Diseño técnico de un banco de pruebas para diagnostico y evaluación de equipos de electrónica industrial de potencia

Abstract

This project was developed at Alfa Electronic SAS, an organization specializing in the maintenance, repair, and diagnostics of technological assets within the industrial power electronics sector. In this environment, the technical laboratories require robust testing infrastructures that allow them to subject single-phase and three-phase equipment to controlled nominal and critical operating conditions, thereby guaranteeing the reliability and quality of post-repair technical service. Based on the operators' experience with the test bench, a diagnostic assessment was conducted on the test bench currently in operation at the company. Limitations were identified in the overcurrent protection systems, deficiencies in the power dissipation mechanisms of the resistive load banks, and a marked absence of automated control. Furthermore, the current platform lacks a pre-charge system for the capacitive stages and real-time monitoring. This restricts its versatility when working with equipment and leaves operators exposed to electrical hazards due to the lack of a standardized control environment. To address this problem, a complete redesign of the test bench was proposed. The proposal includes sizing electrical protections to meet the company's needs, analytically calculating a bank of segmented resistive loads, and conceptually implementing a DC bus with a pre-charging system. It also envisions integrating a PLC to manage security and alarms in real time, linked to an HMI interface for centralized visualization of all variables. As a result, a detailed 3D model of the chassis and internal cabinet layout was developed in SolidWorks, allowing for validation of the front panel's ergonomics and the forced ventilation arrangement. Furthermore, the Bill of Materials (BOM) and the main technical documentation were finalized, including connection diagrams, AC/DC power distribution plans, and control logic schematics. The feasibility of physical construction is now subject to management's budgetary evaluation.