AC and DC voltage resistance insulation tester
The automated design of the AC/DC withstand voltage insulation tester solves the problems of operator fatigue and equipment aging caused by manual operation, achieving efficient and convenient electrical safety testing and meeting the stringent requirements of modern industry.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- XIAN XIGU XINCHUANG ELECTRONIC TECH CO LTD
- Filing Date
- 2025-07-28
- Publication Date
- 2026-06-23
Smart Images
Figure CN224399538U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electrical measurement and automated testing technology, specifically to an AC / DC withstand voltage insulation tester. Background Technology
[0002] In the manufacturing and quality inspection of electronic components and electrical products, AC / DC withstand voltage testing and insulation resistance testing are crucial steps to ensure product safety and reliability. Withstand voltage testing primarily verifies the insulation performance of the device under test under high voltage conditions. By applying a test voltage higher than the normal operating voltage, it detects whether breakdown or excessive leakage current will occur. Insulation resistance testing evaluates the resistive characteristics of insulating materials to ensure they meet safety standards.
[0003] Currently, most withstand voltage testers and insulation testers on the market rely on manual operation. Testers need to manually set test parameters, such as test voltage, test time, and judgment current, and start the test via physical buttons. During batch testing, operators must repeatedly perform the following steps: manually connect the device under test and ensure correct wiring; set the test mode; adjust test parameters; start the test and observe the results; and manually record the data. In this traditional testing method, testers need to frequently operate buttons, resulting in high workload and fatigue; manual data recording may lead to errors or omissions; long-term, high-frequency button operation accelerates button aging and affects equipment lifespan; and paper records or scattered spreadsheets make data statistics and analysis difficult, affecting quality traceability. Utility Model Content
[0004] This utility model provides an AC / DC withstand voltage insulation tester, which, through innovative design, constitutes an advanced testing system integrating automation, high precision, high efficiency, and intelligent management. It has achieved a qualitative leap in terms of test quality, ease of operation, production efficiency, and safety, and fully meets the stringent requirements of modern industry for electrical safety testing equipment. It has significant technological progress and practical value.
[0005] To achieve the above objectives, this utility model provides the following technical solution: an AC / DC withstand voltage insulation tester, comprising: a main control unit for executing test programs and controlling the coordinated operation of various modules; a high-voltage output module for generating the AC / DC high voltage required for testing; a precision current detection module for detecting the leakage current of the device under test; a multi-channel test interface for connecting multiple devices under test; an automatic switching unit for automatically switching test channels; a data storage module for automatically recording test data; and a human-machine interface for displaying test information and receiving operation commands.
[0006] Preferably, the main control unit runs an automated testing program written in Python to achieve automated control of the testing process.
[0007] Preferably, the high-voltage output module provides an adjustable AC / DC test voltage of 0-5kV with a step accuracy of 1V.
[0008] Preferably, the precision current detection module has a detection resolution of 0.1μA and a detection range of 0-20mA.
[0009] Preferably, the multi-channel test interface supports parallel testing of at least 8 devices under test.
[0010] Preferably, the automatic switching unit uses a relay matrix to achieve automatic switching of test channels.
[0011] Preferably, the data storage module supports automatic recording of test data and can export it as an Excel or PDF report.
[0012] Preferably, the human-computer interaction interface is a touch screen, reducing the use of physical buttons.
[0013] Preferably, it also includes a remote communication interface that supports LAN / USB / RS232 communication to enable remote monitoring and control.
[0014] Preferably, it also includes an audible and visual alarm device that automatically triggers an alarm when the leakage current exceeds a preset value.
[0015] The beneficial effects of this utility model are:
[0016] By using Python programming to control the entire testing process, the traditional manual operation mode is completely replaced, improving test consistency by over 90%. It also supports complex test logic programming, significantly reducing the technical requirements for operators and lowering training costs by 50%. Combined with a touchscreen human-machine interface, the number of operation steps is reduced by 70%, completely eliminating the wear and tear problem of physical buttons.
[0017] The system features high-resolution leakage current detection of 0.1μA and high-voltage output capability adjustable from 0-5kV (1V step), with voltage regulation accuracy of 0.02%. It can meet the microampere-level leakage current detection requirements of harsh fields such as medical equipment, and can also cover the testing of all scenarios from low-voltage components to high-voltage equipment.
[0018] By adopting an 8-channel parallel test architecture with automatic switching via a relay matrix, the test throughput is increased by 800%, the switching speed is as fast as less than 10ms, and the lifespan exceeds 1 million cycles, perfectly solving the problem of low efficiency in traditional single-channel testing.
[0019] Test data is automatically recorded and supports exporting to Excel / PDF reports, reducing the data error rate to below 0.1% and establishing a complete quality traceability system. The remote communication interface supports integration with the MES system, providing a data foundation for intelligent manufacturing.
[0020] The system integrates an audible and visual alarm device with an abnormal response time of less than 50ms, and works in conjunction with an overcurrent protection mechanism to ensure the safety and reliability of the high-voltage testing process.
[0021] These innovative designs together constitute an advanced testing system that integrates automation, high precision, high efficiency, and intelligent management. It has achieved a qualitative leap in terms of test quality, ease of operation, production efficiency, and safety, fully meeting the stringent requirements of modern industry for electrical safety testing equipment, and has significant technological progress and practical value. Attached Figure Description
[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0023] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0024] Figure 2 This is a schematic diagram of the system structure of this utility model.
[0025] In the diagram: 1. Main control unit; 2. High voltage output module; 3. Precision current detection module; 4. Multi-channel test interface; 5. Automatic switching unit; 6. Data storage module; 7. Human-machine interface; 8. Housing; 9. Front panel. Detailed Implementation
[0026] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. 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.
[0027] according to Figure 1 , Figure 2As shown, an AC / DC withstand voltage insulation tester includes: a housing 8, the housing 8 having a front panel 9, and a main control unit 1 for executing test programs and controlling the coordinated operation of various modules; a high-voltage output module 2 for generating the AC / DC high voltage required for testing; a precision current detection module 3 for detecting the leakage current of the device under test; a multi-channel test interface 4 for connecting multiple devices under test; an automatic switching unit 5 for automatically switching test channels; a data storage module 6 for automatically recording test data; and a human-machine interface 7 for displaying test information and receiving operation commands. The main control unit 1, high-voltage output module 2, precision current detection module 3, automatic switching unit 5, and data storage module 6 are all fixedly installed inside the housing 8, while the multi-channel test interface 4 and human-machine interface 7 are respectively arranged on the front panel 9 for easy movement and operation of the equipment. The main control unit 1 serves as the core of the system, and connects via a data bus such as I... 2 C. Connects to all modules via SPI or parallel bus to achieve bidirectional communication. This includes: sending voltage setting commands to the high-voltage output module 2; receiving leakage current data from the precision current detection module 3; controlling channel selection in the automatic switching unit 5; interacting with the data storage module 6 to read and write test data; and receiving commands and outputting test status through the human-machine interface 7.
[0028] The input side of the high-voltage output module 2 receives voltage / frequency parameters sent by the main control unit 1, where the digital signal is converted by a DAC. The output side is connected to the input of the automatic switching unit 5 via a high-voltage cable to provide the high voltage required for testing.
[0029] The precision current detection module 3 is connected in series in the high-voltage circuit. Its detection end is connected to the output end of the automatic switching unit 5 and connected in series with the device under test to collect leakage current in real time. The signal output end is fed back to the main control unit 1 after being converted by ADC.
[0030] The input side of the automatic switching unit 5 receives the high-voltage signal from the high-voltage output module 2. The output side is connected to the multi-channel test interface 4 via a multi-channel relay matrix, and channel switching is controlled by the main control unit 1.
[0031] The protection circuit is linked with the main control unit 1 to forcibly cut off the high voltage in case of overcurrent.
[0032] The multi-channel test interface 4 is a physical interface and uses standard test terminals, such as banana plugs or probes. Each channel is independently connected to the device under test. Its electrical connection is through a relay to form a closed test loop with the high-voltage output module 2 and the current detection module.
[0033] The data storage module 6 is directly integrated into the main control unit 1, such as through embedded Flash or via an external USB / SD card interface. It receives and stores test data sent by the main control unit 1.
[0034] The human-machine interface 7 is connected to the main control unit 1 via a serial interface to receive operation commands, such as starting the test and setting parameters, and output and display the test progress, results and alarm information.
[0035] As a preferred embodiment, the main control unit 1 runs an automated testing program written in Python to automate the testing process. The high-voltage output module 2 provides an adjustable AC / DC test voltage of 0-5kV with a step accuracy of 1V. The precision current detection module 3 has a detection resolution of 0.1μA and a detection range of 0-20mA. The multi-channel test interface 4 supports parallel testing of at least 8 devices under test. The automatic switching unit 5 uses a relay matrix to achieve automatic switching of test channels. The data storage module 6 supports automatic recording of test data and can export reports in Excel or PDF format. The human-machine interface 7 is a touchscreen, reducing the use of physical buttons. A remote communication interface is also included, supporting LAN / USB / RS232 communication for remote monitoring and control. An audible and visual alarm device is also included, automatically triggering an alarm when leakage current exceeds a preset value.
[0036] These optimized solutions significantly improve the performance and practicality of the tester. Among them, the automated test program written in Python serves as the core of the main control unit 1, realizing intelligent control of the test process. This not only completely replaces the traditional manual operation mode, improving test consistency by more than 90%, but also supports flexible programming of complex test logic, greatly reducing the technical requirements for operators and reducing training costs by 50%. The high-voltage output module 2 provides an adjustable AC / DC test voltage of 0-5kV, adjusted in 1V steps. This design not only meets the testing needs of all scenarios from low-voltage components to high-voltage equipment, but also ensures that the voltage regulation accuracy reaches 0.02%, fully covering mainstream safety testing standards.
[0037] The precision current detection module 3 features a high resolution of 0.1μA and a wide detection range of 0-20mA, enabling it to accurately capture minute changes in leakage current. It is particularly suitable for applications with stringent leakage current requirements, such as medical equipment, and offers an 8-fold improvement in detection capability compared to traditional equipment. The multi-channel test interface 4 supports parallel testing of at least 8 devices under test. Combined with the automatic switching unit 5 implemented using a relay matrix, this increases test throughput by 800%, while avoiding contact problems caused by manual wiring. The switching speed is as fast as less than 10ms and the lifespan exceeds 1 million cycles.
[0038] The data storage module 6 automatically records test data and exports reports in Excel / PDF format, reducing the data recording error rate to below 0.1% and establishing a complete quality traceability system. The touchscreen human-machine interface 7 replaces traditional physical buttons, reducing operation steps by 70%, completely eliminating button wear and tear, and supporting more intuitive test scheme configuration. Remote communication interfaces include multiple methods such as LAN / USB / RS232, enabling not only remote monitoring and control but also integration with the MES system, laying the foundation for building an intelligent testing network. The addition of an audible and visual alarm device allows the system to respond quickly within 50ms when an anomaly is detected, ensuring operators are promptly aware of dangerous situations through multi-sensory warnings.
[0039] These preferred technical solutions together constitute a highly automated, high-precision, and high-efficiency testing system, which has achieved significant improvements in test quality, ease of operation, data management, and security, and fully meets the stringent requirements of modern industrial production for electrical safety testing equipment.
[0040] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.
Claims
1. An AC / DC withstand voltage insulation tester, characterized in that... ,include: The main control unit (1) is used to execute the test program and control the coordinated operation of each module; High voltage output module (2) is used to generate AC / DC high voltage required for testing; A precision current detection module (3) is used to detect the leakage current of the device under test; A multi-channel test interface (4) is used to connect multiple devices under test; Automatic switching unit (5) is used to automatically switch test channels; Data storage module (6) is used to automatically record test data; The human-computer interaction interface (7) is used to display test information and receive operation instructions.
2. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The main control unit (1) runs an automated testing program written in Python to achieve automated control of the testing process.
3. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The high-voltage output module (2) provides an adjustable AC / DC test voltage of 0-5kV with a step accuracy of 1V.
4. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The precision current detection module (3) has a detection resolution of 0.1μA and a detection range of 0-20mA.
5. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The multi-channel test interface (4) supports parallel testing of at least 8 devices under test.
6. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The automatic switching unit (5) uses a relay matrix to achieve automatic switching of the test channels.
7. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The data storage module (6) supports automatic recording of test data and can export it as an Excel or PDF report.
8. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: The human-computer interaction interface (7) is a touch screen, which reduces the use of physical buttons.
9. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: It also includes a remote communication interface that supports LAN / USB / RS232 communication, enabling remote monitoring and control.
10. The AC / DC withstand voltage insulation tester according to claim 1, characterized in that: It also includes an audible and visual alarm device that automatically triggers an alarm when leakage current exceeds a preset value.