Intelligent control device test tool
By designing an intelligent control device test fixture with integrated relays and LED indicator lights, the problems of a monotonous and error-prone testing process were solved, efficient and accurate functional testing was achieved, and the shipment qualification rate was improved.
Patent Information
- Application Number
- CN202422981291.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-04
- Publication Date
- 2025-09-19
- Estimated Expiration
- 2034-12-04
AI Technical Summary
The testing process of the intelligent control device in the existing technology is simple, cumbersome and prone to errors, resulting in a low shipment qualification rate. In addition, the position indicator light is unstable during dynamic simulation input, making it impossible to effectively test the coordination between hardware and software.
A test fixture for an intelligent control device is designed, which includes an input test part, an output test part, a high-voltage live display part, etc. The device to be tested is connected through wiring connectors and terminal blocks, and relays and LED indicator lights are used to realize integrated and visual testing of functions. An operation process card is provided to standardize the operation process.
It realizes systematic, integrated and visual testing of intelligent control devices, improves work efficiency, reduces error rate and ensures the accuracy and consistency of testing.
Smart Images
Figure CN223362534U_ABST
Abstract
Description
Technical Field
[0001] The utility model mainly relates to the technical field of switch cabinet control testing, in particular to a testing tool for an intelligent control device. Background Art
[0002] The intelligent control device of the switch cabinet integrates multiple functions such as circuit breaker status display, circuit breaker position display, grounding switch position display, spring energy storage display, high-voltage live display, temperature and humidity simulation control function, intelligent anti-error prompt function, opening and closing function, contact, cable joint temperature measurement function, communication function, etc. It optimizes the layout of the switch cabinet, saves space, facilitates centralized management, and facilitates real-time observation of the operating status without opening the cabinet door, providing protection for safe operation and maintenance. In order to ensure that each device produced can meet the qualified shipping conditions, it needs to be tested. In theory, each function is tested separately. After testing one function, the next function is tested, and then the next function is tested. Each function is a separate system without interfering with each other. This seems to be able to verify the quality of the software and hardware of the produced intelligent control device. But in fact, there will be the following problems:
[0003] When testing dynamic analog inputs, the tester uses a shorting wire to short-circuit the position contact with the common terminal, causing the corresponding position indicator strip to light up. However, shorting can be unstable, sometimes intermittent, and unable to maintain a constant state. This prevents a good test of the coordination between the position indicator strip hardware and software, leaving potential problems.
[0004] Test heating outlets, ventilation outlets, alarm outlets, lighting outlets, and other outlets using a multimeter's on / off position. If the outlet is open, the multimeter sounds; if it's blocked, the multimeter remains silent. During production quality inspection, two test leads touch both ends of an outlet. This can lead to the test leads accidentally touching each other, leading to the QC department deeming the outlet normal and shipping the product. However, in reality, the outlet's performance was not accurately tested, creating potential safety issues.
[0005] Single function testing is not systematic and may lead to neglecting one thing while focusing on another, resulting in a very low shipment qualification rate. Utility Model Content
[0006] The technical solution of the present invention aims to solve the technical problem that the existing technical solutions are too simple, and provides a solution that is significantly different from the existing technology. It mainly provides a test tool for an intelligent control device to solve the technical problems raised in the above background technology that the previous intelligent control tests had no tooling, the tests were simple, the tests were cumbersome, and were prone to errors.
[0007] The technical solution adopted by the utility model to solve the above technical problems is:
[0008] A test tool for an intelligent control device includes a box body, on which are provided an input test part, an output test part, and a high-voltage live display part. The input test part, the output test part, and the high-voltage live display part all include a relay arranged in the box body and an indicator light arranged on the surface of the box body; the box body is provided with a wiring connector and a terminal block, the wiring connector is used to lead out the control line in the test tool, and the terminal block is used to connect the control device.
[0009] Furthermore, the input test part includes a button switch, a first LED indicator light, a first relay and wiring accessories. The button switch is electrically connected to the first relay to realize the control of the on and off of the first relay; a group of opening points of the first relay is used to connect to the input part of the control device, and another group of opening points of the first relay is electrically connected to the first LED indicator light on the test tool.
[0010] Furthermore, the number of button switches, first LED indicators, and first relays on the input test part is equal and is configured in a one-to-one correspondence with the number of input parts of the control device.
[0011] Furthermore, the output test part includes a second LED indicator light, a second relay and wiring accessories. The second relay is electrically connected to the relay output on the control device to realize the control of the power on and off of the second relay; the second LED indicator light is electrically connected to the open point on the second relay.
[0012] Furthermore, the number of the second LED indicator lights and the second relays on the output test part is equal and is configured in a one-to-one correspondence with the number of the control device outlets.
[0013] Furthermore, the high-voltage live display part includes a transformer, a transformer control switch, a terminal switch, a third relay, a third LED indicator and wiring accessories. The transformer control switch is electrically connected to the transformer, and the three terminal switches are electrically connected to the secondary side of the transformer in parallel, and the three terminal switches are output in parallel to the three-phase terminals to simulate a three-phase grid; the third relay is electrically connected to the live locking relay output on the control device to realize the control of the power on and off of the third relay; the third LED indicator is electrically connected to the open point on the third relay.
[0014] Furthermore, the transformer control switch and terminal switch are both rocker-type switches.
[0015] Furthermore, the box body is also provided with a communication output part, a device power supply part, a control device fixing part and a status display part.
[0016] Furthermore, the communication output section includes a USB-to-485 bus for connecting to a host computer, a fourth LED indicator, and a wiring accessory terminal. The USB-to-485 bus is used to connect to the host computer, and the wiring accessory terminal is used to connect the host computer, the fourth LED indicator, and the control device. Through the external serial port, a computer can send a command to the control device to modify fixed parameters, thereby achieving functional logic operations such as automatic low-temperature heating output, high-temperature ventilation output, and high-humidity heating output.
[0017] Furthermore, the fixed part of the control device includes a fixed tool fixture, a wiring connector and wiring accessories. The fixed tool fixture is plugged into the test tool through the wiring connector to introduce the control line of the test tool into the control device and / or indicator equipment.
[0018] Compared with the prior art, the beneficial effects of the present invention are:
[0019] The test fixture provided by the utility model is connected to the intelligent control device to be tested through a wiring connector and a terminal block. The fixture is provided with an input test part, an output test part, a high-voltage live display part, etc., and each part includes an indicator light provided on the surface of the box. All functions of the intelligent control can be tested through this fixture. During the debugging process of each function, an LED light prompt is provided, which is convenient for observing the quality of the intelligent control software and hardware. In addition, the function debugging state is continuous and can be debugged multiple times. Therefore, this test fixture has the advantages of systematization, integration, simplification, and visualization, which can greatly improve work efficiency and reduce the error rate. This can solve the problems of single testing, cumbersome testing, and error-prone testing.
[0020] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 This is a schematic diagram of the test section of the intelligent control test fixture in the present invention;
[0022] Figure 2 Draw a schematic diagram of the test part for the intelligent control test fixture in this utility model;
[0023] Figure 3 This is a schematic diagram of the high-voltage live display part of the intelligent control test tool in this utility model;
[0024] Figure 4 The following are diagrams of the terminal section of the intelligent control test fixture accessory in the present invention, wherein Figure (a) is a three-view diagram of the box; Figure (b) is a schematic diagram of the wiring connector; and Figure (c) is a schematic diagram of the terminal block.
[0025] Figure 5 This is a schematic diagram of the status display part of the intelligent control test tooling in the present utility model.
[0026] In the figure: J1-J17 are Chint JZX-22F / 4Z(D) 220VAC relays; LED1-LED17 are M12 metal waterproof indicator lights; SB1-SB6 are M12 high-quality small single-pole double-throw on-off two-position adjustable rocker toggle switches; ZM1 is an AC-01A three-in-one switched socket with an indicator light and fuse; ZM2-ZM5 are KCD4 boater switches with red lights; HC1 is a HE rectangular heavy-duty connector with a 48-pin double-buckle side outlet; terminal blocks 1 and 2 are 2EDGWC-5.08mm-22P wall-mounted terminal blocks; TB is a 220V to 36V isolation transformer; terminal block 3 is a UK1.5N DIN-rail terminal block assembly; the enclosure is the 115*310*285 plastic frame XD-4; the wiring is one flat flexible cable; and there are several 35mm DIN rails. DETAILED DESCRIPTION
[0027] In order to facilitate the understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings, but the present invention can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the content disclosed in the present invention more thorough and comprehensive.
[0028] It should be noted that when an element is referred to as being "fixed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this article are for illustrative purposes only.
[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly used by technicians in the technical field of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.
[0030] Example 1: An intelligent control test fixture includes an input test part, an output test part, a high voltage live display part, an accessory terminal part, a communication output part, a device power supply part, a control device fixing part, and a status display part. Specifically:
[0031] 1) Please refer to the attached Figure 1The input test section consists of a single-pole, double-throw (SPDT) on-off two-position toggle switch, an LED metal indicator (the first LED indicator), a Chint JZX-22F / 2Z(D) 220VAC relay (the first relay), and wiring accessories. By toggling the toggle switch, the corresponding position changes of an actual high-voltage switch are simulated. When the toggle switch is in the ON position, the relay energizes; when it is in the OFF position, the relay de-energizes. The two sets of relay contacts are connected: one to the control (control input) and the other to the position indicator light on the test fixture panel. The first set of relay contacts are connected to the control input position and the control input common terminal, respectively. When the relay contacts close, the corresponding control light bar illuminates, testing the simulated control light bar. The second set of contacts controls the LED metal indicator on the test fixture panel. When closed, the panel's LED metal indicator illuminates. Simultaneously, the simulated control bar and the LED metal indicator on the test fixture panel illuminate. When both illuminate, the control position is correct and there are no faults, providing a double guarantee for input test observation. The input test part is equipped with button switches, metal LED indicators, and relays according to the number of control input devices, which correspond one to one. The tooling is labeled and easy to observe.
[0032] 2) Please refer to the attached Figure 2 The output test part is composed of an LED metal indicator light (the second LED indicator light), a Chint JZX-22F / 4Z(D) 220VAC relay (the second relay), wiring accessories, etc. The output test relay coil in the tooling is controlled to be energized and de-energized through the relay outlet on the intelligent control device. The output point of the control body is closed, the relay coil of the test tooling is energized, and the metal LED indicator light is on, proving that the output of the corresponding output of the control is normal. The number of output relays and indicator lights is configured according to the number of outputs of the control device, one to one, and labeled for easy observation and identification. Regardless of whether the control device is operated through automatic logic or manual operation, the corresponding output of the output can be achieved. The on and off of the tooling output indicator light is used to indicate whether the output of the control device is normal or not.
[0033] 3) Please refer to the attached Figure 3The high-voltage live display section consists of a 220V to 36V transformer, a rocker switch, a Chint JZX-22F / 2Z(D) 220VAC relay (third relay), an LED metal indicator (third LED indicator), and wiring accessories. This test fixture is powered by mains electricity, eliminating the need for additional transformers and rectifiers. Rocker switch ZM2, the transformer control switch, is located on the rear panel of the test fixture. When turned ON, it supplies 220V AC to the isolation transformer. It must remain closed during live display function testing. The secondary side outputs a single-phase 36V voltage. This 36V secondary voltage is output in parallel via three rocker switches (ZM3, ZM4, and ZM5) (terminal switches) to terminals UA, UB, UC, and UN, which are then connected to the control unit to simulate the live state of a high-voltage switchgear busbar. This is also located on the rear panel of the test fixture to simulate a three-phase busbar. The high-voltage live display works as follows: When the high-voltage live terminals of the control device are connected to the three-phase power supply of the high-voltage sensors A, B, and C, the corresponding high-voltage live LEDs on the panel illuminate, indicating that the corresponding busbars A, B, and C are live. When phases A, B, and C are de-energized, the lock release indicator on the panel illuminates, and the electromagnetic lock output is closed. When any phase A, B, or C is energized, the lock release indicator on the panel turns off, and the electromagnetic lock output turns open. If someone stands in front of the cabinet during this time, the instrument will issue a voice prompt, "This cabinet's main circuit is energized." To verify the live display function of the control device, a 220V to 36V AC transformer is used to reduce the voltage and output it in parallel through three rocker switches to simulate actual three-phase operation. The three-phase 36V voltage is input to the live input terminal of the control device. By controlling the rocker switches on and off, the control device simulates conditions such as one phase being energized, two phases being energized, three phases being energized, and all three phases being de-energized. At the same time, the control device locks the output and controls the tooling relay coil. When all three phases are de-energized, the relay closes, and the live lockout light on the tooling panel illuminates. If any phase becomes energized, the relay loses power and the lockout light goes out. This tests the control device's live display function and the live lockout relay.
[0034] 4) Please refer to the attached Figure 4 (a)-(c), the accessory terminal section includes:
[0035] The box is 310mm long, 285mm wide, and 115mm high. The specification is XD-4. The color is light blue. The material is 1mm thick steel plate. The box is equipped with a 35mm wide guide rail, on which the relay is mounted.
[0036] The aviation plug is the connection between the test fixture and the outside world. It uses a HE rectangular heavy-duty connector with a 48-pin double-buckle side-outlet. The female plug is shown in the figure. All control lines inside the test fixture are led out through this plug. Different control devices have different models, dimensions, sizes, terminal layouts, and wiring methods. Corresponding fixtures can be made for different models. Each set of fixtures has a reserved aviation socket male head for easy plugging into the fixture. The wiring inside the fixture is based on the terminal layout of the test control body.
[0037] The terminal block is installed inside the test fixture and is the link with the control body; all wiring uses 1 flat soft wire.
[0038] 5) The communication output section consists of a USB-to-485 bus, wiring accessory terminals, and an LED metal indicator (the fourth LED indicator). To test the communication function, plug the bus into the host computer, open the serial port debugging assistant, and send the corresponding commands to establish communication between the two parties. By issuing commands to modify fixed parameters, functional logic actions such as automatic low-temperature heating output, high-temperature ventilation output, and high-humidity heating output can be achieved. These can be seen on the corresponding LEDs on the test fixture, and the transmit and receive indicators on the control device will also flash regularly, confirming that the control communication function is functioning properly.
[0039] 6) The power supply consists of a three-in-one tee switch, a national standard tee power cord (with plug), and wiring accessories. This tool is directly connected to the mains, requiring no conversion or rectification. The tee switch has a built-in fuse. In the event of an overcurrent short circuit, the fuse will burn out, protecting the tool from damage. Replacing the fuse will restore normal power.
[0040] 7) The fixed portion of the control device consists of the corresponding fixture, wiring connectors, and wiring accessories. Switch status indicators and intelligent control devices vary in size, thickness, and wiring location, requiring different fixtures. To enable a single test fixture to test control devices, indicators, and other equipment, customized fixtures are required. The test fixture includes reserved connectors for various control line outputs. The control device fixture plugs into the test fixture via connectors, allowing control lines to be routed to the control device. By operating the fixture, the control device's functionality can be tested. Similarly, the indicator fixture plugs into the test fixture via connectors, allowing control lines to be routed to the indicator device. By operating the fixture, the indicator's functionality can be tested. The control device fixture and indicator fixture require adjustment of their respective connectors based on their respective device wiring, while the connectors on the test fixture remain unchanged. If new products are developed later, the connectors on the fixture can be adjusted in this way to test the functionality of the new product.
[0041] 8) Status display part, refer to the attached Figure 5The test fixture consists of a metal LED indicator, a single-pole double-throw on / off toggle switch, and a label embedded in the front panel of the test fixture. The toggle switch's position indicates whether it's in the on or off state. The metal LED indicator can indicate the various states of the tested control. By observing the on / off status of the indicator, it's easy to determine whether the corresponding control is functioning properly, providing intuitive diagnostic criteria for fault analysis.
[0042] Once implemented, this fixture facilitates testing of various control device functions, reducing the failure rate during shipment. This compact fixture takes up minimal space, is easily relocated, and boasts a high level of integration, allowing for customized testing solutions to meet the testing requirements of different products and functions. It utilizes common components and is powered by mains electricity, resulting in simple energy requirements, safety, and efficiency. Its simplified operation allows for testing devices anytime, anywhere, without requiring specialized equipment, improving production efficiency.
[0043] Example 2: This example differs from Example 1 in that:
[0044] In this embodiment, an operation process card is developed. Each operation step is marked with text and diagrams, reminding the operator of the correct sequence of steps at any time. The operation process card is placed in the tooling accessory basket. Every employee can immediately start the operation by reading the process card. The operation process card contains the detailed operation process, as shown in the table on the following page.
[0045]
[0046] Other aspects are the same as those of the first embodiment.
[0047] The above description of the present invention is illustrative in combination with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited to the above-mentioned method. As long as such non-substantial improvements are made by adopting the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the scope of protection of the present invention.
Claims
1. A test tool for an intelligent control device, characterized by: It includes a box body, on which are provided an input test part, an output test part, and a high-voltage live display part. The input test part, the output test part, and the high-voltage live display part all include relays arranged in the box body and indicator lights arranged on the surface of the box body; the box body is provided with a wiring connector and a terminal block, the wiring connector is used to lead out the control line in the test tooling, and the terminal block is used to connect the control device.
2. The intelligent control device testing tool according to claim 1, characterized in that: The input test part includes a button switch, a first LED indicator light, a first relay and wiring accessories. The button switch is electrically connected to the first relay to realize the control of the power on and off of the first relay; a group of opening points of the first relay is used to connect to the input part of the control device, and another group of opening points of the first relay is electrically connected to the first LED indicator light on the test tool.
3. The intelligent control device testing tool according to claim 2, characterized in that: The number of button switches, first LED indicator lights, and first relays on the input test part is equal and is configured in a one-to-one correspondence with the number of input parts of the control device.
4. The intelligent control device testing tool according to claim 1, characterized in that: The output test part includes a second LED indicator light, a second relay and wiring accessories. The second relay is electrically connected to the relay output on the control device to realize the control of the power on and off of the second relay; the second LED indicator light is electrically connected to the open point on the second relay.
5. The intelligent control device testing tool according to claim 4, characterized in that: The number of the second LED indicator lights and the second relays on the output test part is equal and is configured in a one-to-one correspondence with the number of the control device outlets.
6. The intelligent control device testing tool according to claim 1, characterized in that: The high-voltage live display part includes a transformer, a transformer control switch, a terminal switch, a third relay, a third LED indicator light and wiring accessories. The transformer control switch is electrically connected to the transformer, and the three terminal switches are electrically connected to the secondary side of the transformer in parallel, and the three terminal switches are output in parallel to the three-phase terminals to simulate a three-phase busbar; the third relay is electrically connected to the live locking relay outlet on the control device to realize the control of the power on and off of the third relay; the third LED indicator light is electrically connected to the open point on the third relay.
7. The intelligent control device testing tool according to claim 6, characterized in that: The transformer control switch and terminal switch are both rocker-type switches.
8. The intelligent control device testing tool according to any one of claims 1 to 7, characterized in that: The box body is also provided with a communication output part, a device power supply part, a control device fixing part and a status display part.
9. The intelligent control device testing tool according to claim 8, characterized in that: The communication output part includes a USB to 485 bus, a fourth LED indicator light and a wiring accessory terminal. The USB to 485 bus is used to connect to a computer host, and the wiring accessory terminal is used to connect the computer host, the fourth LED indicator light and the control device.
10. The intelligent control device testing tool according to claim 8, characterized in that: The fixed part of the control device includes a fixed tool fixture, a wiring connector and wiring accessories. The fixed tool fixture is plugged into the test tool through the wiring connector to introduce the control line of the test tool into the control device and / or indicator equipment.