A relay automatic testing system

Abstract

This utility model relates to the field of relay testing technology and discloses an automatic relay testing system for aircraft component maintenance. The system includes: a test circuit unit comprising an optocoupler chip circuit, a main control circuit, a communication circuit, and a resistor network. The optocoupler chip circuit drives the relays, the main control circuit receives and sends test commands and data, and the resistor network collects discrete signals emitted by the relays; a test host computer, whose software is connected to the test circuit unit and is used to send test control commands, process test data, and display test results; an external power supply for driving the relays; and a USB power supply for powering the test circuit unit. The system can simultaneously test multiple relays, achieving short testing times, high efficiency, low maintenance costs, and a simple, easy-to-implement circuit structure.

Description

Technical Field

[0001] This utility model relates to the field of relay testing technology, and specifically to an automatic relay testing system. Background Technology

[0002] The ER134 relay, with its superior performance, has already made a name for itself in the field of ultra-miniature RF switches, especially in the UHF frequency range, where it demonstrates unparalleled applicability. Its typical application in handheld radio transceivers is a testament to its outstanding performance. Not only does it excel in RF performance, but its compact size, low-power coil design, and high reliability make it the preferred solution for transmit-receive switching.

[0003] However, in maintenance practice, newly manufactured ER134 relays sometimes experience intermittent failures due to storage conditions or other unforeseen factors; ER134 relays older than 7 years can also experience mechanical contact aging due to frequent use, leading to improper removal of aircraft accessories. This unreliability and intermittent failure undoubtedly pose a significant challenge to maintenance personnel, severely impacting their troubleshooting efficiency and consequently reducing overall maintenance quality. Furthermore, existing aircraft accessory testing equipment cannot effectively and efficiently test ER134 relays, nor can it pinpoint the faulty relay in circuits with multiple relays installed simultaneously. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this utility model is to provide an automatic relay testing system that can help maintenance personnel quickly identify and resolve relay faults, significantly improve troubleshooting efficiency, and ensure a steady improvement in repair quality. This will allow the superior performance of the ER134 relay to be fully utilized, providing a solid guarantee for the stable operation of the radio transceiver.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] An automatic relay testing system includes:

[0007] The test circuit unit includes an optocoupler chip circuit, a main control circuit, a communication circuit, and a resistor network. The optocoupler chip circuit is used to drive the relay to work, the main control circuit is used to receive and send test commands and data, and the resistor network is used to collect discrete signals emitted by the relay.

[0008] The host computer is connected to the test circuit unit and is used to send test control commands, process test data and display test results.

[0009] An external power source, used to drive the relay;

[0010] The USB power supply is used to power the test circuit unit.

[0011] In this invention, preferably, the optocoupler chip circuit includes multiple optocoupler chips, each of which is connected to two relay interfaces, and the relay interfaces are connected to the corresponding relay to be tested.

[0012] In this invention, preferably, each relay interface is connected to a resistor network, which includes six resistors. Each resistor is connected to pins 1-3 and 5-7 of the relay interface to collect discrete signals from each relay contact.

[0013] In this invention, preferably, pins 5 and 7 of the optocoupler chip are connected to pin 4 of the corresponding relay interface, and pin 8 of the relay interface is grounded.

[0014] In this invention, preferably, pins 1 and 7 of the relay interface are connected to a 5V power supply after a resistor, and pins 2, 3, 5, and 6 are connected to the ground terminal after a series resistor.

[0015] In this invention, preferably, pins 1 and 3 of the optocoupler chip are connected in series with resistors and then connected to the control signals sent by the main control circuit.

[0016] In this utility model, preferably, a protection circuit is also included. The protection circuit includes external interfaces J1 and J8. Pins 1 and 2 of the external interface J1 are connected to an external 12V / 28V power supply. The external 12V / 28V power supply is also connected in series with a resistor R1 and a diode D1 and then grounded. Pins 1 and 2 of the external interface J8 are grounded.

[0017] In this invention, preferably, the test host computer software and the test circuit unit communicate with each other via the RS232 communication protocol.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] This utility model's system enables functional testing of ER134 relays in maintenance practice, solving the problem of automatic relay testing.

[0020] It can test multiple relays simultaneously, completing the test in a short time with high efficiency;

[0021] Low maintenance costs: Traditional testing equipment requires regular TPM and self-testing. This system is designed to reduce potential maintenance costs, making the equipment run more efficiently.

[0022] This system has a simple circuit structure, is easy to implement, and can be replicated. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of an automatic relay testing system according to the present invention.

[0024] Figure 2 This is a circuit diagram of the test circuit unit of an automatic relay testing system according to the present invention.

[0025] Figure 3 This is a circuit diagram of an embodiment of the automatic relay testing system described in this utility model.

[0026] Figure 4 This is a protection circuit diagram of an automatic relay testing system according to the present invention.

[0027] Figure 5 This is the main control circuit diagram of an automatic relay testing system according to the present invention. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0029] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is considered "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is considered "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] Please see Figure 1and Figure 2 This utility model provides an automatic relay testing system that can perform comprehensive functional testing on ER134 relays. This system helps maintenance personnel quickly identify and resolve faults, significantly improving troubleshooting efficiency and ensuring a steady improvement in repair quality. The testing system specifically includes:

[0032] The test circuit unit is connected between the test host computer and the relay under test. The test circuit unit includes an optocoupler chip circuit, a main control circuit, a communication circuit, and a resistor network. The optocoupler chip circuit is used to drive the relay to work. The main control circuit is used to receive and send test commands and data. The resistor network is used to collect discrete signals emitted by the relay. After receiving the test command, the main control circuit drives the relay to work through the optocoupler chip circuit, then receives the discrete signals of the relay collected by the resistor network, and then converts them into the resistance of the relay contacts under test through the AD conversion function inside the main control circuit. Finally, the test data is sent to the test host computer through the communication circuit.

[0033] It also includes a host computer for testing. The host computer software is communicatively connected to the test circuit unit and is used to send test control commands, process test data, and display test results. The host computer first sends test commands to the main control circuit, which then controls the relay to be tested. At the same time, it receives the test data returned by the main control circuit and displays the test results through the display component.

[0034] It also includes an external power supply and a USB power supply. The external power supply is used to drive the relay, and the USB power supply is used to power the test circuit unit.

[0035] In this embodiment, the optocoupler chip circuit includes multiple optocoupler chips, each of which is connected to two relay interfaces, and the relay interfaces are connected to the corresponding relay to be tested.

[0036] In this embodiment, each relay interface is connected to a resistor network, which includes six resistors. Each resistor is connected to pins 1-3 and 5-7 of the relay interface to collect discrete signals from each relay contact.

[0037] In this embodiment, pins 5 and 7 of the optocoupler chip are respectively connected to pin 4 of the corresponding relay interface, and pin 8 of the relay interface is grounded.

[0038] In this embodiment, pins 1 and 7 of the relay interface are connected to a 5V power supply after a resistor, and pins 2, 3, 5, and 6 are connected to the ground terminal after a series resistor.

[0039] In this embodiment, pins 1 and 3 of the optocoupler chip are connected in series with resistors and then connected to the control signals sent by the main control circuit.

[0040] Specifically, such as Figure 3 As shown, this embodiment includes optocoupler chips U1-U5, each of which is connected to two relay interfaces. The connection structure of each optocoupler chip with the relay interface and resistor network is identical; therefore, one is used as an example for explanation. Pins 1 and 3 of optocoupler chip U1 are connected to control signals IN1 and IN2 sent by the main control circuit via resistors R6 and R8, respectively. Pins 2 and 4 of optocoupler chip U1 are grounded. Pins 6 and 8 of optocoupler chip U1 are connected to a 12V / 28V power supply via resistors R2 and R3, respectively. Pins 5 and 7 of optocoupler chip U1 are connected to pin 4 of the corresponding relay interface 1 and relay interface 2, respectively. Pins 1 and 7 of relay interface 1 are connected to a +5V power supply via resistors R4 and R5, respectively. Pins 2, 3, 5, and 6 are... Connect resistors R7, R10, R11, and R9 in series to the ground terminal. Connect pin 8 of relay interface 1 to the ground terminal. Resistors R4, R5, R7, R10, R11, and R9 form a resistor network to collect discrete signals emitted by each contact of the relay corresponding to relay interface 1. Transmit the signals to the main control circuit. The 10-bit AD sampling module built into the main control chip of the main control circuit converts the input discrete signals into digital signals and feeds back the corresponding detection results to the test host computer. The test host computer compares the data to determine whether the relay test is passed.

[0041] like Figure 4 As shown, this embodiment also includes a protection circuit, which includes external interfaces J1 and J8. Pins 1 and 2 of external interface J1 are connected to an external 12V / 28V power supply. The external 12V / 28V power supply is also connected in series with resistor R1 and diode D1 before being grounded. Pins 1 and 2 of external interface J8 are grounded. The 12V / 28V power supply is input from external interface J1 and then current-limited by resistor R1. One path of the power supply current powers the optocoupler chip, and the other path passes through diode D1. Because diode D1 is forward-biased, the current can flow smoothly through the loop, and the circuit works normally. If external interface J1 is mistakenly connected to a reverse voltage or if an external load generates reverse current, diode D1 will reverse-biased cutoff, directly cutting off the dangerous current loop and protecting resistor R1 and optocoupler chip from damage by reverse voltage.

[0042] like Figure 5As shown, the main control circuit primarily uses the ATMEGA16U2-MU series control chip. The control chip IC4 connects to a USB-to-serial port circuit, a reset and startup configuration circuit, buttons, and a reset circuit. It also includes a linear voltage regulator chip U3, which uses the AMS1117-3.3 series chip. This chip steps down the input 5V or 12V voltage to 3.3V to power the control chip IC4 and peripheral circuits, ensuring voltage stability for the main control circuit. Peripheral capacitors C8 and C9 are used for filtering to reduce power fluctuations.

[0043] In this embodiment, the test host computer software and the test circuit unit communicate with each other via the RS232 communication protocol. The corresponding communication circuit uses an RS232 circuit to receive test commands and send test data.

[0044] The above description is a detailed description of the preferred embodiments of the present utility model. However, the embodiments are not intended to limit the scope of the patent application of the present utility model. All equivalent changes or modifications made under the technical spirit of the present utility model should fall within the patent scope covered by the present utility model.

Claims

1. A relay automatic testing system, characterized by, include: The test circuit unit includes an optocoupler chip circuit, a main control circuit, a communication circuit, and a resistor network. The optocoupler chip circuit is used to drive the relay to work, the main control circuit is used to receive and send test commands and data, and the resistor network is used to collect discrete signals emitted by the relay. The host computer is connected to the test circuit unit and is used to send test control commands, process test data, and display test results. An external power source, used to drive the relay; The USB power supply is used to power the test circuit unit.

2. The automatic relay testing system according to claim 1, characterized in that, The optocoupler chip circuit includes multiple optocoupler chips, each of which is connected to two relay interfaces, and the relay interfaces are connected to the corresponding relays to be tested.

3. The automatic relay testing system of claim 2, wherein Each of the relay interfaces is connected to a resistor network, which includes six resistors. Each resistor is connected to pins 1-3 and 5-7 of the relay interface, respectively, for acquiring discrete signals from each relay contact.

4. The automatic relay testing system of claim 3, wherein Pins 5 and 7 of the optocoupler chip are connected to pin 4 of the corresponding relay interface, and pin 8 of the relay interface is grounded.

5. The automatic relay testing system of claim 4, wherein, Pins 1 and 7 of the relay interface are connected to a 5V power supply via a resistor, while pins 2, 3, 5, and 6 are connected to ground via a series resistor.

6. The automatic relay testing system of claim 2, wherein Pins 1 and 3 of the optocoupler chip are connected in series with resistors and then connected to the control signals sent by the main control circuit.

7. The automatic relay testing system of claim 1, wherein It also includes a protection circuit, which includes external interfaces J1 and J8. Pins 1 and 2 of the external interface J1 are connected to an external 12V / 28V power supply. The external 12V / 28V power supply is also connected in series with a resistor R1 and a diode D1 and then grounded. Pins 1 and 2 of the external interface J8 are grounded.

8. The automatic relay testing system of claim 1, wherein, The test host computer software and the test circuit unit communicate with each other via the RS232 communication protocol.

Images