A new energy automobile resistor high temperature anti-cracking performance test device

Abstract

The utility model provides a new energy automobile resistor high temperature anti -cracking performance testing device, including control cabinet, the integrated installation of touch -sensitive screen, air switch and audible -visual alarm have in control cabinet, control cabinet installation setting is in test board one side, water tank is located the just below of absorption window that opens in test board, is installed to set up sample power port and electric nozzle in absorption window department, installs the temperature probe and visual camera in fixed mounting of test board monitoring seat installation setting, the utility model discloses a controller host computer + power box control resistor high temperature, micro -water pump + electric nozzle complex water condition, with visual camera + processing host computer automatic detection crack, exempt from artificial error, still through many components monitoring temperature, water level, current, guarantees the safety of test, provides accurate data for resistor reliability verification.

Description

Technical Field

[0001] This utility model belongs to the field of resistor testing technology, and in particular relates to a high-temperature crack resistance testing device for resistors in new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, ceramic automotive resistors, as key components in vehicle electrical systems, need to operate stably under complex conditions such as high temperature and humidity for extended periods. Their high-temperature crack resistance directly determines the resistor's lifespan and the safety of the entire vehicle's electrical system. When exposed to coolant splashes or changes in ambient humidity at high temperatures, ceramic materials are prone to internal stress due to thermal expansion and contraction, leading to cracks, abnormal resistance values, short circuits, and even safety accidents. Therefore, conducting precise high-temperature crack resistance tests on ceramic automotive resistors is a core aspect of factory testing and reliability verification for new energy vehicle components.

[0003] However, current high-temperature crack resistance testing equipment for ceramic automotive resistors in the industry has the following technical shortcomings: Existing testing equipment is mostly general-purpose electrical component testing equipment. It does not have dedicated test parameters designed for the thermophysical properties of ceramic materials (such as high-temperature brittleness and thermal conductivity). The adjustment flexibility of key parameters such as heating current and water spray interval is poor, and it cannot accurately simulate the actual working condition of resistors in new energy vehicles, which is "high-temperature heating-water cooling". This results in a large deviation between the test results and the actual use scenario.

[0004] Traditional testing equipment requires manual visual inspection of the resistor surface for cracks. This is not only prone to missed or incorrect judgments due to differences in subjective judgment, but also cannot capture minute cracks, resulting in low testing efficiency and difficulty in meeting the rapid testing needs of batch components.

[0005] The existing equipment lacks real-time monitoring of key parameters during the test—such as the temperature distribution at different locations of the resistor (which can easily lead to misjudgment due to local overheating), the water level in the water tank (the water pump will run dry and damage the equipment when there is a lack of water), and the test current (abnormal current can easily burn out the sample). The test cannot be automatically terminated under abnormal conditions, which can easily cause sample damage, equipment failure, or even safety hazards.

[0006] Therefore, it is essential to invent a high-temperature crack resistance testing device for resistors in new energy vehicles. Utility Model Content

[0007] To address the aforementioned technical problems, this utility model provides a high-temperature crack resistance testing device for resistors in new energy vehicles, comprising a control cabinet, a touch screen, an air switch, an audible and visual alarm, a test bench, a water tank, an absorption window, a sample power port, an electric nozzle, a monitoring seat, a temperature probe, and a vision camera. The touch screen, air switch, and audible and visual alarm are integrated and installed on the control cabinet, which is mounted on one side of the test bench. The water tank is located directly below the absorption window on the test bench. The sample power port and electric nozzle are installed at the absorption window. The temperature probe and vision camera are mounted on the monitoring seat fixedly installed on the test bench.

[0008] Preferably, the control cabinet has a built-in vision processing host, a controller host, and a power supply box. The controller host is connected to both the vision processing host and the power supply box. The vision processing host is connected to the vision camera via electrical signals. The controller host is connected to the temperature probe, the audible and visual alarm, and the miniature water pump. The controller host controls the sample power port through the power supply box.

[0009] Preferably, the vision camera and temperature probes are fixedly mounted on the lower slope of the monitoring base, wherein three temperature probes are arranged around the vision camera and aligned with the ceramic automotive resistor inserted into the sample power port.

[0010] Preferably, the sample power port is installed on the slope of the absorption window and is matched with the position of the vision camera and the temperature probe.

[0011] Preferably, an electric nozzle is installed at a position opposite to the sample power port, and the electric nozzle is embedded in the vertical side of the absorption window.

[0012] Preferably, the electric nozzle is connected to the water tank via a pipe and a micro water pump. The electric nozzle can spray the liquid inside the water tank onto the ceramic automotive resistor inserted into the sample power port. The inner wall of the water tank is provided with a water level module, which is connected to the controller host.

[0013] Compared with the prior art, the present invention has the following beneficial effects: This invention utilizes the linkage control of a "controller host + power supply box" to flexibly set parameters such as heating current and heating time, precisely controlling the high-temperature heating state of the resistor. Simultaneously, through the directional water spraying design of a "micro water pump + electric nozzle" combined with timed interval water spraying logic, it perfectly replicates the actual working condition of "high-temperature heating - water cooling" of new energy vehicle resistors, ensuring that the test results are highly consistent with the actual performance of the components, and providing accurate data support for the reliability verification of ceramic automotive resistors.

[0014] This invention replaces traditional manual observation with an automated detection combination of a "visual camera + visual processing host": the visual camera is fixed on the inclined surface of the monitoring seat and aligned with the resistor, and automatically takes a picture after water is sprayed; the visual processing host analyzes the image in real time, which can accurately identify minute cracks and avoid omissions and misjudgments caused by human subjective errors; at the same time, no manual supervision is required, which greatly improves the testing efficiency of batch parts and reduces labor costs.

[0015] This invention features three temperature probes positioned around a vision camera and aligned with the resistor, enabling simultaneous acquisition of temperature data from different locations on the resistor. This avoids test deviations caused by localized overheating and ensures stable temperature conditions. The water level module on the inner wall of the water tank is connected to the controller host, monitoring the water level in real time. In case of water shortage, the controller immediately stops the test and triggers an audible and visual alarm to prevent damage to the micro water pump from running dry. The controller host monitors the test current in real time through the power supply box, records the current curve, and quickly terminates the test in case of abnormalities, preventing resistor burnout or circuit failure, thus comprehensively ensuring the safety of the test process and the integrity of the sample. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0017] Figure 2 This is another overall structural schematic diagram of this utility model.

[0018] Figure 3 This is a utility model Figure 2 A magnified schematic diagram of the structure at point A.

[0019] Figure 4 This is an electrical schematic diagram of the present invention.

[0020] In the picture: 1. Control cabinet; 2. Touch screen; 3. Air switch; 4. Audible and visual alarm; 5. Test bench; 6. Water tank; 7. Absorption window; 8. Sample power port; 9. Electric nozzle; 10. Monitoring seat; 11. Temperature probe; 12. Vision camera. Detailed Implementation

[0021] To enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0022] In the description of the embodiments, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the present invention and for 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. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of the utility model, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in the present utility model based on the specific circumstances.

[0023] As attached Figure 1 To be continued Figure 4 As shown: This utility model provides a high-temperature crack resistance testing device for resistors in new energy vehicles, comprising a control cabinet 1, a touch screen 2, an air switch 3, an audible and visual alarm 4, a test bench 5, a water tank 6, an absorption window 7, a sample power port 8, an electric nozzle 9, a monitoring seat 10, a temperature probe 11, and a vision camera 12. The control cabinet 1 integrates the touch screen 2, the air switch 3, and the audible and visual alarm 4. The control cabinet 1 is installed on one side of the test bench 5. The water tank 6 is located directly below the absorption window 7 on the test bench 5. The sample power port 8 and the electric nozzle 9 are installed at the absorption window 7. The temperature probe 11 and the vision camera 12 are installed on the monitoring seat 10 fixedly installed on the test bench 5.

[0024] Furthermore, the surface of control cabinet 1 is treated with electrostatic powder coating (industrial gray color), providing excellent corrosion resistance and impact resistance. Inside, a custom-designed metal bracket securely houses the vision processing host, controller host, and power supply box in designated areas: the controller host is centrally located, the vision processing host is bolted to a bracket on the left side of the controller host, and the power supply box is installed on the right side of the controller host (15cm away to allow for heat dissipation). The controller host and vision processing host are bidirectionally connected via a Cat5e shielded network cable, enabling the transmission of "photo capture trigger commands" (controller host → vision processing host) and "crack analysis result data" (vision processing host → controller host). The controller host and power supply box are connected via two copper core control wires, used to send control signals such as "current adjustment" and "power supply start / stop" to the power supply box. The vision processing host establishes an electrical signal connection with the vision camera 12 via a high-definition video cable with a BNC connector, allowing real-time reception of resistor surface image data captured by the vision camera 12, avoiding image distortion caused by electromagnetic interference. The controller host is also connected to the temperature probe 11, the audible and visual alarm 4, and the miniature water pump via dedicated signal lines: a PT100 platinum resistance thermometer signal line (temperature resistant 200℃) is used with the temperature probe 11 to collect resistor temperature data; a relay control line is used with the audible and visual alarm 4 to trigger the audible and visual alarm function; and a DC control line (compatible with the water pump's 12V operating voltage) is used with the miniature water pump to realize the water pump's start / stop and speed regulation. In addition, the controller host indirectly controls the sample power port 8 through the power supply box. Specifically, the controller host outputs a "target current value" signal to the power supply box, and the voltage regulation module inside the power supply box converts the mains power into a set current based on the signal, which is then transmitted to the sample power port 8 via wires to provide a stable power supply for the ceramic automotive resistor inserted into that port.

[0025] Furthermore, the monitoring base 10 is made of 6061 aluminum alloy (lightweight and with good heat dissipation). Its bottom is designed with a 30-45° inclined detection mounting surface, where both the vision camera 12 and the temperature probe 11 are fixedly mounted. The vision camera 12 is screwed onto a pre-set mounting hole in the center of the inclined surface via a metal mounting base with silicone shock-absorbing pads. The camera lens focal length is set to 16mm, and the lens axis is perpendicular to the inclined surface to ensure that the shooting angle can completely cover the surface of the resistor inserted into the sample power port 8 (the shooting resolution is 1920×1080, and the frame rate is 25fps). Three temperature probes 11 (all PT100 platinum resistance probes, measuring range -50℃~400℃, accuracy ±0.5℃) are respectively embedded in the front, left and right positions of the vision camera 12 through high-temperature resistant ceramic fixing sleeves (material is alumina ceramic, temperature resistance 800℃). The distance between two adjacent temperature probes 11 is 5cm, forming a triangular layout centered on the vision camera 12. The detection end of each temperature probe 11 protrudes 1cm from the ceramic fixing sleeve, maintaining a distance of 3~5mm from the surface of the resistor into which the sample power port 8 is inserted. They correspond to the middle heating area, the area near the left lead, and the area near the right lead of the resistor, respectively. Temperature data at different key positions of the resistor can be collected simultaneously and transmitted to the controller host in real time through the signal line.

[0026] Furthermore, the absorption window 7 is a rectangular opening (15cm × 10cm) on the test bench 5. A 45° inclined 304 stainless steel mounting plate (i.e., the inclined surface of the absorption window 7) is welded to the edge of the opening. The surface of the mounting plate is polished to reduce water residue. The sample power port 8 is screwed to the center of the stainless steel mounting plate via a PTFE insulated base. The sample power port 8 itself consists of two copper conductive terminals (tin-plated to prevent oxidation) and a nylon insulating shell. One end of the conductive terminal is connected to the output terminal of the power supply box via a high-temperature resistant wire, and the other end is used to insert the pin of a ceramic automotive resistor to achieve power supply connection. The sample power port 8 is highly matched with the positions of the vision camera 12 and the temperature probe 11: When the ceramic automotive resistor is inserted into the sample power port 8, the central axis of the resistor is completely aligned with the optical axis of the lens of the vision camera 12. The surface of the resistor is directly facing the detection end of the three temperature probes 11, and the edge of the resistor is 2cm away from the opening edge of the absorption window 7. This avoids water from splashing out of the absorption window 7 when spraying water, and ensures that the vision camera 12 can clearly photograph the surface of the resistor (without obstruction) and the temperature probes 11 can accurately collect the temperature (without detection blind spots).

[0027] Furthermore, the electric nozzle 9 adopts a brass body + stainless steel nozzle structure (wear-resistant, corrosion-resistant, service life ≥10,000 times), with a nozzle diameter of 0.5mm. The water spray can be controlled by an electromagnetic valve, and the water pressure adjustment range is 0.2~0.5MPa. An M10 threaded hole is pre-set on the vertical side of the absorption window 7. The electric nozzle 9 is screwed into this threaded hole via an external thread, with the nozzle head extending 2cm beyond the vertical side. The water spray centerline of the electric nozzle 9 forms a 30° angle with the surface of the resistor into which the sample power port 8 is inserted. The water droplet is precisely concentrated in the central heating area of ​​the resistor (coinciding with the shooting center of the vision camera 12), ensuring that the water flow acts evenly on the high-temperature surface of the resistor, simulating the actual working condition of a new energy vehicle resistor being cooled by water. Simultaneously, the installation height of the electric nozzle 9 is 5cm lower than the height of the sample power port 8 to prevent water from splashing back onto the conductive terminals of the sample power port 8 during spraying, thus preventing the risk of short circuits.

[0028] Furthermore, the electric nozzle 9 is connected to the miniature water pump via a food-grade PVC pipe. One end of the pipe is connected to the inlet of the electric nozzle 9 via a quick connector, and the other end is connected to the outlet of the miniature water pump via a flexible hose connector. The pipe is wrapped with a 5mm thick layer of insulation cotton to prevent changes in ambient temperature from affecting the water temperature. The miniature water pump is a DC brushless water pump, fixed to the top of the water tank 6 by a metal bracket. The inlet of the miniature water pump is connected to the inside of the water tank 6 through a 50-mesh nylon filter screen, which can filter impurities in the water (such as dust and scale) to prevent clogging of the nozzle 9. The water tank 6 is made of high-density polyethylene (10L capacity, impact-resistant and aging-resistant). The top of the water tank 6 has a 5cm diameter inlet with a threaded sealing cap, and the bottom has a brass drain valve (for easy water changing and cleaning). The water tank 6 is located directly below the absorption window 7, which can recover the water flowing down through the absorption window 7 after being sprayed by the electric nozzle 9, realizing water recycling. An ultrasonic level sensor (i.e., "water level module") is installed on the upper middle part of the inner wall of water tank 6 (corresponding to 2 / 3 of the water tank capacity). This sensor is connected to the controller host via a two-core signal line and can detect the water level in water tank 6 in real time. When the water level is lower than the preset lower limit (corresponding to 1 / 3 of the water tank capacity), the sensor sends a water shortage signal to the controller host. The controller host immediately stops the operation of the micro water pump, cuts off the power supply from the power box to the sample power port 8, and triggers the audible and visual alarm 4. The test can only be restarted after the operator adds deionized water (the test liquid is deionized water to avoid impurities in the water forming scale on the resistor surface and affecting the test results) to the preset water level.

[0029] The working principle is as follows: First, before the test begins, the operator sets the relevant test operations through the touch screen 2 on the control cabinet 1. At the same time, the ceramic automotive resistor is inserted into the sample power port 8 at the absorption window 7, and deionized water is added to the water tank 6. Then, the air switch 3 on the control cabinet 1 is closed to power on the entire device, completing the preparation work before the test.

[0030] Next, after the test is started, the controller host in control cabinet 1 triggers the power supply box in control cabinet 1. The power supply box supplies power to the inserted ceramic automotive resistor through the sample power port 8, causing the resistor to enter the heating state and start the high-temperature working condition simulation.

[0031] Then, during the heating process of the resistor, the temperature probe 11 on the monitoring base 10 continuously collects temperature information at different locations of the resistor and transmits the information to the controller host in the control cabinet 1 to monitor the temperature status of the resistor in real time.

[0032] After reaching the set heating stage, the controller in control cabinet 1 starts the micro water pump. The micro water pump draws water from the water tank 6, and the water flows through the pipe to the electric nozzle 9 on the vertical side of the absorption window 7. The electric nozzle 9 sprays the water onto the surface of the resistor, which is in a high-temperature state, simulating the working condition of the resistor being cooled by water. The sprayed water flows back into the water tank 6 below through the absorption window 7, realizing water recycling.

[0033] Meanwhile, after the water spraying process is completed, the controller host in the control cabinet 1 is linked with the vision processing host in the control cabinet 1. The vision processing host controls the vision camera 12 on the monitoring base 10 to take pictures of the resistor surface. The vision camera 12 transmits the captured images to the vision processing host, which analyzes the images to determine whether there is a crack on the resistor surface.

[0034] If the vision processing host detects a crack in the resistor, it will send the result back to the controller host in control cabinet 1. The controller host will immediately stop the test and trigger the audible and visual alarm 4 on control cabinet 1 to issue an alarm. In addition, during the test, the water level module on the inner wall of water tank 6 monitors the water level in water tank 6 in real time. If the water level is lower than the preset lower limit, it will transmit a water shortage signal to the controller host in control cabinet 1. The controller host will also stop the test and trigger the audible and visual alarm 4. If the controller host in control cabinet 1 detects an abnormal test current, it will also immediately terminate the test and trigger the audible and visual alarm 4.

[0035] Finally, after the test is completed normally or stopped due to an abnormality, the operator can view the relevant data during the test through the touch screen 2 on the control cabinet 1, or store the test data through external devices to complete the entire test process.

[0036] Any technical solution that achieves the above-mentioned technical effects by utilizing the technical solution described in this utility model, or by designing a similar technical solution inspired by the technical solution described in this utility model, falls within the protection scope of this utility model.

Claims

1. A high-temperature crack resistance testing device for resistors in new energy vehicles, characterized in that, The test bench includes a control cabinet (1), a touch screen (2), an air switch (3), an audible and visual alarm (4), a test bench (5), a water tank (6), an absorption window (7), a sample power port (8), an electric nozzle (9), a monitoring seat (10), a temperature probe (11), and a vision camera (12). The control cabinet (1) is equipped with the touch screen (2), the air switch (3), and the audible and visual alarm (4). The control cabinet (1) is installed on one side of the test bench (5). The water tank (6) is located directly below the absorption window (7) on the test bench (5). The sample power port (8) and the electric nozzle (9) are installed at the absorption window (7). The temperature probe (11) and the vision camera (12) are installed on the monitoring seat (10) which is fixedly installed on the test bench (5).

2. The high-temperature crack resistance test device for resistors in new energy vehicles as described in claim 1, characterized in that: The control cabinet (1) contains a vision processing host, a controller host and a power supply box. The controller host is connected to the vision processing host and the power supply box respectively. The vision processing host is electrically connected to the vision camera (12). The controller host is connected to the temperature probe (11), the audible and visual alarm (4) and the micro water pump. The controller host controls the sample power port (8) through the power supply box.

3. The high-temperature crack resistance testing device for resistors in new energy vehicles as described in claim 2, characterized in that: The vision camera (12) and temperature probes (11) are fixedly installed on the lower slope of the monitoring base (10), wherein three of the temperature probes (11) are arranged around the vision camera (12) and aligned with the ceramic automotive resistor inserted into the sample power port (8).

4. The high-temperature crack resistance test device for resistors in new energy vehicles as described in claim 3, characterized in that: The sample power port (8) is installed on the slope of the absorption window (7) and is matched with the position of the vision camera (12) and the temperature probe (11).

5. The high-temperature crack resistance testing device for resistors in new energy vehicles as described in claim 4, characterized in that: An electric nozzle (9) is installed at a position opposite to the sample power port (8), and the electric nozzle (9) is embedded in the vertical side of the absorption window (7).

6. The high-temperature crack resistance testing device for resistors in new energy vehicles as described in claim 5, characterized in that: The electric nozzle (9) is connected to the water tank (6) via a pipe and a micro water pump. The electric nozzle (9) can spray the liquid inside the water tank (6) onto the ceramic automotive resistor inserted into the sample power port (8). The inner wall of the water tank (6) is equipped with a water level module, which is connected to the controller host.

Images