CN107271896B - Safety relay testing device and testing method thereof - Google Patents
Safety relay testing device and testing method thereof Download PDFInfo
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- CN107271896B CN107271896B CN201710647972.3A CN201710647972A CN107271896B CN 107271896 B CN107271896 B CN 107271896B CN 201710647972 A CN201710647972 A CN 201710647972A CN 107271896 B CN107271896 B CN 107271896B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/327—Testing of circuit interrupters, switches or circuit-breakers
- G01R31/3277—Testing of circuit interrupters, switches or circuit-breakers of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches
- G01R31/3278—Testing of circuit interrupters, switches or circuit-breakers of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches of relays, solenoids or reed switches
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Abstract
The invention provides a safety relay testing device and a testing method thereof, wherein the safety relay testing device comprises an MCU (microprogrammed control Unit) controller, a relay contact testing module, a relay coil testing module, a power protection control unit and a key input circuit; when the test is carried out, the MCU controller is used for controlling the coil resistance measurement and clamping stagnation test switching circuit to carry out coil resistance measurement and clamping stagnation test switching; when measuring the coil resistance and the contact resistance, the MCU controller draws an action characteristic diagram of the relay according to the coil resistance and the contact resistance; when the clamping stagnation test is carried out, the set coil power supply voltage, the test times, the test pull-in time and the test interval time are input through the key input circuit. The invention has scientific design and strong practicability, and can carry out automatic test and repeated test on the safety relay test device.
Description
Technical Field
The invention relates to the field of safety relays, in particular to a safety relay testing device and a testing method thereof.
Background
The safety relay is arranged on a relay control board in a platform controller (PEDC), and is mainly used for executing action signals of controlling the shielding door such as permission, door opening, door closing, interlocking and locking, and controlling a door head DCU to open and close the shielding door. At present, two safety relays are commonly used in a subway shielded door system, namely two manufacturers of German Henshele and Japan Song-Shi. The failure rate of a platform controller (PEDC) of the subway shield door is high, and the failure of a safety relay on a relay control board inside the PEDC is found to be high in the maintenance process, so that the operation of a main line is seriously influenced.
The structure of the safety relay has the following defects: the mechanical structure is complex, the weight is large, the contact size is long, and fatigue is easy to generate; the contact and the coil are not sealed, dust is easy to enter, and the contact can be damaged by ignition after long-time use. Because the purchase price of the relay is higher, the purchase period is long, and when the fault occurs, the emergency fault treatment is carried out on the safety relay for quickly removing the fault, and the treatment method comprises the steps of repairing the contact of the relay, polishing, cleaning and then reinstalling the contact of the relay, or replacing the contact with serious damage.
In the maintenance process, a testing device is lacked, and the relay can be tested only manually by a conventional method. The fault diagnosis and test time of the relay is long, and the maintenance efficiency is influenced by repeated operation of maintainers. There are also some testing devices available, such as: patent application No. 201610847392.4 testing device and testing method for safety relay provides a testing device and testing method for safety relay, which judges whether the working state of the relay contact is normal or not by changing the voltage provided by the relay coil and observing the light emitting diode corresponding to the contact state with eyes. When the contact resistance is measured, the knob selection switch is switched, the contacts of the relay, which are connected with the corresponding light emitting diodes, are respectively communicated with the ohmmeter, and the resistance value of the connected contact resistance is read through the ohmmeter. Patent application No. 201620684412.6 "testing device for subway signal safety relay and vehicle-mounted relay", uses an oscillating circuit to generate a level-reversal signal output with settable frequency for driving a coil of the relay. Thereby realizing the control to the frequency of the circular telegram of relay and outage, the number of times that the counter recorded has already been run simultaneously.
The conventional method uses an adjustable direct current stabilized voltage power supply and a universal meter for testing the relay. The resistance value of a coil or a contact of the relay is measured by using an ohm gear or an ohmmeter of a multimeter, and the quality of the relay is judged by loading different voltage values on the coil of the relay and measuring the opening and closing actions of the contact of the relay. The test method is complex in operation, different data points need to be measured manually, the operation is complex, and errors and influences caused by human factors are large.
In order to solve the above problems, people are always seeking an ideal technical solution.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a safety relay testing device which is scientific in design, strong in practicability and capable of automatically testing and repeatedly testing a safety relay, and a testing method of the safety relay testing device.
In order to achieve the purpose, the invention adopts the technical scheme that: a safety relay testing device comprises an MCU controller, a relay contact testing module, a relay coil testing module, a power protection control unit and a key input circuit; the power supply comprises a control unit, a power supply input protection control circuit, a DC-DC voltage reduction circuit and a DC-DC numerical control voltage boosting module, wherein the input end of the power supply input protection control circuit is connected with commercial power; the DC-DC numerical control boosting module is sequentially connected to the output end of the power input protection control circuit through a first power protection isolation circuit and a first AC-DC switching power supply and is used for providing 12-120V voltage; the DC-DC voltage reduction circuit is connected to the output end of the power input protection control circuit through a second power protection isolation circuit and a second AC-DC switching power supply in sequence and is used for providing 12V-5V voltage; the relay contact test module comprises a relay contact measurement board card and a first ADC (analog to digital converter) acquisition circuit, wherein the relay contact measurement board card is connected with a contact of a relay to be tested in a four-wire system measurement mode and is connected with the MCU through the first ADC acquisition circuit; the relay coil testing module comprises a coil resistance measuring and clamping stagnation testing switching circuit, a coil resistance measuring board card and a second ADC (analog to digital converter) acquisition circuit; the coil resistance measurement and clamping stagnation test switching circuit is connected with a relay coil to be measured in a four-wire system measurement mode, connected with the coil resistance measurement board card and further connected to the DC-DC numerical control boosting module through a voltage and current acquisition circuit and an electronic switch in sequence; the electronic switch is connected with the MCU controller through an IO isolation driving circuit; the MCU controller is connected with the voltage and current acquisition circuit and the coil resistance measurement board card through the second ADC acquisition circuit, and is connected with the coil resistance measurement and clamping stagnation test switching circuit through the change-over switch state feedback circuit; the key input circuit is connected with the MCU controller and used for setting test parameters.
Based on the above, still include the safety relay test socket, the safety relay test socket sets up ten relay contact measurement integrated circuit boards, two coil resistance measurement integrated circuit boards, RS485 serial interface, USB interface.
Based on the above, the MCU controller is further connected with a temperature and humidity sensor for collecting the temperature and humidity of the test environment, an SD card for storing test data, and an indicator light for indicating the status of the safety relay test socket.
Based on the above, the relay contact measuring board card includes a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse current protection circuit, a contact test interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second signal buffer circuit, a second-stage input signal filter circuit, and an output-stage protection circuit, which are connected in sequence, wherein the first-stage input protection circuit is connected with the contact test interface of the relay, and an output end of the output-stage protection circuit is a voltage feedback signal interface.
Based on the above, the relay contact measurement board card is further provided with a contact resistance comparison circuit for indicating whether contact resistance is normal or abnormal during clamping stagnation test, and comparison voltage of the contact resistance comparison circuit is obtained from the output of the first-stage input signal filter circuit.
Based on the above, the coil resistance measurement board card comprises a reference voltage source, a precise resistance network, a gear switching circuit, a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse current protection circuit, a coil test interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second-stage signal buffer circuit, a second-stage input signal filter circuit and an output-stage protection circuit which are connected in sequence; the gear switching circuit is connected with the MCU controller through a gear switching control circuit, the first-stage input protection circuit is connected with a contact test interface of the relay, and the output end of the output-stage protection circuit is a voltage feedback signal interface.
According to the testing method of the safety relay testing device, the coil resistance measuring and clamping stagnation testing switching circuit is controlled by the MCU controller to carry out coil resistance measuring and clamping stagnation testing switching; when measuring the coil resistance and the contact resistance, the MCU controller controls the electronic switch to be switched on or off so as to supply power to a relay connected to a power supply loop; the DC-DC numerical control boosting module is manually controlled or program-controlled to output different voltages, the coil resistance measuring board is used for measuring coil resistance under different voltages, the coil resistance is uploaded to the MCU controller after analog-digital conversion of the second ADC acquisition circuit, the relay contact measuring board is used for measuring contact resistance under different voltages, and the contact resistance is uploaded to the MCU controller after analog-digital conversion of the first ADC acquisition circuit; the MCU controller draws an action characteristic diagram of the relay according to the coil resistance and the contact resistance; when the clamping stagnation test is carried out, the set coil power supply voltage, the test times, the test pull-in time and the test interval time are input through the key input circuit; the DC-DC numerical control boosting module is used for outputting a set coil power supply voltage in a program-controlled manner, the voltage and current acquisition circuit acquires a line current value under the current voltage, the line current value is uploaded to the MCU controller after analog-digital conversion through the second ADC acquisition circuit, the MCU controller calculates the current coil resistance, the relay contact measuring board is used for measuring the contact resistance under the set coil voltage, and the contact resistance is uploaded to the MCU controller after analog-digital conversion through the first ADC acquisition circuit.
Compared with the prior art, the invention has prominent substantive characteristics and remarkable progress, particularly:
1. through program control of three constant current values (1 mA, 10mA and 100 mA) of fixed gears, the resistance range of the coil resistor can be automatically judged, the constant current value can be automatically switched, the coil resistor of the relay can be automatically tested, and the relay can be repeatedly tested.
2. By programming the constant current value (0-100 mA) loaded on the contacts, each group of contact resistance of the relay can be automatically tested and can be repeatedly tested.
3. The device is provided with 10 contact resistance measuring board card interfaces and 2 coil resistance measuring board card interfaces. And the measurement of the coil resistance and the contact resistance adopts the idea of modular design. The states of all contacts of the relays of various models can be measured simultaneously and in real time by increasing the types and the number of the measuring board cards.
4. The coil resistance and the contact resistance are measured in a constant current source driving mode, a four-wire system wiring measuring method is used for the coil or the contact to be measured, and the influence of a measuring lead and a relay testing base on the resistance to be measured is avoided.
5. The coil power supply voltage of the relay can be adjusted manually or in a program-controlled manner, the output voltage is adjustable (DC 12-120V), and the action characteristics of the relay are automatically drawn through the real-time acquisition of the contact resistance.
6. The jamming test of the relay can be performed. When the contact resistance is tested, a settable reference voltage value serves as a reference resistance value comparison threshold value through a contact resistance value comparison circuit, the resistance value of the contact resistance and the same settable reference voltage value form a comparison circuit, hardware outputs level indication of each group of contact resistance values and the reference resistance values, then high and low level signals are sent to an MCU, a green light is normally tested, and a buzzer alarms and a red light flickers if the test is abnormal; if the test frequency of the abnormal automatic stop test is reached, the relay is blocked, the buzzer gives an alarm, the red light flickers, and the test is automatically stopped.
7. The coil resistance and the contact resistance data obtained by measurement can be communicated with the upper computer software of the PC through RS485 communication, and the test data can be displayed, recorded and analyzed in real time. Meanwhile, the relay state can be stored in the SD card, so that the relay state can be conveniently measured off line, and analysis is carried out by reading the data of the SD card.
Drawings
FIG. 1 is a block diagram of the architecture of the present invention.
Fig. 2 is a block diagram of a safety relay test socket circuit of the present invention.
Fig. 3 is a block diagram of a relay coil testing module of the present invention.
Fig. 4 is a block diagram of a relay contact testing module of the present invention.
Fig. 5 is a circuit diagram of a relay coil testing module of the present invention.
Fig. 6 is a circuit diagram of a relay contact testing module of the present invention.
Detailed Description
The technical solution of the present invention is further described in detail by the following embodiments.
As shown in fig. 1-4, a safety relay testing device comprises an MCU controller, a relay contact testing module, a relay coil testing module, a power protection control unit, and a key input circuit; the power supply comprises a control unit, a power supply input protection control circuit, a DC-DC voltage reduction circuit and a DC-DC numerical control voltage boosting module, wherein the input end of the power supply input protection control circuit is connected with commercial power; the DC-DC numerical control boosting module is sequentially connected to the output end of the power input protection control circuit through a first power protection isolation circuit and a first AC-DC switching power supply and is used for providing 12-120V voltage; the DC-DC voltage reduction circuit is connected to the output end of the power input protection control circuit through a second power protection isolation circuit and a second AC-DC switching power supply in sequence and is used for providing 12V-5V voltage; the relay contact test module comprises a relay contact measurement board card and a first ADC (analog to digital converter) acquisition circuit, wherein the relay contact measurement board card is connected with a contact of a relay to be tested in a four-wire system measurement mode and is connected with the MCU through the first ADC acquisition circuit; the relay coil testing module comprises a coil resistance measuring and clamping stagnation testing switching circuit, a coil resistance measuring board card and a second ADC (analog to digital converter) acquisition circuit; the coil resistance measurement and clamping stagnation test switching circuit is connected with a relay coil to be measured in a four-wire system measurement mode, connected with the coil resistance measurement board card and connected to the DC-DC numerical control boosting module through a voltage and current acquisition circuit and an electronic switch in sequence; the electronic switch is connected with the MCU controller through an IO isolation driving circuit; the MCU controller is connected with the voltage and current acquisition circuit and the coil resistance measurement board card through the second ADC acquisition circuit, and is connected with the coil resistance measurement and clamping stagnation test switching circuit through the change-over switch state feedback circuit; the key input circuit is connected with the MCU controller and used for setting test parameters; through RS485 communication, testing arrangement can communicate with the host computer software of PC for show, record and analysis are carried out test data in real time.
Specifically, as shown in fig. 6, the relay contact measurement board includes a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse current protection circuit, a contact test interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second-stage signal buffer circuit, a second-stage input signal filter circuit, and an output-stage protection circuit, which are connected in sequence, where the first-stage input protection circuit is connected to the contact test interface of the relay, and an output end of the output-stage protection circuit is a voltage feedback signal interface.
The relay contact measuring board card is further provided with a contact resistance comparison circuit used for indicating whether contact resistance is normal or abnormal during clamping stagnation test, and comparison voltage of the contact resistance comparison circuit is taken from the output of the first-stage input signal filter circuit. Through the contact resistance value comparison circuit, the condition of the contact can be quickly obtained when the clamping stagnation test is carried out.
As shown in fig. 5, the coil resistance measurement board card includes a reference voltage source, a precision resistance network, a shift switching circuit, a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse current protection circuit, a coil test interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second-stage signal buffer circuit, a second-stage input signal filter circuit, and an output-stage protection circuit, which are connected in sequence; the gear switching circuit is connected with the MCU controller through a gear switching control circuit, the first-stage input protection circuit is connected with a contact test interface of the relay, and the output end of the output-stage protection circuit is a voltage feedback signal interface. The reference voltage source is used for providing fixed load current and ensuring the stability of the reference voltage source; the gear switching circuit provides reference voltage values of different gears for the constant current circuit, and different constant current values are switched by combining with the gear switching circuit; the low-end driving constant current source circuit and the high-end driving constant current source circuit are used for driving constant current output.
Preferably, the MCU controller is further connected with a temperature and humidity sensor for collecting temperature and humidity of a test environment, an SD card for storing test data, and an indicator light for indicating the state of the safety relay test socket.
When specifically carrying out the structural design, still include the safety relay test socket, the safety relay test socket sets up ten relay contact measurement integrated circuit boards, two coil resistance measurement integrated circuit boards, RS485 serial interface, USB interface.
When the testing method is used, the MCU controller controls the coil resistance measuring and clamping stagnation testing switching circuit to carry out coil resistance measuring and clamping stagnation testing switching;
when measuring the coil resistance and the contact resistance, the MCU controller controls the electronic switch to be switched on or off so as to supply power to a relay connected to a power supply loop; the DC-DC numerical control boosting module is manually controlled or program-controlled to output different voltages, the coil resistance measuring board is used for measuring coil resistance under different voltages, the coil resistance is uploaded to the MCU controller after analog-digital conversion of the second ADC acquisition circuit, the relay contact measuring board is used for measuring contact resistance under different voltages, and the contact resistance is uploaded to the MCU controller after analog-digital conversion of the first ADC acquisition circuit; and the MCU controller draws an action characteristic diagram of the relay according to the coil resistance and the contact resistance, and the state of the relay can be tested through the action characteristics reflected by the contact resistance and the coil resistance, so that the automatic test of the relay is completed.
When the clamping stagnation test is carried out, the set coil power supply voltage, the test times, the test pull-in time and the test interval time are input through the key input circuit; the DC-DC numerical control boosting module is used for outputting a set coil power supply voltage in a program-controlled manner, the voltage and current acquisition circuit acquires a line current value under the current voltage, the line current value is uploaded to the MCU controller after analog-digital conversion through the second ADC acquisition circuit, the MCU controller calculates the current coil resistance, the relay contact measuring board is used for measuring the contact resistance under the set coil voltage, and the contact resistance is uploaded to the MCU controller after analog-digital conversion through the first ADC acquisition circuit. And (5) carrying out clamping stagnation test of the relay. Measuring the closed resistance value of each group of contacts, wherein the testing times are adjustable; the test pull-in time can be set; the test interval time can be set; the measured resistance values of normal test and abnormal test can be set, and the test times of automatic stop of abnormal test can be set. The device can output and set the power supply voltage of the coil in a program-controlled manner, measure the contact resistance values of a plurality of groups of relay contacts simultaneously, record and store the contact resistance values of the groups of contacts, thereby measuring the contact states and resistance values of the coil under different voltage conditions simultaneously and in real time and realizing the automatic test of the relay.
Finally, it should be noted that the above examples are only used to illustrate the technical solution of the present invention and not to limit it; although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that: modifications to the specific embodiments of the invention or equivalent substitutions for parts of the technical features may be made; without departing from the spirit of the present invention, it is intended to cover all aspects of the invention as defined by the appended claims.
Claims (7)
1. A safety relay testing device is characterized in that: the device comprises an MCU controller, a relay contact test module, a relay coil test module, a power protection control unit and a key input circuit;
the power supply comprises a control unit, a power supply input protection control circuit, a DC-DC voltage reduction circuit and a DC-DC numerical control voltage boosting module, wherein the input end of the power supply input protection control circuit is connected with commercial power; the DC-DC numerical control boosting module is sequentially connected to the output end of the power input protection control circuit through a first power protection isolation circuit and a first AC-DC switching power supply and is used for providing 12-120V voltage; the DC-DC voltage reduction circuit is connected to the output end of the power input protection control circuit through a second power protection isolation circuit and a second AC-DC switching power supply in sequence and is used for providing 12V-5V voltage;
the relay contact test module comprises a relay contact measurement board card and a first ADC (analog to digital converter) acquisition circuit, wherein the relay contact measurement board card is connected with a contact of a relay to be tested in a four-wire system measurement mode and is connected with the MCU through the first ADC acquisition circuit;
the relay coil testing module comprises a coil resistance measuring and clamping stagnation testing switching circuit, a coil resistance measuring board card and a second ADC (analog to digital converter) acquisition circuit;
the coil resistance measurement and clamping stagnation test switching circuit is connected with a relay coil to be measured in a four-wire system measurement mode, connected with the coil resistance measurement board card and connected to the DC-DC numerical control boosting module through a voltage and current acquisition circuit and an electronic switch in sequence;
the electronic switch is connected with the MCU controller through an IO isolation driving circuit;
the MCU controller is connected with the voltage and current acquisition circuit and the coil resistance measurement board card through the second ADC acquisition circuit and is connected with the coil resistance measurement and clamping stagnation test switching circuit through a switch state feedback circuit;
the key input circuit is connected with the MCU controller and used for setting test parameters;
the test method of the safety relay test device comprises the following steps:
the MCU controller is used for controlling the coil resistance measurement and clamping stagnation test switching circuit to carry out coil resistance measurement and clamping stagnation test switching;
when measuring the coil resistance and the contact resistance, the MCU controller controls the electronic switch to be switched on or off so as to supply power to a relay connected to a power supply loop; the DC-DC numerical control boosting module is manually controlled or program-controlled to output different voltages, the coil resistance measuring board card is used for measuring the coil resistance under different voltages, the coil resistance is uploaded to the MCU controller after analog-digital conversion of the second ADC acquisition circuit, the relay contact measuring board card is used for measuring the contact resistance under different voltages, and the contact resistance is uploaded to the MCU controller after analog-digital conversion of the first ADC acquisition circuit; the MCU controller draws an action characteristic diagram of the relay according to the coil resistance and the contact resistance;
when the clamping stagnation test is carried out, the set coil power supply voltage, the test times, the test pull-in time and the test interval time are input through the key input circuit; the DC-DC numerical control boosting module is used for outputting a set coil power supply voltage in a program-controlled manner, the voltage and current acquisition circuit acquires a line current value under the current voltage, the line current value is uploaded to the MCU controller after analog-digital conversion through the second ADC acquisition circuit, the MCU controller calculates the current coil resistance, the relay contact measuring board is used for measuring the contact resistance under the set coil voltage, and the contact resistance is uploaded to the MCU controller after analog-digital conversion through the first ADC acquisition circuit.
2. The safety relay testing device of claim 1, wherein: still include the safety relay test socket, the safety relay test socket sets up ten relay contact measurement integrated circuit boards, two coil resistance measurement integrated circuit boards, RS485 serial interface, USB interface.
3. The safety relay testing device of claim 2, wherein: the MCU controller is also connected with a temperature and humidity sensor for collecting the temperature and humidity of the test environment, an SD card for storing test data and an indicator light for indicating the state of the safety relay test socket.
4. The safety relay testing device according to claim 3, characterized in that:
the relay contact measuring board card comprises a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse flow protection circuit, a contact testing interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second-stage signal buffer circuit, a second-stage input signal filter circuit and an output-stage protection circuit which are connected in sequence, wherein the first-stage input protection circuit is connected with the contact testing interface of the relay, and the output end of the output-stage protection circuit is a voltage feedback signal interface.
5. The safety relay testing device according to claim 4, characterized in that: the relay contact measuring board card is further provided with a contact resistance comparison circuit used for indicating whether contact resistance is normal or abnormal during clamping stagnation test, and comparison voltage of the contact resistance comparison circuit is taken from the output of the first-stage input signal filter circuit.
6. The safety relay testing device of claim 3, wherein: the coil resistance measurement board card comprises a reference voltage source, a precision resistance network, a gear switching circuit, a low-end driving constant current source circuit, a high-end driving constant current source circuit, a filter circuit, an output reverse flow protection circuit, a coil test interface, a first-stage input protection circuit, a first-stage signal buffer circuit, a first-stage input signal filter circuit, a second signal buffer circuit, a second-stage input signal filter circuit and an output-stage protection circuit which are connected in sequence; the gear switching circuit is connected with the MCU controller through a gear switching control circuit, the first-stage input protection circuit is connected with a contact test interface of the relay, and the output end of the output-stage protection circuit is a voltage feedback signal interface.
7. The safety relay testing device of claim 1, wherein: the relay contact measuring board card is also provided with a contact resistance value comparison circuit for indicating whether contact resistance is normal or abnormal during clamping stagnation test, and comparison voltage of the contact resistance value comparison circuit is obtained from the first-stage input signal filter circuit and output; when the clamping stagnation test is carried out, the measured resistance values of normal test and abnormal test and the test times of automatic stop of abnormal test are preset, when the test times of automatic stop of abnormal test reach, the clamping stagnation of the relay is indicated, and the test is automatically stopped.
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