output voltage and the average accuracy value.

[0077] Resistance accuracy compensation value refers to the amount of compensation used to offset the influence of the resistor's own accuracy deviation on impedance matching. It is obtained by multiplying the rated output voltage value with the average accuracy value. The unit of resistance accuracy compensation value is ohms, and the unit of rated output voltage is volts. The product of rated output voltage and average accuracy is the degree of voltage change. Since resistance and voltage are proportional, this degree of change is also the degree of resistance change, i.e., the resistance accuracy compensation value.

[0078] Step 4406: Calculate the first deviation threshold by summing the current fluctuation adaptation value and the resistance accuracy compensation value.

[0079] The result obtained by summing the current fluctuation adaptation value and the resistance accuracy compensation value is used as the first deviation threshold.

[0080] Step 441: Extract the impedance difference with the smallest value and define it as the initial screening impedance difference.

[0081] The initial screening impedance difference refers to the impedance difference with the smallest value among all safe parallel combinations. All impedance differences are sorted, and the impedance difference with the smallest value is selected and defined as the initial screening impedance difference.

[0082] Step 442: If the impedance difference of the initial screening is greater than the first deviation threshold, issue a reminder.

[0083] If the initial impedance difference exceeds the first deviation threshold, it means the impedance deviation exceeds the allowable range, the impedance matching accuracy is insufficient, and the system cannot be used. The system will issue a warning.

[0084] Step 443: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is unique, then the corresponding safe parallel combination is defined as the preferred parallel combination.

[0085] The preferred parallel combination refers to the optimal connection scheme that meets the impedance matching accuracy requirements and is easy to operate from multiple parallel connection methods of test resistors 232. The parallel scheme with safe total current and impedance closest to the required value is selected as the preferred parallel combination. If the result is not unique, the scheme with fewer resistors is selected.

[0086] If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is unique, representing a unique impedance deviation that does not exceed the allowable range, the safe parallel combination corresponding to the initial screening impedance difference is defined as the preferred parallel combination.

[0087] Step 4440: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is not unique, then obtain the parallel quantity from the safe parallel combination corresponding to the initial screening impedance difference.

[0088] The fact that the initial screening impedance difference is not unique means that there are multiple initial screening impedance differences that meet the requirement that the impedance deviation does not exceed the allowable range, and further screening is required.

[0089] The number of parallel connections refers to the number of test resistors 232 included in the safe parallel combination corresponding to the initial screening impedance difference. During the enumeration of all parallel combinations, the number of test resistors 232 included in each combination is counted simultaneously and entered into the system as the number of parallel connections. This number can be directly read here.

[0090] Step 4441: Define the safe parallel combination with the smallest number of parallel connections as the preferred parallel combination.

[0091] By comparing the number of parallel connections read from the safe parallel combinations corresponding to the impedance difference in the initial screening, the safe parallel combination with the smallest number of parallel connections is defined as the preferred parallel combination.

[0092] Step 45: Match the corresponding resistor numbers by selecting the best parallel combination and form the reminder parameters.

[0093] Based on the optimal parallel combination, the corresponding resistor number is matched, and the target state of the corresponding reminder light is set to "always on". The set is formed by combining the resistor number and the target state, which is the reminder parameter.

[0094] Step 5: Control the on / off state of the preset reminder light based on the reminder parameters, and at the same time collect the actual status of the switch.

[0095] The reminder light is an indicator device that corresponds one-to-one with the test resistor 232, the control switch 233, and the indicator light 234. It provides feedback on the switch's required state through its illumination status. In this embodiment, an LED light is used.

[0096] The actual state of the switch refers to the current physical on / off state of the control switch that corresponds one-to-one with the test resistor. This state is determined by reading the switch level signal corresponding to the test resistor from the system.

[0097] Step 6: When the actual state of the switch matches the required state, start the test.

[0098] The fact that the actual state of the switch matches the required state means that the actual on / off state of all control switches 233 is completely matched with the target state, the load impedance meets the test requirements, and the test operation can begin.

[0099] After starting the test, the following steps are included: Step 60: Obtain the structure number, define the corresponding activated structure number as the target number, and define the structure number adjacent to the target number as the adjustment number.

[0100] The structure number is a unique identifier assigned to distinguish multiple simulated structures 2 arranged vertically. Each simulated structure 2 is numbered in advance by the staff, and the results are entered into the system.

[0101] The target number refers to the structure number of the simulation structure 2 that is currently running the soft-start test. It is the target object for heat dissipation optimization. The structure number corresponding to the simulation structure 2 that has started the test is defined as the target number.

[0102] The adjustment number refers to the structure number of the simulation structure 2 that is adjacent to the target number simulation structure 2. Based on the sorting logic of the structure number, the preceding and following numbers of the target number are extracted. For example, if the target number is S2, the adjustment numbers are S1 and S3, and a maximum of 2 adjacent numbers can be taken.

[0103] Step 61: Determine the wind force value based on the impedance requirement value.

[0104] Wind force value is a parameter for guiding the operational intensity of the airflow structure. Wind force levels are classified according to impedance requirements. The greater the impedance, the stronger the heat generation, and the higher the wind force value. The corresponding wind force value is found in the wind force correspondence table based on the impedance requirement value. The wind force correspondence table is a data table that records different impedance requirements and their corresponding wind force values. It is obtained by technicians through prior testing and will not be elaborated on here.

[0105] Step 62: Collect the actual status, required status, and sliding distance of the switch corresponding to the adjustment number.

[0106] The sliding distance refers to the target distance that the non-operational adjustment number simulation structure 2 needs to be moved horizontally. It is determined by the staff based on the experimental measurement of the distance that the simulation structure 2 can be moved horizontally, while avoiding affecting the stability of the load simulation device after the movement. The final target distance is pre-entered into the system and can be directly read here.

[0107] Step 63: If the actual state of the switch is inconsistent with the required state of the switch, activate the preset flow guiding structure corresponding to the wind force value and obtain distance data.

[0108] If the actual state of the switch is inconsistent with the required state, it means that the actual on / off state of the control switch 233 corresponding to all test resistors 232 does not match the required state. The test has not been started, and the switch can be moved out for heat dissipation.

[0109] The airflow guiding structure is a device installed on the simulation structure 2 to guide airflow. It is fixedly installed at one end of the simulation structure 2 in the direction of movement, and it conducts heat out of the inside of the simulation structure 2. At the same time, it also guides the hot air inside the simulation structure 2 at adjacent positions to improve the heat dissipation effect.

[0110] Distance data refers to the actual distance between obstacles and the guide structure on the movement path. It is used to determine whether the guide structure can be safely moved out. The specific method for obtaining this data will be disclosed in detail in subsequent steps and will not be elaborated here.

[0111] The method for obtaining distance data includes the following steps: Step 630: Collect the back pressure value and match the standard pressure value and distance limit according to the wind force value.

[0112] The back pressure value is the reverse pressure generated when the airflow encounters an obstacle during the operation of the guide flow structure. It is obtained in real time by a pressure sensor pre-installed at the air outlet of the guide flow structure.

[0113] The standard pressure value refers to the baseline pressure value under "obstacle-free" conditions corresponding to the current wind force value.

[0114] The maximum distance refers to the maximum detection distance when there are no obstacles matching the current wind force value.

[0115] Based on the wind force value, the corresponding standard pressure value and distance limit can be found in the pressure-distance correspondence table. The pressure-distance correspondence table is a data table that records different wind force values ​​and their corresponding standard pressure values ​​and distance limits. It is obtained by technicians through pre-testing and will not be elaborated on here.

[0116] Step 631: When the back pressure value is consistent with the standard pressure value, the upper limit of the distance is used as the distance data.

[0117] If the back pressure value is the same as the standard pressure value, it means that there are no obstacles within the detection range of the flow guide structure. In this case, the upper limit of distance can be used as the distance data.

[0118] The upper limit of the distance is always greater than the sliding distance to avoid collisions of the guide structure during the removal process due to the inability to detect obstacles beyond the sliding distance.

[0119] Step 632: When the back pressure value is inconsistent with the standard pressure value, calculate the pressure difference based on the back pressure value and the standard pressure value.

[0120] The discrepancy between the back pressure value and the standard pressure value indicates that the airflow encountered an obstacle in the movement path during the operation of the guide structure, causing the back pressure value to deviate from the standard pressure value under the condition of no obstacle.

[0121] The pressure difference refers to the absolute difference between the recoil pressure value and the standard pressure value. It is used to estimate the distance to obstacles and is obtained by subtracting the standard pressure value from the recoil pressure value and then calculating the absolute value.

[0122] Step 633: Obtain distance data based on pressure difference matching.

[0123] The larger the pressure difference, the larger the distance data. The corresponding distance data is retrieved from the distance correspondence table based on the pressure difference. The distance correspondence table is a data table that records different pressure differences and their corresponding distance data. It is obtained by technicians through prior testing and will not be elaborated on here.

[0124] Step 640: When the distance data is not less than the sliding distance, control the analog structure 2 corresponding to the adjustment number to move based on the sliding distance.

[0125] If the distance data is not less than the sliding distance, it means that the actual distance between the obstacle on the movement path and the simulated structure 2 meets the preset removal requirements. When the simulated structure 2 moves according to the sliding distance, no collision will occur, and the removal operation can be safely performed.

[0126] Step 6410: When the distance data is less than the sliding distance, obtain the impedance requirement value corresponding to the target number and collect the running time.

[0127] If the distance data is less than the sliding distance, it means that the actual distance between the obstacle on the moving path and the simulated structure 2 has not reached the preset removal requirement. If the movement is made according to the sliding distance, there will be a risk of collision.

[0128] Running time refers to the cumulative duration of time that the simulation structure 2 corresponding to the target number remains in a loaded running state after the test is started. When the actual state of the switch is consistent with the required state of the switch and the test is started, the timing module corresponding to the simulation structure 2 of the target number will automatically start timing to obtain the running time.

[0129] Step 6411: Determine the correction factor based on the impedance requirement and running time.

[0130] The correction factor is a coefficient derived quantified from impedance demand and operating time. It is used to adjust the wind speed value of the regulation number to improve heat dissipation. It is calculated using the formula: k = (k1 * R) 需求 / 100)+(k2*t / 60), where k1 is the weighting coefficient of the impedance requirement value to the wind force value correction, and k2 is the weighting coefficient of the operating time to the wind force value correction. The values ​​are both in the range of 0 to 1, and k1+k2=1. They are preset by the staff and entered into the system. k is the correction coefficient, R requirement is the impedance requirement value, and t is the operating time. Ensure that the correction coefficient is between 0.1 and 1 to prevent wind overload from causing the flow guide structure to fail.

[0131] Step 6412: Calculate and correct the wind force value according to the correction factor.

[0132] Substitute the correction factor and wind force value into the formula to calculate the corrected wind force value. The formula is: Corrected wind force value = Original wind force value * (1 + correction factor).

[0133] Step 6413: Control the operation of the guide structure corresponding to the corrected wind force value.

[0134] Based on the corrected wind force value, the operation of the guiding structure corresponding to the number is adjusted to increase the air volume it blows out, thereby guiding the hot air away from the simulation structure 2 more quickly and improving the heat dissipation effect.

[0135] Step 7: If the impedance requirement is greater than the resistance threshold, then determine the adjustment requirement based on the impedance requirement and the resistance threshold.

[0136] If the impedance requirement is greater than the resistance threshold, it means that a single maximum resistance resistor cannot meet the target impedance, and the total impedance needs to be expanded by series connection.

[0137] The adjustment requirement value refers to the additional impedance increment required to achieve the impedance requirement value, which is calculated by subtracting the resistance threshold from the impedance requirement value.

[0138] Step 8: Determine the series parameters by combining the adjustment requirements and resistance parameters.

[0139] Series parameters refer to a set of structured parameters that correspond one-to-one with the series schemes that meet the impedance matching requirements. They include information such as the unique resistor number and series quantity of all test resistors 232 in the connection method. Based on the resistor parameters, all possible series connection methods of test resistors 232 are enumerated, and the resistor number and series quantity in each connection method are integrated to obtain the series parameters.

[0140] The method for determining the series parameters includes the following steps: Step 80: Obtain the maximum number of resistors from the resistor parameters.

[0141] The maximum number of resistors refers to the total number of test resistors 232 whose resistance values ​​are equal to the resistance threshold in the resistance parameters of the simulated structure 2. In the step of determining the resistance threshold, the number of test resistors 232 whose resistance values ​​are equal to the resistance threshold value is identified simultaneously, defined as the maximum number of resistors, and integrated into the resistance parameters. This number can be directly read here.

[0142] Step 81: Determine several resistance ranges based on the resistance threshold and the maximum resistance quantity.

[0143] Resistance range refers to multiple impedance ranges divided based on resistance thresholds and the maximum number of resistors. This range is used to narrow down the selection of series parameters, with the lower limit being n*R. 阈值 The upper limit of the interval is (n+1)*R 阈值 n starts from 1 and increases until the upper limit of the interval is not less than the adjustment demand value, such as R. 阈值 If the value is 10 and the maximum number of resistors is 3, then the resistance ranges are (10, 20), (20, 30) and (30, 40).

[0144] Step 82: Define the resistance range into which the impedance requirement value falls as the initial screening resistance range.

[0145] The initial screening resistance range refers to the resistance range where the adjustment demand value is located. Series parameters are screened only within this range. The adjustment demand value is compared with the range of all resistance ranges to determine the resistance range containing the adjustment demand value.

[0146] Step 83: Determine the series impedance value and its corresponding initial screening series parameters by combining the initial screening resistance range and all resistance values.

[0147] The series impedance value refers to the total impedance corresponding to each series parameter, and is calculated according to the series circuit impedance formula.

[0148] The initial screening series parameters refer to the structured parameter set corresponding to all possible series schemes within the initial screening resistance range. It involves enumerating all series combinations of one or more resistors within the initial screening resistance range, calculating the series impedance value of each combination, and extracting information such as resistor number and quantity to form the initial screening series parameters.

[0149] Step 84: Update the first deviation threshold based on the resistance accuracy of the resistor number corresponding to the initial screening series parameters and define it as the second deviation threshold.

[0150] The second deviation threshold refers to the critical value after correction of the resistance value accuracy in the initial screening series parameters. Following the derivation logic of the first deviation threshold, the average accuracy is replaced with the weighted average accuracy of the resistance in the initial screening series combination. The current fluctuation adaptation value and accuracy compensation value are recalculated, and the sum is the second deviation threshold.

[0151] Step 85: Select the unique initial series parameter by using the series impedance value, impedance requirement value, and second deviation threshold, and define it as the series parameter.

[0152] From the initial screening of series parameters, the unique set of structured parameters that meet the impedance matching accuracy requirements is selected by quantitative comparison of series impedance value, impedance requirement value and second deviation threshold. The specific selection method will be disclosed in detail in subsequent steps and will not be elaborated here.

[0153] The method for selecting a unique initial series parameter by using the series impedance value, the impedance requirement value, and the second deviation threshold includes the following steps: Step 850: Calculate the absolute deviation value by subtracting the series impedance value from the impedance requirement value.

[0154] The absolute deviation value refers to the absolute difference between the series impedance value and the impedance requirement value of the series combination. It is obtained by subtracting the impedance requirement value from the series impedance value and then calculating the absolute value.

[0155] Step 851: If the absolute deviation value is greater than the second deviation threshold, issue a reminder.

[0156] An absolute deviation value greater than the second deviation threshold indicates that the deviation between the series impedance value corresponding to the initial screening series parameter and the impedance requirement value exceeds the allowable accuracy range. The corresponding series connection method cannot meet the impedance matching requirements of the test, and staff should be notified by issuing a reminder.

[0157] Step 852: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is unique, then define the corresponding initial screening series parameters as series parameters.

[0158] An absolute deviation value that is not greater than the second deviation threshold and whose absolute deviation value uniquely represents that the deviation between the series impedance value corresponding to one and only one initial screening series parameter and the impedance requirement value is within the allowable accuracy range can be directly defined as a series parameter for subsequent operations.

[0159] Step 8530: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is not unique, then compare the series impedance value corresponding to the absolute deviation value.

[0160] An absolute deviation value not exceeding the second deviation threshold and an absolute deviation value that is not unique indicates that there are two or more initial screening series parameters whose deviations from the required impedance value are within the allowable accuracy range, and further comparison and screening are required.

[0161] Step 8531: Define the series parameters by selecting the initial series parameters with the largest series impedance value.

[0162] By comparing the series impedance values ​​corresponding to the absolute deviation values, the initial screening series parameter with the largest series impedance value is defined as the series parameter.

[0163] Step 9: Control the corresponding test resistor 232 to be connected in series based on the series parameters, and update the resistance parameters based on the series test resistor 232, then jump to step 4.

[0164] Based on the series parameter control, the corresponding test resistor 232 is connected in series. The series test resistor 232 can be regarded as a single test resistor 232. Therefore, the resistance parameters need to be updated and corrected. At this time, the impedance requirement value must not be greater than the resistance threshold. Jump to step 4 to continue the operation before test start.

[0165] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A load simulation method for rack soft-start testing, characterized in that, include: Step 1: In response to the connection signal, acquire the rated power, rated output voltage, and resistance parameters; Step 2: Read the resistance value with the largest value from the resistance parameters and define it as the resistance threshold; Step 3: Determine the impedance requirement based on the rated power and rated output voltage; Step 4: If the impedance requirement is not greater than the resistance threshold, then determine the reminder parameters and switch requirement status by combining the impedance requirement and resistance parameters; Step 5: Control the on / off state of the preset reminder light based on the reminder parameters, and at the same time collect the actual status of the switch; Step 6: When the actual state of the switch matches the required state, start the test; Step 7: If the impedance requirement is greater than the resistance threshold, then determine the adjustment requirement based on the impedance requirement and the resistance threshold. Step 8: Determine the series parameters by combining the adjustment requirements and resistance parameters; Step 9: Control the corresponding test resistor (232) to be connected in series based on the series parameters, and update the resistance parameters based on the series test resistor (232), then jump to step 4; The methods for determining the reminder parameters include: Step 40: Read the resistor number and its corresponding resistance value of the test resistor (232) from the resistance parameters; Step 41: Determine the parallel combination and its corresponding parallel impedance value based on the resistor number and its corresponding resistance value, and then determine the total current by combining the parallel impedance value and the rated output voltage; Step 42: Select parallel combinations whose total current is less than the rated current and define them as safe parallel combinations; Step 43: Calculate the impedance difference based on the parallel impedance value of the safe parallel combination and the impedance requirement value. The impedance difference refers to the absolute difference between the parallel impedance value of the safe parallel combination and the impedance requirement value. Step 44: Select the safe parallel combination with the smallest impedance difference and define it as the preferred parallel combination; Step 45: Match the corresponding resistor numbers by selecting the optimal parallel combination and form the reminder parameters; Methods for determining preferred parallel combinations include: Step 440: Determine the first deviation threshold based on the rated current, rated output voltage, and resistance parameters. The first deviation threshold is the critical value for judging whether the impedance difference is acceptable, and it is determined based on the rated current, rated output voltage, and resistance parameters. Step 441: Extract the impedance difference with the smallest value and define it as the initial screening impedance difference; Step 442: If the initial screening impedance difference is greater than the first deviation threshold, issue a warning; Step 443: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is unique, then the corresponding safe parallel combination is defined as the preferred parallel combination. Step 4440: If the initial screening impedance difference is not greater than the first deviation threshold and the initial screening impedance difference is not unique, then obtain the number of parallel connections from the safe parallel combinations corresponding to the initial screening impedance difference. Step 4441: Define the safe parallel combination with the minimum number of parallel connections as the preferred parallel combination; The methods for determining the first deviation threshold include: Step 4400: Obtain the volatility coefficient; Step 4401: Determine the current fluctuation value based on the rated current and fluctuation coefficient; Step 4402: Read the resistance value accuracy of the corresponding resistor number in the safe parallel combination from the resistor parameters; Step 4403: Calculate the average accuracy based on the accuracy of all read resistance values; Step 4404: Calculate the current fluctuation adaptation value by combining the rated output voltage, current fluctuation value, and rated current. The current fluctuation adaptation value refers to the upper limit of the equivalent impedance deviation corresponding to the current fluctuation value, which is obtained by the formula: Current fluctuation adaptation value = U * I 允 / I 额 2 Where U is the rated output voltage, I 允 I represents the current fluctuation value. 额 Rated current; Step 4405: Calculate the resistance accuracy compensation value by multiplying the rated output voltage and the average accuracy. Step 4406: Calculate the first deviation threshold by summing the current fluctuation adaptation value and the resistance accuracy compensation value.

2. The load simulation method for rack soft-start testing according to claim 1, characterized in that, Methods for determining series parameters include: Step 80: Obtain the maximum number of resistors from the resistor parameters; Step 81: Determine several resistance ranges based on the resistance threshold and the maximum resistance quantity; Step 82: Define the resistance range into which the impedance requirement value falls as the initial screening resistance range; Step 83: Combine the initial screening resistance range and all resistance values ​​to determine the series impedance value and its corresponding initial screening series parameters. The initial screening series parameters refer to the set of structured parameters corresponding to all possible series schemes within the initial screening resistance range. Enumerate all series combinations of one or more resistors within the initial screening resistance range, calculate the series impedance value of each combination, extract the resistor number and quantity information, and form the initial screening series parameters. Step 84: Update the first deviation threshold based on the resistance accuracy of the resistor number corresponding to the initial screening series parameters and define it as the second deviation threshold; Step 85: Select the unique initial series parameter by using the series impedance value, impedance requirement value, and second deviation threshold, and define it as the series parameter.

3. The load simulation method for rack soft-start testing according to claim 2, characterized in that, Methods for selecting unique initial series parameters based on series impedance value, impedance requirement value, and second deviation threshold include: Step 850: Calculate the absolute deviation value by subtracting the series impedance value from the impedance requirement value; Step 851: If the absolute deviation value is greater than the second deviation threshold, issue a reminder; Step 852: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is unique, then define the corresponding initial screening series parameters as series parameters. Step 8530: If the absolute deviation value is not greater than the second deviation threshold and the absolute deviation value is not unique, then compare the series impedance value corresponding to the absolute deviation value. Step 8531: Define the series parameters by selecting the initial series parameters with the largest series impedance value.

4. A load simulation device for rack soft-start testing, controlled by a load simulation method for rack soft-start testing as described in any one of claims 1 to 3, comprising a frame (1), characterized in that, It also includes a simulation structure (2) installed inside the frame (1) for soft-start testing of the cabinet; The simulation structure (2) includes a connection interface (22) for electrical connection with the cabinet and multiple sets of resistor components (23) for electrical connection with the cabinet. The resistor assembly (23) includes a switching power supply (231) for providing a power source, several test resistors (232) for increasing the load impedance, several control switches (233) for controlling the on / off state of the test resistors (232), and several indicator lights (234) corresponding to the on / off state of the control switches (233). The test resistors (232), control switches (233) and indicator lights (234) are set in a one-to-one correspondence.

5. The load simulation device for rack soft-start testing according to claim 4, characterized in that, The bottom of the frame (1) is also fixedly equipped with several universal pulleys (3) for controlling movement and several handles (4) for easy manual gripping. The simulation structure (2) is provided in several parts. The simulation structure (2) is arranged in sequence and located inside the frame (1) and detachably connected to the frame (1). The simulation structure (2) also includes a housing (21) for carrying the connection interface (22) and the resistor assembly (23) and several cooling fans (24) fixedly installed on the side wall of the housing (21). The cooling fans (24) are used to dissipate heat from the resistor assembly (23).

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