CN112611953A - Monitoring system and monitoring method for high-voltage welding fault of aluminum-based circuit board - Google Patents
Monitoring system and monitoring method for high-voltage welding fault of aluminum-based circuit board Download PDFInfo
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- CN112611953A CN112611953A CN202011400362.1A CN202011400362A CN112611953A CN 112611953 A CN112611953 A CN 112611953A CN 202011400362 A CN202011400362 A CN 202011400362A CN 112611953 A CN112611953 A CN 112611953A
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- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2801—Testing of printed circuits, backplanes, motherboards, hybrid circuits or carriers for multichip packages [MCP]
- G01R31/281—Specific types of tests or tests for a specific type of fault, e.g. thermal mapping, shorts testing
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Abstract
The invention discloses a high-voltage welding fault monitoring system and a monitoring method for an aluminum-based circuit board, belonging to the field of aluminum-based circuit board process manufacturing; a monitoring system and a monitoring method for high-voltage welding faults of an aluminum-based circuit board comprise the following steps: the device comprises a high-pressure welding unit, an energy recording unit, a fault testing unit, an analysis positioning unit and a feedback unit; the invention can effectively and quickly weld by utilizing high voltage for welding, and can simultaneously carry out welding test on the circuit board when the welding is finished, wherein the welding test comprises the steps of collecting voltage signals, pulse signals and control signals on the circuit board, observing whether the output physical quantities of different parts are in a normal range to judge whether the circuit board normally works or not by constructing a test circuit, analyzing and judging the fault reasons and the parts of the circuit board by the data of a test item, analyzing and positioning the faults and feeding the faults back to the system, thereby facilitating the system to monitor the faults.
Description
Technical Field
The invention belongs to the field of aluminum-based circuit board process manufacturing, relates to an aluminum-based circuit board, and particularly relates to a high-voltage welding fault monitoring system and a monitoring method for the aluminum-based circuit board.
Background
With the development of high density and multiple functions of aerospace electronic products, the development of power electronic products towards high efficiency and high power becomes a necessary trend. In particular to a high-power output electronic product represented by a power supply product; the aluminum-based printed circuit board has excellent heat dissipation performance, because the printed board assembly assembled by the aluminum-based printed circuit board can dissipate heat in time in the working process, the temperature rise of devices is avoided from influencing the work of equipment, meanwhile, the aluminum-based printed circuit board has high mechanical strength and toughness, the manufacturing of large-area printed circuits can be realized, and components with large weight can be mounted. At present, the thickness of an optional aluminum substrate in the market can reach 3.2mm, foreign power supply development units have combined a circuit board and a mounting base plate, and the aluminum-based printed circuit board has a good shielding function, can prevent radiation and interference of electromagnetic waves, and ensures normal work of the circuit. The aluminum-based printed circuit board has the excellent performance, so that the aluminum-based printed circuit board is widely applied to the fields of industrial equipment, power supply equipment and the like, particularly LED lighting engineering.
In the production of the aluminum-based printed circuit board, the layout of circuit board components is required, so that the installation and welding of via holes are carried out; however, in the prior art, most of production circuit boards are mechanically and fully-automatically welded, but when welding is performed, heat dissipation is fast, so that the welding temperature cannot completely soak soldering tin, and a welding spot alloy layer is difficult to form, so that the bonding force of the welding plate in a via hole is poor, the welding spot is unreliable, if high-pressure welding is adopted, the welding reliability cannot be guaranteed, and meanwhile, the circuit board after high-pressure welding needs to be tested during welding, so that the stability of subsequent welding is guaranteed.
Disclosure of Invention
The purpose of the invention is as follows: the monitoring system and the monitoring method for the high-voltage welding fault of the aluminum-based circuit board are provided to solve the problems.
The technical scheme is as follows: a high-voltage welding fault monitoring system for an aluminum-based circuit board comprises:
the high-voltage welding unit converts input voltage into pulse high-voltage electricity; the energy with smaller power is slowly input into the energy storage module for a longer time to be stored, and is compressed and converted, and is input into the welding device with extremely high power density in an extremely short time to weld the circuit board;
the energy recording unit records the energy consumption of high-pressure welding, and provides convenience for the research of energy consumption rules; therefore, the damage degree of the welding to the circuit board is known according to the high-voltage energy, and the input voltage is adjusted for subsequent work;
the fault testing unit is used for testing the aluminum-based circuit board subjected to high-pressure welding, so that parameters of all states are obtained to verify the function of the tested board;
the analysis positioning unit is used for analyzing and confirming the type of the fault problem and positioning the position of the fault problem in the area with the problem in the test;
and the feedback unit feeds back the fault test result to the master control end, so that fault personnel can know the test condition and adjust subsequent work, and fault monitoring is realized.
Preferably, the high pressure welding unit includes: the device comprises an energy storage module, a pulse module, a matching transmission module and a switch module;
the energy storage module is provided with a plurality of energy storage blocks; the pulse module outputs pulse voltage through compression and voltage conversion; the matching transmission module is matched with the welding device so as to transmit energy; the switch module is used for controlling the input and output of energy between the modules.
Preferably, the fault testing unit comprises a control module, a parameter measuring module, a data processing module and an output module;
the control module can perform a plurality of tasks simultaneously through the multi-core control circuit, and simultaneously can open one or more switches to close one or more channels and also can close one or more switches to connect one or more driving devices; the simultaneous control module includes: a signal generating circuit; respectively generating and outputting digital signals, analog signals and pulse signals
The parameter measurement module is used for carrying out performance test on the aluminum-based circuit board which completes high-voltage electric welding, and comprises the steps of collecting voltage signals, pulse signals and control signals on the circuit board, judging whether the circuit board normally works or not by constructing a test circuit and observing whether output physical quantities of different parts are within a normal range or not, and judging fault reasons and parts of the circuit board through data analysis of test items;
the data processing module mainly realizes signal conversion between a test interface in the parameter measurement module and a specific interface of a unit to be tested, and comprises a voltage reduction isolation circuit and an I/V conversion circuit; the voltage reduction isolation circuit stabilizes input test voltage and isolates test signals from electric signals, so that the stability of the test signals is ensured; meanwhile, the I/V conversion circuit converts the input voltage signal into a current signal for output, so that the I/V conversion circuit is more suitable for outputting a signal by a circuit board;
the output module is responsible for mutual transmission among the modules and simultaneously outputs various data detected by the fault testing unit with the monitoring system.
Preferably, the analysis positioning unit performs fault analysis on the whole circuit board by the fault testing unit, performs worst selection of calculation problems according to fault problems, and analyzes factors causing occurrence of each layer of events as intermediate events or bottom events, thereby completing integral construction of the fault problems; meanwhile, qualitatively analyzing the faults, identifying all reasons causing the problems, and then quantitatively analyzing to obtain the problem occurrence probability and relevant importance parameters; and determining the location of the target fault element of the circuit board according to the analysis result.
Preferably, the fault analysis performed by the analysis positioning unit can be divided into the following modules: the system comprises an event module, a judgment module, an analysis module, a classification module and a positioning module;
the event module accurately describes and records the time when the fault occurs and various parameters of the fault at the time when the fault occurs to each time of detecting the fault of the circuit board; meanwhile, for a more complex fault problem, the more detailed the description of the event module is, even if the event quantity is large, the simplification cannot be realized, otherwise, the fault event is not clearly distinguished or the concept is disordered, so that the analysis positioning unit is disordered and the next work cannot be accurately carried out;
the judging module judges whether the fault event belongs to a system fault state, the system fault state is possibly caused according to the system working state and the working efficiency, when the fault event is caused by a system working component, the event is classified as a system fault, and if the fault event is positive, the event is classified as a circuit board fault;
the analysis module accurately stages all fault time and can accurately define the fault time; thereby preventing confusion from event to event;
the classification module determines the maximum type of the fault event and determines boundary conditions of different subtypes, so that hierarchical analysis is performed according to the total type and the classification is performed step by step, and therefore the reason causing the fault is determined from top to bottom and the type is positioned;
the positioning module is used for sorting and optimizing various fault events, constructing a fault system, carrying out quantitative analysis and qualitative analysis on the faults, confirming fault positions and outputting data signals according to the types of the determined fault events, and automatically removing the faults which cannot exist or the events which cannot occur basically during analysis, so that the analyzed results and positioning are more valuable and reliable and clear at a glance.
Preferably, the analyzing and positioning unit determines the maximum type of the fault event, and needs to perform system automatic detection, and may be divided into the following steps:
s1, the system records the system according to the type according to the possible fault, thereby forming a fault system;
s2, completing the functional test of the data acquisition system hardware through the automatic detection of the system, and ensuring that no error occurs in signal output and acquisition in the analysis positioning process;
s3, automatically running the system self-test when the test software is started each time, if the self-test fails, prompting a fault by the test software, and exiting the test program; the system enters an analysis positioning program through self-checking, so that the design ensures that the system does not misjudge an analysis positioning result due to self problems during operation, and the reliability of the equipment is improved;
s4, performing self-checking on the searched system hardware one by one, and recording self-checking results in an array; if all the hardware passes the self-checking, analyzing and positioning software output system to pass the self-checking; otherwise, outputting a system self-checking fault, and closing the program by the upper-layer software;
and S5, when the automatic detection of the system is completed, fault analysis and positioning are carried out.
Preferably, the feedback unit includes: the device comprises a data reading module, a device control module and a communication module;
the data reading module adopts a multi-channel multiplexing mode, and when a plurality of tasks are carried out, the fed-back data signals are distributed and read, so that the reading rate is ensured;
the device control module is used for controlling channel switches in the data reading module, and can open one or more switches to close one or more channels and also close one or more switches to connect one or more channels;
the communication module sequence is mainly used for power control of the system on the high-voltage welding unit and data reading work of the operation state of the welding equipment during work; in order to ensure the reliability of serial port communication, 5 times of continuous reading of the serial port is adopted, and if no response is received in the reading or a frame length error sent by the system is received, the system automatically sends an error prompt; and if a correct response is received or the length of the system frame is correct in the circulation process, jumping out of the circulation and carrying out the next task.
Preferably, the circuit board is welded at high voltage, the welded circuit board is detected by welding the circuit board by generating high-voltage pulse electricity, and faults of the circuit board are analyzed, positioned and fed back to the system, so that the system can monitor the circuit board conveniently; the method is characterized by comprising the following steps:
step 1, inputting voltage energy into an energy storage block slowly for a long time so as to store the voltage energy; meanwhile, when welding is needed, the switch module opens the output end of the energy storage module and inputs voltage energy to the pulse module;
step 2, connecting the welding equipment through a matching transmission module, and carrying out work welding on the part needing to be welded by high-voltage pulse electricity;
step 3, when welding is carried out, the energy recording unit records the size of high-voltage pulse electricity;
step 4, testing the circuit board after welding is completed, so as to detect faults and firstly generate signals;
step 5, a test task channel is established through a control module in the fault test unit, then a task is executed, digital quantity to be output is written into the task channel, the task is finished and cleared after the task is output, and at the moment, a required digital quantity is generated in the task output channel, so that a digital signal is output;
step 6, establishing an input channel, configuring the frequency, duty ratio and idle state parameters of an output signal, then establishing a timer, configuring the number of output pulses, starting to execute a task, configuring output waiting time, clearing the task after the task is finished and outputting a pulse signal;
step 7, firstly, a data acquisition channel is created, then analog quantity signal parameters to be output are configured, wherein the analog quantity signal parameters comprise frequency, amplitude and signal types, then the generated signals are written into the created channel, and finally, a task is executed and an analog signal is output;
step 8, simultaneously acquiring voltage signals, pulse signals and control signals on the circuit board by the parameter measuring module, processing data with output signals, and outputting the processed data to an analysis positioning unit;
step 9, the analysis positioning unit carries out system self-checking and fault analysis on the whole circuit board, and carries out positioning; and a feedback signal is output through the feedback unit.
Preferably, when generating digital signals, analog signals and pulse signals, monitoring is performed to acquire the signals, and data extraction is performed on the signals, so that various parameters at the moment can be known.
Has the advantages that: the invention utilizes high voltage to weld, and utilizes the pulse module to generate high voltage pulse electricity to weld the circuit board, thereby effectively and rapidly welding, and simultaneously can carry out welding test on the circuit board when the welding is finished.
Drawings
FIG. 1 is a system block diagram of the present invention.
Fig. 2 is a block diagram of the operation of the high pressure welding unit of the present invention.
Fig. 3 is a block diagram of the operation of the analytic location unit of the present invention.
Fig. 4 is a flow chart of the operation of the self-test of the fault system of the present invention.
Detailed Description
As shown in fig. 1, in this embodiment, a system and a method for monitoring high-voltage welding faults of an aluminum-based circuit board includes: the device comprises a high-pressure welding unit, an energy recording unit, a fault testing unit, an analysis positioning unit and a feedback unit.
In a further embodiment, preferably, the high pressure welding unit comprises: the device comprises an energy storage module, a pulse module, a matching transmission module and a switch module;
the energy storage module is provided with a plurality of energy storage blocks; the pulse module outputs pulse voltage through compression and voltage conversion; the matching transmission module is matched with the welding device so as to transmit energy; the switch module is used for controlling the input and output of energy between the modules.
In a further embodiment, the fault testing unit comprises a control module, a parameter measuring module, a data processing module and an output module;
the control module can perform a plurality of tasks simultaneously through the multi-core control circuit, and simultaneously can open one or more switches to close one or more channels and also can close one or more switches to connect one or more driving devices; the simultaneous control module includes: a signal generating circuit; respectively generating and outputting digital signals, analog signals and pulse signals
The parameter measurement module is used for carrying out performance test on the aluminum-based circuit board which completes high-voltage electric welding, and comprises the steps of collecting voltage signals, pulse signals and control signals on the circuit board, judging whether the circuit board normally works or not by constructing a test circuit and observing whether output physical quantities of different parts are within a normal range or not, and judging fault reasons and parts of the circuit board through data analysis of test items;
the data processing module mainly realizes signal conversion between a test interface in the parameter measurement module and a specific interface of a unit to be tested, and comprises a voltage reduction isolation circuit and an I/V conversion circuit; the voltage reduction isolation circuit stabilizes input test voltage and isolates test signals from electric signals, so that the stability of the test signals is ensured; meanwhile, the I/V conversion circuit converts the input voltage signal into a current signal for output, so that the I/V conversion circuit is more suitable for outputting a signal by a circuit board;
the output module is responsible for mutual transmission among the modules and simultaneously outputs various data detected by the fault testing unit with the monitoring system.
In a further embodiment, the analysis positioning unit performs fault analysis on the whole circuit board by the fault testing unit, performs worst selection of calculation problems according to fault problems, and analyzes factors causing occurrence of each layer of events as intermediate events or bottom events, thereby completing the overall construction of the fault problems; meanwhile, qualitatively analyzing the faults, identifying all reasons causing the problems, and then quantitatively analyzing to obtain the problem occurrence probability and relevant importance parameters; and determining the location of the target fault element of the circuit board according to the analysis result.
In a further embodiment, the method is characterized in that, according to the fault analysis performed by the analysis positioning unit, the following modules can be divided: the system comprises an event module, a judgment module, an analysis module, a classification module and a positioning module;
the event module accurately describes and records the time when the fault occurs and various parameters of the fault at the time when the fault occurs to each time of detecting the fault of the circuit board; meanwhile, for a more complex fault problem, the more detailed the description of the event module is, even if the event quantity is large, the simplification cannot be realized, otherwise, the fault event is not clearly distinguished or the concept is disordered, so that the analysis positioning unit is disordered and the next work cannot be accurately carried out;
the judging module judges whether the fault event belongs to a system fault state, the system fault state is possibly caused according to the system working state and the working efficiency, when the fault event is caused by a system working component, the event is classified as a system fault, and if the fault event is positive, the event is classified as a circuit board fault;
the analysis module accurately stages all fault time and can accurately define the fault time; thereby preventing confusion from event to event;
the classification module determines the maximum type of the fault event and determines boundary conditions of different subtypes, so that hierarchical analysis is performed according to the total type and the classification is performed step by step, and therefore the reason causing the fault is determined from top to bottom and the type is positioned;
the positioning module is used for sorting and optimizing various fault events, constructing a fault system, carrying out quantitative analysis and qualitative analysis on the faults, confirming fault positions and outputting data signals according to the types of the determined fault events, and automatically removing the faults which cannot exist or the events which cannot occur basically during analysis, so that the analyzed results and positioning are more valuable and reliable and clear at a glance.
In a further embodiment, the analyzing and positioning unit determines the maximum type of the fault event, which requires automatic detection of the system, and the method can be divided into the following steps:
s1, the system records the system according to the type according to the possible fault, thereby forming a fault system;
s2, completing the functional test of the data acquisition system hardware through the automatic detection of the system, and ensuring that no error occurs in signal output and acquisition in the analysis positioning process;
s3, automatically running the system self-test when the test software is started each time, if the self-test fails, prompting a fault by the test software, and exiting the test program; the system enters an analysis positioning program through self-checking, so that the design ensures that the system does not misjudge an analysis positioning result due to self problems during operation, and the reliability of the equipment is improved;
s4, performing self-checking on the searched system hardware one by one, and recording self-checking results in an array; if all the hardware passes the self-checking, analyzing and positioning software output system to pass the self-checking; otherwise, outputting a system self-checking fault, and closing the program by the upper-layer software;
and S5, when the automatic detection of the system is completed, fault analysis and positioning are carried out.
In a further embodiment, the feedback unit comprises: the device comprises a data reading module, a device control module and a communication module;
the data reading module adopts a multi-channel multiplexing mode, and when a plurality of tasks are carried out, the fed-back data signals are distributed and read, so that the reading rate is ensured;
the device control module is used for controlling channel switches in the data reading module, and can open one or more switches to close one or more channels and also close one or more switches to connect one or more channels;
the communication module sequence is mainly used for power control of the system on the high-voltage welding unit and data reading work of the operation state of the welding equipment during work; in order to ensure the reliability of serial port communication, 5 times of continuous reading of the serial port is adopted, and if no response is received in the reading or a frame length error sent by the system is received, the system automatically sends an error prompt; and if a correct response is received or the length of the system frame is correct in the circulation process, jumping out of the circulation and carrying out the next task.
In a further embodiment, the circuit board is welded at high voltage, high-voltage pulse electricity is generated to weld the circuit board, the welded circuit board is detected, and faults of the circuit board are analyzed, positioned and fed back to a system, so that the system can monitor the circuit board conveniently; the method is characterized by comprising the following steps:
step 1, inputting voltage energy into an energy storage block slowly for a long time so as to store the voltage energy; meanwhile, when welding is needed, the switch module opens the output end of the energy storage module and inputs voltage energy to the pulse module;
step 2, connecting the welding equipment through a matching transmission module, and carrying out work welding on the part needing to be welded by high-voltage pulse electricity;
step 3, when welding is carried out, the energy recording unit records the size of high-voltage pulse electricity;
step 4, testing the circuit board after welding is completed, so as to detect faults and firstly generate signals;
step 5, a test task channel is established through a control module in the fault test unit, then a task is executed, digital quantity to be output is written into the task channel, the task is finished and cleared after the task is output, and at the moment, a required digital quantity is generated in the task output channel, so that a digital signal is output;
step 6, establishing an input channel, configuring the frequency, duty ratio and idle state parameters of an output signal, then establishing a timer, configuring the number of output pulses, starting to execute a task, configuring output waiting time, clearing the task after the task is finished and outputting a pulse signal;
step 7, firstly, a data acquisition channel is created, then analog quantity signal parameters to be output are configured, wherein the analog quantity signal parameters comprise frequency, amplitude and signal types, then the generated signals are written into the created channel, and finally, a task is executed and an analog signal is output;
step 8, simultaneously acquiring voltage signals, pulse signals and control signals on the circuit board by the parameter measuring module, processing data with output signals, and outputting the processed data to an analysis positioning unit;
step 9, the analysis positioning unit carries out system self-checking and fault analysis on the whole circuit board, and carries out positioning; and a feedback signal is output through the feedback unit.
In a further embodiment, when generating digital signals, analog signals and pulse signals, the monitoring system collects the signals and extracts the data from the signals, thereby obtaining the parameters at the moment.
The working principle is as follows: the input voltage energy is slowly input into the energy storage block for a long time so as to be stored; meanwhile, when welding is needed, the switch module opens the output end of the energy storage module and inputs voltage energy to the pulse module; the high-voltage pulse welding device is connected with each welding device through a matching transmission module, and meanwhile, the high-voltage pulse electricity is used for carrying out work welding on the positions needing to be welded; when welding is carried out, the energy recording unit records the size of high-voltage pulse electricity; testing the circuit board after welding is completed, so as to detect faults and firstly generate signals; a test task channel is established through a control module in a fault test unit, then a task is executed, digital quantity to be output is written into the task channel, the task is finished and cleared after the task is output, and at the moment, a required digital quantity is generated in the task output channel, so that a digital signal is output; establishing an input channel, configuring the frequency, duty ratio and idle state parameters of an output signal, then establishing a timer and configuring the number of output pulses, starting to execute a task, configuring output waiting time, clearing the task after the task is finished and outputting a pulse signal; firstly, a data acquisition channel is created, then analog quantity signal parameters to be output are configured, wherein the analog quantity signal parameters comprise frequency, amplitude and signal types, then the generated signals are written into the created channel, and finally, a task is executed and an analog signal is output; meanwhile, the parameter measurement module collects voltage signals, pulse signals and control signals on the circuit board, processes data with output signals and outputs the processed data to the analysis positioning unit; the analysis positioning unit carries out system self-check, carries out fault analysis on the whole circuit board and carries out positioning at the same time; and a feedback signal is output through the feedback unit.
It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. The invention is not described in detail in order to avoid unnecessary repetition.
Claims (9)
1. A high-voltage welding fault monitoring system for an aluminum-based circuit board is characterized by comprising:
the high-voltage welding unit converts input voltage into pulse high-voltage electricity; the energy with smaller power is slowly input into the energy storage module for a longer time to be stored, and is compressed and converted, and is input into the welding device with extremely high power density in an extremely short time to weld the circuit board;
the energy recording unit records the energy consumption of high-pressure welding, and provides convenience for the research of energy consumption rules; therefore, the damage degree of the welding to the circuit board is known according to the high-voltage energy, and the input voltage is adjusted for subsequent work;
the fault testing unit is used for testing the aluminum-based circuit board subjected to high-pressure welding, so that parameters of all states are obtained to verify the function of the tested board;
the analysis positioning unit is used for analyzing and confirming the type of the fault problem and positioning the position of the fault problem in the area with the problem in the test;
and the feedback unit feeds back the fault test result to the master control end, so that fault personnel can know the test condition and adjust subsequent work, and fault monitoring is realized.
2. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board as claimed in claim 1, wherein the high-voltage welding unit comprises: the device comprises an energy storage module, a pulse module, a matching transmission module and a switch module;
the energy storage module is provided with a plurality of energy storage blocks; the pulse module outputs pulse voltage through compression and voltage conversion; the matching transmission module is matched with the welding device so as to transmit energy; the switch module is used for controlling the input and output of energy between the modules.
3. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board according to claim 1, wherein the fault testing unit comprises a control module, a parameter measuring module, a data processing module and an output module;
the control module can perform a plurality of tasks simultaneously through the multi-core control circuit, and simultaneously can open one or more switches to close one or more channels and also can close one or more switches to connect one or more driving devices; the simultaneous control module includes: a signal generating circuit; respectively generating and outputting digital signals, analog signals and pulse signals
The parameter measurement module is used for carrying out performance test on the aluminum-based circuit board which completes high-voltage electric welding, and comprises the steps of collecting voltage signals, pulse signals and control signals on the circuit board, judging whether the circuit board normally works or not by constructing a test circuit and observing whether output physical quantities of different parts are within a normal range or not, and judging fault reasons and parts of the circuit board through data analysis of test items;
the data processing module mainly realizes signal conversion between a test interface in the parameter measurement module and a specific interface of a unit to be tested, and comprises a voltage reduction isolation circuit and an I/V conversion circuit; the voltage reduction isolation circuit stabilizes input test voltage and isolates test signals from electric signals, so that the stability of the test signals is ensured; meanwhile, the I/V conversion circuit converts the input voltage signal into a current signal for output, so that the I/V conversion circuit is more suitable for outputting a signal by a circuit board;
the output module is responsible for mutual transmission among the modules and simultaneously outputs various data detected by the fault testing unit with the monitoring system.
4. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board according to claim 1, wherein the analysis positioning unit performs fault analysis on the whole circuit board by the fault testing unit, performs calculation problem worst selection according to the fault problem, and analyzes a factor causing each layer of events to occur as a middle event or a bottom event, so as to complete the whole construction of the fault problem; meanwhile, qualitatively analyzing the faults, identifying all reasons causing the problems, and then quantitatively analyzing to obtain the problem occurrence probability and relevant importance parameters; and determining the location of the target fault element of the circuit board according to the analysis result.
5. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board as claimed in claim 4, is characterized in that the system can be divided into the following modules according to the fault analysis performed by the analysis positioning unit: the system comprises an event module, a judgment module, an analysis module, a classification module and a positioning module;
the event module accurately describes and records the time when the fault occurs and various parameters of the fault at the time when the fault occurs to each time of detecting the fault of the circuit board; meanwhile, for a more complex fault problem, the more detailed the description of the event module is, even if the event quantity is large, the simplification cannot be realized, otherwise, the fault event is not clearly distinguished or the concept is disordered, so that the analysis positioning unit is disordered and the next work cannot be accurately carried out;
the judging module judges whether the fault event belongs to a system fault state, the system fault state is possibly caused according to the system working state and the working efficiency, when the fault event is caused by a system working component, the event is classified as a system fault, and if the fault event is positive, the event is classified as a circuit board fault;
the analysis module accurately stages all fault time and can accurately define the fault time; thereby preventing confusion from event to event;
the classification module determines the maximum type of the fault event and determines boundary conditions of different subtypes, so that hierarchical analysis is performed according to the total type and the classification is performed step by step, and therefore the reason causing the fault is determined from top to bottom and the type is positioned;
the positioning module is used for sorting and optimizing various fault events, constructing a fault system, carrying out quantitative analysis and qualitative analysis on the faults, confirming fault positions and outputting data signals according to the types of the determined fault events, and automatically removing the faults which cannot exist or the events which cannot occur basically during analysis, so that the analyzed results and positioning are more valuable and reliable and clear at a glance.
6. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board as claimed in claim 5, wherein the analysis positioning unit determines the maximum type of the fault event, and needs to perform automatic system detection, and the method comprises the following steps:
s1, the system records the system according to the type according to the possible fault, thereby forming a fault system;
s2, completing the functional test of the data acquisition system hardware through the automatic detection of the system, and ensuring that no error occurs in signal output and acquisition in the analysis positioning process;
s3, automatically running the system self-test when the test software is started each time, if the self-test fails, prompting a fault by the test software, and exiting the test program; the system enters an analysis positioning program through self-checking, so that the design ensures that the system does not misjudge an analysis positioning result due to self problems during operation, and the reliability of the equipment is improved;
s4, performing self-checking on the searched system hardware one by one, and recording self-checking results in an array; if all the hardware passes the self-checking, analyzing and positioning software output system to pass the self-checking; otherwise, outputting a system self-checking fault, and closing the program by the upper-layer software;
and S5, when the automatic detection of the system is completed, fault analysis and positioning are carried out.
7. The system for monitoring the high-voltage welding fault of the aluminum-based circuit board as claimed in claim 1, wherein the feedback unit comprises: the device comprises a data reading module, a device control module and a communication module;
the data reading module adopts a multi-channel multiplexing mode, and when a plurality of tasks are carried out, the fed-back data signals are distributed and read, so that the reading rate is ensured;
the device control module is used for controlling channel switches in the data reading module, and can open one or more switches to close one or more channels and also close one or more switches to connect one or more channels;
the communication module sequence is mainly used for power control of the system on the high-voltage welding unit and data reading work of the operation state of the welding equipment during work; in order to ensure the reliability of serial port communication, 5 times of continuous reading of the serial port is adopted, and if no response is received in the reading or a frame length error sent by the system is received, the system automatically sends an error prompt; and if a correct response is received or the length of the system frame is correct in the circulation process, jumping out of the circulation and carrying out the next task.
8. A monitoring method for the aluminum-based circuit board high-voltage welding fault monitoring system as claimed in any one of claims 2 to 7, wherein when the circuit board is subjected to high-voltage welding, the circuit board is welded by generating high-voltage pulse electricity, the welded circuit board is detected, and the fault of the circuit board is analyzed, positioned and fed back to the system, so that the system can monitor the circuit board conveniently; the method is characterized by comprising the following steps:
step 1, inputting voltage energy into an energy storage block slowly for a long time so as to store the voltage energy; meanwhile, when welding is needed, the switch module opens the output end of the energy storage module and inputs voltage energy to the pulse module;
step 2, connecting the welding equipment through a matching transmission module, and carrying out work welding on the part needing to be welded by high-voltage pulse electricity;
step 3, when welding is carried out, the energy recording unit records the size of high-voltage pulse electricity;
step 4, testing the circuit board after welding is completed, so as to detect faults and firstly generate signals;
step 5, a test task channel is established through a control module in the fault test unit, then a task is executed, digital quantity to be output is written into the task channel, the task is finished and cleared after the task is output, and at the moment, a required digital quantity is generated in the task output channel, so that a digital signal is output;
step 6, establishing an input channel, configuring the frequency, duty ratio and idle state parameters of an output signal, then establishing a timer, configuring the number of output pulses, starting to execute a task, configuring output waiting time, clearing the task after the task is finished and outputting a pulse signal;
step 7, firstly, a data acquisition channel is created, then analog quantity signal parameters to be output are configured, wherein the analog quantity signal parameters comprise frequency, amplitude and signal types, then the generated signals are written into the created channel, and finally, a task is executed and an analog signal is output;
step 8, simultaneously acquiring voltage signals, pulse signals and control signals on the circuit board by the parameter measuring module, processing data with output signals, and outputting the processed data to an analysis positioning unit;
step 9, the analysis positioning unit carries out system self-checking and fault analysis on the whole circuit board, and carries out positioning; and a feedback signal is output through the feedback unit.
9. The monitoring method for the aluminum-based circuit board high-voltage welding fault monitoring system as claimed in claim 8, wherein when digital signals, analog signals and pulse signals are generated, the monitoring is performed by acquiring signals and extracting data of the signals, so that parameters at the moment can be obtained.
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| CN114325198A (en) * | 2021-12-29 | 2022-04-12 | 浙江时空道宇科技有限公司 | Test device and test system |
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Application publication date: 20210406 |