Automatic seasoned detection method of gas discharge tube and system
One, technical field
The invention belongs to gas discharge tube electrical performance test device, be specifically related to automatic seasoned detection method of a kind of gas discharge tube and system.
Two, background technology
Ceramet gas discharge tube is a kind of lightning protection device of switching mode; The general pottery that adopts is as package casing; Be full of the stable inert gas of electric property in the discharge tube, the electrode of discharge tube generally has two electrodes, three electrodes and three kinds of structures of five electrodes.When the interpolar at discharge tube applies certain voltage, just produce uneven electric field, under effect of electric field at interpolar; Gas begins to dissociate; When applied voltage reached the interpolar field intensity and surpasses the dielectric strength of inert gas, two interpolars will produce electric arc, ionized gas; Produce " negative resistance charactertistic ", thereby transfer conduction state to by state of insulation at once.Be electric field strength when surpassing the breakdown strength of gas, just cause gap discharge, thereby limited voltage across poles.That is to say that when external surge voltage did not reach its operation voltage, discharge tube was high resistant (insulation resistance reaches more than the 1000M Ω) state; In case and surge voltage is when reaching its operation voltage; Electric breakdown phenomena takes place in discharge tube internal discharge gap immediately, and this moment, discharge tube was equivalent to a good conductor, and surge voltage promptly is short-circuited to rapidly near no-voltage in the time at 50ns; Surge current is imported ground rapidly, thereby equipment is played a protective role.When surge voltage disappeared, discharge tube then extinguished immediately
And revert to high-impedance state, wait for action next time quietly.
The cermet discharge tube is widely used in fields such as post and telecommunications, railway signal, radio and television, computer, household electrical appliance, instrument; It has advantages such as volume is little, power is big, the life-span is long, the impulsive discharge time-delay is lacked, insulate, interelectrode capacitance is little, is present ideal overvoltage lightning protection device.Because the development of information superhighway now; Popularizing of computer networking and cable TV, to the lightning protection of transmission line and overvoltage protection require increasingly high, like this; Just necessarily require discharge tube to have stable dc breakdown voltage and less impact flashover voltage; Also need the ability of bigger shock-resistant electric current, that is to say, have higher requirement for the quality of gas discharge tube.
The production procedure of gas discharge tube is broadly divided into following several stages: one, parts prepare, two, assembling and make, three, seasoned and check (failure analysis), four, surface treatment, five, quality is finally confirmed and the processing of delivering.Can find out from five top stages; Phase III just seasoned and the check (failure analysis) stage in the whole production link in occupation of very important position; Its purpose is to improve the electronics emission; Guarantee the stability of product electrical quantity, this also is that every family produces the important link that the enterprise of discharge tube all dare not ignore.At present; General enterprise all adopts artificial seasoned one by one mode; That is to say, stand in the high-voltage great-current that on the insulation cushion each discharge tube was carried out 1 ~ 4 second by the hand-held Hi-pot test rod of operative employee and impact, simultaneously; Receiving the arc light color sent when high-tension current impacts and the ammeter reading above the instrument desk according to discharge tube, making preliminary judgement the discharge tube quality is whether qualified.Yet for 1,000,000 discharge tube industry, this is that an efficient is extremely low and for the very unsafe a kind of method of workman's person for output.The patent No. is how 200810018003 patents of invention reduce and done useful exploration aspect volume and the capacity of conventional AC aging device; The seasoned device of a kind of system controlled by computer gas discharge tube is disclosed; It by row to gas discharge tube from original position seasoned one by one up to every row last, begin next column then.In addition, because the adjacent two seasoned time intervals of row are fixed value, cause the local overheating phenomenon of experimental class easily, so once seasoned process may exert an influence to adjacent gas discharge tube.
Three, summary of the invention
The problem that the present invention mainly solves provides automatic seasoned detection method of a kind of highly effective gas-discharge pipe and system.
For addressing the above problem, the automatic seasoned detection method of the gas discharge tube that the present invention proposes comprises following step:
The first step: under the state of the big electric current of cutoff high, several discharge tubes are put into the frock clamp of corresponding size, and with the Hi-pot test rod screens of corresponding specification and quantity, reliable to guarantee being connected of pipe and seasoned anchor clamps.
Second step: estimated the connection reliability in a last step, and, returned the first step and connect again,, get into next step operation if qualified if find to have pipe not connect fully reliably.
The 3rd step: according to concrete production technology; Confirm whether the seasoned parameter that the native system panel shows corresponds to actual needs; Be whether put into each operating time of seasoned basically group and actual seasoned basically group number of frock clamp correct, whether the time interval between each seasoned basically group is reasonable, also can be as required; Through key being set with seasoned parameter renegotiation new settings on system's panel, perhaps pre-set parameter is accessed use.
The 4th step: start native system.
The 5th step: the microprocessor of native system is according to the parameter setting in the 3rd step; Undertaken seasoned by group; The seasoned work that every completion is one seasoned basically group is just judged the current parameters that each gas discharge tube of this group flows through automatically; The qualified LED lamp of just lighting the relevant position, underproof pipe is not then lighted corresponding lamp.
The 6th step: the microprocessor of native system is according to the parameter setting in the 3rd step; The seasoned work that every completion is one seasoned basically group is just counted, and preestablishes numeral when accumulative total real work number reaches, and just accomplishes this flow process; The cutoff high electric current continues otherwise got back to for the 5th step.
The 7th step: finish.
Further, in the first step of above-mentioned steps, can 8 gas discharge tubes be one seasoned basically group, with seasoned unit of 48 seasoned basically group formation, promptly at most once can detect 384 discharge tubes.
Further again, in the 3rd step of above-mentioned steps, can also judge automatically whether discharge tube has quality problems such as gas leakage, indicate with the LED lamp in seasoned end back simultaneously, rejecting under the state of safety with the handled easily worker has defective product.
Further again, in the 5th step of above-mentioned steps, can control the time interval between the seasoned working cell as required flexibly.
The automatic seasoned detection system of using in the automatic seasoned detection method of above-mentioned gas discharge tube of gas discharge tube mainly comprises the high-tension current source, current sampling module; The system power supply operational module, keyboard input and parameter display module also comprise LED lamp display module; Relay control module; The data allocations module, microprocessor module, decoding module.Wherein, the system power supply operational module is used to accomplish the AC-to-DC conversion for civil power, and the 5V working power of native system microprocessor and other chips is provided, and also for current sampling module and relay control module working power is provided simultaneously; Current sampling module is used to obtain the current parameters that gas discharge tube passes through when seasoned; When record flow through discharge tube seasoned electric current just often; This module output high level; Output low level when electric current is lower than set point, and this level outputed to LED lamp display module to drive the corresponding LED lamp; The high-tension current source is used for to gas discharge tube providing when seasoned high-voltage great-current; Microprocessor module is the nucleus module of native system, is used to control the program running of native system; The data that decoding module is used to obtain from microprocessor module output are deciphered, and decode results is outputed to the data allocations module; For the data of avoiding decoding module output are disturbed by LED display module and relay control module; Native system has added the data allocations module especially, be used for the data of decoding module output isolate and amplify after output to LED display module and relay control module respectively.Relay control module is used to control the ON time and the blanking time in high-tension current source.The keyboard input parameter display module is used to accomplish demonstration and the input of customer parameter and other the keyboard operation function of operational factor under the control of microprocessor module.
As the preferred version of the automatic seasoned detection system of this gas discharge tube, above-mentioned LED display module has 48 row, and corresponding 48 seasoned basically group, 8 LED of every row are with corresponding each 8 gas discharge tube of seasoned basically group.
Further; The LED display module of native system can be provided with a LED light for each seasoned basically group separately; With convenient each order of work of seasoned basically group of observing, also according to actual needs individual setting some or several seasoned basically group work independently and other working groups do not work.
Further again; All contain with seasoned basically group of corresponding each unit in the LED display module of native system and latch chip and chip for driving formation; Be used for detection signal to each 8 gas discharge tube of seasoned basically group and show and latch, be beneficial to the seasoned subsequent operation that finishes the back operative employee.
Compared with prior art, beneficial effect of the present invention is:
1) to have adopted with 8 gas discharge tubes be one seasoned basically group to native system, with 48 seasoned basically group mode that constitutes a seasoned unit product carried out seasonedly, improved the seasoned efficient of product greatly.
2) to have adopted the PIC microprocessor be that core is accurately controlled (the working control time precision is brought up to 0.01 second) to the seasoned time to native system, overcome traditional not enough problem (maximal accuracy of traditional control method is 0.1 second) of time relay precision control.
3) native system has adopted the LED lamp as indicating mode; Overcome in traditional seasoned process and to have relied on the macroscopic problem of operative employee, avoided the injury of strong aura that gas discharge tube sends and arc light in seasoned process for operator's naked eyes.
4) native system in use; Operate according to factory's preliminary setting parameter fully; In the whole service process, need not the operative employee intervenes; Overcome the problem of operative employee's hot line job in traditional seasoned process, the invisible injury for the operative employee of electromagnetic field that high-voltage great-current produces has in the course of the work also been avoided simultaneously in the danger of having avoided the operative employee in seasoned process, to get an electric shock owing to misoperation.
5) the whole seasoned process of efficient microprocessor complete monitoring of native system employing, the operate miss of having avoided the operative employee behind long-time hard work, to produce has greatly improved product quality.
Four, description of drawings
Fig. 1 is a schematic flow sheet of the present invention.
Fig. 2 is a circuit structure block diagram of the present invention.
Fig. 3 is microprocessor control and decoding circuit schematic diagram.
Fig. 4 detects and the signal judging circuit schematic diagram for precision current.
Fig. 5 latchs and the display circuit schematic diagram for seasoned LED lamp.
Five, embodiment
Do further elaboration below in conjunction with accompanying drawing and embodiment for the present invention.The automatic seasoned detection method of gas discharge tube is following, as shown in Figure 1, and the automatic seasoned detection method of gas discharge tube comprises following a few step:
The first step: under the state of the big electric current of cutoff high, maximum 384 (8X48) discharge tube put into the frock clamp of corresponding size by the operative employee, and with the Hi-pot test rod screens of corresponding specification and quantity, reliable to guarantee being connected of pipe and seasoned anchor clamps.
Second step: estimated the connection reliability in a last step by the operative employee,, return the first step and connect again,, get into next step operation if qualified if find to have pipe not connect fully reliably.
The 3rd the step: by the operative employee according to concrete production technology; Confirming whether the seasoned parameter that the native system panel shows corresponds to actual needs (is whether put into each operating time of seasoned basically group and actual seasoned basically group number of frock clamp correct; Whether the time interval between each seasoned basically group is reasonable); Also can be as required, through key being set with seasoned parameter renegotiation new settings on system's panel, perhaps pre-set parameter is accessed use.
The 4th step: start native system.
The 5th step: the microprocessor of native system is according to the parameter setting in the 3rd step; Undertaken seasoned by group; The seasoned work that every completion is one seasoned basically group is just judged the current parameters that each gas discharge tube of this group flows through automatically; The qualified LED lamp of just lighting the relevant position, underproof pipe is not then lighted corresponding lamp.
The 6th step: the microprocessor of native system is according to the parameter setting in the 3rd step; The seasoned work that every completion is one seasoned basically group is just counted, and preestablishes numeral when accumulative total real work number reaches, and just accomplishes this flow process; The cutoff high electric current continues otherwise got back to for the 5th step.
In the 3rd one of above-mentioned steps, can also judge automatically whether discharge tube has quality problems such as gas leakage.
Fig. 2 is the circuit structure block diagram of the automatic seasoned detection system of gas discharge tube.Native system comprises the high-tension current source, current sampling module, LED lamp display module, relay control module, data allocations module, system power supply operational module, microprocessor module, decoding module, keyboard input and parameter display module.Wherein, the system power supply operational module is used to accomplish the AC-to-DC conversion for civil power, and the 5V working power of native system microprocessor and other chips is provided, and also for current sampling module and relay control module working power is provided simultaneously; Current sampling module is used to obtain the current parameters that gas discharge tube passes through when seasoned; When record flow through discharge tube seasoned electric current just often; This module output high level; Output low level when electric current is lower than set point, and this level outputed to LED lamp display module to drive the corresponding LED lamp; The high-tension current source is used for to gas discharge tube providing when seasoned high-voltage great-current; Microprocessor module is the nucleus module of native system, is used to control the program running of native system; The data that decoding module is used to obtain from microprocessor module output are deciphered, and decode results is outputed to the data allocations module; For the data of avoiding decoding module output are disturbed by LED display module and relay control module; Native system has added the data allocations module especially, be used for the data of decoding module output isolate and amplify after output to LED display module and relay control module respectively.The LED display module amounts to 48 row (corresponding 48 seasoned basically group), 8 LED of every row (with corresponding each 8 gas discharge tube of seasoned basically group); Relay control module is used to control the ON time and the blanking time in high-tension current source.The keyboard input parameter display module is used to accomplish demonstration and the input of customer parameter and other the keyboard operation function of operational factor under the control of microprocessor module.
Fig. 3 is microprocessor control and decoding circuit schematic diagram.The complete machine power unit is sent into high accuracy voltage-stabilizing device U1 and U2 with the low-voltage AC of complete machine power transformer output after through full-bridge rectification, filtering; The direct current of U1 output+12V also through the filtering once more of C1 and C4, is sent into relay control module after the alternating component of removal remnants.The direct current of U2 output+5V also passes through C7, for whole system working power is provided after the filtering once more of C8; P0 is the inner reseting interface of complete machine, uses for close beta; W1, W2 are whole system and upper PC communication interface control end.(the decoder output signal judgment part that is this circuit) formed by 48 show circuits in decoder output signal judgment part, and each loop comprises a current-limiting resistance and a LED lamp, an end connection+5V power supply of current-limiting resistance; It is anodal that the other end connects LED; The negative pole of LED links to each other with the output of decoding circuit, if decoding circuit is output as high level, then the LED lamp is not worked; If decoding circuit is output as low level, then LED lamp work.The current-limiting resistance of this part be chosen as key, if current-limiting resistance is excessive, then LED's is luminous very dark, impact effect.If current-limiting resistance is too small, then the electric current through LED can be very big, can influence the life-span of LED and might burn decoding circuit.The microprocessor control section is the core of system, and its microprocessor U3 that mainly contains a slice microchip company forms, and the decoding part mainly contains 3 independently coding chip U4, U5; U6 forms, and these 3 coding chips are same model, and they are 23 years old; 22,21,20 pin are input; 1 ~ 17 pin is output, and 18,19 select Enable Pin for sheet.The external high-quality crystal oscillator of 13,14 pin of microprocessor U3 is for the accurate timing of whole system provides possibility.8,9,10 pin of microprocessor U3 are the control end of coding chip, each Self Control a slice coding chip, and when control end was high level, coding chip was started working, if low level, then coding chip quits work.15,16,17,18 pin of microprocessor U3 are the input port 23,22,21 of coding output port and coding chip U4; 20 corresponding connections, 23,24,25,26 pin of microprocessor U3 are the input port 23 of coding output port and coding chip U5; 22,21,20 corresponding connections, 38,39 of microprocessor U3; 40,30 pin are input port 23,22,21, the 20 corresponding connections of coding output port and coding chip U5.After the native system start, U3, U4, U5; U6 all is in init state, after program running, according to predefined program parameter; At first the corresponding coding chip of 8,9,10 foot control systems through microprocessor U3 makes it get into operating state; Simultaneously, the coding output port output encoder of microprocessor U3 has the decoder compiling more later on through decoder output output.2 ~ 7 pin and 19 ~ 22 of microprocessor U3,27 ~ 29 pin are digital position control and the display interface of showing.
Fig. 4 detects and the signal judging circuit schematic diagram for precision current.The decoded signal of the decoding circuit output from microprocessor control and decoding circuit schematic diagram (Fig. 3) is sent into U9 ~ U14 and U15 ~ U20 respectively here.U9 ~ U14 is 6 inverting amplifier groups; Every inverting amplifier all has 8 output ports, adds up 48 output ports altogether, and P9 ~ P14 is 68 sockets; Each socket all is connected with the output of inverting amplifier; Formed 48 auxiliary relay interface circuit, by 48 high power AC contactors of this 48 auxiliary relay controls, one seasoned basically group of each high power AC contactor control; So just accomplished right each independent control of seasoned basically group, also avoided of the interference of high power AC contactor simultaneously for native system.U15 ~ U20 is the interface chip that control signal arrives demonstration, and its main purpose is for the further amplification of decoded signal and removes and disturb.
Current detecting partly has 8 same units and forms; Each unit all links to each other with high precision current transformer through connector P1 ~ P8; High-voltage great-current sampling that will be through gas discharge tube also carries out being input to after the halfwave rectifier input of optocoupler U1-1 ~ U8-1 through a diode D1 ~ D8, and the inside triode of optocoupler and external NPN triode Q1 ~ Q8 form a darlington structure.8 gas discharge tubes of these 8 unit and a seasoned basically unit are corresponding one by one mutually, to realize the inspection of size of current.Choose the operation principle of first this circuit of unit interprets now: when high precision current transformer has detected electric current and flows through gas discharge tube; Export a little current signal; This signal is input to later among the optocoupler U1-1 through the halfwave rectifier of diode D1, and the inside triode of optocoupler U1-1 just drives external triode Q1, the collector electrode connection+5V power supply of external triode Q1 after sensing the photoelectricity coupled signal of input; Emitter is just exported high level, can drive the LED lamp of back.
Fig. 5 latchs and the display circuit schematic diagram for seasoned LED lamp.This is made up of 48 identical unit, and is corresponding with 48 seasoned basically group.Each unit all latchs chip and chip for driving and constitutes, and is used for detection signal to each 8 gas discharge tube of seasoned basically group and shows and latch, and is beneficial to the seasoned subsequent operation that finishes the back operative employee.Existing is example interpretation work principle with the first module: whole unit is by latching chip U1 and chip for driving U2 forms; Be connected to 11 pin of this unit latches chip U1 and with 1 pin ground connection from the control signal that precision current detects and the 18th pin of " control signal to show " interface chip U15 of signal judging circuit (Fig. 4) is exported; When 11 pin of U1 are high level; Then latch the output level of chip and follow the incoming level variation; When 11 pin of U1 transfer low level to, the level of each input when the 11 pin level that the output level that then latchs chip latchs U1 change from high to low.The level that is latched is direct driving LED lamp after the amplification of chip for driving U2.