Intelligent detection device for power-on aging of multi-path cascade coil assembly

Abstract

The utility model discloses a multipath cascade coil assembly power-on aging intelligent detection device, which relates to the technical field of hydraulic servo valve detection, adopts a cascade expansion mode, and can meet the requirement of the actual production coil aging number according to the number of field actual aging coil loads and the number of cascade splicing coil aging test boards. Through matched testing software, the actual current magnitude and the aging time duration of a coil assembly needing to be aged are independently set, the actual coil current value and the coil resistance value in the aging process are monitored in real time, the abnormal coil assembly is subjected to color distinguishing alarm management, and the fault time and state are recorded; and the actual production process requirements of the field coil assembly can be well met, and the convenience and operability are greatly improved.

Description

Technical Field

[0001] This utility model relates to the field of hydraulic servo valve testing technology, and more specifically to an intelligent testing device for the aging of multi-channel cascaded coil assemblies under power. Background Technology

[0002] Currently, the coil assembly is a crucial component of the torque motor in electro-hydraulic servo valves, and its proper functioning determines whether the electro-hydraulic servo valve can operate normally. Enamelled wire is a major component of the coil assembly. When enamelled wire is wound into a coil, there is a possibility that pinhole sections may adhere to areas with thinner enamel films. If this occurs under high temperatures or continuous energization, the enamel film may peel off, causing short circuits, open circuits, or a decrease in resistance, thus affecting the normal operation of the electro-hydraulic servo valve.

[0003] After the servo valve coil assembly is manufactured, applying a certain current and time to the coil assembly can cure and improve the performance of the enameled wire, and screen out defective enameled wire coils. According to the above process route, the coil assembly aging process using a traditional analog current amplifier has been applied in small-batch production of coil assemblies. However, using a traditional analog current control device is cumbersome in terms of current setting, cannot monitor the current of each channel coil in real time, cannot record process fault data, is inconvenient for centralized data management, and requires a significant amount of time for worker operation.

[0004] Therefore, how to provide an intelligent detection device that can improve operability and convenience while meeting the actual production requirements for coil aging is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0005] In view of this, the present invention provides an intelligent detection device for energized aging of multi-channel cascaded coil components, so as to solidify and improve the performance of coil components in the mass production process, screen out coil components with enameled wire defects, ensure the quality and pass rate of coil components, and avoid quality problems during subsequent product assembly and customer on-site use.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A multi-channel cascaded coil assembly power-on aging intelligent detection device is disclosed. The detection device is composed of several test units spliced ​​together. Each test bench includes: a test bench panel, alligator clips, coil assembly fixing armature, a 4-channel 485 CNC constant current source module, an adjustable DC regulated power supply, a USB to 485 hub, an industrial control computer, and consists of 485 communication interface A, 485 communication interface B, power interface A, and power interface B.

[0008] The test bench panel includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by a fixed wiring alligator clip and a coil assembly fixing armature.

[0009] One end of the alligator clip is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wires, and the coil assembly is placed in the coil assembly fixed armature.

[0010] The adjustable DC regulated power supply is connected to power interface A to provide DC regulated power to a single test bench, which powers the 4-channel 485 digital control constant current source module respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded from power interface B to the power input port A of the next test bench.

[0011] The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the communication interface A is connected to the internal 4-channel 485 numerical control constant current source module.

[0012] Optionally, the test bench panel includes 20 coil assembly aging channels, arranged in a 5-row, 4-column configuration, and numbered uniformly from 1 to 20.

[0013] Optionally, the industrial control computer converts the computer's USB communication signal into eight independent 485 communication interfaces via a computer USB interface, data cable, and USB-to-485 hub module. The eight 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in parallel.

[0014] Optionally, the 4-channel 485 CNC constant current source module includes an ARM microcontroller, a digital-to-analog converter module, an analog-to-digital converter module, a power supply regulator, a constant current source driver module, a load under test module, and a current sampling module; the ARM microcontroller is connected to the digital-to-analog converter module, the analog-to-digital converter module, and the power supply regulator respectively; the analog-to-digital converter module, the constant current source driver module, the current sampling module, the load under test module, and the power supply regulator are connected in sequence.

[0015] Optionally, the ARM main control microcontroller also includes a 485 transceiver interface and a USB transceiver interface.

[0016] Optionally, the ARM main control microcontroller also includes a fault indicator light connected to the I / O interface.

[0017] As can be seen from the above technical solution, compared with the prior art, this utility model discloses a multi-channel cascaded coil assembly power-on aging intelligent detection device. Adopting a cascaded expansion method, it can cascade and splice the number of coil aging test boards according to the actual number of coils being aged on-site, thus meeting the actual production coil aging requirements. Through the accompanying testing software, the actual current magnitude and aging time length of the coil assembly to be aged can be independently set, and the actual coil current value and coil resistance value during the aging process can be monitored in real time. Abnormal coil assemblies are distinguished by color for alarm management, and the fault time and status are recorded. This can better meet the actual production process requirements of coil assemblies on-site, and its convenience and operability are greatly improved. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0019] Figure 1 A schematic diagram of the intelligent detection device for energized aging of coil components provided by this utility model;

[0020] Figure 2 This is a schematic diagram of the structure of a single test bench for the coil assembly provided by this utility model, wherein Figure a is a front view and Figure b is a bottom view;

[0021] Figure 3 The structural schematic diagram provided for this utility model is a block diagram of the principle of a single module of a 4-channel 485 CNC constant current source.

[0022] Among them, 1-test bench panel; 2-wiring alligator clip; 3-coil assembly fixing armature. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] This utility model discloses an intelligent detection device for the aging of multi-channel cascaded coil assemblies under power-on conditions. Based on the actual process requirements of coil production and considering ease of operation and management, this intelligent detection device for the aging of multi-channel cascaded coil assemblies under power-on conditions was developed and designed. The principle block diagram of this detection device is shown below. Figure 1 As shown in the diagram, a schematic diagram of a single test bench is as follows: Figure 2 As shown, Figure a is the front view and Figure b is the bottom view. A single test bench consists of one test bench panel 1, 20 alligator clips 2, 20 coil assembly fixing armatures 3, five 4-channel 485 CNC constant current source modules, one high-precision adjustable DC regulated power supply, one power interface A input terminal, one USB to 485 hub, one industrial control computer and one set of test software; one 485 communication interface A input terminal, one power cascade output interface B, and one 485 cascade output communication interface B.

[0025] Test bench panel 1 includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by a fixed wiring alligator clip 2 and a coil assembly fixing armature 3;

[0026] One end of the alligator clip 2 is connected to the current output terminal of the 4-channel 485 CNC constant current source module; the other end is connected to both ends of the coil assembly wires, and the coil assembly is placed in the coil assembly fixing armature 3.

[0027] A high-precision adjustable DC regulated power supply is connected to power interface A to provide DC regulated power to a single test bench, which powers the 4-channel 485 digitally controlled constant current source module. At the same time, the DC voltage provided by the DC regulated power supply is cascaded from power interface B to the power input port of the next test bench.

[0028] The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the 485 communication interface B is connected to the 4-channel 485 CNC constant current source module.

[0029] In one specific embodiment, the test bench panel 1 includes 20 coil assembly aging channels, arranged in a 5-row, 4-column configuration, and numbered uniformly from 1 to 20.

[0030] In one specific embodiment, the industrial control computer converts the computer's USB communication signal into eight independent 485 communication interfaces through a computer USB interface, data cable, and USB-to-485 hub module. The eight 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in a parallel manner.

[0031] In a specific embodiment, such as Figure 3As shown, the 4-channel 485 CNC constant current source module includes an ARM microcontroller, a digital-to-analog converter module, an analog-to-digital converter module, a power supply regulator, a constant current source driver module, a load under test module, and a current sampling module. The ARM microcontroller is connected to the digital-to-analog converter module, the analog-to-digital converter module, and the power supply regulator, respectively. The analog-to-digital converter module, the constant current source driver module, the current sampling module, the load under test module, and the power supply regulator are connected in sequence.

[0032] In one specific embodiment, the ARM main control microcontroller also includes a 485 transceiver interface and a USB transceiver interface.

[0033] In one specific embodiment, the ARM microcontroller also includes a fault indicator light connected to the I / O interface.

[0034] The intelligent detection device for aging of multi-channel cascaded coil components under power-on conditions in this embodiment includes the following steps:

[0035] Step 1: Select a single test bench panel 1, such as... Figure 2 As shown in the center view, the panel has 20 coil assembly aging channels, arranged in 5 rows and 4 columns, and numbered uniformly from 1 to 20. Each coil is surrounded by a wiring alligator clip 2 and a coil assembly fixing armature 3 for easy installation and testing. One end of the wiring alligator clip 2 is connected to the current output terminal of the 4-channel 485 digital control constant current source module; the other end is connected to both ends of the coil assembly wires and places the coil assembly in the coil assembly fixing armature 3 to simulate the load.

[0036] Step 2: The high-precision adjustable DC regulated power supply provides a DC regulated power of 12-20V to a single test bench through power interface A, which powers five 4-channel 485 digitally controlled constant current source modules respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded from power interface B to the power input port of the next test bench.

[0037] Step 3: The industrial control computer converts the computer's USB communication signal into eight independent RS-485 communication interfaces via the computer's USB interface, data cable, and USB-to-RS-485 hub module. These eight RS-485 communication interfaces communicate in parallel with the four-channel RS-485 CNC constant current source modules in each individual test bench. This parallel communication significantly improves the communication speed. Theoretically, one RS-485 interface can communicate with 255 four-channel RS-485 CNC constant current source modules, and each four-channel RS-485 CNC constant current source module can control four coils, meaning one RS-485 module can control 1020 coil assemblies. The eight RS-485 interfaces can simultaneously perform aging tasks on 8160 coil assemblies. Due to the modular design, different current paths can be configured according to customer requirements, making maintenance extremely convenient.

[0038] Step 4: The 4-channel 485 CNC constant current source module is the core of the detection device, and its principle block diagram is as follows. Figure 3 As shown, the module is designed and developed using an embedded ARM microcontroller to complete data processing. The peripheral components include a 16-bit high-precision DAC8830 chip to control the current output and a 24-bit high-precision ADS1256IDB chip to complete the current data feedback acquisition task. The module uses the standard MODBUS protocol and 485 interface to complete data communication and transmission. This module features high current control accuracy, stable data transmission, and convenient computer management.

[0039] Step 5: The industrial control computer and testing software centrally manage and transmit data to the 4-channel 485 CNC constant current source module, enabling real-time monitoring and recording of process data such as setting different types of current specifications, setting the working load power-on time, and real-time monitoring of the current and coil resistance of each group of coils. The software also uses color-coded alarm management to distinguish abnormal currents after a coil failure.

[0040] Step 6: When the coil assembly begins aging, first turn on the DC power supply to power each 485 module constant current source circuit board. Simultaneously, open the test software on the industrial control computer and establish software communication. After communication is established, set the rated current value through the software according to the current specifications of the aging coil. Click [Current Monitoring] to display the current monitoring interface. Click [Read], and the interface will begin displaying the actual current and resistance values. According to the actual test requirements, install and fix the coils on the aging test boards 1-8 respectively. Observe the computer's current control monitoring interface. If the coil installation is correct, the computer monitoring screen will display the actual current and resistance values, and the table color will be green, indicating that the coil installation is normal. If the table is red, it indicates that the coil is not installed correctly or there is a problem; reinstall or troubleshoot the issue.

[0041] Starting January 1, 2024, an independently developed multi-channel cascaded intelligent detection device for aging and screening coil assemblies in the production process was used. This device consists of eight independent test aging boards, capable of simultaneously testing 160 coil assemblies at a time. According to process requirements, each batch of coil assemblies needs to undergo a continuous aging process at the rated current for 48 hours. As of May 30, 2024, a total of 8,000 coil assemblies with different current specifications had completed aging and screening tests, identifying 10 problematic coil assemblies. This demonstrates that the detection device effectively prevents problematic coils from entering the production site and being installed in torque motors or servo valve products, thus preventing malfunctions at customer sites.

[0042] This intelligent aging detection device for multi-channel cascaded coil assemblies employs a multi-channel cascaded splicing method combined with a digital software management system, capable of simultaneously aging up to 8160 coil assemblies. The current control management system can accurately output any current value within the range of 0-200mA based on the current value set by the host computer software. It features convenient current setting, high current output control accuracy, wide adjustable range, good stability, and easy operation. Besides coil assembly aging testing, it is also suitable for various applications requiring constant current, such as small DC motor drives and LED testing.

[0043] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0044] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A smart detection device for energized aging of multi-channel cascaded coil assemblies, characterized in that, The testing device is composed of several testing devices. A single test bench includes: a test bench panel (1), a wire alligator clip (2), a coil assembly fixing armature (3), a 4-channel 485 CNC constant current source module, an adjustable DC regulated power supply, a USB to 485 hub, an industrial control computer, 485 communication interface A, 485 communication interface B, power interface A, and power interface B. The test bench panel (1) includes multiple coil assembly aging channels; each coil assembly aging channel is surrounded by a fixed wiring alligator clip (2) and a coil assembly fixed armature (3); One end of the wiring alligator clip (2) is connected to the current output terminal of the 4-channel 485 digital control constant current source module; the other end is connected to both ends of the coil assembly wire, and the coil assembly is placed in the coil assembly fixed armature (3); The adjustable DC regulated power supply is connected to power interface A to provide DC regulated power to a single test bench, which powers the 4-channel 485 digital control constant current source module respectively. At the same time, the DC voltage provided by the DC regulated power supply is cascaded from power interface B to the power input port A of the next test bench. The industrial control computer is electrically connected to the 485 hub module; the 485 hub module is connected to the 485 communication interface A; and the 485 communication interface A is connected to the 4-channel 485 numerical control constant current source module.

2. The intelligent detection device for energized aging of multi-channel cascaded coil assemblies according to claim 1, characterized in that, The test bench panel (1) includes 20 coil assembly aging channels, arranged in a 5-row, 4-column configuration, and numbered uniformly from 1 to 20.

3. The intelligent detection device for energized aging of multi-channel cascaded coil assemblies according to claim 1, characterized in that, The industrial control computer converts the computer's USB communication signals into eight independent 485 communication interfaces via a computer USB interface, data cable, and USB-to-485 hub module. The eight 485 communication interfaces communicate with the 485 constant current source modules in each individual test bench in parallel.

4. The intelligent detection device for energized aging of multi-channel cascaded coil assemblies according to claim 1, characterized in that, The 4-channel 485 CNC constant current source module includes an ARM microcontroller, a digital-to-analog converter module, an analog-to-digital converter module, a power supply regulator, a constant current source driver module, a load under test module, and a current sampling module. The ARM microcontroller is connected to the digital-to-analog converter module, the analog-to-digital converter module, and the power supply regulator, respectively. The analog-to-digital converter module, the constant current source driver module, the current sampling module, the load under test module, and the power supply regulator are connected in sequence.

5. The intelligent detection device for energized aging of a multi-channel cascaded coil assembly according to claim 4, characterized in that, The ARM microcontroller also includes a 485 transceiver interface and a USB transceiver interface.

6. The intelligent detection device for energized aging of a multi-channel cascaded coil assembly according to claim 4, characterized in that, The ARM microcontroller also includes a fault indicator light connected to the I / O interface.

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