Low-Voltage Testing Device for High-Voltage Frequency Converters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing debugging methods for high-voltage frequency converters are cumbersome, costly, and inefficient due to the complexity of high-voltage equipment, making it difficult to simulate and test high-voltage conditions safely and effectively, leading to potential faults and repair challenges.
Innovation Solution
A low-voltage testing device for high-voltage frequency converters, featuring a tap transformer, power portion, monitoring box, analog interface board, voltage detecting portion, and remote control portion, utilizing MOSFETs, FPGA, CPLD, and optical fiber connections to simulate on-load testing and control system software testing, providing a safe and reliable low-voltage platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage testing is performed under self-operating conditions, then testing completeness is improved, but safety and operational risk worsen due to the dangerous nature of high-voltage environments
Solution Approach 1:
The patent creates a low-voltage copy system that replicates the high-voltage frequency converter's control architecture and power unit interfaces. The monitoring box, analog interface board, and power portion form a simplified model that mimics the real system's behavior, allowing complete functional testing without exposing personnel to high-voltage dangers.
2Measurement precision
If high-voltage equipment is used for testing, then testing accuracy is improved, but device complexity and cost worsen due to the hugeness of equipment and high-voltage wire connections
Solution Approach 1:
The testing device is segmented into three independent modules: a tap transformer for voltage transformation, a power portion with three groups of power units for simulating power converter output, and a monitoring box for control system testing. Each module can be independently configured and tested, reducing overall system complexity while maintaining testing accuracy.
Solution Approach 2:
The patent introduces an optical fiber communication system as an intermediary between the monitoring box and power units. This optical interface board converts electrical signals to optical signals for transmission, providing electrical isolation and simplifying connections compared to direct high-voltage wiring, while maintaining signal integrity for accurate testing.
3Reliability
If high-voltage testing is performed, then fault detection capability is improved, but ease of operation worsens due to inconvenience of connections and high cost
Solution Approach 1:
The low-voltage testing device creates a simplified copy of the high-voltage system that maintains all critical functional characteristics. The monitoring box replicates the main controller's CPU board, phase control boards, and interface boards, allowing complete fault detection of control system issues without the operational complexities of high-voltage connections and expensive equipment handling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables reliable and efficient simulation of high-voltage frequency converter operations, reducing costs and simplifying maintenance, ensuring stable operation and continuous production in industries like metallurgy and electric power, with a safe and reliable low-voltage platform.
Implementation Method 1
send control optical signals to a power unit via an electric-to-optical transducer
Data Source
AI summary
A low-voltage testing device for a high-voltage frequency converter of a serial superposition voltage type including a tap transformer, power portion, monitoring box, analog interface board, voltage detecting portion and remote control portion, in which the tap transformer is connected to the power portion, the power portion is connected to the voltage detecting portion, the monitoring box is connected to the power portion via an optical fiber and the analog interface board is connected to the monitoring box and the remote control portion respectively.