An automatic measurement and control method, device and computer equipment of a dry-type transformer temperature controller

Abstract

This invention discloses an automatic measurement and control method, device, and computer equipment for a dry-type transformer temperature controller. The method includes: S1, setting the parameters of the measurement and control module according to the model and requirements of the temperature controller to be tested; S2, powering on the temperature controller and confirming that all indicator lights and digital tubes are lit, and starting the measurement and control module for automatic testing; S3, testing all communication lines; if communication is successful, proceed to step S4; S4, calibrating the temperature controller; if all calibrations pass, proceed to step S5; otherwise, directly proceed to step S6 at the calibration failure point; S5, power-off detection and deleting test records; S6, outputting test results. This invention improves detection accuracy through multi-stage closed-loop calibration, while also enabling rapid fault location, adaptability to batch testing, significantly reducing human error, and improving testing efficiency.

Description

Technical Field

[0001] This invention relates to the field of dry-type transformer temperature controller technology, specifically to an automatic measurement and control method, device, and computer equipment for a dry-type transformer temperature controller. Background Technology

[0002] Dry-type transformer temperature controllers are crucial monitoring devices used to monitor transformer winding temperatures, automatically control fans, and ensure safe transformer operation. Dry-type transformer temperature controllers employ push-button and digital tube displays, a method that is low-cost, highly resistant to interference, and less demanding in high and low temperature environments, making it widely popular. However, because the temperature controller uses a digital tube display, many functions cannot be intuitively described and must be represented by numbers and letters. Our traditional testing method involves: first, using a multimeter in continuity mode to test the relay output point; the multimeter should conduct when the relay output is normal; then, directly connecting an AC220V indicator light to the fan output; the indicator light should illuminate when the fan is required, indicating the fan relay is functioning correctly; next, connecting a switch to the door switch; when the switch is closed, an alarm should sound; finally, connecting the temperature controller sensor to a calibration resistor and testing temperature changes based on resistance changes. This method results in long production testing times, low efficiency, wasted manpower and resources, and even missed functional tests due to high production volumes. Summary of the Invention

[0003] This invention addresses at least one technical problem in the prior art by disclosing an automatic measurement and control method, device, and computer equipment for a dry-type transformer temperature controller. The invention first presets the measurement and control module parameters according to the temperature controller model, completes the self-test of the display device after power-on, and then starts automatic testing. Finally, it automatically outputs the test results and fault location. Through multi-stage closed-loop calibration, the detection accuracy is improved. At the same time, it can quickly locate faults, adapt to batch testing, significantly reduce human error, and improve testing efficiency and product reliability.

[0004] This invention is achieved through the following technical solution:

[0005] This invention first provides an automatic measurement and control method for a dry-type transformer temperature controller, comprising the following steps:

[0006] S1. Set the parameters of the test and control module according to the model and requirements of the temperature controller to be tested;

[0007] S2. Power on the temperature controller and confirm that all indicator lights and digital displays are lit. Start the measurement and control module to perform automatic testing.

[0008] S3. Test all communication lines. If communication fails, check the communication circuit until communication is successful. If communication is successful, proceed to step S4.

[0009] S4. Perform pre-calibration checks, benchmark calibration, sampling calibration, and post-calibration checks on the temperature controller. If all calibrations pass, proceed to step S5; otherwise, proceed directly to step S6 at the node where calibration fails.

[0010] S5. Power failure detection, and delete test records;

[0011] S6. Output test results: If the result shows that the test was successful, replace the next thermostat; if the result shows that the test was unsuccessful, output the fault location.

[0012] As a further embodiment, S4 includes:

[0013] S41. Pre-calibration check: Connect the preset resistor. If the calibration passes, proceed to step S42; otherwise, proceed to step S6.

[0014] S42. Reference calibration: Connect the preset standard resistor and set the low temperature calibration point of the temperature controller. If the low temperature calibration point is displayed correctly and the fan running indicator light is on, the calibration is successful and proceed to step S43; otherwise, proceed to step S6.

[0015] S43. Sampling and calibration: Connect the preset standard resistor and set the low and high calibration points of the temperature controller. If the high temperature calibration point is displayed correctly and the equipment fault indicator light is on, the calibration is successful and proceed to step S44; otherwise, proceed to step S6.

[0016] S44. Post-calibration check: Connect the set resistor. If the temperature controller displays the correct temperature and the over-temperature alarm indicator is on, the calibration is successful. Proceed to step S5. Otherwise, proceed to step S6.

[0017] As a further embodiment, the control module is powered via a circuit breaker and connected to a control power indicator light. Terminals 5, 6, 8, and 9 of the control module are resistor-selective, controlling the sensor module of the temperature controller. Terminals 13 and 14 are used to connect to a control success indicator light; terminals 13 and 15 are used to connect to a control failure indicator light; terminals 13 and 16 control the temperature controller's power output; terminal 17 is a common terminal; terminals 17 and 18 control a relay from the temperature controller's fan output point. The normally open contact of the relay closes and connects to the control module's input point to detect fan operation and display the indicator light. Terminals 17 and 18... Terminal 9 is connected to the control module's input point via the temperature controller's over-temperature alarm output node. It is used to detect the over-temperature alarm relay output and display it via the over-temperature alarm indicator light. Terminals 17 and 20 are connected to the control module's input point via the temperature controller's over-temperature trip output node. They are used to detect the over-temperature trip relay output and display it via the over-temperature trip indicator light. Terminals 17 and 21 are connected to the control module's input point via the temperature controller's equipment fault output node. They are used to detect the equipment fault relay output and display it via the equipment fault indicator light. A button is installed between terminals 17 and 28, and between terminals 17 and 29, for starting and stopping the test.

[0018] As a further solution, the measurement and control module and the temperature controller communicate via RS485.

[0019] As a further solution, when the temperature controller does not require parameter modification, the model can be selected in the measurement and control module and the default settings can be directly entered. At this time, the measurement and control device enters standby mode to prepare for automatic testing.

[0020] When the temperature controller needs to be set with parameters, select the model to enter the parameter setting mode, set the parameters, and then enter the standby mode to prepare for automatic testing.

[0021] The present invention also provides an automatic measurement and control device for a dry-type transformer temperature controller, including a housing and a measurement and control module and a detection auxiliary module installed inside it, wherein the control panel of the measurement and control module and the operation terminal of the detection auxiliary module are both embedded in the door panel of the housing.

[0022] As a further solution, the testing auxiliary module includes several switches, buttons, and indicator lights. The switches are the switch for the temperature controller and the switch for the measurement and control module. The buttons include an emergency stop button and a start button for starting the test.

[0023] As a further solution, the door panel is provided with a first window for embedding a thermostat, and a clamp for fixing the thermostat is symmetrically installed on both sides of the first window. A bracket for supporting the thermostat is welded on the inner wall of the door panel.

[0024] The present invention also provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the method.

[0025] The features and beneficial effects of this invention are as follows:

[0026] (1) This invention first presets the measurement and control module parameters according to the temperature controller model, and after powering on and completing the self-test of the display device, it starts automatic testing; the front-end communication line is detected and communication faults are checked, and then pre-calibration checks, benchmark calibration, sampling calibration and post-calibration checks are performed in sequence. If the calibration is abnormal, it directly enters the subsequent process; then power-off testing is carried out to verify the power-off parameter storage capability and the trip indicator alarm function. After powering on, the temporary records and fault records generated by the test can be cleared; finally, the test results and fault locations are automatically output. The whole process realizes standardized and automated full-process testing, is compatible with multiple models of temperature controllers, checks hardware and communication risks in advance, and improves the testing accuracy through multi-stage closed-loop calibration; at the same time, it verifies the reliability of power-off storage and alarms, automatically clears test records to avoid interfering with normal operation, and can also quickly locate faults, adapt to batch testing, greatly reduce human error, improve testing efficiency and product reliability.

[0027] (2) This invention verifies the initial response of the temperature controller to a known temperature point by checking before calibration, and quickly determines whether the channel hardware is normal; it performs dual-point calibration of high and low temperature standard points by combining benchmark calibration and sampling calibration, eliminates linear error, and improves the accuracy of full-range temperature measurement; it verifies the temperature measurement accuracy of the temperature controller after calibration by checking after calibration, forming a closed-loop control of "input-calibration-feedback", ensuring the accuracy and stability of calibration results; when calibration fails, it directly outputs the test results, which can avoid redundant execution of invalid test processes, and can directly record fault nodes, improving test efficiency and fault location efficiency.

[0028] (3) After powering on, the present invention first confirms that the indicator lights and digital tubes are all lit, and then starts the automatic test, realizing the basic hardware self-test before the test, avoiding misjudgment of results due to display abnormalities in subsequent tests; and the one-click start automatic test process does not require manual step-by-step intervention, improving test efficiency and reducing human operation omissions. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention, 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 of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1This is a schematic diagram of the main view of the automatic measurement and control device according to an embodiment of the present invention;

[0031] Figure 2 This is a schematic diagram illustrating the application state of the automatic measurement and control device described in an embodiment of the present invention;

[0032] Figure 3 This is a circuit diagram of the measurement and control module described in an embodiment of the present invention;

[0033] Figure 4 This is a wiring diagram of the seventeenth and eighteenth terminals as described in an embodiment of the present invention;

[0034] Figure 5 This is a circuit diagram of the fan operation indicator light according to an embodiment of the present invention;

[0035] Figure 6 This is a circuit diagram of the first resistor selection control according to an embodiment of the present invention;

[0036] Figure 7 This is a circuit diagram of the second resistor selection control according to an embodiment of the present invention;

[0037] Figure 8 This is a circuit diagram of the temperature controller described in an embodiment of the present invention;

[0038] Figure 9 This is a wiring diagram of the sensor in the temperature controller described in an embodiment of the present invention;

[0039] Figure 10 This is a schematic diagram showing the model number of the temperature controller on the control panel according to an embodiment of the present invention;

[0040] Figure 11 This is a schematic diagram of parameter settings in the control panel according to an embodiment of the present invention;

[0041] Figure 12 This is a schematic diagram of the adjustment parameters in the control panel according to an embodiment of the present invention;

[0042] Figure 13 This is a schematic diagram of the standby state as described in an embodiment of the present invention;

[0043] Figure 14 This is a schematic diagram illustrating successful communication as described in an embodiment of the present invention;

[0044] Figure 15 This is a schematic diagram illustrating a communication failure as described in an embodiment of the present invention;

[0045] Figure 16 This is a schematic diagram of the pre-calibration inspection described in an embodiment of the present invention;

[0046] Figure 17 This is a schematic diagram of the reference calibration described in an embodiment of the present invention;

[0047] Figure 18 This is a schematic diagram of the sampling calibration described in an embodiment of the present invention;

[0048] Figure 19 This is a schematic diagram of the post-calibration inspection as described in an embodiment of the present invention;

[0049] Figure 20 This is a schematic diagram of the power-off detection described in an embodiment of the present invention;

[0050] Figure 21 This is a schematic diagram of power-on recovery as described in an embodiment of the present invention;

[0051] Figure 22 This is a schematic diagram of record clearing as described in an embodiment of the present invention;

[0052] Figure 23 This is a schematic diagram illustrating the successful completion of the test as described in an embodiment of the present invention;

[0053] Figure 24 This is a schematic diagram illustrating a test failure as described in an embodiment of the present invention;

[0054] Figure 25 This is a flowchart of the automatic measurement and control method described in an embodiment of the present invention.

[0055] Explanation of reference numerals in the attached figures:

[0056] 1-Box body; 11-Door panel; 12-Shell; 2-Control module; 3-Button; 4-Temperature controller; 5-Clamp; 6-Door panel switch; 7-Switch. Detailed Implementation

[0057] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below, and embodiments of the present invention will be provided, but this does not limit the scope of the present invention.

[0058] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0059] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0060] An automatic monitoring and control device for a dry-type transformer temperature controller, such as Figures 1 to 9 As shown, it includes:

[0061] The housing 1 includes a door panel 11 and a shell 12 hinged to one side. The shell 12 is used to accommodate the measurement and control module 2, the detection auxiliary module and the temperature controller 4. The door panel 11 is used to embed the control screen of the temperature controller, the control screen of the detection auxiliary module and the control screen of the measurement and control module 2.

[0062] The measurement and control module is connected to the temperature controller 4 and the detection auxiliary module circuit respectively, and is used to detect the temperature of the transformer temperature controller before calibration, the calibration temperature and the calibration temperature.

[0063] The detection auxiliary module, including switch 7, button 3 and indicator light, is used to assist the measurement and control module 2 in detecting the temperature controller 4.

[0064] The automatic measurement and control device of this application achieves integrated, automated, and visualized operation of the temperature controller calibration process through the coordinated cooperation of the housing, measurement and control module, and detection auxiliary module. It not only solves the problems of cumbersome operation, large error, and poor protection in traditional calibration methods, but also improves the reliability of calibration results through closed-loop detection and status feedback. It can be widely used in the factory testing and on-site calibration of dry-type transformer temperature controllers, significantly improving testing efficiency and quality control level.

[0065] In some embodiments, switch 7 serves as both the switch for the temperature controller and the switch for the measurement and control module. Button 3 includes an emergency stop button for power-off in emergency situations and a start button for initiating testing. Each button, switch, and indicator light is marked with its function to prevent operational errors, improve operational accuracy, and facilitate quick location of the corresponding button, switch, and indicator light, thereby improving work efficiency. This design allows operators to intuitively grasp the testing progress and results, avoiding test failures caused by misoperation and improving the controllability and safety of the calibration process. The combination of switches, buttons, and indicator lights supports the testing of temperature controllers of different models and with different calibration procedures. The indicator lights synchronously reflect the corresponding status, allowing the device to adapt to the calibration needs of various temperature controllers without hardware modification, significantly improving the device's versatility and compatibility.

[0066] In some embodiments, a door panel switch 6 is also installed on the door panel 11. The door panel switch 6 is a one-button switch. By setting a one-button door panel switch, the operator only needs to press a single point to complete the opening, closing, and locking of the door panel. The operation is simple, time-saving, and labor-saving, without the need for cumbersome alignment or rotation operations. A single person can quickly complete the cabinet opening and closing operations. The one-button switch is sensitive to triggering and has clear action feedback, making it less prone to jamming and accidental contact, and has high operational reliability. At the same time, it has a high degree of structural integration and occupies little door panel installation space, which facilitates overall layout and assembly wiring, effectively reducing production and assembly costs. Furthermore, it can form a linkage and interlock with the internal measurement and control electrical circuit to realize the safety logic of power off when the door is opened and power on when the door is closed, effectively avoiding accidental contact with internal live components during operation and maintenance, and greatly improving the safety and protection level of on-site operation and maintenance of dry-type transformer measurement and control devices. The one-button switch is vibration-resistant, has a long mechanical service life, is suitable for complex working conditions in industrial sites, and is more convenient for later disassembly, replacement, and maintenance.

[0067] In some embodiments, the door panel 11 has a first window for embedding the thermostat 4. A clamp 5 for fixing the thermostat 4 is symmetrically installed on both sides of the first window. A bracket for supporting the thermostat 4 is welded to the inner wall of the door panel 11. After embedding the control panel of the thermostat 4 into the first window, the clamp 5 clamps the screws on both sides of the thermostat 4 to fix and stabilize the thermostat. Because the thermostat is embedded, the bracket is located inside the housing 12, effectively supporting the thermostat 4 and preventing it from falling. Preferably, the bracket has a spring probe that contacts the screws of the thermostat and a terminal block for connecting other modules. The bracket integrates both the spring probe and the terminal block, with one path connecting to the thermostat and another path connecting to other functional modules, resulting in high structural integration, a compact layout, and saving installation space. Furthermore, the spring probe's elastic contact with the thermostat screws ensures reliable electrical connection and signal acquisition, preventing loose connections and open circuits, resulting in more stable and accurate detection data. The spring probe has elastic extension and contraction capabilities, which can compensate for installation deviations and height errors, automatically adapt to the position of the temperature controller screw, reduce the assembly alignment accuracy requirements, and thus improve installation and testing efficiency. Preferably, clamp 5 is an insulating clamp.

[0068] The enclosure of this application houses the measurement and control module, the testing auxiliary module, and the temperature controller, achieving integrated testing device functionality. The door panel integrates the temperature controller, the control panel of the measurement and control module, and the testing auxiliary module, forming an integrated "operation-display-control" interface. Operators can complete all calibration operations without opening the enclosure, significantly improving the convenience and efficiency of on-site testing. The enclosed enclosure provides physical protection for the internal electrical modules, effectively isolating them from dust, moisture, and mechanical impact, preventing interference from the on-site environment to precision circuits, and extending the equipment's lifespan. The hinged door panel design balances protection and maintainability, facilitating later module maintenance and troubleshooting.

[0069] In some embodiments, the measurement and control module is powered by a circuit breaker and connected to a measurement and control power indicator light. Terminals 5, 6, 8, and 9 of the measurement and control module are resistor-selective, controlling the sensor module of the temperature controller. Terminals 13 and 14 are used to connect to a measurement and control success indicator light; terminals 13 and 15 are used to connect to a measurement and control failure indicator light; and terminals 13 and 16 are used to control the power output of the temperature controller.

[0070] Terminal 17 is a common terminal. Terminals 17 and 18 control the relay via the temperature controller's fan output point. The normally open contact of the relay closes and connects to the control module's input point to detect fan operation and display the indicator light. Terminals 17 and 19 connect to the control module's input point via the temperature controller's over-temperature alarm output point to detect the over-temperature alarm relay output and display the indicator light. Terminals 17 and 20 connect to the control module's input point via the temperature controller's over-temperature trip output point to detect the over-temperature trip relay output and display the indicator light.

[0071] Terminals 17 and 21 are connected from the temperature controller's fault output node to the control module's input point to detect the fault relay output and display it on the indicator light.

[0072] A button is installed between terminals 17 and 28, and between terminals 17 and 29, respectively, for starting and stopping the test. Terminals 60 and 61 are RS485 communication interfaces between the control module and the temperature controller. Through these two lines, the control module and the temperature controller can transmit data to each other, realizing the communication function test.

[0073] Specifically, the measurement and control module is powered by circuit breaker No. 1. The second and third terminals of the measurement and control module are connected to the power indicator light. The fifth, sixth, eighth, and ninth terminals are set as resistance selectors. The fifth and sixth terminals are connected to the first resistance selector, and one end of the sixth terminal is connected to the power neutral line N' via relay K2. Relay K2 is connected in parallel with relay K3. The eighth and ninth terminals are connected to the second resistance selector, and the ninth terminal is connected to the power neutral line N' via relay K1. The measurement and control module uses relay switching to detect the temperature before calibration, the calibration temperature, and the temperature after calibration of the sensor in the temperature controller. This connection method eliminates the need for manual wiring when testing the temperature controller, greatly improving the testing efficiency.

[0074] Preferably, the model of relay K1, relay K1 and relay K1 is MY4N-220V.

[0075] A control success indicator is connected between terminals 13 and 14 of the control module, and a control failure indicator is connected between terminals 13 and 14. Terminals 13 and 16 are respectively connected to the two power terminals (live wire and neutral wire) of circuit breaker No. 2. The two terminals of the thermostat are respectively connected to circuit breaker No. 2, and a thermostat power indicator is also installed between the two power terminals (live wire and neutral wire) of the thermostat. Through this connection method, terminals 13 and 16 can control the power output of the thermostat. Relay K1 is installed between the fan output terminals WK-13 and WK-14 of the thermostat. Relay K... The two normally open contacts of relay K1 are connected to the seventeenth and eighteenth terminals of the measurement and control module, respectively. The fan output terminal of the temperature controller controls the fan operation relay coil. When the temperature controller detects that the fan start-up conditions are met, it outputs a signal to energize the coil of relay K1, and its normally open contacts close. The seventeenth and eighteenth terminals, through the closed relay contacts, connect the fan operation status signal to the switch input terminal of the measurement and control module. After the measurement and control module detects the closed signal, it drives the fan operation indicator light to light up, providing intuitive feedback that the fan is in operation, and realizing real-time detection and visual indication of the fan operation status.

[0076] The seventeenth terminal is a common terminal. The over-temperature alarm output terminals WK-15 and WK-16 of the temperature controller are connected to the seventeenth and nineteenth terminals of the control module, respectively. The nineteenth terminal is a digital input terminal. This connection allows the control module to detect the over-temperature alarm relay output of the temperature controller 4 (whether it exceeds the set temperature) and display it via the over-temperature indicator light. The over-temperature alarm terminal WK-18 of the temperature controller is connected to the twentieth terminal of the control module. The twentieth terminal is a digital input terminal. This connection allows the control module to detect the over-temperature trip relay output of the temperature controller 4 and display it via the trip indicator light. The equipment fault terminal WK-20 of the temperature controller is connected to the twenty-first terminal of the control module. The twentieth terminal is a digital input terminal. This connection allows the control module to detect the over-temperature trip relay output of the temperature controller 4 and display it via the trip indicator light. A start button is installed between terminals 28 and 17 of the measurement and control module, and a stop button is installed between terminals 29 and 17. Both the start and stop buttons are mounted on door panel 11, providing convenient start and stop functionality for testing. Terminals 60 and 61 of the measurement and control module are connected to terminals WK-11 and WK-12 of the temperature controller, respectively, enabling data transmission between the measurement and control module and the temperature controller.

[0077] After the temperature controller is connected to the monitoring and control module and the test is initiated, simply press the start button to begin the test. If an error occurs during the test, press the stop button. After the test is complete, remove the temperature controller and test another unit, saving time and effort.

[0078] The measurement and control module is connected to the temperature controller and the detection auxiliary module circuits respectively, enabling temperature data acquisition and comparative verification in three key stages: before calibration, during calibration, and after calibration, forming a complete calibration closed-loop process. By monitoring temperature data at different stages in real time, calibration deviations can be detected in a timely manner, avoiding linear errors caused by single-point calibration, and significantly improving the accuracy and consistency of temperature calibration for the temperature controller.

[0079] In some embodiments, the temperature sensor terminals of the thermostat include a V+ power supply terminal, an A-phase temperature acquisition terminal WK-22, a B-phase temperature acquisition terminal WK-23, and a C-phase temperature acquisition terminal WK-24, which are used to connect to a three-phase winding temperature sensor to realize real-time acquisition of the temperatures of the transformer's A, B, and C phase windings.

[0080] The V+ power supply terminal is connected to four different resistor groups, each containing a three-wire resistor (A / B / C) to correspond to different calibration conditions, and to simulated resistors with different temperatures and resistance values.

[0081] Specifically, the first group of resistors is used for pre-calibration checks. The resistance is 60KΩ, and the temperature controller should display 37℃ to confirm that the probe channel hardware is fault-free. The wiring numbers for the three-wire resistors A / B / C are K2-9, K2-10, and K2-11, respectively.

[0082] The second group of resistors is used for reference calibration. The resistance is 100KΩ, and the temperature controller should display 25℃. Set the temperature controller's low-temperature calibration point to complete zero-point calibration. The connection numbers for the three-wire resistors A / B / C are K2-5, K2-6, and K2-7, respectively.

[0083] The third group of resistors is used for sampling calibration. The resistance is 2KΩ, and the temperature controller should display 144℃. Set the high-temperature calibration point on the temperature controller and complete the full-scale calibration. The connection numbers for the three-wire resistors A / B / C are K3-9, K3-10, and K3-11, respectively.

[0084] The fourth group of resistors is used for post-calibration testing. The resistance is 20KΩ, and the temperature controller should display 66℃ to confirm calibration linearity and accuracy. The connection numbers for the three-wire resistors A / B / C are K3-5, K3-6, and K3-7, respectively.

[0085] The specific circuit connections are as follows:

[0086] 1. Phase A temperature acquisition terminal WK-22

[0087] Connect terminal 9 → K1-9 → K2-9 → K3-9 (Line A, corresponding to 60KΩ / 37℃ and 2KΩ / 144℃).

[0088] Connect terminal 5 → K1-5 → K2-5 → K3-5 (B line, corresponding to 100KΩ / 25℃ and 20KΩ / 66℃)

[0089] 2. Phase B temperature acquisition terminal WK-23

[0090] Connect terminal 10 → K1-10 → K2-10 → K3-10 (Line A, corresponding to 60KΩ / 37℃ and 2KΩ / 144℃).

[0091] Connect terminal 6 → K1-6 → K2-6 → K3-6 (B line, corresponding to 100KΩ / 25℃ and 20KΩ / 66℃)

[0092] 3. C-phase temperature acquisition terminal WK-24

[0093] Connect terminal 11 → K1-11 → K2-11 → K3-11 (Line A, corresponding to 60KΩ / 37℃ and 2KΩ / 144℃).

[0094] Connect terminal 7 → K1-7 → K2-7 → K3-7 (B line, corresponding to 100KΩ / 25℃ and 20KΩ / 66℃)

[0095] Among them, the C line of the three-wire system is the common compensation line. The repeated markings are omitted in the figure. In fact, all C lines (such as K2-11, K2-7, K3-11, K3-7) will eventually be connected to the common compensation terminal of the thermostat to eliminate the wire resistance error.

[0096] The process of installing thermostat 4 into the cabinet is as follows:

[0097] After embedding one side of the control panel of thermostat 4 into window number one, thermostat 4 will be positioned on the bracket. Clamp the screws on both sides of thermostat 4 with clamp 5, then connect the screws on the back of the thermostat to the spring probe on the bracket. Connect the terminals according to the wiring method described above. Even different models of thermostats have essentially the same function, so you can connect the corresponding function terminals. After connecting the thermostat to the measurement and control module, turn it on and wait for testing. Simply press the start button to begin testing. If an error occurs during testing, press the stop button. After testing is complete, remove the thermostat and test another one, saving time and effort.

[0098] When using the automatic measurement and control device of this application to test the temperature controller, it is only necessary to install the temperature controller in the corresponding position and connect the necessary wiring harness. Then, the display can be obtained from the control screen outside the door by directly operating the button. The measurement and control module replaces the traditional operation mode of manually connecting external resistors and manually reading the data. It can automatically complete the temperature data acquisition, comparison and recording, reducing the reading errors and wiring errors caused by manual operation. At the same time, it reduces the dependence on the professional skills of the operator and realizes the standardization and automation of the temperature controller calibration process.

[0099] An automatic measurement and control method for a dry-type transformer temperature controller, such as Figures 10 to 25 As shown, it includes the following steps:

[0100] S1. Set the parameters of the test and control module according to the model and requirements of the temperature controller to be tested;

[0101] This step ensures the standardization and consistency of subsequent testing procedures by pre-locking test parameters (such as calibration temperature points, resistance values, and communication protocols), thereby reducing errors caused by manual settings.

[0102] S2. Power on the temperature controller and confirm that all indicator lights and digital displays are lit. Start the measurement and control module to perform automatic testing.

[0103] After powering on, first confirm that all indicator lights and digital tubes are lit before starting the automatic test. This achieves basic hardware self-check before testing, avoiding misjudgment of results due to display abnormalities in subsequent tests. In addition, the one-click start automatic test process eliminates the need for manual step-by-step intervention, improving testing efficiency and reducing human error.

[0104] S3. Test all communication lines. If communication fails, check the communication circuit until communication is successful. If communication is successful, proceed to step S4.

[0105] This step is set before automatic testing to locate communication link faults (such as wiring errors, interface damage, or protocol incompatibility) in advance, avoiding test process interruptions or data loss due to communication failures. It effectively ensures stable data interaction between the measurement and control module and the temperature controller, providing a reliable data transmission foundation for subsequent calibration, power failure detection, and other steps.

[0106] S4. Perform pre-calibration checks, benchmark calibration, sampling calibration, and post-calibration checks on the temperature controller. If all calibrations pass, proceed to step S5; otherwise, proceed directly to step S6 at the node where calibration fails.

[0107] This step verifies the temperature controller's initial response to known temperature points through pre-calibration checks, quickly determining if the channel hardware is functioning correctly. Dual-point calibration at high and low temperature standard points is performed using a combination of benchmark calibration and sampling calibration to eliminate linear errors and improve the accuracy of full-range temperature measurement. Post-calibration checks verify the temperature measurement accuracy of the calibrated temperature controller, forming a closed-loop control of "input-calibration-feedback" to ensure the accuracy and stability of the calibration results. When calibration fails, the test results are directly output, avoiding redundant execution of invalid test procedures and directly recording fault points, improving testing and fault location efficiency.

[0108] S5. Power-off detection and deletion of test records: When performing power-off function tests, on the one hand, it verifies whether the internal parameters of the equipment can be reliably saved and not lost after power failure, and on the other hand, it requires that the trip indicator light should light up normally when power is off; after power is restored and operation resumes, the temporary records and fault records generated in this test should be cleared to avoid the test records being retained and interfering with daily operation.

[0109] The combined design of power failure detection and record clearing in this step enables rapid verification of equipment reliability during power failures and restoration of the test environment. Specifically, the power failure parameter preservation verification ensures that the temperature controller's configuration parameters are not lost after an unexpected power outage, avoiding functional abnormalities caused by power failures during field operation; the trip indicator light is used to simulate power failure fault scenarios, verifying the effectiveness of the equipment's fault alarm logic and improving equipment operational safety; clearing test records upon power-on prevents temporary fault records and test data generated during this test from interfering with the subsequent normal operation of the equipment, while ensuring a clean test environment for the next test and not affecting the accuracy of the test results.

[0110] S6. Output test results: If the result shows that the test was successful, replace the next thermostat; if the result shows that the test was unsuccessful, output the fault location.

[0111] If the test is successful in this step, it will be directly transferred to the next temperature controller, achieving efficient connection of batch testing; if the test fails, the fault location will be directly output, eliminating the need for manual troubleshooting, greatly reducing fault diagnosis costs and improving maintenance and rework efficiency.

[0112] This testing method first presets the measurement and control module parameters according to the temperature controller model. After power-on and completion of the display device self-test, automatic testing begins. The front-end communication line is checked and communication faults are investigated. Then, pre-calibration checks, benchmark calibration, sampling calibration, and post-calibration checks are performed sequentially. Calibration anomalies directly proceed to the next process. Subsequently, power-off testing is conducted to verify the power-off parameter retention capability and the trip indicator alarm function. After power-on, temporary and fault records generated during testing are cleared. Finally, the test results and fault locations are automatically output. The overall process achieves standardized and automated testing, is compatible with multiple temperature controller models, proactively identifies hardware and communication vulnerabilities, and improves testing accuracy through multi-stage closed-loop calibration. It also verifies the reliability of power-off storage and alarms, automatically clears test records to avoid interfering with normal operation, quickly locates faults, adapts to batch testing, significantly reduces human error, and improves testing efficiency and product reliability.

[0113] S4 includes the following method:

[0114] S41. Pre-calibration check: Connect 60KΩ, corresponding to a temperature controller of 37℃, to confirm that the probe channel hardware is fault-free. If the calibration passes, proceed to step S42; otherwise, proceed to step S6.

[0115] S42. Reference calibration: Connect a 100KΩ standard resistor and set the low temperature calibration point of the temperature controller. If the low temperature calibration point is displayed correctly and the fan running indicator light is on, the calibration is successful and proceed to step S43. Otherwise, proceed to step S6.

[0116] S43. Sampling calibration: Connect a 2KΩ standard resistor and set the low and high calibration points of the temperature controller. If the high temperature calibration point is displayed correctly and the equipment fault indicator light is on, the calibration is successful and proceed to step S44; otherwise, proceed to step S6.

[0117] S44. Post-calibration check: Connect a 20KΩ resistor. If the temperature controller displays the correct temperature and the over-temperature alarm indicator is on, the calibration is successful. Proceed to step S5. Otherwise, proceed to step S6.

[0118] Example 1

[0119] The temperature controller is being tested for the first time by the monitoring and control device. This includes the following methods:

[0120] A1. Determine the model of the temperature controller, its built-in functions, and its compatibility with the measurement and control module, such as... Figure 10 As shown, the display screen of the measurement and control device shows the model of the temperature controller. Each line represents a temperature controller model. The model of this application is Nabc. Selecting this line will enter the parameter setting mode.

[0121] A2, such as Figures 11 to 13 As shown, set the parameters. Click on the parameter setting mode to adjust the parameters. The control screen will display: Parameter Adjustment Mode. Adjust the parameters according to actual needs, such as... Figure 12 As shown, when the temperature controller does not require parameter modification, the default settings can be selected directly; at this time, the monitoring and control device enters standby mode.

[0122] A3. Place the temperature controller under test into the corresponding position of the testing and control device, connect the corresponding terminals, turn on the power of the temperature controller, and confirm that all LED indicators and digital tubes are lit when powered on. Manually check the buttons, and then operate the start button to enter the automated test.

[0123] A4. Automated Testing:

[0124] A41. Communication testing, such as... Figure 14 and Figure 15 As shown: If the temperature controller and the measurement and control module cannot communicate, all tests cannot be performed. If there is a communication error, the control panel will display "Communication Failure". The staff needs to check the communication circuit of the temperature controller. When the communication test is successful, the control panel will display "Communication Test" and proceed to the next test.

[0125] A42. Calibration Test: (e.g.) Figures 16 to 19 As shown, the pre-calibration check connects a 60KΩ resistor, corresponding to a temperature controller temperature of 37℃. This pre-calibration check is to verify that the sampled values ​​are within the pre-calibration high and low setpoint range, confirming that the probe channel hardware is fault-free.

[0126] For baseline calibration, connect a 100KΩ standard resistor; the temperature controller should display 25℃, completing zero-point calibration. For sampling calibration, connect a 2KΩ standard resistor; the temperature controller should display 144℃, completing full-scale calibration. Both baseline and sampling calibrations calibrate the high and low points on both sides of the sampled value to ensure sampling accuracy. During baseline calibration, the fan operation indicator light will illuminate; during sampling calibration, the equipment fault indicator light will illuminate.

[0127] After calibration, connect a 20KΩ resistor. The temperature controller should display 66℃, and the over-temperature alarm indicator should illuminate. This check confirms the calibration linearity and accuracy. Once the calibration test passes, proceed to the next step.

[0128] A43, such as Figures 20 to 22 As shown, power failure detection and record clearing: Power failure detection checks whether parameters are saved after a power failure, and the over-temperature trip indicator light illuminates simultaneously. After power is restored, records generated during the test can be cleared.

[0129] A44. Output test results: (e.g.) Figure 23 As shown, if the test is successful, the control panel will display "Test completed successfully". At this point, the test is over, the device is powered off, and a new temperature controller is replaced.

[0130] like Figure 24As shown, if the test fails, the fault location is displayed on the right side of the control panel. As can be seen from the figure, the fault point appears in row 2, column 4, which is an alarm. We can check the soldering problem of the alarm relay and quickly troubleshoot the fault.

[0131] The meanings of the numbers displayed in the control panel are shown in Table 1.

[0132] Table 1

[0133]

[0134] Example 2

[0135] The only difference from Example 1 is that the thermostat model does not require manual parameter modification. As long as the model is compatible, the test can be performed automatically by simply pressing the start button.

[0136] Example 3

[0137] The only difference from Example 1 is that this model of temperature controller has been tested before, so the parameters do not need to be set again. The test can be performed automatically by simply pressing the start button.

[0138] This application forms a complete closed loop for temperature controller factory / field testing, covering all dimensions of equipment functionality, accuracy, and reliability verification, from parameter setting, hardware self-testing, communication verification, multi-stage calibration, power-down reliability testing to result output. Fault jump logic is set at each key node to directly locate faults in different stages such as communication, calibration, and power-down, avoiding redundant execution of ineffective test processes and significantly improving testing efficiency. The automated testing process replaces traditional manual step-by-step operations, reducing errors caused by human intervention, ensuring the consistency and traceability of test results, and adapting to mass production or large-scale field calibration scenarios. Temporary records are automatically cleared after power-down testing to avoid confusion between test data and operational data, ensuring normal use of the equipment after delivery, and providing a clean environment for the next test.

[0139] This embodiment also provides a computer device applicable to an automatic measurement and control method for a dry-type transformer temperature controller, including a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to realize the automatic measurement and control method for a dry-type transformer temperature controller as proposed in the above embodiment.

[0140] This embodiment also provides a storage medium on which a computer program is stored. When the program is executed by a processor, it implements an automatic measurement and control method for a dry-type transformer temperature controller as proposed in the above embodiment.

[0141] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0142] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0143] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-including system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0144] More specific examples (a non-exhaustive list) of computer-readable media include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which programs can be printed, because programs can be obtained electronically, for example, by optically scanning the paper or other media, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0145] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0146] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An automatic measurement and control method for a dry-type transformer temperature controller, characterized in that: Includes the following steps: S1. Set the parameters of the test and control module according to the model and requirements of the temperature controller to be tested; S2. Power on the temperature controller and confirm that all indicator lights and digital displays are lit. Start the measurement and control module to perform automatic testing. S3. Test all communication lines. If communication fails, check the communication circuit until communication is successful. If communication is successful, proceed to step S4. S4. Perform pre-calibration checks, benchmark calibration, sampling calibration, and post-calibration checks on the temperature controller. If all calibrations pass, proceed to step S5; otherwise, proceed directly to step S6 at the node where calibration fails. S5. Power failure detection, and delete test records; S6. Output test results: If the result shows that the test was successful, replace the next thermostat; if the result shows that the test was unsuccessful, output the fault location.

2. The automatic measurement and control method for a dry-type transformer temperature controller according to claim 1, characterized in that: S4 includes: S41. Pre-calibration check: Connect the preset resistor. If the calibration passes, proceed to step S42; otherwise, proceed to step S6. S42. Reference calibration: Connect the preset standard resistor and set the low temperature calibration point of the temperature controller. If the low temperature calibration point is displayed correctly and the fan running indicator light is on, the calibration is successful and proceed to step S43; otherwise, proceed to step S6. S43. Sampling and calibration: Connect the preset standard resistor and set the low and high calibration points of the temperature controller. If the high temperature calibration point is displayed correctly and the equipment fault indicator light is on, the calibration is successful and proceed to step S44; otherwise, proceed to step S6. S44. Post-calibration check: Connect the set resistor. If the temperature controller displays the correct temperature and the over-temperature alarm indicator is on, the calibration is successful. Proceed to step S5. Otherwise, proceed to step S6.

3. The automatic measurement and control method for a dry-type transformer temperature controller according to claim 1, characterized in that: The measurement and control module is powered by a circuit breaker and connected to a measurement and control power indicator light. Terminals 5, 6, 8, and 9 of the module are resistor-selective, controlling the sensor module of the temperature controller. Terminals 13 and 14 are used to connect to the measurement and control success indicator light; terminals 13 and 15 are used to connect to the measurement and control failure indicator light; terminals 13 and 16 control the power output of the temperature controller; terminal 17 is a common terminal. Terminals 17 and 18 control a relay from the temperature controller's fan output point. The normally open contact of the relay closes and connects to the measurement and control module's input point to detect fan operation and display the indicator light. Terminals 17 and 19 are... The over-temperature alarm output node of the temperature controller is connected to the input point of the measurement and control module to detect the over-temperature alarm relay output and display it through the over-temperature alarm indicator light; the seventeenth and twentieth terminals are connected to the input point of the measurement and control module by the over-temperature trip output node of the temperature controller to detect the over-temperature trip relay output and display it through the over-temperature trip indicator light; the seventeenth and twenty-first terminals are connected to the input point of the measurement and control module by the equipment fault output node of the temperature controller to detect the equipment fault relay output and display it through the equipment fault indicator light; a button is installed between the seventeenth and twenty-eighth terminals and between the seventeenth and twenty-ninth terminals to start and stop the test.

4. The automatic measurement and control method for a dry-type transformer temperature controller according to claim 1, characterized in that: The measurement and control module and the temperature controller communicate via RS485.

5. The automatic measurement and control method for a dry-type transformer temperature controller according to claim 1, characterized in that: When the temperature controller does not need to be modified, after selecting the model in the measurement and control module, it will directly enter the default settings. At this time, the measurement and control device enters the standby state and prepares for automatic testing. When the temperature controller needs to be set with parameters, select the model to enter the parameter setting mode, set the parameters, and then enter the standby mode to prepare for automatic testing.

6. An automatic measurement and control device for a dry-type transformer temperature controller, employing the automatic measurement and control method for the dry-type transformer temperature controller according to any one of claims 1 to 5, characterized in that: It includes the enclosure and the measurement and control module and detection auxiliary module installed inside it, and the control panel of the measurement and control module and the operation terminal of the detection auxiliary module are both embedded in the door panel of the enclosure.

7. The automatic measurement and control device for a dry-type transformer temperature controller according to claim 6, characterized in that: The testing auxiliary module includes several switches, buttons, and indicator lights. The switches are the switch for the temperature controller and the switch for the testing and control module. The buttons include an emergency stop button and a start button for starting the test.

8. The automatic measurement and control device for a dry-type transformer temperature controller according to claim 7, characterized in that: The door panel has a first window for embedding a thermostat. A clamp for fixing the thermostat is symmetrically installed on both sides of the first window. A bracket for supporting the thermostat is welded on the inner wall of the door panel.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 5.

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