A direct current high voltage test control method

CN122882900APending Publication Date: 2026-10-09FUJIAN RUISIKE MEDICAL TECHNOLOGY CO LTD +1
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Patent Information

Application Number
CN202610803220.0
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Priority Date
2026-03-11
Filing Date
2026-06-05
Publication Date
2026-10-09

AI Technical Summary

Technical Problem

这种模式导致测试流程割裂,各环节衔接依赖人工判断与操作,效率低下且难以保证每次测试条件的一致性

Benefits of technology

[0016]1、本发明通过将定位、抽真空、升压、同步采集、数据融合与风险评估等步骤有机整合为一个连贯、自动化的控制流程,彻底改变了传统手动操作模式,大幅提高了测试效率,并确保了测试条件的严格一致性与可重复性;

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Abstract

The present application relates to the field of automation control and high-voltage test technology, in particular to a direct current high-voltage test control method for insulation test of superconducting cyclotron electrostatic deflection plate. The method comprises: automatically calibrating, positioning and adjusting the measured piece to the test position; establishing a vacuum environment in stages; after the vacuum meets the requirements, step-voltage is applied according to a preset strategy, and heterogeneous time sequence signals such as leakage current, optical radiation and mechanical strain are synchronously collected; time alignment and feature extraction are performed on the multi-source signals to generate a multi-dimensional fusion feature vector flow; a risk assessment model is used to calculate a comprehensive insulation risk coefficient in real time, and compared with a multi-stage dynamic threshold value to adaptively adjust the voltage raising strategy or execute a safety protection action; and the whole process data is automatically recorded and a traceable test report is generated. Through multi-source information fusion and dynamic risk assessment, the present application realizes automatic closed-loop control of the test process, and significantly improves the safety, accuracy and efficiency of high-voltage insulation test.
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Description

Technical Field

[0001] This invention relates to the field of automated control system technology, and in particular to a DC high voltage test control method. Background Technology

[0002] As a key piece of equipment in modern particle therapy and nuclear physics research, the superconducting cyclotron accelerator relies on its core component—the electrostatic deflection plate—which must operate stably under high DC voltage and high vacuum conditions ranging from tens to hundreds of kilovolts to deflect high-energy particle beams. The insulation performance of the electrostatic deflection plate directly determines the safety and reliability of the accelerator's operation. Any minute insulation defect can lead to high-voltage breakdown, arcing, and damage to expensive components, potentially triggering a cascading failure and causing severe economic losses and operational risks. Therefore, rigorous and reliable insulation performance testing of the electrostatic deflection plate before assembly or during maintenance is crucial.

[0003] Currently, traditional methods for DC high-voltage testing of such high-value, high-requirement components have significant limitations. The testing process is typically completed manually in stages using multiple independent devices. This model leads to a fragmented testing workflow, with each step relying on manual judgment and operation, resulting in low efficiency and difficulty in ensuring consistency of test conditions for each instance. More importantly, the monitoring methods are singular and isolated, usually only monitoring the basic electrical parameter of leakage current. However, the precursors to insulation failure are often the evolution of multi-physical field coupling; for example, partial discharge is accompanied by weak pulse currents, light radiation, and mechanical vibrations caused by discharge impacts. Traditional methods cannot simultaneously acquire and correlate these heterogeneous signals, leading to the omission of a large amount of potential fault symptoms and severely delayed safety assessments. They rely heavily on operator experience to handle situations after obvious breakdown occurs, posing significant safety hazards.

[0004] Furthermore, the testing process lacks systematic risk dynamic assessment and closed-loop control capabilities. The boost strategy is typically a fixed, stepped or uniform increase, unable to adaptively adjust based on the real-time status of the device under test. Data recording throughout the test is fragmented, making it difficult to form a complete, synchronized, and traceable data archive, which is detrimental to subsequent in-depth analysis and quality traceability.

[0005] Therefore, there is an urgent need for an integrated, automated, and intelligent DC high-voltage test control method to achieve closed-loop management of the entire process from preparation and execution to evaluation, and to provide early warning of potential insulation faults through multi-source information fusion and real-time risk assessment, thereby fundamentally improving the safety, accuracy, and efficiency of testing. Summary of the Invention

[0006] In view of the above, it is necessary to provide a DC high voltage test control method to solve the problems existing in the background technology.

[0007] This application discloses a DC high-voltage test control method for insulation testing of electrostatic deflection plates in a superconducting cyclotron, comprising the following steps: S1. The zero point is automatically calibrated through the positioning subsystem and the electrostatic deflection plate is adjusted to the preset test position. S2. Vacuum the test environment subsystem in stages until the vacuum level meets the test requirements. S3. After the vacuum requirement is met, the DC high voltage is applied and gradually increased by the high voltage application and monitoring subsystem according to the preset strategy. At the same time, the central control unit coordinates the synchronous acquisition subsystem to synchronously acquire heterogeneous time-series data during the test. The heterogeneous time-series data includes at least: electrical response signals measured by the high voltage circuit, optical radiation signals acquired by optical sensors, and mechanical strain signals measured by the sensor array deployed on the support structure of the test piece. S4. The data fusion processor performs time alignment and feature extraction on the synchronously acquired heterogeneous time-series data to generate a multi-dimensional fusion feature vector stream characterizing the instantaneous insulation state of the test component. S5. Through the risk assessment and control module, based on the multi-dimensional fused feature vector flow, the risk assessment model is called to calculate the comprehensive insulation risk coefficient in real time, and the coefficient is compared with the preset dynamic correlation multi-level threshold to dynamically adjust the output strategy of the high voltage application and monitoring subsystem or execute safety protection actions. S6. The host computer automatically records and stores all key parameters, events, multi-dimensional fused feature vectors, and comprehensive insulation risk coefficients throughout the entire test process to form a traceable test report.

[0008] In some embodiments, step S2 specifically includes: The programmable logic controller controls the start-up and shutdown sequence of the mechanical pump and the molecular pump according to the monitoring signal of the vacuum gauge, so as to achieve the preset vacuum threshold in a stepwise manner. The process involves first starting the mechanical pump for rough evacuation, and then starting the molecular pump once the vacuum level reaches the first threshold to establish and maintain the vacuum level to meet the test requirements. In some embodiments, step S5, specifically, includes: dynamically adjusting the output strategy of the high-voltage application and monitoring subsystem or performing safety protection actions. When the comprehensive insulation risk coefficient is lower than the first risk threshold, the high voltage application and monitoring subsystem is controlled to continue to increase the voltage at a preset rate. When the comprehensive insulation risk coefficient reaches or exceeds the first risk threshold but is lower than the second risk threshold, the high voltage application and monitoring subsystem is controlled to suspend voltage increase, and the monitoring sampling frequency of the optical radiation signal in the synchronous acquisition subsystem is increased. When the comprehensive insulation risk coefficient reaches or exceeds the second risk threshold, the high voltage application and monitoring subsystem is immediately controlled to cut off the high voltage output and perform safety protection actions, thus determining that the test has failed.

[0009] In some embodiments, in step S3, the preset strategy for the high voltage application and monitoring subsystem to apply and gradually increase the DC high voltage is as follows: The initial output voltage is 1KV. After that, every first preset time interval and if the leakage current is detected to be lower than the corresponding safety threshold, the output voltage will be increased by 2KV until the preset maximum test voltage is reached.

[0010] In some embodiments, after step S5, a test result determination step is further included: If the output voltage rises to the preset maximum voltage and remains stable at that voltage for more than the preset duration, and the failure condition of cutting off the high voltage is not triggered throughout the process, then the electrostatic deflection plate is deemed to have passed the insulation test.

[0011] In some embodiments, the method is performed based on a DC high-voltage test and control system, the system comprising: A central control unit, comprising a programmable logic controller and a host computer that communicate with each other; The positioning subsystem, connected to the programmable logic controller, is used to support, adjust, and regulate the spatial position of the electrostatic deflection plate under test. The test environment subsystem, connected to the programmable logic controller, is used to establish and maintain the vacuum test environment required for testing. The high voltage application and monitoring subsystem is connected to the programmable logic controller via a communication network and is used to apply DC high voltage to the electrostatic deflection plate and monitor electrical parameters in real time. The synchronous acquisition subsystem, coordinated by the programmable logic controller, is used to synchronously acquire three types of heterogeneous time-series data during the test process: electrical response signals measured by the high-voltage circuit, optical radiation signals acquired by the optical sensors, and mechanical strain signals measured by the sensor array deployed on the support structure of the test piece. The data fusion processor, connected to the synchronous acquisition subsystem, is used to perform time alignment and feature extraction on the received synchronous heterogeneous time-series data stream, and output a multi-dimensional fusion feature vector representing the instantaneous state of the device under test. The risk assessment and control module, connected to the data fusion processor, includes a risk assessment model; the risk assessment and control module is configured to: receive the multi-dimensional fusion feature vector, call the risk assessment model to calculate the comprehensive insulation risk coefficient, and adjust the output strategy of the high voltage application and monitoring subsystem or execute safety protection actions in real time according to the preset multi-level thresholds dynamically associated with the coefficient. The central control unit coordinates and controls the positioning subsystem, the test environment subsystem, the high-voltage application and monitoring subsystem, the synchronous acquisition subsystem, the data fusion processor, and the risk assessment and control module to achieve a full-process test from position calibration, test environment establishment, high-voltage application, multi-source synchronous monitoring, dynamic risk assessment to data recording.

[0012] In some embodiments, the positioning subsystem includes a stepper motor driver, a stepper motor connected to the stepper motor driver, and a position feedback sensor for real-time position detection, forming a position closed-loop control loop. The programmable logic controller (PLC) performs deviation compensation control on the stepper motor based on the signal from the position feedback sensor. The test environment subsystem includes a mechanical pump and a molecular pump connected in sequence. The PLC controls the start-stop sequence of the mechanical pump and the molecular pump based on the monitoring signal from the vacuum gauge to achieve a preset vacuum threshold in a graded manner. The high-voltage application and monitoring subsystem includes a high-voltage power supply, a current-limiting resistor network connected in series with the output terminal of the high-voltage power supply, a discharge resistor branch connected in parallel in the test loop, and a leakage current detection instrument for detecting leakage current in the loop. The high-voltage power supply communicates with the PLC via the Modbus TCP protocol.

[0013] In some embodiments, the system further includes an industrial camera connected to the host computer. The industrial camera continuously records during the test to visually monitor whether the electrostatic deflection plate experiences arcing or discharge. The host computer is configured to: provide a human-machine interface for remotely setting test parameters and starting / stopping the test process; display and record in real time the operating data of the positioning subsystem, the test environment subsystem, the high voltage application and monitoring subsystem, the synchronous acquisition subsystem, the data fusion processor, and the risk assessment and control module; and store and export complete test process data to form a traceable data archive.

[0014] In some embodiments, the programmable logic controller is configured to perform the following automated test process: Control the positioning subsystem to perform a return-to-origin operation and adjust the electrostatic deflection plate to the test position; The test environment subsystem is controlled to establish a vacuum, and the molecular pump is started after the vacuum level reaches a first threshold. After the vacuum level reaches the second threshold, the high voltage application and monitoring subsystem is controlled to gradually increase the output voltage with a preset voltage gradient. During the high-voltage application process, the risk assessment and control module dynamically adjusts the voltage boosting strategy according to the real-time calculated comprehensive insulation risk coefficient: when the risk coefficient is lower than the first threshold, continue boosting voltage at the original rate; when the risk coefficient reaches the first threshold but is lower than the second threshold, suspend voltage boosting and increase the optical monitoring sampling frequency; when the risk coefficient reaches or exceeds the second threshold, immediately cut off the high-voltage output and determine the test fails; If the output voltage is stably maintained at the preset maximum voltage for more than the preset duration and no failure condition is triggered, the test is determined to be qualified.

[0015] In some embodiments, the electrical connection of the DC high-voltage test system adopts a modular design, comprising: a power distribution module for converting input alternating current into direct current of different levels; a standardized terminal block for centrally connecting the input and output signals of the programmable logic controller and various peripheral devices; and a network switching module for expanding network communication ports. Advantageous Effects

[0016] 1. The present invention organically integrates positioning, vacuumizing, voltage boosting, synchronous acquisition, data fusion, risk assessment and other steps into a coherent and automatic control flow, completely changes the traditional manual operation mode, greatly improves test efficiency, and ensures strict consistency and repeatability of test conditions; 2. The present invention generates a multi-dimensional fused feature vector that can more comprehensively and earlier characterize the precursor of insulation failure by performing synchronous acquisition and fusion processing on three types of heterogeneous time-series signals including electrical response, optical radiation and mechanical strain. This makes up for the defect that traditional methods only rely on a single leakage current parameter for judgment, and provides a multi-dimensional evidence chain for safety early warning.

[0017] 3. The present invention enables the test process to have intelligent dynamic risk response capability by introducing an adaptive control strategy based on a comprehensive insulation risk coefficient and multi-level dynamic thresholds. The system can automatically perform differential actions such as continuing voltage boosting, pausing for observation or emergency cutting off according to the real-time status of the tested piece, upgrading safety protection from passive response to active early warning and protection, and fundamentally improving the safety of the test process; 4. This invention unifies and coordinates all subsystems and modules, including positioning, vacuum establishment, high-voltage application, multi-source synchronous monitoring, data fusion, and risk assessment, through a central control unit. This integrates previously fragmented manual operations into a coherent and automated process, significantly improving testing efficiency and ensuring strict consistency and repeatability of test conditions. More importantly, it constructs a closed-loop control chain for multi-dimensional perception, real-time analysis, and dynamic decision-making. Based on real-time comprehensive risk assessment, the system can proactively intervene in high-voltage output strategies or execute protection measures, transforming passive response into proactive protection and fundamentally enhancing the inherent safety of the entire testing process. By employing a closed-loop control circuit composed of a stepper motor driver, a stepper motor, and a position feedback sensor, the positioning subsystem can compensate for drive deviations in real time, achieving adjustment and locking of the spatial position of the electrostatic deflection plate. This ensures a high degree of consistency in the relative positional relationship between the test piece, the high-voltage electrode, and various sensors in each test, eliminating test variables introduced by positioning errors and laying a solid foundation for obtaining reliable and comparable insulation performance data. 5. In this invention, the high-voltage application and monitoring subsystem is connected to the main control unit via a communication network, enabling remote and safe control of hazardous high-voltage equipment. The integrated current-limiting resistor network, discharge resistor branch, and real-time leakage current monitoring instrument constitute a multi-layered electrical safety protection system, which can effectively limit fault current, quickly release residual charge, and provide the most direct key parameters for condition assessment.

[0018] 6. This invention utilizes an industrial camera connected to a host computer to continuously monitor the tested area during testing. This system can directly capture and record visible phenomena such as arcing and discharge, providing an intuitive and vivid visual evidence chain for insulation failure analysis. This evidence, corroborated by electrical and strain signals, greatly enhances the accuracy and reliability of fault diagnosis and location. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments 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.

[0020] Figure 1 This is an overall system block diagram according to one embodiment of the present invention; Figure 2 This is a partial detailed system block diagram of one embodiment of the present invention; Figure 3 This is a schematic diagram of the test process in one embodiment of the present invention; Figure 4 This is a schematic diagram of the electrical connection of the high-voltage component in one embodiment of the present invention; Figure 5 This is a schematic diagram of the PLC wiring principle in one embodiment of the present invention.

[0021] Explanation of key component symbols: 1. Host computer; 2. Programmable logic controller; 3. Stepper motor driver; 4. Stepper motor; 11. Position feedback sensor; 12. Mechanical pump; 13. Molecular pump power supply; 14. Molecular pump; 15. Vacuum gauge power supply; 16. Vacuum gauge; 17. High voltage power supply; 18. Industrial camera; 5. Synchronous acquisition subsystem; 6. Data fusion processor; 7. Risk assessment and control module. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0023] Please see Figures 1-5 This embodiment provides a technical solution: a DC high voltage test control method, for details please refer to Figure 3 It includes the following steps: S1. The zero point is automatically calibrated by the positioning subsystem and the electrostatic deflection plate is adjusted to the preset test position.

[0024] The central control unit instructs the positioning subsystem to perform a "return to origin" operation to calibrate the mechanical zero point. Subsequently, the programmable logic controller (PLC), based on the preset test position parameters on the host computer, drives the stepper motor in the positioning subsystem to precisely move and lock the electrostatic deflection plate under test into the test position. To ensure high accuracy, this positioning process employs closed-loop control with a position feedback sensor, which detects the actual position of the platform in real time and feeds it back to the PLC for deviation compensation, thereby stabilizing the positioning accuracy within the preset range.

[0025] S2. Vacuum the test environment subsystem in stages until the vacuum level meets the test requirements.

[0026] After positioning is complete, the central control unit activates the test environment subsystem to establish a vacuum environment. This step employs a staged vacuuming strategy: the programmable logic controller (PLC) first controls the mechanical pump to perform a rough vacuum in the test chamber. The vacuum gauge provides real-time feedback on the pressure within the chamber to the PLC. When the vacuum level reaches a preset first threshold (e.g., better than 1 Pa), the PLC automatically issues a command to activate the molecular pump, initiating the deep vacuuming phase. Through this staged activation method, the system can efficiently and safely ensure that the vacuum level meets the test requirements (e.g., reaching and stabilizing at better than 1 × 10⁻⁶ Pa). The second threshold of Pa), and effectively protect the molecular pump from atmospheric impact.

[0027] S3. After the vacuum requirement is met, the DC high voltage is applied and gradually increased by the high voltage application and monitoring subsystem according to the preset strategy. At the same time, the central control unit coordinates the synchronous acquisition subsystem to synchronously acquire heterogeneous time-series data during the test. The heterogeneous time-series data includes at least: electrical response signals measured by the high voltage circuit, optical radiation signals acquired by optical sensors, and mechanical strain signals measured by the sensor array deployed on the support structure of the test piece.

[0028] Once the programmable logic controller confirms that the vacuum level has stabilized and meets the test requirements, the central control unit issues a command to control the high-voltage application and monitoring subsystem to start working, and simultaneously initiates data acquisition.

[0029] For high voltage application, a preset stepped voltage boosting strategy is adopted: the initial output is 1KV DC voltage. Thereafter, at intervals of a first preset time period (e.g., 60 seconds), if the programmable logic controller detects through a leakage current detection instrument that the circuit leakage current is stable and below the corresponding safety threshold, the output voltage is automatically increased by 2KV. This cycle continues, gradually increasing the voltage to the preset maximum test voltage.

[0030] In terms of synchronous acquisition, throughout the entire boost and hold process, the programmable logic controller (PLC) issues a unified timing signal to trigger the synchronous acquisition subsystem to simultaneously acquire three types of heterogeneous timing signals at a high sampling rate: electrical response signals from the high-voltage circuit (e.g., the waveform and amplitude of leakage current), optical radiation signals from optical sensors (capturing faint flashes generated by discharge), and mechanical strain signals from the sensor array on the support structure of the device under test (sensing micro-vibrations caused by discharge impacts or electrostriction). These three types of data streams with consistent timestamps lay the data foundation for subsequent multiphysics correlation analysis.

[0031] S4. The data fusion processor performs time alignment and feature extraction on the synchronously acquired heterogeneous time-series data to generate a multi-dimensional fusion feature vector stream characterizing the instantaneous insulation state of the test component.

[0032] The synchronous acquisition subsystem sends multi-source data streams with consistent timestamps to the data fusion processor in real time. The data fusion processor then performs the following operations: First, time alignment is performed, which corrects for minor time errors between channels caused by differences in signal transmission or sensor response, ensuring that the information at each sampling point is strictly synchronized in the time dimension.

[0033] Secondly, feature extraction is performed, which involves extracting time-domain and frequency-domain features sensitive to insulation status from the aligned signals. For example, extracting high-frequency ripple components and pulse counts from leakage current signals, intensity and pulse width from optical radiation signals, and energy spectral density of mechanical strain signals in specific frequency bands.

[0034] Finally, a fused feature vector is generated, which combines the features extracted from all channels at the same moment to create a multi-dimensional fused feature vector. This vector more comprehensively characterizes the instantaneous insulation state of the device under test at a given moment than any single signal. Over time, this forms a continuous stream of multi-dimensional fused feature vectors.

[0035] S5. Through the risk assessment and control module, based on the multi-dimensional fused feature vector flow, the risk assessment model is called to calculate the comprehensive insulation risk coefficient in real time, and the coefficient is compared with the preset dynamic correlation multi-level threshold to dynamically adjust the output strategy of the high voltage application and monitoring subsystem or execute safety protection actions.

[0036] A multi-dimensional fused feature vector stream is input to the risk assessment and control module in real time. This module embeds a risk assessment model based on, for example, historical fault data training or empirical rules. The model continuously solves the input vector, outputting a quantified and dimensionless comprehensive insulation risk coefficient (e.g., between 0 and 1). The module then compares this coefficient with preset, dynamically correlated multi-level thresholds and executes closed-loop control decisions based on the comparison results. When the comprehensive insulation risk coefficient is less than the first risk threshold (e.g., 0.3), the current state of the tested component is determined to be normal, and the system controls the high voltage application and monitoring subsystem to continue to execute the original voltage boosting or stabilizing strategy.

[0037] When the first risk threshold ≤ comprehensive insulation risk coefficient < second risk threshold (e.g., 0.6), a potential insulation risk is identified. The system proactively adjusts its control strategy: immediately suspends the current voltage boosting process and generates a command to increase the sampling frequency of the optical monitoring channel in the synchronous acquisition subsystem, entering a high-attention "close observation" state to determine whether the risk signs will further develop.

[0038] When the comprehensive insulation risk coefficient is greater than or equal to the second risk threshold, an extremely high risk of flashover or breakdown is identified. Without relying on manual judgment, the system immediately executes the highest level of safety protection actions: it issues a command to the high-voltage application and monitoring subsystem to cut off the high-voltage power supply output and connect the discharge resistor branch in the test circuit to quickly and safely release residual charge, while simultaneously determining that the test has "failed".

[0039] S6. The host computer automatically records and stores all key parameters, events, multi-dimensional fused feature vectors, and comprehensive insulation risk coefficients throughout the entire test process to form a traceable test report.

[0040] Throughout the entire testing process, the host computer software automatically recorded the operating status of all devices, set parameters, collected raw data, generated fusion feature vectors, and risk coefficients.

[0041] Regarding the determination of the final test result: If the voltage successfully rises from the initial value to the preset maximum test voltage and remains stable at that voltage for more than the preset time (e.g., 30 minutes), and the failure condition of cutting off the high voltage as described in step S5 is not triggered throughout the process, the system automatically determines that the electrostatic deflection plate insulation test is "qualified".

[0042] Regardless of whether the test results are satisfactory or not, after the process is completed, the host computer automatically integrates all key parameters, multi-source synchronous data, fused feature vector evolution, comprehensive insulation risk coefficient curve, and all operation and alarm events, and packages them into a structured, timestamped, traceable test report, which is then stored in the database. This report facilitates subsequent querying, playback, analysis, and export.

[0043] By organically combining steps S1 to S6 above, the control method provided by this invention constructs a complete technology chain from precise environmental preparation, multi-dimensional synchronous perception, deep data fusion analysis to adaptive safety decision-making and closed-loop control. This method significantly improves the automation level, safety, and intelligence of DC high-voltage insulation testing, and is particularly suitable for performance verification of high-value, high-requirement components such as electrostatic deflection plates in superconducting cyclotron accelerators, possessing significant engineering application value.

[0044] Furthermore, the above method is implemented based on an integrated test and control system. This system mainly includes a central control unit, and subsystems connected to the central control unit, including a positioning subsystem, a test environment subsystem, a high-voltage application and monitoring subsystem, a synchronous acquisition subsystem, a data fusion processor, and a risk assessment and control module. The central control unit includes a programmable logic controller (PLC) and a host computer that communicate with each other. The former is responsible for real-time logic control and signal acquisition of the underlying equipment, while the latter is responsible for advanced human-machine interaction, data management, and process monitoring. This system is mainly used for insulation performance testing of the critical electrostatic deflection plates in superconducting cyclotron accelerators. The core of the system lies in achieving full automation and intelligence from preparation and execution to safety assessment. The system mainly relies on the central control unit for overall coordination. See details... Figure 1 , Figure 2 , Figure 4 and Figure 5 The central control unit comprises a programmable logic controller (PLC) 2 and a host computer 1 that communicate with each other. The PLC 2 is responsible for real-time logic control and signal acquisition of the underlying devices, while the host computer 1 provides advanced human-machine interaction, data management, and process monitoring functions. Through this architecture, the system can systematically control the positioning subsystem, the testing environment subsystem, and the high-voltage application and monitoring subsystem, and coordinate the synchronous acquisition subsystem 5. The acquired multi-source data is processed by the data fusion processor 6, and finally analyzed in real-time by the risk assessment and control module 7, which then feeds back control commands, thus forming a closed loop of perception, analysis, decision-making, and control.

[0045] This completely changes the traditional high-voltage testing process, which was characterized by isolated processes, asynchronous data, and reliance on manual experience for safety. Through centralized scheduling by the central control unit, each subsystem works collaboratively in a time-series manner, ensuring a high degree of consistency in testing conditions. More importantly, by synchronously collecting heterogeneous data and performing real-time fusion analysis, the system can capture early signs of insulation failure from multiple dimensions—electrical, optical, and mechanical—achieving proactive safety protection based on a multi-dimensional chain of evidence, greatly improving the safety of the testing process and the reliability of the results.

[0046] It should be noted that the present invention aims to coordinate the positioning subsystem, the test environment subsystem, and the high-voltage application and monitoring subsystem through a central control unit, forming an integrated and automated test platform. Each subsystem is interconnected through standardized electrical and communication interfaces and is uniformly scheduled by the central control unit to execute preset test procedures.

[0047] This integrated architecture enables unified management and seamless connection of the testing process, eliminating efficiency losses and operational errors caused by manual switching between stages. Centralized scheduling by the central control unit ensures strict timing and logical consistency of testing steps, laying a system foundation for obtaining reliable and repeatable test results.

[0048] The central control unit is the brain of the system, tightly coupled between a programmable logic controller (PLC) 2 and a host computer 1 (industrial computer) via a communication network (such as Ethernet). The PLC, as the lower-level control core, communicates directly with the actuators and sensors of each subsystem, responsible for real-time logic control and data acquisition. The host computer 1 provides a graphical human-machine interface (HMI) for remote parameter setting, process start / stop, data visualization, storage, and management. The two work collaboratively: the host computer 1 is responsible for issuing high-level instructions and data analysis, while the PLC ensures rapid and reliable response from the underlying devices.

[0049] The architecture of the host computer and PLC combines the powerful data processing and display capabilities of a computer with the high reliability and real-time performance of a PLC in industrial field control. This allows complex testing processes to be flexibly configured and monitored, while also achieving stable and reliable execution, which is key to realizing full-process automation and remote safe operation.

[0050] The synchronous acquisition subsystem 5 is uniformly triggered by the programmable logic controller 2, ensuring that the three types of heterogeneous data—the electrical response signal from the high-voltage circuit, the discharge light radiation signal captured by the optical sensor, and the mechanical strain (or vibration) signal measured by the sensor array on the support structure—have strictly synchronized timestamps. This lays the foundation for subsequent correlation analysis.

[0051] The data fusion processor 6 receives time-stamped data streams. Its primary task is to time-align data from different acquisition channels, eliminating minor deviations caused by transmission and sampling delays. Subsequently, the processor extracts key time-domain and frequency-domain features from each signal (such as the ripple component of leakage current, the intensity and frequency of optical pulses, and the mechanical vibration energy of specific frequency bands), combining them into a multi-dimensional fused feature vector. This vector more comprehensively characterizes the instantaneous state of the device under test at a given moment than any single signal. The risk assessment and control module 7, with its embedded risk assessment model (e.g., a machine learning model or empirical rule model trained on historical fault data), calculates this feature vector in real time, outputting a quantified comprehensive insulation risk coefficient. The risk assessment and control module 7 compares this coefficient with preset multi-level dynamic thresholds to decide whether to continue increasing the voltage, pause observation, or immediately cut off the high voltage. This enables the system to have adaptive risk control capabilities.

[0052] In some embodiments, the positioning subsystem includes a stepper motor driver 3, a stepper motor 4 connected to the stepper motor driver 3, and a position feedback sensor 11 for real-time position detection, forming a position closed-loop control loop. The programmable logic controller 2 performs deviation compensation control on the stepper motor 4 based on the signal from the position feedback sensor 11.

[0053] like Figure 1 As shown, the positioning subsystem includes a stepper motor driver 3, stepper motors 4 (left and right axes), and a position feedback sensor 11 (such as a left / right axis resistance scale). The stepper motor driver 3 receives pulses and direction signals from the PLC, driving the stepper motor 4 to rotate, which in turn moves the platform supporting and adjusting the electrostatic deflection plate via a mechanical transmission mechanism (such as a lead screw). The position feedback sensor 11 detects the actual position of the platform in real time and feeds the signal back to the analog input module of the PLC. The PLC compares the received position feedback value with the set target position, calculates the position deviation, and performs closed-loop compensation control by adjusting the pulse signals sent to the driver.

[0054] By introducing a closed-loop control circuit consisting of position feedback sensor 11, problems such as step loss and cumulative error that may exist in stepper motor 4 are effectively overcome. Through real-time deviation compensation by PLC, the final positioning accuracy of electrostatic deflection plate can be stably controlled within ±0.01mm, ensuring a high degree of consistency in the spatial position of the sample in each test.

[0055] In some embodiments, the test environment subsystem includes a mechanical pump 12 and a molecular pump 14 connected in sequence. The programmable logic controller 2 controls the start-stop sequence of the mechanical pump 12 and the molecular pump 14 according to the monitoring signal of the vacuum gauge 16, so as to reach a preset vacuum threshold in a stepwise manner.

[0056] The test environment subsystem is used to establish and maintain a vacuum environment within the test chamber. This system employs a staged vacuuming strategy, primarily consisting of a mechanical pump 12 (rough pump) and a molecular pump 14 (vacuum pump). At the start of the process, the PLC first controls the mechanical pump 12 to initiate preliminary vacuuming. A vacuum gauge 16 (connected to the PLC via a vacuum gauge power supply 15) monitors the chamber pressure in real time. When the vacuum level reaches a first preset threshold (e.g., better than 1 Pa), the PLC issues a command to activate the molecular pump power supply 13, which in turn drives the molecular pump 14 to further increase the vacuum level to a higher level required for the test (a second threshold, e.g., better than 1 × 10⁻³ Pa). The PLC controls the start-stop sequence and operating status of the two pump stages based on the signal logic from the vacuum gauge 16, ensuring an efficient and stable vacuuming process.

[0057] The staged vacuuming strategy conforms to the physical laws of vacuum acquisition, enabling rapid and stable achievement of the target vacuum level while protecting the molecular pump 14 from atmospheric impact. Automatic sequential control based on the vacuum level signal via PLC avoids potential errors or inappropriate timing during manual operation, improving the reliability and efficiency of vacuum establishment and providing the necessary environmental protection for high-pressure testing.

[0058] In some embodiments, the high voltage application and monitoring subsystem includes a high voltage power supply 17, a current-limiting resistor network connected in series with the output terminal of the high voltage power supply 17, a discharge resistor branch connected in parallel in the test circuit, and a leakage current detection instrument for detecting leakage current in the circuit. The high voltage power supply 17 communicates with the programmable logic controller 2 via the Modbus TCP protocol.

[0059] This subsystem is responsible for applying a high DC voltage to the electrostatic deflection plate and monitoring key electrical parameters. Its core is the high-voltage power supply 17 (maximum output DC 60kV), which communicates with the PLC via a network switch using the Modbus TCP protocol, receiving voltage settings and start / stop control from the PLC. The safety design of the high-voltage output is crucial: such as... Figure 4 As shown, the output is connected in series with a current-limiting resistor network consisting of 50kΩ and 10MΩ resistors to limit the inrush current during short circuits or discharges. A discharge resistor branch is connected in parallel in the test circuit; this branch conducts to protect the equipment when an abnormal overcurrent occurs. A leakage current detector is connected in series with the circuit ground terminal to measure the minute leakage current flowing through the device under test in real time. Its signal (typically 4-20mA or 0-10V) is sent to the PLC analog input module.

[0060] The current-limiting resistor network and the bleeder resistor branch constitute multiple layers of safety protection, reducing the risk of damage to the power supply and other parts of the system in the event of high-voltage arcing or breakdown. The high-voltage power supply 17 uses Modbus TCP communication, enabling remote control and status monitoring of the high-voltage output, which is a core component for achieving automated high-voltage testing and safe remote operation. Real-time leakage current monitoring provides the most direct criterion for judging the insulation condition.

[0061] In some embodiments, the system further includes an industrial camera 18 connected to the host computer 1, which continuously records during the test to visually monitor whether the electrostatic deflection plate experiences arcing or discharge.

[0062] The system is equipped with 18 industrial cameras (5 megapixels, DC 5V power supply), which are directly connected to the host computer 1 via a network cable. During high-voltage testing, the host computer 1 controls the cameras to continuously record video footage inside the test chamber. Operators can observe the footage in real time on the host computer 1 interface or review the recordings to check for visible phenomena such as corona discharge, arcing, or breakdown discharge on the electrostatic deflection plate and its surroundings under high voltage.

[0063] Visual monitoring is an important supplement to electrical parameter monitoring (such as leakage current). Some partial discharges or surface flashovers may not immediately cause significant abrupt changes in leakage current, but they will be visually apparent. This component provides a non-contact, intuitive means of condition monitoring, which, combined with electrical monitoring, forms a more comprehensive and reliable basis for failure judgment, further improving the accuracy of test results.

[0064] In some embodiments, the host computer 1 is equipped with dedicated software that provides a graphical human-machine interface. Its main functions include: remotely setting all test parameters such as test location, vacuum target, boost gradient, and risk threshold; one-click start / stop of the entire test process; real-time display of the status and data curves of each subsystem (such as vacuum change curve, boost curve, leakage current curve, risk coefficient curve, etc.) on the screen; and synchronously storing all operating data, event logs, video recordings, and the output results of the data fusion processor 6 and the risk assessment and control module 7. The data is ultimately integrated into a structured, timestamped data archive.

[0065] This system achieves digitalization, transparency, and traceability of the testing process. Operators can complete all operations and monitoring from the control room without having to be physically present in the high-voltage hazardous area. The complete data archive not only includes the final test results (pass / fail) but also records all details of the entire testing process, including any minor anomalies. This provides a rich data foundation for subsequent product quality traceability, insulation performance degradation research, and iterative optimization of risk assessment models.

[0066] The host computer 1 is equipped with custom-developed test control and data management software. Its main functions include: 1) providing an intuitive human-machine interface, allowing users to remotely set all parameters such as test position, vacuum threshold, high-voltage boosting program, and pass / fail criteria through graphics, buttons, and input boxes, and start and stop the test process with one click; 2) real-time display and recording, dynamically displaying data such as positioning coordinates, vacuum degree, output voltage, leakage current, and equipment status uploaded by the PLC in the form of curves, numbers, and dashboards, and synchronously storing them in the database; 3) data archiving and export, automatically generating structured data archives for each test, including time series of all key parameters, operation event logs, alarm records, and associated video files, supporting querying and exporting to standard format reports.

[0067] The host computer software integrates scattered data streams into an information flow, achieving transparency in the testing process and standardization of data management. This greatly simplifies operations and lowers the professional skill threshold for personnel. The resulting traceable data archives not only serve the determination of individual test results but also provide valuable data assets for product performance analysis, process improvement, and equipment maintenance.

[0068] In some embodiments, the programmable logic controller 2 has a complete automated testing procedure embedded within it. The advantage of this procedure is that it standardizes and automates the testing process, significantly reducing human intervention and misjudgments. The procedure typically follows: Initialization and positioning: The control positioning subsystem performs a return-to-origin operation, and then drives the stepper motor 4 to move the electrostatic deflection plate under test to the preset test position.

[0069] Establish vacuum: Start the mechanical pump 12 of the test environment subsystem. When the vacuum gauge 16 reading reaches the starting condition of the molecular pump 14 (first threshold, such as 1 Pa), the molecular pump 14 is automatically started. Continue evacuating until the second threshold required for the test (such as 10^-3 Pa) is reached.

[0070] Gradient voltage boost and dynamic risk assessment: Once the vacuum conditions are met, the programmable logic controller 2 instructs the high-voltage application and monitoring subsystem to start outputting voltage. The voltage boost uses a preset voltage gradient, starting at a lower 1KV. If the leakage current detected within a first preset time period (e.g., 60 seconds) is stable and below a certain first threshold, the voltage is automatically increased by 2KV, and so on in a step-by-step manner until the preset maximum test voltage is reached. Throughout the entire voltage boost and stabilization process, the risk assessment and control module 7 operates in the background.

[0071] When the comprehensive insulation risk coefficient calculated in real time is lower than a certain first risk threshold, the system determines that the state is safe and continues to increase or stabilize the voltage according to the original strategy.

[0072] When the risk coefficient reaches the first risk threshold but is below the more severe second risk threshold, it indicates the emergence of potential risk signs. At this time, the system will not immediately cut off the high voltage, but will pause the voltage boost (or maintain it at the current voltage) and simultaneously increase the optical monitoring sampling frequency (e.g., trigger the synchronous acquisition subsystem to sample the optical channel at a higher frequency), entering a "close observation period" to collect more data to determine whether the signs will develop.

[0073] If the risk factor reaches or exceeds the second risk threshold, the system determines that there is a risk of immediate breakdown or severe degradation, immediately cuts off the high-voltage output, and determines that the test has failed. Simultaneously, the bleeder resistor branch activates to rapidly release energy.

[0074] Judgment and Termination: If the output voltage successfully rises to the maximum voltage and remains stable at that voltage for more than the preset time (e.g., 30 minutes), and no failure conditions are triggered throughout the process, the system automatically determines that the electrostatic deflection board insulation test is qualified. Subsequently, it automatically executes the closing steps such as voltage reduction, discharge, and venting (if necessary).

[0075] To enhance system reliability, maintainability, and scalability, a modular design is adopted for the overall electrical connections. This translates to greater ease of deployment and maintenance.

[0076] Power distribution module: Converts the input 220V / 380V AC power into various levels of DC power required by the system (such as 24V for PLC / sensor, ±15V for analog circuits, 5V for digital circuits, etc.) through different switching power supplies and linear power supplies, and is equipped with overcurrent and overvoltage protection.

[0077] Standardized terminal blocks: All signal lines from field sensors (such as position encoders, vacuum gauges 16, current sensors, strain gauges) and control lines to actuators (such as motor drivers, pump relays, high-voltage power supply start / stop signals) are first connected to clearly labeled terminal blocks, and then connected to the I / O modules of the programmable logic controller 2 via pre-fabricated cables. This greatly simplifies wiring, troubleshooting, and component replacement.

[0078] Network switching module: Provides sufficient Ethernet ports for connecting programmable logic controller 2, host computer 1, high voltage power supply 17 (when network communication is supported), and other network devices that may be added in the future (such as network cameras and smart meters).

[0079] Practical Notes: When assembling the cabinet, high-voltage wiring (such as pump motor power supply, high-voltage power input) and low-voltage wiring (control signals, communication lines) should be strictly separated. Avoid long parallel runs. If necessary, use shielded cables and single-end grounding to suppress electromagnetic interference. Each connection point on the terminal block should have a clear and durable label.

[0080] like Figure 5 As shown, the system's electrical connections employ a clear modular design: Power distribution module: The input AC220V mains power is divided into multiple paths. One path is converted to DC24V via a 24V switching power supply to power low-voltage control equipment such as PLC, stepper driver, sensor, and switch; another AC220V path directly serves as the power supply for mechanical pump 12; the third path is connected to PDU (Power Distribution Unit) to power devices with their own power supplies, such as molecular pump power supply 13, vacuum gauge power supply 15, high-voltage power supply 17, and camera adapter.

[0081] Signal connection module: The PLC's input / output (I / O) signals are connected to peripheral devices (such as limit switches, pump and valve control circuits, and sensor signals) via standardized terminal blocks. This ensures neat and standardized wiring, facilitating inspection, maintenance, and subsequent channel expansion.

[0082] Network communication module: Using an industrial network switch, expand network ports to connect devices such as PLC, host computer 1, and high-voltage power supply 17 (when network communication is supported) to build the communication backbone network of the control system.

[0083] The modular design in this embodiment results in a clear system structure and well-defined functional zones. Standardized terminal blocks simplify field wiring, reduce wiring error rates, and facilitate faster troubleshooting and maintenance. Independent power distribution reduces interference between loads of different types. This enhances the system's engineering sophistication, reliability, and maintainability, and also facilitates future functional expansion or modifications to meet diverse testing needs.

[0084] In summary, through the organic integration of the aforementioned hardware subsystems, control logic, and software functions, a highly efficient, safe, and intelligent DC high-voltage testing platform has been constructed. It is particularly suitable for verifying the high-voltage insulation performance of high-value, high-requirement components such as the electrostatic deflection plates of superconducting cyclotron accelerators, significantly improving the efficiency and reliability of product development and quality inspection processes, and possessing significant engineering application value.

[0085] In this document, the directional terms such as front, back, top, and bottom are defined according to the positions of the components in the accompanying drawings and the positions between the components, and are only used for clarity and convenience in expressing the technical solution. It should be understood that the use of directional terms should not limit the scope of protection claimed by this invention.

[0086] Obviously, the above-described embodiments are only some embodiments of the present invention, and not all embodiments. The present invention is not limited to the details of the above embodiments. Any appropriate changes or modifications made by those skilled in the art are considered to be within the scope of the patent of the present invention.

Claims

1. A DC high-voltage test control method for insulation testing of electrostatic deflection plates in a superconducting cyclotron accelerator, characterized in that, Includes the following steps: S1. The zero point is automatically calibrated and the electrostatic deflection plate is adjusted to the preset test position through the positioning subsystem; S2. Vacuum the test environment subsystem in stages until the vacuum level meets the test requirements. S3. After the vacuum requirement is met, the DC high voltage is applied and gradually increased by the high voltage application and monitoring subsystem according to the preset strategy. At the same time, the central control unit coordinates the synchronous acquisition subsystem to synchronously acquire heterogeneous time-series data during the test. The heterogeneous time-series data includes at least: electrical response signals measured by the high voltage circuit, optical radiation signals acquired by optical sensors, and mechanical strain signals measured by the sensor array deployed on the support structure of the test piece. S4. The data fusion processor performs time alignment and feature extraction on the synchronously acquired heterogeneous time-series data to generate a multi-dimensional fusion feature vector stream characterizing the instantaneous insulation state of the test component. S5. Through the risk assessment and control module, based on the multi-dimensional fused feature vector flow, the risk assessment model is called to calculate the comprehensive insulation risk coefficient in real time, and the coefficient is compared with the preset dynamic correlation multi-level threshold to dynamically adjust the output strategy of the high voltage application and monitoring subsystem or execute safety protection actions. S6. The host computer automatically records and stores all key parameters, events, multi-dimensional fused feature vectors, and comprehensive insulation risk coefficients throughout the entire test process to form a traceable test report.

2. The DC high voltage test control method according to claim 1, characterized in that, Step S2 specifically includes: The programmable logic controller controls the start-up and shutdown sequence of the mechanical pump and the molecular pump according to the monitoring signal of the vacuum gauge, so as to achieve the preset vacuum threshold in a stepwise manner. The process begins with the mechanical pump being started for rough evacuation. Once the vacuum level reaches the first threshold, the molecular pump is then started to establish and maintain the vacuum level to meet the test requirements.

3. The DC high voltage test control method according to claim 1, characterized in that, In step S5, the dynamic adjustment of the output strategy of the high-voltage application and monitoring subsystem or the execution of safety protection actions specifically includes: When the comprehensive insulation risk coefficient is lower than the first risk threshold, the high voltage application and monitoring subsystem is controlled to continue to increase the voltage at a preset rate. When the comprehensive insulation risk coefficient reaches or exceeds the first risk threshold but is lower than the second risk threshold, the high voltage application and monitoring subsystem is controlled to suspend voltage increase, and the monitoring sampling frequency of the optical radiation signal in the synchronous acquisition subsystem is increased. When the comprehensive insulation risk coefficient reaches or exceeds the second risk threshold, the high voltage application and monitoring subsystem is immediately controlled to cut off the high voltage output and perform safety protection actions, thus determining that the test has failed.

4. The DC high voltage test control method according to claim 1, characterized in that, In step S3, the preset strategy for the high voltage application and monitoring subsystem to apply and gradually increase the DC high voltage is as follows: The initial output voltage is 1KV. After that, every first preset time interval and if the leakage current is detected to be lower than the corresponding safety threshold, the output voltage will be increased by 2KV until the preset maximum test voltage is reached.

5. The DC high voltage test control method according to claim 1, characterized in that, Following step S5, the test result determination step is also included: If the output voltage rises to the preset maximum voltage and remains stable at that voltage for more than the preset duration, and the failure condition of cutting off the high voltage is not triggered throughout the process, then the electrostatic deflection plate is deemed to have passed the insulation test.

6. The DC high voltage test control method according to claim 1, characterized in that, The method is executed based on a DC high-voltage test and control system, the system comprising: A central control unit, comprising a programmable logic controller and a host computer that communicate with each other; The positioning subsystem, connected to the programmable logic controller, is used to support and adjust the spatial position of the electrostatic deflection plate under test. The test environment subsystem, connected to the programmable logic controller, is used to establish and maintain the vacuum test environment required for testing. The high voltage application and monitoring subsystem is connected to the programmable logic controller via a communication network and is used to apply DC high voltage to the electrostatic deflection plate and monitor electrical parameters in real time. The synchronous acquisition subsystem, coordinated by the programmable logic controller, is used to synchronously acquire three types of heterogeneous time-series data during the test process: electrical response signals measured by the high-voltage circuit, optical radiation signals acquired by the optical sensors, and mechanical strain signals measured by the sensor array deployed on the support structure of the test piece. The data fusion processor, connected to the synchronous acquisition subsystem, is used to perform time alignment and feature extraction on the received synchronous heterogeneous time-series data stream, and output a multi-dimensional fusion feature vector representing the instantaneous state of the device under test. The risk assessment and control module, connected to the data fusion processor, includes a risk assessment model; the risk assessment and control module is configured to: receive the multi-dimensional fusion feature vector, call the risk assessment model to calculate the comprehensive insulation risk coefficient, and adjust the output strategy of the high voltage application and monitoring subsystem or execute safety protection actions in real time according to the preset multi-level thresholds dynamically associated with the coefficient. The central control unit coordinates and controls the positioning subsystem, the test environment subsystem, the high-voltage application and monitoring subsystem, the synchronous acquisition subsystem, the data fusion processor, and the risk assessment and control module to achieve a full-process test from position calibration, test environment establishment, high-voltage application, multi-source synchronous monitoring, dynamic risk assessment to data recording.

7. The DC high voltage test control method according to claim 2, characterized in that, The positioning subsystem includes a stepper motor driver, a stepper motor connected to the stepper motor driver, and a position feedback sensor for real-time position detection, forming a position closed-loop control loop. The programmable logic controller (PLC) performs deviation compensation control on the stepper motor based on the signal from the position feedback sensor. The test environment subsystem includes a mechanical pump and a molecular pump connected in sequence. The PLC controls the start-stop sequence of the mechanical pump and the molecular pump based on the monitoring signal from the vacuum gauge to achieve a preset vacuum threshold in a stepwise manner. The high-voltage application and monitoring subsystem includes a high-voltage power supply, a current-limiting resistor network connected in series with the output terminal of the high-voltage power supply, a discharge resistor branch connected in parallel in the test loop, and a leakage current detection instrument for detecting leakage current in the loop. The high-voltage power supply communicates with the PLC via the Modbus TCP protocol.

8. The DC high voltage test control method according to claim 1, characterized in that, The system further comprises an industrial camera connected to the upper computer, wherein the industrial camera performs continuous recording during the test and is configured to visually monitor whether sparking or discharging occurs on the electrostatic deflection plate, and the upper computer is configured to: provide a human-computer interaction interface to remotely set test parameters and start / stop the test process; display and record in real time the operating data of the positioning subsystem, the test environment subsystem, the high voltage application and monitoring subsystem, the synchronous acquisition subsystem, the data fusion processor and the risk assessment and control module; and store and export complete test process data to form a traceable data archive.

9. The DC high voltage test control method according to claim 7, characterized in that, The programmable logic controller is configured to execute the following automated test procedures: control the positioning subsystem to perform a homing operation and adjust the electrostatic deflection plate to a test position; control the test environment subsystem to establish a vacuum, and start the molecular pump after the vacuum degree reaches a first threshold; after the vacuum degree reaches a second threshold, control the high voltage application and monitoring subsystem to gradually increase the output voltage according to a preset voltage gradient; during the high voltage application process, the risk assessment and control module dynamically adjusts the voltage boosting strategy according to the real-time calculated comprehensive insulation risk coefficient: when the risk coefficient is lower than the first threshold, continue boosting at the original rate; when the risk coefficient reaches the first threshold but is lower than the second threshold, suspend boosting and increase the optical monitoring sampling frequency; when the risk coefficient reaches or exceeds the second threshold, immediately cut off the high voltage output and determine the test as failed; if the output voltage is stably maintained at the preset maximum voltage for more than a preset duration and no failure condition is triggered, the test is determined to be qualified.

10. A DC high-voltage test control method according to claim 6, characterized in that, The electrical connection of the DC high voltage test system adopts a modular design, comprising: a power distribution module for converting input alternating current into direct current of different grades; a standardized terminal block for centrally connecting the input and output signals of the programmable logic controller and various peripheral devices; and a network switching module for expanding network communication ports.