An inverter aging online monitoring device

Abstract

The utility model discloses an inverter aging on -line monitoring equipment, solved the inverter aging test equipment test throughput little, the problem of low integration in the prior art. The utility model discloses a control cabinet and the test box body of setting in control cabinet left and right two sides, be equipped with N layer storage board in the test box body, N is equal to or greater than 2, be equipped with the detection station of row and column arrangement on the storage board, the test box body top is equipped with heating device and air circulation device, and heating device, air circulation device all with the PLC electric connection in control cabinet, all be equipped with program -controlled power supply and the on -off tester in the test box body, and PLC, program -controlled power supply and on -off tester all with the industrial computer electric connection in control cabinet. The utility model integrates temperature control, power supply, measurement, control in one, realized from the whole process automation of product on -shelf to test completion, and the test efficiency and consistency have been improved greatly.

Description

Technical Field

[0001] This utility model relates to the field of power electronic product testing technology, and in particular to an aging and online monitoring device for F1L inverter assembly. Background Technology

[0002] Inverters are key components in fields such as new energy vehicles, and their reliability is paramount. Finished product aging testing is a crucial step in screening for early-failure products and ensuring factory quality. Traditional inverter aging tests typically employ simple oven heating combined with external power and manual measurement, which has the following drawbacks: 1. Low automation: The testing process relies on manual operation and recording, resulting in low efficiency and a high risk of errors; the throughput per test is also low. 2. Weak monitoring capabilities: It is impossible to monitor the dynamic operating status of internal components such as relays in real time during high-temperature aging, making it difficult to detect intermittent faults. 3. Difficult data traceability: Test data records are incomplete or non-standardized, making it difficult to trace and analyze problems after they occur. 4. Poor testing flexibility: It cannot easily achieve multi-channel independent testing or dynamically change test parameters (such as voltage), and the utilization rate of test resources is low. Therefore, there is an urgent need for a highly integrated, automated aging test device with online monitoring and data traceability capabilities. Utility Model Content

[0003] To address the shortcomings in the aforementioned background technology, this utility model proposes an online monitoring device for inverter aging, which solves the problems of low test throughput and low integration in existing inverter aging test equipment.

[0004] The technical solution of this utility model is implemented as follows: An online monitoring device for inverter aging includes a control cabinet and test chambers arranged on the left and right sides of the control cabinet; the test chambers are equipped with N layers of shelves, N≥2, and the shelves are equipped with test stations arranged in rows and columns; the top of the test chambers is equipped with a heating device and a wind circulation device, both of which are electrically connected to a PLC in the control cabinet; each test chamber is equipped with a programmable power supply and a continuity tester, and the PLC, programmable power supply, and continuity tester are all electrically connected to an industrial computer in the control cabinet. This integrates temperature control, power supply, measurement, and control into one unit, achieving full automation from product placement to test completion, significantly improving testing efficiency and consistency. This utility model can monitor the working status of internal relays in real time during high-temperature aging and can dynamically change test conditions, effectively screening out potentially defective products. Further optimization involves a top cavity at the top of the test chamber, where the heating and air circulation devices are integrated. This integrated design makes the structure more compact, does not occupy the effective volume of the test area, and increases the testing area.

[0005] Further optimization involves a heating device comprising a hot air blower and an air guide plate mounted on the side wall of the test chamber. The air guide plate contains an air guide cavity, which is connected to the hot air blower's outlet via an air guide pipe. Several air outlets are located on the side of the air guide plate facing the shelf. This design achieves uniform airflow heating. The air guide plate covers the entire height of the side wall, and the air outlets correspond one-to-one with each shelf, ensuring each shelf receives an equal amount of hot air. This completely eliminates the "hot at the top, cold at the bottom" phenomenon caused by single-point airflow from the top, improving the consistency of the aging curve.

[0006] Further optimization involves setting air guide plates on both sides inside the test chamber, with several parallel limiting grooves on the air guide plates, and limiting blocks that cooperate with the limiting grooves on both sides of the placement plate.

[0007] Further optimization includes a circulating fan and a cooling fan installed at the top of the test chamber, an exhaust valve and an intake valve on the side wall of the test chamber, and several ventilation holes evenly distributed on the shelf. During operation, the circulating fan circulates the internal hot air, further improving heating uniformity; in addition, after the test, opening the cooling fan and the intake and exhaust valves can quickly cool the interior.

[0008] Further optimization involves providing n horizontal bars and m vertical bars on the upper surface of the shelf, where n≥1 and m≥1. The n horizontal bars and m vertical bars form (n+1)×(m+1) testing stations, enabling the inverter to be clamped in place in one go, thus improving its stability, while also forming physical isolation.

[0009] Further optimization involves installing an insulating bracket at the testing station, with elastic clips on both sides of the bracket; this allows for the one-step clamping, insulation, and anti-loosening of the inverter.

[0010] Further optimization involves installing one continuity tester and N programmable power supplies inside a test chamber, and having N PLCs inside the control cabinet, with each PLC corresponding to one of the N programmable power supplies.

[0011] Further optimization involves the industrial computer communicating with the programmable power supply and PLC via the Modbus protocol, and communicating with the continuity tester via the SCPI protocol.

[0012] Further optimization involves installing a temperature sensor inside the test chamber, which is electrically connected to an industrial computer. The temperature sensor detects the temperature inside the test chamber and transmits the temperature signal to the industrial computer, which then controls the heating and air circulation devices to form a closed-loop control system.

[0013] The beneficial effects of this utility model are as follows: 1. High integration and automation: It integrates temperature control, power supply, measurement and control into one, realizing full-process automation from product placement to test completion, which greatly improves test efficiency and consistency.

[0014] 2. Online real-time monitoring and diagnosis: It can monitor the working status of the internal relays of the product in real time during the high-temperature aging process, and can dynamically change the test conditions to effectively screen out products with potential defects.

[0015] 3. Powerful data traceability capabilities: All test data is linked and stored with product identity and location information, establishing a complete traceable database to facilitate subsequent quality analysis and problem tracking.

[0016] 4. Flexible and efficient multi-station operation: Adopting a multi-threaded host computer software architecture, it supports two or more test chambers to work independently and in parallel without interference, thereby improving equipment utilization and test throughput.

[0017] 5. User-friendly operation: The intelligent control of PLC + industrial computer reduces the complexity and error rate of manual operation.

[0018] 6. Excellent temperature control: The combination of heating device and air circulation device can achieve uniform and efficient heating to the set temperature, and can also cool down quickly after the work is completed, improving the testing efficiency. Attached Figure Description

[0019] To more clearly illustrate the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the overall front view of this utility model; Figure 2 This is a schematic diagram of the internal structure of this utility model; Figure 3 This is a schematic diagram of the internal structure of the test chamber of this utility model; Figure 4 This is a schematic diagram of the shelf structure; Figure 5 A schematic diagram of the preset timing for aging tests. Detailed Implementation

[0021] 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.

[0022] Example 1, such as Figure 1 ,2 As shown, an online monitoring device for inverter aging includes a control cabinet 1 and test chambers 2 located on the left and right sides of the control cabinet 1. One control cabinet corresponds to two test chambers, increasing the throughput of a single test. The test chamber 2 has N layers of shelves 4, where N≥2. The shelves 4 have rows and columns of testing stations, each holding one inverter (finished inverter assembly). Laser-engraved QR codes can be placed at each testing station for quick identification of the corresponding inverter when an anomaly is detected. The multi-layer shelf and row / column testing station design supports simultaneous testing of multiple inverters, significantly improving aging test efficiency and making it suitable for large-scale production scenarios. The top of the test chamber 2 has a heating device 5 and a ventilation device 6. Both the heating device 5 and the ventilation device 6 are electrically connected to a PLC inside the control cabinet 1. The top heating device and the ventilation device work together, achieving uniform temperature distribution within the chamber (±1℃ accuracy) through PLC closed-loop control. This simulates a high-temperature aging environment, accelerates fault exposure, and shortens the testing cycle. Each test chamber 2 is equipped with a programmable power supply 7 and a continuity tester 8. The PLC, power supply 7, and continuity tester 8 are all electrically connected to the industrial computer 9 in control cabinet 1. The PLC controls temperature, air circulation, and power output in real time, responding to millisecond-level faults. The industrial computer centrally processes continuity tester data, automatically generates aging curve reports, and supports MES system integration, enabling full traceability of test data. The industrial computer, i.e., the host computer system, employs multi-threading technology, allowing for simultaneous independent control of two chambers. Using a multi-threaded host computer software architecture, it supports two or more aging chambers operating independently and in parallel without interference, improving equipment utilization and test throughput; and enabling flexible and efficient multi-station operation.

[0023] In this embodiment, the industrial computer 9 communicates with the programmable power supply 7 and the PLC via the Modbus protocol, and with the continuity tester 8 via the SCPI protocol. The test chamber 2 has a top cavity, within which the heating device 5 and the air circulation device 6 are integrated. The heater, fan, and air duct are integrated into the top cavity, without occupying the effective volume of the test area, resulting in high integration. The top cavity can be a single module, eliminating the need for production line changes or fault repairs to stop and disassemble the chamber. A temperature sensor is installed inside the test chamber 2, electrically connected to the industrial computer 9. The temperature sensor detects the temperature inside the test chamber and transmits the temperature signal to the industrial computer, thereby controlling the heating device and the air circulation device to form a closed-loop control system.

[0024] The control cabinet can also be equipped with a barcode scanner. During operation, the operator places the inverter on the shelf and connects the test leads, then uses the barcode scanner to enter the product serial number. The host computer system provides voice prompts indicating the location number. The host computer then calls the preset test configuration file (including parameters such as temperature and duration) and starts the test. The PLC controls the heating device to raise the temperature inside the test chamber (working chamber) to 80°C and maintain this temperature for 1 hour. During this period, the host computer controls the programmable power supply to change the output voltage (8.5V, 12.5V, 16.5V) according to a predetermined procedure and controls the product relay to engage / disengage. Simultaneously, a continuity tester monitors the product status in real time. All data, including product ID, location, status data, and environmental parameters, is recorded in the industrial computer's database. If a product abnormality is detected, its location number will be immediately highlighted in red on the interface. After the test, the air circulation device is activated to cool the device, and the equipment is shut down once the temperature drops to 40°C. This invention integrates temperature control, power supply, measurement, and control into one unit, achieving full automation from product placement to test completion, significantly improving testing efficiency and consistency. Furthermore, it can monitor the working status of internal relays in real time during high-temperature aging and dynamically change test conditions, effectively screening out potentially defective products.

[0025] Example 2, as Figure 3 As shown, an online aging monitoring device for inverters is further optimized based on Embodiment 1. In this embodiment, the heating device 5 includes a hot air blower 51 and an air guide plate 52 disposed on the side wall of the test chamber 2. The air guide plate 52 has an air guide cavity, which is connected to the air outlet of the hot air blower 51 through an air guide pipe 53. The side of the air guide plate 52 facing the shelf 4 has several air outlets. The hot air from the hot air blower 51 enters the air guide cavity of the air guide plate through the air guide pipe, and then is discharged towards the shelf through the air outlets. The air guide plate covers the entire height of the side wall, and the air outlets are arranged one-to-one with each shelf, so that each shelf receives an equal amount of hot air, completely eliminating the "hot at the top and cold at the bottom" phenomenon caused by single-point air supply from the top, and improving the consistency of the aging curve. The hot air blower 51 adopts a variable frequency fan with a linearly adjustable wind speed of 0.5–2 m / s. The high-speed airflow is first depressurized inside the cavity, and then overflows evenly from the Φ3mm array holes. The turbulence noise is then reduced by the perforated plate, thus achieving a noise reduction effect.

[0026] As a preferred embodiment, the air guide plates 52 are positioned on both sides inside the test chamber 2, forming a two-sided air outlet structure to improve heating efficiency and heating uniformity. The air guide plates 52 have several parallel limiting grooves 54, which are integrally extruded with the air guide cavity. The sides of the shelf 4 have limiting blocks 41 that mate with the limiting grooves 54. By engaging the shelf with limiting grooves of different heights, the height of the shelf can be adjusted to accommodate the testing of different inverter models. The limiting blocks have built-in spring steel balls that self-lock with a "click" when pushed in, ensuring the stability of the shelf.

[0027] In this preferred embodiment, the air circulation device 6 includes a circulating fan 61 and a cooling fan 64 mounted on the top of the test chamber 2. An exhaust valve 62 and an intake valve 63 are located on the side wall of the test chamber 2, and several ventilation holes are evenly distributed on the shelf 4. During operation, hot air from the hot air blower enters the chamber, the exhaust and intake valves are closed, and the circulating fan starts, allowing the hot air to circulate within the chamber, improving heating efficiency. After the test, the hot air blower and circulating fan are turned off, and the cooling fan, exhaust valve, and intake valve are opened, allowing hot air inside the chamber to be quickly expelled and cold air outside to quickly enter, achieving rapid cooling of the chamber. The equipment is shut down after the temperature drops to 40°C.

[0028] like Figure 4 As shown, in this embodiment, the upper surface of the shelf 4 is provided with n horizontal bars and m vertical bars, where n≥1 and m≥1. The n horizontal bars and m vertical bars form (n+1)×(m+1) testing stations. Taking n=4, m=5, and N=3 as an example, one layer forms 30 stations, for a total of 90 stations; one enclosure can test 90 inverters simultaneously. The horizontal and vertical bars form a 2mm high "well"-shaped guardrail, which automatically aligns with the edge when the inverter is pushed in. It should be noted that the interior of the vertical bars can be hollow, with a 5×2mm long groove on the front, where all high-temperature test lines can be concealed. The cover plate can be fastened to flatten the surface; the wire harnesses do not cross, greatly reducing the short-circuit rate. The spacer material is anodized aluminum, which has fast heat conduction and low thermal inertia. To further improve the stability of the inverter, an insulating bracket 42 is provided at the testing station. The insulating bracket 42 has elastic cards on both sides for clamping the inverter. The inverter's DC terminals are automatically locked in place by elastic clips with a simple push. These clips are nickel-plated beryllium copper, extending their service life. Furthermore, a miniature normally closed detection switch can be embedded within the clip holder, automatically triggering an alarm if not fully inserted. The insulating clip holder is at the same height as the spacer bar, with a completely flat surface, allowing unobstructed airflow from the ventilation holes, with hot air directly passing over the inverter. By adding this small module of "insulating clip holder + double-sided elastic clips" to the testing station, clamping, insulation, and anti-loosening are all achieved in one step, ensuring the stability and safety of the test.

[0029] In this embodiment, a continuity tester 8 and N programmable power supplies 7 are installed inside a test chamber 2. The control cabinet 1 contains N PLCs, with each PLC corresponding one-to-one with one of the N programmable power supplies 7. The programmable power supplies provide a precise and adjustable test voltage to the product under test, and the continuity tester is used to detect the continuity status of the internal circuits of the product in real time. Two temperature sensors are installed on each layer to improve temperature control accuracy.

[0030] The specific testing process is as follows: Initialization: The operator places the product, connects the cables, and scans the code. The system follows the location-specific voice prompts; after clicking "Start," the aging and testing procedures will begin.

[0031] Heating: The host computer sends a command, and the PLC controls the heating device and circulating fan to start, so that the temperature of the working chamber rises to 80℃ at a uniform rate.

[0032] Constant temperature aging: Start timing for 1 hour after the temperature stabilizes. The host computer will follow the preset timing sequence (e.g., ...). Figure 5 (As shown) The programmable power supply switches the output voltage and sends commands to enable / disable product relays K1 / K2 and K3 / K4 sequentially. The continuity tester continuously monitors the status of the N terminal of the OBC interface, recording data to the database once per minute.

[0033] Anomaly Handling: If the monitoring data does not meet expectations (such as disconnection when the circuit is on), the host computer will immediately mark the corresponding area code of the product in red on the software interface.

[0034] Cooling Completion: After 1 hour of aging, the host computer instructs the PLC to open the inlet and exhaust air valves; shut down the circulating fan and start the cooling fan to force cooling of the working chamber. When the temperature sensor detects that the temperature has dropped to 40℃, the system automatically shuts down all equipment, saves the recorded data to the database, and the test is complete. The database record format includes the zone number, product serial number, and 4-digit status monitoring data. The status data bits represent the K1 / K2 enable status, K3 / K4 enable status, OBC interface N status, and overall product qualification status, achieving standardized and refined data management.

[0035] It should be noted that this utility model improves the equipment components and does not involve improvements to the circuit or control program. This utility model only controls the operation and shutdown of various electronic devices through a PLC control system. Since the PLC control system is a mature automatic control system in industry, this utility model will not elaborate on the circuit and control program content.

[0036] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An online monitoring device for inverter aging, characterized in that: It includes a control cabinet (1) and test chambers (2) set on the left and right sides of the control cabinet (1); the test chambers (2) are equipped with N layers of shelves (4), N≥2, and the shelves (4) are equipped with test stations set in rows and columns; the top of the test chambers (2) is equipped with a heating device (5) and a wind circulation device (6), the heating device (5) and the wind circulation device (6) are electrically connected to the PLC in the control cabinet (1), the test chambers (2) are equipped with a programmable power supply (7) and a continuity tester (8), the PLC, the programmable power supply (7) and the continuity tester (8) are electrically connected to the industrial computer (9) in the control cabinet (1).

2. The inverter aging online monitoring device according to claim 1, characterized in that: The test chamber (2) has a top cavity, and the heating device (5) and the air circulation device (6) are integrated in the top cavity.

3. The inverter aging online monitoring device according to claim 1 or 2, characterized in that: The heating device (5) includes a hot air blower (51) and a guide plate (52) set on the side wall of the test chamber (2). The guide plate (52) has a guide cavity inside, and the guide cavity is connected to the air outlet of the hot air blower (51) through the guide pipe (53). The guide plate (52) has several air outlet holes on the side facing the shelf (4).

4. The inverter aging online monitoring device according to claim 3, characterized in that: The air guide plate (52) is set on both sides inside the test chamber (2). The air guide plate (52) is provided with several parallel limiting grooves (54). The two sides of the shelf (4) are provided with limiting blocks (41) that cooperate with the limiting grooves (54).

5. The inverter aging online monitoring device according to claim 1 or 4, characterized in that: The air circulation device (6) includes a circulating fan (61) and a cooling fan (64) installed on the top of the test chamber (2). The test chamber (2) is provided with an exhaust valve (62) and an intake valve (63) on its side wall. Several ventilation holes are evenly distributed on the shelf (4).

6. The inverter aging online monitoring device according to claim 5, characterized in that: The upper surface of the shelf (4) is provided with n horizontal bars and m vertical bars, n≥1, m≥1, and the n horizontal bars and m vertical bars form (n+1)×(m+1) detection stations.

7. The inverter aging online monitoring device according to claim 6, characterized in that: An insulating card holder (42) is provided at the testing station, and elastic cards are provided on both sides of the insulating card holder (42).

8. The inverter aging online monitoring device according to claim 1, 4, or 7, characterized in that: A continuity tester (8) and N programmable power supplies (7) are set in a test box (2). N PLCs are set in the control cabinet (1), and the N PLCs correspond one-to-one with the N programmable power supplies (7).

9. The inverter aging online monitoring device according to claim 8, characterized in that: The industrial computer (9) communicates with the programmable power supply (7) and PLC via the Modbus protocol, and communicates with the continuity tester (8) via the SCPI protocol.

10. The inverter aging online monitoring device according to claim 1 or 9, characterized in that: A temperature sensor is installed inside the test chamber (2), and the temperature sensor is electrically connected to the industrial computer (9).

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