Research And Development Of Automated Manual Switch Fatigue Life Testing System

Manual control switch is the most widely used control unit with highest usage frequency in control system, and its service life directly affects the reliability of the whole system. The existing life testers for low voltage switch have many defects, such as unconformity with the test specification, high failure rate, low efficiency and so on. In order to accelerate the progress of switch test industry and develop a test specification, it has great significance to research and design a new multifunctional intelligent test system for switch fatigue life.This thesis takes a new type of fatigue life test system for low voltage switch in button type as research object. The overall design and each module’s implementation method have been conducted. And based on the above work, the feasibility of the scheme design has been verified through experiment. Firstly, the brief introduction of the present condition of the instrument for testing switch’s life and related technology development trend were expounded. According to the national standard about low switch test and product’s functional requirements, an overall program of the automatic test system for manual control switch was proposed, including mechanical structure design and monitoring system development. Then the realization method for structure design, hardware circuit of monitoring system, real-time communication method and software development were elaborated respectively. And the mechanical structure employs the vertical structure of up-and-down combination, the design process of isometric cam mechanism was introduced in detail. Besides, mechanism’s motion stability was analyzed by ADAMS. The distributed control system was used in monitoring system with LabVIEW and PLC as the core. The OPC Server and DataSocket network communication technology were used to realize real-time communication. PLC control program and the HMI interface in the system were designed with modular programming ideas. Finally, it is verified that the overall design can conform to the requirements of the performance indicators by experiment.This thesis provides a useful basis and guidance for the future design and research of such kind of non-standard automation equipment. It may be a good reference.