CN109324251B - Converter module test system - Google Patents
Converter module test system Download PDFInfo
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- CN109324251B CN109324251B CN201710635801.9A CN201710635801A CN109324251B CN 109324251 B CN109324251 B CN 109324251B CN 201710635801 A CN201710635801 A CN 201710635801A CN 109324251 B CN109324251 B CN 109324251B
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Abstract
A converter module testing system, comprising: the power supply device is used for supplying power to the tested converter module and the electric appliance in the test system; the pulse distribution device is used for providing a pulse driving signal for the converter to be tested; the test process control device is used for sending corresponding control signals to the power supply device and the pulse distribution device so that the power supply device provides electric energy for electric appliances of the tested converter module and the test process control module, and the pulse distribution device generates corresponding pulse driving signals and sends the pulse driving signals to the tested converter module; and the automatic measuring device is used for carrying out corresponding function test on the converter module to be tested according to the control command sent by the test process control device. The system can greatly improve the testing efficiency of the converter module, and the time for testing one converter module can be usually less than or equal to 5 minutes, so that the requirement of the beat time of an automatic production line can be effectively met.
Description
Technical Field
The invention relates to the technical field of converters, in particular to a converter module testing system.
Background
The converter module is an electrical device which changes the voltage, frequency, phase number and other electric quantity or characteristics of a power supply system, and mainly comprises: rectifiers (AC/DC), inverters (DC/AC), alternating current converters (AC/AC) and direct current converters (DCchopper), which are widely used in the fields of locomotive conversion, industrial conversion, wind power generation, ship electric drive, etc.
However, in the production process of the converter module, the efficiency and quality of the production of the product are seriously hindered due to various technical disadvantages of the existing testing devices. Meanwhile, as the productivity of the converter module product is improved, the quality control requirement in the production process tends to be stricter. Therefore, a new automatic testing system for the converter module is needed.
Disclosure of Invention
In order to solve the above problems, the present invention provides a converter module testing system, which includes:
the power supply device is used for supplying power to the tested converter module and the electric appliance in the test system;
the pulse distribution device is connected with the tested converter module and used for providing a pulse driving signal for the tested converter;
the test process control device is connected with the pulse distribution device and the power supply device and used for sending corresponding control signals to the power supply device and the pulse distribution device so as to enable the power supply device to provide electric energy for electric appliances of the tested converter module and the test process control module, and enable the pulse distribution device to generate corresponding pulse driving signals and send the pulse driving signals to the tested converter module;
and the automatic measuring device is connected with the test process control device and is used for carrying out corresponding function test on the converter module to be tested according to the control command sent by the test process control device.
According to an embodiment of the invention, the system further comprises a production line OPC server and an MES information device, wherein the production line OPC server is configured to query converter module production order information in the MES information device, download the converter module production order information when the converter module production order information is queried, and transmit the converter-under-production information in the converter module production order information to the test process control device, so that the test process control device configures a corresponding test program sequence according to the converter-under-production information.
According to one embodiment of the invention, the system further comprises:
and the production line end data acquisition device is connected with the test process control device and is used for detecting whether the tested converter module enters or leaves a test station, correspondingly generating an in-place indication signal or a dislocation indication signal and sending the in-place indication signal or the dislocation indication signal to the test process control device.
According to one embodiment of the invention, when receiving the in-place indication signal and receiving the test start signal, the test process control device is configured to send a corresponding control signal to the power supply device to control the power supply device to supply power to the converter module under test.
According to an embodiment of the present invention, the pulse distribution apparatus includes:
the switching value signal conditioning module is connected with the test process control device and is used for carrying out isolated conditioning on the switching value signal sent by the test process control device;
the first buffer is connected with the switching value signal conditioning module;
the pulse driving signal generating module is connected with the first buffer and used for generating and outputting a pulse driving signal of a corresponding channel according to the isolated and conditioned switching value signal;
the second buffer is connected with the pulse driving signal generation module;
a signal shaping module connected with the second buffer.
According to one embodiment of the present invention, the automatic measuring device includes:
the capacitor charging module is connected between the power supply device and the converter module to be tested;
and the first voltage detection circuit is connected with the capacitor charging module and used for measuring the voltage at two ends of the capacitor charging module and transmitting the generated first voltage signal to the test process control device.
According to an embodiment of the present invention, the test process control device is configured to determine whether the voltage represented by the first voltage signal is greater than or equal to a preset charging voltage, and if so, send a corresponding control signal to the pulse distribution device, so that the pulse distribution device generates a corresponding pulse driving signal and transmits the pulse driving signal to the converter module under test.
According to an embodiment of the present invention, the automatic measuring device further comprises:
the main loop routing switching module comprises a first switching unit and a second switching unit, wherein the first switching unit is correspondingly connected with each output port of the converter module to be tested, the second switching unit is connected with the capacitor charging module, and the first switching unit and the second switching unit are matched to conduct a conductive loop between a specified output port of the converter module to be tested and the anode or the cathode of the capacitor charging module;
an inductive load module connected between the first switching unit and the second switching unit;
the current detection circuit is connected with the inductive load module and used for measuring the current flowing through the inductive load module to obtain a detection current signal;
and the second voltage detection circuit is connected with each output port of the converter module to be detected and is used for detecting the voltage between the appointed output port of the converter module to be detected and the anode or the cathode of the capacitor charging module to obtain a detection voltage signal.
According to one embodiment of the invention, the converter module under test comprises a plurality of legs of the same structure, each leg comprising a top tube IGBT and a bottom tube IGBT, wherein,
when an upper tube IGBT in a bridge arm is tested, the first switching unit and the second switching unit conduct a conductive loop between an output port corresponding to the upper tube IGBT to be tested and a negative electrode of the capacitor charging module under the control of the test process control device, and meanwhile, the second voltage detection circuit is configured to detect a voltage between the output port corresponding to the upper tube IGBT to be tested and the negative electrode of the capacitor charging module;
when a lower tube IGBT in one bridge arm is tested, the first switching unit and the second switching unit conduct a conductive loop between an output port corresponding to the tested lower tube IGBT and the anode of the capacitor charging module under the control of the test process control device, and meanwhile, the second voltage detection circuit is configured to detect voltage between the output port corresponding to the tested upper tube IGBT and the anode of the capacitor charging module.
According to an embodiment of the present invention, the automatic measuring device further comprises:
and the safe discharge module is connected between the anode and the cathode of the capacitor charging module and is used for absorbing residual electric energy in the conductive loop.
The method for testing the converter module in the prior art adopts a manual testing mode for testing the converter module, and the testing efficiency is extremely low because the mode is usually more than half an hour. When a large quantity of products are produced and tested, the problem of low efficiency of the manual testing mode is more prominent, and the delivery process of the products is seriously hindered.
However, the converter module testing system provided by the invention can greatly improve the testing efficiency of the converter module. The time for testing one converter module by the system can be less than or equal to 5 minutes generally, so that the requirement of the beat time of an automatic production line can be effectively met. Meanwhile, the test system provided by the invention can realize the fusion of the test equipment and the automatic production line and the interaction of an MES information system, and the main PLC of the production line can monitor the working state of the test equipment in real time and automatically upload a test result report to the MES information system.
The IGBT driving pulse required by the existing testing technology needs manual control, and the pulse characteristic cannot be reset, so that misoperation is easily caused. However, the testing system provided by the invention does not need manual intervention in the testing process of the converter module, and the main loop route switching module and the measuring route switching module of the system can automatically match with the testing path to finish automatic measurement and data acquisition. Meanwhile, the pulse distribution device in the system can automatically match IGBT driving pulse output according to the characteristics of different types and series of converter modules.
In addition, the switch KM8 in the safety discharge module in the system provided by the invention is in a normally closed state, and the switch KM9 is in a normally open state. When the system is abnormally powered off, the switch KM8 can still effectively discharge the residual electric quantity of the tested piece, so that the safety discharge effectiveness is fully ensured. Meanwhile, a tested piece of the system is completely isolated from a power supply of the control equipment, so that secondary damage of the testing equipment caused by abnormity of the tested piece is avoided. In addition, on the safety execution logic, various power-off and power-on in the system have an interlocking function, so that the safety of operation is fully ensured. The test system provided by the invention has wide test parameter coverage, and is preferably compatible with a full-system converter module with the maximum input voltage DC4000V and the maximum power of 1200 KW.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required in the description of the embodiments or the prior art:
FIG. 1 is a schematic block diagram of a current transformer module testing system according to one embodiment of the present invention;
FIG. 2 is a schematic diagram of a specific circuit structure of a current transformer module testing system according to an embodiment of the invention;
FIG. 3 is a schematic diagram of a pulse distribution apparatus according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of an automatic measuring device according to one embodiment of the present invention;
FIG. 5 is a schematic workflow diagram of a converter module testing system according to one embodiment of the present invention;
fig. 6 is a schematic diagram of a test flow for testing an a-phase IGBT according to an embodiment of the present invention.
Detailed Description
The following detailed description of the embodiments of the present invention will be provided with reference to the drawings and examples, so that how to apply the technical means to solve the technical problems and achieve the technical effects can be fully understood and implemented. It should be noted that, as long as there is no conflict, the embodiments and the features of the embodiments of the present invention may be combined with each other, and the technical solutions formed are within the scope of the present invention.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details or with other methods described herein.
Additionally, the steps illustrated in the flow charts of the figures may be performed in a computer system such as a set of computer-executable instructions and, although a logical order is illustrated in the flow charts, in some cases, the steps illustrated or described may be performed in an order different than here.
The testing of the converter module generally adopts a manual testing mode, the testing efficiency of the testing mode is low, the time consumed for testing one converter module usually exceeds 30 minutes, and certain potential safety hazards exist in high-voltage testing.
Meanwhile, the IGBT driving pulse output used in the existing testing method of the converter module needs manual control, and the pulse characteristic cannot be reset, so that misoperation is easily caused. When the testing steps are switched, the existing testing method of the converter module needs manual switching-on and switching, and the mode is low in efficiency and has high-voltage electric shock risks.
Aiming at the problems of the existing converter module test system, the invention provides a novel converter module test system. The system can realize automatic measurement of the converter module, thereby shortening the test time of the converter module.
In order to more clearly illustrate the principle and advantages of the converter module testing system provided by the present invention, the converter module testing system is further described below with reference to the schematic structural diagram of the converter module testing system in the present embodiment shown in fig. 1 and the specific circuit diagram of the converter module testing system shown in fig. 2.
As shown in fig. 1, the current transformer module testing system provided in this embodiment preferably includes: a power supply device 101, a test process control device 102, a pulse distribution device 103, and an automatic measurement device 104.
Specifically, as shown in fig. 2, in the present embodiment, the power supply device 101 preferably includes: a first dc power supply 101a, a second dc power supply 101b, a third dc power supply 101c, a fourth dc power supply 101d, and a fifth dc power supply 101 e. In the present embodiment, the first dc power supply 101a, the second dc power supply 101b, the fourth dc power supply 101d, and the fifth dc power supply 101e are preferably programmable power supplies, which can provide electric power to the outside under the control of the test process control device 102.
In order to improve the reliability and safety of the system operation, in the embodiment, the first dc power supply 101a is preferably implemented by a high-voltage program-controlled dc power supply DSP4000-2A, the first dc power supply 101a is capable of providing 0-4000W dc power to the converter module 105 to be tested, the second dc power supply 101b is preferably implemented by N5770A, and the second dc power supply 101b is capable of providing 110V dc power to the control part of the converter module to be tested. The third dc power supply 101c is preferably implemented using PXC-2903148. the third dc power supply 101c is capable of providing 24 vdc to the test process control device 102 and to some of the powered devices in the automatic measuring device 104. The fourth dc power supply 101d is preferably implemented using IPD-12003SLU, and the fourth dc power supply 101d can provide 110 vdc to the high voltage contactor coil in the automatic measuring device 104. The fifth dc power supply 101e is preferably implemented using IPD-3303SLU, and the fifth dc power supply 101e can output 24V dc power to the pulse distribution apparatus 103.
It should be noted that in other embodiments of the present invention, the power supply device 101 may also be implemented by using other reasonable power supply devices or circuits according to actual needs, and the present invention is not limited thereto.
The pulse distribution device 103 is connected to the test process control device 102 and the converter module 105 to be tested, and can provide a pulse driving signal to the converter module 105 to be tested under the control of the test process control device 102, so that the corresponding IGBT in the converter module 105 to be tested operates, and thus the operating IGBT can be tested.
The test process control device 102 is connected to the power supply device 101 and the pulse distribution device 103, and is configured to send corresponding control signals to the power supply device 101 and the pulse distribution device 103, so that the power supply device 101 provides power to the current-consuming devices in the current transformer module 105 to be tested and the test process control module 102, and the pulse distribution device 103 generates corresponding pulse driving signals and sends the pulse driving signals to the current transformer module 105 to be tested.
In this embodiment, as shown in fig. 2, according to actual needs, the converter module testing system may further include a production line OPC server 201 and an MES information device 203. The production line OPC server 201 is connected to the MES information device 203 through the production line ethernet switch 202. In this embodiment, before the test starts, the automatic production line OPC server 201 will periodically query the converter module production order information in the MES information device 203. If the production line OPC server 201 inquires the converter module production order information from the MES information device 203, the converter module production order information is automatically downloaded to the server.
After the converter module production order information is downloaded, the production line OPC server 201 determines the converter-under-production information according to the converter module production order information, and transmits the converter-under-production information to the test process control device 102 connected thereto, so that the test process control device 102 configures a corresponding test program sequence according to the model of the product-under-production. In addition, after the test procedure sequence is configured, the test process control device 102 may also complete initialization and resource configuration of each current sub-module, so as to prepare for testing of the converter module to be started.
In order to improve the automation level of the converter module testing system, in this embodiment, as shown in fig. 2, the converter module testing system may further include a production line data acquisition device 204. The production line end data acquisition device 204 is connected to the test process control device 102, and is capable of detecting whether the tested converter module enters or leaves the test station, and correspondingly generating an in-place indication signal or a leaving indication signal, and sending the in-place indication signal or the leaving indication signal to the test process control device 102.
In this embodiment, when receiving the in-place indication signal and the test start signal, the test process control device 102 sends a corresponding control signal to the power supply device 101 to control the power supply device 101 to supply power to the converter module 105 under test.
In particular, the in-line data collection device 204 preferably includes an RFID information collection module, and the test process control device 102 preferably includes an in-line master PLC module 214 and a test control module 205. When the production line end data acquisition device 204 reads that the converter module tray enters the test station, the wiring indicator lamp on the station automatically lights to remind an operator to connect the test wire harness. At the same time, the safety door electromagnetic lock will fail to allow the operator to perform door opening wiring operations. The USB6525 digital IO sends the received workstation "run" status flag to the production line master PLC module 214. When the operator finishes the wiring operation, the wiring harness on-site signal fails, the operator closes the safety door and simultaneously starts the test starting button to send a test starting signal to the test process control device 102, so that the automatic test process of the converter module is started. At this time, the test control module will control the power supply device 101 to power on the converter module under test 105, and at the same time, start the automatic measurement device 104 to perform corresponding data measurement on the converter module under test. The test process control device 102 controls the pulse distribution device 103 to generate and output a corresponding pulse driving signal, so as to implement the test of the power unit in the tested converter module 105.
Fig. 3 shows a schematic structural diagram of the pulse distribution device 103 in the present embodiment.
In this embodiment, in order to test different types and series of converter modules, the characteristics of the IGBT pulse driving signal output by the pulse distribution device 103 may be reset. Specifically, as shown in fig. 3, the test control module can select a program burning file of the pulse drive signal generation module 301 according to the model of the currently-manufactured product, and the test control module 205 burns the program burning file into the memory of the pulse drive signal generation module 301 through the XILINX emulator 302 via the JATG programming interface 303, so as to realize the program in the memory to be matched with the IGBT drive pulse characteristic of the currently-manufactured product signal.
In this embodiment, the pulse signal generating module 301 is preferably implemented by a CPLD programmable logic device. Of course, in other embodiments of the present invention, the pulse signal generating module 301 may be implemented by other reasonable devices or circuits, and the present invention is not limited thereto.
The switching value signal modulation module 304 performs isolation modulation on the switching value signal transmitted from the test station PLC module 206 in the test process control device, and transmits the switching value signal to the first buffer 305 connected thereto, and then the first buffer 305 performs processing and transmits the switching value signal to the pulse driving signal generation module 301 connected thereto.
The pulse driving signal generating module 301 can generate and output a pulse driving signal of a corresponding channel according to the identified switching value, and transmit the pulse driving signal to the second buffer 306 connected thereto, and then transmit the pulse driving signal to the optical fiber transceiver 308 after being subjected to shaping filtering by the signal shaping module 307, so as to be sent to the measured converter module 105 by the optical fiber transceiver 308.
In this embodiment, the signal shaping module 307 preferably employs a schmitt shaping circuit. Of course, in other embodiments of the present invention, the signal shaping module 307 may be implemented by other reasonable devices or circuits, and the present invention is not limited thereto.
Meanwhile, it should be noted that in other embodiments of the present invention, the pulse distribution device 103 may also use other reasonable circuits or devices to transmit the pulse driving signal to the tested current transformer module 105, and the present invention is not limited thereto.
In this embodiment, the pulse distribution device 103 preferably receives 16 paths of DC24V switching value signals from the test station PLC module, and finally outputs 16 paths of IGBT pulse driving signals. Of course, in other embodiments of the present invention, the number of paths of the signals received and/or output by the pulse distribution device 103 may also be other reasonable values (for example, 10 paths of IGBT pulse driving signals, etc.), and the present invention is not limited thereto.
As shown again in fig. 2, in the present embodiment, the automatic measuring device 104 preferably includes: a capacitor charging module 207 and a first voltage detection circuit 208. The capacitor charging module 207 is connected between the power supply device 101 and the converter module 105 to be tested. The first voltage detection circuit 208 is coupled to the capacitive charging module 207 and is capable of measuring the voltage across the capacitive charging module 207 and transmitting the generated first voltage signal to the test station PLC module 206.
Specifically, in this embodiment, the test station PLC module 206 determines whether the voltage represented by the first voltage signal is greater than or equal to a predetermined charging voltage. If the voltage represented by the first voltage signal is greater than or equal to the preset charging voltage, the test station PLC module 206 sends a corresponding switching value signal to the pulse distribution device 103, so that the pulse distribution device 103 can output a corresponding pulse driving signal, and the corresponding IGBT in the converter module 105 to be tested is driven to operate by the pulse driving signal.
In this embodiment, the automatic measuring device 104 preferably further includes: the circuit comprises a main loop switching module 209, an inductive load module 210, a current detection module 211, a second voltage detection circuit 212 and a safety discharge module 213. The main loop switching module 209 includes a first switching unit and a second switching unit. The first switching unit is correspondingly connected with each output port of the tested converter module, and the second switching unit is connected with the capacitor charging module. The inductive load module 210 is connected between the first switching unit and the second switching unit, and the first switching unit and the second switching unit can cooperatively conduct the conductive loop between the designated output port of the converter module under test 105 and the positive electrode or the negative electrode of the capacitive charging module 207.
The current detection circuit 211 is connected to the inductive load module 210, and is configured to detect a current flowing through the inductive load module 210 to obtain a detection current signal. The second voltage detection circuit 212 is connected to each output port of the converter module under test 105, and is configured to detect a voltage between each output port of the converter module under test 105 and the positive electrode or the negative electrode of the capacitor charging module 207, and obtain a corresponding detection voltage signal.
Fig. 4 shows a specific structural diagram of the automatic measuring device in the present embodiment.
As shown in fig. 4, in this embodiment, the converter module 105 to be tested includes IGBTs V1-V10, the capacitor charging module 207 includes a capacitor C1, an anode and a cathode of the capacitor C1 are respectively connected to an anode of an input terminal and a cathode of the input terminal of the converter module 105 to be tested, and an anode of the capacitor C1 is connected to an anode of the high-voltage dc power supply through a controllable switch KM 0.
The first switching unit comprises five controllable switches (i.e. a first controllable switch KM1, a second controllable switch KM2, a third controllable switch KM3, a fourth controllable switch KM4 and a fifth controllable switch KM5) corresponding to the number of output ports of the converter module under test. First ends of the five controllable switches are respectively connected to five output ports of the converter module 105 to be tested, and second ends of the five controllable switches are connected to the first end of the inductive load module 210.
In this embodiment, the current detecting circuit 211 preferably includes a high voltage current probe H1, and the high voltage current probe H1 is disposed between the second switching unit and the second end of the inductive load module 210, so that it can detect the value of the current flowing through the inductive load module, thereby obtaining a detected current signal. Specifically, in the present embodiment, the inductance L1 in the inductive load module 210 is preferably an adjustable inductance, and the adjustment range of the adjustable inductance L1 is preferably 0-40 nH. Of course, in other embodiments of the present invention, the inductive load module 210 may also select an adjustable inductor with other adjustable ranges according to actual needs, and the present invention is not limited thereto.
As shown in fig. 4, in the present embodiment, the second switching unit preferably includes a sixth controllable switch KM6 and a seventh controllable switch KM 7. First ends of the sixth controllable switch KM6 and the seventh controllable switch KM7 are both connected with the current detection circuit 211, and second ends of the sixth controllable switch KM6 and the seventh controllable switch KM7 are respectively connected with the anode and the cathode of the capacitor charging module.
The safety discharge module 213 preferably includes an eighth controllable switch KM8, a ninth controllable switch KM9, and a first discharge resistor R1 and a second discharge resistor R2. The first end of a circuit formed by the eighth controllable switch KM8 and the first discharging resistor R1 in series is connected with the anode of the capacitor charging module, and the second end is connected with the cathode of the capacitor charging module. Similarly, the first end of the circuit formed by the ninth controllable switch KM9 and the second discharging resistor R2 connected in series is connected to the positive pole of the capacitor charging module, and the second end is connected to the negative pole of the capacitor charging module.
The second voltage detection circuit 212 is connected to each output port of the converter module under test 105, and is configured to detect a voltage between each output port of the converter module under test 105 and a positive electrode or a negative electrode of the capacitor charging module 207, so as to obtain a corresponding detection voltage signal.
Specifically, as shown in fig. 4, in the present embodiment, the second voltage detection circuit 212 preferably includes a third switching unit and a fourth switching unit. Similarly to the first switching unit, the third switching unit also includes five controllable switches (i.e. a tenth controllable switch KM10, an eleventh controllable switch KM11, a twelfth controllable switch KM12, a thirteenth controllable switch KM13 and a fourteenth controllable switch KM14) corresponding to the number of output ports of the converter module under test. First ends of the five controllable switches are respectively connected with five output ports of the converter module under test 105 correspondingly, and second ends of the five controllable switches are connected in common and connected with the first high-voltage differential detection point T2_ 1.
In the present embodiment, the fourth switching unit preferably includes a fifteenth controllable switch KM15 and a sixteenth controllable switch KM 16. First ends of a fifteenth controllable switch KM15 and a sixteenth controllable switch KM16 are connected in common and are connected with the second high voltage differential detection point T2_2, and second ends of the fifteenth controllable switch KM15 and the sixteenth controllable switch KM16 are connected with the positive pole and the negative pole of the capacitor charging module 207, respectively.
In this embodiment, in order to ensure the safety in the test process, the ninth controllable switch KM9 in the safety discharge module is normally closed, and the tenth controllable switch KM10 is normally open, so that the ninth controllable switch KM9 can also effectively discharge the residual electric quantity at the tested piece end when the system is abnormally powered off.
In order to more clearly illustrate the operation principle and the operation process of the test system of the current transformer module provided in this embodiment, the system is further described below with reference to the operation flowchart of the test system shown in fig. 5.
As shown in fig. 5, before the test starts, the system will perform initialization for each control unit and sub-module in step S501. The OPC server of the automatic production line will query the converter module production order information in the MES information device at regular time in step S502, and when the converter module production order information is queried from the MES information device, the production line OPC server will automatically download the order information to the server, and download the current model of the product under production (i.e. the converter under production information) in the order information to the production line master PLC in step S503.
The production line master PLC transmits the model of the product under production to the test control module in step S504, so that the test control module configures the corresponding test program sequence according to the current model of the product under production in step S505, and completes the resource configuration of each sub-module currently.
The main PLC module of the production line reads whether the pallet of the produced product enters the workstation or not through the data collecting device (e.g., RFID information collecting module) of the production line in step S506. Wherein, when producing line main PLC and reading through RFID information acquisition module and getting into the test station at current transformer module tray, the wiring pilot lamp on the station will light automatically to remind the operator to connect the test pencil, the emergency exit electromagnetic lock will lose efficacy and allow the wiring operation of opening the door simultaneously, USB6525 digital I/O sends station "operation" status flag for producing line main PLC module. The production line master PLC module transmits the tray positioning signal to the test control module in step S507.
In step S508, the system determines whether the tested piece (i.e. the tested converter module) is wired. After wiring is finished, the on-site signal of the wire harness is invalid, the safety door is closed by an operator, meanwhile, the test starting button is started, and the test system starts an automatic test process. At this time, the test control module controls the program-controlled dc power supply to power on the converter module under test according to the test program sequence in step S509, and starts the first voltage detection circuit to monitor the voltages at the two ends of the charging capacitor. In this embodiment, the first voltage detection circuit is preferably implemented by using a 34460A multimeter, but of course, in other embodiments of the present invention, the first voltage detection circuit can be implemented by using other reasonable devices or circuits, and the present invention is not limited thereto.
In step S510, the system determines whether the capacitor charging voltage (i.e., the voltage across the capacitor charging circuit) reaches a predetermined charging voltage according to the voltage signal transmitted from the first voltage detection circuit. When the capacitor charging voltage reaches the preset charging voltage, the pulse distribution device outputs a corresponding phase-sequence upper tube IGBT or lower tube IGBT pulse driving signal in step S511, and switches the test phase-sequence route to the main loop and the detection test loop in step S512. That is, the system will synchronously route closed the inductive load loop high voltage contactor (i.e., the controllable switch in the main loop routing switch module) and the pickup test loop high voltage contactor (i.e., the controllable switch in the second voltage detection loop) in step S512.
At this time, a high voltage differential probe of the TDS3012C dual-channel oscilloscope is connected to the first high voltage differential detection point T2_1 and the second high voltage differential detection point T2_2, respectively, and is capable of testing and collecting the voltage waveform of the detection test loop in step S513 through the high voltage differential probe, and at the same time, the high voltage current probe is used for testing and collecting the current waveform of the inductive load loop, comparing the measured and collected waveform data with a program preset qualification criterion, and recording the comparison result. After the measurement and collection are completed, the system closes the safety discharging module to start the discharging loop in step S514, so as to absorb the residual electric quantity in the loop by using the safety discharging module, and start the execution of the next round of test sequence.
The system judges whether all the test sequences are executed completely in step S515, if all the test sequences are executed completely, the system indicates that all the phase sequence IGBTs are tested completely, and at this time, the system turns off the output of the program-controlled direct-current power supply (namely, turns off the power supply of the tested piece and each submodule) through the test control module in step S516, and sends the test result to the production line main PLC module in step S517, so as to upload the test report data and the test report data to the MES information system.
Meanwhile, the system determines whether the tested piece is disconnected in step S518, and if the tested piece is disconnected, the system controls the test routing subsystem to reset in step S519. Specifically, after all test sequences are executed, the disconnecting indicator lamp on the station is automatically turned on, the electromagnetic lock of the safety door fails to allow the door to be opened and the disconnecting operation is allowed, and at the moment, an operator needs to reset the dismantled wire harness to enable the on-site signal of the wire harness to be effective. Then, when the operator closes the safety door and starts the test start button, the test routing system completes the reset, and the current-producing converter module tray is moved out of the test station in step S520, thereby completing the whole test process.
In this embodiment, the first voltage detection circuit 208 is preferably implemented by a 34460A multimeter. When the test control module controls the automatic power supply device to power on the tested converter module, the 34460A multimeter is started to monitor the voltage at the two ends of the capacitor charging module. The second pedicle voltage detection circuit 212 is preferably implemented by using a TDS3012C dual-channel oscilloscope, a high-voltage differential probe of the TDS3012C dual-channel oscilloscope is used for testing the voltage waveform of the acquisition detection test loop, a high-voltage current probe is used for testing the current waveform of the acquisition load loop, the measured and acquired waveform data is compared with a preset qualified criterion, and a comparison result is recorded.
The specific operation of the automatic test module will be further described with reference to the schematic diagram of the phase a test flow shown in fig. 6.
As shown in fig. 6, taking phase sequence a as an example, the system performs a test procedure, a test station PLC initialization, and the like in step S601 before the test starts, then closes controllable switch KM0 in step S602, and starts the high voltage dc voltage regulator to charge the capacitor charging module in step S603.
The system determines whether the capacitor charging voltage reaches a predetermined charging voltage in step S604. When the 34460A multimeter detects that the charging voltage of the capacitor reaches the preset value of the program (i.e., the preset charging voltage), the test program determines in step S605 whether the phase a upper tube IGBT test or the phase a lower tube GIBT test is required at this time. If the a-phase-top-tube IGBT test is performed, the system outputs a-phase-top-tube pulse driving signal by using the pulse distribution device in step S606, and then the system controls the controllable switch KM7 to close in step S607, so that the programmable high-voltage direct-current power supply powers on the converter module to be tested.
Meanwhile, the system also closes the controllable switch KM1, the controllable switch KM7, the controllable switch KM10 and the controllable switch KM16 in step S608. The controllable switch KM1 and the controllable switch KM7 are closed, so that a conductive loop between the A-phase output port of the tested converter module and the negative electrode of the program-controlled high-voltage direct-current power supply is conducted, and a load loop is conducted. The controllable switch KM10 is closed to enable the electrical connection between the a-phase output port of the converter module under test and the first high-voltage differential detection point T2_1 to be conducted, and the controllable switch KM16 is closed to enable the electrical connection between the negative electrode of the program-controlled high-voltage direct-current power supply and the second high-voltage differential detection point T2_2 to be conducted. Thus, the system can acquire the a-phase main loop current waveform by using the current detection circuit in step S609 and acquire the a-phase detection loop positive-phase voltage waveform by using the second voltage detection circuit in step S610.
Subsequently, the system closes the controllable switch KM8 in step S616, thereby starting the discharging loop. During the discharging process of the discharging loop, the system further determines whether the discharging voltage of the capacitor (i.e. the voltage across the capacitor charging module) is 0 in step S617. If the capacitor discharge voltage is 0, it indicates that the system has completed discharging, which in turn indicates the end of the IGBT test procedure on phase a tubes.
Similarly, if the system determines in step S605 that the a-phase lower tube IGBT needs to be tested, the system outputs an a-phase lower tube pulse driving signal in step S611 by using the pulse distribution device, and then the system controls the controllable switch KM0 to close in step S612, so that the programmable high-voltage dc power supply powers on the converter module to be tested.
Meanwhile, the system also closes the controllable switch KM1, the controllable switch KM6, the controllable switch KM10 and the controllable switch KM15 in step S613. The controllable switch KM1 and the controllable switch KM6 are closed, so that a conductive loop between the A-phase output port of the tested converter module and the anode of the programmable high-voltage direct-current power supply is conducted, and a load loop is conducted. The controllable switch KM10 is closed to enable the electric connection between the A-phase output port of the tested converter module and the first high-voltage differential detection point T2_1 to be conducted, and the controllable switch KM15 is closed to enable the electric connection between the anode of the program-controlled high-voltage direct-current power supply and the second high-voltage differential detection point T2_2 to be conducted. The system thus collects the a-phase main loop current waveform using the current sensing circuit in step S614 and the a-phase detector loop positive phase voltage waveform using the second voltage sensing circuit in step S615.
Subsequently, the system closes the controllable switch KM8 in step S616, thereby starting the discharging loop. During the discharging process of the discharging loop, the system further determines whether the discharging voltage of the capacitor (i.e. the voltage across the capacitor charging module) is 0 in step S617. If the capacitor discharge voltage is 0, it indicates that the system has finished discharging, and thus indicates the end of the IGBT test process for the phase a lower tube.
The method for testing the converter module in the prior art adopts a manual testing mode for testing the converter module, and the testing efficiency is extremely low because the mode is usually more than half an hour. When a large quantity of products are produced and tested, the problem of low efficiency of the manual testing mode is more prominent, and the delivery process of the products is seriously hindered.
However, the converter module testing system provided by the invention can greatly improve the testing efficiency of the converter module. The time for testing one converter module by the system can be less than or equal to 5 minutes generally, so that the requirement of the beat time of an automatic production line can be effectively met.
Meanwhile, the test system provided by the invention can realize the fusion of the test equipment and the automatic production line and the interaction of an MES information system, and the main PLC of the production line can monitor the working state of the test equipment in real time and automatically upload a test result report to the MES information system.
The IGBT driving pulse required by the existing testing technology needs manual control, and the pulse characteristic cannot be reset, so that misoperation is easily caused. However, the testing system provided by the invention does not need manual intervention in the testing process of the converter module, and the main loop route switching module and the measuring route switching module of the system can automatically match with the testing path to finish automatic measurement and data acquisition. Meanwhile, the pulse distribution device in the system can automatically match IGBT driving pulse output according to the characteristics of different types and series of converter modules.
In addition, the switch KM8 in the safety discharge module in the system provided by the invention is in a normally closed state, and the switch KM9 is in a normally open state. When the system is abnormally powered off, the switch KM8 can still effectively discharge the residual electric quantity of the tested piece, so that the safety discharge effectiveness is fully ensured. Meanwhile, a tested piece of the system is completely isolated from a power supply of the control equipment, so that secondary damage of the testing equipment caused by abnormity of the tested piece is avoided. In addition, on the safety execution logic, various power-off and power-on in the system have an interlocking function, so that the safety of operation is fully ensured. The test system provided by the invention has wide test parameter coverage, and is preferably compatible with a full-system converter module with the maximum input voltage DC4000V and the maximum power of 1200 KW.
It is to be understood that the disclosed embodiments of the invention are not limited to the particular structures or process steps disclosed herein, but extend to equivalents thereof as would be understood by those skilled in the relevant art. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
Reference in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase "one embodiment" or "an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment.
While the above examples are illustrative of the principles of the present invention in one or more applications, it will be apparent to those of ordinary skill in the art that various changes in form, usage and details of implementation can be made without departing from the principles and concepts of the invention. Accordingly, the invention is defined by the appended claims.
Claims (9)
1. A converter module testing system, the system comprising:
the power supply device is used for supplying power to the tested converter module and the electric appliance in the test system;
the pulse distribution device is connected with the tested converter module and used for providing a pulse driving signal for the tested converter;
the test process control device is connected with the pulse distribution device and the power supply device and used for sending corresponding control signals to the power supply device and the pulse distribution device so as to enable the power supply device to provide electric energy for electric appliances of the tested converter module and the test process control module, and enable the pulse distribution device to generate corresponding pulse driving signals and send the pulse driving signals to the tested converter module;
the automatic measuring device is connected with the test process control device and is used for carrying out corresponding function test on the converter module to be tested according to the control command sent by the test process control device;
wherein the pulse distribution device comprises: the switching value signal conditioning module is connected with the test process control device and is used for carrying out isolated conditioning on the switching value signal sent by the test process control device;
the first buffer is connected with the switching value signal conditioning module;
the pulse driving signal generating module is connected with the first buffer and used for generating and outputting a pulse driving signal of a corresponding channel according to the isolated and conditioned switching value signal;
the second buffer is connected with the pulse driving signal generation module;
a signal shaping module connected with the second buffer.
2. The system of claim 1, further comprising a production line OPC server and an MES information device, wherein the production line OPC server is configured to query converter module production order information in the MES information device, download the converter module production order information when the converter module production order information is queried, and transmit the converter-under-production information in the converter module production order information to the test process control device, so that the test process control device configures a corresponding test program sequence according to the converter-under-production information.
3. The system of claim 1 or 2, wherein the system further comprises:
and the production line end data acquisition device is connected with the test process control device and is used for detecting whether the tested converter module enters or leaves a test station, correspondingly generating an in-place indication signal or a dislocation indication signal and sending the in-place indication signal or the dislocation indication signal to the test process control device.
4. The system of claim 3, wherein upon receiving an in-place indication signal and receiving a test initiation signal, the test process control device is configured to send a corresponding control signal to the power supply device to control the power supply device to provide power to the converter module under test.
5. The system of claim 4, wherein the automatic measuring device comprises:
the capacitor charging module is connected between the power supply device and the converter module to be tested;
and the first voltage detection circuit is connected with the capacitor charging module and used for measuring the voltage at two ends of the capacitor charging module and transmitting the generated first voltage signal to the test process control device.
6. The system of claim 5, wherein the test process control device is configured to determine whether the voltage characterized by the first voltage signal is greater than or equal to a preset charging voltage, and if so, to send a corresponding control signal to the pulse distribution device to cause the pulse distribution device to generate a corresponding pulsed drive signal and transmit the pulsed drive signal to the converter module under test.
7. The system of claim 5 or 6, wherein the automatic measuring device further comprises:
the main loop routing switching module comprises a first switching unit and a second switching unit, wherein the first switching unit is correspondingly connected with each output port of the converter module to be tested, the second switching unit is connected with the capacitor charging module, and the first switching unit and the second switching unit are matched to conduct a conductive loop between a specified output port of the converter module to be tested and the anode or the cathode of the capacitor charging module;
an inductive load module connected between the first switching unit and the second switching unit;
the current detection circuit is connected with the inductive load module and used for measuring the current flowing through the inductive load module to obtain a detection current signal;
and the second voltage detection circuit is connected with each output port of the converter module to be detected and is used for detecting the voltage between the appointed output port of the converter module to be detected and the anode or the cathode of the capacitor charging module to obtain a detection voltage signal.
8. The system of claim 7, wherein the converter module under test comprises a plurality of identically configured legs, each leg comprising a top tube IGBT and a bottom tube IGBT, wherein,
when an upper tube IGBT in a bridge arm is tested, the first switching unit and the second switching unit conduct a conductive loop between an output port corresponding to the upper tube IGBT to be tested and a negative electrode of the capacitor charging module under the control of the test process control device, and meanwhile, the second voltage detection circuit is configured to detect a voltage between the output port corresponding to the upper tube IGBT to be tested and the negative electrode of the capacitor charging module;
when a lower tube IGBT in one bridge arm is tested, the first switching unit and the second switching unit conduct a conductive loop between an output port corresponding to the tested lower tube IGBT and the anode of the capacitor charging module under the control of the test process control device, and meanwhile, the second voltage detection circuit is configured to detect voltage between the output port corresponding to the tested upper tube IGBT and the anode of the capacitor charging module.
9. The system of claim 7, wherein the automatic measuring device further comprises:
and the safe discharge module is connected between the anode and the cathode of the capacitor charging module and is used for absorbing residual electric energy in the conductive loop.
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| CN112114573B (en) * | 2019-06-20 | 2021-12-24 | 株洲中车时代电气股份有限公司 | New energy passenger vehicle motor controller function testing device and method based on automatic production line |
| CN110618330A (en) * | 2019-09-27 | 2019-12-27 | 上海科梁信息工程股份有限公司 | Current transformer detection platform and detection method |
| CN111751694A (en) * | 2020-06-24 | 2020-10-09 | 中电科仪器仪表有限公司 | Multi-processor fusion measurement and control system, method and tester for microwave semiconductor device |
| CN113358996B (en) * | 2021-05-28 | 2024-03-12 | 特变电工西安柔性输配电有限公司 | Universal testing device and method for power module of flexible direct current converter valve |
| CN113484714B (en) * | 2021-07-27 | 2024-08-09 | 远景能源有限公司 | Converter test platform and test method |
| CN118732542A (en) * | 2023-03-29 | 2024-10-01 | 中车株洲电力机车研究所有限公司 | A converter module debugging device |
| CN116859091B (en) * | 2023-06-27 | 2025-04-01 | 杭州高坤电子科技有限公司 | A bridge arm switching device, a test system and a test method for a power device |
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