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CN-121995208-A - Multi-parameter automatic detection system for relay

CN121995208ACN 121995208 ACN121995208 ACN 121995208ACN-121995208-A

Abstract

The application relates to the technical field of relay multi-parameter automatic detection systems, and particularly discloses a relay multi-parameter automatic detection system, aiming at solving the problems of insufficient transient signal capturing capability, low parameter measurement reliability and poor universality of traditional detection equipment in a relay. The system comprises a relay clamping device, a multichannel signal excitation unit, a high-precision sensing acquisition unit, a time sequence synchronous control unit, a data processing analysis unit and a man-machine interaction terminal, wherein the programmable excitation signal is used for simulating the actuation and release process, synchronously acquiring multichannel electrical response signals of contacts and coils at high speed, calculating key parameters such as contact resistance, actuation/release voltage and time delay based on time sequence logic verification, and the clamping device adopts a replaceable interface module to adapt to various relay types, and the system supports remote communication and automatic generation of test reports. The application can realize the multi-parameter automatic detection of the relay with high precision, high efficiency and high reliability, and meets the severe requirement of intelligent manufacturing on the on-line detection of the electronic element.

Inventors

  • WANG YAOLONG

Assignees

  • 西安蒲石纳芯信息科技有限责任公司

Dates

Publication Date
20260508
Application Date
20260225

Claims (10)

  1. 1. A relay multiparameter automated detection system, comprising: The relay clamping device is configured to electrically connect and physically fix the relay to be tested, and ensure that the contact and the coil terminal are in stable and reliable electrical contact with an external test circuit in the test process; The multichannel signal excitation unit is configured to apply a programmable excitation signal to a coil of the relay to be tested, and dynamically adjust excitation amplitude, rising edge slope and duration so as to simulate the actuation and release processes under different working conditions; The high-precision sensing acquisition unit is configured to synchronously acquire multiple paths of electrical response signals of the relay to be tested under the excitation action, and convert the acquired analog signals into digital signals to be output; The time sequence synchronous control unit is configured to coordinate the working time sequence of the multichannel signal excitation unit and the high-precision sensing acquisition unit, and ensure that the application time of the excitation signal is aligned with the sampling window of the sensing signal; The data processing analysis unit is configured to receive the digital signals, calculate contact resistance, coil pull-in voltage, pull-out voltage, pull-in time, pull-out time and rebound time, and perform logic verification on time sequence relevance among parameters; and the man-machine interaction terminal is configured to receive the test configuration instruction and display the real-time test waveform, the parameter calculation result and the system diagnosis information.
  2. 2. The multi-parameter automatic detection system of a relay according to claim 1, wherein the high-precision sensing acquisition unit comprises a plurality of mutually independent voltage sampling sub-channels and current sampling sub-channels, each sampling sub-channel is independently provided with a differential isolation amplifier with a high common mode rejection ratio, a low-pass anti-aliasing filter and a high-speed analog-to-digital conversion circuit, the isolation amplification circuit adopts a photoelectric isolator or a magnetic isolation amplifier with high linearity, the bandwidth of the isolation amplification circuit is configured to cover all high-frequency harmonic components generated by rebound of a contact of the relay, the sampling frequency of the analog-to-digital converter is configured to be greater than or equal to one megahertz, so that the time resolution of the system to the transient process of the relay is better than one microsecond, each sampling sub-channel is provided with independent analog ground and digital ground planes, and signal decoupling among the channels is realized through an electromagnetic isolation technology, and the isolation circuit is configured to suppress crosstalk noise from a coil driving circuit when measuring low contact resistance.
  3. 3. The multi-parameter automatic relay detection system according to claim 1, wherein the multi-channel signal excitation unit comprises a programmable linear direct current power supply, a pulse width modulation waveform generation circuit, a high linearity power amplifier and a polarity switching matrix, the multi-channel signal excitation unit is provided with bidirectional program control capability, the polarity switching matrix is configured to switch excitation directions of two ends of a coil according to test requirements so as to evaluate the influence of residual magnetism on the performance of the relay, in a single test flow, the multi-channel signal excitation unit is configured to sequentially execute four stages of actuation excitation, steady state maintenance, release excitation and static observation, and dynamically insert a steady state maintenance stage with a preset time between the two excitation, and the duration of the steady state maintenance stage is configured to perform millisecond-level setting according to the thermal balance requirements of the relay so as to simulate the temperature rise and magnetic circuit evolution process of the relay in an actual industrial control cycle.
  4. 4. The multi-parameter automatic detection system of the relay according to claim 1, wherein the relay clamping device comprises a base seat and a replaceable interface module arranged on the base seat, the base seat is provided with a universal signal transmission busbar and a positioning clamping groove, the replaceable interface module is configured to adapt to relay types of different packaging forms, pin layouts and pin materials, a plurality of groups of flexible contact electrodes, an automatic pressing mechanism and a spring loading mechanism are integrated in the replaceable interface module, the spring loading mechanism ensures that the contact pressure applied by each test probe on a pin of the relay is within a preset pressure range by using feedback control of a precision pressure sensor, the pressure range is configured to be enough to puncture an oxide layer on the surface of the pin and avoid mechanical deformation of the pin, and the relay clamping device is further connected with a visual alignment module, and the visual alignment module is configured to automatically identify geometric center deviation of the pin and drive a pneumatic translation table to conduct coordinate compensation.
  5. 5. The multi-parameter automatic relay detection system according to claim 1, wherein the timing synchronization control unit comprises a constant temperature crystal oscillator, a field programmable logic gate array and a precision timing counter, the constant temperature crystal oscillator is used as a high-stability clock source, the frequency stability of the constant temperature crystal oscillator is superior to the level of parts per million, the clock jitter is limited to be within ten nanoseconds, the precision timing counter is configured to realize microsecond scheduling of the action timing of each unit, ensure sub microsecond alignment of the signal triggering moment of the multichannel signal excitation unit and the sampling starting moment of the high-precision sensing acquisition unit on a time axis, and is further configured with an external reference source locking interface for supporting receiving second pulse synchronous signals of a global positioning system or a Beidou navigation system, and the detection system with dispersed geographic positions realizes absolute time alignment within the whole network range through an external timing mechanism.
  6. 6. A multi-parameter automatic detection system of a relay according to claim 1 is characterized in that a data processing analysis unit is configured to execute contact resistance calculation logic based on a sliding window, the data processing analysis unit selects a sliding window with a preset length to carry out data interception in a stable interval after a contact is completely closed, arithmetic average operation is carried out on a voltage drop sampling value sequence at two ends of the contact and a current sampling value sequence flowing through the contact respectively in the sliding window to obtain average voltage drop and average current value, the average voltage drop is divided by the average current value to obtain a contact resistance measurement value, the data processing analysis unit is configured to execute a ramp scanning mode aiming at detection of a pull-in voltage and a release voltage, current change of a contact loop is monitored in real time in the process of changing a coil voltage by a preset step slope, and when the contact current reaches a preset closing threshold or a break threshold, a coil voltage instantaneous value at the moment is recorded and is defined as the pull-in voltage and the release voltage respectively.
  7. 7. The multi-parameter automatic detection system of a relay according to claim 1, wherein a parameter validity judging module is arranged in the data processing analysis unit, the parameter validity judging module is configured to execute an evaluation algorithm based on logic consistency, the parameter validity judging module is configured to judge whether a current measured value is in a physical state space or not through monitoring the corresponding relation between the amplitude change of a coil excitation signal and the contact conduction state in real time, when full-scale attraction voltage is applied to the coil but current fluctuation of a contact loop is severe or the contact fails to be opened in a preset window after the coil is powered off, abnormal diagnosis logic is automatically triggered, if incomplete closing of the contact is detected due to mechanical abrasion or foreign matter interference, the parameter validity judging module is configured to automatically mark a contact resistance value obtained by the measurement as invalid data and send an alarm signal to the man-machine interaction terminal, and the data processing analysis unit is further configured with a time stamp comparison module to extract attraction time, release time and return time by calculating the time difference between the coil excitation signal jump time and the contact action time.
  8. 8. The multi-parameter automatic detection system of the relay according to claim 1, wherein the man-machine interaction terminal is provided with an industrial Ethernet interface, an RS485 interface or a wireless local area network module and is configured to synchronize locally generated test data to a remote cloud server in real time, the man-machine interaction terminal is configured to receive batch test task instructions from an upper quality management system and realize automatic distribution of detection processes, the system is further connected with a blockchain certification module, each test data, a system log and a calibration record are subjected to encryption hash processing after being generated and form a data block with a timestamp, consensus backup is carried out on a plurality of nodes in a cluster to ensure that original detection data cannot be tampered, the man-machine interaction terminal is further configured with a three-dimensional virtual laboratory interface, electric and mechanical parameters obtained through testing are mapped into a relay physical model in real time by utilizing a digital twin technology, and motion trail and magnetic field spatial distribution of an iron core are displayed through animation.
  9. 9. The multi-parameter automatic detection system of a relay according to claim 1, wherein the data processing analysis unit further comprises a nonlinear dynamics analysis module, a frequency response function extraction module and a high-frequency rebound analysis module, wherein the nonlinear dynamics analysis module is configured to map voltage sampling values into Gao Weixiang spaces, quantitatively evaluate stability of a mechanical system by calculating correlation dimensions and Lyapunov indexes, the frequency response function extraction module is configured to calculate a dynamic transfer function of the relay under coil excitation by means of a cross spectral density operation of an excitation signal and a response signal, and identify microcracks of contact spring plates by monitoring positions and bandwidth changes of resonance peaks in the transfer function, and the high-frequency rebound analysis module is configured to perform a second derivative operation on current waveforms at contact action moments, position contact micro-separation moments and calculate arc energy dissipation in a rebound process by means of an energy equivalent principle so as to evaluate ablation degrees of contact surfaces.
  10. 10. A multi-parameter automatic detection system for a relay according to claim 1 is characterized in that the system adopts a multi-level shielding measure on a physical structure, a system shell is made of a metal material with high conductivity to form a faraday cage structure, signal transmission among functional units adopts twisted pairs with shielding layers and is matched with a common mode choke filter, a front-end conditioning circuit of the high-precision sensing acquisition unit adopts a temperature drift compensation technology, zero offset and gain factors of an operational amplifier are dynamically adjusted through arranging a multi-point temperature sensor on a circuit board, the system is further provided with a self-calibration and health monitoring subsystem, the subsystem comprises a built-in standard source and a precise reference resistor and is configured to be switched to a calibration mode before each test is started, system drift caused by environmental temperature and device aging is automatically compensated through cyclic measurement of the built-in standard component, and when measurement deviation of a sampling channel exceeds a preset value and cannot be compensated through an algorithm, the system automatically locks the channel and a maintenance warning prompt is popped up at a man-machine interface.

Description

Multi-parameter automatic detection system for relay Technical Field The application belongs to the technical field of automatic testing and detection of electrical elements, and particularly relates to a multi-parameter automatic detection system of a relay. Background With the rapid development of the power electronics industry, the relay is used as a core basic element for circuit control and protection, and the stability and reliability of the performance of the relay are directly related to the operation safety of a power system and various electronic devices. The traditional quality detection means gradually evolves from the manual test of single parameters to the integration and intellectualization direction, and aims to ensure the action accuracy of the element under a complex electromagnetic environment through high-precision parameter analysis. Particularly in the high-reliability application fields of aerospace, automatic control, rail transit and the like, the relay needs to bear extremely high operation frequency and environmental stress, so that comprehensive and real-time evaluation of multiple performance indexes of the relay becomes a key link for guaranteeing the safe operation of an industrial chain. The relay multi-parameter automatic detection is used as an important means for improving the factory qualification rate and research and development verification efficiency of products, and key indexes such as contact resistance, coil pull-in voltage, release voltage and action time are synchronously acquired mainly through integrating a high-precision sampling module and an automatic control logic. The core of the technical direction is to construct a test environment capable of simulating actual working conditions, and the electric signals acquired by the sensor are subjected to digital processing, so that the quantitative evaluation of the comprehensive performance of the relay is completed under the condition of no manual intervention. However, the detection system in the prior art often faces the bottleneck that the sampling precision and the detection rate are difficult to balance, so that small transient electrical fluctuations are easy to ignore when processing large-scale samples to be detected. Meanwhile, the traditional equipment has insufficient time sequence correlation analysis capability for different physical quantities, and is difficult to capture the dynamic characteristic evolution of the relay in the process of actuation and release, so that the detection result can not completely reflect the actual abrasion state of the element. In addition, the automation degree of the existing system is still limited to the repeated execution of a single flow, and the lack of the deep integration and logic verification capability of multi-source heterogeneous detection data leads to the extremely easy generation of erroneous judgment or missed judgment when facing to non-standard signal feedback. Accordingly, a relay multiparameter automated detection system is desired. Disclosure of Invention The invention aims to provide a multi-parameter automatic detection system for a relay, which can effectively solve the problems in the background technology. In order to achieve the above purpose, the technical scheme adopted by the invention is as follows: The utility model provides a multi-parameter automatic detecting system of relay, includes relay clamping device, multichannel signal excitation unit, high accuracy sensing collection unit, time sequence synchronous control unit, data processing analysis unit and man-machine interaction terminal, wherein: the relay clamping device is configured to electrically connect and physically fix the relay to be tested, so that the contact and the coil terminal are ensured to be in stable and reliable electrical contact with an external test circuit in the test process; The multi-channel signal excitation unit is configured to apply programmable voltage or current excitation signals to coils of the relay to be tested, and can dynamically adjust excitation amplitude, rising edge slope and duration time so as to simulate the actuation and release processes under different working conditions; the high-precision sensing acquisition unit is configured to synchronously acquire multiple paths of electrical response signals of the relay to be tested under the excitation action, wherein the multiple paths of electrical response signals comprise voltage drops at two ends of a contact, current flowing through the contact, voltage at two ends of a coil and current in a coil loop, and convert the acquired analog signals into digital signals to be output; the time sequence synchronous control unit is configured to coordinate working time sequences of the multichannel signal excitation unit and the high-precision sensing acquisition unit, ensure that the application time of the excitation signal is aligned with a sampling window of the sensing signal strictly, and co