A full-automatic cable matching and insulation comprehensive tester and testing method

Abstract

The application provides a full-automatic cable pairing and insulation comprehensive tester, which comprises a host and a slave machine, the host comprises a multi-path host test port, a host grounding port, a host control unit, a relay matrix, a low-voltage coding signal source, a high-voltage source module and a host current detection circuit; the multi-path host test port is used for connecting each core wire of the first end of a multi-core cable to be tested, and the host grounding port is used for connecting a host side grounding row; the slave machine comprises a multi-path slave machine test port, a slave machine grounding port, a slave control unit and a multi-path independent slave machine current detection circuit corresponding to each slave machine test port; the multi-path slave machine test port is used for connecting each core wire of the second end of a multi-core cable to be tested, and the slave machine grounding port is used for connecting a slave machine side grounding row. The application does not need to lay additional communication cables, simplifies the field operation process, effectively reduces the field operation difficulty and operation workload, and significantly improves the convenience and efficiency of cable detection operation.

Description

Technical Field

[0001] This invention relates to the field of power system cable testing technology, and in particular to a fully automatic cable pairing and insulation comprehensive tester and testing method. Background Technology

[0002] In the cable laying and daily operation and maintenance of power plants and substations, the pairing inspection and insulation resistance test of multi-core cables are indispensable basic core procedures. Among them, the cable pairing inspection is used to verify the one-to-one correspondence and conductivity of each core wire at both ends of the cable, and the insulation resistance test is used to detect the insulation performance of the core wires to ground and between core wires. The accuracy and efficiency of the above two inspections directly affect the installation and commissioning quality of electrical equipment, and are also related to the long-term safety and stability of the power system.

[0003] However, most mainstream integrated testing equipment on the market currently has a low degree of automation, and most still rely on manual switching of testing channels for testing. For testing 16-core or higher multi-core cables, the manual operation process is cumbersome, time-consuming, and the overall testing efficiency is low. At the same time, frequent manual intervention is prone to operational errors, resulting in false positives and false negatives, and the reliability of the equipment cannot be effectively guaranteed. Existing integrated testing equipment is mostly a master-slave type, which is convenient for testing when the two ends of the cable are located at different locations, but communication depends on additional wiring. A dedicated communication cable must be laid between the master and slave units, or the signal communication medium must be forced to rely on the cable shielding layer or spare cable to complete the signal exchange. This is not suitable for large substations and power plants with complex cable paths and long cable distances. Moreover, existing insulation testing equipment is mostly geared towards the insulation of high-voltage systems, ignoring the numerous low-voltage control cables, instrument cables, and other secondary circuit cables. It cannot meet the insulation testing needs of cables of different specifications and voltage levels, and its applicable scenarios are limited. Summary of the Invention

[0004] This application provides a fully automatic cable pairing and insulation comprehensive tester and test method. It adopts a separate independent structure design of main unit and auxiliary unit. There is no need to lay a dedicated communication cable between the main unit and the auxiliary unit. It can complete bidirectional signal interaction and fully automatic detection operation by relying on the cable under test and the field grounding system, effectively overcoming various defects of the prior art.

[0005] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.

[0006] According to a first aspect of the embodiments of this application, a fully automatic cable pairing and insulation comprehensive tester is provided, including a main unit and a sub-unit. The main unit and the sub-unit are separate and independent structures, and are connected by the multi-core cable to be tested. The host includes multiple host test ports, a host grounding port, a main control unit, a relay matrix, a low-voltage coded signal source, a high-voltage source module, and a host current detection circuit. The multiple host test ports are used to connect to the cores of the multi-core cable under test at its first end. The host grounding port is used to connect to the host-side grounding busbar. The main control unit is used to implement overall logic control of the test instrument, data processing, and human-machine interaction functions. The relay matrix is ​​connected to the main control unit and, under the control of the main control unit, selectively connects each host test port to the low-voltage coded signal source, the high-voltage source module, or the host grounding port. The host current detection circuit is used to collect the operating current of the line detection circuit and the leakage current of the insulation detection circuit. The auxiliary unit includes multiple auxiliary unit test ports, an auxiliary unit grounding port, a slave control unit, and multiple independent auxiliary unit current detection circuits corresponding to each auxiliary unit test port; the multiple auxiliary unit test ports are used to connect to each core wire at the second end of the multi-core cable under test, and the auxiliary unit grounding port is used to connect to the auxiliary unit side grounding busbar; According to one embodiment of this application, the auxiliary current detection circuit integrates a sampling resistor, an optocoupler isolation device, and a comparator for independently and in real-time monitoring of the current on / off status of the corresponding port. The auxiliary unit also includes a port indicator unit and a port number display unit. The port indicator unit is equipped with an LED indicator and a buzzer for each auxiliary test port, and provides an audible and visual prompt when the host test port number is identified. The port number display unit adopts a digital tube or segment LCD structure to synchronously display the identified host test port number. The auxiliary current detection circuit monitors the current operating status of each port in real time. When a valid current pulse train is detected at any port, the slave control unit completes digital encoding and decoding by analyzing the pulse width to identify the corresponding host test port number. It synchronously controls the corresponding LED indicator to light up and the buzzer to sound, and displays the corresponding host test port number through the port number display unit. The host LCD screen synchronously updates and displays the conduction status of the corresponding core wire.

[0007] According to one embodiment of this application, the high-voltage source module provides four adjustable DC high-voltage outputs of 250V, 500V, 1000V, and 2500V. The main control unit starts the high-voltage source module according to the voltage level selected through the host operation panel and controls the relay matrix to complete the automatic switching and matching of the detection channels.

[0008] According to one embodiment of this application, the slave unit further includes an isolation power supply module. The isolation power supply module adopts a floating ground design, and the reference ground of the slave control unit and the internal circuit of the slave unit is not directly connected to the slave unit grounding port. The slave unit achieves power supply isolation through the isolation power supply module and signal isolation through an optocoupler isolation device to isolate the potential difference interference between the master-side grounding bus and the slave-side grounding bus.

[0009] According to one embodiment of this application, the main unit further includes a color LCD screen and a power management module. The color LCD screen is used to display the test mode, voltage level, detection status of each core wire, and insulation resistance detection value in real time. The power management module supports dual working modes of AC mains power supply and built-in battery power supply. The auxiliary unit also includes a built-in rechargeable battery, which provides independent power supply for the auxiliary unit.

[0010] According to one embodiment of this application, the integrated tester includes a line detection mode, specifically including: The main control unit controls the relay matrix to sequentially connect each host test port to the low-voltage coded signal source. The low-voltage coded signal source outputs a pulse-coded current signal carrying the corresponding port number information. The pulse-coded current signal is transmitted through the core wires of the multi-core cable under test to the corresponding auxiliary test port, and then sequentially flows back to the host through the auxiliary internal circuit, the auxiliary grounding port, the auxiliary side grounding bus, the earth, the host side grounding bus, and the host grounding port, forming a closed detection loop. The auxiliary current detection circuits of each auxiliary unit monitor the current status of the corresponding port in real time. When the slave control unit detects a valid pulse-coded current signal at any port, it decodes the pulse-coded current signal to identify the corresponding host test port number, thereby completing the automatic identification and continuity detection of the correspondence between the core wires of the multi-core cable under test.

[0011] According to one embodiment of this application, in the wire pairing detection mode, if the host does not detect the current of the closed detection loop within a preset time, it determines that there is an open circuit fault in the corresponding core wire and displays a fault message on the host display screen; if the slave does not detect a valid pulse-coded current signal, it automatically skips the current detection sequence number and waits for the next frame detection signal until the wire pairing detection of all core wires of the multi-core cable under test is completed.

[0012] According to one embodiment of this application, the integrated tester includes an insulation detection mode, specifically including: The main control unit controls the relay matrix to connect the core wire to be tested with the high-voltage source module and automatically switches the detection channel. The host current detection circuit collects the leakage current. The main control unit calculates the insulation resistance based on the output voltage of the high-voltage source module and the collected leakage current, and automatically completes the insulation test of each core wire.

[0013] According to one embodiment of this application, the insulation detection mode further includes: During the insulation test, the relay matrix connects the single core wire to be tested to the positive terminal of the high-voltage source module, while switching all other core wires and cable shielding to the ground state. The host current detection circuit collects the leakage current of the leakage current loop formed through the core wire under test, insulation layer, shielding layer or ground. During the insulation test between core wires, the main control unit controls the relay matrix to sequentially connect any two core wires to the positive terminal of the high-voltage source module and the measuring terminal, respectively, while the remaining core wires remain suspended. The leakage current between the core wires is collected group by group, and the insulation resistance value between the core wires is calculated. The main control unit is also used to automatically determine whether the insulation performance is qualified based on the calculated insulation resistance value.

[0014] According to a second aspect of the embodiments of this application, a fully automatic cable pairing and insulation comprehensive testing method is provided, which is implemented based on the fully automatic cable pairing and insulation comprehensive tester described in the first aspect. The method includes the following steps: S1. Wiring: Connect each core wire at one end of the multi-core cable to the corresponding host test port, and connect each core wire at the other end of the multi-core cable to the corresponding slave test port. Connect the host grounding port and the slave grounding port to the host side grounding busbar and the slave side grounding busbar, respectively. S2. Line Detection: The main control unit controls the relay matrix to sequentially connect the host test port to the low-voltage coded signal source, sending pulse coded current signals carrying port number information to each core wire. The pulse coded current signals form a closed detection loop through the core wires of the multi-core cable under test and the return path composed of the auxiliary unit grounding port, the earth, and the host unit grounding port. The auxiliary unit decodes and identifies the corresponding host test port number and provides a prompt. The host unit determines the conduction or open circuit status of each core wire based on whether a closed detection loop current is detected. S3. Insulation test: After selecting the test voltage level, the main control unit starts the high voltage source module and controls the relay matrix to automatically switch the test channel, complete the insulation test of each core wire to ground one by one, and then automatically switch to complete the insulation test between core wires of each core wire combination one by one. The insulation resistance value is calculated based on the collected leakage current, and the insulation performance is automatically determined to be qualified. S4. After the test is completed, the high-voltage output circuit is automatically cut off and the residual charge of the multi-core cable under test is discharged. All test data are integrated to generate and store the test report.

[0015] Compared with existing technologies, the beneficial effects of adopting the above technical solution are as follows: (1) No additional communication cables need to be laid between the main unit and the auxiliary unit of the present invention. Signal interaction can be completed by relying on the cable body under test and the field grounding system, which simplifies the field operation process, effectively reduces the difficulty and workload of field operation, and significantly improves the convenience and efficiency of cable testing. It is especially suitable for large substations and power plants with complex cable paths and long cable distances.

[0016] (2) The present invention adopts pulse code recognition technology, which has high detection accuracy and strong anti-interference ability. It does not need to rely on clock synchronization mechanism, can effectively resist strong electromagnetic interference on site, greatly improve the accuracy of core wire number recognition and the overall stability of equipment operation, and is highly adaptable to industrial operation sites with complex grounding systems and harsh electromagnetic environment, such as power plants and substations.

[0017] (3) The present invention realizes full automation of the detection process. There is no need for manual switching of detection channels one by one or manual recording of detection data. The detection results are automatically stored and the detection report is automatically generated, which greatly improves the work efficiency, effectively avoids manual detection errors, and improves the reliability of detection.

[0018] (4) The present invention is equipped with four adjustable insulation test voltages of 250V, 500V, 1000V and 2500V, which fully covers various cable specifications from weak current control to medium and high voltage power. It can be adapted to various power field testing operation scenarios. The equipment has strong adaptability to operating conditions and is applicable to a wide range of scenarios.

[0019] (5) The auxiliary unit of the present invention adopts a floating ground isolation design, which can completely isolate the potential difference interference between the grounding bars on both sides of the main unit and the auxiliary unit, effectively protecting the internal circuit of the equipment from damage, and ensuring the integrity of the detection signal transmission and the accuracy of the detection data.

[0020] (6) The wire detection and insulation detection modes of the present invention adopt a hardware modular reuse design, which effectively simplifies the hardware structure of the equipment and reduces the equipment cost while ensuring the integrity of the equipment functions and the detection accuracy. Attached Figure Description

[0021] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0022] Figure 1 This is a schematic diagram of a fully automatic cable pairing and insulation comprehensive tester according to an embodiment of this application.

[0023] Figure 2This is a flowchart illustrating the testing method of the fully automatic cable pair and insulation comprehensive tester according to an embodiment of this application.

[0024] Reference numerals: 1-Main unit; 2-Sub-unit; 3-Multi-core cable under test; 4-Main unit side grounding busbar; 5-Sub-unit side grounding busbar; 11-Main unit test port; 12-Main unit grounding port; 13-Main control unit; 14-Relay matrix; 15-Low voltage coded signal source; 16-High voltage source module; 17-Main unit current detection circuit; 18-Color LCD display; 19-Power management module; 21-Sub-unit test port; 22-Sub-unit grounding port; 23-Slave control unit; 24-Sub-unit current detection circuit; 25-Port indicator unit; 26-Port number display unit; 27-Isolated power supply module; 28-Built-in rechargeable battery. Detailed Implementation

[0025] The embodiments of this application are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar modules or modules having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. Rather, the embodiments of this application include all variations, modifications, and equivalents falling within the spirit and scope of the appended claims.

[0026] To address the shortcomings of existing technologies, this application provides a fully automatic cable pairing and insulation comprehensive tester. Please refer to [link / reference]. Figure 1 The integrated tester adopts a separate independent structure design of main unit 1 and auxiliary unit 2. There is no need to lay a dedicated communication cable between main unit 1 and auxiliary unit 2. It can complete bidirectional signal interaction and fully automatic detection operation by relying on the multi-core cable 3 under test and the field grounding system.

[0027] Specifically, the host 1 includes a multi-channel host test port 11, a host grounding port 12, a main control unit 13, a relay matrix 14, a low-voltage coded signal source 15, a high-voltage source module 16, a host current detection circuit 17, a color LCD display 18, and a power management module 19. Among them, the multi-channel host test port 11 is used to connect to each core wire at one end of the multi-core cable 3 under test, and the host grounding port 12 is used to connect to the host side grounding busbar 4 through a dedicated grounding wire; the main control unit 13 adopts an industrial-grade single-chip microcomputer to realize the overall logic control of the equipment, the processing of test data, and the human-machine interaction function; the relay matrix 14 is connected to the main control unit 13, and can selectively connect each host test port 11 to the low-voltage encoding signal source 15, the high-voltage source module 16, or the grounding terminal under the control of the main control unit 13; the low-voltage encoding signal source 15 is used to output a pulse encoding current signal dedicated to line detection; the high-voltage source module 16 can output DC high voltage at different levels to adapt to the insulation detection requirements of different types of cables; the host current detection circuit 17 is used to collect the working current of the line circuit and the leakage current of the insulation test in real time.

[0028] The auxiliary unit 2 includes multiple auxiliary unit test ports 21, one auxiliary unit grounding port 22, a slave control unit 23, 16 independent auxiliary unit current detection circuits 24, a port indicator unit 25, a port number display unit 26, an isolated power supply module 27, and a built-in rechargeable battery 28. The multiple auxiliary unit test ports 21 are used to connect to the cores of the multi-core cable 3 under test at the other end. The auxiliary unit grounding port 22 is used to connect to the auxiliary unit side grounding busbar 5 via a dedicated grounding wire. The slave control unit 23 is used to complete pulse signal decoding and port indicator control logic. Each of the 16 independent auxiliary unit current detection circuits 24 integrates sampling resistors, optocoupler isolation devices, and comparators, enabling independent real-time monitoring of the current on / off status of the corresponding ports.

[0029] In this embodiment, a tester suitable for 16-core cables will be used as an example for subsequent description. The main unit 1 and the auxiliary unit 2 each correspond to 16 test ports. It should be noted that the number of test ports is not limited to 16. Those skilled in the art can increase or decrease the number of test ports according to the core count of the cable under test, for example, setting it to 8, 24, or 32 ports, all of which fall within the protection scope of this invention.

[0030] In this embodiment, the host 1 also includes a color LCD screen 18 for real-time display of test modes, voltage levels, detection status of each core wire, and insulation resistance detection values. The high-voltage source module provides four adjustable DC high-voltage outputs of 250V, 500V, 1000V, and 2500V. The main control unit starts the high-voltage source module according to the voltage level selected through the color LCD screen and controls the relay matrix to complete the automatic switching and matching of detection channels. It also includes a power management module 19 that supports dual working modes of AC 220V mains power supply and built-in battery power supply, adaptable to various complex field operation scenarios.

[0031] In this embodiment, the auxiliary unit 2 also includes a port indicator unit 25 and a port number display unit 26. The port indicator unit 25 is equipped with LED indicator lights and buzzers for each auxiliary unit test port 21 to realize the sound and light prompts of the detection status. The port number display unit 26 adopts a digital tube or segment LCD structure to synchronously display the test terminal number corresponding to the host 1. Furthermore, the auxiliary unit 2 also includes an isolated power supply module 27. The isolated power supply module 27 adopts a floating ground design, and the reference ground of the slave control unit 23 and the internal circuitry of the auxiliary unit is not directly connected to the auxiliary unit's grounding port 22. The auxiliary unit 2 achieves power supply isolation through the isolated power supply module 27 and signal isolation through optocoupler isolation devices to isolate potential difference interference between the host-side grounding bus 4 and the auxiliary-side grounding bus 5. Simultaneously, the auxiliary unit 2 has a built-in rechargeable battery 28 that provides independent power, ensuring portable operation of the equipment.

[0032] To better illustrate the working process of the comprehensive tester in this embodiment, the following will be combined with... Figure 2 The line testing mode and insulation testing mode of this comprehensive tester will be used as examples for a detailed introduction.

[0033] The wire detection mode employs current pulse digital encoding transmission technology, enabling fully automatic core wire identification and continuity testing without the need for dedicated communication cables. Specifically, the main control unit 13 of host 1 controls the relay matrix 14 to sequentially connect host test ports 11 (numbers 1 to 16) to the low-voltage encoded signal source 15. For any Nth test port, the low-voltage encoded signal source 15 outputs a pulse-encoded current signal carrying the corresponding port's unique number information. This pulse encoding uses binary encoding, with each pulse train containing a start bit, data bits, and stop bits, accurately identifying the host terminal number and ensuring the uniqueness and accuracy of signal identification.

[0034] The pulse-coded current signal is transmitted through the core wire of the multi-core cable under test 3 to the corresponding test port 21 of the auxiliary machine 2, and then flows back to the main machine 1 through the internal circuit of the auxiliary machine, the grounding port 22 of the auxiliary machine, the grounding bus 5 of the auxiliary machine side, the earth, the grounding bus 4 of the main machine side, and the grounding port 12 of the main machine side, forming a complete closed detection circuit.

[0035] The 16-channel independent current detection circuit 24 of the auxiliary unit 2 monitors the current operating status of each port in real time. When a valid current pulse train is detected at any port, the slave control unit 23 completes digital encoding and decoding by analyzing the pulse width and accurately identifies the corresponding host terminal number. It synchronously controls the LED indicator of the port to light up and the buzzer to sound, and displays the corresponding host terminal number through the port number display unit 26. The color LCD screen 18 of the host 1 updates and displays the conduction status of the corresponding core wire synchronously.

[0036] If the host 1 does not detect a closed-loop current within a preset time (e.g., 5 seconds), it determines that there is an open circuit fault in the corresponding core wire. The corresponding port on the color LCD screen 18 will light up with a fault indication and display the abnormal open circuit result. If the slave unit 2 does not detect a valid pulse signal, it will automatically skip the current detection sequence number and wait for the next frame of detection signal input until the fully automatic wire pairing detection of all 16 core wires is completed. After all core wire pairing detections are completed, the host 1 will automatically integrate all detection data, generate and display a complete pairing test report.

[0037] Please continue to refer to this. Figure 2 The insulation testing mode, based on Ohm's law R=U / I, achieves accurate calculation of insulation resistance and supports adaptive switching of multiple high voltage levels. It can automatically complete the entire process of core wire-to-ground insulation and core wire-to-core insulation testing. Operators can select any DC high voltage level (250V, 500V, 1000V, 2500V) via the main unit 1's control panel. The main control unit 13 activates the high voltage source module 16 according to the selected voltage level and controls the relay matrix 14 to automatically switch and match the testing channels. Simultaneously, the main unit's current detection circuit collects leakage current values ​​in real time. The main control unit combines the preset detection voltage and the measured current values ​​to accurately calculate the corresponding core wire's insulation resistance to ground and automatically determines whether the insulation performance is qualified. The test results are displayed synchronously on the main unit's LCD screen in real time.

[0038] During the insulation-to-ground test, the relay matrix 14 connects the single core wire to be tested to the positive terminal of the high-voltage source module 16, while switching all other core wires and cable shielding to the ground state. The high-voltage current forms a leakage current loop through the core wire under test, the insulation layer, the shielding layer, or the ground. The main current detection circuit 17 collects the leakage current value in real time. The main control unit 13 combines the preset detection voltage and the measured current value to accurately calculate the insulation resistance value of the corresponding core wire to ground and automatically determines whether the insulation performance is qualified. The test results are displayed synchronously on the color LCD screen 18 in real time.

[0039] After the single-core wire insulation test is completed, the equipment automatically switches to the core wire insulation test mode. The main control unit 13 controls the relay matrix 14 to connect any two core wires to the positive terminal of the high-voltage source module 16 and the measuring terminal respectively, while the remaining core wires remain suspended. The leakage current between the core wires is collected group by group, and the insulation resistance value is calculated. Based on the calculated insulation resistance value, the equipment automatically determines whether the insulation performance is qualified, thus completing the inter-core wire insulation test for all core wire combinations. After all insulation test procedures are completed, the host 1 automatically integrates all test data, generates and stores a complete cable insulation test report, enabling the test data to be traceable and viewable. Subsequently, the equipment automatically disconnects the high-voltage output circuit to completely discharge the residual charge in the tested cable, completing a single complete insulation test operation.

[0040] It should be noted that the auxiliary unit 2 in this embodiment adopts a floating ground isolation design: the reference ground of the slave control unit 23 and the surrounding circuits is not directly connected to the auxiliary unit grounding port 22. Power supply isolation is achieved through the isolation power module 27, and signal isolation transmission is achieved through the optocoupler isolation device. This can completely isolate the potential difference interference between the grounding bars on both sides of the host 1 and the auxiliary unit 2, which can effectively protect the internal circuits of the equipment from damage and ensure the integrity of the detection signal transmission and the accuracy of the detection data.

[0041] Furthermore, the wire detection and insulation detection modes in this embodiment adopt a modular hardware reuse design, sharing the relay matrix 14, main control unit 13, color LCD display 18 and power management module 19. Only the low-voltage encoding signal source 15 and the high-voltage source module 16 are independent of each other, and electrical isolation and working mode switching are achieved through relays. While ensuring the integrity of equipment functions and detection accuracy, the hardware structure of the equipment is effectively simplified.

[0042] Furthermore, this embodiment also provides a fully automatic cable pairing and insulation comprehensive testing method, based on the aforementioned fully automatic cable pairing and insulation comprehensive tester. The method includes the following steps: S1. Wiring: Connect each core wire at one end of the multi-core cable to the corresponding host test port, and connect each core wire at the other end of the multi-core cable to the corresponding slave test port. Connect the host grounding port and the slave grounding port to the host side grounding busbar and the slave side grounding busbar, respectively. S2. Line Detection: The main control unit controls the relay matrix to sequentially connect the host test port to the low-voltage coded signal source, sending pulse coded current signals carrying port number information to each core wire. The pulse coded current signals form a closed detection loop through the core wires of the multi-core cable under test and the return path composed of the auxiliary unit grounding port, the earth, and the host unit grounding port. The auxiliary unit decodes and identifies the corresponding host test port number and provides a prompt. The host unit determines the conduction or open circuit status of each core wire based on whether a closed detection loop current is detected. S3. Insulation test: After selecting the test voltage level, the main control unit starts the high voltage source module and controls the relay matrix to automatically switch the test channel, complete the insulation test of each core wire to ground one by one, and then automatically switch to complete the insulation test between core wires of each core wire combination one by one. The insulation resistance value is calculated based on the collected leakage current, and the insulation performance is automatically determined to be qualified. S4. After the test is completed, the high-voltage output circuit is automatically cut off and the residual charge of the multi-core cable under test is discharged. All test data are integrated to generate and store the test report.

[0043] For those skilled in the art, the specific meanings of the above terms in this invention can be understood according to the specific circumstances; the accompanying drawings in the embodiments are used to clearly and completely describe the technical solutions in the embodiments of this invention. Obviously, the described embodiments are some embodiments of this invention, but not all embodiments. Generally, the components of the embodiments of this invention described and shown in the accompanying drawings can be arranged and designed in various different configurations.

[0044] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A fully automatic cable pairing and insulation comprehensive tester, characterized in that, It includes a main unit and a secondary unit, which are separate and independent structures, and are connected by a multi-core cable to be tested; The host includes multiple host test ports, a host grounding port, a main control unit, a relay matrix, a low-voltage coded signal source, a high-voltage source module, and a host current detection circuit; The multi-channel host test port is used to connect each core wire at the first end of the multi-core cable under test, and the host grounding port is used to connect to the host-side grounding busbar; the main control unit is used to realize the overall logic control of the tester, the processing of test data, and the human-machine interaction function; the relay matrix is ​​connected to the main control unit and is used to selectively connect each of the host test ports to the low-voltage coded signal source, the high-voltage source module, or the host grounding port under the control of the main control unit; the host current detection circuit is used to collect the working current of the wire detection circuit and the leakage current of the insulation detection; the low-voltage coded signal source is used to output a pulse coded current signal dedicated to wire detection; the high-voltage source module provides multiple levels of DC high voltage; The auxiliary unit includes multiple auxiliary unit test ports, an auxiliary unit grounding port, a slave control unit, and multiple independent auxiliary unit current detection circuits corresponding to each auxiliary unit test port. The multiple auxiliary unit test ports are used to connect to each core wire at the second end of the multi-core cable under test, and the auxiliary unit grounding port is used to connect to the auxiliary unit side grounding busbar. The slave control unit is used to complete pulse signal decoding and port indication control logic. Each auxiliary unit current detection circuit is used to independently monitor the current on / off status of the corresponding port in real time.

2. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The auxiliary unit also includes a port indicator unit and a port number display unit. The port indicator unit is equipped with LED indicator lights and buzzers for each auxiliary unit test port, and is used to provide audible and visual prompts when the host test port number is identified. The port number display unit adopts a digital tube or segment LCD structure to synchronously display the identified host test port number. The auxiliary unit current detection circuit monitors the current operating status of each port in real time. When a valid current pulse train is detected at any port, the slave control unit completes digital encoding and decoding by analyzing the pulse width to identify the corresponding host test port number. It synchronously controls the corresponding LED indicator light to light up and the buzzer to sound, and displays the corresponding host test port number through the port number display unit. The host LCD screen synchronously updates and displays the conduction status of the corresponding core wire.

3. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The high-voltage source module provides four adjustable DC high-voltage outputs of 250V, 500V, 1000V, and 2500V. The main control unit starts the high-voltage source module according to the voltage level selected through the host operation panel and controls the relay matrix to complete the automatic switching and matching of the detection channels.

4. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The auxiliary unit also includes an isolation power supply module, which adopts a floating ground design. The reference ground of the slave control unit and the internal circuit of the auxiliary unit is not directly connected to the grounding port of the auxiliary unit. The auxiliary unit achieves power supply isolation through the isolation power supply module and signal isolation through optocoupler isolation devices to isolate the potential difference interference between the grounding busbar on the host side and the grounding busbar on the auxiliary unit side.

5. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The main unit also includes a color LCD screen and a power management module. The color LCD screen is used to display the test mode, voltage level, detection status of each core wire, and insulation resistance detection value in real time. The power management module supports dual working modes of AC mains power supply and built-in battery power supply. The auxiliary unit also includes a built-in rechargeable battery, which provides independent power supply for the auxiliary unit.

6. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The comprehensive tester includes a line-to-line testing mode, specifically including: The main control unit controls the relay matrix to sequentially connect each host test port to the low-voltage coded signal source. The low-voltage coded signal source outputs a pulse-coded current signal carrying the corresponding port number information. The pulse-coded current signal is transmitted through the core wires of the multi-core cable under test to the corresponding auxiliary test port, and then sequentially flows back to the host through the auxiliary internal circuit, the auxiliary grounding port, the auxiliary side grounding bus, the earth, the host side grounding bus, and the host grounding port, forming a closed detection loop. The auxiliary current detection circuits of each auxiliary unit monitor the current status of the corresponding port in real time. When the slave control unit detects a valid pulse-coded current signal at any port, it decodes the pulse-coded current signal to identify the corresponding host test port number, thereby completing the automatic identification and continuity detection of the correspondence between the core wires of the multi-core cable under test.

7. The fully automatic cable pairing and insulation comprehensive tester according to claim 6, characterized in that, In the wire detection mode, if the host does not detect the current of the closed detection loop within a preset time, it is determined that there is an open circuit fault in the corresponding core wire, and a fault prompt is displayed on the host screen. If the auxiliary unit does not detect a valid pulse-coded current signal, it will automatically skip the current detection sequence number and wait for the next frame of detection signal until the wire connection detection of all cores of the multi-core cable under test is completed.

8. The fully automatic cable pairing and insulation comprehensive tester according to claim 1, characterized in that, The comprehensive tester includes an insulation testing mode, specifically including: The main control unit controls the relay matrix to connect the core wire to be tested with the high-voltage source module and automatically switches the detection channel. The host current detection circuit collects the leakage current. The main control unit calculates the insulation resistance based on the output voltage of the high-voltage source module and the collected leakage current, and automatically completes the insulation test of each core wire.

9. The fully automatic cable pairing and insulation comprehensive tester according to claim 8, characterized in that, The insulation detection mode also includes: During the insulation test, the relay matrix connects the single core wire to be tested to the positive terminal of the high-voltage source module, while switching all other core wires and cable shielding to the ground state. The host current detection circuit collects the leakage current of the leakage current loop formed through the core wire under test, insulation layer, shielding layer or ground. During the insulation test between core wires, the main control unit controls the relay matrix to sequentially connect any two core wires to the positive terminal of the high-voltage source module and the measuring terminal, respectively, while the remaining core wires remain suspended. The leakage current between the core wires is collected group by group, and the insulation resistance value between the core wires is calculated. The main control unit is also used to automatically determine whether the insulation performance is qualified based on the calculated insulation resistance value.

10. A fully automatic method for comprehensive testing of cable pairing and insulation, characterized in that, Based on the fully automatic cable pairing and insulation comprehensive tester according to any one of claims 1 to 9, the method includes the following steps: S1. Wiring: Connect each core wire at one end of the multi-core cable to the corresponding host test port, and connect each core wire at the other end of the multi-core cable to the corresponding slave test port. Connect the host grounding port and the slave grounding port to the host side grounding busbar and the slave side grounding busbar, respectively. S2. Line Detection: The main control unit controls the relay matrix to sequentially connect the host test port to the low-voltage coded signal source, sending pulse coded current signals carrying port number information to each core wire. The pulse coded current signals form a closed detection loop through the core wires of the multi-core cable under test and the return path composed of the auxiliary unit grounding port, the earth, and the host grounding port. The auxiliary unit decodes and identifies the corresponding host test port number and provides a prompt. The host determines the conduction or open circuit status of each core wire based on whether a closed detection loop current is detected. S3. Insulation test: After selecting the test voltage level, the main control unit starts the high voltage source module and controls the relay matrix to automatically switch the test channel, complete the insulation test of each core wire to ground one by one, and then automatically switch to complete the insulation test between core wires of each core wire combination one by one. The insulation resistance value is calculated based on the collected leakage current, and the insulation performance is automatically determined to be qualified. S4. After the test is completed, the high-voltage output circuit is automatically cut off and the residual charge of the multi-core cable under test is discharged. All test data are integrated to generate and store the test report.

Images