Automatic testing device for dual-power change-over switch controller

Abstract

The utility model provides an automatic test device for a dual-power change-over switch controller, relates to the technical field of dual-power switches, and comprises a power supply module, a switch module, a control module, a load module, a user module, a logic test control board and an interconnection line communicated with the controller. The method is clear in logic organization, small in code amount, easy to modify and high in reliability, the research and development efficiency is improved, automatic testing is very suitable for repeated testing of previous test cases after logic modification in the research and development stage, repeated work of manual testing is reduced, meanwhile, the automatic testing can also be used for factory testing of devices, the overall design cost is low, universality is high, and the method is suitable for popularization and application. Manual test errors are reduced, research and development efficiency is improved, research and development verification time can be greatly shortened, program extension is flexible, and the method is suitable for wide popularization.

Description

Technical Field

[0001] This utility model relates to the field of dual power supply switch technology, and in particular to an automatic testing device for a dual power supply transfer switch controller. Background Technology

[0002] Dual power transfer switches are mainly used in emergency power supply systems. They are switching devices that automatically switch the load circuit from one power source to another (backup) power source to ensure the continuous and reliable operation of important loads. As the demand for dual power transfer switches increases, their control logic becomes more and more complex. The control logic varies in different application scenarios, which brings challenges to research and development and testing. In order to ensure the quality of dual power transfer switches, logic testing of the controller is particularly important.

[0003] Currently, testing of dual-power transfer switches is divided into R&D and production phases. The production phase primarily tests the overall performance of the switch, which cannot cover all control logic. Therefore, controller logic function testing is mainly conducted during the R&D phase. R&D often relies heavily on manual testing, with a very low proportion of automated testing. Furthermore, the logic control program undergoes frequent changes during R&D, and some control logic has a ripple effect, requiring repeated and extensive testing. This process generally suffers from long testing cycles, low testing efficiency, large errors in manual testing, and insufficient test coverage. Moreover, it is crucial to expose controller logic problems during the R&D phase. If problems are only discovered during production testing or at the customer's site, it not only delays production but also makes the problems difficult to reproduce. Even minor issues can escalate into significant problems with severe consequences.

[0004] Therefore, we propose an automatic testing device for dual power transfer switch controllers. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies, specifically the deficiencies in current dual-power switch testing processes.

[0006] 1. It requires repeated and extensive testing, and generally suffers from many problems such as long testing cycles, low detection efficiency, large errors in manual testing, and insufficient test coverage;

[0007] 2. Logic problems of the controller should be exposed during the R&D stage as much as possible. If problems are discovered during production testing or at the customer's site, it will not only delay production, but the problems may also be difficult to reproduce. Even small problems may escalate into very big problems, with serious consequences.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] An automatic testing device for a dual power transfer switch controller includes:

[0010] Power supply module, switch module, control module, load module, and user module;

[0011] Logic test control board and interconnects that communicate with the controller.

[0012] As a preferred embodiment of this utility model, the load module comprises: an instrument, device, or circuit system that requires a power supply.

[0013] As a preferred embodiment of this utility model, the power supply module includes: a first power supply and a second power supply, and the power supply module is used to supply power to the load.

[0014] As a preferred embodiment of this utility model, the switch module includes: a first switch and a second switch, wherein the first switch is used to control the circuit connection state between the first power supply and the load, and the second switch is used to control the circuit connection state between the second power supply and the load.

[0015] As a preferred embodiment of this utility model, the user module includes: an interface between the user and the dual power transfer switch, through which the user can obtain various information of the dual power transfer switch in real time and interact with the dual power transfer switch.

[0016] In a preferred embodiment of this utility model, the switch module is electrically connected to the control module, and the control module is used to control the state of the switch module, mainly consisting of a data acquisition unit, a logic control unit, and a protection unit.

[0017] As a preferred embodiment of this utility model, the acquisition unit is responsible for acquiring data information such as the voltage of the two power supplies and the current of the electrical load;

[0018] The acquisition unit and the switching module are both electrically connected to the logic control unit. The logic control unit can control the state of the switching module according to the voltage of the first power supply, the voltage of the second power supply, and the current of the load.

[0019] The protection unit is responsible for the protection logic control of the entire dual power transfer switch. It monitors the dual power transfer switch in real time and minimizes the impact on the entire dual power transfer switch when encountering abnormal situations such as illegal operation, short circuit, or energy storage failure.

[0020] The control unit is the brain of the entire dual power transfer switch, and it integrates a set conversion logic program to control the switching mechanism in different modes.

[0021] As a preferred embodiment of this utility model, the logic test control board is provided with multiple interface terminals for communicating with the controller, which are used for interconnecting various communication signals with the controller.

[0022] Compared with the prior art, the beneficial effects of this utility model are:

[0023] In this invention, the device avoids frequent wiring tests, has a clear logical structure, less code, is easy to modify, has high reliability, and improves R&D efficiency. The automatic testing is very suitable for repeating the previous test cases after logic modifications during the R&D phase, reducing repetitive work of manual testing. At the same time, the automatic testing can also be used for factory testing of the device. The overall design cost is low, the versatility is strong, it reduces the error of manual testing and improves R&D efficiency, can significantly shorten the R&D verification time, and the program is flexible and suitable for widespread promotion. Attached Figure Description

[0024] Figure 1 A block diagram of a dual power transfer switch structure for an automatic testing device for a dual power transfer switch controller provided by this utility model;

[0025] Figure 2 The present invention provides a priority diagram of the main operating modes of a conventional controller for an automatic testing device for a dual power transfer switch controller.

[0026] Figure 3 An example block diagram of the automatic control mode logic switching control of an automatic testing device for a dual power supply transfer switch controller provided by this utility model;

[0027] Figure 4 A block diagram of a logic test control board for an automatic test device for a dual power supply transfer switch controller provided by this utility model;

[0028] Figure 5 A flowchart illustrating the verification process of an automatic testing device for a dual-power transfer switch controller provided by this utility model. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0030] To facilitate understanding of this utility model, a more comprehensive description of this utility model will be provided below with reference to relevant embodiments, and several embodiments of this utility model will be given. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of this utility model more thorough and complete.

[0031] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0033] Example

[0034] like Figure 1-5 As shown, this utility model provides a technical solution including:

[0035] Power supply module, switch module, control module, load module, and user module;

[0036] Traditional manual testing requires manually connecting various signal terminals and simulating control states under different operating modes to verify whether the control logic meets design requirements. Manual testing involves a large workload and a long testing cycle. Therefore, many control logics are only tested once or very few times, making it difficult to verify probabilistic anomalies caused by program stability. Moreover, test results can vary depending on the tester's ability.

[0037] The testing device consists of a logic test control board and interconnects that communicate with the controller. The main architecture of the logic test control board is as follows: Figure 4 As shown.

[0038] The logic test control board has multiple interface terminals for communicating with the controller, used for interconnecting various communication signals with the controller. Most of the interface terminals have specified port uses for connecting general controller signals. For example, terminal 1 is used to connect switch control signals, terminal 2 is used to connect micro-motion position feedback signals, terminal 3 is used to connect controller reset signals, and so on. A small number of terminals can be customized according to the specific design requirements of the controller to meet the differentiated design needs of the controller.

[0039] In addition to the actual external signal connection interfaces, the board also has two communication buses. Communication bus one is RS485, and communication bus two is a custom four-port communication interface. Designers can choose which bus to use to communicate with the logic test control board for internal logic signals such as controller status information and fault information, based on the specific hardware design of the controller. RS485 is the most commonly used communication interface between the controller and the user; almost all controllers have an RS485 interface. Therefore, it can be temporarily used for communication with the internal signals on the logic test control board during automatic testing without requiring any changes to the controller's design. The other four-port communication interface is reserved as a backup option, depending on the controller under test and the compatibility of the control chip's interface with the logic control unit on the logic test control board. For example, it can be an I2C or SPI communication interface to provide more options for the automatic testing scheme. The design principle is to provide testers with flexible testing schemes without changing any changes to the main controller design.

[0040] The logic control unit is the brain of the logic test control board. It is responsible for simulating the control state of the controller in various working modes, setting preset execution actions and monitoring the controller status. After the expected time is over, it compares whether the switch position and controller status meet the expected results. If they do, it continues to execute the next test. If they do not meet, it will activate the alarm unit to prompt the tester to handle the abnormal results in a timely manner.

[0041] The logic control unit can simulate the control state of the dual power transfer switch controller under different operating modes, such as automatic control mode, button control mode, and communication mode. By simulating these control states, the logic control unit can perform comprehensive testing on the dual power transfer switch to verify its performance and reliability under different operating modes. At the same time, the logic control unit can also set preset execution actions, such as issuing switch switching commands within a specific time, and monitor the controller's status and switch position to determine whether the test results meet expectations.

[0042] If the test results do not meet expectations, the logic control unit will activate the alarm unit to prompt the tester to handle the abnormal results in a timely manner. The alarm unit can be an audible and visual alarm, an alarm message on a display screen, etc. The specific form depends on the actual needs and design considerations. The tester can quickly locate the problem based on the alarm message and take corresponding measures to repair and debug it.

[0043] Analog logic control units are not limited to microcontrollers, FPGAs, PLCs, or any combination thereof.

[0044] The load module comprises instruments, equipment, or circuit systems that require power supply. These loads can be of various types, such as motors, pumps, and fans in industrial production, or lighting systems, elevators, and air conditioning systems in commercial buildings.

[0045] The load module is the end user of the entire dual power transfer switch system, and its normal operation is crucial to ensuring the continuity of production and daily life. Therefore, ensuring that the dual power transfer switch can quickly and reliably switch between different power sources to meet the power supply needs of the load is one of the important tasks of this automatic testing device.

[0046] The power module includes a first power source and a second power source. The power module is used to supply power to the load. The first power source and the second power source can be different types of power sources, such as mains power and a backup generator, different mains power lines, or battery packs. Under normal circumstances, the main power source (usually the first power source) provides power to the load. When the main power source fails, the dual power transfer switch automatically switches to the backup power source to ensure continuous power supply to the load.

[0047] In many commercial and industrial settings, mains power is the primary source of electricity. However, mains power can fail for various reasons, such as power outages or voltage fluctuations. To address this, a backup generator is typically installed. When mains power fails, a dual-power transfer switch automatically activates the backup generator and switches the load to generator power.

[0048] In critical locations such as hospitals and data centers, two different mains power lines may be connected. This allows a dual-power transfer switch to quickly switch to the other line if one line fails, ensuring continuous power supply to the load.

[0049] In applications where power reliability is extremely critical, such as communication base stations and aerospace equipment, battery packs may be used as backup power. Battery packs can immediately provide power to the load in the event of a mains power failure and can automatically recharge themselves after the mains power is restored, ready for the next use.

[0050] The switching module includes a first switch and a second switch. The first switch controls the circuit connection between the first power supply and the load, and the second switch controls the circuit connection between the second power supply and the load. These two switches are typically composed of electromagnetic relays or solid-state relays, and can quickly switch power supplies according to control signals. For example, when a main power supply failure is detected, the control module sends a signal to open the first switch and simultaneously close the second switch, switching the load to the backup power supply.

[0051] The number of changeover switches is not limited to two, three, or four switches... The more switches there are, the more complex the control logic becomes, and the more necessary an automatic testing device is. It can be applied simply by adjusting the relevant test code according to the control logic.

[0052] The user module includes: The user module serves as the interface between the user and the dual power transfer switch, typically including a display screen, buttons, indicator lights, etc. Users can obtain various information about the dual power transfer switch in real time through this interface, such as power status, switch position, and fault alarms, and can interact with the dual power transfer switch through this interface. For example, users can set the operating mode and parameters of the dual power transfer switch through the buttons, and can also view the current operating status and historical records through the display screen.

[0053] The switch module is electrically connected to the control module. The control module is used to control the state of the switch module and mainly consists of a data acquisition unit, a logic control unit, and a protection unit.

[0054] The sampling unit is responsible for collecting data such as the voltage of the two power supplies and the current of the load. Through sensors and other devices, it monitors the voltage of the power supplies and the current of the load in real time, providing accurate data support to the logic control unit. For example, when the power supply voltage fluctuates significantly, the sampling unit can detect it promptly and transmit the data to the logic control unit so that appropriate control measures can be taken. The sampling unit can use various types of sensors, such as voltage sensors and current sensors. These sensors can convert the voltage and current of the power supply into electrical signals, which are then transmitted to the sampling unit for processing.

[0055] The acquisition unit and the switching module are both electrically connected to the logic control unit. The logic control unit can control the state of the switching module according to the voltage of the first power supply, the voltage of the second power supply, and the current of the load.

[0056] The protection unit is responsible for the protection logic control of the entire dual power transfer switch. It monitors the dual power transfer switch in real time and minimizes the impact on the entire dual power transfer switch when encountering abnormal situations such as illegal operation, short circuit, or energy storage failure. When an abnormal situation is detected, the protection unit will immediately take corresponding protection measures, such as disconnecting the switch and issuing an alarm signal, to prevent the fault from escalating and to protect the safety of equipment and personnel.

[0057] The logic control unit is the brain of the entire dual-power transfer switch. It integrates a pre-set transfer logic program to control the switch switching mechanism in different modes. Currently, conventional dual-power transfer switches support multiple operating modes to facilitate monitoring and switching control in various application scenarios, including automatic control mode, button control mode, communication mode, remote mode, exit mode, and local mode. Each mode has its own input terminals for inputting switch switching control signals, as well as various signal terminals such as current power status and switch position signals. The control unit determines the switch opening and closing state based on the priority of the operating mode and the status of the corresponding terminals. The control logic is quite complex. The main operating mode priorities of conventional controllers are as follows: Figure 2 As shown, and in the example block diagram of automatic control mode logic transition control. Figure 3 As shown.

[0058] Taking the automatic control mode as an example, the verification process of this automatic testing device is as follows: Figure 5 As shown.

[0059] S1. The logic control unit sets the control mode to automatic control mode with mains power-mains power mode, and the working mode is automatic transfer and automatic recovery. S1 is the main power supply.

[0060] S2. The current status of the controller is as follows: the power supply status of S1 and S2 is normal, S1 and S2 are not set to be disabled, the fault confirmation delay T1 is 5s, the conversion delay T4 is 4s, the transient dwell delay T2 is 2s, the return delay T3 is 3s, the current switch status is S1 closed and S2 open, and there are no abnormal states such as current short circuit or energy storage fault.

[0061] S3. If at this time, the logic control unit sets the power state of S1 to change from normal to fault state, the controller's preset control logic is as follows:

[0062] a. The control logic process of issuing a switch S1 trip command after the controller detects a fault in the main power supply S1, starts the fault confirmation delay T1 and the switching delay T4:

[0063] Within the fault confirmation delay T1 (5S), monitor whether the power status of S1 has returned to normal. If it returns to normal within 5S, the switch control logic does not perform any action. If the power status of S1 is still in the fault state when the 5S delay ends, the conversion delay T4 (4S) is started. If the power status of S1 returns to normal within the 4S delay, the T4 conversion delay ends, and the switch control logic does not perform any action. If the power status of S1 is still in the fault state when the 4S delay ends, the controller issues a command to open the switch S1. Assuming that the switch S1 is expected to open within 100ms, the protection module starts timing from the moment the open command is issued. If the micro-motion position is in the double open state within 100ms, it is considered that the conversion is normal; otherwise, the controller will set the S1 open conversion timeout alarm.

[0064] b. Control logic process for issuing a switch closing command after the controller detects that the switch is in the double open position and initiates a transient delay T2:

[0065] Assuming the controller detects that switch S1 is in the open state at 80ms, a transient delay T2 (2S) is initiated. If both switches remain in the open state within 2S, power supply S1 is in a fault state and power supply S2 is in a normal state, then the controller will issue a closing command for switch S2 when the T2 delay ends. Assuming that switch S2 is expected to close within 200ms, the protection module starts timing from the moment the closing command is issued. If the micro-motion position is S1 open and S2 closed within 200ms, the transition is considered normal; otherwise, the controller will set an S2 closing transition timeout alarm.

[0066] S4. During the execution of the above control logic, the detection behavior of the logic test control unit on the logic test control board is as follows:

[0067] a. When the S1 power supply failure is set, the tripping (T1+T4) time monitoring is performed. If the S1 tripping command is received at the end of the monitoring time, the micro-motion state of switch S1 is set to the tripping state within the expected tripping action time, and then feedback is sent to the controller. Otherwise, the control logic unit sets the abnormal alarm signal to promptly prompt the test personnel to check the abnormal verification situation.

[0068] b. Continue to monitor the closing (T2) time. If the S2 closing command is received at the end of the monitoring time, the S2 micro-motion state of the switch is set to the closing state within the expected closing action time of the switch, and then feedback is sent to the controller. Otherwise, the control logic unit sets the abnormal alarm signal to promptly prompt the test personnel to check the abnormal verification situation.

[0069] c. Continue to monitor the controller's switch status. If there is no switch switching command and no other abnormal logic alarms or other abnormal signals, store the switching record, automatically increase the number of revolutions by one, and display it on the auxiliary indicator unit.

[0070] S5. Steps 3 and 4 above are a transition action in automatic control mode. Testers can set the number of times this action is executed according to the design. For example, if it is set to 100 times, the logic test control unit will repeat the above action 100 times to verify whether there are design defects such as transition anomalies and logic metastability.

[0071] S6. During automatic testing, whenever the controller executes a switch switching command, or any of the following changes occur: switch position, alarm information, power status, delay parameter change, or operating mode, the logic test control unit will store it as an event record in the storage unit to help testers analyze the controller logic and test status.

[0072] S7. The logic test control unit encodes all test items. After encoding, it combines the corresponding number of times the test item is executed. The currently executing verification item and the number of times can be displayed on the auxiliary indicator unit. The auxiliary indicator unit can be displayed intuitively on the screen. Of course, in order to save on component costs, it is simpler and more convenient to use digital tubes or LED indicator lights for cyclic display.

[0073] This solution is low in cost, highly versatile, reduces human testing errors and improves R&D efficiency. It can significantly shorten R&D verification time, and the program is flexible in expansion, making it suitable for widespread adoption.

[0074] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic testing device for a dual-power transfer switch controller, characterized in that, include: Power supply module, switch module, control module, load module, and user module; Logic test control board and interconnecting cables for communication with the controller; The load module comprises: instruments, equipment, or circuit systems that require power supply; The power module includes: a first power supply and a second power supply, and the power module is used to supply power to the load; The switching module includes: a first switch and a second switch, wherein the first switch is used to control the circuit connection state between the first power supply and the load, and the second switch is used to control the circuit connection state between the second power supply and the load. The user module includes an interface between the user and the dual power transfer switch, through which the user can obtain information about the dual power transfer switch in real time and interact with the dual power transfer switch.

2. The automatic testing device for a dual-power transfer switch controller according to claim 1, characterized in that, The switch module is electrically connected to the control module. The control module is used to control the state of the switch module and mainly consists of a data acquisition unit, a logic control unit, and a protection unit.

3. An automatic testing device for a dual-power transfer switch controller according to claim 2, characterized in that, The acquisition unit is responsible for acquiring the voltage and load current data of the two power sources; The acquisition unit and the switching module are both electrically connected to the logic control unit. The logic control unit can control the state of the switching module according to the voltage of the first power supply, the voltage of the second power supply, and the current of the load. The protection unit is responsible for the protection logic control of the entire dual power transfer switch. It monitors the dual power transfer switch in real time and minimizes the impact on the entire dual power transfer switch when encountering illegal operation, short circuit, energy storage fault, or other abnormal conditions. The logic control unit is the brain of the entire dual-power transfer switch, and it integrates a set transfer logic program to control the switching mechanism in different modes.

4. An automatic testing device for a dual-power transfer switch controller according to claim 3, characterized in that, The logic test control board is equipped with multiple interface terminals for communicating with the controller, which are used for interconnecting communication signals with the controller.

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