Expansion device for output port of insulation tester applied to insulation test of collector ring

Abstract

The utility model discloses an expansion device of an insulation tester output port for a collector ring insulation test, and relates to the field of collector ring insulation test. The expansion device comprises a channel sorting module and a customized adaptation box; the channel sorting module and the customized adapter box are respectively arranged in the two plastic junction boxes; the channel sorting module and the customized adapter box are connected with each other through a test expansion bus; the channel sorting module comprises a programmable controller, a switching value output module, a 220VAC power supply, an insulation tester positive and negative pole input port, a relay group and a test expansion bus; the customized adapter box comprises a test point, a collector ring outgoing line, an expansion bus input port and a wiring terminal. According to the invention, the output port of the insulation tester is divided into multiple paths through the expansion device, so that the insulation performance between different rings of the collector ring and the insulation performance between the rings and the shell can be inspected; according to the invention, collector rings of different models can be rapidly and accurately tested.

Description

Technical Field

[0001] This invention relates to the field of insulation testing of customized bus rings, specifically to an expansion device for the output port of an insulation tester. Background Technology

[0002] In terms of existing bus ring insulation testing, manual testing is the main method. During the testing process, too many channels need to be tested, which can easily lead to missed tests and incorrect tests. In addition, it is not easy to track and record the insulation resistance of the same product at different stages during manual testing, which is not conducive to the design update and improvement of bus rings.

[0003] The purpose of this invention is to address the issue that while this device relies heavily on existing PLCs and relays, it can also be quickly deployed to suit various environments and conditions, enabling it to perform insulation tests on different busbars. The invention aims to examine the insulation between busbars and the insulation between the busbar and the housing. By using this device, and building upon existing insulation resistance testers with communication capabilities, along with customized software on a host computer, the device can be controlled to achieve rapid testing, reduce manual labor, record the insulation of all loops, facilitate macroscopic comparative data analysis, and promote product structure upgrades. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides an expansion device for the output port of an insulation tester used for bus ring insulation testing, relating to the field of bus ring insulation testing. The expansion device includes a channel sorting module and a custom adapter box; the channel sorting module and the custom adapter box are respectively housed in two plastic junction boxes; the channel sorting module and the custom adapter box are interconnected via a test expansion bus; the channel sorting module includes a programmable controller, a switch output module, a 220VAC power supply, positive and negative input ports of the insulation tester, a relay group, and a test expansion bus; the custom adapter box includes test points, bus ring leads, expansion bus input ports, and terminals. This invention divides the output port of the insulation tester into multiple channels through the expansion device, enabling the examination of insulation performance between different bus rings and insulation performance between the ring and the housing; this invention can quickly and accurately test different types of bus rings.

[0005] The specific technical solution adopted in this invention is as follows:

[0006] An expansion device for the output port of an insulation tester used for bus ring insulation testing, the expansion device including a channel sorting module 1 and a custom adapter box 7; the channel sorting module 1 and the custom adapter box 7 are interconnected via a test expansion bus 6.

[0007] The channel sorting module 1 includes a programmable controller 11, a digital output module 12, a 220VAC power supply 3, positive and negative input ports 4 of an insulation tester, a relay group 5, a test expansion bus 6, and a communication line 2. The 220VAC power supply 3 inputs electrical power to the programmable controller 11 and the digital output module 12. The digital output module 12 is an expansion module of the programmable controller 11, and the digital output module 12 is connected to the programmable controller 11 via a ribbon cable. The programmable controller 11 is used to control the expanded test points of the expansion device. The channel sorting module 1 is installed in a plastic junction box. The junction box of the channel sorting module 1 has mounting holes of a size corresponding to the positive and negative input ports 4 of the insulation tester. The positive and negative input ports 4 of the insulation tester are installed on the channel sorting module. The junction box of component 1 has mounting holes; the positive and negative terminals of the insulation tester's positive and negative input ports 4 are cross-connected to the contacts of relay group 5; relay group 5 includes relay group A and relay group B, which are arranged side by side; the switch output module 12 includes two output points, which are respectively connected to the coils of relay group A and relay group B, and are used to control relay group A and relay group B; the test expansion bus 6 consists of two bundles of cables with different polarities, and the polarity is not fixed; the main contacts of relay group A are connected to one bundle of cables of test expansion bus 6, and the main contacts of relay group B are connected to the other bundle of cables of test expansion bus 6; one end of the communication line 2 is connected to the programmable controller 11, and the other end is connected to the host computer, and is used to receive control commands from the host computer.

[0008] The customized adapter box 7 includes test points 8, bus ring leads 10, expansion bus input ports 13, and terminals 14. Test points 8 consist of multiple small holes spaced 30-40mm apart, arranged in a matrix on the panel of the customized adapter box 7. The customized adapter box 7 is installed inside a plastic junction box. The junction box of the customized adapter box 7 has mounting holes of a size matching the expansion bus input ports 13, which are installed within these holes. The bus ring leads 10 and expansion bus input ports 13 are connected via terminals 14, as are the expansion bus input ports 13 and test points 8. The other end of the test expansion bus 6 is connected to the expansion bus input port 13. The bus ring 9 is connected to the terminals 14 via the bus ring leads 10.

[0009] Furthermore, the customized adapter box 7 can be either an ABS terminal box or a PC junction box.

[0010] Furthermore, a quick-connect socket is installed on the panel of the customized adapter box 7. The quick-connect socket is used to lead the wiring terminal 14 inside the customized adapter box 7 to the test point 8. When the number of loops of the bus ring 9 is n, the number of terminals of the wiring terminal 14 is n+1. The number of test points 8 is equal to the number of terminals of the wiring terminal 14, and the number of test points 8 is n+1.

[0011] Furthermore, the relay group 5 is of PLC output type, and the relay group 5 is selected as a DC relay; the magnetic poles of the DC relay coil are fixed, and the contact is stable.

[0012] Furthermore, both the extension line bus 6 and the bus ring lead 10 are cables, which are made of polyvinyl chloride with single-layer insulation, and have an insulation class greater than 500V and a cross-sectional area of ​​0.75mm². 2 The flexible wire.

[0013] Furthermore, an adapter socket is provided between the channel sorting module 1 and the customized adapter box 7 for connecting the channel sorting module 1 and the customized adapter box 7; the test expansion bus 6 contains a plug, and the channel sorting module 1 connects to the quick-connect socket on the customized adapter box 7 through the plug on the test expansion bus 6.

[0014] Furthermore, the wiring terminals 14 are arranged parallel to the long axis of the internal space of the adapter box 7; the odd-numbered terminals of the wiring terminals 14 are connected to one bundle of cables in the test expansion bus 6, and the even-numbered terminals of the wiring terminals 14 are connected to another bundle of cables in the test expansion bus 6.

[0015] Furthermore, the odd-numbered loops in the bus ring 9 are connected to the odd-numbered terminals in the terminal block 14 via the bus ring lead wire 10.

[0016] The technical effects of this invention are as follows:

[0017] The expansion device of this invention is used for safety and insulation testing between bus rings. This invention divides the output port of the insulation tester into multiple channels via the expansion device, enabling the examination of insulation performance between different bus rings and between the ring and the housing. Using the expansion device of this invention, different models of bus rings can be tested quickly and accurately. The expansion device of this invention is used for data statistics of insulation tests at different stages of customized bus rings and for data comparison of different individuals of the same model. The host computer can control the device and the insulation tester to automatically test the insulation data at various locations between bus rings. Attached Figure Description

[0018] Figure 1 This is a test connection diagram of the output port expansion device of the insulation tester of the present invention;

[0019] Figure 2 This is a schematic diagram of the output port expansion device of the insulation tester of the present invention.

[0020] In the diagram: 1 is the channel sorting module, 11 is the programmable controller, 12 is the switch output module, 2 is the communication line, 3 is the 220VAC power supply, 4 is the positive and negative input ports of the insulation tester, 5 is the relay group, 6 is the test expansion bus, 7 is the custom adapter box, 8 is the test point, 9 is the bus ring, 10 is the bus ring lead, 13 is the expansion bus input port, and 14 is the terminal block. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] like Figure 1 As shown, an expansion device for the output port of an insulation tester used for bus ring insulation testing is provided. The expansion device includes a channel sorting module 1 and a custom adapter box 7. The channel sorting module 1 and the custom adapter box 7 are interconnected via a test expansion bus 6.

[0023] The channel sorting module 1 includes a programmable controller 11, a digital output module 12, a 220VAC power supply 3, positive and negative input ports 4 of an insulation tester, a relay group 5, a test expansion bus 6, and a communication line 2. The 220VAC power supply 3 inputs electrical power to the programmable controller 11 and the digital output module 12. The digital output module 12 is an expansion module of the programmable controller 11, and the digital output module 12 is connected to the programmable controller 11 via a ribbon cable. The programmable controller 11 is used to control the expanded test points of the expansion device. The channel sorting module 1 is installed in a plastic junction box. The junction box of the channel sorting module 1 has mounting holes of a size corresponding to the positive and negative input ports 4 of the insulation tester. The positive and negative input ports 4 of the insulation tester are installed in the channel sorting module. Inside the mounting holes of the junction box of module 1; the positive and negative terminals of the positive and negative input ports 4 of the insulation tester are respectively cross-connected to the contacts of relay group 5; relay group 5 includes relay group A and relay group B, which are arranged side by side; the switch output module 12 includes two output points, which are respectively connected to the coils of relay group A and relay group B, and are used to control relay group A and relay group B; the test expansion bus 6 consists of two buses of different polarities, and the polarity is not fixed; the main contacts of relay group A are connected to one of the bundles of test expansion bus 6, and the main contacts of relay group B are connected to the other bundle of test expansion bus 6; one end of the communication line 2 is connected to the programmable controller 11, and the other end is connected to the host computer, and is used to receive control commands from the host computer.

[0024] The custom adapter box 7 includes test points 8, bus ring leads 10, expansion bus input ports 13, and terminal blocks 14. Test points 8 consist of multiple small holes spaced 30-40mm apart, arranged in a matrix on the panel of the custom adapter box 7. The custom adapter box 7 is housed in a plastic junction box, which has mounting holes of a size matching the expansion bus input ports 13. The expansion bus input ports 13 are installed within these mounting holes. The bus ring leads 10 and expansion bus input ports 13 are connected via terminal blocks 14, as are the expansion bus input ports 13 and test points 8. The other end of the test expansion bus 6 is connected to the expansion bus input port 13. The bus ring 9 is connected to the terminal blocks 14 via the bus ring leads 10.

[0025] like Figure 2 As shown, when the test loop of the bus ring 9 is insulated from the housing of the bus ring 9, the expansion port connected to the test loop of the bus ring 7 is connected as the positive terminal through a sorting relay, and the housing is the negative terminal. On the expansion ports of the two sets of relays A and B, any set of relays can be selected and connected to the housing.

[0026] Furthermore, the customized adapter box 7 can be either an ABS terminal box or a PC junction box.

[0027] Furthermore, a quick-connect socket is installed on the panel of the customized adapter box 7. The quick-connect socket is used to lead the wiring terminal 14 inside the customized adapter box 7 to the test point 8. During the test, the test point 8 first alarms to confirm. When the number of loops of the bus ring 9 is n, the number of terminals of the wiring terminal 14 is n+1. The number of test points 8 is equal to the number of terminals of the wiring terminal 14, and the number of test points 8 is n+1. The wiring terminal 14 is used to connect the output of the bus ring 9.

[0028] Furthermore, the relay group 5 is of PLC output type, and the relay group 5 is selected as a DC relay; the magnetic poles of the DC relay coil are fixed, and the contact is stable.

[0029] Furthermore, the relay group 5 includes a socket, and both the socket and the terminal block 14 of the relay group 5 are selected as spring terminals.

[0030] Furthermore, both the extension line bus 6 and the bus ring lead 10 are cables, which are made of polyvinyl chloride with single-layer insulation, and have an insulation class greater than 500V and a cross-sectional area of ​​0.75mm². 2 The flexible wire.

[0031] Furthermore, an adapter socket is provided between the channel sorting module 1 and the customized adapter box 7 for connecting the channel sorting module 1 and the customized adapter box 7; the test expansion bus 6 contains a plug, and the channel sorting module 1 connects to the quick-connect socket on the customized adapter box 7 through the plug on the test expansion bus 6.

[0032] Furthermore, the wiring terminals 14 are arranged parallel to the long axis of the internal space of the adapter box 7; the wiring terminals 14 are arranged in an odd-even sequence; the test expansion buses 6 are connected to the wiring terminals 14 in an odd-even sequence, with the odd-numbered wiring terminals connected to one bundle of test expansion buses 6 and the even-numbered wiring terminals connected to the other bundle of test expansion buses 6.

[0033] Furthermore, the bus ring lead 10 is connected to the terminal 14 in sequence according to the internal arrangement of the bus ring 9, that is, the odd-numbered loops in the bus ring 9 are connected to the odd-numbered terminals in the terminal 14.

[0034] During use, the device can be set to multiple modes for rapid detection:

[0035] Mode 1: Since the bus loops to be tested are arranged sequentially at intervals on two polarity extension points, all NO contacts can be closed simultaneously. If there is an abnormality, test sequentially. If not, connect one polarity extension point to the positive terminal and the other polarity extension point to the negative terminal. Close all loops on the positive terminal and test the loops on that polarity extension point to ground. If there is an abnormality, test sequentially. If not, change the polarity of the extension point and test all remaining loops to ground. If there is an abnormality, test sequentially. If not, only three tests are needed.

[0036] Mode 2: Closing one point on one polarity extension point and closing all points on the other polarity extension point allows for testing the insulation of one loop to other loops as much as possible; closing one point on one polarity extension point and closing the housing on the other polarity extension point allows for testing the loop's connection to ground.

[0037] Mode 3: Closing one point on one polarity extension point and closing the adjacent loop on the other polarity extension point, and repeating this process, can test the insulation between all nearby loops. The insulation between nearby loops in the bus ring can directly reflect the specific loop insulation condition of the bus ring. Closing one point on one polarity extension point and closing the shell on the other polarity extension point, and repeating this process, can test the grounding condition of that loop.

[0038] For insulation resistance testers with communication capabilities, the output ports of the insulation tester can be expanded by controlling intermediate relays through a programmable controller, and the bus ring can be connected to the device more quickly through a customized adapter box.

[0039] The device consists of a channel sorting module and a custom adapter box. The channel sorting module includes a programmable controller and a relay, and has external power input interface, communication interface, output port wiring of insulation resistance tester, and expansion harness. The custom adapter box has external expansion connection socket, bus ring connection hole, and panel self-test point.

[0040] The following are just the specific choices and functions of each component type.

[0041] Among them, the insulation resistance tester with communication function is the execution mechanism for each test.

[0042] The programmable controller in this device can be selected as a programmable controller with a relay output port and a DC input power supply. Depending on the actual needs, a programmable controller with multiple expansion channels can be selected.

[0043] Providing a separate DC power supply for the programmable controller can reduce the impact of external circuits on the device.

[0044] In this method, the programmable controller and its expansion modules are divided into two parts, which control two queues of relays respectively.

[0045] When selecting a relay, DC relays should be preferred because AC relays require stable connection of their main contacts due to the presence of choke coils and the frequency cycle of AC power.

[0046] The main contacts of the relay are directly connected to the output port of the insulation tester. In order to prevent the insulation tester from damaging the programmable controller and the relay and affecting the test results, a relay with a main contact and coil withstand voltage rating higher than the operating voltage of the device should be selected.

[0047] The relay can be selected as 1NO / 1CO to energize and test one test loop. If necessary, 2NO / 2CO can be selected to energize and test two parallel test loops at the same time, so as to test two identical bus loops at the same time. Once an alarm is triggered at this point, manual verification is required to determine which product is abnormal.

[0048] Among them, spring-type terminals are preferred for relay sockets. Screw terminals are more susceptible to damage because the screw is exposed on the outside, which can affect the performance of the device. Spring connections have the connecting wires inside, which are less affected and will remain a reliable contact over time. Screw connections are more prone to loosening over time.

[0049] The main factors that determine the insulation voltage that the device can withstand are: the withstand voltage rating of the relay main contacts and coil, the withstand voltage rating from the output port of the insulation tester to the outer casing of the device's end adapter box, and the withstand voltage rating between the positive and negative extension paths from the output port of the insulation tester.

[0050] The custom adapter box is designed to quickly connect the bus ring's lead wires, with the internal terminals arranged in two rows, to the device.

[0051] Among them, the customized adapter box can be used for common engineering applications such as ABS terminal boxes and PC junction boxes.

[0052] The size of the customized adapter box is determined by the number of points to be tested. The internal wiring terminals are divided into two categories: odd and even. Each category is an extension of one end of the tester's output port. This is achieved by selecting wiring terminals with insulation levels that meet the requirements and by arranging them reasonably.

[0053] Among them, spring-type terminals should be selected for the wiring terminals in the customized adapter box. Screw terminals are more susceptible to damage because the screws are exposed on the outside, which can affect the performance of the device. Spring connections are internal and less susceptible to damage. Over time, they will remain secure. Screw connections are more prone to loosening over time.

[0054] Among them, the customized adapter box can install quick-connect sockets, such as banana sockets, on the panel as needed, and bring out the internal test points. When a test alarm is triggered at a certain point, it can be confirmed through the test points on the adapter box panel.

[0055] When the test loop of the customized adapter box is used to insulate the housing, due to the principle of insulation testing, the expansion port connected to the test loop should be connected as the positive terminal through the sorting relay, and the housing should be the negative terminal. Therefore, one of the expansion ports of the two rows of relay groups should be reserved to connect to the housing.

[0056] The insulation class of the internal wiring terminal 14 of the custom adapter box 7 should be higher than the insulation voltage setting value of the device.

[0057] The insulation class of the test expansion bus 6 should be higher than the insulation voltage setting value of the device.

[0058] The dielectric (air) withstand voltage between the coil and relay contacts of relay group 5 should be higher than the insulation voltage setting value of the device.

Claims

1. An extension device applied to the output port of an insulation tester for busbar insulation test, characterized in that, The expansion device includes a channel sorting module and a custom adapter box; the channel sorting module and the custom adapter box are interconnected via a test expansion bus.

2. The extension for the output of an insulation tester of claim 1, wherein, The channel sorting module includes a programmable controller (PLC), a digital output module, a 220VAC power supply, positive and negative input ports for an insulation tester, a relay group, a test expansion bus, and communication lines. The 220VAC power supply provides electrical power to the PLC and the digital output module. The digital output module is an expansion module of the PLC, connected to the PLC via a ribbon cable. The PLC controls the expanded test points of the expansion device. The channel sorting module is housed in a plastic junction box, which has mounting holes corresponding to the size of the positive and negative input ports of the insulation tester. The port is installed in the mounting hole of the junction box of the channel sorting module; the positive and negative terminals of the positive and negative input ports of the insulation tester are respectively cross-connected to the contacts of the relay group; the relay group includes relay group A and relay group B, which are arranged side by side; the switch output module includes two output points, which are respectively connected to the coils of relay group A and relay group B, and are used to control relay group A and relay group B; the test expansion bus consists of two bundles of cables with different polarities, and the polarity is not fixed; the main contacts of relay group A are connected to one bundle of cables of the test expansion bus, and the main contacts of relay group B are connected to the other bundle of cables of the test expansion bus; One end of the communication line is connected to the programmable controller, and the other end is connected to the host computer to receive control commands from the host computer.

3. The extension for the output of an insulation tester of claim 1, wherein, The customized adapter box includes test points, bus ring leads, an expansion bus input port, and terminal blocks. The test points are multiple small holes spaced 30-40mm apart, arranged in a matrix on the adapter box panel. The adapter box is housed in a plastic junction box, which has mounting holes of a size matching the expansion bus input port. The expansion bus input port is installed within these mounting holes. The bus ring leads and the expansion bus input port are connected via terminal blocks, as are the expansion bus input port and the test points. The other end of the expansion bus is connected to the expansion bus input port. The bus ring is connected to the terminal block via a bus ring lead wire.

4. The extension for the output of an insulation tester of claim 1, wherein, The customized adapter box can be either an ABS terminal box or a PC junction box.

5. The extension for the output of an insulation tester of claim 3, wherein, The panel of the customized adapter box is equipped with a quick-connect socket, which is used to lead the wiring terminals inside the customized adapter box to the test points; when the number of loops of the bus ring is n, the number of terminals of the wiring terminal is n+1; the number of test points is equal to the number of terminals of the wiring terminal, and the number of test points is n+1.

6. The extension for the output of an insulation tester of claim 2, wherein, The relay group is of PLC output type, and the relay group is selected as DC relays; The test expansion bus is a cable, which is made of polyvinyl chloride with single-layer insulation and is a flexible wire with an insulation class greater than 500V and a cross-sectional area of ​​0.75mm².

7. The extension for the output of an insulation tester of claim 3, wherein, The busbar lead is a cable, which is made of polyvinyl chloride with a single layer of insulation. The cable is a flexible wire with an insulation class greater than 500V and a cross-sectional area of ​​0.75mm².

8. The extension for the output of an insulation tester of claim 1, wherein, An adapter socket is provided between the channel sorting module and the custom adapter box to connect the two; the test expansion bus contains a plug, and the channel sorting module connects to the quick-connect socket on the custom adapter box through the plug on the test expansion bus.

9. The extension for the output of an insulation tester of claim 3, wherein, The wiring terminals are arranged parallel to the long axis of the internal space of the adapter box; the odd-numbered terminals in the wiring terminals are connected to one bundle of cables in the test expansion bus, and the even-numbered terminals in the wiring terminals are connected to another bundle of cables in the test expansion bus.

10. The extension for the output of an insulation tester of claim 3, wherein, The odd-numbered loops in the bus ring are connected to the odd-numbered terminals in the terminal block via bus ring leads.

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