AC hot-state voltage withstanding test system with high safety

Abstract

This utility model relates to a highly safe AC hot withstand voltage test system, which includes an isolation transformer, a step-up transformer, an output contactor, a voltage sampling module, and a phase control module. The mains power supply provides the test device with a working voltage U1 via the isolation transformer and output contactor. The test voltage, after being regulated by the phase control module, is output as a test voltage U3 to the N and PE terminals of the test device via the step-up transformer and output contactor. The voltage sampling module collects the secondary voltage of the isolation transformer in real time and feeds it back to the phase control module. The phase control module dynamically adjusts the delayed output of the step-up transformer to keep U3 and the live-to-ground voltage U5 equal in real time. This invention, through the coordinated operation of the isolation transformer and the phase control module, eliminates the risk of overvoltage damage to the test device caused by live-to-ground voltage fluctuations, automatically maintains the equivalence between U5 and U3 during hot testing, and significantly improves test safety and equipment protection reliability.

Description

Technical Field

[0001] This utility model relates to the field of electronic measurement technology, specifically to a highly secure AC hot withstand voltage test system. Background Technology

[0002] The current method for hot withstand voltage testing of electrical products involves applying a working voltage U1 between the live and neutral wires of the product under test, while simultaneously applying a withstand voltage test voltage U3 between the neutral and ground wires. Because the stability of the live-to-ground voltage U5 is not considered, when the mains power phase changes, the live-to-ground voltage U5 will fluctuate with the phase difference (φ angle) between the working voltage U1 and the test voltage U3, resulting in highly unstable live-to-ground voltage fluctuations. Such voltage fluctuations may exceed the withstand voltage limit of the product under test, potentially causing equipment burnout. Utility Model Content

[0003] The technical problem this invention aims to solve is to overcome the shortcomings of existing hot withstand voltage testing methods that neglect dynamic compensation of the voltage between the live wire and the ground wire, which can lead to potential damage to the tested product. This invention provides a highly safe AC hot withstand voltage testing system that, through a hardware collaborative structure of an isolation transformer, a step-up transformer, and a phase control module, achieves automatic equal-value control of the live wire-to-ground voltage U5 and the neutral wire-to-ground voltage U3, preventing excessive fluctuations in the live-to-ground voltage U5 from damaging the tested product.

[0004] This highly secure AC hot withstand voltage test system includes an isolation transformer, a step-up transformer, an output contactor, a voltage sampling module, and a phase control module. The AC mains input is connected sequentially to the live wire (L) and neutral wire (N) of the test object via the isolation transformer and the output contactor, outputting a working voltage U1. The withstand voltage input is connected sequentially to the neutral wire (N) and ground wire (PE) of the test object via the phase control module, the step-up transformer, and the output contactor, outputting a test voltage U3. The input of the voltage sampling module is connected to the secondary side of the isolation transformer, and the output of the voltage sampling module is connected to the phase control module.

[0005] Specifically, the voltage sampling module includes a voltage divider resistor and a CS5460 chip connected to the voltage divider resistor. The voltage divider resistor is connected in series on the secondary side of the isolation transformer, and the signal output terminal of the CS5460 chip is connected to the signal input terminal of the phase control module.

[0006] Specifically, the phase control module includes an IR2110 driver chip, an SGH40N60UFD power module, and a CPU control module with a built-in STM32F103VCT6 processing chip. The input terminal of the IR2110 driver chip is connected to the signal output terminal of the CS5460 chip via the CPU control module, and the output terminal of the IR2110 driver chip is connected to the control input terminal of the SGH40N60UFD power module.

[0007] Furthermore, it also includes a human-computer interaction touch screen, which is serially connected to the USART interface of the CPU control module.

[0008] This utility model discloses a highly safe AC hot withstand voltage test system that overcomes the shortcomings of existing hot withstand voltage test methods, which neglect dynamic compensation of the voltage between the live wire and the ground wire, thus causing potential damage to the tested product. Through the hardware collaborative structure of isolation transformer, step-up transformer and phase control module, it realizes automatic equal value control of the live wire-to-ground voltage U5 and the neutral wire-to-ground voltage U3, preventing the test product from being damaged by excessive fluctuations in the live wire-to-ground voltage U5. Attached Figure Description

[0009] The following description, in conjunction with the accompanying drawings, further illustrates the high-safety AC hot withstand voltage testing system of this utility model:

[0010] Figure 1 This is a wireframe diagram illustrating the logic structure and connection principle of this highly secure AC hot withstand voltage test system.

[0011] Figure 2 This is the circuit diagram of the voltage sampling module of this highly secure AC hot withstand voltage test system;

[0012] Figure 3 This is the circuit diagram of the SGH40N60UFD power module in the phase control module of the high-safety AC hot withstand voltage test system.

[0013] Figure 4 This is a circuit diagram of the CPU control module in the phase control module of this highly secure AC hot withstand voltage test system.

[0014] In the picture:

[0015] 1-Isolation transformer;

[0016] 2-Boost converter;

[0017] 3- Output contactor;

[0018] 4-Voltage sampling module; 41-Voltage divider resistor; 42-CS5460 chip;

[0019] 5-Phase control module; 51-IR2110 driver chip; 52-SGH40N60UFD power module; 53-CPU control module;

[0020] 6-Human-computer interaction touch screen. Detailed Implementation

[0021] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0022] In the description of this utility model, it should be understood that the terms "left", "right", "front", "rear", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0023] The present invention will be further described below with specific embodiments, but the scope of protection of the present invention is not limited to the following embodiments.

[0024] Implementation method 1: such as Figure 1 As shown, this highly secure AC hot withstand voltage test system includes an isolation transformer 1, a step-up transformer 2, an output contactor 3, a voltage sampling module 4, and a phase control module 5.

[0025] The mains power input is connected sequentially to the live wire (L) and neutral wire (N) of the test object via the isolation transformer 1 and output contactor 3, and outputs a working voltage U1. The withstand voltage test voltage input is connected sequentially to the neutral wire (N) and ground wire (PE) of the test object via the phase control module 5, booster 2, and output contactor 3, and outputs a test voltage U3. The input terminal of the voltage sampling module 4 is connected to the secondary side of the isolation transformer 1, and the output terminal of the voltage sampling module 4 is connected to the phase control module 5. The phase control module 5 integrates the phase compensation function into the hardware circuit. Through this circuit module, the output phase of U3 is dynamically adjusted to keep the live wire-to-ground voltage U5 and the neutral wire-to-ground voltage U3 constant and equal, avoiding voltage fluctuations that could damage the equipment. At the same time, the isolation transformer 1 provides physical isolation, effectively blocking the impact of mains power surges on the test system.

[0026] Implementation method 2: such as Figure 1 , 2As shown, the voltage sampling module 4 of this high-safety AC hot withstand voltage test system includes a voltage divider resistor 41 and a CS5460 chip 42 connected to the voltage divider resistor 41. The voltage divider resistor 41 is connected in series on the secondary side of the isolation transformer 1, and the signal output terminal of the CS5460 chip 42 is connected to the signal input terminal of the phase control module 5. The CS5460 chip 42, in conjunction with the voltage divider resistor 41, achieves high-precision real-time acquisition of the U1 voltage. The remaining structures and components are as described in Embodiment 1 and will not be repeated.

[0027] Implementation method 3: such as Figure 1 , 3 As shown in Figure 4, the phase control module 5 of this high-safety AC hot withstand voltage test system includes an IR2110 driver chip 51, an SGH40N60UFD power module 52, and a CPU control module 53 with a built-in STM32F103VCT6 processing chip. The input terminal of the IR2110 driver chip 51 is connected to the signal output terminal of the CS5460 chip 42 via the CPU control module 53, and the output terminal of the IR2110 driver chip 51 is connected to the control input terminal of the SGH40N60UFD power module 52. The STM32F103VCT6 processor calculates the phase angle φ=arccos(U1 / (2×U3)) based on the voltage signal acquired by the CS5460 chip. The IR2110 chip generates an SPWM drive waveform with a lag angle of φ based on the phase angle modulation, driving the SGH40N60UFD power module to output the test voltage with a delay. The remaining structures and components are as described in Embodiment 1 and will not be described again.

[0028] Implementation method 4: such as Figure 1 As shown, this highly secure AC hot withstand voltage test system also includes a human-machine interface touch screen 6, which is serially connected to the USART interface of the CPU control module 53. It is used to set parameters such as the test voltage and test time required for the test. The remaining structures and components are as described in Embodiment 1 and will not be repeated.

[0029] During operation: The mains input is output as a working voltage U1 through the isolation transformer to the live-neutral terminal of the product under test. Simultaneously, the phase control module generates an SPWM drive signal based on the preset withstand voltage value U3, which is then boosted by the transformer to generate a test voltage U3 with a lag angle of φ, applied to the neutral-ground terminal. The voltage sampling module acquires the U1 waveform in real time and feeds it back to the phase control module. The built-in processor dynamically calculates φ=arccos(U1 / (2×U3)). By adjusting the phase delay of the SPWM waveform, the voltage U5 between the live and ground wires is kept equal to U3, preventing excessive fluctuations in the live-ground voltage U5 from damaging the product under test. This hardware-level closed-loop control requires no manual intervention. While eliminating the risk of voltage fluctuations, the physical isolation layout of the isolation transformer and the boost transformer blocks abnormal voltage interference, further ensuring the safety of the testing process.

[0030] This highly secure AC hot withstand voltage test system overcomes the shortcomings of existing hot withstand voltage test methods that neglect dynamic compensation of the voltage between the live wire and the ground wire, which can lead to potential damage to the tested product. Through the hardware collaborative structure of the isolation transformer, the step-up transformer, and the phase control module, it achieves automatic equal-value control of the live wire-to-ground voltage U5 and the neutral wire-to-ground voltage U3, preventing excessive fluctuations in the live wire-to-ground voltage U5 from damaging the tested product.

[0031] The above description illustrates the main features, basic principles, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments or examples described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the above embodiments or examples should be considered exemplary and not restrictive. The scope of this utility model is defined by the appended claims rather than the foregoing description, and therefore all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0032] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A highly secure AC hot withstand voltage testing system, characterized by: It includes an isolation transformer (1), a step-up transformer (2), an output contactor (3), a voltage sampling module (4), and a phase control module (5), among which, The mains power input is connected to the live wire L and neutral wire N of the test product in sequence through the isolation transformer (1) and the output contactor (3), and outputs the working voltage U1 to it; the withstand voltage test voltage input is connected to the neutral wire N and ground wire PE of the test product in sequence through the phase control module (5), the booster (2) and the output contactor (3), and outputs the test voltage U3; the input terminal of the voltage sampling module (4) is connected to the secondary side of the isolation transformer (1), and the output terminal of the voltage sampling module (4) is connected to the phase control module (5).

2. The AC hot withstand voltage test system with high safety according to claim 1, characterized in that: The voltage sampling module (4) includes a voltage divider resistor (41) and a CS5460 chip (42) connected to the voltage divider resistor (41). The voltage divider resistor (41) is connected in series on the secondary side of the isolation transformer (1). The signal output terminal of the CS5460 chip (42) is connected to the signal input terminal of the phase control module (5).

3. The AC hot withstand voltage test system with high safety according to claim 2, characterized in that: The phase control module (5) includes an IR2110 driver chip (51), an SGH40N60UFD power module (52), and a CPU control module (53) with a built-in STM32F103VCT6 processing chip. The input terminal of the IR2110 driver chip (51) is connected to the signal output terminal of the CS5460 chip (42) via the CPU control module (53), and the output terminal of the IR2110 driver chip (51) is connected to the control input terminal of the SGH40N60UFD power module (52).

4. The AC hot withstand voltage test system with high safety according to claim 3, characterized in that: It also includes a human-computer interaction touch screen (6), which is serially connected to the USART interface of the CPU control module (53).

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