High-integration serial port surge protector and multi-stage protection control method

Abstract

The invention discloses a high-integration serial port surge protector and a multi-stage protection control method, the protector comprises a first plug, a second plug, a connecting line and a PCB, the first plug comprises a plurality of plugging terminals and a first insulation body wrapping the plurality of plugging terminals; the second plug comprises a plurality of jack terminals and a second insulating body wrapping the plurality of jack terminals; the connecting line is connected between the first plug and the second plug; the PCB is located in the first plug or the second plug and is provided with a first-stage protection module used for discharging large-energy surge current caused by lightning stroke and a second-stage protection module used for absorbing residual energy and restraining fast voltage spikes. And the first-stage protection module and the second-stage protection module are connected through a circuit to form multi-stage collaborative protection. According to the protector, through integrated design and TSS / TVS multi-stage cooperative protection, small-sized, low-cost and high-reliability surge protection is realized, and the protector is suitable for industrial control and communication equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of surge protection devices, and in particular to a highly integrated serial port surge protector and a multi-stage protection control method. Background Art

[0002] Traditional serial port surge protectors adopt a split design and are assembled from multiple components such as an independent housing, a PCB, a metal baffle, and wiring terminals, resulting in a large volume, inconvenient installation, and a complex production process (such as welding and encapsulation), with high material and assembly costs. In addition, the connection of multiple components is prone to poor contact, high failure rate, and the need for overall replacement during maintenance, making it difficult to meet the requirements of industrial 4.0 and 5G devices for miniaturization and high-density integration.

[0003] Existing solutions rely on single-stage protection (such as TVS or MOV), with insufficient response speed, limited energy dissipation capacity, and low voltage clamping accuracy. Although there have been attempts at multi-stage redundant designs, they further increase costs due to additional circuits and components and exacerbate reliability issues. High-frequency and high-speed interfaces and extreme environment applications require picosecond-level response, miniaturization, and high reliability, which are difficult to achieve with traditional solutions.

[0004] Existing optimization solutions (such as TVS+MOV parallel or multi-stage circuits) have improved performance but have not solved the problems of structural complexity and cost. There is an urgent need in the market for an innovative solution with high integration, low cost, and multi-stage collaborative protection to balance miniaturization, high performance, and high reliability and meet the upgraded requirements for surge protection in the industrial, communication, and military fields. Summary of the Invention

[0005] In view of this, in view of the deficiencies of the existing technology, the main purpose of the present invention is to provide a highly integrated serial port surge protector and a multi-stage protection control method, which achieve miniaturized, low-cost, and highly reliable surge protection through an integrated design and TSS / TVS multi-stage collaborative protection, and are applicable to industrial control and communication devices.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] A highly integrated serial port surge protector, comprising a first plug, a second plug, a connecting wire and a PCB board. The first plug includes a plurality of insertion terminals and a first insulating body covering the outside of the plurality of insertion terminals; the second plug includes a plurality of jack terminals and a second insulating body covering the outside of the plurality of jack terminals; the connecting wire is connected between the first plug and the second plug; the PCB board is located in the first plug or the second plug, and the PCB board has a first-stage protection module for discharging large-energy surge current caused by lightning strikes and a second-stage protection module for absorbing residual energy and suppressing fast voltage spikes. The first-stage protection module and the second-stage protection module are connected by a circuit to form a multi-stage collaborative protection.

[0008] As a preferred solution: The first-stage protection module uses a semiconductor discharge tube TSS; the second-stage protection module uses a transient voltage suppression diode TVS.

[0009] As a preferred solution: The trigger voltage of the semiconductor discharge tube TSS is higher than the clamping voltage of the transient voltage suppression diode TVS, forming a gradient voltage configuration.

[0010] As a preferred solution: The response time of the semiconductor discharge tube TSS is in the microsecond level, and the response time of the transient voltage suppression diode TVS is in the picosecond level, covering transient threats in the full time range.

[0011] As a preferred solution: The first plug is a male head, the PCB board is integrally formed with the first insulating body of the first plug, and the plurality of insertion terminals are electrically connected to the PCB board; one end of the connecting wire is electrically connected to the PCB board, and the other end is electrically connected to the plurality of jack terminals.

[0012] As a preferred solution: The first plug further includes a base and a plug housing. The base is fixed on the PCB board, and the lower ends of the plurality of insertion terminals are electrically connected to the PCB board through the base; the plug housing is sleeved outside the base, and a cavity is formed in the plug housing, and the plurality of insertion terminals extend out of the cavity.

[0013] As a preferred solution: The bottom of the plug housing has a connecting portion for covering the base. The end of the base connected to the PCB board has an annular step, and the connecting portion is provided with a limiting inner edge corresponding to the annular step, and the limiting inner edge is clamped on the annular step.

[0014] As a preferred solution: The PCB board is provided with a relief hole for the locking screw to pass through, and a protruding hole corresponding to the locking screw is provided on the plug housing. The locking screw extends out from the rear end of the first insulating body through the relief hole and the protruding hole.

[0015] A multi-level protection control method applied to the serial port surge protector includes:

[0016] Step S10: Respond to microsecond-level transient high voltage through TSS and discharge the large current caused by lightning strikes;

[0017] Step S20: Suppress the residual voltage spike after TSS discharge through TVS with a picosecond-level response speed;

[0018] Step S30: Use the gradient voltage configuration formed by the high trigger voltage of TSS and the low clamping voltage of TVS to avoid single-stage overload.

[0019] It also includes the following dynamic optimization steps:

[0020] Dynamic threshold adjustment: Real-time detect the rising rate and amplitude of the input-side voltage through the voltage monitoring module, and dynamically adjust the trigger threshold of TSS by the logic control chip to adapt to different intensities of transient threats;

[0021] Adaptive clamping control: Connect a variable resistor in series between TVS and the ground, and adjust the resistance value by the logic control chip according to the characteristics of the backend load, so that the clamping voltage of TVS precisely matches the safety requirements of the backend circuit;

[0022] Verify the collaborative protection performance through the following test methods:

[0023] Graded energy impact test: Apply lightning current waveforms of different intensities to verify that TSS undertakes the main surge energy and TVS suppresses the residual voltage;

[0024] Dynamic response synchronization test: Monitor the response time difference between TSS and TVS to ensure that the action timings of the two match and avoid protection blind spots.

[0025] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, as can be seen from the above technical solutions, by integrating the PCB board inside the first plug, redundant structures such as traditional shells and metal baffles are eliminated, significantly reducing the volume and simplifying the installation process; adopting the collaborative protection technology of TSS and TVS, combined with the gradient voltage configuration, realizing multi-level energy discharge and precise voltage clamping, effectively covering transient threats in the full time range and improving the protection reliability; through dynamic threshold adjustment, adaptive clamping control and closed-loop feedback mechanism, the protection parameters are optimized in real time to ensure the safety of the backend circuit; at the same time, the modular design reduces the material and production costs, is applicable to multiple scenarios such as industrial control and communication equipment, and has high integration, low cost and strong compatibility, solving the technical pain points of the traditional surge protector with complex structure, high cost and large protection blind spots.

[0026] To more clearly elaborate the structural features and effects of the present invention, the following will be described in detail in combination with the drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a three-dimensional schematic diagram of the protector of the present invention;

[0028] Figure 2 This is a three-dimensional schematic diagram of the protector of the present invention from another perspective;

[0029] Figure 3 is a cross-sectional schematic diagram of a first plug of the present invention;

[0030] Figure 4 It is an exploded perspective schematic diagram of the protector of the present invention;

[0031] Figure 5 This is a schematic exploded perspective view of the protector of the present invention from another perspective;

[0032] Figure 6 A three-dimensional schematic diagram of the internal structure of the first plug and the second plug of the present invention;

[0033] Figure 7 It is an exploded perspective schematic diagram of a first plug of the present invention;

[0034] Figure 8 It is a three-dimensional schematic diagram of the plug housing of the present invention;

[0035] Figure 9 This is a schematic diagram of the circuit connection principle of the present invention;

[0036] Figure 10 It is a schematic diagram of the control method steps of the present invention.

[0037] Description of the accompanying drawings:

[0038] 10. First plug; 11. Plug terminal; 12. First insulating body; 13. Base; 131. Annular step; 14. Plug housing; 141. Cavity; 142. Connecting part; 143. Extension hole; 144. Limiting inner eaves; 20. Second plug; 21. Socket terminal; 22. Second insulating body; 30. Connecting wire; 40. PCB board; 41. First level protection module; 42. Second level protection module; 43. Avoidance hole; 50. Locking screw. DETAILED DESCRIPTION

[0039] The present invention Figures 1 to 10 As shown, a highly integrated serial port surge protector and a multi-level protection control method, the serial port surge protector includes a first plug 10, a second plug 20, a connecting line 30 and a PCB board 40, wherein:

[0040] The first plug 10 includes a plurality of plug-in terminals 11 and a first insulating body 12 covering the outside of the plurality of plug-in terminals 11; the second plug 20 includes a plurality of socket terminals 21 and a second insulating body 22 covering the outside of the plurality of socket terminals 21; the connecting wire 30 is connected between the first plug 10 and the second plug 20; the PCB board 40 is located in the first plug 10 or the second plug 20, and the PCB board 40 has a first-stage protection module 41 for discharging large-energy surge current caused by lightning strikes and a second-stage protection module 42 for absorbing residual energy and suppressing fast voltage spikes. The first-stage protection module 41 and the second-stage protection module 42 are connected by a circuit to form a multi-stage collaborative protection.

[0041] The first-stage protection module 41 uses a semiconductor discharge tube TSS; the second-stage protection module 42 uses a transient voltage suppression diode TVS. The trigger voltage of the semiconductor discharge tube TSS is higher than the clamping voltage of the transient voltage suppression diode TVS, forming a gradient voltage configuration. The response time of the semiconductor discharge tube TSS is in the microsecond level, and the response time of the transient voltage suppression diode TVS is in the picosecond level, covering transient threats in the full time range.

[0042] The first plug 10 is a male head, and the PCB board 40 is fixedly embedded in the first insulating body 12 of the first plug 10, and the plurality of plug-in terminals 11 are electrically connected to the PCB board 40; one end of the connecting wire 30 is electrically connected to the PCB board 40, and the other end is electrically connected to the plurality of socket terminals 21. The first plug 10 further includes a base 13 and a plug housing 14. The base 13 is fixed on the PCB board 40, and the lower ends of the plurality of plug-in terminals 11 are electrically connected to the PCB board 40 through the base 13; the plug housing 14 is sleeved outside the base 13, and a cavity 141 is formed in the plug housing 14, and the plurality of plug-in terminals 11 extend out of the cavity 141.

[0043] The bottom of the plug housing 14 has a connecting portion 142 for covering the base 13. One end of the base 13 connected to the PCB board 40 has an annular step 131. The connecting portion 142 is provided with a limiting inner edge 144 corresponding to the annular step 131, and the limiting inner edge 144 is clamped on the annular step 131 to improve the bonding stability between the plug housing 14 and the base 13. The PCB board 40 is provided with an avoidance hole 43 for the locking screw 50 to pass through, and a protruding hole 143 corresponding to the locking screw 50 is provided on the plug housing 14. The locking screw 50 extends out from the rear end of the first insulating body 12 through the avoidance hole 43 and the protruding hole 143.

[0044] Embed the PCB board 40 inside the first plug 10, eliminating components such as the outer shell and metal baffle in the traditional structure, and significantly simplifying the overall structure. Compared with the discrete component design of traditional surge protectors, this surge protector greatly reduces space occupancy and is more convenient to install; moreover, by reducing extra components such as the outer shell and baffle, the circuit layout is optimized, and the material and production costs are reduced; after the structure is simplified, the production process is more efficient and the yield rate is increased.

[0045] Adopt a multi-stage collaborative protection formed by connecting the first-stage protection module 41 and the second-stage protection module 42 through a circuit, which has the following advantages:

[0046] Multi-stage energy discharge: Adopt TSS (semiconductor discharge tube) + TVS (transient voltage suppressor diode) collaborative protection, and process lightning surge in two stages (TSS discharges large energy, TVS suppresses residual spikes).

[0047] Complementary response speed: Combine TSS (microsecond-level response) with TVS (picosecond-level response) to cover transient threats in the full time range.

[0048] Voltage gradient design: The high trigger voltage of TSS and the low clamping voltage of TVS form a gradient to avoid single-stage overload and extend the device life.

[0049] Enhanced reliability: TSS undertakes the main surge energy, reduces the burden on TVS, and improves the overall reliability of the system.

[0050] Wide range of application scenarios: Suitable for lightning protection of DB15 serial communication systems in industrial control, telecommunications, local area networks, and commercial / military fields, with strong compatibility.

[0051] Automatic recovery function: After the transient voltage disappears, the lightning arrester automatically returns to the high-impedance state without manual intervention, making it more convenient to use.

[0052] Circuit principle description: This solution adopts TSS (semiconductor discharge tube) and TVS (transient voltage suppressor diode) collaborative protection. When a transient high voltage is generated by a lightning surge, TSS conducts first with a microsecond-level response and discharges more than 80% of the large-energy current; TVS then performs secondary clamping on the residual voltage spikes at a picosecond speed. Through the gradient configuration of the high trigger voltage of TSS (such as 800V) and the low clamping voltage of TVS (such as 30V), a two-stage energy discharge path is formed. At the same time, the protection circuit is embedded inside the terminal block using PCB integrated layout, reducing the signal transmission path length and the risk of induced overvoltage. After the transient threat disappears, TSS and TVS automatically return to the high-impedance state to ensure the continuous and stable operation of the system.

[0053] A multi-stage protection control method applied to the serial port surge protector, which includes:

[0054] Step S10: Respond to microsecond-level transient high voltage through TSS to discharge the large current caused by lightning strikes;

[0055] On the PCB board 40, the semiconductor discharge tube (TSS) is directly welded between the input-side terminal and the ground wire, and the path length ≤ 10 mm to reduce the influence of inductance. When the input voltage exceeds the TSS trigger threshold (such as 800 V), the internal PN junction avalanche breaks down, and the on-resistance drops to the milliohm level. For the 8 / 20 μs lightning current waveform (peak value 25 kA), more than 80% of the energy is discharged, and the discharge capacity ≥ 1200 J. By optimizing the doping concentration and junction capacitance of the TSS chip, the response time is controlled within the range of 1 - 5 μs.

[0056] Step S20: Suppress the residual voltage spike after TSS discharge through TVS with a picosecond-level response speed;

[0057] The transient voltage suppression diode (TVS) is connected in parallel to the input end of the backend circuit, and a low junction capacitance design (≤ 1 pF) is adopted. When the voltage rise rate ≥ 1 kV / ns, the residual voltage is clamped to ≤ 30 V with a response speed of ≤ 100 ps. A 10 Ω current-limiting resistor is connected in series between the TVS and the TSS, and the signal path is shortened through PCB layout to ensure that the TVS trigger delay (≤ 50 ns) is synchronized with the TSS conduction timing to avoid protection blind spots.

[0058] Step S30: Utilize the gradient voltage configuration formed by the high trigger voltage of TSS and the low clamping voltage of TVS to avoid single-stage overload and extend the service life of the device.

[0059] The TSS trigger threshold (800 V) and the TVS clamping voltage (30 V) form a gradient configuration with ΔV ≥ 770 V to ensure that the TSS responds to large surges first. The ΔV is monitored in real time through a differential amplifier (AD8276). If ΔV < 500 V (such as TVS aging), the logic control chip (STM32F4) automatically adjusts the TSS trigger threshold up to 1000 V to maintain the gradient relationship. Voltage sampling points are set on the PCB, and the feedback signal is sent to the control chip to achieve dynamic matching.

[0060] The multi-stage protection control method further includes the following dynamic optimization steps:

[0061] Dynamic threshold adjustment: The voltage rise rate and amplitude of the input-side voltage are detected in real time through the voltage monitoring module, and the TSS trigger threshold is dynamically adjusted by the logic control chip to adapt to different intensities of transient threats;

[0062] A high-speed comparator (TLV3501) is used to detect the input voltage rise rate (dV / dt), and the logic chip executes the PID algorithm: if dV / dt ≥ 5 kV / μs and the peak value ≥ 1 kV, the TSS trigger threshold is increased to 960 V through a digital potentiometer (AD5290); if dV / dt < 2 kV / μs and the peak value < 800 V, the nominal threshold is restored. The TVS ground terminal is connected in series with a digital potentiometer, and the resistance value is dynamically adjusted according to the load current collected by the Hall sensor (ACS712) to make the clamping voltage satisfy V clamp ≤ 0.7×V 额定 .

[0063] Adaptive clamping control: An adjustable resistor is connected in series between the TVS and the ground, and the logic control chip adjusts the resistance value according to the characteristics of the backend load to make the clamping voltage of the TVS accurately match the safety requirements of the backend circuit.

[0064] Multi-level protection control method, and the collaborative protection performance is verified through the following test methods:

[0065] Graded energy impact test: Apply lightning current waveforms of different intensities to verify that the TSS undertakes the main surge energy and the TVS suppresses the residual voltage; apply an 8 / 20 μs waveform and a 25 kA peak current to the TSS, and use a high-voltage probe (Tektronix P6015A) to verify that its discharged energy ≥ 1200 J; apply a 1 kV / μs voltage spike to the TVS and measure the residual voltage ≤ 15 V.

[0066] Dynamic response synchronization test: Monitor the response time difference between the TSS and the TVS to ensure that the action timings of the two match and avoid protection blind spots. Apply a 0 V → 1 kV step voltage (rise time ≤ 10 ns) to the input side, and monitor the conduction delay difference between the TSS and the TVS through a high-speed oscilloscope. It is required that the TVS response delay ≤ 50 ns and the two-stage timing difference < 1 μs.

[0067] Closed-loop feedback verification: The current sensor monitors the discharge current of the TSS. If the rated value is exceeded by 80% continuously for 3 times, an alarm is triggered and the TSS threshold is reduced to 90%; the voltage sampling circuit calibrates the TVS clamping voltage fluctuation to ≤ ±2%.

[0068] The design focus of the present invention lies in integrating the PCB board inside the first plug, eliminating redundant structures such as traditional enclosures and metal baffles, significantly reducing the volume and simplifying the installation process; adopting the collaborative protection technology of TSS and TVS, combined with gradient voltage configuration, to achieve multi-level energy discharge and precise voltage clamping, effectively covering transient threats in the full time range and enhancing the protection reliability; through dynamic threshold adjustment, adaptive clamping control and closed-loop feedback mechanism, optimizing the protection parameters in real time to ensure the safety of the backend circuit; at the same time, the modular design reduces the material and production costs, is applicable to multiple scenarios such as industrial control and communication equipment, and has high integration, low cost and strong compatibility, solving the technical pain points of complex structure, high cost and large protection blind area of traditional surge protectors.

[0069] The above are only the preferred embodiments of the present invention, and do not impose any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A highly integrated serial port surge protector, characterized in that: The invention comprises a first plug, a second plug, a connecting wire and a PCB board, wherein the first plug comprises a plurality of plug-in terminals and a first insulating body covered on the outside of the plurality of plug-in terminals; the second plug comprises a plurality of socket terminals and a second insulating body covered on the outside of the plurality of socket terminals; the connecting wire is connected between the first plug and the second plug; the PCB board is located in the first plug or the second plug, and the PCB board has a first-level protection module for discharging a large energy surge current caused by a lightning strike and a second-level protection module for absorbing residual energy and suppressing fast voltage spikes, and the first-level protection module and the second-level protection module are connected through a circuit to form a multi-level coordinated protection.

2. The highly integrated serial port surge protector according to claim 1, characterized in that: The first-level protection module adopts a semiconductor discharge tube TSS; the second-level protection module adopts a transient voltage suppression diode TVS.

3. The highly integrated serial port surge protector according to claim 2, characterized in that: The trigger voltage of the semiconductor discharge tube TSS is higher than the clamping voltage of the transient voltage suppression diode TVS, forming a gradient voltage configuration.

4. The highly integrated serial port surge protector according to claim 2, characterized in that: The response time of the semiconductor discharge tube TSS is in microseconds, and the response time of the transient voltage suppression diode TVS is in picoseconds, covering the transient threats in the full time range.

5. The highly integrated serial port surge protector according to claim 1, characterized in that: The first plug is a male plug, the PCB board and the first insulating body of the first plug are integrally formed, and the multiple plug terminals are electrically connected to the PCB board; one end of the connecting wire is electrically connected to the PCB board, and the other end is electrically connected to the multiple socket terminals.

6. The highly integrated serial port surge protector according to claim 5, characterized in that: The first plug also includes a base and a plug shell, the base is fixed on the PCB board, and the lower ends of the multiple plug-in terminals are electrically connected to the PCB board through the base; the plug shell is sleeved on the outside of the base to form a cavity in the plug shell, and the multiple plug-in terminals extend from the cavity.

7. The highly integrated serial port surge protector according to claim 6, characterized in that: The bottom of the plug housing has a connecting portion for covering the base, and the base has an annular step at one end connected to the PCB board. The connecting portion is provided with a limiting inner edge corresponding to the annular step, and the limiting inner edge is clamped on the annular step.

8. The highly integrated serial port surge protector according to claim 6, characterized in that: The PCB board is provided with an avoidance hole for the locking screw to pass through, and the plug housing is provided with an extension hole corresponding to the locking screw, and the locking screw extends from the rear end of the first insulating body through the avoidance hole and the extension hole.

9. A multi-level protection control method applied to a serial port surge protector as claimed in any one of claims 1 to 8, characterized in that: include: Step S10: Responding to microsecond transient high voltage through TSS to discharge the large current caused by lightning strike; Step S20: suppressing the residual voltage spike after TSS discharge with a picosecond response speed through TVS; Step S30: utilizing the gradient voltage configuration formed by the high trigger voltage of the TSS and the low clamping voltage of the TVS to avoid single-stage overload.

10. The control method according to claim 9, characterized in that: The following dynamic optimization steps are also included: Dynamic threshold adjustment: The voltage monitoring module detects the rising rate and amplitude of the input voltage in real time, and the logic control chip dynamically adjusts the trigger threshold of TSS to adapt to transient threats of different intensities; Adaptive clamping control: An adjustable resistor is connected in series between the TVS and the ground, and the logic control chip adjusts the resistance value according to the back-end load characteristics, so that the clamping voltage of the TVS accurately matches the safety requirements of the back-end circuit; The collaborative protection performance is verified by the following test methods: Graded energy impact test: Apply lightning current waveforms of different intensities to verify that the TSS bears the main surge energy and the TVS suppresses the residual voltage; Dynamic response synchronization test: monitor the response time difference between TSS and TVS to ensure that the action timing of the two matches and avoid protection blind spots.

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