A frequency converter component and whole machine maintenance testing device
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHAANXI ZHONGJI HUAQING MECHANICAL & ELECTRICAL CO LTD
- Filing Date
- 2025-09-17
- Publication Date
- 2026-08-07
AI Technical Summary
[0003]分离式测试效率低下：对元器件进行测试时，需先拆解整机，再使用独立的测试设备（如LCR表、半导体测试仪），单次测试耗时长达数小时，严重影响维修或质检进度
[0016]1、通过多级测试融合架构及智能接口系统，无需拆解整机即可完成从元器件级到整机级的全覆盖测试，结合并行测试机制，测试时间缩短，解决了分离式测试低效的问题。
Smart Images
Figure CN224609213U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of frequency converter repair and testing technology, and in particular to a frequency converter component and whole machine repair and testing device. Background Technology
[0002] In the fields of industrial frequency converter repair and power electronic device manufacturing quality inspection, the performance of testing equipment directly affects repair efficiency and product quality. Current frequency converter testing technologies have several shortcomings:
[0003] Separate testing is inefficient: When testing components, the entire machine must be disassembled first, and then independent testing equipment (such as LCR meter, semiconductor tester) must be used. A single test can take up to several hours, which seriously affects the progress of maintenance or quality inspection.
[0004] There are blind spots in whole-machine testing: Traditional whole-machine testing can only monitor macroscopic parameters such as voltage and current, and cannot obtain key parameters of internal components in real time (such as IGBT junction temperature and drive signal distortion). This results in a high rate of missed detection of hidden faults, which poses potential risks to equipment operation.
[0005] Poor compatibility: Existing testing equipment is difficult to adapt to components with different package types (such as TO-247, IGBT modules) and frequency converters with different topologies (such as two-level and three-level frequency converters), requiring frequent replacement of testing equipment or fixtures, which is cumbersome. Utility Model Content
[0006] The purpose of this utility model is to overcome the shortcomings of the existing technology and propose a frequency converter component and whole machine maintenance and testing device.
[0007] To achieve the above objectives, the present invention adopts the following technical solution:
[0008] A testing and repair device for inverter components and the entire unit includes: a multi-level testing unit, an intelligent interface system, and a control and monitoring unit; the multi-level testing unit is connected to the inverter under test through the intelligent interface system to perform component-level and unit-level testing; the control and monitoring unit is electrically connected to the multi-level testing unit and the intelligent interface system respectively, and is used to control the testing process, monitor test data in real time, perform fault tracing, and manage energy; the intelligent interface system is used to realize interface adaptation and signal transmission between the multi-level testing unit and the inverter under test.
[0009] Preferably, the multi-level testing unit includes a component testing module and a complete machine testing module; the component testing module is used to perform parameter testing on components such as capacitors, IGBTs, and drive chips of the frequency converter; the complete machine testing module is used to perform operational testing on the complete frequency converter with a power range of 0.5kW-1000kW.
[0010] Preferably, the component testing module includes a capacitance testing unit and an IGBT dynamic testing unit; the capacitance testing unit uses a four-wire Kelvin connection; the IGBT dynamic testing unit integrates a dual-pulse testing circuit for quantitative analysis of the IGBT's switching losses.
[0011] Preferably, the whole machine test module includes a wide-range input power supply and a digital twin load; the wide-range input power supply is used to simulate power grid disturbances; the digital twin load is based on a real-time simulator and is used to simulate the dynamic characteristics of a motor or fan.
[0012] Preferably, the intelligent interface system includes a reconfigurable needle bed clamp and an optical fiber isolated signal acquisition module; the reconfigurable needle bed clamp supports at least eight package types and achieves millisecond-level switching through pneumatic pressing; the optical fiber isolated signal acquisition module is used to synchronously capture the driver board optocoupler signal and the IGBT gate waveform.
[0013] Preferably, the control and monitoring unit includes an online monitoring subunit, a fault tracing subunit, and an energy management subunit; the online monitoring subunit is used to collect high-frequency ripple of the bus current and the temperature field of the radiator in real time during the operation of the whole machine; the fault tracing subunit realizes fault root cause location based on knowledge graph and multiphysics simulation; the energy management subunit adopts bidirectional energy feedback technology and supports overload testing.
[0014] Preferably, the control and monitoring unit further includes an active protection subunit; the active protection subunit has an overcurrent self-healing function and can switch to a redundant test circuit within a preset time to avoid secondary damage to the device under test.
[0015] The beneficial effects of this utility model are:
[0016] 1. Through a multi-level test fusion architecture and intelligent interface system, full-coverage testing from the component level to the whole machine level can be completed without disassembling the whole machine. Combined with the parallel testing mechanism, the testing time is shortened, solving the problem of inefficiency in separate testing.
[0017] 2. The built-in online monitoring subunit can monitor component parameters such as capacitor ESR / capacitance value and IGBT switching loss in real time during the operation of the whole machine. Combined with high-frequency sampling of bus current high-frequency ripple and infrared thermal imaging of heat sink temperature field data, the rate of missed detection of hidden faults is greatly reduced.
[0018] 3. The reconfigurable bed-of-nails fixture in the intelligent interface system supports at least eight package types, has a wide range of input power to adapt to different power grid conditions, and digital twin loads to simulate various load characteristics, making it compatible with different packaged components and different topology frequency converters.
[0019] 4. The system adopts bidirectional energy feedback technology and combines it with dynamic load matching to test energy consumption, which meets the requirements of energy conservation and environmental protection.
[0020] 5. The overcurrent self-healing function of the active protection subunit can switch to the redundant circuit in a short time to avoid secondary damage to the device under test and improve the safety of the test process. Attached Figure Description
[0021] Figure 1 This is a diagram of the overall system architecture.
[0022] Figure 2 This is a block diagram of the internal structure of a multi-level test unit.
[0023] Figure 3 This is a block diagram of the internal structure of the control and monitoring unit;
[0024] Figure 4 This is a block diagram of the online monitoring subunit structure.
[0025] Figure 5 This is a block diagram of the fault tracing subunit. Detailed Implementation
[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.
[0027] Reference Figure 1-5 This utility model discloses a frequency converter component and complete machine repair and testing device, which aims to solve the technical problem of separate testing of components and the complete machine in traditional testing, and realize integrated and efficient testing from the component level to the complete machine level. The core structure of the device includes multi-level testing units, intelligent interface system and control and monitoring unit. Each module completes comprehensive testing and monitoring of the frequency converter through precise signal connection and coordinated control.
[0028] Overall Structure and Connections: The multi-level test unit, as the core execution module of the testing function, establishes a physical and signal connection with the inverter under test through an intelligent interface system, realizing the transmission of test signals and the simulation of test conditions. The control and monitoring unit, as the "central system" of the device, is connected to the multi-level test unit and the intelligent interface system via electrical signals. On the one hand, it sends test process control commands to both, and on the other hand, it receives and processes various data generated during the test in real time, while also undertaking fault analysis and energy regulation functions. The intelligent interface system acts as a connecting bridge, ensuring the compatibility between the multi-level test unit and the inverter under test and the accuracy of signal acquisition through a reconfigurable hardware interface and an isolated signal transmission mechanism.
[0029] Component Testing Module: This module is specifically designed for precise testing of the performance parameters of core components in the frequency converter, providing data support for component quality inspection and troubleshooting. It includes:
[0030] Capacitor testing unit: It adopts a four-wire Kelvin connection method. This connection method can effectively eliminate the influence of test lead resistance and contact resistance on the measurement results, ensuring high-precision measurement of key parameters such as equivalent series resistance (ESR) and capacitance value of capacitors, and providing a reliable basis for judging the aging degree or performance quality of capacitors.
[0031] IGBT Dynamic Test Unit: Integrates a dual-pulse test circuit. By applying a specific dual-pulse drive signal to the IGBT, it can capture the voltage and current waveforms during the IGBT's turn-on (Eon) and turn-off (Eoff) processes, thereby quantifying and analyzing its switching losses and accurately assessing the IGBT's dynamic performance and health status.
[0032] Whole Machine Testing Module: This module comprehensively tests the operating performance of the frequency converter under different operating conditions, covering various industrial frequency converters with power ranges from 0.5kW to 1000kW. It includes:
[0033] Wide-range input power supply: It can simulate various disturbance scenarios in the actual power grid, such as voltage surges, drops, and harmonic injection. By adjusting the input voltage range and harmonic content, the adaptability and operational stability of the frequency converter in complex power grid environments can be verified.
[0034] Digital twin load: Based on a real-time simulator, a virtual load model is built, which can accurately simulate the dynamic characteristics of different types of loads such as motors, fans, and pumps, including load torque fluctuations and speed response. The inverter can be tested under load without relying on the actual physical load, reducing testing costs and expanding testing scenarios.
[0035] The specific composition and functions of the intelligent interface system: This system is key to achieving seamless switching testing between components and the complete machine. Through flexible interface adaptation and high-precision signal acquisition, it ensures test compatibility and data reliability.
[0036] Reconfigurable bed-of-needle fixture: Featuring a modular design, it supports at least eight common component package types (such as DIP-24, SMD-48, etc.). Through a pneumatic pressing drive mechanism, it can automatically switch between different fixtures within milliseconds, eliminating the need for frequent manual fixture changes, significantly improving testing efficiency and meeting the rapid testing needs of components with different packages.
[0037] Fiber optic isolated signal acquisition module: This module uses fiber optic transmission technology to achieve electrical isolation of the signal, effectively avoiding electromagnetic interference between the test system and the inverter under test. It can simultaneously capture the optocoupler signal from the driver board and the gate waveform of the IGBT, ensuring the integrity and accuracy of signal acquisition under high-frequency, high-voltage testing environments, providing high-quality raw data for subsequent fault analysis.
[0038] The specific composition and functions of the control and monitoring unit: This unit is responsible for intelligent control, data monitoring, and safety assurance throughout the entire testing process, achieving intelligent testing through the collaboration of multiple sub-units.
[0039] Online monitoring subunit: During the operation of the frequency converter, high-frequency ripple signals of the bus current are acquired in real time through a high-frequency sampling circuit (e.g., 10MHz sampling rate), while the temperature field distribution of the radiator is monitored through an infrared thermal imaging component. These data can intuitively reflect the internal electrical status and heat dissipation performance of the frequency converter, providing data support for the early detection of hidden faults.
[0040] Fault Origin Subunit: Integrating knowledge graph and multiphysics simulation technology. The knowledge graph constructs a fault rule base by associating historical fault data (such as the correspondence between capacitor value decrease and bus voltage fluctuation); the multiphysics simulation is based on methods such as finite element analysis (FEA) to simulate the impact of electrical, thermal and mechanical stress on components, accurately locate the root cause of faults (such as solder joint cracks, component aging, etc.), and significantly shorten the fault diagnosis time.
[0041] Energy Management Subunit: Employing bidirectional energy feedback technology, excess energy output by the inverter during testing (such as braking energy) is fed back to the grid or energy storage unit via an energy conversion circuit, achieving energy recycling. It also supports overload testing, simulating the inverter's operation under 0% to 150% rated load to verify its overload capacity, and reducing test energy consumption through dynamic load matching technology.
[0042] Active protection subunit: Serving as a safety barrier during the testing process, it monitors the current signal in the test circuit in real time. When an abnormal situation such as overcurrent is detected, it can quickly switch to a redundant test circuit within a preset time (e.g., 2μs), cutting off the fault path and preventing secondary damage to the inverter under test due to continuous abnormal current, significantly improving the safety of the testing process.
[0043] Through the coordinated operation of the above modules, this device achieves full-coverage testing from the component level to the complete machine level. It can complete multi-dimensional performance evaluation without disassembling the whole machine, effectively solving the problems of low efficiency, poor compatibility, and high rate of missed detection of hidden faults in traditional testing. It provides an efficient and accurate testing solution for industrial frequency converter repair and power electronic device production quality inspection.
[0044] Working principle of this utility model:
[0045] Multi-level test unit working principle: The component test module performs high-precision measurement of ESR / capacitance value of capacitors through the four-wire Kelvin connection of the capacitor test unit, and analyzes IGBT switching losses through the dual-pulse test circuit of the IGBT dynamic test unit; the wide-range input power supply of the whole machine test module simulates the disturbances such as power grid surges, drops, and harmonics, and the digital twin load simulates the dynamic characteristics of motors / fans, realizing the testing of the whole machine under different operating conditions.
[0046] The working principle of the intelligent interface system is as follows: The reconfigurable needle bed clamp switches in milliseconds according to the interface type of the tested component or the whole machine through pneumatic pressing, realizing the "single board - whole machine" interface adaptation; the fiber optic isolated signal acquisition module synchronously captures the optical coupler signal of the driver board and the IGBT gate waveform, ensuring the accuracy of signal acquisition and anti-interference.
[0047] The control and monitoring unit operates as follows: The online monitoring subunit collects high-frequency ripple of the bus current and the radiator temperature field during the operation of the entire machine in real time and transmits them to the control center; the fault tracing subunit uses a knowledge graph to associate historical fault data and combines multiphysics simulation to locate the root cause of the fault; the energy management subunit uses bidirectional energy feedback technology to feed excess energy back to the grid during the test process and dynamically matches the load to support overload testing; the active protection subunit monitors the current signal in real time and switches to redundant test loops when an overcurrent occurs to achieve overcurrent protection.
[0048] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.
Claims
1. A device for repairing and testing inverter components and the entire unit, characterized in that, include: Multi-level testing units, intelligent interface systems, and control and monitoring units; The multi-level test unit is connected to the inverter under test through an intelligent interface system to perform component-level and whole-machine-level testing. The control and monitoring unit is electrically connected to the multi-level test unit and the intelligent interface system respectively to control the test process, monitor test data in real time, perform fault tracing and energy management. The intelligent interface system is used to realize interface adaptation and signal transmission between the multi-level test unit and the inverter under test.
2. The inverter component and complete machine maintenance and testing device according to claim 1, characterized in that, The multi-level testing unit includes a component testing module and a complete machine testing module; the component testing module is used to perform parameter testing on the capacitors, IGBTs, and drive chip components of the frequency converter; the complete machine testing module is used to perform operational testing on the complete frequency converter with a power range of 0.5kW-1000kW.
3. The inverter component and complete machine maintenance and testing device according to claim 2, characterized in that, The component testing module includes a capacitor testing unit and an IGBT dynamic testing unit; the capacitor testing unit uses a four-wire Kelvin connection; the IGBT dynamic testing unit integrates a dual-pulse testing circuit for quantitative analysis of the IGBT's switching losses.
4. The inverter component and complete machine maintenance and testing device according to claim 2, characterized in that, The complete machine testing module includes a wide-range input power supply and a digital twin load; the wide-range input power supply is used to simulate power grid disturbances; the digital twin load is based on a real-time simulator and is used to simulate the dynamic characteristics of a motor or fan.
5. The inverter component and complete machine repair and testing device according to claim 1, characterized in that, The intelligent interface system includes a reconfigurable needle bed clamp and an optical fiber isolated signal acquisition module; the reconfigurable needle bed clamp supports at least eight package types and achieves millisecond-level switching through pneumatic pressing; the optical fiber isolated signal acquisition module is used to synchronously capture the driver board optocoupler signal and the IGBT gate waveform.
6. The inverter component and complete machine maintenance and testing device according to claim 1, characterized in that, The control and monitoring unit includes an online monitoring subunit, a fault tracing subunit, and an energy management subunit. The online monitoring subunit is used to collect high-frequency ripple of the bus current and the temperature field of the radiator in real time during the operation of the whole machine. The fault tracing subunit realizes the root cause of the fault based on knowledge graph and multiphysics simulation. The energy management subunit adopts bidirectional energy feedback technology and supports overload testing.
7. A frequency converter component and complete machine maintenance and testing device according to claim 6, characterized in that, The control and monitoring unit also includes an active protection subunit; the active protection subunit has an overcurrent self-healing function and can switch to a redundant test circuit within a preset time to avoid secondary damage to the device under test.