An automatic testing device

Abstract

This invention provides an automatic testing device to solve the problems of low testing efficiency and cumbersome manual operation in existing technologies. It includes: an industrial control computer connected to a microcomputer-based test and protection device, a switch input detection module, and a relay output signal generator; the microcomputer-based test and protection device, whose outputs are connected to the analog input interfaces of the device under test; the switch input detection module, whose outputs are connected to the switch output terminals of the device under test; the relay output signal generator, whose outputs are connected to the switch input terminals of the device under test; a barcode input module, a touch screen, indicator lights, and an alarm, all mounted on the device panel and connected to the industrial control computer; and a network communication module connected to the industrial control computer, including at least two network interfaces, one for connecting to the time synchronization interface of the device under test and the other for connecting to the MES system. This solution achieves automatic interface docking and automatic testing, significantly improving efficiency, ensuring safety and reliability, and reducing the risk of manual intervention and errors.

Description

Technical Field

[0001] This utility model relates to the field of electronic information technology, and in particular to an automatic testing device. Background Technology

[0002] Currently, the testing of relay protection devices mainly relies on manual operation. Testers must manually connect test leads, adjust the current and voltage parameters of the microcomputer protection tester, and check the operation of each switch, resulting in a cumbersome, time-consuming, and inefficient testing process. Furthermore, the recording and traceability of test results depend on manual transcription, which is prone to data errors and omissions, failing to meet the power system's requirements for testing automation and data traceability. Therefore, there is an urgent need for a testing device that can automatically complete parameter setting, signal output, switch detection, and data management to improve testing efficiency and reliability. Summary of the Invention

[0003] Based on the above background, in order to overcome the problems of low testing efficiency, cumbersome manual operation and inconvenient data management, the present invention provides an automatic testing device, which mainly includes: an industrial control computer, connected to a microcomputer test and protection instrument, a switch input detection module and a relay output signal generator;

[0004] The microcomputer-based test and protection instrument has its output terminals connected to the analog input interfaces of the device under test.

[0005] A digital input detection module, whose output is connected to the digital output terminal of the device under test;

[0006] A relay output signal generator, the output of which is connected to the digital input terminal of the device under test;

[0007] The barcode input module, touch screen, indicator lights, and alarms on the device panel are all connected to the industrial computer.

[0008] The network communication module connects to the industrial control computer and includes at least two network interfaces, which are respectively connected to the time synchronization interface of the device under test and the MES system.

[0009] Preferably, the device panel also includes: an interface test panel, the interface test panel including multiple wiring terminals, and the microcomputer protection tester including a first microcomputer protection tester and a second microcomputer protection tester.

[0010] Preferably, the output terminal of the first microcomputer protection tester is connected to the interface test panel via a multi-core shielded cable. The interface test panel is connected to the output terminal of the first microcomputer protection tester for the protection current output interface and the measurement current output interface of the device under test.

[0011] The output of the second microcomputer protection tester is connected to the interface test panel via a multi-core shielded cable. The interface test panel is connected to the output of the second microcomputer protection tester to the measured voltage output interface and the zero-sequence voltage output interface of the device under test.

[0012] Preferably, the relay output signal generator includes a relay and a drive circuit, and its output terminal is connected to the switch input terminal of the device under test through relay contacts.

[0013] Preferably, the first microcomputer protection tester, the second microcomputer protection tester, and the relay output signal generator are connected to the industrial control computer via RS485.

[0014] Preferably, the device under test is a relay protection device or a microprocessor protection device of the power system.

[0015] Preferably, the switch input detection module is connected to the corresponding terminal block on the interface test panel, and the optocoupler isolation circuit and signal conditioning circuit are connected sequentially through the terminal block, and then connected to the digital input interface of the industrial control computer via RS485.

[0016] Preferably, the automatic testing device also includes: an indicator light group installed on the top of the cabinet; multiple cabinet doors on the front of the cabinet; an industrial control computer installed in the upper cabinet space; a display screen, a barcode input module, a touch screen, and an alarm installed on the upper cabinet doors, wherein the display screen is used to output the screen display content of the device under test; an automatic connection unit for the device under test installed in the middle cabinet space; safety light curtains installed on both sides of the cabinet doors; and a first microcomputer protection tester and a second microcomputer protection tester installed in the lower cabinet space.

[0017] Preferably, the automatic connection unit for the device under test includes: a fixture frame, a lifting mechanism, and an interface test panel mounting plate; the fixture frame is fixed to the central cabinet, and a set of device under test limiters and a set of device under test screen limiters are provided on the upper surface of the fixture frame; a guide post is fixedly connected to each of the four corners of the fixture frame; the bottom of the lifting mechanism is fixed to the fixture frame, and the lifting slider is fixedly connected to the interface test panel mounting plate; a sleeve is fixedly connected to each of the four corners of the interface test panel mounting plate, corresponding to the guide posts; the lifting mechanism includes a pair of lead screws, which are rotatably connected to the fixture frame through bearings; a servo motor mounting bracket is fixedly connected to the bottom of the fixture frame, and the servo motor is fixed to the servo motor mounting bracket. On the mounting bracket, the output end is fixedly connected to the bottom of one of the lead screws. The lifting slider is mounted on the lead screw. The upper part of a pair of lead screws is connected to a fixed angle iron through a bearing. The fixed angle iron is fixedly connected to the inner wall of the middle cabinet. A gear is fixedly sleeved on the lead screw below the fixed angle iron. The two gears on the pair of lead screws are meshed with a synchronous belt. The synchronous belt has teeth on its inner side. A baffle is fixed on the lead screw below the synchronous belt. The interface test panel mounting plate is provided with a camera shooting avoidance hole. The camera shooting avoidance hole is located above the screen of the device under test. A camera is mounted on the interface test panel mounting plate, facing the screen of the device under test. An interface test panel is mounted below the interface test panel mounting plate at the position corresponding to the device under test.

[0018] Ideally, the servo motor, camera, and safety light curtain are all connected to the industrial electromechanical system, and the camera and display screen are connected via an HDMI cable.

[0019] The beneficial effects of this utility model include: significantly improving testing efficiency and shortening testing time through centralized control by an industrial control computer and automated testing processes; effectively enhancing the system's anti-interference capability by adopting optocoupler isolation and shielded cable design, ensuring accurate and reliable test data; integrating barcode scanning and MES system docking functions to realize automatic recording and full traceability of test data; and reducing human error through standardized testing processes, improving the consistency and reliability of test results.

[0020] The automated lifting mechanism enables precise docking of test interfaces, completely replacing manual wiring operations, improving testing efficiency, and eliminating the risk of wiring errors. A servo motor-driven lifting system, combined with a guide column structure, ensures stable interface connections. An industrial computer centrally controls the entire testing process, while a camera captures real-time data from the equipment screen, forming a closed-loop "mechanical-electrical-vision" inspection system. The modular cabinet integrates safety light curtain protection and a layered layout, ensuring operational safety while optimizing space utilization. This design boasts advantages such as high automation, excellent safety, and strong scalability, significantly reducing the technical requirements for operators. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the module connections of an automated testing device in a preferred embodiment;

[0022] Figure 2 This is a schematic diagram of the structure of an automatic testing device according to a preferred embodiment;

[0023] Figure 3 This is a first three-dimensional structural schematic diagram of the automatic connection unit of the device under test according to a preferred embodiment;

[0024] Figure 4 This is a second three-dimensional structural schematic diagram and a partially enlarged structural schematic diagram of the automatic connection unit of the device under test according to a preferred embodiment. Detailed Implementation

[0025] In view of this, the present invention provides an automatic testing device, and the preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

[0026] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, 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.

[0027] In addition, it should be understood that in the description of the embodiments of this utility model, the words "first" and "second" are used only for the purpose of distinguishing descriptions and should not be construed as indicating or implying relative importance, nor should they be construed as indicating or implying order.

[0028] See Figure 1 As shown, an automatic testing device includes: an industrial control computer 1, connected to a microcomputer test and protection device, a digital input detection module 6, and a relay output signal generator 4; the microcomputer test and protection device, whose output terminals are respectively connected to the analog input interface of the device under test (DUT) A; the digital input detection module 6, whose output terminal is connected to the digital output terminal of DUT A; the relay output signal generator 4, whose output terminal is connected to the digital input terminal of DUT A; a barcode input module, a touch screen 9, an indicator light group 11, and an alarm 10, all mounted on the device panel, are connected to the industrial control computer 1; and a network communication module 7, connected to the industrial control computer 1, including at least two network interfaces, respectively connected to the time synchronization interface of DUT A and the MES system.

[0029] Specifically, the device adopts a modular design. The internal casing integrates a microprocessor-based test and protection instrument, a switch input detection module 6, a relay output signal generator 4, and a network communication module 7. An interface test panel 5 is mounted on the device panel, and the interface test panel 5 includes multiple wiring terminals. The microprocessor-based protection tester includes a first microprocessor-based protection tester 2 and a second microprocessor-based protection tester 3. The device under test, A, is a relay protection device or a microprocessor-based protection device for a power system.

[0030] The interface test panel 5 includes at least 7 interfaces, including: Interface #1: connected to the protection current input interface of the device under test (DUT) A; Interface #2: connected to the measurement current input interface of DUT A; Interface #3: connected to the measurement voltage input interface of DUT A; Interface #4: connected to the zero-sequence voltage input interface; Interface #5: connected to the digital output terminal of DUT A; Interface #6: connected to the digital input terminal of DUT A; and Interface #7: connected to the network interface of DUT A.

[0031] The device panel integrates a barcode input module 8 for barcode input of the device under test A. The test results are associated with the barcode, ensuring the traceability of the device under test A.

[0032] The output of the first microcomputer protection tester 2 is connected to the interface test panel 5 via a multi-core shielded cable. The interface test panel 5 is connected to the protection current output interface and the measurement current output interface of the device under test A via interface #1 and interface #2, respectively, to provide protection current and measurement current to the device under test A. The output of the second microcomputer protection tester 3 is connected to the interface test panel 5 via a multi-core shielded cable. The interface test panel 5 is connected to the measurement voltage output interface and the zero-sequence voltage output interface of the device under test A via interface #3 and interface #4, to provide measurement voltage and zero-sequence voltage to the device under test A.

[0033] The industrial control computer 1 controls the first microcomputer protection tester 2 and / or the second microcomputer protection tester 3 to trigger the corresponding test condition signals. For example, when performing a protection current test, the industrial control computer 1 controls the first microcomputer protection tester 2 to output a 20A short-circuit fault current. When the device under test A receives and collects the short-circuit fault current, it triggers its own protection action and sends a trip signal.

[0034] The digital input detection module 6 is used to detect the output signals of the device under test (DUT) A. This module connects to the corresponding terminals on the interface test panel 5, and sequentially connects to the optocoupler isolation circuit and the signal conditioning circuit through the terminals. It is then connected to the digital input interface of the industrial computer 1 via RS485. Output signal detection occurs when the DUT A sends a high or low level signal, which is received by the digital input detection module 6, processed by the circuit, and then sent to the industrial computer 1. The industrial computer 1 verifies whether the DUT A has correctly identified the signal and sends the corresponding correct command. If the command from the DUT A is verified to be correct, the next step is performed.

[0035] The relay output signal generator 4 includes a relay and a drive circuit. Its output terminal is connected to interface #6 via relay contacts and then to the switch input terminal of the device under test (DUT) A. Under input signal control, the industrial control computer 1 sends a relay action command to control the corresponding relay to open or close. The first microcomputer protection tester 2, the second microcomputer protection tester 3, and the relay output signal generator 4 are connected to the industrial control computer 1 via RS485. The relay opening or closing signal is sent through interface #6 to the switch input interface of the connected DUT A, controlling the circuit breaker of DUT A to perform the corresponding opening or closing action.

[0036] The following specific embodiment illustrates the automatic testing process executed by the automatic testing device.

[0037] Step 1: Simulate fault output

[0038] Industrial computer 1 sends a command to the microcomputer protection tester via RS485, requesting it to output a fault current of 5A and maintain normal voltage;

[0039] The microcomputer protection tester actually outputs a current of 5A and a normal voltage.

[0040] Step Two: Decision-Making for Device A (Protection Device)

[0041] The protection device continuously samples and monitors in real time. When the current value is 5A and the voltage value is normal, the protection device performs overcurrent protection logic judgment, determines that overcurrent protection is required, and sends a trip signal. This signal is connected to the industrial control computer 1 through the switch input detection module 6.

[0042] Step 3: Verification of Industrial Computer 1

[0043] The industrial computer 1 reads the model of the switch input detection module 6 via RS485, and after receiving the signal that the protection device has acted correctly, records the action time.

[0044] Step 4: Relay Control

[0045] The industrial control computer 1 issues a control command to control the relay output signal generator 4 to activate the relay and send a trip signal to the protection device;

[0046] Step 5: Protection device response

[0047] After receiving the trip command through the switch input terminal of the protection device, the tripping process is executed.

[0048] Step Six: Network Time Synchronization and Result Upload

[0049] The industrial control computer 1 performs network time synchronization with the protection device via the network port, and uploads the structured test report to the MES system after all tests are completed.

[0050] The above is an introduction to the electrical control connection and testing principle of the automatic testing device. The mechanical structure of the automatic testing device in this embodiment will be described in detail below.

[0051] There are many ways to design the structure of an automatic testing device, and it is not limited to the method described in this embodiment. As long as it includes all the modules of the automatic testing device in this embodiment and is connected correctly, it is acceptable. How the modules are placed in the cabinet is not the focus of this utility model embodiment.

[0052] In this embodiment, an indicator light group 11 is installed on the top of the cabinet, multiple cabinet doors are provided on the front of the cabinet, an industrial control computer 1 is installed in the upper cabinet space, and a display screen 12, a barcode input module 8, a touch screen 9 and an alarm 10 are provided on the upper cabinet doors. The display screen 12 is used to output the screen display content of the device under test A. The barcode input module 8, the touch screen 9, the alarm 10 and the indicator light group 11 are connected to the industrial control computer 1 through the digital input interface of the industrial control computer 1.

[0053] The automatic connection unit for device A under test is installed in the middle cabinet space, and safety light curtains 13 are installed on both sides of the cabinet door. When an operator places device A under test, the safety light curtains 13 detect the operator and will not trigger the automatic connection unit of device A under test, ensuring the operator's safety. The first microcomputer protection tester 2 and the second microcomputer protection tester 3 are installed in the lower cabinet space. Other modules of the automatic testing device are installed inside the cabinet according to their telecommunication connection methods.

[0054] The automatic connection unit for device under test (DUT) A includes: a fixture frame 14, a lifting mechanism, and sleeves 16. The fixture frame 14 is fixed to the central cabinet. A set of DUT A limiters 26 and a set of DUT A screen limiters 26 are provided on the upper surface of the fixture frame 14. A guide post 15 is fixedly connected to each of the four corners of the fixture frame 14. The bottom of the lifting mechanism is fixed to the fixture frame 14. The lifting slider 19 is fixedly connected to the interface test panel mounting plate 17. A sleeve 16 is fixedly connected to each of the four corners of the interface test panel mounting plate 17, corresponding to the guide posts 15. The lifting mechanism includes a pair of lead screws 18, which are rotatably connected to the fixture frame 14 via bearings 22. A servo motor mounting bracket 24 is fixedly connected to the bottom of the fixture frame 14. A servo motor 25 is fixed to the servo motor mounting bracket 24, and its output end is connected to one of the lead screws. The bottom of the lead screw 18 is fixedly connected, and the lifting slider 19 is mounted on the lead screw 18. The upper part of the pair of lead screws 18 is connected to the fixed angle iron 21 through the bearing 22. The fixed angle iron 21 is fixedly connected to the inner wall of the middle cabinet. The gear 29 is fixedly sleeved on the lead screw 18 below the fixed angle iron 21. The two gears 29 on the pair of lead screws 18 are meshed with the synchronous belt 20, and the synchronous belt 20 has teeth on its inner side. The lead screw below the synchronous belt 20 is fixed with a baffle 23, which limits the synchronous belt 20. The interface test panel mounting plate 17 is provided with a camera shooting avoidance hole 28, which is located above the screen of the device under test A. The camera 27 is mounted on the interface test panel mounting plate 17, facing the screen of the device under test A. The interface test panel 5 is mounted below the interface test panel mounting plate 17 at the position corresponding to the device under test A. The servo motor 25, camera 27, and safety light curtain 13 are all electrically connected to the industrial control computer 1. The camera 27 is connected to the display screen 12 through an HDMI cable.

[0055] System startup phase: After receiving the test command, the industrial control computer 1 first detects the safety status of the work area through the safety light curtain 13. When it is confirmed that there are no operator limbs, the servo motor 25 is initialized and the lifting mechanism is reset to the standby position. The device under test A is placed in front of the barcode scanner, the information of the device under test A is read, and the industrial control computer 1 retrieves the corresponding test parameters.

[0056] Automatic docking stage: Industrial computer 1 controls servo motor 25 to rotate forward and backward. Servo motor 25 drives lead screw 18, which in turn drives the double lead screw 18 to rotate synchronously via synchronous belt 20. Lifting slider 19, installed on lead screw 18, moves vertically along lead screw 18, causing interface test panel 5 to move downward. Limiter 26 of device under test A ensures accurate positioning of the device, and the structure of guide post 15 and sleeve 16 ensures docking perpendicularity. When servo motor 25 drives lifting slider 19 to the set position, it stops, and the corresponding terminal of device under test A is inserted and connected.

[0057] Test execution phase: Interface test panel 5 establishes an electrical connection with device under test A; industrial camera 27 captures images of device under test A's screen through the clearance hole, and transmits the images to display screen 12 in real time via HDMI; industrial control computer 1 synchronously controls the microcomputer protection tester to output test signals, and the switch quantity detection module collects the response signals of device under test A in real time.

[0058] Test completion phase: Industrial computer 1 generates a test report and uploads data through the MES system; servo motor 25 rotates in reverse and the lifting mechanism resets to its initial position; alarm 10 and touch screen 9 indicate that the test is complete and prepare for the next round of testing.

Claims

1. An automatic test apparatus, characterized by, include: The industrial control computer is connected to the microcomputer test and protection instrument, the switch input detection module, and the relay output signal generator. The microcomputer-based test and protection instrument has its output terminals connected to the analog input interfaces of the device under test. A digital input detection module, whose output is connected to the digital output terminal of the device under test; A relay output signal generator, the output of which is connected to the digital input terminal of the device under test; The barcode input module, touch screen, indicator light group and alarm set on the device panel are all connected to the industrial control computer; The network communication module is connected to the industrial control computer and includes at least two network interfaces, which are respectively connected to the time synchronization interface of the device under test and the MES system.

2. The automatic testing device as described in claim 1, characterized in that, The device panel also includes: an interface test panel, which includes multiple wiring terminals; and the microcomputer test and protection instrument includes a first microcomputer protection tester and a second microcomputer protection tester.

3. The automatic testing device as described in claim 2, characterized in that, The output terminal of the first microcomputer protection tester is connected to the interface test panel via a multi-core shielded cable. The interface test panel is connected to the output terminal of the first microcomputer protection tester as the protection current output interface and the measurement current output interface of the device under test. The output terminal of the second microcomputer protection tester is connected to the interface test panel via a multi-core shielded cable. The interface test panel is connected to the output terminal of the second microcomputer protection tester to the measurement voltage output interface and the zero-sequence voltage output interface of the device under test.

4. The automatic testing device as described in claim 1, characterized in that, The relay output signal generator includes a relay and a drive circuit, and its output terminal is connected to the switch input terminal of the device under test through relay contacts.

5. The automatic testing device as described in claim 1, characterized in that, The first microcomputer protection tester, the second microcomputer protection tester, and the relay output signal generator are connected to the industrial control computer via RS485.

6. The automatic testing apparatus as described in claim 1, characterized in that, The device under test is a relay protection device or a microcomputer protection device of a power system.

7. The automatic testing device as described in claim 2, characterized in that, The switch input detection module is connected to the corresponding terminals on the interface test panel. The terminals are sequentially connected to the optocoupler isolation circuit and the signal conditioning circuit, and then connected to the digital input interface of the industrial control computer via RS485.

8. The automatic testing apparatus as described in claim 1, characterized in that, Also includes: Indicator lights are installed on the top of the cabinet, and multiple cabinet doors are set on the front of the cabinet. The industrial control computer is installed in the upper cabinet space, and the upper cabinet doors are equipped with a display screen, barcode input module, touch screen and alarm. The display screen is used to output the screen display content of the device under test. The automatic connection unit of the device under test is installed in the middle cabinet space, and safety light curtains are installed on both sides of the cabinet doors. The first microcomputer protection tester and the second microcomputer protection tester are installed in the lower cabinet space.

9. The automatic testing apparatus as described in claim 8, characterized in that, The automatic connection unit for the device under test includes: a fixture frame, a lifting mechanism, and an interface test panel mounting plate; the fixture frame is fixed to the central cabinet, and a set of device under test limiters and a set of device under test screen limiters are provided on the upper surface of the fixture frame; a guide post is fixedly connected to each of the four corners of the fixture frame; the bottom of the lifting mechanism is fixed to the fixture frame, and the lifting slider is fixedly connected to the interface test panel mounting plate; a sleeve is fixedly connected to each of the four corners of the interface test panel mounting plate, corresponding to the guide posts; the lifting mechanism includes a pair of lead screws, which are rotatably connected to the fixture frame through bearings; a servo motor mounting bracket is fixedly connected to the bottom of the fixture frame, and the servo motor is fixed on the servo motor mounting bracket. The output end is fixedly connected to the bottom of one of the lead screws. The lifting slider is mounted on the lead screw. The upper part of the pair of lead screws is connected to the fixed angle iron through the bearing. The fixed angle iron is fixedly connected to the inner wall of the middle cabinet. The gear is fixedly sleeved on the lead screw below the fixed angle iron. The two gears on the pair of lead screws are meshed with the synchronous belt. The synchronous belt has teeth on its inner side. A baffle is fixed on the lead screw below the synchronous belt. The interface test panel mounting plate is provided with a camera shooting avoidance hole. The camera shooting avoidance hole is located above the screen of the device under test. The camera is mounted on the interface test panel mounting plate and is set facing the screen of the device under test. An interface test panel is installed below the interface test panel mounting plate at the position corresponding to the device under test.

10. The automatic testing apparatus as described in claim 9, characterized in that, The servo motor, the camera, and the safety light curtain are all connected to the industrial control computer. The camera and the display screen are connected via an HDMI cable.

Images