US-12625195-B2 - Multi-functional integrated testing system

US12625195B2US 12625195 B2US12625195 B2US 12625195B2US-12625195-B2

Abstract

A test system to conduct a sequence of electrical tests of an electrical cable is disclosed. The system includes a testing unit, a set of sensors, and two circuits. The two circuits are switchably coupled to a common voltage source and selectively electrically coupleable to the electric cable to enable the testing unit to conduct a respective test of the electrical cable.

Inventors

Xuan Yi
Cong Li
Han Xiong
Yihe Hua
Karim Younsi

Assignees

GE AVIATION SYSTEMS LLC

Dates

Publication Date: 20260512
Application Date: 20231023

Claims (20)

1 . A test system for testing an electrical cable having a first end and an opposing second end, and further having an electrically conductive element circumferentially surrounded by a first electrically insulative layer, the electrical cable further including an unshielded portion and a shielded portion including a first electrically conductive shield circumferentially surrounding the first electrically insulative layer, the first end electrically coupled to the second end to define a loop, the test system comprising: a voltage source configured to supply a first voltage signal; a current transformer having an annular core defining a bore, a primary winding, and a secondary winding, the primary winding being wound around a leg of the annular core, with the unshielded portion of the electrical cable being disposable through the bore to define the secondary winding; a first circuit having a first leg coupled to the voltage source via a first node and arranged electrically in series between the voltage source and an upstream end of the primary winding, the first leg having a first switch, the first circuit further including a second leg arranged in series between a downstream end of the primary winding and the voltage source via a second node, the second leg having a second switch, wherein the first circuit is configured to receive the first voltage signal when the first switch and the second switch are closed; an electrically conductive enclosure defining an interior space, arranged to operatively receive the shielded portion of the electrical cable within the interior space, the first electrically conductive shield being coupleable to the electrically conductive enclosure, the electrically conductive enclosure being couplable to an electrical ground; a second circuit coupled electrically in parallel with the first circuit, the second circuit coupled to the voltage source via the first node and arranged in series between the voltage source and the secondary winding, the second circuit including a third leg having a third switch, the second circuit further including a fourth leg arranged in series between the electrically conductive enclosure and the voltage source via the second node, the fourth leg including a fourth switch, wherein the second circuit is configured to receive the first voltage signal when the third switch and fourth switches are closed; a first current sensor configured to sense a first electrical current in the electrically conductive element at the unshielded portion of the electrical cable and to generate a first current sensor signal indicative of a first value of the first electrical current; a second current sensor configured to sense a second electrical current through the second node and to generate a second current sensor signal indicative of a second value of the second electrical current; a third current sensor configured to sense a third electrical current in the shielded portion of the electrical cable, and to generate a third current sensor signal indicative of a third value of the third electrical current, the third electrical current defined by a sum of the first electrical current and a fourth electrical current induced in the first electrically conductive shield; a testing unit comprising a first test module and a second test module, the testing unit communicatively coupled to the voltage source to receive a status signal indicative of a value of the first voltage signal therefrom, and further communicatively coupled to the first current sensor, the second current sensor, and the third current sensor to receive the first, second, and third current sensor signals respectively therefrom; wherein, when the third switch and the fourth switch are closed, the first test module is configured to determine the value of the first voltage signal, determine a magnitude of at least one of the first electrical current and the third electrical current, and to correlate the magnitude of the at least one of the first electrical current and the third electrical current with the value of the first voltage signal; and wherein, when the first switch and the second switch are closed, the second test module is configured to determine a difference between the first electrical current and the third electrical current and to correlate the magnitude of the at least one of the first electrical current and the third electrical current with the value of the first voltage signal.
2 . The test system of claim 1 , wherein the first switch and the second switch define a first set of switches, and the third switch and the fourth switch define a second set of switches, wherein the first set of switches are interlocked with the second set of switches, such that only one of the first set of switches or the second set of switches is closed at a time.
3 . The test system of claim 2 , wherein the first set of switches are arranged in a double-pole, single-throw configuration, and the second set of switches are arranged in a double-pole, single-throw configuration.
4 . The test system of claim 2 , wherein the testing unit is communicatively coupled to the first set of switches and the second set of switches to selectively control a respective operation thereof.
5 . The test system of claim 1 , wherein the value of the first voltage signal is defined by magnitude and a frequency.
6 . The test system of claim 1 , wherein the voltage source includes a signal generator communicatively coupled to an amplifier, the amplifier configured to selectively modify a voltage received from the signal generator to define the first voltage signal.
7 . The test system of claim 1 , wherein the electrically conductive enclosure comprises a hypobaric chamber.
8 . The test system of claim 7 , wherein the electrically conductive enclosure comprises a chamber controller communicatively coupled with the testing unit.
9 . The test system of claim 8 , wherein the interior space of the electrically conductive enclosure is selectively pressurized to a predetermined atmospheric pressure, and wherein, when the third switch and the fourth switch are closed, the first test module is further configured to correlate the magnitude of the at least one of the first electrical current and the third electrical current with the predetermined atmospheric pressure.
10 . The test system of claim 8 , wherein the interior space of the electrically conductive enclosure is pressurized to a predetermined atmospheric pressure, and wherein, when the first switch and the second switch are closed, the second test module is further configured to correlate the magnitude of the at least one of the first electrical current and the fourth electrical current with the predetermined atmospheric pressure.
11 . The test system of claim 1 , wherein the first test module is a partial discharge test module.
12 . The test system of claim 11 , wherein a partial discharge event at the first electrically insulative layer causes the fourth electrical current to flow in the first electrically conductive shield.
13 . The test system of claim 1 , wherein the second test module is an EMI test module.
14 . The test system of claim 13 , wherein the first electrical current induces the fourth electrical current in the first electrically conductive shield.
15 . The test system of claim 1 , wherein the electrical cable further includes a second electrically insulative layer circumferentially surrounding the electrically conductive element and circumferentially surrounded by the first electrically insulative layer, and wherein the shielded portion further includes a second electrically conductive shield circumferentially surrounding the second electrically insulative layer, the second electrically conductive shield circumferentially surrounded by the first electrically insulative layer.
16 . The test system of claim 1 , further comprising: a first temperature sensor configured to sense a first temperature of the electrically conductive element and to supply a first temperature sensor signal indicative of the first temperature of the electrically conductive element; a second temperature sensor configured to sense a second ambient temperature proximal the electrical cable, and to supply a second temperature sensor signal indicative of the second ambient temperature; and wherein the testing unit further comprises a third test module communicatively coupled to the first and second temperature sensors to receive the first and second temperature sensor signals therefrom when the first switch and the second switch are closed, and further configured to determine the first temperature and the second ambient temperature.
17 . The test system of claim 16 , wherein the third test module is further configured to determine a difference between the first temperature and the second ambient temperature, and to correlate the difference between the first temperature and the second ambient temperature with the first electrical current.
18 . The test system of claim 16 , further comprising a third temperature sensor configured to sense a third temperature of the first electrically conductive shield, and to supply a third temperature sensor signal indicative of the third temperature; and wherein the third test module is communicatively coupled to the third temperature sensor to receive the third temperature sensor signal therefrom, determine the third temperature, and further configured to determine a difference between the third temperature and the second ambient temperature, and to correlate the difference between the third temperature and the second ambient temperature with the first electrical current.
19 . The test system of claim 18 , wherein the interior space of the electrically conductive enclosure is selectively pressurized to a predetermined atmospheric pressure, and wherein the third test module is further configured to correlate the magnitude of the first electrical current with the predetermined atmospheric pressure.
20 . The test system of claim 16 , further comprising a fourth temperature sensor configured to sense a fourth temperature of the annular core, and to supply a fourth temperature sensor signal indicative of the fourth temperature; and wherein the third test module is communicatively coupled to the fourth temperature sensor to receive the fourth temperature sensor signal therefrom, determine the fourth temperature, and further configured to determine a difference between the fourth temperature and the second ambient temperature, and to correlate the difference between the fourth temperature and the second ambient temperature with the first electrical current.

Description

TECHNICAL FIELD This disclosure relates generally to testing apparatus, and more specifically to a multi-functional integrated test apparatus for testing conductors. BACKGROUND Commercial aircraft and other applications, including industrial, commercial and residential applications, typically include an electrical power distribution system. The electrical power distribution system distributes electricity to loads via electrical cables. Prior to installation, the electrical cables, or representative samples thereof, are subjected to a range of tests designed to verify that the cables satisfy predetermined performance specifications to meet the operational needs of the application. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1A is a perspective view of an electrical cable. FIG. 1B is a cross-section of the electrical cable of FIG. 1A. FIG. 1C is a schematic view of a cross-section of a shielded portion of the electrical cable of FIG. 1A. FIG. 1D a cross-section of another aspect of the electrical cable of FIG. 1A. FIG. 1E a cross-section of still another aspect of the electrical cable of FIG. 1A. FIG. 1F a cross-section of still another aspect of the electrical cable of FIG. 1A. FIG. 1G is a schematic view of a cross-section of a shielded portion of the electrical cable of FIG. 1F. FIG. 2 is a schematic diagram of a testing system in accordance with aspects as described herein. FIG. 3 is a schematic diagram of another exemplary testing system in accordance with aspects as described herein. DETAILED DESCRIPTION Aspects of the present disclosure are directed to a testing apparatus and system, and more specifically to a multi-functional integrated test apparatus and system for testing an insulated conductor, such as a cable. For purposes of illustration, the present disclosure will be described with respect to testing an electrical cable. The disclosure can have applicability for testing a variety of electrical conductors, including for example rigid bus bars, and can be used to provide benefits in industrial, commercial, military, and residential applications. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all aspects described herein should be considered exemplary. As used herein, the terms “first,” “second,” and “third” and the like, can be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Furthermore, as used herein, the term “set” or a “set” of elements can be any number of elements, including only one. All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the present disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. As used herein, elements being “electrically connected,” “electrically coupled,” or “in signal communication” include an electric transmission or signal being sent, received, or communicated to or from such connected or coupled elements. Furthermore, such electrical connections or couplings can include a wired or wireless connection, or a combination thereof. In non-limiting examples, connections or disconnections can be selectively configured to provide, enable, disable, or the like, an electrical connection between respective elements. Non-limiting example electrical connections or disconnections can be enabled or operated by way of switching, bus tie logic, or any other connectors configured to enable or disable the energizing of an electrical load downstream of the connection. Additionally, while terms such as “voltage”, “current”, and “power” can be used herein, it will be evident to one skilled in the art that these terms can be interrelated when describing aspects of the electrical circuit, or circuit operations. As used herein, a controllable switching element, or a “switch” is an electrical device that can be controllable to operate or toggle between a first mode of operation, wherein the switch is “closed” intending to tran