An energy feedback type analog load and a system with energy feedback

Abstract

The present application belongs to the technical field of electronic product burn-in test, and particularly relates to an energy feedback type simulation load and a system with energy feedback; the present application takes a FlyBack power converter as a core, collects output electric signals of a product to be burned-in through a voltage and current sampling module, generates a control signal through an error operation feedback module, adjusts PWM wave parameters of the FlyBack power converter, makes the load present a pure resistance characteristic, simultaneously unidirectionally feeds back output electric energy of the product to be burned-in to a DC power supply bus, realizes energy recycling, simplifies a system structure, and reduces test cost.

Description

Technical Field

[0001] This invention belongs to the field of electronic product aging testing technology, specifically relating to an energy feedback analog load and a system with energy feedback. Background Technology

[0002] Before mass production, power electronic products need to undergo long-term aging tests at rated power to eliminate the risk of early product failure and stabilize operating parameters. Currently, the industry commonly uses resistors as the aging test load. In this method, all the electrical energy output by the product under test is dissipated as heat through the resistor, consuming a huge amount of electrical energy during the test. This not only causes serious energy waste but also requires additional heat dissipation equipment, significantly increasing testing costs. Existing energy feedback solutions mostly adopt grid-connected structures, requiring complex equipment such as grid-connected inverters and grid synchronization detection. The system structure is large and costly to build, and the energy needs to undergo multiple AC-DC conversions, resulting in significant conversion losses. In practical applications, the economic benefits are limited, and it cannot meet the needs of mass production lines for high-volume, low-cost aging tests. There is an urgent need for a technical solution that can solve the above problems. Summary of the Invention

[0003] To address the problems existing in the prior art, this invention proposes an energy-feedback analog load and a system with energy feedback, including an energy-feedback analog load body and a DC power supply bus. The input terminal of the energy-feedback analog load body is connected to the DC output terminal of the product being aged, and the output terminal of the energy-feedback analog load body is connected to the DC power supply bus. The energy-feedback analog load body includes a FlyBack power converter, a voltage sampling module, a current sampling module, and an error calculation feedback module. The input terminal of the voltage sampling module is electrically connected to the DC output terminal of the product being aged, and the input terminal of the current sampling module is also electrically connected to the DC output terminal of the product being aged. The error calculation feedback module... The input terminal of the error calculation feedback module is connected to the output terminal of the voltage sampling module and the output terminal of the current sampling module, respectively. The output terminal of the error calculation feedback module is connected to the feedback terminal of the FlyBack power converter. The output voltage of the FlyBack power converter is clamped and fixed by the bus voltage of the DC power supply bus. The FlyBack power converter adjusts the period and duty cycle of the PWM wave based on the error control signal output by the error calculation feedback module, and controls the input current and input voltage of the FlyBack power converter to maintain a linear proportional relationship, so that the energy feedback analog load body presents pure resistive characteristics from the input side, and the output power of the mature product is unidirectionally fed back to the DC power supply bus.

[0004] Preferably, the error calculation feedback module includes an operational amplifier and a PI adjustment unit. The operational amplifier and the PI adjustment unit perform differential calculation and proportional-integral adjustment on the voltage sampling signal output by the voltage sampling module and the current sampling signal output by the current sampling module to generate an error control signal related to the input voltage and current deviation, dynamically adjust the input impedance of the FlyBack power converter, and maintain the linear proportional relationship between the input current and the input voltage of the FlyBack power converter.

[0005] More preferably, the voltage sampling module adopts a high-voltage resistor voltage divider sampling circuit, the current sampling module adopts a Hall current sensor sampling circuit or a high-precision sampling resistor series sampling circuit, the voltage sampling signal collected by the voltage sampling module is transmitted to the input terminal of the error calculation feedback module, and the current sampling signal collected by the current sampling module is transmitted to the input terminal of the error calculation feedback module.

[0006] More preferably, the energy transmission direction of the FlyBack power converter is unidirectional from the side of the aging product to the DC power supply bus, the power conversion efficiency of the FlyBack power converter is not less than 95%, and the FlyBack power converter transmits the power output from the aging product to the DC power supply bus after DC-to-DC conversion.

[0007] More preferably, the system includes stackable AC / DC conversion modules, one or more aging control modules, and one or more aging products. The input terminal of the stackable AC / DC conversion module is connected to an external AC mains power supply, and the output terminal of the stackable AC / DC conversion module is connected in parallel to a DC power supply bus. The power supply terminal of the aging control module is electrically connected to the DC power supply bus. The acquisition terminal of the aging control module is connected to the power supply circuit and output circuit signal of the corresponding aging product. The power supply terminal of the aging product is powered by the aging control module, and the output terminal of the aging product is connected to the input terminal of an energy feedback analog load body.

[0008] More preferably, the product to be aged includes a power supply product and a BLDC motor driver. When the product to be aged is a power supply product, the DC output terminal of the power supply product is directly connected to the input terminal of the energy feedback analog load body. When the product to be aged is a BLDC motor driver, the UVW output terminals of the BLDC motor driver are connected in sequence to a three-phase rectifier bridge and an LC filter circuit, and the rectified and filtered DC voltage terminal is connected to the input terminal of the energy feedback analog load body.

[0009] More preferably, the LC filter circuit includes a filter inductor and a filter capacitor. The LC filter circuit filters out the PWM pulse ripple output by the BLDC motor driver and outputs a DC voltage to the input terminal of the energy feedback analog load body.

[0010] More preferably, the aging control module has a built-in voltage and current limiting unit, a DC / DC voltage conversion unit, and a communication interface. The voltage and current limiting unit limits and protects the power supply voltage and current of the product being aged. The DC / DC voltage conversion unit converts the DC voltage of the DC power supply bus into a DC voltage that meets the power supply requirements of the product being aged. The communication interface establishes a communication connection with the host computer to transmit the aging data and operating status data of the product being aged.

[0011] More preferably, the stackable AC / DC conversion module supports modular parallel expansion, with a power rating of 50kW to 500kW for a single stackable AC / DC conversion module, a DC output voltage rating of 300V to 800V for the stackable AC / DC conversion module, and each stackable AC / DC conversion module has a current sharing control function to achieve uniform distribution of the output current of each stackable AC / DC conversion module.

[0012] Preferably, the number of aging control modules corresponds one-to-one with the number of products being aged. A single aging control module can independently manage a single product being aged, and a single aging control module can also independently manage multiple products being aged in parallel. Multiple aging control modules support linkage control and batch aging tests, realizing synchronous aging operations and independent status monitoring of multiple products being aged.

[0013] Technical effects:

[0014] This invention utilizes a Flyback topology combined with dual-sampling closed-loop feedback control to make the simulated load exhibit pure resistive characteristics, ensuring aging test results consistent with traditional resistive loads. Simultaneously, the output power of the aged product is directly fed back to the DC power supply bus, achieving closed-loop energy recycling. This solves the core problems of high energy consumption of traditional resistive loads, complex structure of existing grid-connected feedback systems, and high cost, significantly improving energy utilization efficiency, simplifying system structure, and reducing aging test costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a diagram of the energy-feedback analog load and the system with energy feedback of the present invention;

[0017] Figure 2 This is a schematic diagram of the energy feedback closed-loop control of the present invention;

[0018] Figure 3 This is a schematic diagram of the sampling and FlyBack power conversion of the analog load closed-loop control with feedback according to the present invention.

[0019] Figure 4 This is a schematic diagram of the overall deployment architecture of the energy feedback aging test system of the present invention;

[0020] Figure 5 This is a schematic diagram of the topology of the three-phase bridge rectifier and LC filter circuit of the present invention. Detailed Implementation

[0021] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0022] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0023] Technical problems with existing technologies: Traditional aging tests use resistive loads, and all electrical energy is dissipated as heat, resulting in serious energy waste. Existing grid-connected feedback systems have complex structures, large conversion losses, and high costs, which cannot meet the needs of mass production lines for high-volume, low-cost testing.

[0024] Based on this, please refer to Figures 1-5This embodiment provides an energy-feedback analog load and a system with energy feedback, including an energy-feedback analog load body and a DC power supply bus. The input terminal of the energy-feedback analog load body is connected to the DC output terminal of the product being aged, and the output terminal of the energy-feedback analog load body is connected to the DC power supply bus. The energy-feedback analog load body includes a FlyBack power converter, a voltage sampling module, a current sampling module, and an error calculation feedback module. The input terminal of the voltage sampling module is electrically connected to the DC output terminal of the product being aged, and the input terminal of the current sampling module is electrically connected to the DC output terminal of the product being aged. The error calculation feedback module... The input terminals are connected to the output terminals of the voltage sampling module and the current sampling module, respectively. The output terminal of the error calculation feedback module is connected to the feedback terminal of the FlyBack power converter. The output voltage of the FlyBack power converter is clamped and fixed by the DC power supply bus voltage. Based on the error control signal output by the error calculation feedback module, the FlyBack power converter adjusts the period and duty cycle of the PWM wave to maintain a linear proportional relationship between the input current and the input voltage, so that the energy feedback analog load exhibits pure resistive characteristics from the input side, unidirectionally feeding back the output energy of the aged product to the DC power supply bus. It is worth mentioning that the core control logic of this solution is that the voltage sampling module collects the DC input voltage output by the aged product in real time, and the current sampling module collects the average DC current output by the aged product in real time. After the two signals are synchronously input to the error calculation feedback module, the calculation processing is completed through the preset resistance characteristic control logic to generate the error control signal. The core control formula for the pure resistive characteristic is:

[0025] ;

[0026] In the formula This refers to the input current of the FlyBack power converter, measured in amperes. This is the input voltage of the FlyBack power converter, in volts. The equivalent resistance value, in ohms, is preset to simulate the load. The error calculation feedback module substitutes the real-time acquired input voltage and current into the above formula to calculate the deviation between the actual operating parameters and the preset equivalent resistance parameter. Based on the deviation, it generates a corresponding error control signal and transmits it stably to the feedback terminal of the FlyBack power converter. The output terminal of the FlyBack power converter is directly connected to the DC power supply bus. The output voltage is clamped and fixed by the bus voltage, and will not fluctuate with changes in input voltage or load status. The formula for the relationship between its input / output voltage and PWM duty cycle is as follows:

[0027] ;

[0028] In the formula This refers to the PWM duty cycle of the switching transistor in the FlyBack power converter, with a value ranging from zero to one. This refers to the number of turns in the primary winding of the FlyBack transformer. The number of turns in the secondary winding of the FlyBack transformer is a dimensionless fixed parameter. Based on the above two sets of core formulas, the FlyBack power converter continuously receives error control signals, dynamically adjusts the period and duty cycle of the PWM wave, and changes its input impedance in real time to ensure that the input current and input voltage always maintain a strictly linear proportional relationship. From the input side, the overall load is completely equivalent to a purely resistive load. At the same time, the DC power output from the aged product is isolated and converted by the transformer and then unidirectionally transmitted to the DC power supply bus, completing the recycling of electrical energy. The entire conversion process does not require additional grid-connected equipment, and the structure is simple and the operation is stable. Based on the above complete control logic and formula derivation, combined with the disclosed circuit connection relationship and workflow, those skilled in the art can completely reproduce the core function of this solution without creative labor, ensuring that the technical solution has sufficient feasibility and repeatability. Technical effect achieved: By combining the FlyBack topology with dual sampling closed-loop control, the dual functions of pure resistive load characteristics and DC bus energy feedback are realized, solving the problems of high energy consumption of traditional loads and complex structure of existing feedback systems, and realizing the recycling of energy from aging tests.

[0029] The existing technology has the following technical problems: the error calculation stage lacks a clear closed-loop adjustment logic, which makes it impossible to stably maintain the pure resistive characteristics of the simulated load, and it is prone to current fluctuations, affecting the stability of aging tests.

[0030] Based on this, the error calculation feedback module includes an operational amplifier and a PI adjustment unit. The operational amplifier and the PI adjustment unit perform differential calculation and proportional-integral adjustment on the voltage sampling signal output by the voltage sampling module and the current sampling signal output by the current sampling module to generate an error control signal related to the input voltage and current deviation, dynamically adjust the input impedance of the FlyBack power converter, and maintain the linear proportional relationship between the input current and the input voltage of the FlyBack power converter. It is worth mentioning that the operational amplifier is responsible for performing real-time differential calculations on the voltage and current sampling signals, quickly extracting the deviation values ​​between the two signals, and synchronously transmitting the deviation values ​​to the PI control unit. The PI control unit performs proportional and integral calculations on the deviation values. The proportional calculation is used to quickly respond to changes in deviation and shorten the adjustment response time, while the integral calculation is used to eliminate static deviations and avoid continuous fluctuations in the input current. The signal after dual regulation finally forms a stable error control signal. This signal continuously acts on the feedback terminal of the FlyBack power converter, correcting the converter's operating state in real time, dynamically matching changes in input voltage, and always maintaining a linear proportional relationship between input current and input voltage. This ensures that the analog load maintains stable pure resistive characteristics without current jitter or parameter drift throughout the process, guaranteeing continuous stability during aging tests. The achieved technical effect: By forming a closed-loop control system with the operational amplifier and PI control unit, the deviation between the input current and the preset value is quickly eliminated, the pure resistive characteristics of the analog load are stably maintained, and the stability of aging tests is improved.

[0031] Existing technologies suffer from several technical problems: insufficient sampling circuit accuracy and slow response speed lead to lag and errors in closed-loop control, hindering the accurate realization of pure resistive characteristics and affecting the stability of energy feedback. To address this, the voltage sampling module employs a high-voltage resistor voltage divider sampling circuit, while the current sampling module uses a Hall current sensor sampling circuit or a high-precision sampling resistor series sampling circuit. The voltage sampling signal acquired by the voltage sampling module is transmitted to the input of the error calculation feedback module, and the current sampling signal acquired by the current sampling module is also transmitted to the input of the error calculation feedback module. Notably, the high-voltage resistor voltage divider sampling circuit constructs a voltage divider network through multiple high-voltage resistors in series, enabling stable acquisition of high-voltage DC signals with zero signal transmission delay and extremely low distortion, maintaining the original characteristics of the sampled signal throughout. The Hall current sensor sampling circuit uses a non-contact sampling method, eliminating losses in the main circuit and offering fast response speed covering current changes across the entire frequency band. The high-precision sampling resistor series sampling circuit achieves current acquisition through low-temperature coefficient sampling resistors, resulting in accurate and highly consistent sampling values. Both current sampling methods can be flexibly selected based on the actual testing scenario. After the two sampling circuits synchronously acquire signals, the complete electrical signal is directly transmitted to the error calculation feedback module without signal attenuation or interference. This provides accurate and real-time input data for closed-loop control, ensuring the precise realization of pure resistive characteristics. The achieved technical effect is as follows: Through a high-voltage resistor voltage divider circuit and a high-precision current sampling circuit, the accuracy and response speed of the sampled signal are guaranteed, providing accurate input for closed-loop control and ensuring the precise realization of pure resistive characteristics.

[0032] The existing technology suffers from several technical problems: bidirectional energy flow leads to DC bus voltage fluctuations, affecting system power supply stability, and also suffers from low conversion efficiency and limited energy recovery. Therefore, the FlyBack power converter unidirectionally transmits energy from the aging product side to the DC power supply bus. The FlyBack power converter has an energy conversion efficiency of no less than 95%. It converts the output energy from the aging product from DC to DC before delivering it to the DC power supply bus. Notably, the FlyBack power converter employs a unidirectional energy transmission topology and incorporates unidirectional power devices, allowing only the output energy from the aging product to flow to the DC power supply bus, completely blocking the reverse flow of bus energy back to the aging product side, thus fundamentally avoiding bus voltage fluctuations caused by reverse energy surges. The converter internally employs low-loss power switching transistors and a high-permeability transformer to reduce line and magnetic losses during power conversion, maintaining a high overall power conversion efficiency. Almost all the power output from the mature product is delivered to the DC power supply bus after conversion, resulting in a high energy recovery rate. No additional cooling equipment is required, and the system maintains high efficiency and stability throughout operation. The achieved technical effects include: avoiding bus voltage fluctuations through unidirectional energy transfer, maintaining high conversion efficiency, improving energy recovery, and ensuring stable system operation.

[0033] The existing technology suffers from several technical problems: lack of a complete system power supply and testing architecture, inability to perform batch aging tests on multiple products, and inability to adapt to the testing requirements of different types of power products. Therefore, the proposed system includes stackable AC / DC conversion modules, one or more aging control modules, and one or more products to be aged. The input of the stackable AC / DC conversion modules is connected to external AC mains power, and the output is connected in parallel to a DC power supply bus. The power supply terminal of the aging control modules is electrically connected to the DC power supply bus, and the acquisition terminal of the aging control modules is connected to the power supply circuit and output circuit signals of the corresponding products to be aged. The power supply terminal of the products to be aged is powered by the aging control modules, and the output terminal of the products to be aged is connected to the input terminal of an energy feedback analog load. Notably, the stackable AC / DC conversion modules convert external AC mains power into stable DC power, and multiple modules are connected in parallel to the DC power supply bus to jointly construct a DC power supply network with adjustable power capacity. The aging control module obtains operating power from the DC power supply bus and simultaneously manages the on / off switching of the power supply circuit of the product being aged. It also collects the electrical parameters of the output circuit in real time. The product being aged is independently powered by the aging control module, and its output is stably connected to an energy feedback analog load, forming a complete closed-loop architecture of power supply, testing, and energy feedback. Multiple products can be connected simultaneously, meeting the needs of mass production line batch aging tests and adapting to testing scenarios for products of different power levels. The achieved technical effect: By constructing a complete testing architecture through stackable AC / DC modules and the aging control module, it enables batch aging tests of multiple products, adapting to the testing needs of products with different power ratings.

[0034] The existing technology has a technical problem: it cannot simultaneously adapt to both DC output power supply products and AC output motor driver products, limiting its applicable scenarios. Therefore, the product to be aged includes power supply products and BLDC motor drivers. When the product to be aged is a power supply product, its DC output terminal is directly connected to the input terminal of the energy feedback analog load. When the product to be aged is a BLDC motor driver, the UVW output terminals of the BLDC motor driver are sequentially connected to a three-phase rectifier bridge and an LC filter circuit. The rectified and filtered DC voltage terminal is then connected to the input terminal of the energy feedback analog load. It is worth noting that the power supply product is a DC output product, and its output terminal can directly match the input interface of the energy feedback analog load without the need for additional conversion circuitry, making the connection convenient and the signal stable. BLDC motor drivers output three-phase AC signals, which cannot be directly connected to DC-input analog loads. Therefore, a three-phase rectifier bridge converts the three-phase AC power into pulsating DC power, which is then processed by subsequent circuitry to form a stable DC signal before being sent to the energy feedback analog load. Both products employ differentiated connection methods, enabling them to complete aging tests and energy feedback, significantly expanding the system's applicability. The achieved technical effect is: by using differentiated connection methods to adapt to both DC output power supplies and AC output motor drivers, the system's applicable scenarios are expanded, meeting the testing needs of various product types.

[0035] The existing technology has the following technical problem: the PWM pulse ripple output by the BLDC motor driver causes input voltage fluctuations, affecting the control accuracy and operational stability of the analog load. Based on this, the LC filter circuit includes a filter inductor and a filter capacitor. The LC filter circuit filters out the PWM pulse ripple output by the BLDC motor driver and outputs a DC voltage to the input terminal of the energy feedback analog load. It is worth mentioning that the filter inductor and filter capacitor form a passive filter network. The filter inductor suppresses sudden changes in high-frequency pulse current and blocks high-frequency ripple components in the PWM pulse. The filter capacitor absorbs voltage fluctuations in the circuit and smooths the output voltage waveform. Working together, they can completely filter out the PWM pulse ripple output by the BLDC motor driver, converting the pulsating DC into a smooth and stable DC voltage, eliminating the interference of ripple on the analog load control loop, allowing the energy feedback analog load to receive a stable input voltage, and ensuring closed-loop control accuracy and system operational stability. The achieved technical effect: By filtering out PWM pulse ripple through the LC filter circuit, a stable DC voltage is output, ensuring the control accuracy of the analog load and the operational stability of the system.

[0036] Existing technologies suffer from several technical limitations: they cannot provide power supply protection and status monitoring for the products being aged, cannot achieve centralized control of batch products, and are unsuitable for automated testing scenarios on mass production lines. To address these issues, the aging control module incorporates a voltage and current limiting unit, a DC / DC voltage conversion unit, and a communication interface. The voltage and current limiting unit limits and protects the power supply voltage and current of the products being aged. The DC / DC voltage conversion unit converts the DC voltage of the DC power supply bus to a DC voltage suitable for the power supply requirements of the products being aged. The communication interface establishes a communication connection with the host computer, transmitting aging data and operational status data of the products being aged. Notably, the voltage and current limiting unit monitors the power supply parameters of the products being aged in real time, immediately cutting off the power supply when the voltage or current exceeds a preset threshold to prevent damage from overvoltage or overcurrent. The DC / DC voltage conversion unit converts the high-voltage DC power supply to a suitable low-voltage DC power supply according to the power supply requirements of different products being aged, meeting the power supply requirements of various product types. The communication interface continuously transmits data such as aging duration, operational parameters, and fault status to the host computer, enabling centralized monitoring and remote management of batch products, fully adapting to the automated aging test operation mode of mass production lines. Technical effects achieved: Product protection, power supply adaptation and centralized monitoring are realized through multiple functional units, adapting to the automated aging test scenarios of mass production lines and improving test management efficiency.

[0037] The existing technology suffers from several technical problems: the fixed power capacity of the DC power supply network cannot flexibly adapt to the testing needs of different numbers and power products, and expansion is difficult. To address this, the proposed stackable AC / DC conversion module supports modular parallel expansion. A single stackable AC / DC conversion module has a power rating of 50kW to 500kW and a DC output voltage rating of 300V to 800V. Each stackable AC / DC conversion module has a current sharing control function, achieving uniform distribution of the output current across all modules. Notably, the stackable AC / DC conversion module adopts a standardized interface design, allowing for the free addition or reduction of the number of modules according to testing power requirements without modifying the existing wiring, making expansion simple and quick. Each module has a built-in current sharing control circuit that adjusts the output current in real time to ensure that the output current of each module remains consistent when multiple units are connected in parallel, preventing single-module overload. The DC output voltage covers common industrial test voltage levels, matching products of different power and voltage levels, flexibly adapting to the needs of both small-scale R&D testing and large-scale mass production testing. The achieved technical effect: Through modular parallel expansion and current sharing control, flexible expansion of the DC power supply network is realized, adapting to aging test requirements of different scales and power.

[0038] Technical problems existing in the prior art: it is impossible to realize synchronous aging and independent control of multiple products, the operation is complicated during batch testing, and the high-efficiency testing requirements of mass production lines cannot be met. Based on this, the number of the aging control modules corresponds to the number of products to be aged one by one. A single aging control module can independently control a single product to be aged, and a single aging control module can also independently control a plurality of parallel products to be aged. A plurality of aging control modules support linkage control and batch aging test, so as to realize synchronous aging operation and independent state monitoring of a plurality of products to be aged. It is worth mentioning that each aging control module correspondingly manages the designated product to be aged, and can independently set aging parameters, start-stop time and monitoring thresholds, so as to realize independent control of a single product. A plurality of aging control modules establish a linkage relationship through an internal bus, receive a unified control instruction, start or stop aging operation synchronously, complete the testing tasks of a plurality of products in batches, and feed back the independent operation status of each product in real time at the same time, without manual operation one by one, which greatly simplifies the batch testing process and improves the operation efficiency of aging testing on mass production lines. Achieved technical effects: through one-to-one control and multi-module linkage, synchronous aging and independent monitoring of multiple products are realized, the batch testing process is simplified, and the testing efficiency of mass production lines is improved.

[0039] Unless otherwise specified, the device elements involved in the above embodiments are all conventional device elements, and unless otherwise specified, the connection methods and control methods involved are all conventional connection methods and control methods.

[0040] The present invention has been described in detail above with reference to the embodiments, but those skilled in the art can understand that without departing from the purpose of the present invention, various specific parameters in the above embodiments can be modified to form a plurality of specific embodiments, which are all within the common variation scope of the present invention, and will not be elaborated one by one herein.

Claims

1. An energy-feedback analog load and a system with energy feedback, comprising an energy-feedback analog load body and a DC power supply bus, wherein the input terminal of the energy-feedback analog load body is used to connect to the DC output terminal of the aging product, and the output terminal of the energy-feedback analog load body is connected to the DC power supply bus, characterized in that, The energy feedback analog load body includes a FlyBack power converter, a voltage sampling module, a current sampling module, and an error calculation feedback module. The input terminal of the voltage sampling module is electrically connected to the DC output terminal of the product being aged. The input terminal of the current sampling module is also electrically connected to the DC output terminal of the product being aged. The input terminal of the error calculation feedback module is connected to the output terminals of both the voltage and current sampling modules. The output terminal of the error calculation feedback module is connected to the feedback terminal of the FlyBack power converter. The output voltage of the FlyBack power converter is clamped and fixed by the bus voltage of the DC power supply bus. Based on the error control signal output by the error calculation feedback module, the FlyBack power converter adjusts the period and duty cycle of the PWM wave to control the input current and input voltage to maintain a linear proportional relationship, so that the energy feedback analog load body exhibits pure resistive characteristics from the input side, unidirectionally feeding back the output energy of the product being aged to the DC power supply bus.

2. The energy-feedback analog load and system with energy feedback according to claim 1, characterized in that, The error calculation feedback module includes an operational amplifier and a PI adjustment unit. The operational amplifier and the PI adjustment unit perform differential calculation and proportional-integral adjustment on the voltage sampling signal output by the voltage sampling module and the current sampling signal output by the current sampling module to generate an error control signal related to the input voltage and current deviation, dynamically adjust the input impedance of the FlyBack power converter, and maintain the linear proportional relationship between the input current and the input voltage of the FlyBack power converter.

3. The energy-feedback analog load and system with energy feedback according to claim 1, characterized in that, The voltage sampling module uses a high-voltage resistor voltage divider sampling circuit, and the current sampling module uses a Hall current sensor sampling circuit or a high-precision sampling resistor series sampling circuit. The voltage sampling signal collected by the voltage sampling module is transmitted to the input terminal of the error calculation feedback module, and the current sampling signal collected by the current sampling module is transmitted to the input terminal of the error calculation feedback module.

4. The energy-feedback analog load and system with energy feedback according to claim 1, characterized in that, The energy transmission direction of the FlyBack power converter is unidirectional from the side of the aging product to the DC power supply bus. The power conversion efficiency of the FlyBack power converter is not less than 95%. The FlyBack power converter converts the power output from the aging product from DC to DC and then transmits it to the DC power supply bus.

5. The energy-feedback analog load and system with energy feedback according to claim 1, characterized in that, The system includes stackable AC / DC conversion modules, one or more aging control modules, and one or more aging products. The input of the stackable AC / DC conversion modules is connected to an external AC mains power supply, and the output of the stackable AC / DC conversion modules is connected in parallel to a DC power supply bus. The power supply terminal of the aging control modules is electrically connected to the DC power supply bus. The acquisition terminal of the aging control modules is connected to the power supply circuit and output circuit signal of the corresponding aging product. The power supply terminal of the aging product is powered by the aging control modules, and the output terminal of the aging product is connected to the input terminal of an energy feedback analog load body.

6. The energy-feedback analog load and system with energy feedback according to claim 5, characterized in that, The product being aged includes a power supply and a BLDC motor driver. When the product being aged is a power supply, the DC output terminal of the power supply is directly connected to the input terminal of the energy feedback analog load body. When the product being aged is a BLDC motor driver, the UVW output terminals of the BLDC motor driver are connected in sequence to a three-phase rectifier bridge and an LC filter circuit, and the rectified and filtered DC voltage terminal is connected to the input terminal of the energy feedback analog load body.

7. The energy-feedback analog load and system with energy feedback according to claim 6, characterized in that, The LC filter circuit includes a filter inductor and a filter capacitor. The LC filter circuit filters out the PWM pulse ripple output by the BLDC motor driver and outputs a DC voltage to the input terminal of the energy feedback analog load body.

8. The energy-feedback analog load and system with energy feedback according to claim 5, characterized in that, The aging control module has a built-in voltage and current limiting unit, a DC / DC voltage conversion unit, and a communication interface. The voltage and current limiting unit limits and protects the power supply voltage and current of the product being aged. The DC / DC voltage conversion unit converts the DC voltage of the DC power supply bus into a DC voltage that meets the power supply requirements of the product being aged. The communication interface establishes a communication connection with the host computer to transmit the aging data and operating status data of the product being aged.

9. The energy-feedback analog load and system with energy feedback according to claim 5, characterized in that, The stackable AC / DC conversion module supports modular parallel expansion. The power rating of a single stackable AC / DC conversion module is 50kW to 500kW, and the DC output voltage rating of the stackable AC / DC conversion module is 300V to 800V. Each stackable AC / DC conversion module has a current sharing control function to achieve uniform distribution of the output current of each stackable AC / DC conversion module.

10. The energy-feedback analog load and system with energy feedback according to claim 5, characterized in that, The number of aging control modules corresponds one-to-one with the number of products being aged. A single aging control module can independently manage a single product being aged, and a single aging control module can also independently manage multiple products being aged in parallel. Multiple aging control modules support linkage control and batch aging tests, enabling synchronous aging operations and independent status monitoring of multiple products being aged.

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