Alternating-current generator controller tester

Abstract

The utility model discloses an alternating-current generator controller tester, which relates to the technical field of equipment testing and comprises a power supply unit, a main control unit, a power supply control unit, a power supply parameter acquisition unit, an alternating-current signal output unit, a level detection unit, a logic control unit and a display unit. When no matched alternating-current generator is provided, the correctness of protection control work of the controller is checked; when an alternating-current generator is matched, the correctness of the controller for controlling motor power generation and protection control work is checked. A single-function automatic test function is achieved, and test data are displayed on a screen after the test is completed; during testing, operation steps are displayed in sequence, and fault positions can be judged according to correctness of operation step results. A modular design is adopted, a standard RS485 communication protocol is adopted among the modules, hardware resources are reserved, and debugging, maintenance and upgrading are facilitated. All equipment components are directly connected through aviation plugs, connection is stable, and work is reliable; the mature technology is adopted, performance is reliable, and operation is stable.

Description

Technical Field

[0001] This utility model relates to the field of equipment testing technology, specifically to an AC generator controller tester. Background Technology

[0002] Patent CN201662701U discloses a simple-to-operate ordnance integrated detector, filed on December 17, 2009. This detector includes a PC104 control subsystem and functional circuit boards. The PC104 control subsystem includes a CPU module and a digital I / O module. The functional circuit boards include relay circuits, rocket pulse filtering and shaping circuits, rocket pulse generation circuits, and cannon pulse generation circuits. The functional circuit boards are connected to the digital I / O module and the CPU module, respectively. An AC generator controller is a key device for ensuring the safe operation of an aircraft's avionics system. It controls the generation of AC motors and ensures a stable and reliable output AC voltage. The AC generator controller has functions such as overload protection, overcurrent protection, undervoltage protection, overvoltage protection, underfrequency protection, and overfrequency protection, and outputs fault signals and detection signals. Existing controller testing equipment operates by jogging and manually adjusting voltage regulation, frequency regulation, and control operations. Fault codes need to be viewed using an external acquisition board. This reduces the workload of testing personnel to some extent and improves the efficiency of power-on testing. While existing technologies can complete the entire machine test and are reliable in operation and control, the overall operation requires a high level of technical skill from the test personnel, involves complex operating procedures, and requires a large number of devices. Furthermore, all operations are manually controlled, each step requiring relevant professional knowledge, making it tedious and resulting in low overall testing efficiency. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide an AC generator controller tester.

[0004] The objective of this utility model is achieved through the following technical solution:

[0005] This utility model discloses an AC generator controller tester, comprising a power supply unit, a main control unit, a power control unit, a power parameter acquisition unit, an AC signal output unit, a level detection unit, a logic control unit, and a display unit. The output terminal of the power supply unit is connected to the input terminals of the main control unit and the power control unit, respectively. The output terminal of the power control unit is connected to the input terminal of the power parameter acquisition unit. The output terminal of the main control unit is connected to the input terminal of the AC signal output unit. The output terminal of the AC signal output unit is connected to the input terminals of the power parameter acquisition unit and the logic control unit, respectively. The output terminal of the power parameter acquisition unit is connected to the input terminal of the logic control unit, respectively. The output terminal of the logic control unit is connected to the level detection unit and the input terminal of a first device under test, respectively. The input terminal of the logic control unit is connected to the output terminal of a second device under test, respectively. The main control unit is also connected to the level detection unit and the display unit, respectively. The level detection unit is also connected to the first device under test.

[0006] Furthermore, the power supply unit includes a fuse, a main power switch, and a switching power supply. The input terminal of the fuse is connected to an external power source, the output terminal of the fuse is connected to the input terminal of the main power switch, the output terminal of the main power switch is connected to the input terminal of the switching power supply, and the output terminal of the switching power supply is connected to the input terminals of the main control unit and the power control unit, respectively. The switching power supply is also connected to a power indicator light.

[0007] Furthermore, the power control unit includes a relay, the input terminal of which is connected to the output terminal of the power unit, and the output terminal of which is connected to the input terminal of the power parameter acquisition unit.

[0008] Furthermore, the power parameter acquisition unit includes an AC / DC detection module and an AC voltage and current measurement chip. The input terminal of the AC / DC detection module is connected to the output terminal of the power control unit, the output terminal of the AC / DC detection module is connected to the input terminal of the AC voltage and current measurement chip, and the output terminal of the AC voltage and current measurement chip is connected to the input terminal of the logic control unit.

[0009] Furthermore, the main control unit includes a core controller and an FPGA. The core controller is connected to the FPGA, and the FPGA is connected to the power supply unit and the AC signal output unit. The FPGA is also equipped with peripheral circuits, including a bus transceiver chip and a transformer.

[0010] Preferably, it further includes a human-computer interaction unit, and the main control unit is provided with a communication interface. The communication interface is connected to a communication interface chip, and the main control unit communicates with the human-computer interaction unit through the communication interface chip.

[0011] Furthermore, the AC signal output unit includes a power amplifier U1. A first resistor R1 is connected to a potentiometer W1 and a capacitor C4 in sequence and then connected to the non-inverting input pin of the power amplifier U1. A first diode D1 is connected to a fourth resistor R4 and a fifth resistor R5 in sequence and then also connected to the non-inverting input pin of the power amplifier U1. A seventh resistor R7 is connected between the inverting input pin and the output pin of the power amplifier U1. The output pin of the power amplifier U1 is connected to the fifth capacitor C5 and then connected to the input terminal of the power parameter acquisition unit and the logic control unit.

[0012] Furthermore, the level detection unit includes an inverter, which is connected to the main control unit and the first device under test, respectively, and the input terminal of the inverter is connected to the output terminal of the logic control unit.

[0013] Furthermore, the logic control unit includes a relay matrix and a driver chip. The relay matrix is ​​connected to the driver chip. The input terminals of the relay matrix are respectively connected to the output terminals of the AC signal output unit, the second device under test, and the power parameter acquisition unit. The output terminals of the relay matrix are connected to the input terminals of the first device under test and the level detection unit.

[0014] Furthermore, the display unit includes a display, and the main control unit is provided with a serial port, through which the display is connected to the main control unit.

[0015] The beneficial effects of this utility model are:

[0016] 1) When a matching AC generator is not available, this utility model checks the correctness of the protection and control operation of the controller; when a matching AC generator is available, this utility model checks the correctness of the controller's motor power generation and protection and control operation.

[0017] 2) It has an automatic single-function test function, and the test data is displayed on the screen after the test is completed; the operation steps are displayed in sequence during the test, and the fault location can be judged based on the correctness of the operation step results; it adopts a modular design, and the modules use the standard RS485 communication protocol, and reserve hardware resources to facilitate debugging, maintenance and upgrades.

[0018] 3) All equipment components are directly connected using aviation plugs, ensuring stable connection and reliable operation; mature technology is adopted, ensuring reliable performance and stable operation; the human-machine interface is user-friendly, simple, and provides abundant prompts. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of an embodiment of the present utility model;

[0020] Figure 2 This is a circuit diagram of the power supply unit according to an embodiment of the present utility model;

[0021] Figure 3 This is a schematic diagram of a three-phase AC parameter measurement circuit according to an embodiment of the present invention;

[0022] Figure 4 This is a schematic diagram of the microcontroller circuit according to an embodiment of the present invention;

[0023] Figure 5 This is a schematic diagram of the fault code bus receiving and processing circuit according to an embodiment of the present invention;

[0024] Figure 6 This is a schematic diagram of the RS232 communication interface circuit according to an embodiment of the present invention;

[0025] Figure 7 This is a schematic diagram of the RS485 communication interface circuit according to an embodiment of the present invention;

[0026] Figure 8 This is a schematic diagram of the AC signal output circuit according to an embodiment of the present invention;

[0027] Figure 9 This is a schematic diagram of the level detection unit circuit according to an embodiment of the present invention;

[0028] Figure 10 This is a schematic diagram of a relay matrix circuit according to an embodiment of the present invention;

[0029] Figure 11 This is a schematic diagram of the panel layout according to an embodiment of the present utility model. Detailed Implementation

[0030] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0031] This utility model discloses a tester for an AC generator controller, aiming to overcome the aforementioned problems in the prior art. It provides a built-in DC power supply and fault code handling program. The AC power supply is generated through a combination of external and internal simulation. All power parameter settings are completed using a programmable control method. The entire unit is tested using a semi-automatic programmable control method to test the AC generator controller. Its main functions include verifying the normal operation of the special-type generator controller, the normal operation of the power generation control function, the normal operation of various fault protection functions, and checking the output 1553B fault codes.

[0032] For example, the AC generator controller tester uses 220×(1±10%)VAC, 50Hz AC power as its operating power supply. When an external 220×(1±10%)VAC, 50Hz AC power supply is connected, it is converted to 28×(1±10%)VDC DC power through the internal switching power supply of the tester, with a total power consumption of ≤100W. When supplying +28V DC power to the generator controller, the IM1253B module is used to collect the DC power supply parameters of the controller. The device generates a single-phase AC0V-5V, 400Hz adjustable AC signal. External AC power supplies include three-phase four-wire AC115V, 400Hz, three-phase four-wire AC60-200V, 400Hz programmable power supplies, and three-phase three-wire AC80V, 600Hz-1000Hz programmable power supplies. The aforementioned AC signals utilize the RN8302 AC parameter metering chip to acquire the current, voltage, and frequency of the AC power supply, displaying the acquired parameters on the LCD screen. The host computer communicates with the programmable AC power supply via RS485 to adjust and control the amplitude and frequency of the AC voltage input to the controller. During testing, the 1553B fault code output by the controller is acquired and received by the HI-1573 and EP4CE622C8N, and displayed on the LCD screen by the microcontroller. Internally, the AC generator controller tester uses a ULN2803 to control the relay matrix circuit, completing the step-by-step control of each signal. Input control uses Omron power relays. Automatic operation and logic are controlled by the STM32F103VET6 microcontroller software program. The controller output signal and relay feedback signal are judged and processed by the level detection unit. The entire testing process of the AC generator controller tester is controlled via the LCD screen, with the internal microprocessor performing semi-automatic testing.

[0033] For example, this utility model includes a power supply unit, a main control unit, a power control unit, a power parameter acquisition unit, an AC signal output unit, a level detection unit, a logic control unit, and a display unit, as shown in the schematic diagram below. Figure 1 As shown, the output terminal of the power supply unit is connected to the input terminals of the main control unit and the power control unit, respectively. The output terminal of the power control unit is connected to the input terminal of the power parameter acquisition unit. The output terminal of the main control unit is connected to the input terminal of the AC signal output unit. The output terminal of the AC signal output unit is connected to the input terminals of the power parameter acquisition unit and the logic control unit, respectively. The output terminal of the power parameter acquisition unit is connected to the input terminal of the logic control unit, respectively. The output terminal of the logic control unit is connected to the input terminals of the level detection unit and the first device under test (AC generator controller), respectively. The input terminal of the logic control unit is connected to the output terminal of the second device under test (AC generator). The main control unit is also connected to the level detection unit and the display unit, respectively. The level detection unit is also connected to the first device under test.

[0034] For example, the power supply unit includes a fuse, a main power switch, and a switching power supply. The input terminal of the fuse is connected to an external power source, and the output terminal of the fuse is connected to the input terminal of the main power switch. The output terminal of the main power switch is connected to the input terminal of the switching power supply, and the output terminal of the switching power supply is connected to the input terminals of the main control unit and the power control unit, respectively. The switching power supply also has a power indicator light connected to it. A circuit diagram of the power supply unit is shown below. Figure 2 As shown, considering the power consumption of the equipment and the device under test (DUT) and the actual working environment, and prioritizing ease of operation and use, the AC generator controller tester uses 220×(1±10%)VAC, 50Hz AC power as its operating power supply. When an external 220×(1±10%)VAC, 50Hz AC power supply is connected, the external power passes through a 3A fuse and the main power switch before entering the switching power supply, which converts it to 28VDC DC power, eliminating the need for an external 220VAC to 28VDC power adapter. The 3A fuse used is a common 5×20mm glass tube fuse, effectively protecting the AC generator controller tester from overcurrent and short-circuit faults. To indicate the power supply status of the AC generator controller tester and quickly locate fault points, a power indicator light is designed. This indicator light has a rated operating voltage of 28VDC, meeting the requirement for indicating the 28×(1±10%)VDC power supply status. Therefore, the main power switch adopts the LAS0-B1Y-22Z / G / 24VDC illuminated push-button switch. This rocker switch has a rated contact current of 10A, meeting the AC 3A control requirement. The indicator light has a rated operating voltage of 28VDC, meeting the requirement of indicating the power supply status at 28×(1±10%)VDC. The switching power supply selected is the Mean Well LRS-200-24 model, with an input voltage range of 85VAC~264VAC, a frequency range of 47Hz~63Hz, an output voltage adjustment range of 21.6VDC~28.8VDC, a rated output current of 4.5A, and overload, overvoltage, and overtemperature protection functions. By adjusting the potentiometer on the switching power supply, the output voltage can be adjusted to 28VDC, meeting the operating requirements of an input of 220×(1±10%)VAC, 50Hz, and an output of 28×(1±10%)VDC.

[0035] For example, the power control unit includes a relay, the input terminal of which is connected to the output terminal of the power supply unit, and the output terminal of the relay is connected to the input terminal of the power parameter acquisition unit. Since the device has multiple input power types, to ensure stable and safe input power, prevent damage to the AC generator controller tester due to incorrect input power connection caused by human error, and improve ease of use, the device uses Y50X-1419TJ2 / Y50X-1419ZK10 aviation connectors. This model of connector is stable, of excellent quality, and inexpensive. At the power interface, all power supplies are equipped with 3A fuses, and Omron relays LY3NJ and LY4NJ are used for main input control. This ensures that there is no internal power input when the main power switch is in the off state.

[0036] For example, the power parameter acquisition unit includes an AC / DC detection module and an AC voltage and current measurement chip. The input terminal of the AC / DC detection module is connected to the output terminal of the power control unit, the output terminal of the AC / DC detection module is connected to the input terminal of the AC voltage and current measurement chip, and the output terminal of the AC voltage and current measurement chip is connected to the input terminal of the logic control unit. A schematic diagram of the three-phase AC parameter measurement circuit is shown below. Figure 3 As shown, the power parameter acquisition unit is used to measure the output voltage and current of the AC generator controller tester. The output DC current and voltage use the mature IM1253B AC / DC detection module, while the AC voltage and current measurement chip uses the RN8302B. This chip is characterized by its multi-functionality, high precision, and low power consumption. It provides full-wave fundamental active and reactive power, with a dynamic range of 10000:1, a nonlinear error of less than 0.1%, and supports a wide voltage measurement range (measured from 1V to 230V). It can measure currents from microamps to hundreds of amperes, which fully meets the testing requirements. All acquired parameters are processed by the microcontroller and displayed in real time on the LCD screen, and the parameters are fed back to the main control unit.

[0037] For example, the main control unit includes a core controller and an FPGA. The core controller is connected to the FPGA, and the FPGA is connected to the power supply unit and the AC signal output unit. The main control unit performs the control and management of the entire system, such as controlling the AC waveform simulation unit to generate the required AC signals, measuring AC voltage and current, outputting display information, data communication, and controlling the test logic. A schematic diagram of the microcontroller circuit is shown below. Figure 4As shown, to ensure the AC generator controller tester has stable signal processing capabilities, the microcontroller uses a 32-bit high-performance ARM Cortex-M3 series MCU as the core controller, specifically the STM32F103VET6. This controller has abundant peripheral resources and stable, high-speed signal processing capabilities. For processing high-speed 1553 data, the main controller also uses an EP4CE622C8N FPGA. This FPGA has a maximum operating frequency of 400MHz, fully meeting the requirements of the AC generator controller tester for high-speed, multi-channel signal acquisition and output. The FPGA also includes peripheral circuitry, including a bus transceiver chip and a transformer. A schematic diagram of the fault code bus receiving and processing circuit is shown below. Figure 5 As shown, the FPGA chip is surrounded by an external circuit consisting of an HI-1573PSI bus transceiver chip and a PM-DB2725EX transformer.

[0038] For example, it also includes a human-computer interaction unit. The main control unit is provided with a communication interface, which is connected to a communication interface chip. The main control unit communicates with the human-computer interaction unit through the communication interface chip. A schematic diagram of the RS232 communication interface circuit is shown below. Figure 6 As shown, communication between the control unit and the human-machine interface unit can be achieved using an RS232 communication interface. The RS232 communication interface chip used is the ADM3251, which has an isolation circuit. A schematic diagram of the RS485 communication interface circuit is shown below. Figure 7 As shown, the communication between the control unit and the human-machine interface unit can also be achieved using RS485 communication. The RS485 communication interface chip is ADM2483, which has a maximum communication rate of 500kbps and allows up to 256 transceivers to be installed on the bus. It also features isolation circuitry.

[0039] For example, the AC signal output unit includes an AC signal output amplifier circuit, which includes a power amplifier U1. A first resistor R1 is connected in sequence to a potentiometer W1 and a capacitor C4, and then connected to the non-inverting input pin of the power amplifier U1. A first diode D1 is connected in sequence to a fourth resistor R4 and a fifth resistor R5, and then also connected to the non-inverting input pin of the power amplifier U1. A seventh resistor R7 is connected between the inverting input pin and the output pin of the power amplifier U1. The output pin of the power amplifier U1 is connected to the fifth capacitor C5 and then connected to the input terminal of the power parameter acquisition unit and the logic control unit. A schematic diagram of the AC signal output circuit is shown below. Figure 8 As shown, the AC signal output amplifier circuit mainly realizes the analog and voltage regulation of 0VAC-5VAC, 400Hz AC signals. The maximum amplitude is adjusted and regulated by the output of the LM1875T power amplifier, and the output amplitude and signal frequency are controlled by the microcontroller.

[0040] For example, the level detection unit includes an inverter, which is connected to both the main control unit and the first device under test. The input of the inverter is connected to the output of the logic control unit. A schematic diagram of the level detection unit circuit is shown below. Figure 9 As shown, the level detection unit is mainly used to determine the operating status of the internal controller of the equipment, provide feedback and timely judgment on whether the program control process is running normally, and handle abnormal situations in a timely manner. It also detects the detection signal output by the controller and displays it on the indicator light. All signals are shaped and filtered by a 74HC04 inverter before processing.

[0041] For example, the logic control unit includes a relay matrix and a driver chip. The relay matrix is ​​connected to the driver chip. The input terminals of the relay matrix are respectively connected to the output terminals of the AC signal output unit, the second device under test (DUT), and the power parameter acquisition unit. The output terminals of the relay matrix are connected to the input terminals of the first DUT and the level detection unit. A schematic diagram of the relay matrix circuit is shown below. Figure 10 As shown, the logic control unit mainly consists of a relay matrix. The relay group is driven by the ULN2803 driver chip, which can realize the control of multiple AC and DC signals. In order to improve the stability and reliability of the control, high-power Omron relays of model LY4NJ / LY3NJ / LY2NJ are selected.

[0042] For example, the display unit includes a monitor, and the main control unit is equipped with a serial port, through which the monitor is connected to the main control unit. The display unit uses a 16-bit true-color intelligent LCD touchscreen display. The OCM800480T700-2D (7-inch display) and OCM800480T500-2D (5-inch display) are high-performance, low-power, and easy-to-use 64K-color TFT true-color displays developed using a 32-bit ARM processor + FPGA dual-core control architecture. They can be directly connected to an MCU with a UART serial interface. Users only need to send commands to the terminal via the serial port to complete the corresponding operations. The monitor uses a 32-bit ARM processor + FPGA dual-core control architecture, has built-in 1GB Flash, supports image storage of any size, and fully meets testing requirements.

[0043] For example, the panel layout diagram is as follows Figure 11 As shown, for ease of operation, use, and maintenance, the generator controller tester's chassis adopts a standard 6U chassis design. The outer shell is gray, with external dimensions ≤427mm×260mm×360mm and an overall weight ≤10kg. It features good chemical corrosion resistance, portability, shock resistance, and moisture resistance. The equipment's panel is made of 5052 rust-resistant aluminum, with a powder-coated surface followed by silkscreen printing. This avoids issues such as lettering fading or becoming illegible after long-term use. The equipment panel is custom-designed and laid out according to ergonomics and functionality.

[0044] The above description is merely a preferred embodiment of this utility model. It should be understood that this utility model is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the concept described herein through the above teachings or related technologies or knowledge. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of this utility model should be protected within the scope of the appended claims.

Claims

1. An AC generator controller tester, characterized in that: The device includes a power supply unit, a main control unit, a power control unit, a power parameter acquisition unit, an AC signal output unit, a level detection unit, a logic control unit, and a display unit. The output of the power supply unit is connected to the input of the main control unit and the power control unit. The output of the power control unit is connected to the input of the power parameter acquisition unit. The output of the main control unit is connected to the input of the AC signal output unit. The output of the AC signal output unit is connected to the input of the power parameter acquisition unit and the logic control unit. The output of the power parameter acquisition unit is connected to the input of the logic control unit. The output of the logic control unit is connected to the level detection unit and the input of a first device under test (DUT). The input of the logic control unit is connected to the output of a second DUT. The main control unit is also connected to the level detection unit and the display unit. The level detection unit is also connected to the first DUT.

2. The AC generator controller tester according to claim 1, characterized in that: The power supply unit includes a fuse, a main power switch, and a switching power supply. The input terminal of the fuse is connected to an external power source, and the output terminal of the fuse is connected to the input terminal of the main power switch. The output terminal of the main power switch is connected to the input terminal of the switching power supply, and the output terminal of the switching power supply is connected to the input terminals of the main control unit and the power control unit, respectively. The switching power supply is also connected to a power indicator light.

3. The AC generator controller tester according to claim 1, characterized in that: The power control unit includes a relay, the input terminal of which is connected to the output terminal of the power unit, and the output terminal of which is connected to the input terminal of the power parameter acquisition unit.

4. The AC generator controller tester according to claim 1, characterized in that: The power parameter acquisition unit includes an AC / DC detection module and an AC voltage and current measurement chip. The input terminal of the AC / DC detection module is connected to the output terminal of the power control unit, the output terminal of the AC / DC detection module is connected to the input terminal of the AC voltage and current measurement chip, and the output terminal of the AC voltage and current measurement chip is connected to the input terminal of the logic control unit.

5. The AC generator controller tester according to claim 1, characterized in that: The main control unit includes a core controller and an FPGA. The core controller is connected to the FPGA, and the FPGA is connected to the power supply unit and the AC signal output unit. The FPGA is also equipped with peripheral circuits, including a bus transceiver chip and a transformer.

6. The AC generator controller tester according to claim 5, characterized in that: It also includes a human-computer interaction unit. The main control unit is provided with a communication interface, which is connected to a communication interface chip. The main control unit communicates with the human-computer interaction unit through the communication interface chip.

7. The AC generator controller tester according to claim 1, characterized in that: The AC signal output unit includes a power amplifier U1. A first resistor R1 is connected to a potentiometer W1 and a capacitor C4 in sequence and then connected to the non-inverting input pin of the power amplifier U1. A first diode D1 is connected to a fourth resistor R4 and a fifth resistor R5 in sequence and then connected to the non-inverting input pin of the power amplifier U1. A seventh resistor R7 is connected between the inverting input pin and the output pin of the power amplifier U1. The output pin of the power amplifier U1 is connected to the fifth capacitor C5 and then connected to the input terminal of the power parameter acquisition unit and the logic control unit.

8. The AC generator controller tester according to claim 1, characterized in that: The level detection unit includes an inverter, which is connected to the main control unit and the first device under test, respectively. The input terminal of the inverter is connected to the output terminal of the logic control unit.

9. The AC generator controller tester according to claim 1, characterized in that: The logic control unit includes a relay matrix and a driver chip. The relay matrix is ​​connected to the driver chip. The input terminals of the relay matrix are respectively connected to the output terminals of the AC signal output unit, the second device under test, and the power parameter acquisition unit. The output terminals of the relay matrix are connected to the input terminals of the first device under test and the level detection unit.

10. An AC generator controller tester according to claim 1, characterized in that: The display unit includes a display, and the main control unit is equipped with a serial port, through which the display is connected to the main control unit.

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