An electric vibration testing system, method and controller

Abstract

The present specification provides an electric vibration test system, method and controller, which judges the working condition according to the output value of the temperature sensor group, dynamically adjusts the analog signal sent to the frequency converter according to the output value of the temperature sensor group; in the normal temperature and high temperature working condition, the analog signal is adjusted according to the first curve and the second curve respectively; in the case that the change rate of the temperature detection value is the same, the value of the analog signal on the first curve is smaller than that on the first straight line, except for the two end point values on the first curve; in the case that the change rate of the temperature detection value is the same, the value of the analog signal on the second curve is greater than that on the second straight line, except for the two end point values on the second curve. The present scheme adjusts the analog signal according to different curves in different working conditions, breaks through the limitation of the existing constant frequency or single linear control, and solves the problem that the existing control mode cannot consider the damage of the cooling fan, heat dissipation and energy saving.

Description

Technical Field

[0001] This application relates to the field of industrial reliability testing equipment technology, and in particular to an electric vibration testing system, method and controller. Background Technology

[0002] Electric vibration table testing systems are widely used in product reliability testing in industries such as automotive, aerospace, rail transportation, electronics, and military. As a core device simulating the vibration environment that products experience during transportation and use, the operational stability of the electric vibration table directly determines the accuracy and reliability of the test results, and the coil heat dissipation effect is one of the key factors ensuring the long-term stable operation of the electric vibration table.

[0003] In electric vibration testing systems, the excitation coil and drive coil (i.e., the coil of the moving part) continuously generate heat during operation. If this heat cannot be dissipated in time, the coil temperature will rise abnormally, affecting the vibration accuracy of the vibration table and even burning out the coil, causing equipment failure. For electric vibration testing systems with low heat dissipation requirements, air cooling is commonly used in the industry. The corresponding cooling device is mainly a cooling fan, and the main drive component of this type of fan is usually a three-phase asynchronous motor.

[0004] With the continuous advancement of low-carbon, intelligent, and connected processes in the industrial sector, the traditional constant-frequency and constant-voltage operation mode of three-phase asynchronous motors, due to their low energy efficiency and poor speed regulation flexibility, is gradually failing to meet the requirements of high-quality development for energy conservation, emission reduction, and precise control. Against this backdrop, the combination of cooling fans and frequency converters, with their advantages of flexible speed adjustment and controllable energy consumption, has become the mainstream solution for industrial equipment drives. The cooling fan drive system of electric vibration tables is also gradually adopting this combination solution for upgrades and transformations.

[0005] However, existing air-cooled heat dissipation systems for electric vibration tables based on cooling fans and frequency converters still have significant technical defects, specifically in the following two aspects: Firstly, most small and medium-sized frequency converters widely used in the industry currently employ PWM (Pulse Width Adjustment) control. Their high carrier frequency causes the stator windings of the cooling fan to experience a large voltage rise rate in a short period of time during frequent frequency adjustment. This voltage surge can easily cause destructive damage to the inter-turn insulation of the cooling fan, significantly shortening the motor's service life and increasing equipment maintenance costs and downtime risks. Secondly, vibration test scenarios are characterized by diverse and extreme operating conditions. The heat generation of the coils varies greatly under different test conditions, posing a severe challenge to the control of the cooling fan's heat dissipation effect. Existing control strategies are difficult to balance heat dissipation effect and energy-saving requirements: if the fan speed is reduced to maximize energy saving, insufficient heat dissipation will result, which can easily cause the excitation coil and drive coil in the vibration system to burn out under high-temperature conditions; if the cooling effect is pursued at the expense of keeping the cooling fan running at full load for a long time, energy consumption will increase significantly.

[0006] In summary, the existing frequency conversion control schemes for air-cooled heat dissipation systems of electric vibration tables have technical drawbacks such as high risk of motor insulation damage and an inability to simultaneously achieve heat dissipation and energy saving, making them unsuitable for the diverse operating conditions required for vibration testing. Summary of the Invention

[0007] This specification provides an electric vibration testing system, method, and controller to solve the problem that existing frequency conversion control schemes for electric vibration table air-cooled heat dissipation systems are difficult to balance in terms of heat dissipation fan damage, heat dissipation, and energy saving.

[0008] To solve the above-mentioned technical problems, this specification provides an electric vibration testing system, comprising: an excitation coil for passing current through to generate a magnetic field; a moving coil including a drive coil, a support frame, and a bearing platform for the object under test; the moving coil vibrates based on the force exerted by the drive coil in the magnetic field after being energized and transmits the vibration to the object under test; the excitation coil and the drive coil are arranged in a common air duct; a temperature sensor group including at least two temperature sensors disposed in the winding gap of the excitation coil and / or in the winding of the moving coil; a cooling fan disposed at one end of the air duct for forming airflow in the air duct to assist in heat dissipation; a frequency converter for receiving control signals sent by a controller and converting them into the power supply frequency of the cooling fan; the controller for determining the operating condition based on the output value of the temperature sensor group; and dynamically adjusting the analog signal sent to the frequency converter according to the operating condition and the output value of the temperature sensor group; wherein, under normal temperature operating conditions, the analog signal sent to the frequency converter is adjusted according to a first curve; under high temperature operating conditions, the analog signal is adjusted according to a first curve. The analog signal sent to the inverter is adjusted according to the second curve; the first curve is a curve showing the rate of change of the analog signal value with the output value of the temperature sensor group; when the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints of the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line; the first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal adjustment, and the maximum and minimum analog signal output in response to the analog signal adjustment; the second curve is a curve showing the rate of change of the analog signal value with the output value of the temperature sensor group; when the output value of the temperature sensor group is the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line; the second straight line is a virtual straight line drawn based on the maximum and minimum temperature output value that causes the analog signal adjustment, and the maximum and minimum analog signal output in response to the analog signal adjustment.

[0009] In some embodiments, as the rate of change of the output value of the temperature sensor group gradually increases, the slope of the first curve also gradually increases; and / or, as the output value of the temperature sensor group gradually increases, the slope of the second curve gradually decreases.

[0010] In some embodiments, the operating condition further includes an over-temperature condition; under the over-temperature condition, the controller sends a predetermined current signal to the frequency converter, the predetermined current signal being used to instruct the frequency converter to control the cooling fan to stop operating.

[0011] In some embodiments, under normal operating conditions, during sinusoidal sweep frequency testing or random testing, a calculation adjustment is performed every 2 to 2.5 minutes; the calculation adjustment refers to calculating the rate of change of the output value of the temperature sensor group and adjusting the analog signal sent to the frequency converter according to the rate of change.

[0012] In some embodiments, the temperature sensor group includes at least: a first temperature sensor disposed in the lower excitation duct region; a second temperature sensor disposed in the winding of the moving coil; and a signal processing circuit connected to the output terminals of the first temperature sensor and the second temperature sensor; wherein the output value of the signal processing circuit is not less than the maximum value among the detection values ​​of the first temperature sensor and the second temperature sensor.

[0013] In some embodiments, the first curve is a smoothly transitioning curve or a polyline composed of multiple line segments; or, the second curve is a smoothly transitioning curve or a polyline composed of multiple line segments.

[0014] A second aspect of this specification provides an electric vibration testing method, comprising: determining the operating condition of the electric vibration testing system based on the output value of a temperature sensor group; dynamically adjusting the analog signal sent to the frequency converter based on the operating condition and the output value of the temperature sensor group; wherein, under normal temperature operating conditions, the analog signal sent to the frequency converter is adjusted according to a first curve; under high temperature operating conditions, the analog signal sent to the frequency converter is adjusted according to a second curve; the first curve is a curve showing the change in the value of the analog signal with the rate of change of the output value of the temperature sensor group; when the rate of change of the output value of the temperature sensor group is the same, the values ​​of the analog signal on the first curve, except for the two endpoints, are... The value of the analog signal on the first straight line is less than the value of the analog signal on the second straight line; the first straight line is a virtual straight line drawn based on the rate of change of the maximum and minimum temperature output values ​​that cause the analog signal adjustment, and the maximum and minimum analog signals output in response to the analog signal adjustment; the second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group; when the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line; the second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal adjustment, and the maximum and minimum analog signals output in response to the analog signal adjustment.

[0015] A third aspect of this specification provides an electric vibration testing device, comprising: a judgment unit for judging the operating condition of the electric vibration testing system based on the output value of a temperature sensor group; and an adjustment unit for dynamically adjusting the analog signal sent to the frequency converter based on the operating condition and the output value of the temperature sensor group. Specifically, under normal temperature conditions, the analog signal sent to the frequency converter is adjusted according to a first curve; under high temperature conditions, the analog signal is adjusted according to a second curve. The first curve is a curve showing the change in the value of the analog signal as a function of the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, the analog signal on the first curve, except for the two endpoints, is adjusted accordingly. The value of the analog signal is less than the value of the analog signal on the first straight line; the first straight line is a virtual straight line drawn based on the rate of change of the maximum and minimum temperature output values ​​that cause the analog signal adjustment, and the maximum and minimum analog signals output in response to the analog signal adjustment; the second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group; when the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line; the second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal adjustment, and the maximum and minimum analog signals output in response to the analog signal adjustment.

[0016] The fourth aspect of this specification provides a controller, including: a memory and a processor, the processor and the memory being communicatively connected to each other, the memory storing computer instructions, and the processor executing the computer instructions to implement the electric vibration testing method described in the second aspect.

[0017] The fifth aspect of this specification provides a computer storage medium storing computer program instructions that, when executed, implement the electric vibration testing method described in the second aspect.

[0018] The sixth aspect of this specification provides a computer program product comprising a computer program that, when executed by a processor, implements the electric vibration testing method described in the second aspect.

[0019] The electric vibration testing system, method, and controller provided in this manual, under normal temperature conditions, adjust the analog signal sent to the frequency converter according to the "rate of change of the output value of the temperature sensor group" based on the "first curve." Except for the two endpoints of the first curve, the values ​​of the analog signal on the first curve are lower than those on the first straight line. Compared to the high signal output of the first straight line, the first curve outputs a lower analog signal per unit temperature rise cycle, thereby driving the cooling fan to operate at a slower speed. This setting, while meeting the basic heat dissipation requirements of the excitation coil, fundamentally avoids energy waste caused by "overheating," thus meeting the core requirements of low-carbon development in the industrial sector.

[0020] The slope of the first curve increases progressively, meaning that the higher the rate of temperature rise, the faster the rate of change of the analog signal AO1. This design can precisely match the short-term temperature rise requirements caused by "increased test duration and test type switching," ensuring both reliable and stable heat dissipation and avoiding the mechanical vibration impact of sudden speed changes on the heat dissipation system. This indirectly ensures the operational stability of the electric vibration testing system and guarantees the accuracy of product reliability test results.

[0021] The electric vibration testing system, method, and controller provided in this manual adjust the analog signal sent to the frequency converter according to the "second curve" based on the "output value of the temperature sensor group" under high-temperature conditions. Except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than that on the second straight line. Compared with the low signal output of the second straight line, the second curve outputs a higher analog signal per unit temperature rise cycle. This allows the cooling fan to run at a faster speed, increases the airflow velocity in the air duct, and enhances the heat dissipation of the excitation coil. At the same time, it indirectly increases the airflow supply to the central air gap where the drive coil is located, fundamentally avoiding magnetic field fluctuations and decreased vibration accuracy caused by abnormal coil temperature rise, and even preventing equipment failures caused by coil burnout. This provides core assurance for extreme reliability testing in industries such as automotive, aerospace, and military.

[0022] The slope of the second curve decreases gradually, and nearly half of the slope slows down when the temperature exceeds 80℃. The core advantage of this design is that it rapidly enhances heat dissipation capacity in the early stages of temperature rise, and the timely and powerful heat dissipation effect drives the vibration system to quickly return to normal operating conditions and switch back to energy-saving control mode; when the temperature approaches 80℃ and the motor is close to full load, it avoids blindly increasing the output signal and prevents energy waste caused by the saturation of the cooling fan speed, thus achieving the dual goals of "high-temperature and efficient heat dissipation + precise and controllable energy consumption".

[0023] The electric vibration testing system, method, and controller provided in this manual, through adjusting the analog signal using the first and second curves, also achieve the following technical effects: 1. Intelligent switching of operating conditions to adapt to diverse and extreme testing needs. Specifically, the two curves are precisely divided based on normal temperature and high temperature operating conditions, combined with signal interval isolation of 4-12mA and 12-20mA, realizing the intelligent control logic of "observing the rate of change at normal temperature (prioritizing energy saving + predicting trends) and observing the absolute value at high temperature (prioritizing safety + powerful heat dissipation)," which can adapt to the diverse and extreme characteristics of electric vibration testing systems and conforms to the trend of intelligent development in the industrial field; 2. Comprehensive solution to technical pain points and promotion of heat dissipation system upgrades. Specifically, this hyperbolic control scheme comprehensively breaks through the limitations of existing constant frequency or single linear control from four dimensions: "motor insulation protection, coil heat dissipation guarantee, precise energy consumption control, and safety protection backup." It solves the technical drawbacks of existing control methods in balancing heat dissipation fan damage, heat dissipation, and energy saving, ensuring the long-term stable operation of the electric vibration testing system. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of a structural system for an electric vibration testing system provided in this specification. Figure 2 This is a schematic diagram of the excitation coil. Figure 3 This is a schematic diagram showing the positional relationship between the excitation system and the moving coil. Figure 4 for Figure 2 Enlarged detail of the area circled in the middle (M); Figure 5 A circuit diagram illustrating the control of the cooling fan based on the output values ​​of the first and second temperature sensors; Figure 6 This is a schematic diagram showing the positional relationship between the first curve and the first straight line; Figure 7 This is a schematic diagram showing the positional relationship between the second curve and the second straight line; Figure 8 This is an alternative structural diagram of the electric vibration testing system provided in this specification. Figure 9 This is a schematic flowchart of an electric vibration testing method provided in this specification. Figure 10 This is a schematic diagram of the controller provided in this manual. Detailed Implementation

[0026] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this application.

[0027] This specification provides an electric vibration testing system, such as Figure 1 As shown, it includes excitation coil A, moving coil B, temperature sensor group C, cooling fan D, frequency converter E, and controller F.

[0028] Excitation coil A is used to pass current through it to generate a magnetic field.

[0029] In conventional vibration tests (such as sinusoidal sweep frequency tests and random vibration tests), a direct current can be passed through excitation coil A, thereby generating a constant magnetic field with a fixed magnitude and direction. Under conventional vibration testing, the vibration parameters of the vibration table (such as frequency, amplitude, and acceleration) are entirely determined by the alternating current parameters of the drive coil (i.e., the moving coil in the following text), and are independent of the magnetic field of excitation coil A. The constant magnetic field strength ensures that the correspondence between "drive current and drive force" is stable, and the vibration parameters will not drift due to magnetic field fluctuations during the test, thus guaranteeing the accuracy and repeatability of the test results.

[0030] Under special operating conditions, the current flowing through excitation coil A can be adjusted during parameter configuration or calibration before testing to ensure test accuracy and stability.

[0031] like Figure 2 As shown, the excitation coil A may include an upper excitation coil A1 and a lower excitation coil A2. The upper and lower excitation coils A1 and A2 are important components of the excitation system. The excitation system may also include a magnetic ring A3. The magnetic ring A3 is a ring-shaped permanent magnet component, adapted to the ring structure of the excitation system, and installed in the magnetic circuit gap region corresponding to the upper and lower excitation coils A1 and A2, arranged coaxially with them. The entire excitation system adopts a closed-loop design. When direct current is applied to the upper and lower excitation coils A1 and A2, an electromagnetic excitation magnetic field is generated. The magnetic ring A3 itself carries a permanent magnet magnetic field, and the magnetic fields of the two are superimposed within the frame, ultimately forming a magnetic field in the air gap region of the cavity in the middle of the excitation system (i.e., Figure 2The empty space at the center of the ring converges to form a stable, uniform, and strong magnetic field, providing the magnetic field basis for the driving coil B1 of the moving coil B to generate the Ampere force.

[0032] Figure 2 The blank space at the center of the middle ring is used to set the drive coil B1 in the moving coil B. Figure 3 This is a schematic diagram showing the positional relationship between the excitation system and the moving coil B.

[0033] The moving coil B includes a drive coil B1, a support frame, and a platform supporting the object under test. The moving coil B vibrates based on the force exerted on it in the magnetic field after the drive coil B1 is energized, and transmits the vibration to the object under test.

[0034] The moving coil B of the electric vibration testing system is an integrated moving component, the core of which is the drive coil B1. The drive coil B1 (also called the moving coil winding) is an electromagnetic winding wound around the support frame, serving as the power source for the moving coil B to drive the object under test. When the drive coil B1 is energized, it experiences an Ampere force in the magnetic field generated by the excitation system; this force varies with the direction of the current in the drive coil B1.

[0035] The support frame serves to support the drive coil B1 and the mounting platform. The object under test is fixed on the mounting platform to ensure that the object under test vibrates synchronously with the moving coil B.

[0036] Temperature sensor group C includes temperature sensors disposed in the windings of excitation coil A and / or drive coil B.

[0037] Figure 4 for Figure 2 A magnified view of the area circled in the middle, M. Here, G represents the winding gap of the upper excitation coil A1, and CT represents the location of the temperature sensor within the upper excitation coil A1. Figure 4 The grid in the diagram represents the excitation winding.

[0038] The temperature sensor can specifically be a thermocouple wire, i.e., a thin wire. These temperature-sensing thin wires are inserted into the gaps of the excitation coil winding, specifically at the wire leads of the excitation coil winding.

[0039] In some embodiments, the temperature sensor group C includes a first temperature sensor disposed in the winding gap of the excitation coil and a second temperature sensor disposed in the winding gap of the drive coil, as well as a signal processing circuit connected to the first and second temperature sensors. The output value of the signal processing circuit is not less than the maximum value among the detection values ​​of the first and second temperature sensors.

[0040] The terms "first temperature sensor" and "second temperature sensor" are used only to distinguish sensors installed in different areas and do not represent actual individual sensors. The first temperature sensor may include multiple temperature sensors, with the maximum or average value of these sensor readings serving as its output value. For example, one temperature sensor can be installed in each of the same air duct areas of the upper and lower excitation coils, and the output value of the temperature sensor group can be determined based on the readings of the two sensors. Similarly, the second temperature sensor may also include multiple temperature sensors, with the maximum or average value of these sensor readings serving as its output value.

[0041] In addition to the first and second temperature sensors, temperature sensor group C may also include a third temperature sensor located in other positions. In this case, the output value of temperature sensor group C may be higher than the maximum value detected by the first and second temperature sensors. The first, second, and third temperature sensors may be located in a common air duct.

[0042] When the temperature sensor group C includes only the first temperature sensor and the second temperature sensor, the output value of the temperature sensor group C can be equal to the maximum value among the detection values ​​of the first temperature sensor and the second temperature sensor.

[0043] Figure 5 This is a circuit diagram illustrating the control of a cooling fan based on the output values ​​of a first temperature sensor and a second temperature sensor. The output signals from the first and second temperature sensors are pre-amplified and their amplitudes increased before being input into a comparison module. The module compares the signals to find the signal with the largest detected value, then converts the voltage signal output from the comparison module into an industrial standard 4-20mA current signal, which is then passed through an ammeter (i.e.,...). Figure 5 The current value is detected in real time by the ammeter (MA), and finally transmitted to the PLC or other controllers used to control the frequency converter through the current signal output terminal (+ / -) to control the speed adjustment of the cooling fan driven by the frequency converter.

[0044] The analog control signal input from the controller to the frequency converter is rapidly switched on and off by power switching transistors such as IGBTs or MOSFETs inside the frequency converter to obtain a high-voltage PWM wave (voltage wave, not current wave) that can drive the cooling fan. This high-voltage PWM wave is directly connected to the stator winding input terminal of the cooling fan via a cable to achieve variable frequency speed control of the fan. Due to the inductive characteristics of the stator winding, the high-frequency carrier component of the PWM voltage wave is filtered out by the winding's inductance, preventing the formation of a pulse current in the winding. This results in a continuous, approximately sinusoidal alternating current flowing through the winding, with a frequency consistent with the fan's fundamental frequency set by the frequency converter, rather than the carrier frequency. However, although the current in the winding is approximately sinusoidal, the high steepness of the PWM voltage wave (i.e., high dv / dt) directly acts on the winding input terminal. This high voltage rise rate creates local overvoltage in the first turn of the winding, causing corona discharge and insulation aging. This is the core reason for the "inter-turn insulation damage" mentioned in the background section.

[0045] By setting a first temperature sensor and a second temperature sensor, and using the maximum value detected by the two sensors to control the cooling fan, the stable temperature signal of the excitation coil is used as the reference for cooling fan control. Combined with the maximum temperature signal of the drive coil, heat dissipation regulation is achieved, forming a temperature control logic of "stable reference + on-demand speed adjustment". This eliminates the root cause of frequent frequency conversion adjustments of the cooling fan, reduces the repeated effects of PWM wave height dv / dt voltage surges on the stator winding inter-turn insulation, and ultimately solves the problem of easily destructive damage to inter-turn insulation. Simultaneously, it takes into account both the core operational requirements of stable Ampere force in the electric vibration testing system and the heat dissipation reliability of the cooling fan, achieving dual protection for the performance of the main equipment and the lifespan of the cooling fan. This can be understood from the following three aspects: 1. The stable current If of the excitation coil ensures its temperature stability, providing a stable temperature control reference signal for the cooling fan. Specifically, because the Ampere force requires a constant excitation current If, the heating power of the excitation coil is determined by this constant current without additional fluctuations. Therefore, the temperature of the excitation coil is relatively stable without random fluctuations. Based on this characteristic, the excitation coil temperature value detected by the first temperature sensor is a stable DC signal, without irregular small fluctuations. The cooling fan control signal based on this has inherent stability, fundamentally avoiding meaningless frequent frequency adjustments caused by temperature control fluctuations, and allowing the inverter to maintain a relatively fixed output frequency for the cooling fan.

[0046] 2. The randomness of the current Id in the drive coil leads to a random temperature. Using only the temperature reading would cause frequent changes in the cooling fan's speed. Using the maximum value from both sensors avoids this drawback. Specifically, the current Id in the drive coil needs to be adjusted in real-time according to the change in the required Ampere force F for vibration, and has no fixed value. Therefore, the heat output of the drive coil fluctuates randomly with the current, and the corresponding temperature also exhibits irregular random changes. If the temperature detection value at the drive coil is selected as the basis for cooling fan control, the fan control signal will fluctuate frequently with the random fluctuations in the drive coil temperature, triggering frequent speed increases and decreases in the cooling fan. The inverter will then frequently adjust its output frequency, generating high dv / dt PWM voltage waves that repeatedly impact the stator winding inter-turn insulation, exacerbating insulation damage. Using the maximum value from both sensors as the control basis prevents the frequent fluctuations in the drive coil temperature detection value from completely dominating the cooling fan control. Only when the drive coil temperature rises above the stable temperature of the excitation coil will the drive coil temperature detection value dominate the cooling fan speed adjustment. This avoids the control signal fluctuations caused by a single drive coil temperature reading and achieves precise heat dissipation.

[0047] 3. The stable control signal of the cooling fan is directly transmitted to the inverter side and brings about key changes: the inverter no longer needs to frequently adjust the output frequency and no longer continuously generate high-frequency, high-dv / dt PWM pulse voltages. The stator winding of the cooling fan is subjected to continuous voltage at a stable frequency in most cases. "Intermittent and sudden voltage impacts during frequent frequency conversion" are very few (almost none). This can fundamentally solve the problem of the inter-turn insulation of the cooling fan stator winding being easily damaged.

[0048] In an electric vibration testing system, the air duct is a closed or semi-closed flow channel structure designed according to a preset path. Its core function is to constrain and guide the airflow precisely through the area of ​​the heat-generating components, constructing a complete heat dissipation loop of "air intake → heat exchange → exhaust". It is also a key bridge connecting the cooling fan D with the excitation coil A and the drive coil B1. The excitation coil A and the drive coil B1 share the same air duct.

[0049] The air duct in the electric vibration testing system includes an air inlet, a main air duct section, flow guiding components, and an air outlet. The air inlet is directly connected to the air outlet of the cooling fan D, serving as the entrance for cold air into the air duct. The main air duct section is the core area of ​​the air duct and the main flow channel covering the upper excitation coil, lower excitation coil, and drive coil. The main air duct section is designed as a ring, U-shape, or straight line according to the structure of the magnetic circuit cavity, ensuring that the airflow can evenly sweep the surfaces and gaps of all heat-generating components. The main air duct is equipped with flow guiding components such as baffles and flow dividers to optimize airflow distribution. For example, it prevents airflow from concentrating in a certain area, forcing the airflow to be split and flow through the upper and lower excitation coils respectively, ensuring uniform heat dissipation. The air outlet is located at the end of the air duct and is used to discharge the hot air after heat exchange with the heat-generating components.

[0050] A cooling fan D is positioned at one end of the air duct to create airflow within the duct to aid in heat dissipation. The cooling fan D can be located at either the air inlet or the air outlet. The cooling fan D uses its impeller rotation to blow cool outside air into the air duct, or draws air out at the air outlet to create negative pressure, driving air circulation within the duct and forming an airflow path through the heat-generating components. Forced convection heat exchange removes the heat generated by the excitation coil and drive coil.

[0051] The cooling fan D includes a variable frequency three-phase asynchronous motor and an impeller. The output shaft of the variable frequency three-phase asynchronous motor is directly connected to the impeller. The rotation of the motor drives the impeller to rotate, generating airflow. The impeller is mounted on the output shaft of the variable frequency three-phase asynchronous motor, and its rotational speed is adjusted according to the motor speed, thus determining the airflow and air pressure of the fan. The cooling fan D also includes a volute or fan casing as a guide and protection component, which surrounds the outside of the impeller and serves to constrain the airflow direction and improve air pressure efficiency.

[0052] Inverter E receives control signals from controller F and converts them into the power supply frequency for cooling fan D. Inverter E controls cooling fan D, specifically the variable frequency three-phase asynchronous motor within it. The core function of inverter E is to convert the mains frequency AC power (typically 50Hz / 60Hz) into AC power with adjustable frequency and voltage, thereby achieving stepless and precise adjustment of the cooling fan's speed.

[0053] Inverter E receives the analog control signal output from controller F (for example, the output of controller F can be a 4-20mA analog control signal) and linearly converts the signal value into the output frequency, thereby realizing the adjustment of the fan speed and adapting to different operating conditions such as low-temperature energy saving and high-temperature enhanced heat dissipation. For example, 4mA is converted into the lowest output frequency (such as 5Hz, corresponding to zero or extremely low fan speed), and 20mA is converted into the rated output frequency (such as 50Hz, corresponding to full fan speed).

[0054] The controller F is used to determine the current operating condition based on the output values ​​of the temperature sensor group; and dynamically adjusts the analog signal sent to the frequency converter D according to the operating condition and the output values ​​of the temperature sensor group. The operating conditions include normal temperature operating conditions and high temperature operating conditions.

[0055] Under normal temperature conditions, the analog signal sent to the inverter is adjusted according to the first curve. Under high temperature conditions, the analog signal sent to the inverter is adjusted according to the second curve. The first curve represents the rate of change of the analog signal value with the output value of the temperature sensor group, and the second curve represents the rate of change of the analog signal value with the output value of the temperature sensor group.

[0056] When the rate of change of the output values ​​of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the rate of change of the maximum and minimum temperature output values ​​(i.e., the output values ​​of the temperature sensor group) that cause the analog signal adjustment, and the maximum and minimum analog signals output in response to the analog signal adjustment.

[0057] The first curve and the first straight line intersect at their two endpoints. In other words, as the rate of change of the output value of the temperature sensor group gradually increases, the slope of the first curve also gradually increases.

[0058] When the output values ​​of the temperature sensor group are the same, except for the two endpoints on the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the analog signal adjustment.

[0059] The second curve and the second straight line intersect at the two endpoints of the second curve. That is, as the output value of the temperature sensor group gradually increases, the slope of the second curve gradually decreases.

[0060] like Figure 6 As shown, when the rate of change of the output value of the temperature sensor group is 8, the value of the analog signal on the first curve is AO1(1), while the value of the analog signal on the first straight line is AO1(2), and AO1(1) < AO1(2). Figure 7 As shown, when the output value of the temperature sensor group is 70, the value of the analog signal on the second curve is AO2 (1), and the value of the analog signal on the second straight line is AO2 (2), AO2 (1) > AO2 (2).

[0061] Typically, when the output value of the temperature sensor array changes, the rate of change of the output value is amplified and mapped by the controller F (e.g., according to the following first and second mapping relationships) into an industry-standard 4-20mA current signal. Under normal temperature conditions, this is converted into a 4-12mA current signal, and under high temperature conditions, it is converted into a 12-20mA current signal. Therefore, 4mA is the minimum analog signal output in response to analog signal adjustment under normal temperature conditions, and 12mA is the maximum analog signal output in response to analog signal adjustment under normal temperature conditions; 12mA is the minimum analog signal output in response to analog signal adjustment under high temperature conditions, and 20mA is the maximum analog signal output in response to analog signal adjustment under high temperature conditions.

[0062] Accordingly, under the first mapping relationship between the rate of change of the output value of the temperature sensor group and the industrial standard current signal, at normal temperature conditions, the rate of change of the output value of the temperature sensor group corresponding to the "minimum analog signal output in response to analog signal adjustment" (e.g., 4mA) is as follows: Figure 6 The 4 on the horizontal axis represents the rate of change of the minimum temperature sensor group output value that causes the analog signal adjustment; the rate of change of the temperature sensor group output value corresponding to the "maximum analog signal output in response to analog signal adjustment" (e.g., 12mA) represents the minimum temperature sensor group output value that causes the analog signal adjustment. Figure 6 The 10 on the horizontal axis represents the rate of change of the temperature sensor group output value that causes the analog signal to adjust.

[0063] Similarly, under the second mapping relationship between the temperature sensor group and the industrial standard current signal, under high-temperature operating conditions, the temperature output value corresponding to the "minimum analog signal output in response to analog signal adjustment" (e.g., 12mA) is (e.g., ...). Figure 7 The 60 on the horizontal axis represents the minimum temperature output value that causes the analog signal to adjust; the temperature output value corresponding to the maximum analog signal output in response to analog signal adjustment (e.g., 20mA) is... Figure 7 The 90 on the horizontal axis is the maximum temperature output value that causes the analog signal to adjust.

[0064] In some embodiments, the expression for the first curve corresponding to normal temperature conditions can be: Y=X 2 / 30+13 X / 15, where X represents the output value of the temperature sensor group and Y represents the analog signal sent by the controller to the frequency converter.

[0065] In some embodiments, on the second curve, the analog signal AO2 corresponding to 60℃ is 12mA, the analog signal AO2 corresponding to 70℃ is 16mA, the analog signal AO2 corresponding to 80℃ is 18.66mA, and the analog signal AO2 corresponding to 90℃ is 20mA. Then, the approximate slope values ​​of each segment on the second curve can be calculated as follows: K1=(16-12) / (70-60)=0.4, K2=(18.66-16) / (80-70)=0.266, K3=(20-18.66) / (90-80)=0.134, K1>K2>K3. It can be seen that as the temperature gradually increases, the slope of the second curve gradually decreases.

[0066] In some embodiments, the first curve is a smoothly transitioning curve or a polyline composed of multiple line segments; or, the second curve is a smoothly transitioning curve or a polyline composed of multiple line segments.

[0067] In some embodiments, the operating condition further includes an over-temperature condition. Under the over-temperature condition, the controller F sends a predetermined current signal to the frequency converter E, the predetermined current signal being used to instruct the frequency converter E to control the cooling fan D to stop operating.

[0068] The predetermined current signal can be a small current value, such as a non-zero small current value (e.g., 4mA). In the event of a disconnection fault in the signal line between controller F and inverter E, the signal received by inverter E will be 0mA. Sending a non-zero small current value from controller F to inverter E to stop the cooling fan D can prevent frequent false fault reports from inverter E, thus avoiding impacts on system stability. Furthermore, the electric vibration testing system operates in a strong electromagnetic interference environment, where analog signals are susceptible to magnetic field and current interference during transmission. If 0mA is used as the signal to stop the cooling fan, even slight electromagnetic interference could cause the control signal to fluctuate to 0mA under non-over-temperature conditions, leading to erroneous shutdown of the cooling fan D, which in turn could cause coil overheating and affect test accuracy.

[0069] Under normal operating conditions, during sinusoidal frequency sweep testing or random testing, a calculation adjustment is performed every 2 to 2.5 minutes. This calculation adjustment refers to calculating the rate of change of the output values ​​of the temperature sensor group and adjusting the analog signal sent to the frequency converter based on this rate of change.

[0070] Normal temperature operating conditions correspond to low-level testing scenarios in electric vibration testing systems. By setting periodic calculations and adjustments every 1.5 to 2.5 minutes, the frequency of fan adjustments can be precisely controlled (in a single routine sinusoidal frequency sweep or 10-minute test, the cooling fan speed only needs to be adjusted 4-5 times). This setting can also significantly reduce the number of frequency conversion adjustments in the inverter's EPWM control mode, reduce the voltage rise rate (dv / dt) impact on the cooling fan motor stator windings, significantly mitigate destructive damage to inter-turn insulation, and reduce equipment maintenance costs and the risk of unplanned downtime.

[0071] In existing technologies, during a single routine sinusoidal frequency sweep (1 oct / min) or a 10-minute random test, the fan speed typically adjusts more than 10 times, and may even exhibit more frequent and irregular speed adjustments. The core reason for this is that the control logic of existing technologies has significant flaws. 1. The control system relies on a single basis and lacks differentiation and predictability of operating conditions. Existing technologies mostly employ linear control based on absolute temperature values ​​or fixed threshold control, without distinguishing between normal and high-temperature operating conditions, nor introducing "temperature change rate" as an indicator for predicting heat dissipation needs. As long as the coil temperature fluctuates slightly (e.g., ±1℃), the frequency converter will trigger speed adjustment, failing to distinguish between "slow temperature drift" and "rapid temperature rise caused by sudden changes in operating conditions," thus leading to frequent speed adjustments.

[0072] 2. Lack of speed regulation frequency constraint mechanism. Current technology lacks a program constraint to calculate and determine the temperature rise every 1.5 to 2.5 minutes. The temperature control system responds in real-time to minute changes in the temperature signal, causing the fan speed to repeatedly rise and fall within a short period. For example, in a sinusoidal frequency sweep test, as the frequency changes slowly, even small fluctuations in coil heat generation can trigger multiple speed regulation actions.

[0073] 3. The control curve is a linear standard straight line (such as the first and second straight lines mentioned above), resulting in an overly sensitive response. Existing technologies often use standard straight lines with fixed slopes as control curves. Temperature and analog signals are linearly positively correlated, lacking the nonlinear design of this solution where "under normal temperature conditions, the control signal is lower than the standard control straight line (i.e., the first straight line), and the slope increases," and "under high temperature conditions, the control signal is higher than the standard control straight line (i.e., the second straight line), and the slope decreases." This fails to suppress ineffective speed regulation under low load conditions, further increasing the frequency of speed adjustments. For example, the second straight line in existing technologies is: Y=8 / 30 (X -60)+12, while the second curve of this scheme is: Y=-X 2 / 150+19 / 15 X-40, where X represents the output value of the temperature sensor group and Y represents the analog signal sent by the controller to the frequency converter.

[0074] Such frequent speed adjustments lead to high-frequency frequency conversion, which continuously impacts the inter-turn insulation of the motor stator winding, significantly shortening the motor's service life and causing unnecessary energy waste.

[0075] In the aforementioned electric vibration testing system, the frequency converter plays a crucial role. By monitoring the real-time frequency, DC voltage, output current, and output voltage of the frequency converter, the protection during the startup process and operation of the cooling fan can be improved. By monitoring the temperature of the internal control board of the frequency converter and the internal winding temperature of the cooling fan, measures to prevent chemical risks can be added (if the control board overheats due to a fault, it may cause control signal disorder and thus cause cooling fan failure). By calculating and monitoring the real-time power of the cooling fan, the data presentation of the control device can be enriched, and economic benefits, energy-saving effects, and carbon reduction can be transformed into more concise core data, which can be presented more intuitively to the users of the electric vibration testing system.

[0076] like Figure 8As shown, the inverter and controller (such as a PLC controller) can share and exchange data via serial communication, while the controller and display screen can strengthen the definition and connection of variables (used to distinguish operating conditions) via Ethernet communication. The local display screen can be configured with separate configuration windows to display energy-saving data, operating status, debugging parameters, fault diagnosis, etc., conveying more high-value information within a single window compared to the traditional inverter control panel display method. Compared to the traditional method of debugging parameters item by item, a one-click data entry option can be set up. All data can be stored separately in the internal memory according to the cooling fan parameters. Users of the electric vibration testing system only need to select the parameter option of the target motor to complete the one-click entry of all debugging data.

[0077] Based on scenarios where the equipment and control room are not in the same physical space, the system can achieve communication between the host computer and the controller using a server platform. Users of the electric vibration testing system can monitor the system's heat dissipation in real time through the host computer. When any alarm occurs during actual operation, the electric vibration testing system can automatically shut down for protection and simultaneously send the fault information to the host computer for display. Users of the electric vibration testing system can remotely query and verify fault codes and then promptly go to the site for in-depth diagnosis and troubleshooting. This setup allows for a closer connection between people and machines, preventing potential risks caused by malfunctions in the heat dissipation equipment and strengthening the logical chain of fault diagnosis.

[0078] It should be noted that the control method of this solution differs from that of a typical air conditioner, specifically in the following aspects: 1. The core control objective and the controlled object are fundamentally different. The heat dissipation of electric vibration testing targets the core heat-generating components of the equipment (excitation coil, drive coil), which is a precise heat dissipation at the equipment component level. The goal is to ensure stable coil temperature, prevent magnetic field fluctuations and decreased vibration accuracy, and protect the cooling fan, balancing heat dissipation, energy saving, and fan lifespan. On the other hand, air conditioning control targets enclosed spaces (indoor / industrial machine rooms), which is a space-level temperature and humidity regulation. The goal is to meet human comfort or constant temperature and humidity requirements for conventional industrial equipment. The controlled object is the air in the space, not specific equipment components.

[0079] 2. The characteristics of the heat source and the detection logic are different. The heat source of the electric vibration testing system is the excitation and drive coil. The current of the excitation coil is stable, which leads to a stable temperature. The current of the drive coil is random, which leads to a random temperature. Therefore, dual sensors are needed to take the maximum value, with the stable excitation temperature as the benchmark, to avoid frequent fluctuations in the drive temperature to a certain extent. On the other hand, the heat source of the air conditioner is the human body, conventional equipment, and environmental heat exchange in the space. The heat generation is relatively uniform and there is no obvious difference between "stable" and "random". Generally, multi-point average temperature measurement or single-point temperature measurement is used in the space. There is no need to take extreme values ​​as the control basis, and the detection logic is simpler.

[0080] 3. Differences in Control Logic and Regulation Strategies. This section should focus on the previously discussed hyperbolic and segmented control. Electric vibration testing for heat dissipation uses segmented operating conditions and differentiated regulation: at normal temperature, the rate of temperature change is considered (first curve, increasing slope, prioritizing energy saving and predicting temperature rise to avoid sudden speed changes); at high temperature, the absolute temperature value is considered (second curve, decreasing slope, prioritizing efficient heat dissipation and controllable energy consumption). There is also isolation between the 4-12mA and 12-20mA signal ranges, with intelligent switching. In contrast, air conditioning control mostly uses single linear PID regulation, linearly adjusting the compressor and fan speeds based on the difference between the set temperature and the actual temperature. There is no segmented distinction between "rate of change" and "absolute value," nor is there a need to design curve slopes for specific operating conditions of equipment components; the regulation strategy is more universal.

[0081] 3. Different actuator control requirements. The actuator for electric vibration testing is a cooling fan (driven by a frequency converter). The core requirement is to avoid frequent frequency changes, because frequent frequency changes can cause the PWM wave height dv / dt to impact the inter-turn insulation of the fan stator winding. Therefore, the control signal must be stable. The cause of frequent frequency changes is eliminated by "stable reference + on-demand speed adjustment". In addition, the speed adjustment must match the short-term temperature rise to avoid sudden changes that cause mechanical oscillation. On the other hand, the actuators of air conditioners are compressors and indoor and outdoor fans. Their frequency conversion control does not have the special constraint of "inter-turn insulation damage". Frequent frequency conversion is a conventional control method. It is only necessary to balance energy saving and temperature control accuracy. There is no need to deliberately avoid small sudden changes in speed. The actuator control requirements are more inclined towards general frequency conversion energy saving.

[0082] 4. Energy-saving logic and priorities differ. Energy saving in electric vibration testing is based on precise energy saving according to the heat dissipation needs of equipment components. It prevents excessive heat dissipation at normal temperature (the first curve outputs a lower analog quantity than a linear curve, and the fan operates at low speed), and prevents ineffective energy consumption at high temperature (the slope is halved after 80℃ to avoid fan saturation). The premise of energy saving is to ensure the accuracy of equipment operation and the life of the fan. Heat dissipation and fan protection have higher priorities than energy saving. On the other hand, the energy saving of air conditioning is based on general energy saving of space temperature and humidity. It reduces energy consumption while meeting comfort / environmental requirements by adjusting the compressor load through frequency conversion. Although comfort / environmental constant temperature has a high priority, it does not have the additional premise of "accuracy protection of equipment components and special life protection of actuators". Its energy-saving logic is simpler.

[0083] 5. Different operating condition adaptability and response requirements. Electric vibration testing systems face diverse and extreme operating conditions (increased test duration, test type switching, and sudden short-term temperature rise), so the control response is required to accurately match the short-term temperature rise. The first curve's increasing slope realizes that "the higher the temperature rise rate, the faster the signal changes," predicting the temperature rise trend. In contrast, air conditioning operates under relatively stable conditions and does not have a significant need for "short-term sudden temperature rise." The control response focuses on "stable temperature control and avoiding temperature fluctuations," and there is no need to design a response strategy with an increasing slope for sudden temperature rises. The operating condition adaptability is more inclined towards normal steady state.

[0084] 6. Different system coupling. The heat dissipation system of the electric vibration test is strongly coupled to the main equipment (vibration table). The heat dissipation effect directly affects the vibration accuracy, magnetic field stability and even the accuracy of the test results of the main equipment. Heat dissipation control is the core link for the reliable operation of the main equipment. On the other hand, the air conditioning system is weakly coupled to the equipment in the controlled space. The air conditioning only provides a stable ambient temperature and does not directly affect the core operating parameters of the equipment (such as accuracy and performance). It only provides auxiliary environmental protection for the operation of the equipment.

[0085] This specification also provides a method for testing electric vibration, such as Figure 9 As shown, it includes the following S10 and S20.

[0086] S10: Determine the operating condition of the electric vibration testing system based on the output value of the temperature sensor group.

[0087] The temperature sensor group can be a group that includes temperature sensors located in the winding gaps of the excitation coil and / or drive coil, or it can include temperature sensor groups located in other positions within the electric vibration testing system. This electric vibration testing method focuses on setting the control curve and does not impose limitations on the temperature sensor group. S20: Dynamically adjust the analog signal sent to the frequency converter according to the operating conditions and the output value of the temperature sensor group; wherein, under normal temperature conditions, the analog signal sent to the frequency converter is adjusted according to the first curve; under high temperature conditions, the analog signal sent to the frequency converter is adjusted according to the second curve.

[0088] The first curve is a curve showing how the value of the analog signal changes with the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

[0089] The second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group. When the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

[0090] The description and function of this method can be understood by referring to the corresponding section on electric vibration testing systems, and will not be repeated here.

[0091] The electric vibration testing system and method provided in this manual, under normal temperature conditions, adjusts the analog signal sent to the frequency converter according to the "rate of change of the output value of the temperature sensor group" based on the "first curve." Except for the two endpoints of the first curve, the values ​​of the analog signal on the first curve are lower than those on the first straight line. Compared to the high signal output of the first straight line, the first curve outputs a lower analog signal per unit temperature rise cycle, thereby driving the cooling fan to operate at a slower speed. This setting, while meeting the basic heat dissipation requirements of the excitation coil, fundamentally avoids energy waste caused by "overheating," thus meeting the core requirements of low-carbon development in the industrial sector.

[0092] The slope of the first curve increases progressively, meaning that the higher the rate of temperature rise, the faster the rate of change of the analog signal AO1. This design can precisely match the short-term temperature rise requirements caused by "increased test duration and test type switching," ensuring both reliable and stable heat dissipation and avoiding the mechanical vibration impact of sudden speed changes on the heat dissipation system. This indirectly ensures the operational stability of the electric vibration testing system and guarantees the accuracy of product reliability test results.

[0093] The electric vibration testing system, method, and controller provided in this manual adjust the analog signal sent to the frequency converter according to the "second curve" based on the "output value of the temperature sensor group" under high-temperature conditions. Except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than that on the second straight line. Compared with the low signal output of the second straight line, the second curve outputs a higher analog signal per unit temperature rise cycle. This allows the cooling fan to run at a faster speed, increases the airflow velocity in the air duct, and enhances the heat dissipation of the excitation coil. At the same time, it indirectly increases the airflow supply to the central air gap where the drive coil is located, fundamentally avoiding magnetic field fluctuations and decreased vibration accuracy caused by abnormal coil temperature rise, and even preventing equipment failures caused by coil burnout. This provides core assurance for extreme reliability testing in industries such as automotive, aerospace, and military.

[0094] The slope of the second curve decreases gradually, and nearly half of the slope slows down when the temperature exceeds 80℃. The core advantage of this design is that it rapidly enhances heat dissipation capacity in the early stages of temperature rise, and the timely and powerful heat dissipation effect drives the vibration system to quickly return to normal operating conditions and switch back to energy-saving control mode; when the temperature approaches 80℃ and the motor is close to full load, it avoids blindly increasing the output signal and prevents energy waste caused by the saturation of the cooling fan speed, thus achieving the dual goals of "high-temperature and efficient heat dissipation + precise and controllable energy consumption".

[0095] The electric vibration testing system, method, and controller provided in this manual, through adjusting the analog signal using the first and second curves, also achieve the following technical effects: 1. Intelligent switching of operating conditions to adapt to diverse and extreme testing needs. Specifically, the two curves are precisely divided based on normal temperature and high temperature operating conditions, combined with signal interval isolation of 4-12mA and 12-20mA, realizing the intelligent control logic of "observing the rate of change at normal temperature (prioritizing energy saving + predicting trends) and observing the absolute value at high temperature (prioritizing safety + powerful heat dissipation)," which can adapt to the diverse and extreme characteristics of electric vibration testing systems and conforms to the trend of intelligent development in the industrial field; 2. Comprehensive solution to technical pain points and promotion of heat dissipation system upgrades. Specifically, this hyperbolic control scheme comprehensively breaks through the limitations of existing constant frequency or single linear control from four dimensions: "motor insulation protection, coil heat dissipation guarantee, precise energy consumption control, and safety protection backup." It solves the technical drawbacks of existing control methods in balancing heat dissipation fan damage, heat dissipation, and energy saving, ensuring the long-term stable operation of the electric vibration testing system.

[0096] This specification provides an electric vibration testing device that can be used to implement the above-described electric vibration testing method. The device includes a judgment unit and an adjustment unit.

[0097] The judgment unit is used to determine the operating condition of the electric vibration testing system based on the output value of the temperature sensor group.

[0098] The adjustment unit is used to dynamically adjust the analog signal sent to the frequency converter according to the operating conditions and the output value of the temperature sensor group; wherein, under normal temperature conditions, the analog signal sent to the frequency converter is adjusted according to the first curve; under high temperature conditions, the analog signal sent to the frequency converter is adjusted according to the second curve.

[0099] The first curve is a curve showing how the value of the analog signal changes with the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

[0100] The second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group. When the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

[0101] The description and function of this device can be understood by referring to the corresponding section on electric vibration testing systems, and will not be repeated here.

[0102] This invention also provides a controller, such as... Figure 10 As shown, the controller may include a processor 1001 and a memory 1002, wherein the processor 1001 and the memory 1002 can be connected via a bus or other means. Figure 10 Taking the example of a connection between China and Israel via a bus.

[0103] Processor 1001 may be a central processing unit (CPU). Processor 1001 may also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, or combinations thereof.

[0104] The memory 1002, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs, non-transitory computer-executable programs, and modules, such as the program instructions / modules (e.g., judgment unit and adjustment unit) corresponding to the electric vibration testing method in the embodiments of the present invention. The processor 1001 executes various functional applications and data processing of the processor by running the non-transitory software programs, instructions, and modules stored in the memory 1002, thereby implementing the electric vibration testing method in the above system embodiments.

[0105] The memory 1002 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function; the data storage area may store data created by the processor 1001, etc. Furthermore, the memory 1002 may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, the memory 1002 may optionally include memory remotely located relative to the processor 1001, and these remote memories may be connected to the processor 1001 via a network. Examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0106] The one or more modules are stored in the memory 1002 and, when executed by the processor 1001, implement the above-described electric vibration testing method.

[0107] The specific details of the controller described above can be understood by referring to the relevant descriptions and effects in the system embodiments, and will not be repeated here.

[0108] This specification also provides a computer storage medium storing computer program instructions, which, when executed, implement the above-described electric vibration testing method.

[0109] This specification also provides a computer program product comprising a computer program that, when executed by a processor, implements the above-described electric vibration testing method.

[0110] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. The storage medium can be a magnetic disk, optical disk, read-only memory (ROM), random access memory (RAM), flash memory, hard disk drive (HDD), or solid-state drive (SSD), etc.; the storage medium can also include combinations of the above types of memory.

[0111] The various embodiments in this specification are described in a progressive manner. For the same or similar parts between the various embodiments, please refer to each other. The focus of each embodiment is to describe the differences from other embodiments.

[0112] The systems, devices, modules, or units described in the above embodiments can be implemented by computer chips or entities, or by products with certain functions.

[0113] For ease of description, the above devices are described separately by function as various units. Of course, in implementing this application, the functions of each unit can be implemented in one or more software and / or hardware.

[0114] As can be seen from the above description of the embodiments, those skilled in the art can clearly understand that this application can be implemented by means of software plus necessary general-purpose hardware platforms. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute certain parts of the methods of various embodiments of this application.

[0115] This application can be used in a wide variety of general-purpose or special-purpose computer system environments or configurations. For example: personal computers, server computers, handheld or portable devices, tablet devices, multiprocessor systems, microprocessor-based systems, set-top boxes, programmable consumer electronics devices, network PCs, minicomputers, mainframe computers, distributed computing environments including any of the above systems or devices, etc.

[0116] This application can be described in the general context of computer-executable instructions, such as program modules, that are executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform a specific task or implement a specific abstract data type. This application can also be practiced in distributed computing environments where tasks are performed by remote processing devices connected via a communication network. In distributed computing environments, program modules can reside in local and remote computer storage media, including storage devices.

[0117] Although this application has been described through embodiments, those skilled in the art will know that this application has many modifications and variations without departing from the spirit of this application, and it is intended that the appended claims cover such modifications and variations without departing from the spirit of this application.

Claims

1. An electric vibration testing system, characterized in that, include: Excitation coil, used to pass current through it to generate a magnetic field; The moving coil includes the drive coil, the support frame, and the platform on which the object under test is placed. The moving coil vibrates based on the force exerted on the magnetic field by the driving coil after it is energized, and transmits the vibration to the object under test; the excitation coil and the driving coil are arranged in a common air duct; A temperature sensor group, including temperature sensors disposed in the winding gap of the excitation coil and / or the drive coil; A cooling fan is installed at one end of the air duct to generate airflow in the air duct to assist in heat dissipation. The frequency converter is used to receive control signals sent by the controller and convert them into the power supply frequency of the cooling fan; The controller is used to determine the current operating condition based on the output value of the temperature sensor group; and to dynamically adjust the analog signal sent to the frequency converter based on the operating condition and the output value of the temperature sensor group. Specifically, under normal operating conditions, the analog signal sent to the frequency converter is adjusted according to the first curve; under high operating conditions, the analog signal sent to the frequency converter is adjusted according to the second curve. The first curve is a curve showing how the value of the analog signal changes with the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal to adjust, and the maximum and minimum analog signal output in response to the adjustment of the analog signal. The second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group. When the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

2. The electric vibration testing system according to claim 1, characterized in that, As the rate of change of the output value of the temperature sensor group gradually increases, the slope of the first curve also gradually increases. And / or, As the output value of the temperature sensor group gradually increases, the slope of the second curve gradually decreases.

3. The electric vibration testing system according to claim 1, characterized in that, The operating conditions also include: over-temperature conditions; Under the over-temperature condition, the controller sends a predetermined current signal to the frequency converter, which is used to instruct the frequency converter to control the cooling fan to stop operating.

4. The electric vibration testing system according to claim 1, characterized in that, Under normal operating conditions, during sinusoidal frequency sweep testing or random testing, a calculation adjustment is performed every 2 to 2.5 minutes. The calculation adjustment refers to calculating the rate of change of the output value of the temperature sensor group and adjusting the analog signal sent to the frequency converter according to the rate of change.

5. The electric vibration testing system according to claim 1, characterized in that, The temperature sensor group includes at least: The first temperature sensor is installed in the winding gap of the excitation coil; The second temperature sensor is located in the winding gap of the drive coil; A signal processing circuit is connected to the output terminals of the first temperature sensor and the second temperature sensor; the output value of the signal processing circuit is not less than the maximum value among the detection values ​​of the first temperature sensor and the second temperature sensor.

6. The electric vibration testing system according to claim 1, characterized in that, The first curve is a curve with a smooth transition or a broken line composed of multiple line segments; Alternatively, the second curve may be a smoothly transitioned curve or a broken line composed of multiple line segments.

7. A method for testing electric vibration, characterized in that, include: The operating condition of the electric vibration testing system is determined based on the output values ​​of the temperature sensor group. The analog signal sent to the frequency converter is dynamically adjusted according to the operating conditions and the output value of the temperature sensor group; wherein, under normal temperature conditions, the analog signal sent to the frequency converter is adjusted according to the first curve; under high temperature conditions, the analog signal sent to the frequency converter is adjusted according to the second curve. The first curve is a curve showing how the value of the analog signal changes with the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal to adjust, and the maximum and minimum analog signal output in response to the adjustment of the analog signal. The second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group. When the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

8. An electric vibration testing device, characterized in that, include: The judgment unit is used to determine the operating condition of the electric vibration testing system based on the output value of the temperature sensor group. The adjustment unit is used to dynamically adjust the analog signal sent to the frequency converter according to the operating conditions and the output value of the temperature sensor group; wherein, under normal temperature conditions, the analog signal sent to the frequency converter is adjusted according to a first curve; under high temperature conditions, the analog signal sent to the frequency converter is adjusted according to a second curve. The first curve is a curve showing how the value of the analog signal changes with the rate of change of the output value of the temperature sensor group. When the rate of change of the output value of the temperature sensor group is the same, except for the two endpoints on the first curve, the value of the analog signal on the first curve is less than the value of the analog signal on the first straight line. The first straight line is a virtual straight line drawn based on the maximum and minimum rate of change of the temperature output value that causes the analog signal to adjust, and the maximum and minimum analog signal output in response to the adjustment of the analog signal. The second curve is a curve showing how the value of the analog signal changes with the output value of the temperature sensor group. When the output values ​​of the temperature sensor group are the same, except for the two endpoints of the second curve, the value of the analog signal on the second curve is greater than the value of the analog signal on the second straight line. The second straight line is a virtual straight line drawn based on the maximum and minimum temperature output values ​​that cause the analog signal to adjust, and the maximum and minimum analog signals output in response to the adjustment of the analog signal.

9. A controller, characterized in that, include: The system includes a memory and a processor, which are interconnected. The memory stores computer instructions, and the processor executes these computer instructions to implement the electric vibration testing method of claim 7.

10. A computer storage medium, characterized in that, The computer storage medium stores computer program instructions, which, when executed, implement the electric vibration testing method of claim 7.

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