A multi-channel surge automated test system and a test method thereof

Abstract

The application relates to the technical field of electromagnetic compatibility test, and discloses a multi-channel surge automatic test system and a test method thereof, the system comprising a control host, a surge signal generator and a multi-channel coupling decoupling network, the three being networked through Ethernet communication; the control host is integrated with an automatic test software module and an embedded control system module, realizes man-machine interaction, test sequence arrangement, instruction analysis and cooperative control; the surge signal generator receives instructions and accurately generates a surge pulse signal conforming to a standard, supports synchronous phase triggering; the multi-channel coupling decoupling network realizes automatic multi-configuration switching of test channels through a loop switching system composed of solid-state switch units. The application realizes full-process automation of surge test, eliminates human operation errors, eliminates high-voltage operation safety hazards, greatly improves test efficiency and result reliability, and has good scalability and adapts to complex test requirements.

Description

Technical Field

[0001] This invention relates to the field of electromagnetic compatibility testing technology, specifically to a multi-channel automated surge testing system and its testing method. Background Technology

[0002] Surge immunity testing is a core test item in the field of electromagnetic compatibility testing. Its core purpose is to evaluate the ability of electrical or electronic equipment to withstand high-energy transient overvoltage surges from power lines and interconnected signal lines. This test must strictly follow the IEC61000-4-5 international standard and equivalent national standards (such as GB / T17626.5).

[0003] In standard test configurations, surge pulses need to be applied to the device under test (EUT) through a coupling / decoupling network (CDN). For single-phase power port devices, multiple line combination tests, such as line-to-line, line-to-protective ground, and line-to-line with reverse polarity, need to be covered. For multi-phase devices and multi-communication port devices, the number of channel combinations to be tested increases exponentially.

[0004] Currently, surge testing still relies primarily on traditional manual operation. Testers must manually complete the coupling / decoupling network wiring, surge generator parameter settings, and surge application. After each test, power must be cut off and wiring manually replaced before proceeding to the next test. This operation mode has many technical drawbacks:

[0005] Extremely low testing efficiency: Manual wiring, inspection, parameter resetting and other auxiliary operations take far longer than the effective testing time. For basic combination testing of simple single-phase three-port equipment, auxiliary operations can take tens of minutes or even hours. The complete surge test cycle of complex industrial equipment can take several days, becoming a bottleneck in product development, certification and production processes.

[0006] Poor reliability and repeatability of test results: Frequent plugging and unplugging of wiring can easily lead to human wiring errors such as incorrect connection, missing connection, and loose connection, resulting in invalid test or even damage to the device under test; When manually setting the voltage, phase angle and other parameters of the surge generator, it is easy to misread or input the wrong parameters; In synchronous phase test, manual operation cannot guarantee that the surge pulse is accurately injected at the specified phase angle of the AC power supply, and the test consistency cannot meet the high standard verification requirements.

[0007] Significant safety hazards exist: surge testing involves high-voltage pulses of several thousand to tens of thousands of volts. Test personnel need to be in close contact with live terminals to complete wiring operations. Electric shock accidents can easily occur when fatigued or negligent.

[0008] Unable to meet complex testing requirements: As product complexity increases and testing standards evolve, complex testing scenarios such as synchronous phase testing and multi-port continuous stress testing are becoming more common. Manual operation is not only difficult to implement, but also cannot achieve the testing objectives due to inherent inaccuracies.

[0009] Existing programmable surge generators on the market only have automation functions limited to remote control of their own parameters. The core step of test loop switching still relies on manual operation. Therefore, there is an urgent need in this field for an automated surge testing solution that integrates the entire process of test loop switching, parameter setting, and trigger execution. Summary of the Invention

[0010] To address the shortcomings of existing technologies, this invention provides a multi-channel automated surge testing system that automates the entire surge testing process, solving the problems of low efficiency, poor reliability, insufficient safety, and inability to execute complex test sequences by manual operation. At the same time, it ensures the consistency and repeatability of test results and improves the scalability and ease of operation of the system.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] A multi-channel automated surge testing system includes a control host, a surge signal generator, and a multi-channel coupling-decoupling network. The three are networked via Ethernet communication to form an integrated automated testing system.

[0013] Control host: As the core control unit of the system, it is the "brain" of the system, and undertakes the responsibilities of command, scheduling and monitoring. It consists of an automatic test software module and an embedded control system module, which work together.

[0014] Automatic testing software module: running on an industrial-grade computer hardware platform, providing a graphical human-computer interaction interface, realizing project management and parameter editing, test sequence arrangement, process monitoring and data management functions, supporting the creation, saving and loading of test projects, editing of complex test parameters such as surge voltage level, waveform parameters, and synchronization phase angle, arranging multi-step test sequences by drag and drop or script, displaying system status and test results in real time, and automatically recording and storing test data;

[0015] Embedded control system module: As a "bridge" between upper-level software and lower-level hardware, it consists of microcontroller units and their peripheral circuits. It realizes the functions of instruction reception and parsing, instruction distribution and collaborative control, and status feedback. It strictly sends instructions to the multi-channel coupling and decoupling network and surge signal generator according to the timing sequence, and collects equipment status information in real time and uploads it to the automatic test software module.

[0016] Surge signal generator: It has remote control capability, receives instructions from the control host and accurately generates high-energy surge pulse waveforms that conform to standards such as IEC61000-4-5. It contains a communication and control module and a surge signal generation circuit. The communication and control module converts digital instructions into internal circuit control signals. The surge signal generation circuit generates surge pulses under its drive and supports synchronous phase triggering with a specified phase angle of AC power supply.

[0017] Multi-channel coupling-decoupling network: This is the key innovative component of the present invention. It upgrades the traditional passive and fixed coupling network into an intelligent switching platform, which consists of a communication and control module and a loop switching system. The communication and control module receives the channel selection command from the control host and drives the loop switching system to operate. The loop switching system consists of a switch matrix composed of multiple solid-state switch units. Each solid-state switch unit controls the on / off state of a current path. By programming the switch combination state, the output of the surge generator is automatically guided to the specified port combination of the device under test without the need for manual plugging and unplugging of cables.

[0018] Furthermore, the control host communicates with the surge signal generator and the multi-channel coupling / decoupling network via Ethernet (TCP / IP protocol), taking advantage of Ethernet's advantages of high speed, long distance, strong anti-interference ability, and ease of networking, making it suitable for laboratory testing environments.

[0019] Furthermore, the solid-state switching units in the circuit switching system employ high-performance electromagnetic relays, thyristors, or power MOSFETs, possessing high voltage isolation capabilities of over 6kV and millisecond-level or even microsecond-level fast switching speeds to ensure reliable surge pulse handling and enable rapid test cycles.

[0020] Furthermore, the system is also equipped with a database that communicates with the automatic testing software module of the control host to store test sequences, test parameters, test results, transient waveform data and information of the device under test, and supports data query, export and report generation.

[0021] Furthermore, to enhance system security and reliability, a timing interlock mechanism and a status self-check mechanism are set up: the embedded control system module of the control host blocks the surge trigger command before receiving a channel switching success confirmation signal; the trigger circuit of the surge signal generator is connected in series with a physical enable relay to achieve hardware-level safety interlock; each solid-state switch unit of the circuit switching system is equipped with an auxiliary contact, and the communication and control module of the multi-channel coupling and decoupling network verifies the consistency of channel connection by reading the status of the auxiliary contact. If an inconsistency is found, the fault is immediately reported and the test is stopped.

[0022] Meanwhile, this invention also provides a multi-channel automated surge testing method based on the above system, comprising the following steps:

[0023] S1: Preset and Arrangement: Create test projects, bind the information of the device under test, edit test parameters and arrange multi-step test sequences through the automatic test software module of the control host;

[0024] S2: Channel establishment, the control host sends a channel switching command to the multi-channel coupling and decoupling network, driving its loop switching system to connect the target test channel;

[0025] S3: Confirmation and preparation, the control host waits and receives the successful switching confirmation signal of the multi-channel coupled-decoupled network;

[0026] S4: Parameter configuration and triggering, the control host sends parameter setting instructions and triggering instructions to the surge signal generator;

[0027] S5: Pulse application and data acquisition. The surge signal generator generates a surge pulse and applies it to the device under test. The system acquires and stores transient waveform data and test results.

[0028] S6: Iteration and looping, repeat the above steps from channel establishment to data acquisition until all test steps are completed;

[0029] S7: Report generation. The system automatically extracts test data and generates a standardized test report.

[0030] The multi-channel automated surge testing system provided by this invention has the following beneficial effects:

[0031] 1. By using a solid-state switch matrix to achieve automatic and rapid switching of test channels, the tedious manual wiring operation is completely eliminated, freeing testers from repetitive work, increasing test efficiency by several times, and significantly shortening the test cycle of product development and certification.

[0032] 2. The fully automated process eliminates human wiring errors and parameter setting deviations, ensuring the consistency of test connections and parameter settings. This makes the results of the same test highly consistent at different times and under different operators, improving the comparability and reliability of test results.

[0033] 3. Enables "unmanned" high-voltage testing operations, eliminating the need for testers to touch live terminals during high-voltage testing, thus fundamentally eliminating the risk of electric shock and ensuring the personal safety of testers;

[0034] 4. The system can accurately execute complex test cases such as synchronous phase testing and multi-port continuous stress testing, providing a more comprehensive and rigorous assessment method for product design verification and meeting the testing standard requirements of modern products;

[0035] 5. The graphical human-computer interaction interface makes the testing process intuitive and easy to understand. Testers do not need to have a high level of professional skills to complete the operation, thus reducing the technical threshold for testers.

[0036] 6. The system adopts a modular design, based on Ethernet communication and a programmable switch matrix, which facilitates the addition of new test channels, integration of different models of test equipment, and flexible adaptation to changes in future test requirements;

[0037] 7. Through software timing interlocks, hardware-level safety interlocks, and channel status self-checking mechanisms, equipment failures or test accidents caused by misoperation are effectively avoided. At the same time, electromagnetic compatibility design suppresses the impact of surge pulses on the control circuit, ensuring long-term stable operation of the system under high voltage and transient impact environments. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0039] Figure 1 This is a schematic diagram of the system workflow according to an embodiment of the present invention;

[0040] Figure 2 This is a system overall structure block diagram according to an embodiment of the present invention;

[0041] Figure 3 This is a schematic diagram of the principle of a multi-channel coupling-decoupling network loop switching system according to an embodiment of the present invention;

[0042] Figure 4 This is a flowchart of the testing method according to an embodiment of the present invention. Detailed Implementation

[0043] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0044] Example 1: Basic System Architecture and Hardware Configuration

[0045] like Figure 2 As shown, the multi-channel surge automated testing system in this embodiment consists of a control host, a surge signal generator, a multi-channel coupling-decoupling network, and a database. The components are networked via Ethernet communication, and the output of the multi-channel coupling-decoupling network is fixedly connected to the device under test.

[0046] Control host: Utilizing an Advantech industrial-grade embedded computer as the hardware platform, equipped with an Intel Core i5 processor, 8GB RAM, and a 256GB SSD, it features electromagnetic interference resistance and robust durability, suitable for long-term stable operation in laboratories. A 10.1-inch industrial touchscreen display is connected to the front, providing a human-machine interface. Internally, it integrates an automatic testing software module and an embedded control system module. The automatic testing software module is developed based on C#, .NET Framework, and WPF framework, and uses an MVVM architecture to design the human-machine interface. The embedded control system module is based on a microcontroller, with firmware developed in C language within the Keil MDK environment.

[0047] Surge signal generator: The EMTEST brand UCS500N programmable surge generator is selected. It supports remote communication and can generate a combination of 1.2 / 50μs voltage wave and 8 / 20μs current wave conforming to the IEC61000-4-5 standard. It also supports synchronous triggering of AC power supply with specified phase angle triggered by external signals.

[0048] Multi-channel coupling / decoupling network: As a customized core component, the chassis is divided into a control area and a loop switching area. The control area is based on the STMicroelectronics STM32H743 series ARM Cortex-M7 core microcontroller, paired with a Microchip LAN8720 Ethernet PHY chip and power management circuitry to achieve communication and logic control. The loop switching area contains standard coupling / decoupling circuitry (18μF coupling capacitor, 40Ω coupling resistor) and a loop switching system. The loop switching system consists of a switching matrix composed of Omron G7L series high-performance power relays. The relay contact capacity meets 250VAC / 30A and can withstand 6kV transient voltage. It is controlled by the microcontroller's GPIO port through the TIULN2803 Darlington transistor array driver chip.

[0049] Database: An embedded SQLite database is used to communicate with the automated testing software module to achieve local storage and management of test data;

[0050] System Connection: The control host is connected to the remote control port of the surge signal generator and the control area of ​​the multi-channel coupling-decoupling network via two Ethernet ports, respectively; the high voltage output terminal of the surge signal generator is connected to the input terminal of the multi-channel coupling-decoupling network via a coaxial cable; the output terminals (L, N, PE, Signal1, Signal2...) of the multi-channel coupling-decoupling network are fixedly connected to the corresponding ports of the device under test via test harnesses.

[0051] Example 2: Software Function and Command Interaction

[0052] The automated testing software module provides five functional views, enabling human-computer interaction throughout the entire testing process;

[0053] Login view: Completes user authentication and permission management, assigning different operation permissions to different users;

[0054] Project configuration view: Enables the creation, saving, and loading of test projects, and binds information such as the model, specifications, and serial number of the device under test 5;

[0055] Sequence Editing View: Provides a graphical sequence editor, allowing users to drag and drop "test steps" onto the timeline to arrange test sequences and configure parameters such as target test channel, surge voltage, synchronization phase angle, polarity, and pulse repetition count for each test step;

[0056] Real-time monitoring view: Graphically displays the current channel connection status, the working status of surge signal generator 2 (ready, charging, triggered, error), and refreshes test results (PASS / FAIL) in real time.

[0057] Data query and report view: Supports querying test data by test item, device under test, test time and other conditions, and can export data and automatically generate standardized test reports in PDF format;

[0058] Embedded control system module: The core is a state machine program, which is responsible for parsing JSON format instructions from the host computer to achieve precise instruction distribution and timing control. For example, when it receives the instruction {"cmd":"switch_channel","target":"L-PE"}, it executes the following in sequence: drive the corresponding GPIO pin to close the relay of the L-PE channel → read the status feedback signal of the relay auxiliary contact → reply to the host computer with {"status":"ok","channel":"L-PE"}; if no feedback signal is received or the feedback signal is abnormal, a fault instruction is replied and the test is stopped.

[0059] Communication Protocol: The control host communicates with the surge signal generator using SCPI standard commands, and the control host communicates with the multi-channel coupling-decoupling network using custom JSON format commands to ensure the accuracy and efficiency of command transmission.

[0060] Example 3: Detailed Test Procedure

[0061] like Figure 4 As shown, taking the single-phase three-port (L, N, PE) test of the device under test as an example, a test sequence containing two test steps is arranged to explain the test method of the present invention in detail:

[0062] Test sequence:

[0063] Step 1: Between the L and N lines, with the AC power supply crossing zero (0°), apply a positive 2kV surge pulse, repeating 5 times;

[0064] Step 2: Between the L-PE lines, at the peak point (90°) of the AC power supply, apply a positive 4kV surge pulse, repeating 5 times.

[0065] Test execution:

[0066] Sequence Arrangement: Users create test projects in the project configuration view of the automatic test software module 11 and bind the information of the device under test; drag two "test steps" in the sequence editing view, configure the above test parameters respectively, and save the test sequence;

[0067] Start Test: When the user clicks the "Start Test" button, the automatic test software module sends the test sequence to the embedded control system module;

[0068] Execution Step 1:

[0069] The embedded control system module sends the instruction {"cmd":"switch_channel","target":"LN"} to the multi-channel coupling-decoupling network;

[0070] After parsing the instructions, the communication and control module of the multi-channel coupling-decoupling network closes the relays corresponding to L and N in the drive loop switching system, opens other relays, and returns {"status":"ok","channel":"LN"} to the control host after completion.

[0071] After receiving the confirmation signal, the control host sends parameter setting instructions to the surge signal generator via SCPI command: VOLTAGE:LEVEL2000, PHASE:SYNC0, POLARITYPOSITIVE, COUNT5, and then sends the trigger instruction INITIATE:START.

[0072] The surge signal generator precisely triggers five 2kV positive surge pulses at a 0° phase angle of the AC power supply, which are then applied to the device under test through the LN channel.

[0073] The system collects transient waveform data of each pulse in real time, records the test results and stores them in the database.

[0074] Perform step 2:

[0075] The control host automatically sends the command {"cmd":"switch_channel","target":"L-PE"} to the multi-channel coupled-decoupled network;

[0076] After the multi-channel coupling-decoupling network completes the channel switching and returns an acknowledgment signal, the control host sends the SCPI command to the surge signal generator: VOLTAGE:LEVEL4000, PHASE:SYNC90, POLARITYPOSITIVE, COUNT5, and then sends the trigger command.

[0077] The surge signal generator precisely triggers five 4kV positive surge pulses at a 90° phase angle of the AC power supply, which are applied to the device under test through the L-PE channel. The system collects and stores the test data.

[0078] Test Completion and Report Generation: After all test steps are completed, the automatic test software module extracts all parameters, waveform data and test results from the database, and calls the ReportLab library to automatically generate a PDF test report. The report includes information about the device under test, test parameters, a summary of the steps and results, transient waveforms and timestamps.

[0079] Example 4: Enhanced Safety and Electromagnetic Compatibility Design

[0080] To ensure the long-term reliability and safety of the system under high pressure and transient impact environments, this embodiment adds the following design based on the above:

[0081] Two-layer interlocking mechanism:

[0082] Software interlock: The state machine program of the embedded control system module is set with strict timing judgment. Before receiving the confirmation signal of successful switching of the multi-channel coupling-decoupling network, it is prohibited to send a trigger command to the surge signal generator.

[0083] Hardware interlock: A physical enable relay controlled by the GPIO port of the control host is connected in series in the trigger circuit of the surge signal generator. The relay closes only after the channel switching is completed, and the trigger circuit is turned on.

[0084] Channel status self-check: Each relay in the loop switching system is equipped with an auxiliary contact. The communication and control module of the multi-channel coupling and decoupling network reads the status of the auxiliary contact in real time and compares it with the control command. If it finds that the command is "closed" but the feedback is "open", or the command is "open" but the feedback is "closed", it immediately reports a "hardware fault" error to the control host. The control host stops the test and issues an alarm in the real-time monitoring view.

[0085] Electromagnetic compatibility design:

[0086] The Ethernet communication between the control host and the multi-channel coupling-decoupling network uses shielded network cables with ferrite cores at both ends to suppress electromagnetic interference.

[0087] A current-limiting resistor is connected in series and a TVS diode is connected in parallel between the GPIO output pin of the microcontroller and the relay driver chip to suppress the impact of the induced electromotive force generated by the surge pulse on the control circuit and protect the control chip.

[0088] The chassis of the multi-channel coupling-decoupling network adopts a metal shielding design to reduce the electromagnetic radiation of surge pulses to the control circuit.

[0089] The embodiments of the present invention are merely typical implementations and are not intended to limit the present invention. Those skilled in the art can make various modifications, equivalent substitutions and improvements without departing from the spirit and principle of the present invention. For example, power relays can be replaced with optocoupler thyristors to improve switching speed, the number of signal line channels can be increased, and industrial-grade databases can be used to achieve data sharing among multiple devices. All such improvements are included within the protection scope of the present invention.

Claims

1. A multi-channel automated surge testing system, characterized in that, The system includes a control host, a surge signal generator, and a multi-channel coupling / decoupling network that are connected in sequence and communicate with each other. The multi-channel coupling / decoupling network is also directly connected to the control host. The control host includes an automatic test software module and an embedded control system module that communicate with each other. The automatic test software module is used to provide a graphical user interface to realize test parameter editing, test sequence arrangement and execution control, and test result storage and display. The embedded control system module is used to parse test instructions and send control commands to the surge signal generator and the multi-channel coupling and decoupling network, while collecting equipment status information and feeding it back to the automatic test software module. The surge signal generator is used to receive instructions from the control host, accurately generate surge pulse signals that conform to electromagnetic compatibility standards, and support synchronous triggering of AC power supply with a specified phase angle. The multi-channel coupling-decoupling network includes a communication and control module and a loop switching system. The communication and control module receives channel switching commands from the control host and drives the loop switching system to operate. The loop switching system consists of a switching matrix composed of multiple solid-state switching units to realize the automatic switching of surge pulse injection channels and complete the automatic connection of different port combinations of the device under test.

2. The multi-channel surge automated testing system according to claim 1, characterized in that, The control host communicates with the surge signal generator and the multi-channel coupling / decoupling network via an Ethernet interface based on the TCP / IP protocol.

3. The multi-channel surge automated testing system according to claim 1, characterized in that, The solid-state switching unit in the circuit switching system is a high-performance electromagnetic relay, thyristor, or power MOSFET. The solid-state switching unit has a high voltage isolation capability of over 6kV and a fast switching speed of milliseconds or less.

4. The multi-channel surge automated testing system according to claim 1, characterized in that, The automatic test software module supports multi-step test sequence programming. The test parameters associated with a single test step include at least the target test channel identifier, surge injection synchronization phase angle, surge voltage level, waveform type, polarity, and pulse repetition count.

5. The multi-channel surge automated testing system according to claim 4, characterized in that, The embedded control system module executes operations sequentially to complete a single test step: first, it sends a channel switching command to the multi-channel coupling-decoupling network; after receiving a successful switching confirmation signal from the multi-channel coupling-decoupling network, it sends parameter setting and triggering commands to the surge signal generator; and it collects and feeds back the status information of the surge signal generator and the multi-channel coupling-decoupling network in real time.

6. The multi-channel surge automated testing system according to any one of claims 1-5, characterized in that, It also includes a database, which is communicatively connected to the automatic testing software module of the control host and is used to store test sequences, test parameters, test results, transient waveform data and corresponding information of the device under test.

7. The multi-channel surge automated testing system according to claim 1, characterized in that, The control host is equipped with a timing interlock mechanism, which blocks the trigger command sent to the surge signal generator before receiving a successful switching confirmation signal from the multi-channel coupling-decoupling network; a physical enable relay is connected in series in the trigger circuit of the surge signal generator to achieve hardware-level safety interlock.

8. The multi-channel surge automated testing system according to claim 1, characterized in that, Each solid-state switch unit of the circuit switching system is equipped with an auxiliary contact. The communication and control module of the multi-channel coupling-decoupling network verifies the consistency of the channel connection status by reading the status of the auxiliary contact. If an inconsistency is found, a fault is immediately reported and the test is stopped.

9. A multi-channel automated surge testing method using the system described in any one of claims 1-8, characterized in that, Includes the following steps: S1: Create test projects through the automatic test software module of the control host, bind the information of the device under test, edit test parameters and arrange test sequences containing at least one test step. Each test step defines the target test channel and a complete set of surge parameters. S2: Start the test sequence. The embedded control system module of the host computer sends a channel switching command to the multi-channel coupling-decoupling network according to the current test step. S3: The communication and control module drive loop switching system of the multi-channel coupled and decoupled network switches to the target test channel. After completion, it returns a switching success confirmation signal to the control host. The control host waits for and confirms the signal. S4: After confirming that the channel switching is successful, the control host sends a parameter setting command to the surge signal generator, which includes surge voltage, synchronization phase angle, waveform type, polarity and number of repetitions, and then sends a trigger command. S5: The surge signal generator accurately generates surge pulse signals according to the instructions, and applies the surge pulses to the device under test through the connected target test channel. At the same time, the system collects and stores the transient waveform data and test results of this test. S6: Repeat steps S2 to S5 until all steps in the test sequence have been completed; S7: The control host extracts all data from the database for this test and automatically generates a standardized test report.

Images