An electric control aging test unit, an aging test cabinet and an electric control aging test system

Abstract

This application discloses an electronically controlled aging test unit, an aging test cabinet, and an electronically controlled aging test system, relating to the field of electronically controlled equipment testing technology. The electronically controlled aging test unit includes a power interface for receiving DC power; an analog handheld controller signal output circuit connected to a programmable controller to generate multiple analog control signals; a motor drive board connected to the power interface to receive power; the motor drive board is also connected to the analog handheld controller signal output circuit to receive control signals; and an energy recovery circuit connected to the motor drive board to recover energy. By integrating the energy recovery circuit, the electrical signals output by the motor drive board are reused, reducing overall energy consumption and energy waste, thus achieving high resource utilization.

Description

Technical Field

[0001] This application relates to the field of electrical control equipment testing technology, and in particular to an electrical control aging test unit, an aging test cabinet, and an electrical control aging test system. Background Technology

[0002] Traditional electronically controlled aging test systems have three major drawbacks:

[0003] 1. Low testing efficiency: The single-loop design limits the number of electrical controls that can be tested at one time;

[0004] 2. Energy waste: The electrical energy tested is converted into heat energy and dissipated through the discharge circuit;

[0005] 3. Incomplete test coverage: It cannot simulate real hand controller signals and is difficult to trigger the full-state operation of the internal power circuit of the electronic control.

[0006] Therefore, there is an urgent need for a highly integrated, low-power solution with comprehensive test coverage. Utility Model Content

[0007] To address the aforementioned problems, the first technical solution adopted in this application is: to provide an electronically controlled aging test unit, comprising:

[0008] A power interface for receiving DC operating power.

[0009] An analog hand controller signal output circuit, which is connected to a programmable controller to generate multiple analog control signals;

[0010] A motor drive board is connected to the power interface to receive operating power; the motor drive board is also connected to the analog hand controller signal output circuit to receive control signals.

[0011] An energy recovery circuit is provided, which is connected to the motor drive board to realize energy recovery.

[0012] In an optional embodiment, the energy recovery circuit includes a rectifier circuit, a boost circuit, and an inverter circuit; the rectifier circuit is connected to the motor drive board to receive AC power and convert it into DC power output; the boost circuit receives the DC power output by the rectifier circuit and boosts it; the inverter circuit is connected to the boost circuit to receive the boosted DC power and convert it into 220V AC power output.

[0013] In an optional embodiment, the rectifier circuit implements rectification based on a full-bridge rectifier; the boost circuit implements boost voltage based on an IGBT switch; and the inverter circuit implements AD / DC current conversion based on a full-bridge topology.

[0014] In an optional embodiment, the analog hand controller signal output circuit includes an opto-isolator, and a signal amplification circuit is provided between the analog hand controller signal output circuit and the motor drive board.

[0015] The second technical solution adopted in this application is: providing an aging test cabinet, including:

[0016] Multiple electronically controlled aging test units as described in any of the preceding items;

[0017] A heat dissipation structure is provided, which is installed on the side wall of the aging test cabinet and in the gap between the electronically controlled aging test unit to achieve heat dissipation.

[0018] In an optional embodiment, the heat dissipation structure includes a forced convection air duct that runs through the cabinet, with an axial fan at the duct inlet.

[0019] The third technical solution adopted in this application is: providing an electronically controlled aging test system, comprising:

[0020] Multiple aging test cabinets as described in any of the preceding items;

[0021] The central control module enables the full-power operation of individual aging test cabinets to be activated in turn according to a preset time sequence.

[0022] In an optional embodiment, the electronically controlled aging test system further includes a power management module; the power management module is connected to the energy recovery circuit to receive 220V AC power.

[0023] In an optional embodiment, the power management module includes a power priority selection circuit and a mains power compensation circuit, and the switching of the main power supply is realized based on the power management module.

[0024] In an optional embodiment, the central control module includes a cabinet current monitoring unit, which controls the working state of the cabinet based on a comparison between the cabinet current and a preset threshold.

[0025] Due to the adoption of the above technical solution, this application has at least one of the following beneficial effects compared with the prior art:

[0026] 1. By integrating an energy recovery circuit, the electrical signals output by the motor drive board are reused; this not only reduces overall energy consumption but also reduces energy waste and improves resource utilization.

[0027] 2. The analog controller signal output circuit can generate multiple analog control signals, which can precisely trigger different states of the internal circuitry of the electronic control unit. This means that during aging tests, actual usage conditions can be simulated more realistically, ensuring comprehensive and detailed testing of the electronic control equipment.

[0028] 3. The analog hand controller signal output circuit includes an opto-isolator and a signal amplification circuit. The opto-isolator helps protect the circuit from electrical interference, improving the stability and reliability of the system; the signal amplification circuit ensures signal strength and quality, making control more precise and reliable. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] in:

[0031] Figure 1 A schematic diagram of the frame of an electronically controlled aging test unit provided in an embodiment of this application;

[0032] Figure 2 for Figure 1 A schematic diagram of the framework of an embodiment of the energy recovery circuit in the figure;

[0033] Figure 3 A schematic diagram of the frame of an aging test cabinet provided in an embodiment of this application;

[0034] Figure 4 This is a schematic diagram of the framework of an electronically controlled aging test system provided in an embodiment of this application. Detailed Implementation

[0035] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It is understood that the specific embodiments described herein are only for explaining this application and not for limiting it. Furthermore, it should be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, not all structures. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0036] The terms "first," "second," etc., used in this application are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0037] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0038] In traditional solutions, the electrical energy output during aging is ultimately converted into heat energy and dissipated through a discharge circuit, resulting in energy waste and additional heat dissipation requirements. This application introduces an energy recovery circuit that converts the AC signal output from the motor drive board into 220V AC power for the aging system through rectification, boosting, and inversion. This design not only reduces overall power consumption but also minimizes energy waste, achieving efficient resource utilization.

[0039] Furthermore, traditional methods cannot simulate the hand controller signal under real-world usage conditions, making it difficult to trigger all states of the internal circuitry of the electronic control unit for full-state testing. The simulated hand controller signal output circuit of this application can precisely control the switching of the internal circuitry of the electronic control unit, generating multiple simulated control signals. This ensures that all test requirements of the power circuit are covered, thereby more accurately simulating actual usage conditions during testing and improving the comprehensiveness and accuracy of the test. Figure 1 As shown, Figure 1 A schematic diagram of the frame of an electronically controlled aging test unit provided in an embodiment of this application includes:

[0040] The power interface is designed to receive DC power from an external source (such as 24V DC). This interface may include components such as reverse connection protection, overcurrent protection, and EMI filters to ensure the stability and safety of the input power.

[0041] The analog hand controller signal output circuit is connected to the programmable controller to generate multiple analog control signals; for example, different pulse width modulation (PWM) signals can be programmed to simulate the operation of various hand controllers.

[0042] Precise simulation of manual controller operation allows the internal circuitry of the electronic control system to be fully tested under various conditions, improving the coverage and accuracy of the test.

[0043] In another embodiment, the analog hand controller signal output circuit includes an opto-isolator, and a signal amplification circuit is provided between the analog hand controller signal output circuit and the motor drive board; the opto-isolator is used to enhance the signal's anti-interference capability, and the signal amplification circuit is used to increase the signal strength. Specifically:

[0044] Opto-isolators effectively cut off electrical connection paths by converting photoelectric signals, reducing the impact of external electromagnetic interference on signals. This ensures stable and accurate signal transmission even in environments with strong electromagnetic interference. Opto-isolators provide electrical isolation, preventing high voltage or current from accidentally entering the control system, thereby protecting sensitive electronic components from damage and improving the overall safety and reliability of the system.

[0045] The signal amplification circuit can compensate for the signal attenuation that may be encountered during long-distance transmission, ensuring that the control signal reaching the motor drive board is strong enough and undistorted. By accurately amplifying the signal, the motor drive board can respond more accurately to the instructions from the analog hand controller signal output circuit, thereby controlling the motor's movement more precisely and improving the control accuracy during the aging test.

[0046] The motor drive board connects to the power interface to receive operating power; it also connects to the analog hand controller signal output circuit to receive control signals. The motor drive board directly obtains the required operating power from the power interface and connects to the analog hand controller signal output circuit via a dedicated interface to receive control signals. Based on the received signals, the motor drive board drives the corresponding motor to perform actions, while simultaneously monitoring parameters such as current and voltage and feeding them back to the control system.

[0047] An energy recovery circuit is connected to the motor drive board to achieve energy recovery; for example... Figure 2 As shown, Figure 2 for Figure 1 A schematic diagram of an embodiment of the energy recovery circuit is shown below. The energy recovery circuit includes a rectifier circuit, a boost circuit, and an inverter circuit. The rectifier circuit converts the AC signal output from the motor drive board into DC power based on a full-bridge rectifier. The full-bridge rectifier consists of four diodes and can effectively convert the positive and negative half-cycle AC signals into unidirectional pulsating DC power.

[0048] The boost circuit uses IGBT switching transistors to boost DC power; it receives DC power from the rectifier circuit and uses PWM (Pulse Width Modulation) control technology to boost the voltage. The output voltage level can be flexibly adjusted as needed.

[0049] The inverter circuit uses a full-bridge topology to convert the boosted DC power back into 220V AC power for system reuse. The inverter circuit includes four power switching devices, and the required AC waveform is generated by precisely controlling the on and off times of these switches. The power switching devices are either MOSFETs or IGBTs, and no restrictions are placed on them.

[0050] By recovering electrical energy that would otherwise be wasted and resupplying it to the aging test system, overall energy consumption is significantly reduced, achieving the goal of energy conservation and environmental protection. The design of the three stages—rectification, boost, and inversion—ensures stable operation throughout the entire process. Targeted technical measures at each stage guarantee the high efficiency and reliability of energy conversion.

[0051] In summary, the electronically controlled aging test unit of this embodiment includes a power interface for receiving DC power; an analog controller signal output circuit connected to a programmable controller to generate multiple analog control signals; a motor drive board connected to the power interface to receive power; the motor drive board connected to the analog controller signal output circuit to receive control signals; and an energy recovery circuit connected to the motor drive board to recover energy. By integrating the energy recovery circuit, the electrical signals output by the motor drive board are reused, reducing overall energy consumption and energy waste, thus achieving high resource utilization.

[0052] This application also provides an aging test cabinet, such as Figure 3 As shown, Figure 3 A schematic diagram of the frame of an aging test cabinet provided in an embodiment of this application, including...

[0053] Multiple electronically controlled aging test units are integrated within an aging test cabinet. Each unit operates independently and can simultaneously perform aging tests on multiple electronically controlled devices. Each unit includes components such as a power interface, an analog hand controller signal output circuit, a motor drive board, and an energy recovery circuit. In this embodiment, the aging test cabinet includes 96 electronically controlled aging test units. In other embodiments, the number of electronically controlled aging test units can be selected differently, and no limitation is imposed on this.

[0054] The heat dissipation structure is located on the side wall of the aging test cabinet and in the gap between the electronically controlled aging test unit to achieve heat dissipation.

[0055] The heat dissipation structure includes forced convection air ducts (not shown) that run through the cabinet. Forced convection air ducts are installed on the sides or rear of the aging test cabinet. These air ducts are designed to run through the entire cabinet to ensure that air can enter from one side and exit from the other side, forming an effective airflow path.

[0056] A certain space is reserved between each electronically controlled aging test unit, and heat sinks or thermally conductive materials are arranged in these spaces to increase the surface heat dissipation area.

[0057] An axial flow fan is installed at the duct inlet to enhance airflow velocity. The selection of the fan must consider its airflow, static pressure, and noise level to meet the needs of different application scenarios. For example, multiple axial flow fans can be connected in parallel to ensure sufficient ventilation.

[0058] The combination of forced convection ducts and axial flow fans significantly increases airflow speed, quickly removing heat generated during aging tests and keeping the equipment operating within a suitable temperature range. This efficient heat dissipation mechanism helps prevent performance degradation or equipment damage due to overheating; a well-designed heat dissipation system maintains stable internal temperatures, reduces the aging rate of electronic components, and thus extends equipment lifespan.

[0059] This application also provides an electronically controlled aging test system, such as Figure 4 As shown, Figure 4 A schematic diagram of the framework of an electronically controlled aging test system provided in an embodiment of this application includes:

[0060] Multiple aging test cabinets are included. In this embodiment, four aging test cabinets are included. In other embodiments, the number of aging test cabinets can be selected separately, and there is no limitation on this.

[0061] The central control module enables the full-power operation of individual aging test cabinets to be activated in turn according to a preset timing sequence.

[0062] The electronic aging test system also includes a power management module; the power management module is connected to the energy recovery circuit to receive 220V AC power; the power management module includes an energy priority selection circuit and a mains power compensation circuit, and realizes the switching of the main power supply based on the power management module; it prioritizes the use of 220V AC power output from the energy recovery circuit as the main power supply; when the recovered energy is insufficient or the power quality is substandard, it automatically switches to external mains power as a supplementary power supply; ensuring that the system always has a stable and reliable power supply, while maximizing the utilization of recovered energy.

[0063] The central control module includes a cabinet current monitoring unit. The central control module controls the working status of the cabinet based on the comparison result between the cabinet current and the preset threshold; it collects the operating current of each cabinet in real time and compares it with the preset threshold; it dynamically adjusts the cabinet working mode according to the current detection result, such as entering current limiting operation, frequency reduction operation, or emergency shutdown protection mechanism.

[0064] The central control module activates each aging test cabinet in turn according to a preset time sequence to run at full power, effectively preventing grid impact caused by multiple cabinets starting at high loads simultaneously and ensuring the safe and stable operation of the power system. The cabinet current monitoring unit acquires operating current data in real time and compares it with the set safety threshold. Once an abnormality is detected, current limiting, speed reduction, or power cut-off measures are immediately taken to effectively prevent equipment overheating or damage. The power management module prioritizes the use of 220V AC power converted from the energy recovery circuit, reducing dependence on external mains power and realizing energy recycling.

[0065] In the several embodiments provided in this application, it should be understood that the disclosed methods and devices can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed.

[0066] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0067] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0068] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. An electronically controlled aging test unit, characterized in that, include: A power interface for receiving DC operating power. An analog hand controller signal output circuit, which is connected to a programmable controller to generate multiple analog control signals; A motor drive board is connected to the power interface to receive operating power; the motor drive board is also connected to the analog hand controller signal output circuit to receive control signals. An energy recovery circuit is provided, which is connected to the motor drive board to realize energy recovery.

2. The electronically controlled aging test unit according to claim 1, characterized in that, The energy recovery circuit includes a rectifier circuit, a boost circuit, and an inverter circuit; the rectifier circuit is connected to the motor drive board to receive AC power and convert it into DC power output; the boost circuit receives the DC power output by the rectifier circuit and boosts it; the inverter circuit is connected to the boost circuit to receive the boosted DC power and convert it into 220V AC power output.

3. The electronically controlled aging test unit according to claim 2, characterized in that, The rectifier circuit is based on a full-bridge rectifier to achieve rectification; the boost circuit is based on an IGBT switch to achieve boost voltage; and the inverter circuit is based on a full-bridge topology to achieve AD / DC current conversion.

4. The electronically controlled aging test unit according to claim 1, characterized in that, The analog hand controller signal output circuit includes an opto-isolator, and a signal amplification circuit is provided between the analog hand controller signal output circuit and the motor drive board.

5. An aging test cabinet, characterized in that, include: Multiple electronically controlled aging test units as described in any one of claims 1-4; A heat dissipation structure is provided, which is installed on the side wall of the aging test cabinet and in the gap between the electronically controlled aging test unit to achieve heat dissipation.

6. The aging test cabinet according to claim 5, characterized in that, The heat dissipation structure includes a forced convection air duct that runs through the cabinet, and an axial flow fan is installed at the air duct inlet.

7. An electronically controlled aging test system, characterized in that, include: Multiple aging test cabinets as described in claim 5 or claim 6; The central control module enables the full-power operation of individual aging test cabinets to be activated in turn according to a preset time sequence.

8. The electronically controlled aging test system according to claim 7, characterized in that, The electronic aging test system also includes a power management module; the power management module is connected to the energy recovery circuit to receive 220V AC power.

9. The electronically controlled aging test system according to claim 8, characterized in that, The power management module includes a power priority selection circuit and a mains power compensation circuit, and the switching of the main power supply is realized based on the power management module.

10. The electronically controlled aging test system according to claim 7, characterized in that, The central control module includes a cabinet current monitoring unit, which controls the working status of the cabinet based on the comparison result between the cabinet current and a preset threshold.

Images