An automated testing method and testing line

Abstract

The application belongs to the technical field of testing, and discloses an automatic testing method and a testing production line. The testing method comprises the following contents: a tray is used in cooperation with a conveying line, so that a testing object is circulated between various testing stations, and the testing object is arranged on the tray; when the docking of the testing object and a testing device needs to be realized, a modular plug-in docking structure is used, so that the testing object and the testing device are quickly plugged in and separated. The testing production line comprises a conveying line, a tray, a common end interface module, an independent end interface module, a linear power source and a plurality of testing devices arranged relative to the conveying line. The application uses a modular plug-in docking structure to replace manual wiring, so as to simplify the connection process of the testing object and the testing device, and to realize the automation of the connection process, thereby simplifying the testing process, improving the testing efficiency and ensuring the safety of personnel.

Description

Technical Field

[0001] This invention belongs to the field of testing technology, specifically relating to an automated testing method and testing production line. Background Technology

[0002] The new energy and new power system are booming: offshore wind power, photovoltaic grid connection, energy storage, rail transit, high voltage frequency conversion and other fields are growing rapidly, and the demand for high voltage DC filter devices continues to rise. As a related application of intelligent manufacturing, it shows a year-on-year upward trend.

[0003] In the production and testing of high-voltage DC filter devices, if manual wiring is used to connect the high-voltage DC filter devices to the testing equipment, the following problems exist: decreased testing efficiency (inefficient manual wiring operations will prolong the entire testing cycle); low repeatability of manual wiring, which may result in wiring errors, miswiring, missed detections, short circuits, and equipment damage; and personnel exposure risks, as frequent disconnection and relocation of wires and handling of products expose personnel to the risks of high-voltage electric shock and arcing due to repeated contact with high-voltage circuits.

[0004] Therefore, an automated testing method and testing production line are needed to address the shortcomings of manual operation, thereby shortening the production cycle, increasing capacity, and enabling rapid product delivery. Summary of the Invention

[0005] In view of the shortcomings of existing technologies, the purpose of this invention is to provide an automated testing method and testing production line.

[0006] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides an automated testing method that uses a pallet and conveyor line structure to allow the test objects to move between various testing stations, with the test objects arranged on the pallet. When it is necessary to connect the test object and the test equipment, a modular plug-in docking structure is adopted to achieve rapid plugging and unplugging between the test object and the test equipment.

[0007] Compared to manually connecting the test object and test equipment at each test station, this invention adopts a modular plug-in docking structure to simplify the connection process and automate it, thereby simplifying the test process, improving test efficiency, and ensuring personnel safety. Specifically, the test objects are placed on a pallet, which works in conjunction with the conveyor line so that the test objects can reach different test stations to complete different test items under the drive of the conveyor line. Regarding the connection and mating, different test items have different test elements. For example, in the electrode and shell test station, the electrodes of the test object are short-circuited as the positive terminal and the shell as the negative terminal. AC high voltage is applied and leakage current is monitored throughout the process to determine whether the insulation between the electrodes and the shell will break down or the leakage current will exceed the standard within a specified time. The wiring required for the test object in this station is different from that in other stations. However, there are so many test stations. Therefore, a common terminal interface module can be set up to connect all the wiring required for the test object to this common terminal interface module. Different test stations can select the corresponding interface unit on the common terminal interface module according to their own needs. On the testing station side, each testing device can be equipped with an independent interface module for wired connection with the corresponding testing device. This standardizes the interfaces of different testing devices in a formal way, making it easier to plug in. In addition, the connection positions of different testing devices may be different. By placing the independent interface module in a suitable plug-in position, it is easy to cooperate with the common interface module. Based on the above solution, the present invention can replace manual wiring to realize the connection between the test object and the test equipment, thereby simplifying the test process, improving test efficiency, and ensuring personnel safety.

[0008] As a preferred embodiment of the present invention, a high-voltage DC filter device is used as the test object, and the test station includes... The manual wiring station connects the test object to the common interface module via wires. The common interface module is also located on the tray. The wiring sequence inspection station checks whether the wiring sequence is qualified. The inter-electrode withstand voltage test station applies a test voltage to determine whether the insulation between the two electrodes of the test object will break down or the leakage current will exceed the standard within a specified time. The high-resistance test station determines the insulation resistance value between the two poles of the test object and judges whether the insulation performance is qualified by comparing it with the set upper and lower limits. At the electrode and shell testing station, the electrodes of the test object are short-circuited as the positive electrode and the shell as the negative electrode. AC high voltage is applied and leakage current is monitored throughout the process to determine whether the insulation between the electrodes and the shell will break down or the leakage current will exceed the standard within a specified time. The high-voltage capacitance and loss test station determines the capacitance and loss of the test object. By comparing it with the baseline data before aging, it determines whether the capacity deviation and loss value of the test object under high-voltage conditions are qualified, and performs reliable discharge after the test. The partial discharge test station applies AC high voltage to the test object and determines whether there are partial discharge defects inside the insulation by measuring the partial discharge quantity. The manual disconnection station disconnects the wired connection between the test object and the common interface module; The camera appearance inspection station determines whether the appearance and size of the test object meet the standards. Offline workstation; Each of the following stations is equipped with an independent terminal interface module for wired connection to the corresponding test equipment: the line sequence inspection station, the inter-electrode withstand voltage test station, the high resistance test station, the electrode shell test station, the high voltage capacitance test station, and the partial discharge test station. When the common-end interface module is plugged into the independent-end interface module of the corresponding workstation, the connection between the test object and the test equipment of the corresponding workstation is realized.

[0009] In this invention, it is further noted that the camera appearance inspection station inspects all five sides of the test object, excluding the bottom side. Before inspection, the manual cable disconnection station disconnects the cables between the test object and the common interface module to prevent these cables from interfering with camera shooting.

[0010] Secondly, the present invention provides an automated testing production line for implementing the aforementioned automated testing method, comprising a conveyor line, a tray, a common end interface module, an independent end interface module, a linear power source, and several testing devices arranged around the conveyor line; The common interface module is arranged on the tray surface through a slider rail structure, and the linear power source is fixed on the tray surface and its output end is connected to the common interface module. The public interface module is configured with several interface units, and each interface unit is connected to the test object via a cable. The independent interface module is configured with corresponding interface unit two according to the needs of different test stations. Interface unit two is wired to the test equipment.

[0011] In this invention, the pallet works in conjunction with the conveyor line, allowing the pallet to move between different testing devices along the conveyor line; When it is necessary to connect and mate the test object and the test equipment, the slider and rail structure guides the movement of the common end interface module, thereby ensuring the accuracy of the connection. The interface unit one in the common end interface module and the interface unit two in the independent end interface module can be connected to complete the connection between the test object and the test equipment. The number of interface unit one is determined according to the test points that the test object needs to bring out. Interface unit two can be inserted into the corresponding position of interface unit one according to the test points to be connected. For points that do not need to be tested, interface unit two is not set for insertion. The power for insertion and separation is provided by a linear power source, which can be an electric cylinder, a pneumatic cylinder, or other type, depending on the actual needs.

[0012] As a preferred technical solution of the present invention, the conveyor line is equipped with a lifting stop cylinder and a position sensor at the corresponding test station position; The position sensor determines whether the tray has moved to the corresponding test station location; The lifting and stopping cylinder lifts the pallet upwards to stop it.

[0013] This invention uses a position sensor to determine whether the pallet is in position. When the pallet is in position, a lifting stop cylinder is used to stop the pallet, so that the pallet stops at the test station. After the test is completed, the lifting stop cylinder descends, and the pallet continues to flow to the next station.

[0014] The beneficial effects of this invention are: by using a modular plug-in structure to replace manual wiring, the connection process between the test object and the test equipment is simplified and the connection process can be automated, thereby simplifying the test process, improving test efficiency, and ensuring personnel safety. Attached Figure Description

[0015] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings; Figure 1 This is a schematic diagram showing the distribution of each test station in the entire testing process in an embodiment of the present invention; Figure 2 This is a schematic diagram of the insertion and docking structure in an embodiment of the present invention; Figure 3 This is a schematic diagram of the common terminal interface module, linear power source, and slide rail slider structure in an embodiment of the present invention; Figure 4 This is a schematic diagram of the independent end interface module in an embodiment of the present invention; The symbols for the main components are explained below: 1. Conveyor line; 2. Common interface module; 201. Interface unit one; 3. Independent terminal interface module; 301. Interface unit two; 4. Linear power source; 5. Manual wiring station; 6. Line sequence inspection station; 7. Inter-electrode withstand voltage test station; 8. High-resistance testing station; 9. Polar shell testing station; 10. High-voltage capacitance loss testing station; 11. Partial discharge testing station; 12. Manual suture removal station; 13. Camera appearance inspection station; 14. Offline workstation. Detailed Implementation

[0016] The technical solutions of the present invention will be described in detail below with reference to specific embodiments and accompanying drawings. The embodiments described herein are specific implementations of the present invention, used to illustrate the concept of the present invention; these descriptions are explanatory and exemplary, and should not be construed as limiting the implementation methods or the scope of protection of the present invention. In addition to the embodiments described herein, those skilled in the art can employ other obvious technical solutions based on the content disclosed in the claims and specification of this application. These technical solutions include those that make any obvious substitutions and modifications to the embodiments described herein. Example 1

[0017] like Figure 1 As shown, this embodiment provides an automated testing method, which adopts a structure of pallet and conveyor line 1 to allow the test object to flow between various test stations, and the test object is arranged on the pallet; When it is necessary to connect the test object and the test equipment, a modular plug-in docking structure is adopted to achieve quick plugging and unplugging between the test object and the test equipment. The testing stations include the following: Manual wiring station 5 connects the test object to the common interface module 2 via wire. The common interface module 2 is also arranged on the tray. Wiring sequence inspection station 6: Check whether the wiring sequence is qualified; Station 7 for inter-electrode withstand voltage testing: The withstand voltage tester applies a test voltage to determine whether the insulation between the two electrodes of the test object will break down or the leakage current will exceed the limit within a specified time. Specifically, the test voltage is 0-20KV, the display is 1V, the power supply accuracy is ±1%, the upper and lower limits of charging leakage current and time are 1A, and the resolution is 0.01mA; the charging time is <1min, and the test time is 0-60s, which is continuously adjustable. The system monitors current and voltage throughout the entire process and provides real-time graphs. Rising phase: Exceeding the upper limit of the test current is considered a defect; when one-third of the charging time has passed, leakage current below the lower limit of the charging current setting is considered a defect, and test voltage above the upper limit of the test voltage is considered a defect. Testing process: Exceeding the upper limit of leakage current is considered a defect; exceeding the upper or lower limit of voltage should trigger an alarm and be considered a defect; no rise during the testing phase is considered a defect; no pass signal is considered a defect. The discharge process is divided into four stages, and the voltage across the test object is monitored in real time. When the voltage drops to the next level, the resistance level is switched to discharge. The fourth stage is short-circuit discharge. Level 1: 8000V ≤ Product Voltage; Level 2: 2000V ≤ Product Voltage < 8000V; Level 3: 20V ≤ Product voltage < 2000V; Level 4: 0V ≤ Product voltage < 20V; The voltage requirement is 5000V, the capacitance is 8200uF, and the discharge must be complete within 1 minute. The discharge must be completely cleaned up before a discharge end signal can be output when the product voltage is detected to be 0V. High-resistance testing station 8 determines the insulation resistance value between the two poles of the test object. By comparing it with the set upper and lower limits, it determines whether the insulation performance is qualified. Specifically, the test time is 0-60s, continuously adjustable, and timing begins when the set voltage reaches 99.9%. If the test fails, subsequent stations will not test. This function can be turned off. Upper and lower limits for the resistance value can be set, and the computer reads the resistance value and determines whether it is within the range; exceeding the range indicates failure. Parameter setting: The industrial control computer reads the MES parameters to complete the setting. Test voltage: 0-6KV, continuously adjustable, display 1V, voltage accuracy ±0.5%. Charging current and time: 1A-2A, charging time <1min. Insulation resistance measurement range: 1MΩ--99GΩ, measurement accuracy 5%. Discharge: Discharge time <1min; (short-circuit discharge >8s, voltage below 0.1V). Resistance discharge and short-circuit discharge are performed. The voltage across the test object is monitored in real time during the discharge process (when the voltage is below 20V). When switching to short-circuit discharge, it is necessary to ensure that the discharge is complete. Only when the voltage of the test object is monitored to be 0V can the discharge end signal be output. Station 9 for electrode and casing testing: The electrode of the test object is short-circuited as the positive terminal, and the casing as the negative terminal. AC high voltage is applied, and leakage current is monitored throughout to determine whether the insulation between the electrode and casing will break down within a specified time or whether the leakage current will exceed the limit. Specifically, the electrode is short-circuited as the positive terminal, and the casing is connected to the negative terminal. The maximum AC voltage for the electrode and casing is 15kV, displayed as 1V, with a voltage accuracy of ±1%. The maximum leakage current for the electrode and casing is 50mA, with a resolution of 0.001mA. The upper and lower limits for the test leakage current are 0.2mA-50mA. The equipment controls the start and stop of the instrument. Parameter settings are completed by the industrial control computer. This includes monitoring voltage, current, boost time, test time, buck time, and lower limit of charging current, with automatic voltage adjustment by the power supply. If a test station fails, subsequent stations will not be tested. Current and voltage are monitored throughout the process. During the boost phase: exceeding the upper limit of the test current is considered a failure. When one-third of the charging time has passed, leakage current below the lower limit of the charging current setting is considered a failure, and test voltage above the upper limit of the test voltage is considered a failure. During the test process: exceeding the upper limit of leakage current is considered a failure; exceeding the upper or lower limit of voltage triggers an alarm and is considered a failure; no boost or test phase is considered a failure; no pass signal is considered a failure. High-voltage capacitance and loss testing station 10 determines the capacitance and loss of the test object. By comparing it with the baseline data before aging, it judges whether the capacity deviation and loss value of the test object under high-voltage conditions are qualified. Reliable discharge is performed after the test. Specifically, the power supply is continuously adjustable from 0 to 500VAC, with 310VAC as the main working voltage and a power supply accuracy of ±3%. The test current is set at 250A, ±10%, 0.1A, with a capacity accuracy of 0.20%, a loss accuracy of ±0.0001, a resolution of 0.000001, and an ESR accuracy of ±0.05mΩ, with a resolution of 0.0001. Test duration: 15 seconds; line current controlled below 15A; test voltage issued by industrial control, automatic voltage adjustment by the equipment, voltage must have threshold alarm; issued parameters include: tested capacity, upper limit of capacity deviation, lower limit of capacity deviation, upper limit of loss, lower limit of loss, etc.; instrument start and stop controlled by the equipment, and reads the capacity and loss values ​​when running stably; reads the baseline data of the product before aging from the database, compares the data, and judges NG if the limit is exceeded; test frequency: 50Hz and 100Hz; after the test at this station is completed, the test object is discharged to ensure clean discharge; the discharge end signal can only be output when the product voltage is monitored to be 0V. Partial discharge test station 11 applies AC high voltage to the test object and determines whether there are partial discharge defects inside the insulation by measuring the partial discharge quantity; Manual disconnection station 12 disconnects the wired connection between the test object and the common interface module 2; Camera appearance inspection station 13 determines whether the appearance and size of the test object meet the standards. Offline workstation 14; Among them, the line sequence inspection station 6, the inter-electrode withstand voltage test station 7, the high resistance test station 8, the electrode shell test station 9, the high voltage capacitance test station 10, and the partial discharge test station 11 are all equipped with an independent terminal interface module 3, which is used to make wired connections with the test equipment of the corresponding station. When the common-end interface module 2 is plugged into the independent-end interface module 3 of the corresponding workstation, the test object is connected to the test equipment of the corresponding workstation.

[0018] In this embodiment, since the testing standards at each testing station vary depending on the specific product specifications, the above solution is only an example of the present invention. The key point is that the present invention uses a modular plug-in docking structure to replace manual wiring, thereby simplifying the connection process between the test object and the test equipment and automating the connection process, thus simplifying the testing process, improving testing efficiency, and ensuring personnel safety. Example 2

[0019] like Figure 1 , 2As shown in Figures 3 and 4, this embodiment provides an automated testing production line, including a conveyor line 1, a tray, a common end interface module 2, an independent end interface module 3, a linear power source 4, and several testing devices arranged around the conveyor line 1. The common interface module 2 is arranged on the surface of the tray via a slider rail structure, and the linear power source 4 is fixed on the surface of the tray and its output end is connected to the common interface module 2. The public interface module 2 is equipped with several interface units 201, and the interface units 201 are connected to the test object via cables. The independent end interface module 3 is equipped with a corresponding interface unit 301 according to the needs of different test stations. The interface unit 301 is connected to the test equipment via a wire. Conveyor line 1 is equipped with lifting stop cylinders and position sensors at the corresponding test stations; The position sensor determines whether the tray has moved to the corresponding test station location; The lifting and stopping cylinder lifts the pallet upwards to stop it.

[0020] In this invention, the pallet cooperates with the conveyor line 1, allowing the pallet to move between different testing devices along with the conveyor line 1; When it is necessary to connect and assemble the test object and the test equipment, the slider rail structure guides the movement of the common end interface module 2, thereby ensuring the accuracy of the connection. The interface unit 201 in the common end interface module 2 connects with the interface unit 301 in the independent end interface module 3 to complete the connection between the test object and the test equipment. The number of interface unit 1 201 is determined according to the test points that the test object needs to bring out. Interface unit 2 301 can be inserted into the corresponding position of interface unit 1 201 according to the test points to be connected. For points that do not need to be tested, interface unit 2 301 is not set for insertion. The power for insertion and separation is provided by linear power source 4, which can be an electric cylinder, a pneumatic cylinder, etc., depending on the actual needs. In terms of determining the position, the present invention uses a position sensor to determine whether the pallet is in place. When the pallet is in place, a lifting stop cylinder is used to stop the pallet, so that the pallet stops at the test station. After the test is completed, the lifting stop cylinder descends, and the pallet continues to flow to the next station.

[0021] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. An automated testing method, characterized in that: Includes the following: The structure of pallet combined with conveyor line (1) is adopted so that the test object can be transferred between various test stations and the test object is arranged on the pallet; When it is necessary to connect the test object and the test equipment, a modular plug-in docking structure is adopted to achieve rapid plugging and unplugging between the test object and the test equipment.

2. The automated testing method according to claim 1, characterized in that: The testing station includes, The manual wiring station (5) connects the test object to the common interface module (2) via wired connection. The common interface module (2) is also arranged on the tray. Wiring sequence inspection station (6) checks whether the wiring sequence is qualified; Inter-electrode withstand voltage test station (7), apply test voltage, and determine whether the insulation between the two poles of the test object will break down or the leakage current will exceed the standard within a specified time; High resistance test station (8) determines the insulation resistance value between the two poles of the test object and determines whether the insulation performance is qualified by comparing it with the set upper and lower limits; Electrode and shell testing station (9): The electrode of the test object is short-circuited as the positive electrode and the shell as the negative electrode. AC high voltage is applied and leakage current is monitored throughout the process to determine whether the insulation between the electrode and the shell will break down or the leakage current will exceed the standard within the specified time. High voltage capacity loss test station (10) determines the capacitance and loss of the test object. By comparing with the baseline data before aging, it determines whether the capacity deviation and loss value of the test object under high voltage conditions are qualified, and performs reliable discharge after the test. Partial discharge test station (11) applies AC high voltage to the test object and determines whether there is a partial discharge defect inside the insulation by measuring the partial discharge quantity; Manual disconnection station (12) disconnects the wired connection between the test object and the common terminal interface module (2); Camera appearance inspection station (13) determines whether the appearance and size of the test object meet the standards; Offline workstation (14); Among them, the line sequence inspection station (6), the inter-electrode withstand voltage test station (7), the high resistance test station (8), the electrode shell test station (9), the high voltage capacitance test station (10), and the partial discharge test station (11) are all equipped with an independent terminal interface module (3) for wired connection with the test equipment of the corresponding station. When the common end interface module (2) is plugged into the independent end interface module (3) of the corresponding workstation, the test object is connected to the test equipment of the corresponding workstation.

3. An automated testing production line for implementing the automated testing method described in claim 1 or 2, characterized in that: Includes a conveyor line (1), a pallet, a common end interface module (2), an independent end interface module (3), a linear power source (4), and several test devices related to the arrangement of the conveyor line (1); The common end interface module (2) is arranged on the surface of the tray through a slider rail structure, and the linear power source (4) is fixed on the surface of the tray and its output end is connected to the common end interface module (2); The public interface module (2) is equipped with several interface units (201), and the interface units (201) are connected to the test object via cables. The independent end interface module (3) is configured with a corresponding interface unit two (301) according to the needs of different test stations. The interface unit two (301) is wired to the test equipment.

4. An automated testing production line according to claim 3, characterized in that: The conveyor line (1) is equipped with a lifting stop cylinder and a position sensor at the corresponding test station position; The position sensor determines whether the tray has moved to the corresponding test station location; The lifting and stopping cylinder lifts the pallet upwards to stop it.

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