A power electronic component quality grading method and system based on production measurement fusion

Abstract

The application discloses a power electronic component quality grading method and system based on production and test fusion, and relates to the technical field of production quality management. The method obtains production process records, component flow records, test results and quality grading tasks, locates production state adjustment time periods and affected processes, forms state adjustment effect product sections, front-end stable product sections and rear-end stable product sections, determines response ranges, response boundaries and test response transition sections, identifies state transition test results, local abnormal test results and continuous abnormal test results, verifies product boundaries and response boundaries, traces test result sources in overlapping product sections, and completes quality grading and quality disposal. The application distinguishes between continuous transitions and abnormal test results caused by process adjustment by combining production state adjustment time periods, component flow positions and test result changes, traces test result sources in overlapping product sections, and makes quality grading and disposal more suitable for actual production processes.

Description

Technical Field

[0001] This invention relates to the field of production quality management technology, specifically to a method and system for quality grading of power electronic components based on the integration of production and testing. Background Technology

[0002] The production process of power electronic components generates production process records such as process execution, equipment operation, status adjustment and product flow. During the testing process, test results reflecting the performance status of the components are generated. Enterprises usually determine the product quality level based on the correlation between production records and test results, which is used for product release, re-inspection and isolation disposal.

[0003] During continuous production, production status adjustments will affect the continuous components that have passed through the corresponding process during the adjustment period, so that the relevant test results will form a continuous transition between the stable state before adjustment and the stable state after adjustment. When the scope of the status adjustment of multiple processes overlaps, the changes in test results caused by different processes will also appear in the same product segment.

[0004] The limitations of existing technologies include at least the following problems: When linking production process records and test results with production batches, recording times, and product identifiers, it is difficult to determine the scope of the impact of production status by utilizing the product boundaries before and after the adjustment of production status and the response boundaries before and after the change of test results. It is also difficult to distinguish between continuous transition responses formed by the handover of production status and local abnormal test results that deviate from the continuous transition relationship of production status within this scope. As a result, the impact of production status is directly identified as quality abnormality, and local abnormal test results are masked by continuous transition responses, affecting the determination of quality level and subsequent quality handling. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a method and system for quality grading of power electronic components based on production and testing integration. This method addresses the problem of inaccurate quality grading of power electronic components caused by the co-occurrence of continuous transition response and local abnormal test results of deviation from the transition relationship caused by production state adjustments, and the difficulty in distinguishing the source of test results when multiple affected product segments overlap.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a quality grading method for power electronic components based on production and testing integration, comprising the following steps: acquiring production process records, component flow records, test results, and quality grading tasks; locating the production state adjustment period and affected processes, forming state adjustment product segments based on component processing periods, and forming front-end stable product segments and back-end stable product segments; analyzing the test results of the two stable product segments, forming front-end response range and back-end response range, checking the test results item by item inwards, and determining the front response boundary, back response boundary, and test response transition segment; analyzing the test results within the transition segment along the flow sequence, forming state transition test results, local abnormal test results, and continuous abnormal test results; verifying the correspondence between the front and back product boundaries and the front and back response boundaries of the same state adjustment product segment, and marking the verified state transition test results as test results caused by the corresponding affected processes; when state adjustment product segments overlap, tracing item by item from the non-overlapping part along the same test index to the overlapping part, and marking the affected processes corresponding to the test results of the overlapping part; processing the test results according to the quality grading task, determining the quality level, and generating a quality disposal task.

[0007] Furthermore, the steps for forming the state adjustment product segment and two stable product segments are as follows: extract the start and end times of state adjustment, the affected processes, and the entry and exit times of components; arrange the components whose processing time overlaps with the production state adjustment time according to the flow order to form the state adjustment product segment, and determine the front product boundary and the back product boundary; extract the components whose affected processes have not undergone state adjustment and whose test results meet the stability conditions in the quality grading task from the front product boundary forward and from the back product boundary backward, respectively, to form the front stable product segment and the back stable product segment.

[0008] Further, the steps for forming the test response transition segment are as follows: extract the highest and lowest test values ​​of each test indicator in the two stable product segments to form the front-end response range and the back-end response range; search backward from the front-end stable product segment for component segments whose test results continuously leave the front-end response range, and determine the first component as the front response boundary; search forward from the back-end stable product segment for component segments whose test results continuously leave the back-end response range, and determine the component that is immediately adjacent to this segment along the flow sequence and enters the back-end response range as the back response boundary; when the front response boundary is located before the back response boundary, determine the continuous components between the two as the test response transition segment.

[0009] Furthermore, the steps for identifying state transition test results and abnormal test results are as follows: compare the upper and lower limits of the two response ranges to determine the unique transition direction from low to high and from high to low; extract the test results that sequentially leave the front-end response range, are arranged according to the transition direction, and enter the back-end response range along the flow sequence to form state transition test results; identify continuous component segments that deviate from the arrangement relationship midway and subsequently meet the arrangement relationship again as local abnormal test results; identify test results that do not meet the arrangement relationship again until the back response boundary as continuous abnormal test results; when no unique transition direction is determined, associate the corresponding test indicators with the source verification task.

[0010] Further, the steps for verifying the correspondence between product boundaries and response boundaries are as follows: map the test response transition segment to the state adjustment product segment; verify that both response boundaries are located within the same state adjustment product segment; verify that the test results before the front response boundary within the state adjustment product segment are within the front-end response range, and the test results after the back response boundary are within the back-end response range; verify that the state transition test results start from the front response boundary and enter the back-end response range at the back response boundary; mark the verified state transition test results as the test results caused by the corresponding affected process.

[0011] Furthermore, the steps for handling partial overlap of product segments in the state adjustment process are as follows: Identify the overlapping product segments and the non-overlapping portions of each product segment in the state adjustment process; trace the same test index backward from the non-overlapping portion in front of the overlapping product segment, and trace the same test index forward from the non-overlapping portion in back of the overlapping product segment; mark the test results that maintain the same transition direction within the overlapping product segment and are continuously connected to the corresponding response boundary as the test results caused by the corresponding affected process; associate the test results marked by multiple processes and those not marked by processes with the source review task.

[0012] Further, the steps for determining the component quality level and generating quality handling tasks are as follows: Read the direct judgment indicators, production status acceptance conditions, quality level conditions, and level order from the quality grading task; match the measured results of the direct judgment indicators with the quality level conditions; match the test results caused by the affected processes with the production status acceptance conditions, and if they fail, classify the level according to the measured results and generate a process handling task; match the test results of local anomalies, continuous anomalies, and test results not marked as caused by affected processes and not associated with source verification tasks with the quality level conditions to determine the remaining indicator levels; determine the quality level according to the level order and generate quality handling tasks; if there are source verification tasks, mark the components to be verified and suspend the generation of product release tasks.

[0013] Furthermore, the steps for performing production status verification are as follows: generate a production status verification task based on the test results marked as being caused by the affected process; verify the production status adjustment period, the operation record of the affected process, and the processing period of the corresponding components at the product boundaries before and after; retain the corresponding mark when the verification passes; cancel the corresponding mark when the verification fails, and rematch the relevant test results with the quality level conditions.

[0014] Further, the steps for handling the inclusion relationship of state adjustment product segments are as follows: Identify the outer and inner state adjustment product segments; trace the same test index inward from the non-overlapping portion of the outer state adjustment product segment before and after the inner state adjustment product segment, marking the outer process test results where the tracking results are continuously connected; extract unmarked continuous components that meet the stability conditions from the front and rear sides of the inner product boundary, and extract the highest and lowest test values ​​of each test index from the continuous components on both sides, forming the inner front-end response range and the inner back-end response range; extract continuous test results that enter the inner back-end response range from the inner front-end response range from the remaining test results, marking them as test results caused by the affected inner process; if no two inner response ranges are formed, associate the corresponding components with the source verification task.

[0015] A power electronic component quality grading system based on production and testing integration includes: a data acquisition module for acquiring production process records, component flow records, test results, and quality grading tasks; a product segment processing module for forming state adjustment product segments, front-end stable product segments, and back-end stable product segments; a response processing module for forming front-end response range, back-end response range, front response boundary, back response boundary, state transition test results, local anomaly test results, and continuous anomaly test results; a boundary verification module for verifying the correspondence between product boundaries and response boundaries; an overlap processing module for handling partial overlap and inclusion relationships of state adjustment product segments; and a quality management module for determining component quality grades and generating quality disposal tasks, source verification tasks, production status verification tasks, and process disposal tasks.

[0016] The present invention has the following beneficial effects: (1) The power electronic component quality classification method based on production and testing integration determines the product segment affected by the state adjustment period and the moment when the component enters or leaves the affected process, as well as the boundaries of the preceding and following products. Then, it selects continuous components from both sides of the product segment whose processes have not been adjusted and whose test results meet the stability conditions to form the preceding and following stable product segments. This allows the time changes in the production record to fall on the specific component and its flow position, reducing the mismatch of the scope of effect caused by only associating batches, numbers and record times. This makes the production state range used for quality classification more in line with the actual processing process of the component.

[0017] (2) The power electronic component quality grading method based on production and testing integration extracts the highest and lowest test values ​​of each test index in the front-end stable product segment and the back-end stable product segment to form the front and back response ranges. It then searches for the positions of components that leave the corresponding response range from two directions, determines the front response boundary, the back response boundary and the test response transition segment, and identifies the test results that enter the back response range from the front response range according to the component flow order. This allows the segmented changes caused by production status adjustments to be handled separately from the local anomalies that recover after midway deviation and the abnormal results that continue to deviate to the back response boundary, reducing the misjudgment of normal handover changes as product defects.

[0018] (3) The power electronic component quality classification method based on production and testing integration traces the non-overlapping parts on both sides of the overlapping product segment inward along the same test index when the product segments under different state adjustment effects partially overlap. It also marks the affected process corresponding to the test results in the overlapping product segment in combination with the transition direction and response boundary connection. When forming an inclusion relationship, the test results of the outer process are marked first, and the inner response range is formed from the unmarked continuous components that meet the stability conditions. This allows the source to be found according to the actual test changes when different process adjustments work together on the same product segment. Components whose source cannot be uniquely determined are included in the review, avoiding direct attribution to the process based on a single time overlap.

[0019] (4) The power electronic component quality grading system based on production and testing integration collects production process records, component circulation records, test results and quality grading tasks through the data acquisition module. The product segment processing module determines the product segment and stable product segment that affect the status adjustment. The response processing module forms the response range, response boundary and abnormal test results. The boundary verification module and overlap processing module verify the source of the impact on the production status. The quality management module completes the grading and disposal according to the actual test results of the direct judgment indicators, the production status acceptance conditions, the quality level conditions and the level sequence. The system suspends the release of components with unknown sources and generates a review task, so that product grading, process inspection, review and disposal are all corresponding to specific records and specific components.

[0020] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0021] Figure 1 This is a flowchart of a quality grading method for power electronic components based on the integration of production and testing, according to the present invention.

[0022] Figure 2 This is a block diagram of a power electronic component quality grading system based on the integration of production and testing according to the present invention. Detailed Implementation

[0023] Please see Figure 1 This invention provides a technical solution: a method for quality grading of power electronic components based on production and testing integration, comprising the following steps: acquiring production process records, component flow records, test results, and quality grading tasks; locating the production state adjustment period and affected processes, forming state adjustment product segments based on component processing periods, and forming front-end stable product segments and back-end stable product segments; analyzing the test results of the two stable product segments, forming front-end response range and back-end response range, checking the test results one by one inward, and determining the front response boundary, back response boundary, and test response transition segment; analyzing the test results within the transition segment along the flow sequence, forming state transition test results, local abnormal test results, and continuous abnormal test results; verifying the correspondence between the front and back product boundaries and the front and back response boundaries of the same state adjustment product segment, and marking the verified state transition test results as test results caused by the corresponding affected processes; when state adjustment product segments overlap, tracing one by one from the non-overlapping part along the same test index to the overlapping part, and marking the affected processes corresponding to the test results of the overlapping part; processing the test results according to the quality grading task, determining the quality level, and generating a quality disposal task.

[0024] The production process records are exported from the production execution system and equipment controller, including production status adjustment record identifier, process identifier, equipment identifier, start and end time of production status adjustment, adjustment items, adjustment record values ​​and equipment operation records; The adjustment record value is the adjusted process parameter value recorded when the production status adjustment is completed. It is used for the integrity verification of the production status adjustment record and the review of the production status. The component flow records are exported from the production traceability system, including component identification, component model, process version, process identification, entry time, exit time, and flow sequence number; The test results are written by the test equipment according to the component identification, including the component identification, test parameters, original measured values ​​and result validity markings; Using the time recorded by the production execution system as the production time benchmark, the offset direction and offset amount in the corresponding clock calibration records of the equipment controller and the production traceability system are read. The start and end times of production status adjustment in the production process record and the entry and exit times in the component flow record are converted into times under the same production time benchmark. Data lacking corresponding clock calibration records are marked as data to be verified and are not included in the analysis of product segments affected by status adjustment.

[0025] The quality grading task is written before the method is executed, including the number of stability judgments, the lower limit of stability, the upper limit of stability, the stability threshold, the number of boundary confirmations, the allowable fluctuation value, the lower limit of source confirmation, the direct judgment index, the production status acceptance conditions, the quality grade conditions, the grade order, and the task processing rules. The number of stability determinations and the number of boundary confirmations are taken from the process card, and each corresponds to at least two consecutive components; A confirmed stable product segment refers to a historical continuous product segment in which the affected process has not undergone production status adjustments, the equipment operation records are continuous, and all components within the segment have been confirmed to be qualified through product inspection. The lower and upper limits of stability are respectively adopted as the lowest and highest original measured values ​​of the corresponding test indicators in the confirmed stable product segment. When the historical lowest original measured value is the same as the historical highest original measured value, the allowable lower and upper limits of the corresponding test indicators in the product inspection specification are adopted as the lower and upper limits of stability. The stability threshold is the upper limit of the stability judgment value of the corresponding test index in the confirmed stable product segment; the normal state transition record refers to the historical continuous record that there is only one adjustment of the production status of the affected process, the equipment operation records before and after the production status adjustment are complete, the relevant components are qualified and the direction of change of the test results conforms to the corresponding response direction relationship between the adjustment item and the test index. The response direction correspondence is determined based on the influence relationship between the production status parameters recorded in the process card and the test indicators. If the process card does not record the correspondence, it is determined based on the historical production records that have been verified and confirmed. The allowed fluctuation value is the upper limit of the reverse change amplitude of adjacent transition position values ​​in the normal state transition record; The reverse change amplitude refers to the difference between two transition position values ​​when the value of the later transition position is lower than the value of the previous transition position along the component flow sequence. The source confirmation lower limit is the lower limit of the source matching value corresponding to the confirmed source process in the historical records where the product segments under the state adjustment effect partially overlap and the source of the test results has been verified and confirmed. Direct judgment indicators, production status acceptance conditions, quality grade conditions, grade order, and task processing rules are written in accordance with product inspection specifications and quality management rules, and the written content is directly read during method execution.

[0026] Stability conditions refer to the following conditions: the number of candidate product segments reaches the stability judgment quantity, the affected process does not undergo production status adjustment, shutdown or reset, the test results have no missing or invalid marks, the original measured values ​​of each test index are between the lower and upper stability limits and the stability judgment value does not exceed the stability threshold. Continuous departure from the response range means that adjacent original measured values ​​that have reached the boundary confirmation number are located on the same side outside the corresponding response range; Continuous connection refers to continuous flow sequence numbers, identical test indicators, and transition position values ​​that continue in the transition direction without any missing or interrupted directions; Directional interruption refers to the situation where, along the component flow sequence, the transition position value of the subsequent component is lower than the difference between the transition position value of the preceding component and the corresponding allowable fluctuation value. The direct determination index is based on the original measured value to determine the index level, and the index level is not changed due to the marking of the affected process. A valid test result means that the component identification, test parameters, and original measured values ​​are all complete, and the result is marked as valid to indicate that the corresponding test result is valid.

[0027] Specifically, the steps for forming the state-adjusting product segment and the two stable product segments are as follows: The start and end times of the extraction status adjustment, the affected processes, and the entry and exit times of components are as follows: Extract records with production status adjustment record identifiers from the production process records, read the start and end times of the production status adjustment, and identify the process corresponding to the process identifier in the record as the affected process; Connect the component flow records according to the process identifier of the affected process, and read the time when the component enters and leaves the affected process according to the component identifier. Records that lack the start and end time of production status adjustment, entry time, and exit time, or whose process identifiers do not match, are marked as data to be verified and are not included in the analysis.

[0028] Components whose processing period overlaps with the production status adjustment period are arranged in the flow order to form a product segment for status adjustment, and the boundaries of the preceding and following products are determined, specifically as follows: The times when the i-th component enters and leaves the affected process are denoted as follows: The start and end times of the production status adjustment are recorded as follows: The overlap duration is obtained using the following formula: ; In the formula, For the duration of overlap, These represent the times when the i-th component enters and leaves the affected process, respectively. These are the start and end times for production status adjustment; When two time periods overlap, the components are included in the product segment for status adjustment and arranged according to the flow sequence number. The first and last components are used as the boundary of the previous product and the boundary of the next product, respectively.

[0029] Components that have not undergone state adjustments in the affected processes and whose test results meet the stability conditions in the quality grading task are extracted from both the front product boundary and the back product boundary, forming a front-end stable product segment and a back-end stable product segment, specifically as follows: The number of stable determinations is used as the number of components included in the candidate window. The first front candidate window is formed by continuously reaching the number of stable determinations before the front product boundary, and the first back candidate window is formed by continuously reaching the number of stable determinations after the back product boundary. The front candidate window moves one component at a time along the direction of decreasing flow number, and the rear candidate window moves one component at a time along the direction of increasing flow number. After each move, a continuous candidate product segment is formed and the stability judgment value of each test index is calculated. The first candidate product segment that meets all stability conditions is determined as the stable product segment in the corresponding direction. If a production status adjustment, shutdown, reset, missing test results, or invalid marker occurs during the candidate window movement, the search in the corresponding direction is stopped, and the stable judgment value of the j-th test index within the candidate product segment m is obtained according to the following formula: ; In the formula, For stable determination values, Let be the original measured value of the j-th test index for the r-th component within the candidate product segment, where n is the number of components. These are the lower and upper stability limits, respectively, with the latter being higher than the former. The interval span term refers to the difference between the highest and lowest original measured values ​​within the candidate product segment, divided by the difference between the corresponding upper and lower stability limits. The adjacent variation term refers to the average result obtained by dividing the absolute value of the difference between the original measured values ​​of adjacent components within the candidate product segment by the difference between the corresponding upper and lower stability limits. The percentage of the interval span item for the j-th test indicator. To correspond to the proportions of adjacent change items, the proportion of the interval span item is calculated as the ratio of the historical average of the interval span item in the confirmed stable product segment to the sum of the historical average of the interval span item and the historical average of adjacent change items. When neither the historical average of the interval span item nor the historical average of adjacent change items has changed, the proportion of the interval span item and the proportion of adjacent change items use the same value. The proportion of the interval span item is written into the quality grading task, and the proportion of adjacent change items is determined by... It is confirmed that the proportion of the interval span term will not be adjusted during the execution of the method; In the quality grading task, if the original measured values ​​of all test indicators participating in the stability determination are between the corresponding lower and upper stability limits, and the stability determination values ​​of all test indicators do not exceed the corresponding stability thresholds, then the candidate product segment is determined as a stable product segment. The first candidate product segment that meets the stability conditions on the front side is the front-end stable product segment, and the first candidate product segment that meets the stability conditions on the back side is the back-end stable product segment. The stable threshold for the j-th test indicator; when no stable product segment is formed in any direction, the corresponding test indicator that does not meet the stability condition is associated with the source verification task, and the formation of the response range, determination of the response boundary and marking of the process source of the test indicator are stopped.

[0030] Specifically, the steps to form the test response transition section are as follows: The highest and lowest test values ​​of each test indicator are extracted from the two stable product segments to form the front-end response range and the back-end response range, as follows: Read all the original measured values ​​of the same test metric within the stable front-end product segment, use the lowest original measured value as the lower limit of the front-end response and the highest original measured value as the upper limit of the front-end response to form the front-end response range, and form the lower limit of the back-end response, the upper limit of the back-end response, and the back-end response range in the same way.

[0031] Starting from the stable product segment at the front end, search backwards for component segments whose test results continuously deviate from the front-end response range. The first component in this sequence is designated as the front response boundary. Specifically: Starting from the last component at the end of the front-end stable product segment, read the same test index one by one. When the adjacent original measured values ​​of the number of boundary confirmations are located on the same side outside the front-end response range, the first component of that segment is determined as the front response boundary.

[0032] Starting from the stable product segment at the back end, trace backwards to component segments whose test results continuously leave the back end response range. Components immediately following this segment in the flow sequence and entering the back end response range are defined as the subsequent response boundary. Specifically: Starting from the position before the first component in the back-end stable product segment, the same test index is read backwards. When the adjacent original measured values ​​that reach the boundary confirmation number are all located on the same side outside the back-end response range, the component that is adjacent to this segment in the forward direction and enters the back-end response range is determined as the back response boundary.

[0033] If any response boundary is not formed, the corresponding test index will be associated with the source verification task, and the formation of the test response transition segment, the identification of the state transition test result, and the marking of the process source will be stopped for that test index.

[0034] When the preceding response boundary is located before the following response boundary, the continuous components between them are defined as the test response transition segment, specifically as follows: When the sequence number of the preceding response boundary is less than that of the following response boundary, the continuous components between the two response boundaries and containing the two response boundaries are extracted to form a test response transition segment. If the requirement is not met, the corresponding test index is associated with the source verification task, and the identification of the state transition test result and the process source marking of the test index are stopped.

[0035] Specifically, the steps for identifying state transition test results and abnormal test results are as follows: By comparing the upper and lower limits of two response ranges, a unique transition direction is determined between low to high and high to low, specifically as follows: When the upper limit of the front-end response is lower than the lower limit of the back-end response, the transition direction is determined from low to high; when the lower limit of the front-end response is higher than the upper limit of the back-end response, the transition direction is determined from high to low. If the two response ranges overlap or their boundaries are connected, no unique transition direction is determined. The corresponding test index is associated with the source review task, and the identification of the state transition test results, local abnormal test results, and continuous abnormal test results of the corresponding test index is stopped.

[0036] The test results that leave the front-end response range in sequence, are arranged according to the transition direction, and enter the back-end response range are extracted along the flow order to form the state transition test results, which are as follows: The average of the upper and lower limits of the two response ranges is taken as the front-end response center. and backend response center The transition position value is obtained only when a unique transition direction is formed, using the following formula. The component corresponding to the previous response boundary is used as the starting inspection position for the state transition test results. The transition position value is read one by one along the direction of increasing flow number: ; In the formula, For transition position values, Let j be the original measured value of the j-th test index for the i-th component. These are the front-end response center and the back-end response center, respectively, and the two response centers are different when forming a unique transition direction; The value of the subsequent transition position shall not be lower than the transition position value and allowable fluctuation value of the previous state transition test result. When the difference is found, the original measured value is included in the state transition test results until it enters the backend response range. Let be the allowable fluctuation value for the j-th test indicator.

[0037] A continuous component segment that deviates from the arrangement relationship midway but subsequently regains the arrangement relationship is identified as a local anomaly test result, specifically as follows: The transition position value exceeds the allowable fluctuation value relative to the previous transition position value already included in the state transition test results. When the change is reversed, the component is identified as deviating from the starting point, and the previous transition position value is used as the recovery reference value; Subsequent transitional position values ​​that reach the boundary confirmation quantity should not be lower than the recovery reference value and the allowable fluctuation value. When the difference is less than the allowable fluctuation value and there is no reverse change, the first component that meets the condition is determined as the recovery position, the original measured value before the deviation from the starting point to the recovery position is determined as the local abnormal test result, and the state transition test result is identified from the recovery position according to the transition direction.

[0038] Test results that fail to re-satisfy the permutation relationship up to the post-response boundary are identified as persistently anomalous test results, specifically as follows: If the transition position value is checked from the starting point backward until the subsequent response boundary does not show a continuous component that meets the boundary confirmation quantity and satisfies the transition direction judgment again, the original measured value from the starting point to the subsequent response boundary is determined as the continuous abnormal test result.

[0039] When no single transition direction is determined, the corresponding test metrics will be associated with the source review task, specifically as follows: Generate a source verification task that includes component identification, affected process, production status adjustment period, response range, and original measured values, and mark it as pending verification.

[0040] Specifically, the steps for verifying the correspondence between product boundaries and response boundaries are as follows: Mapping the test response transition segment to the state adjustment product segment is as follows: Compare the two product segments according to the component identification and serial number, and record the common components and boundary locations.

[0041] Verify that both response boundaries are located within the same state adjustment product segment, specifically: When the flow sequence numbers of the two response boundaries are both located between the front and rear product boundaries of the same state adjustment product segment, location verification is performed.

[0042] The verification status adjustment effect places test results before the front response boundary within the product segment within the front-end response range, and test results after the back response boundary within the back-end response range. Specifically: The section verification is passed when the original measured values ​​of the components before the front response boundary and the components after the back response boundary are all within the front response range and the original measured values ​​of the back response boundary are all within the back response range.

[0043] The verification state transition test results begin at the front response boundary and enter the back-end response range at the rear response boundary, specifically as follows: The transition verification is passed when the first component of the state transition test result corresponds to the front response boundary and the original measured value of the back response boundary is within the back response range.

[0044] The verified state transition test results will be marked as the test results caused by the corresponding affected process, specifically as follows: Write the affected process identifier, production status adjustment record identifier, and verification result into the original measured value record.

[0045] Specifically, the steps for handling overlapping product segments during status adjustment are as follows: The overlapping product segments and the non-overlapping portions of each state adjustment product segment are identified, specifically as follows: Extract the continuous components commonly contained in the product segments with different state adjustment functions according to the circulation sequence number as the overlapping product segments, and take the continuous components after deducting the overlapping product segments from each product segment with different state adjustment functions as the corresponding non-overlapping parts.

[0046] The same test metric is traced backward from the non-overlapping portion before the overlapping product segment, and backward from the non-overlapping portion after the overlapping product segment. Specifically: Read the test indicators and transition directions that have passed the boundary verification in the non-overlapping part, extend them to the overlapping product segments one by one, and record the number of valid traces, the number of continuous connections, and the number of directional interruptions.

[0047] Test results that maintain the same transition direction within overlapping product segments and are continuously connected to the corresponding response boundaries are marked as test results caused by the corresponding affected process, specifically as follows: The affected processes that share common components with the product segment undergoing status adjustment and the overlapping product segment are identified as candidate affected processes. For candidate affected processes whose corresponding non-overlapping parts are located on the front side of the overlapping product segment, the tracking records of the front non-overlapping parts are used. For candidate affected processes whose corresponding non-overlapping parts are located on the back side of the overlapping product segment, the tracking records of the back non-overlapping parts are used. When the same candidate affected process has non-overlapping parts on both sides of the overlapping product segment, the tracking records of both sides are used together for source matching. When no valid tracking records are obtained on either side, the corresponding test results are associated with the source verification task. When valid test results exist within overlapping product segments, the source matching value is obtained for the candidate affected process q and test index j using the following formula: ; In the formula, Let be the source matching value of the j-th test index corresponding to the affected process q. This represents the number of valid test results for the j-th test metric obtained by tracing from the non-overlapping portion before the overlapping product segment to the overlapping product segment. This refers to the number of test results among the aforementioned valid test results that maintain the transition direction corresponding to the affected process q and are continuously connected to the previous response boundary. The number of valid test results for the j-th test metric obtained by tracing from the non-overlapping portion behind the overlapping product segment to the overlapping product segment. This refers to the number of test results among the aforementioned valid test results that maintain the transition direction corresponding to the affected process q and are continuously connected to the subsequent response boundary. This represents the number of adjacent component pairs within the overlapping product segment where the j-th test index experiences a directional interruption. The number of valid test results for the j-th test indicator within the overlapping product segment; The number of valid traces and the number of consecutive connections are both zero for the side that has not obtained a valid trace record. The source matching value is calculated when at least one side has a valid trace record and there are valid test results in the overlapping product segment. The source matching value is not calculated when neither side has a valid trace record. Each adjacent component pair is counted as only one directional interruption; When the source matching value reaches the source confirmation lower limit and is the only highest value among all candidate affected processes, the test results participating in the corresponding continuous connection will be marked as caused by the affected process q.

[0048] Test results marked by multiple processes and those not marked by processes are all associated with the source verification task, specifically: After completing source matching and test result marking, check the test results in overlapping product segments one by one. If any of the following situations occur: test result is marked by multiple affected processes, test result is not marked by any affected process, multiple candidate affected processes obtain the same highest source matching value, all source matching values ​​are lower than the source confirmation lower limit, or none of the candidate affected processes have obtained a valid tracking record, the corresponding test result will be associated with the source verification task, and the product release task of the corresponding component will be suspended.

[0049] Specifically, the steps for determining the component quality level and generating quality handling tasks are as follows: The direct judgment indicators, production status acceptance conditions, quality grade conditions, and grade order in the quality grading task are read as follows: The quality grading task is read according to the component model and process version. The quality grade conditions include the grade range of each test index and the combination conditions of the index grades corresponding to each quality grade. The production status acceptance conditions include the affected process, adjustment items, test indexes, lower limit of test result acceptance, upper limit of test result acceptance, upper limit of continuous action quantity, adjustment record completeness conditions, acceptance pass index grade and disposal rules. The task processing rules record the conditions for generating quality disposal tasks.

[0050] The measured results of the direct determination indicators are matched with the quality grade conditions, specifically as follows: Read the original measured value of the direct judgment indicator and compare it with the grade range in the quality grade conditions to determine the corresponding indicator grade.

[0051] The test results caused by the affected process are matched with the production status acceptance conditions. If the test fails, the level is determined according to the actual test results, and a process handling task is generated. Specifically: Based on the affected process identifier and production status adjustment record identifier carried by the test results caused by the affected process, read the adjustment items in the corresponding production status adjustment record, match the affected process, adjustment items and test indicators with the production status acceptance conditions, compare the original measured value with the lower limit of test result acceptance and the upper limit of test result acceptance of the corresponding test indicator for each piece, count the number of continuously acting components, and verify whether the production status adjustment record meets the condition of complete adjustment record. If all original measured values ​​are within the corresponding acceptance range, the number of continuously acting components does not exceed the upper limit of the number of continuously acting components, and the production status adjustment record meets the condition of complete adjustment record, the production status acceptance is determined to be passed and the affected process mark is retained. For indirect judgment indicators, the acceptance level pre-written in the production status acceptance conditions is determined as the corresponding indicator level. If the test fails, the process will be cancelled according to the production status acceptance rules. The relevant original measured values ​​will be matched with the quality level conditions to determine the corresponding index level. Records will be generated according to the disposal rules, including the affected process, the production status adjustment period, the adjustment items, the failed test results, and the process disposal tasks involving the components.

[0052] The test results of local anomalies, continuous anomalies, and test results not marked as caused by affected processes and not associated with source review tasks are matched with the quality level conditions to determine the remaining indicator levels, specifically as follows: The original measured values ​​are collected according to the component identification, and the index level is determined by comparing them with the grade range.

[0053] The quality levels are determined in order of grading, and quality handling tasks are generated accordingly. The indicator level combination conditions in the quality grading task cover all indicator level combinations that have been completed for grading. The indicator level combination conditions corresponding to each quality level are read step by step according to the pre-written level order. It checks whether the indicator levels that have been determined for the same component meet the current indicator level combination conditions. The first quality level that meets the conditions according to the level order is determined as the component quality level, and the corresponding quality disposal task is generated according to the task processing rules.

[0054] When a source verification task exists, mark the component to be verified and pause the generation of product release tasks, specifically as follows: Read the associated component identifier, write the pending review mark, and stop product release. After the task is closed, re-execute the quality grading steps.

[0055] In this process, quality management personnel read component flow records, production process records, test results, and equipment operation records to process source verification tasks. When the source process can be identified, the corresponding affected process identifier is written. When the test result is confirmed not to be caused by production status adjustment, a non-production status adjustment source mark is written. When the existing records are insufficient to confirm the source of the test result, the source verification task and the pending verification mark are retained, and product release is suspended. After the source confirmation is completed, the source verification task is closed, and the quality grading steps are re-executed according to the confirmation result.

[0056] Specifically, the steps for performing a production status review are as follows: A production status review task is generated based on the test results marked as being caused by the affected process, specifically as follows: The system collects components by adjusting the records of affected processes and production status, and generates a production status review task that records the production status adjustment period, product boundary, response boundary, test indicators, and original measured values.

[0057] Verify the production status adjustment period, the operation records of affected processes, and the processing period of components at the product boundary before and after the process. Specifically: Check whether the start and end times of production status adjustment are within the running period of the affected process, check whether the processing time of the two product boundary components has a common time period with the production status adjustment time period, and check for interruptions in shutdown, reset, and operation records.

[0058] A corresponding marker is retained upon successful verification, specifically: The start and end times of production status adjustment, adjustment items, and adjustment record values ​​are all recorded. The equipment operation record covers the production status adjustment period. There are no shutdowns, resets, or interruptions in the operation record during the production status adjustment period. When the processing time periods of the two product boundary components both share a common time period with this period, the affected process mark is retained and the production status review task is closed. The quality grading steps continue to be executed according to the retained affected process mark.

[0059] If the verification fails, the corresponding mark is removed, and the relevant test results are re-matched with the quality level conditions, specifically as follows: If any verification item is not met, the affected process mark is deleted and the corresponding production status review task is closed. The relevant original measured values ​​are matched with the quality level conditions, the corresponding indicator level is re-determined, and the component quality level determination and quality disposal task generation steps are re-executed according to the updated indicator level.

[0060] Specifically, the steps for handling the inclusion relationship of product segments in the state adjustment process are as follows: The outer layer state adjustment product segment and the inner layer state adjustment product segment are determined as follows: Read the transition sequence numbers of the preceding and following product boundaries of different product segments. If the transition sequence number of the preceding product boundary of one product segment is not greater than that of another product segment, and the transition sequence number of the following product boundary is not less than that of another product segment, then the former is identified as the outer state adjustment product segment, and the latter is identified as the inner state adjustment product segment. If the preceding and following product boundaries of the two state adjustment product segments are the same, then associate the components commonly contained in the two state adjustment product segments with the source verification task, and stop marking the outer process test results and inner process test results under the corresponding inclusion relationship.

[0061] Tracing the same test index inward from the non-overlapping portion of the outer layer state adjustment product segment before and after the inner layer state adjustment product segment, and marking the test results of the outer layer process where the tracking results are continuously connected, specifically: Read the same test index that has passed boundary verification from the non-overlapping part at the front of the outer product segment backward, and read the same test index from the non-overlapping part at the back. When the flow sequence number obtained from the front and back tracking is continuous, the test index is the same, and the transition position value continues in the outer transition direction without any missing or interrupted direction, mark the corresponding test result as caused by the affected process in the outer layer. When there is no non-overlapping part on either side, associate the component corresponding to the product segment with the inner layer state adjustment effect with the source verification task, and stop marking the test results of the outer process and the inner process under the corresponding inclusion relationship.

[0062] Unmarked, stable continuous components are extracted from the front and rear sides of the inner layer's front and rear product boundaries. The highest and lowest test values ​​for each test indicator are then extracted from these components on both sides to form the inner layer's front-end and rear-end response ranges. Specifically: Read the original measured values ​​of each component that is not marked as being caused by the affected process in the outer layer from the component before the boundary of the inner layer front product to the front and from the component after the boundary of the inner layer rear product to the back. The continuous components that meet the stability conditions are respectively identified as the stable product segment at the front end of the inner layer and the stable product segment at the back end of the inner layer. Extract the lowest and highest original measured values ​​of the same test index from the inner front-end stable product segment and the inner back-end stable product segment respectively to form the inner front-end response range and the inner back-end response range.

[0063] Extract the continuous test results that transition from the inner front-end response range to the inner back-end response range from the remaining test results, and mark them as test results caused by the affected inner process. Specifically: Excluding test results already marked as being caused by the outer layer affected processes, compare the upper and lower limits of the inner layer front-end response range and the inner layer back-end response range, and determine the inner layer transition direction according to the aforementioned unique transition direction determination method; Starting from the stable product segment at the inner front end, search backwards for component segments that continuously leave the response range of the inner front end, and determine the first component in that component segment as the inner front response boundary; Starting from the stable product segment at the back end of the inner layer, search forward for component segments that continuously leave the response range of the back end of the inner layer. Components that are immediately adjacent to the component segment along the flow sequence and enter the response range of the back end of the inner layer are identified as the back response boundary of the inner layer. When both the inner layer pre-response boundary and the inner layer post-response boundary are located within the product segment where the inner layer state adjustment is applied, and the inner layer pre-response boundary is located before the inner layer post-response boundary, and the original measured values ​​between the two inner layer response boundaries are continuously connected according to the inner layer transition direction, the corresponding original measured values ​​are marked as caused by the inner layer affected process. When the unique inner layer transition direction is not determined, the components corresponding to the product segment that the inner layer state adjustment effect is applied to the source verification task, and the determination of the inner layer response boundary and the marking of test results caused by the inner layer affected process are stopped.

[0064] If either of the following conditions exists: two inner response ranges are not formed or the inner source determination is incomplete, the corresponding component will be associated with the source verification task, specifically as follows: If any of the following situations occur: lack of continuous components that meet stability conditions on either side; overlap of two inner layer response ranges; boundary connection without determining a unique transition direction; failure to form any inner layer response boundary; inner layer response boundary exceeding the inner layer state adjustment product segment; or inner layer front response boundary not located before the inner layer rear response boundary, the component corresponding to the inner layer state adjustment product segment will be associated with the source verification task, and the marking of test results caused by the affected inner layer process will be stopped.

[0065] Please see Figure 2 This invention provides a technical solution: a power electronic component quality grading system based on production and testing integration, comprising: a data acquisition module for acquiring production process records, component flow records, test results, and quality grading tasks; a product segment processing module for forming a state adjustment product segment, a front-end stable product segment, and a back-end stable product segment; a response processing module for forming a front-end response range, a back-end response range, a front response boundary, a back response boundary, state transition test results, local anomaly test results, and continuous anomaly test results; a boundary verification module for verifying the correspondence between product boundaries and response boundaries; an overlap processing module for handling partial overlap and inclusion relationships of the state adjustment product segment; and a quality management module for determining component quality levels and generating quality disposal tasks, source verification tasks, production status verification tasks, and process disposal tasks.

[0066] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0067] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A quality grading method for power electronic components based on production and testing integration, characterized in that, Includes the following steps: Acquire production process records, component flow records, test results, and quality grading tasks; Identify the production status adjustment period and affected processes, and form product segments with status adjustment effects based on component processing periods, thus creating front-end stable product segments and back-end stable product segments; Analyze the test results of two stable product segments to form the front-end response range and the back-end response range. Check the test results one by one inward to determine the front response boundary, the back response boundary and the test response transition segment. Analyze the test results within the transition section along the flow sequence to form state transition test results, local anomaly test results, and continuous anomaly test results; Verify the correspondence between the product boundaries before and after the adjustment of the same state and the response boundaries before and after the adjustment. Mark the state transition test results that pass the verification as the test results caused by the corresponding affected process. When product segments overlap during status adjustment, the process traces each piece from the non-overlapping part to the overlapping part along the same test index, marking the affected process corresponding to the test results of the overlapping part. The test results are processed according to the quality classification task to determine the quality level and generate quality disposal tasks.

2. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps to form a state-adjusting product segment and two stable product segments are as follows: Extraction status adjustment start and end times, affected processes and component entry and exit times; Components whose processing period overlaps with the production status adjustment period are arranged in the flow order to form a product segment with status adjustment function, and the boundaries of the preceding and following products are determined. Extract components from the front product boundary forward and the back product boundary backward that have not undergone state adjustment in the affected process and whose test results meet the stability conditions in the quality grading task, forming a front-end stable product segment and a back-end stable product segment.

3. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps to form the test response transition section are as follows: Extract the highest and lowest test values ​​of each test indicator from the two stable product segments to form the front-end response range and the back-end response range; Starting from the stable product segment at the front end, search backwards for component segments whose test results continuously deviate from the front-end response range, and determine the first component as the front response boundary. Starting from the stable product segment at the back end, search forward for component segments whose test results continuously leave the back end response range. Components that are immediately adjacent to this segment along the flow sequence and enter the back end response range are identified as the back response boundary. When the front response boundary is located before the back response boundary, the continuous components between the two are defined as the test response transition segment.

4. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps to identify state transition test results and abnormal test results are as follows: By comparing the upper and lower limits of the two response ranges, a unique transition direction is determined between low and high; The test results that leave the front-end response range in sequence, are arranged according to the transition direction, and enter the back-end response range are extracted along the flow sequence to form the state transition test results; A continuous component segment that deviates from the arrangement relationship midway and subsequently satisfies the arrangement relationship again is identified as a local anomaly test result. Test results that fail to satisfy the permutation relationship again until the post-response boundary are identified as persistently abnormal test results; When no single transition direction is determined, the corresponding test indicators will be associated with the source verification task.

5. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps for verifying the correspondence between product boundaries and response boundaries are as follows: Map the test response transition segment to the state adjustment product segment; Verify that both response boundaries are located within the same state adjustment product segment; The verification status adjustment function means that the test results before the front response boundary within the product segment are within the front response range, and the test results after the back response boundary are within the back response range. The verification state transition test results begin at the front response boundary and enter the back-end response range at the rear response boundary; The verified state transition test results are marked as the test results caused by the corresponding affected process.

6. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps for handling overlapping product segments in the status adjustment process are as follows: Identify the overlapping product segments and the non-overlapping portions of the product segments affected by each state adjustment; The same test metric is traced backward from the non-overlapping portion in front of the overlapping product segment, and the same test metric is traced forward from the non-overlapping portion behind the overlapping product segment; Test results that maintain the same transition direction within overlapping product segments and are continuously connected to the corresponding response boundaries are marked as test results caused by the corresponding affected process. Test results marked by multiple processes and those not marked by processes are all associated with the source verification task.

7. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps for determining the component quality grade and generating quality handling tasks are as follows: Read the direct judgment indicators, production status acceptance conditions, quality grade conditions and grade order in the quality grading task; Match the measured results of the direct judgment indicators with the quality grade conditions; Match the test results caused by the affected process with the production status acceptance conditions. If the test results are not passed, classify the process according to the actual test results and generate a process disposal task. Match the results of local anomalies, continuous anomalies, and test results that are not marked as caused by affected processes and are not associated with source review tasks with the quality level conditions to determine the level of other indicators; Determine quality levels in order of gradation and generate quality handling tasks; When a source verification task exists, mark the components to be verified and suspend the generation of product release tasks.

8. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps for performing a production status review are as follows: Generate a production status review task based on test results marked as being caused by affected processes; Verify the production status adjustment period, the operation records of the affected processes, and the processing period of the corresponding components at the product boundaries before and after; The corresponding mark is retained when the verification is successful; If the verification fails, the corresponding mark is removed, and the relevant test results are re-matched with the quality level conditions.

9. The method for quality grading of power electronic components based on production and testing integration according to claim 1, characterized in that, The steps for handling the inclusion relationship of product segments in the status adjustment process are as follows: Determine the product segment that performs state adjustment in the outer layer and the product segment that performs state adjustment in the inner layer; From the non-overlapping portion of the outer state adjustment product segment located before and after the inner state adjustment product segment, trace the same test index inwards, and mark the test results of the outer process that are continuously connected by the tracking results before and after; Extract unmarked continuous components that meet the stability conditions from the front side of the inner front product boundary and the back side of the inner product boundary. Extract the highest and lowest test values ​​of each test index from the continuous components on both sides to form the inner front response range and the inner back response range. Extract the continuous test results that move from the inner front-end response range to the inner back-end response range from the remaining test results, and mark them as test results caused by the affected inner process. If two inner response ranges are not formed, the corresponding component will be associated with the source verification task.

10. A power electronic component quality grading system based on production and testing integration, employing the power electronic component quality grading method based on production and testing integration as described in any one of claims 1 to 9, characterized in that, include: The data acquisition module is used to acquire production process records, component flow records, test results, and quality grading tasks. The product segment processing module is used to form a product segment with state adjustment function and two stable product segments; The response processing module is used to generate response range, response boundaries, state transition test results, and abnormal test results. The boundary verification module is used to verify the correspondence between product boundaries and response boundaries; The overlap processing module is used to handle partial overlap and inclusion relationships of product segments that are subject to state adjustment. The quality management module is used to determine the quality level of components and generate quality handling tasks, source verification tasks, production status verification tasks, and process handling tasks.

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