Detection device

Abstract

This application relates to the field of magnetic core performance testing technology, specifically to a testing device for testing the magnetic core performance of a current sensor. The testing device includes: a magnetic sensor, disposed on one side of the current sensor, for acquiring the magnetic signal of the magnetic core in the current sensor and converting the magnetic signal into a first electrical signal; a pressure applying mechanism, including at least a pressure applying part located above the current sensor, for applying pressure to the current sensor or magnetic sensor to achieve positioning of the magnetic sensor and the magnetic core; and a controller, electrically connected to the magnetic sensor, for obtaining the magnetic detection result signal of the current sensor based on the first electrical signal. This method effectively reduces the false judgment rate of magnetic core performance and ensures the factory quality of the current sensor.

Description

Technical Field

[0001] This application relates to the field of magnetic core performance testing technology, specifically to a testing device. Background Technology

[0002] Current sensors are widely used in electric vehicles, industrial automation, and new energy power generation. The magnetic core in a current sensor achieves non-contact current measurement through electromagnetic conversion. However, during the manufacturing process of current sensors, the magnetic core is highly susceptible to deformation, breakage, and other damage, affecting measurement accuracy. Therefore, testing the performance of the current sensor's magnetic core and screening out products with abnormal performance can ensure the quality of current sensors leaving the factory.

[0003] In related technologies, X-ray non-destructive testing is typically used to perform internal imaging of current sensors, and the acquired X-ray images are used to check for conditions such as positional displacement, breakage, or defects in the magnetic core. However, current sensors have a high degree of integration, and X-ray images are easily affected by shadows and scattering, making it difficult to determine whether the magnetic core has been deformed, broken, or otherwise damaged, leading to an increased misjudgment rate of the magnetic core's performance. Utility Model Content

[0004] In view of the above problems, this application provides a detection device that can reduce the misjudgment rate of magnetic core performance.

[0005] To solve the above-mentioned technical problems, the technical solution adopted in this application is conceived as follows: This application provides a detection device for detecting the magnetic core performance of a current sensor. The detection device includes: a magnetic sensor disposed on one side of the current sensor, used to collect magnetic signals from the magnetic core of the current sensor and convert the magnetic signals into a first electrical signal; a pressure applying mechanism, which includes at least a pressure applying part located above the current sensor, used to apply pressure to the current sensor or the magnetic sensor to achieve positioning of the magnetic sensor and the magnetic core; and a controller electrically connected to the magnetic sensor, used to obtain the magnetic detection result signal of the current sensor based on the first electrical signal.

[0006] In some embodiments, the detection device further includes a support platform, on which the magnetic sensor, pressure application mechanism and controller are all disposed.

[0007] In some embodiments, the detection device further includes: a first power supply electrically connected to the magnetic sensor for supplying power to the magnetic sensor.

[0008] In some embodiments, the detection device includes: a first circuit board, a magnetic sensor disposed above the first circuit board, and a first power supply disposed below the first circuit board.

[0009] In some embodiments, the detection device further includes: a prompting component electrically connected to the controller for generating a prompting message based on the magnetic detection result; the prompting component is disposed on the support platform.

[0010] In some embodiments, the prompting component includes a voice component and / or a display component.

[0011] In some embodiments, the detection device further includes a second circuit board, on which a controller and a prompting component are disposed; the second circuit board is disposed on a support platform.

[0012] In some embodiments, the support platform is provided with a first sink, and the second circuit board, controller and prompting component are disposed in the first sink; the detection device further includes: a cover for covering the opening of the first sink.

[0013] In some embodiments, the detection object of the detection device is a current sensor with a three-phase copper busbar, each phase of the three-phase copper busbar is provided with a magnetic core, and the detection device further includes a bridging component; the detection device includes three magnetic sensors, which are arranged one-to-one with the magnetic cores provided in each phase of the three-phase copper busbar; wherein, the bridging component is used to electrically connect the two ends of the middle copper busbar to the adjacent ends of the other two copper busbars respectively, so that the three-phase copper busbars are arranged in series.

[0014] In some embodiments, the detection device further includes: a second power supply for electrically connecting to the three-phase copper busbar and providing power to the three-phase copper busbar; and a flexible snap-fit ​​component for elastically snapping the second power supply to the three-phase copper busbar.

[0015] In some embodiments, the controller integrates a comparator, a differential amplifier circuit electrically connected to the comparator, and a voltage divider configuration circuit. The differential amplifier circuit is also electrically connected to the magnetic sensor. The differential amplifier circuit processes the first electrical signal to obtain a second electrical signal, and the comparator obtains a magnetic detection result signal based on the second electrical signal and the threshold voltage signal provided by the voltage divider configuration circuit.

[0016] In some embodiments, the voltage divider configuration circuit includes a sliding rheostat and a first voltage divider resistor.

[0017] In some embodiments, the magnetic sensor includes a Hall element.

[0018] In some embodiments, the pressure applying mechanism further includes an operating part, a connecting part, a base, and a connecting rod. The base is disposed on a support platform, the connecting part is hinged to the base and is connected to the operating part and the pressure applying part respectively, and the middle part of the operating part is hinged to the base through the connecting rod. The operating part is used to drive the pressure applying part downward to apply pressure to the current sensor through the connecting part.

[0019] The beneficial effects of the embodiments of this application, which differ from the prior art, are as follows: By placing the magnetic sensor on one side of the current sensor and placing the pressure-applying part of the pressure-applying mechanism above the current sensor, the magnetic sensor can convert the acquired magnetic signal into a first electrical signal. The controller is electrically connected to the magnetic sensor and can obtain the magnetic detection result signal of the current sensor based on the first electrical signal. The pressure-applying part can apply pressure to the current sensor or the magnetic sensor to achieve the positioning of the magnetic sensor and the magnetic core. Compared with simple manual placement, this mechanical pressure fixing method eliminates the positional shift or shaking of the magnetic sensor caused by improper manual operation, which helps to improve the positioning efficiency and positioning effect between the magnetic sensor and the magnetic core. This allows the magnetic sensor and the magnetic core to be stably coupled, thereby improving the acquisition quality and accuracy of the magnetic signal. The first electrical signal converted by the magnetic signal can accurately reflect the true magnetic signal intensity, thereby improving the acquisition quality and accuracy of the magnetic detection result signal. This allows the controller to determine whether the magnetic core has been deformed, broken, or damaged based on the more accurate magnetic detection result signal, effectively reducing the misjudgment rate of the magnetic core performance and ensuring the factory quality of the current sensor. Attached Figure Description

[0020] 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, wherein: Figure 1 This is a schematic diagram of the structure of an embodiment of the detection device provided in this application; Figure 2 yes Figure 1 The diagram shows the structure of the detection device after the cover is hidden. Figure 3 This is a schematic diagram of the structure of the magnetic core of the magnetic sensor and the magnetic core of the current sensor of the detection device provided in this application; Figure 4 yes Figure 1 A schematic diagram of the detection device from another perspective; Figure 5 This is a circuit diagram of the detection device and current sensor provided in this application. Figure 6 This is a schematic diagram of another embodiment of the detection device provided in this application; Figure 7 This is a schematic diagram of another embodiment of the detection device provided in this application.

[0021] The reference numerals in the detailed embodiments are as follows: current sensor 200, magnetic core 210, groove 210a, three-phase copper busbar 220, first-phase copper busbar 221, second-phase copper busbar 222, third-phase copper busbar 223, detection device 100, magnetic sensor 110, Hall element 111, pressure applying mechanism 120, pressure applying part 121, operating part 122, connecting part 123, first connecting section 1231, second connecting section 1232, base 124, connecting rod 125, controller 130, differential amplifier circuit 131, comparator 132, voltage divider configuration circuit 133, sliding rheostat 1331, first voltage divider resistor 1332, support platform 141, first sink 141a, second sink 141b, cover 142, support frame 143, cavity 143a, heat dissipation hole 143b, first power supply 151, low dropout linear regulator 152, second power supply 153, first circuit board 161, second circuit board 162, indicator component 170, indicator light 171, red LED 171a, green LED 171b, buzzer 172, bridging component 180, conductive sheet 181. Detailed Implementation

[0022] 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.

[0023] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application 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, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0024] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0026] 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.

[0027] Current sensors are widely used in electric vehicles, industrial automation, and new energy power generation. The magnetic core in a current sensor achieves non-contact current measurement through electromagnetic conversion. However, during the manufacturing process of current sensors, the magnetic core is highly susceptible to deformation, breakage, and other damage, affecting measurement accuracy. Therefore, testing the performance of the magnetic core and screening out products with abnormal performance is crucial to ensuring the quality of current sensors before they leave the factory. Related technologies typically utilize X-ray non-destructive testing to perform internal imaging of the current sensor, examining the magnetic core for positional misalignment, breakage, or defects. However, the high integration of current sensors makes X-ray images susceptible to interference from shadows and scattering, making it difficult to determine whether the magnetic core has been deformed or broken, leading to a higher misjudgment rate regarding core performance.

[0028] This application provides a detection device 100. For example... Figures 1 to 3As shown, the detection device 100 is used to detect the performance of the magnetic core 210 of the current sensor 200. The detection device 100 includes a magnetic sensor 110, a pressure application mechanism 120, and a controller 130. The magnetic sensor 110 is disposed on one side of the current sensor 200 and is used to collect the magnetic signal of the magnetic core 210 in the current sensor 200 and convert the magnetic signal into a first electrical signal. The pressure application mechanism 120 includes at least a pressure application part 121, which is located above the current sensor 200 and is used to apply pressure to the current sensor 200 to achieve the positioning of the magnetic sensor 110 and the magnetic core 210. The controller 130 is electrically connected to the magnetic sensor 110 and is used to obtain the magnetic detection result signal of the current sensor 200 based on the first electrical signal.

[0029] The magnetic sensor 110 can be positioned above the current sensor 200, or it can be positioned below the current sensor 200. The following embodiment describes the situation with the magnetic sensor 110 positioned below the current sensor 200 as an example.

[0030] The magnetic core 210 can sense a magnetic signal when the current sensor 200 is energized. The magnetic sensor 110 can collect the magnetic signal and convert it into a first electrical signal. The first electrical signal can be a sampling voltage signal output by the magnetic sensor 110 based on the magnetic signal. This sampling voltage signal can include information such as the magnetic field strength corresponding to the magnetic signal and the inherent zero-point offset voltage of the magnetic sensor 110.

[0031] The controller 130 is electrically connected to the magnetic sensor 110 and is used to receive the first electrical signal and acquire the magnetic detection result signal of the current sensor 200 based on the first electrical signal. The magnetic detection result signal can be a judgment signal obtained by the controller 130 after processing such as signal conditioning and threshold comparison based on the first electrical signal. The controller 130 can also determine whether the performance of the magnetic core 210 is normal based on the magnetic detection result signal, and thus determine whether the magnetic core 210 has been deformed, broken or damaged.

[0032] By placing the magnetic sensor 110 on one side of the current sensor 200 and placing the pressure-applying part 121 of the pressure-applying mechanism 120 above the current sensor 200, the magnetic sensor 110 can convert the collected magnetic signal into a first electrical signal. The controller 130 is electrically connected to the magnetic sensor 110 and can obtain the magnetic detection result signal of the current sensor 200 based on the first electrical signal. The pressure-applying part 121 can apply pressure to the current sensor 200 or the magnetic sensor 110 to achieve the positioning of the magnetic sensor 110 and the magnetic core 210. Compared with simple manual placement, this mechanical pressure fixing method eliminates the positional shift or shaking of the magnetic sensor 110 caused by improper manual operation. This helps improve the positioning efficiency and effect between the magnetic sensor 110 and the magnetic core 210, enabling stable coupling between them. This improves the quality and accuracy of magnetic signal acquisition, allowing the first electrical signal converted from the magnetic signal by the magnetic sensor 110 to accurately reflect the true magnetic signal strength. Consequently, the quality and accuracy of the first electrical signal and the magnetic detection result signal are improved. This allows the controller 130 to determine whether the magnetic core 210 has been deformed, broken, or otherwise damaged based on the more accurate magnetic detection result signal, effectively reducing the misjudgment rate of the magnetic core 210's performance and ensuring the factory quality of the current sensor 200.

[0033] The pressure applying mechanism 120, current sensor 200, and magnetic sensor 110 are stacked sequentially, with the magnetic sensor 110 fixed below the current sensor 200, specifically below the groove 210a of the magnetic core 210, with the opening of the groove 210a facing the magnetic sensor 110. The pressure applying part 121 of the pressure applying mechanism 120 is located above the current sensor 200. When the pressure applying part 121 applies downward pressure, the pressure applied by the pressure applying part 121 acts on the corresponding part of the current sensor 200 and the magnetic core 210, causing the magnetic core 210 to move downward, thereby enabling the magnetic sensor 110 to be accurately inserted into the groove 210a of the magnetic core 210, achieving the positioning between the magnetic sensor 110 and the magnetic core 210. By placing the magnetic sensor 110 within the groove 210a of the magnetic core 210, the magnetic sensor 110 can be directly located at the center of the magnetic air gap of the magnetic core 210, which helps to improve the sensitivity of the magnetic sensor 110 and further improves the accuracy of the magnetic signal collected by the magnetic sensor 110.

[0034] In some embodiments, please continue to refer to Figures 1 to 3 The magnetic sensor 110 includes a Hall element 111. The Hall element 111 is disposed below the current sensor 200, specifically directly below the groove 210a of the magnetic core 210, so that when the pressure applying mechanism 120 applies pressure to the current sensor 200, the Hall element 111 can be inserted into the groove 210a and maintain a fixed relative position and air gap.

[0035] When the current sensor 200 and the Hall element 111 work simultaneously, the magnetic core 210 senses the magnetic field and guides the magnetic circuit to the Hall element 111. The magnetic field lines pass perpendicularly through the sensitive area of ​​the Hall element 111. The charge carriers inside the Hall element 111 are deflected under the action of the magnetic field, generating a voltage signal in a direction perpendicular to the current and the magnetic field. This voltage signal is the first electrical signal.

[0036] The Hall element 111 can be a linear Hall sensor or a switch-type Hall sensor, but is not limited to these. The specific model can be selected according to specific needs.

[0037] In some embodiments, the controller 130 may be a microcontroller, a field-programmable gate array, or an application-specific integrated circuit, but is not limited thereto.

[0038] In some embodiments, such as Figure 1 and Figure 2 As shown, the detection device 100 also includes a support platform 141. The magnetic sensor 110, the pressure application mechanism 120, and the controller 130 are all located on the support platform 141.

[0039] The support platform 141 serves as the load-bearing structure for the detection device 100 and the current sensor 200, providing a stable mounting base for the magnetic sensor 110, the pressure application mechanism 120, and the controller 130. The support platform 141 can be made of rigid materials, such as high-strength engineering plastics. On one hand, this prevents leakage current from the magnetic sensor 110, pressure application mechanism 120, and controller 130 from being transmitted to the external structure through the support platform 141, thus improving the insulation performance of the detection device 100. On the other hand, it can resist the force generated by the pressure application mechanism 120 during operation, maintaining structural stability and reducing or preventing loosening or displacement of the magnetic sensor 110, pressure application mechanism 120, and controller 130 due to deformation or shaking of the support platform 141. This helps to improve the relative positional fixation of the magnetic sensor 110 and the magnetic core 210 during the detection process, further improving the quality and accuracy of the magnetic signal acquired by the magnetic sensor 110.

[0040] In some embodiments, such as Figures 1 to 4 As shown, a support frame 143 extends from the edge of the support platform 141 away from the magnetic sensor 110, the pressure mechanism 120 and the controller 130, so as to form a cavity 143a with the support frame 143.

[0041] The support frame 143 can be a hollow structure open at both ends, with the support platform 141 covering one of the openings; alternatively, the support frame 143 can be a hollow structure open at one end and closed at the other, with the support platform 141 covering the opening. By covering the opening of the support frame 143 with the support platform 141, a cavity 143a is formed between the support platform 141 and the support frame 143. The support frame 143 can have various shapes, such as a cuboid, cube, or cylinder, but is not limited to these. The shape of the support platform 141 is adapted to the shape of the support frame 143.

[0042] Cavity 143a can be used to accommodate electrical connection components, such as wire harnesses and cables connecting structures like the magnetic sensor 110, current sensor 200, and controller 130, as well as terminals or miniature connectors for signal transmission. Cavity 143a can also accommodate power supply modules, such as the first power supply 151 and the second power supply 153 described in the following embodiments. Cavity 143a can also accommodate other auxiliary components, such as the prompting component 170 described in the following embodiments. By placing the electrical connection components and power supply modules within cavity 143a, the structures required on support platform 141 can be reduced, thereby preventing structures on support platform 141 from hindering the movement of pressure mechanism 120 and helping to improve the reliability and stability of the movement of pressure mechanism 120.

[0043] The support frame 143 can be made of rigid materials, such as high-strength engineering plastics or metal sheets, but is not limited to these. It can not only further improve the structural strength and stability of the support platform 141 connected to the support frame 143, but also improve the heat dissipation effect of the components located inside the cavity 143a, which helps to extend the service life of the components located inside the cavity 143a.

[0044] The support frame 143 is provided with multiple heat dissipation holes 143b that connect the cavity 143a to the external environment, so that the components inside the cavity 143a can dissipate heat quickly through the heat dissipation holes 143b.

[0045] In some embodiments, such as Figure 3 and Figure 5 As shown, the detection device 100 also includes a first power supply 151. The first power supply 151 is electrically connected to the magnetic sensor 110 and is used to supply power to the magnetic sensor 110.

[0046] The first power supply 151 is a module in the detection device 100 used to provide operating power to the magnetic sensor 110. The first power supply 151 and the magnetic sensor 110 are electrically connected through wires or a flexible circuit board to form a closed power supply circuit.

[0047] In some embodiments, the detection device 100 includes a first circuit board 161. A magnetic sensor 110 is disposed above the first circuit board 161, and a first power supply 151 is disposed below the first circuit board 161.

[0048] The first circuit board 161 is fixed to the side of the support platform 141 facing away from the cavity 143a, i.e., above the support platform 141, to make the structure of the first circuit board 161 more stable and reduce or avoid the risk of the first circuit board 161 collapsing or breaking under the pressure applied by the pressure mechanism 120; alternatively, the first circuit board 161 may also be disposed in the second recess 141b of the support platform 141 facing away from the cavity 143a, and the second recess 141b may be a recess formed on the side of the support platform 141 facing away from the cavity 143a. The magnetic sensor 110 is disposed above the first circuit board 161 so that the Hall element 111 can correspond to the groove 210a of the magnetic core 210.

[0049] The first power supply 151 can be located within the cavity 143a and connected to the magnetic sensor 110 via a wiring channel to conceal the wiring. The first power supply 151 supplies power to the magnetic sensor 110 via the first circuit board 161. More specifically, when the detection device 100 is operating, the output current of the first power supply 151 is delivered to the magnetic sensor 110 via the first circuit board 161.

[0050] By placing the magnetic sensor 110 above the first circuit board 161 and the first power supply 151 below the first circuit board 161, on the one hand, the first power supply 151 and the magnetic sensor 110 are separated in the vertical direction, which helps to reduce the impact of electromagnetic interference generated by the power supply circuit on the magnetic signal collected by the magnetic sensor 110, and can further improve the acquisition accuracy of the magnetic signal; on the other hand, the first circuit board 161 can serve as an intermediate hub between the controller 130 and the magnetic sensor 110, which can optimize the layout and length of the wiring, reduce the loss and interference in the signal transmission process, and enable the signal output by the magnetic sensor 110 to be transmitted to the controller 130 more quickly and stably, effectively improving the response speed and detection accuracy of the detection device 100.

[0051] In some embodiments, such as Figure 5As shown, the detection device 100 also includes a low-dropout regulator (LDO) 152. The LDO 152 can be integrated inside the first power supply 151; alternatively, the LDO 152 can be a separate component connected between the output of the first power supply 151 and the input of the magnetic sensor 110; alternatively, the LDO 152 can be integrated inside the first circuit board 161; alternatively, the LDO 152 can be integrated into the wiring harness connecting the first power supply 151 and the magnetic sensor 110.

[0052] The first power supply 151 may include a USB interface or a Type-C interface. When the low-dropout linear regulator 152 is integrated into the first power supply 151 or the first circuit board 161, the first circuit board 161 is electrically connected to the first power supply 151 via the USB interface or the Type-C interface. When the low-dropout linear regulator 152 is a separate component, the input terminal of the low-dropout linear regulator 152 is electrically connected to the first power supply 151 via the USB interface or the Type-C interface, and the output terminal of the low-dropout linear regulator 152 is electrically connected to the first circuit board 161.

[0053] The low-dropout linear regulator 152 converts the output voltage of the first power supply 151 into a stable 5V or 3.3V voltage and transmits it to the magnetic sensor 110. The low-dropout linear regulator 152 isolates voltage fluctuations and filters out noise, making the voltage transmitted to the magnetic sensor 110 more stable. This provides the magnetic sensor 110 with a stable operating environment unaffected by front-end power supply fluctuations, helping to further improve the quality and accuracy of magnetic signal acquisition.

[0054] In some embodiments, such as Figure 5 As shown, the detection device 100 also includes a prompting component 170. The prompting component 170 is electrically connected to the controller 130 and is used to generate prompting information based on the magnetic detection results. The prompting component 170 is disposed on the support platform 141.

[0055] The prompting component 170 is the output unit for human-computer interaction, that is, the feedback unit of the detection device 100. The prompting component 170 can be installed on the side of the support platform 141 facing away from the cavity 143a; or it can be installed on the side of the support platform 141 facing the cavity 143a.

[0056] The controller 130 controls the operation of the prompting component 170 based on the magnetic detection result signal. Under the control of the controller 130, the prompting component 170 outputs intuitively perceptible prompt information. For example, when the controller 130 determines that the magnetic core 210 is functioning normally based on the magnetic detection result signal, it controls the prompting component 170 to output a first prompt message, allowing the user to confirm that the magnetic core 210 has not been deformed, broken, or damaged. When the controller 130 determines that the magnetic core 210 is malfunctioning based on the magnetic detection result signal, it controls the prompting component 170 to output a second prompt message, allowing the user to confirm that the magnetic core 210 has been deformed, broken, or damaged. The first and second prompt messages are different.

[0057] The prompt component 170 includes, but is not limited to, a voice component and / or a display component. The prompt information can be a visual signal, an auditory signal, or a tactile signal, but is not limited to these.

[0058] More specifically, the voice component includes a buzzer 172, and the display component includes an indicator light 171. The indicator light 171 includes a red LED 171a and a green LED 171b. During the operation of the detection device 100, before the controller 130 receives the magnetic detection result signal, the buzzer 172 is turned off, and the red LED 171a remains constantly lit. When the controller 130 receives the magnetic detection result signal, if the controller 130 determines that the magnetic core 210 is functioning normally based on the magnetic detection result signal, the prompting component 170 will indicate that the red LED 171a is off, the green LED 171b is lit, and the buzzer 172 will sound. The user can determine from this prompting information that the magnetic core 210 is intact. If the controller 130 determines that the magnetic core 210 is malfunctioning based on the magnetic detection result signal, the prompting component 170 will indicate that the red LED 171a remains constantly lit. The user can determine from this prompting information that the magnetic core 210 has been deformed, broken, or otherwise damaged.

[0059] In some embodiments, such as Figure 2 As shown, the detection device 100 also includes a second circuit board 162, and the controller 130 and the prompting component 170 are disposed on the second circuit board 162. The second circuit board 162 is disposed on the support platform 141.

[0060] The second circuit board 162 serves as the carrier for core control and interactive functions, and a controller 130 and a prompting component 170 are mounted on it. The prompting component 170 can be connected to the pins of the controller 130 via traces on the second circuit board 162. The second circuit board 162 is electrically connected to the first circuit board 161, and the first power supply 151 can supply power to the second circuit board 162 through the first circuit board 161.

[0061] By placing both the controller 130 and the prompting component 170 on the second circuit board 162, and then placing the second circuit board 162 on the support platform 141, the control unit and feedback unit of the detection device 100 are highly integrated. This reduces the number of connecting cables, lowers the risk of interference during signal transmission, and improves the stability and reliability of the detection signal. The second circuit board 162 can be spaced apart from the first circuit board 161 to prevent the pressure mechanism 120 or the current sensor 200 from damaging the second circuit board 162.

[0062] In some embodiments, such as Figure 2 As shown, the support platform 141 is provided with a first sink 141a, and the second circuit board 162, controller 130 and prompting component 170 are disposed in the first sink 141a. The detection device 100 also includes a cover 142, which is used to cover the opening of the first sink 141a.

[0063] The first recess 141a can be a depression formed on the side of the support platform 141 facing away from the cavity 143a. The wall of the first recess 141a is provided with a wire hole communicating with the cavity 143a, and the area where the first circuit board 161 is located or the wall of the second recess 141b is provided with a wire hole communicating with the cavity 143a. The first circuit board 161 is electrically connected to the first power supply 151 or the low dropout linear regulator 152 through the wire hole, and is also electrically connected to the second circuit board 162 through the wire hole.

[0064] The area of ​​the cover 142 can be larger than the area of ​​the opening of the first settling tank 141a, so that the cover 142 can completely cover the opening. The cover 142 can be fixed to the support platform 141 by means of bolt connection, snap connection or adhesive connection, so as to improve the covering effect between the cover 142 and the opening.

[0065] By setting a first recess 141a on the support platform 141 and placing the second circuit board 162, controller 130 and prompting component 170 in the first recess 141a, and covering the opening of the first recess 141a with a cover 142, the components such as the second circuit board 162, controller 130 and prompting component 170 can be prevented from being directly exposed on the upper surface of the support platform 141. This not only prevents contaminants such as dust, moisture and oil from entering the circuit, but also prevents external mechanical collisions or accidental touches from causing the second circuit board 162 to shift, pins to be damaged or short-circuited, which helps to improve the service life and working stability of the detection device 100.

[0066] In some embodiments, such as Figure 1 , Figure 2 and Figure 6As shown, the detection object of the detection device 100 is a current sensor 200 with a three-phase copper busbar 220. Each phase of the three-phase copper busbar 220 is provided with a magnetic core 210. The detection device 100 includes three magnetic sensors 110, and the three magnetic sensors 110 are arranged one-to-one with the magnetic core 210 provided on each phase of the three-phase copper busbar 220.

[0067] Each phase of the three-phase copper busbar 220 is equipped with a magnetic core 210. That is, the current sensor 200 includes three magnetic cores 210. The three-phase copper busbar 220 passes through the central through-hole of the corresponding magnetic core 210, ensuring that each phase copper busbar is located at the center of its corresponding magnetic core 210. This ensures that the magnetic field generated by each phase copper busbar after energization can be completely focused by its corresponding magnetic core 210, thereby guaranteeing measurement accuracy. The three magnetic sensors 110 of the detection device 100 are configured one-to-one with the three magnetic cores 210.

[0068] The three-phase copper busbars 220 are connected in series in an S-shape. The magnetic induction direction of the magnetic sensor 110 located in the middle is opposite to that of the other two magnetic sensors 110. That is, the polarity of the Hall element 111 inside the magnetic sensor 110 located in the middle is opposite to that of the Hall element 111 inside the magnetic sensors 110 on both sides, so as to adapt to the change in the current direction in the series circuit of the three-phase copper busbars 220.

[0069] The detection device 100 also includes a bridging assembly 180. The bridging assembly 180 is used to electrically connect the two ends of the middle copper busbar to the adjacent ends of the other two copper busbars, so that the three-phase copper busbars 220 are connected in series.

[0070] The bridging assembly 180 may include two conductive pieces 181. One of the two conductive pieces 181 is used to electrically connect one end of the middle copper busbar to the adjacent end of another copper busbar located on one side, and the other of the two conductive pieces 181 is used to electrically connect the other end of the middle copper busbar to the adjacent end of yet another copper busbar located on the other side.

[0071] More specifically, the three-phase copper busbar 220 includes a first-phase copper busbar 221, a second-phase copper busbar 222, and a third-phase copper busbar 223. The second-phase copper busbar 222 is located in the middle, while the first-phase copper busbar 221 and the third-phase copper busbar 223 are located on opposite sides of the second-phase copper busbar 222 along the arrangement direction of the three-phase copper busbar 220. One of the two conductive pieces 181 is used to electrically connect one end of the second-phase copper busbar 222 to one end of the first-phase copper busbar 221, and the other of the two conductive pieces 181 is used to electrically connect the other end of the second-phase copper busbar 222 to one end of the third-phase copper busbar 223, thus realizing the series connection between the first-phase copper busbar 221, the second-phase copper busbar 222, and the third-phase copper busbar 223. One end of the second phase copper busbar 222 is set on the same side as one end of the first phase copper busbar 221, and the other end of the second phase copper busbar 222 is set on the same side as one end of the third phase copper busbar 223. This shortens the length of the conductive sheet 181, which not only improves the series efficiency of the three-phase copper busbar 220, but also helps to improve the signal transmission efficiency.

[0072] By setting the bridging component 180 to connect the three-phase copper busbars 220 in series, the three-phase copper busbars 220 can be excited simultaneously by connecting the other end of the first phase copper busbar 221 and the other end of the third phase copper busbar 223 to the positive and negative terminals of the same second power supply 153 at both ends of the series circuit. This reduces the number of constant current source circuits, simplifies the external power supply and wiring structure, and reduces the complexity and cost of the testing equipment.

[0073] In some embodiments, such as Figure 5 As shown, the detection device 100 also includes a second power supply 153 and a flexible snap-fit ​​connector (not shown). The second power supply 153 is used to electrically connect to the three-phase copper busbar 220 and provide electrical signals to the three-phase copper busbar 220. The flexible snap-fit ​​connector is used to elastically snap the second power supply 153 to the three-phase copper busbar 220.

[0074] The second power supply 153 can be a constant current source, used to provide a constant current or test signal to the three-phase copper busbar 220 for detection, so as to excite the magnetic core 210 to generate a magnetic field.

[0075] The flexible snap-fit ​​connector is used to achieve electrical connection and mechanical fixation between the second power supply 153 and the three-phase copper busbar 220. More specifically, the flexible snap-fit ​​connector elastically connects the second power supply 153 and the three-phase copper busbar 220, allowing the contact pressure to adapt to the surface condition of the copper busbar, eliminating the risk of signal fluctuations or disconnection due to poor contact, and helping to improve the stability of the magnetic field so that the magnetic field strength can accurately reflect the true performance of the magnetic core 210. Furthermore, the connection between the second power supply 153 and the three-phase copper busbar 220 via the flexible snap-fit ​​connector simplifies the electrical connection operation, making the overall installation process of the detection device 100 more convenient and improving the production efficiency of the detection device 100.

[0076] The flexible snap-fit ​​element can be a spring, a spring sheet, or other flexible conductive element, but is not limited to these.

[0077] In some embodiments, such as Figure 5 As shown, the controller 130 integrates a comparator 132, a differential amplifier circuit 131 electrically connected to the comparator 132, and a voltage divider configuration circuit 133. The differential amplifier circuit 131 is also electrically connected to the magnetic sensor 110. The differential amplifier circuit 131 processes the first electrical signal to obtain a second electrical signal, and the comparator 132 obtains the magnetic detection result signal based on the second electrical signal and the threshold voltage signal provided by the voltage divider configuration circuit 133.

[0078] One end of the differential amplifier circuit 131 is electrically connected to the magnetic sensor 110 to receive the first electrical signal output by the magnetic sensor 110. The function of the differential amplifier circuit 131 is to perform differential operation on the first electrical signal and the reference voltage signal, thereby eliminating the zero-point offset component in the first electrical signal and amplifying the weak differential signal to generate the second electrical signal.

[0079] More specifically, the first electrical signal is a sampling voltage signal, which can be obtained by the following formula: V = I * k + 2.5V, where I is the output current of the second power supply 153, k is the gain coefficient for converting current to voltage, which is related to the sensitivity selection of the Hall element 111 and the sensitivity of the magnetic core 210, and 2.5V is the zero-point output level of the Hall element 111 in the magnetic sensor 110. In some embodiments, the output current I of the second power supply 153 is 200A, and the sensitivity of the Hall element 111 is selected as 1mV / G. In this case, k is 0.002. Substituting into the above formula, the first electrical signal can be obtained, that is, the first electrical signal is 2.9V. The differential amplifier circuit 131 integrates a second voltage divider resistor (not shown in the figure); or, the differential amplifier circuit 131 includes two input terminals, which are used to electrically connect to the independent second voltage divider resistor and the magnetic sensor 110, respectively. The second voltage divider resistor is used to generate a reference voltage signal, which typically corresponds to the zero-point output level of the Hall element 111 in the magnetic sensor 110, i.e., the reference voltage signal is 2.5V. The differential amplifier circuit 131 is used to perform differential amplification on the reference voltage signal and the first electrical signal. That is, firstly, the reference voltage signal is subtracted from the first electrical signal to obtain the differential signal, i.e., the differential signal is 2.9V - 2.5V = 0.4V. Then, the differential amplifier circuit 131 amplifies the differential signal by 5 times to obtain a second electrical signal of 2.0V.

[0080] Differential calculation is performed by differential amplifier circuit 131, which is equivalent to removing the zero-point output level of Hall element 111. Without differential calculation, the voltage after amplification would reach tens of volts, which the system usually cannot withstand. However, with differential calculation, the voltage after amplification is only a few volts, which can eliminate the voltage component interference caused by the zero-point drift of Hall element 111, making the overall system of detection device 100 more stable.

[0081] Comparator 132 is electrically connected to both differential amplifier circuit 131 and voltage divider configuration circuit 133. Comparator 132 receives the amplified second electrical signal and the threshold voltage signal provided by voltage divider configuration circuit 133. The threshold voltage signal includes an upper threshold voltage signal and a lower threshold voltage signal, for example, 2.25V and 1.75V. Comparator 132 compares the second electrical signal with the upper and lower threshold voltage signals. If the second electrical signal falls within the range of the upper and lower threshold voltage signals, comparator 132 outputs a high level; otherwise, it outputs a low level. This output signal is the magnetic detection result signal.

[0082] Understandably, the sampling voltage signal obtained through the above formula is the voltage value corresponding to the first electrical signal converted by the magnetic sensor 110 based on the magnetic signal of the magnetic core 210 when the magnetic core 210 is in an ideal state. That is, the differential signal allows for an error of 0.05V, meaning the differential signal range is 0.4±0.05V, or 0.35V~0.45V. The differential amplifier circuit 131 amplifies this 0.35V~0.45V signal by a factor of 5, obtaining a second electrical signal of 2±0.5V. Therefore, as long as the second voltage signal output by the differential amplifier circuit 131 is within the range of 1.75V~2.25V, it indicates that the magnetic core 210 is performing normally, and the comparator 132 outputs a high level, indicating that the current sensor 200 has passed the test; otherwise, it indicates that the magnetic core 210 is performing abnormally, and the comparator 132 outputs a low level, indicating that the current sensor 200 has failed the test.

[0083] The output of comparator 132 is electrically connected to the input of prompting component 170. If comparator 132 outputs a high level, the red LED 171a of prompting component 170 turns off, the green LED 171b turns on, and the buzzer 172 sounds; if comparator 132 outputs a low level, the red LED of prompting component 170 remains constantly lit.

[0084] In some embodiments, comparator 132 may employ a hysteresis comparator to improve anti-interference capability and prevent misjudgment caused by signal fluctuations.

[0085] In some embodiments, the voltage divider configuration circuit 133 includes a sliding variable resistor 1331 and a first voltage divider resistor 1332.

[0086] The first voltage divider resistor 1332 is used to generate a threshold voltage signal, and the sliding resistor 1331 is used to adjust the first voltage divider resistor 1332 so that the threshold voltage signal generated by the first voltage divider resistor 1332 is within a preset range.

[0087] By configuring the voltage divider circuit 133 to include a sliding rheostat 1331 and a first voltage divider resistor 1332, the resistance value of the sliding rheostat 1331 can be adjusted to compensate for the precision error caused by manufacturing tolerances and the influence of temperature drift during operation of the first voltage divider resistor 1332, thus ensuring that the threshold voltage signal is accurately maintained within a preset range. This fine-tuning mechanism improves the stability of the threshold voltage signal setting in the detection device 100 under long-term operation or different environmental conditions, helps reduce the false judgment rate caused by threshold drift, and ensures the accuracy of the performance test results of the magnetic core 210.

[0088] In some embodiments, such as Figure 1 , Figure 2 , Figure 3 and Figure 7 As shown, the pressure applying mechanism 120 also includes an operating part 122, a connecting part 123, and a base 124. The base 124 is disposed on the support platform 141. The connecting part 123 is hinged to the base 124 and is connected to both the operating part 122 and the pressure applying part 121. The middle part of the operating part 122 is hinged to the base 124 via a connecting rod 125. The operating part 122 is used to drive the pressure applying part 121 downward to apply pressure to the current sensor 200 via the connecting part 123.

[0089] The base 124 is fixed to the support platform 141 and serves as the mounting carrier for the pressure applying mechanism 120. One end of the operating part 122 is a pressing end, and the other end is hinged to the connecting part 123. The middle part of the operating part 122 is hinged to the base 124 via a connecting rod 125. The connecting part 123 includes a first connecting segment 1231 and a second connecting segment 1232 that are connected to each other. The first connecting segment 1231 extends vertically and its bottom end is hinged to the base 124. Its top end is hinged to the other end of the operating part 122. The second connecting segment 1232 is fixedly connected to or integrally formed on the top end of the first connecting segment 1231 and extends away from the operating part 122. The end of the second connecting segment 1232 away from the first connecting segment 1231 is connected to the pressure applying part 121 so that the pressure applying part 121 and the connecting part 123 are relatively fixed. The pressure-applying part 121 has a pressure-applying surface on the side facing the current sensor 200, for applying pressure to the area of ​​the current sensor 200 where the magnetic core 210 is provided.

[0090] When the pressing end of the operating part 122 is pressed manually or by a driving member, the middle part of the operating part 122 rotates around its hinge point with the connecting rod 125, and transmits pressure to the top of the first connecting section 1231 of the connecting part 123. Since the bottom end of the first connecting section 1231 is hinged to the base 124, and the pressing part 121 and the connecting part 123 are relatively fixed, the connecting part 123 can swing relative to the base 124 after being subjected to pressure, thereby driving the pressing part 121 to move downward. When the pressing surface of the pressing part 121 contacts the magnetic core 210, and the Hall element 111 is inserted into the groove 210a of the corresponding magnetic core 210, the pressing part 121 can no longer move downward. At this time, the connecting part 123 and the operating part 122 also stop moving synchronously. At this time, the pressing part 121 completes the pressing operation on the three-phase copper busbar 220 with the preset pressure and stroke.

[0091] The extension direction of the pressure application part 121 is parallel to the arrangement direction of each phase copper busbar in the three-phase copper busbar 220. The orthogonal projection of the pressure application part 121 toward the support platform 141 can cover at least a portion of the area of ​​each magnetic core 210 in all magnetic cores 210, so that the pressure application part 121 can insert the three Hall elements 111 into the groove 210a of the corresponding magnetic core 210 at one time.

[0092] In some embodiments, a first control unit (not shown) is connected between the output terminal of the magnetic sensor 110 and the input terminal of the differential amplifier circuit 131. The first control unit reads the first electrical signal output by the magnetic sensor 110 through an analog-to-digital converter (ADC). The first control unit is used to process, analyze, and save the first electrical signal in real time. Simultaneously, the first control unit can also upload the sampling data corresponding to the first electrical signal to a host computer for data management. In this way, when a batch of current sensors 200 passes the test but has unstable performance, the original first electrical signal data can be retrieved for trend analysis to identify the problem.

[0093] In some embodiments, the output of comparator 132 is provided with a second control unit (not shown). The second control unit is used to read and store the magnetic detection result signal.

[0094] Both the first control unit and the second control unit are microcontroller units (MCUs).

[0095] 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. A detection device, characterized in that, The detection device is used to detect the core performance of a current sensor, and includes: A magnetic sensor, located on one side of the current sensor, is used to collect the magnetic signal of the magnetic core in the current sensor and convert the magnetic signal into a first electrical signal; A pressure-applying mechanism, comprising at least a pressure-applying part located above the current sensor, the pressure-applying part being used to apply pressure to the current sensor or the magnetic sensor to achieve positioning of the magnetic sensor and the magnetic core; The controller is electrically connected to the magnetic sensor and is used to obtain the magnetic detection result signal of the current sensor based on the first electrical signal.

2. The detection device according to claim 1, characterized in that, The detection device further includes: The support platform, the magnetic sensor, the pressure application mechanism and the controller are all located on the support platform.

3. The detection device according to claim 2, characterized in that, The detection device further includes: A first power supply is electrically connected to the magnetic sensor and is used to power the magnetic sensor.

4. The detection device according to claim 3, characterized in that, The detection device includes: The first circuit board, wherein the magnetic sensor is disposed above the first circuit board, and the first power supply is disposed below the first circuit board.

5. The detection device according to claim 2, characterized in that, The detection device further includes: A prompting component, electrically connected to the controller, is used to generate prompting information based on the magnetic detection result; the prompting component is disposed on the support platform.

6. The detection device according to claim 5, characterized in that, The prompting component includes a voice component and / or a display component.

7. The detection device according to claim 5, characterized in that, The detection device further includes a second circuit board, on which the controller and the prompting component are disposed; the second circuit board is disposed on the support platform.

8. The detection device according to claim 7, characterized in that, The support platform is provided with a first sinkhole, and the second circuit board, the controller and the prompting component are disposed in the first sinkhole; The detection device further includes a cover for covering the opening of the first settling tank.

9. The detection device according to claim 2, characterized in that, The detection object of the detection device is the current sensor with a three-phase copper busbar, each phase of the three-phase copper busbar is provided with the magnetic core, and the detection device also includes a bridging component; The detection device includes three magnetic sensors, each corresponding to a magnetic core located in each phase of the three-phase copper busbar. The bridging assembly is used to electrically connect the two ends of the middle copper busbar to the adjacent ends of the other two copper busbars, so that the three-phase copper busbars are connected in series.

10. The detection device according to claim 9, characterized in that, The detection device further includes: The second power supply is used to be electrically connected to the three-phase copper busbar and to provide power to the three-phase copper busbar. A flexible snap-fit ​​connector is used to elastically snap the second power supply to the three-phase copper busbar.

11. The detection device according to claim 1, characterized in that, The controller integrates a comparator, a differential amplifier circuit electrically connected to the comparator, and a voltage divider configuration circuit. The differential amplifier circuit is also electrically connected to the magnetic sensor. The differential amplifier circuit processes the first electrical signal to obtain a second electrical signal, and the comparator obtains the magnetic detection result signal based on the second electrical signal and the threshold voltage signal provided by the voltage divider configuration circuit.

12. The detection device according to claim 11, characterized in that, The voltage divider configuration circuit includes: Sliding rheostat and first voltage divider resistor.

13. The detection device according to claim 1, characterized in that, The magnetic sensor includes a Hall element.

14. The detection device according to claim 2, characterized in that, The pressure-applying mechanism further includes an operating part, a connecting part, a base, and a connecting rod. The base is disposed on the support platform. The connecting part is hinged to the base and is connected to the operating part and the pressure-applying part respectively. The middle part of the operating part is hinged to the base through the connecting rod. The operating part is used to drive the pressure-applying part downward to apply pressure to the current sensor through the connecting part.

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