Capacitor aging detection and energy recovery system

Abstract

The invention relates to the technical field of capacitor detection, in particular to a capacitor aging detection and energy recovery system which mainly comprises a control module, an implosion detection module and an energy recovery module, a transformer of the implosion detection module is coupled in a to-be-detected charging loop, the charging loop at least comprises one aging capacitor, and the energy recovery module is connected with the control module. When the transformer detects the abrupt change magnetic field, an abrupt change signal is generated. According to the invention, the electromagnetic induction principle is utilized, the change of current can be detected in an extremely short time, rapid detection of abrupt change current during implosion is realized, and the system uses the controllable discharge and energy recovery unit, so that the energy of the capacitor is recovered to the power supply system or the energy storage system, energy regeneration is realized, the energy efficiency is improved, and the energy consumption is reduced. And the energy-saving and environment-friendly effects are achieved.

Description

Technical Field

[0001] The present application relates to the field of capacitor detection technology, and in particular to a capacitor aging detection and energy recovery system. Background Art

[0002] Capacitor aging is an essential and critical process in capacitor production. Due to the characteristics of raw materials and limitations of the production process, capacitors may experience microsecond-scale internal implosions or micro-short circuits during the aging charging phase. These internal defects typically do not cause changes in appearance and are difficult to effectively identify with conventional testing equipment. During the course of technological evolution, early equipment used only resistor current limiting to complete capacitor charging aging, resulting in a large number of capacitors with internal implosion defects going undetected. If these defective capacitors were introduced into end products, they would not only shorten the equipment lifespan but could even cause explosions.

[0003] Although the industry has introduced implosion detection capabilities in recent years, the following technical bottlenecks remain: The current mainstream solution relies on voltage fluctuation detection, which cannot capture microsecond-level transient signals. Furthermore, the charging power supply is not isolated from the detection system. The energy released during capacitor implosion directly impacts the detection unit, frequently causing circuit burnout and even paralysis of production-line equipment. Existing capacitor aging and implosion detection systems typically use discharge resistors to discharge the capacitors after aging, converting the stored energy into waste heat. Due to the large number of capacitors used in electronic equipment, large-scale production results in significant energy loss. Summary of the Invention

[0004] The present application provides a capacitor aging detection and energy recovery system that can overcome the above technical deficiencies.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] In a first aspect, the present invention provides a capacitor aging detection and energy recovery system, comprising a control module, an implosion detection module, and an energy recovery module;

[0007] The control module is used to communicate with each module and control the components in each module;

[0008] The implosion detection module includes an aging switch, a first transformer, a voltage comparator, and a latch. The first transformer is coupled to a charging circuit to be detected, and the charging circuit includes at least one aging capacitor. When the first transformer detects a sudden change in the magnetic field, it generates a sudden change signal. After detecting the sudden change signal, the voltage comparator compares the sudden change signal with a set voltage sensitivity to obtain an implosion signal, and outputs the implosion signal to the latch. The latch is used to store the implosion signal and communicate with an external reading device.

[0009] The energy recovery module comprises a switch tube, an inductor, a diode and a recovery capacitor; the switch tube is connected in parallel with the aging capacitor, and discharges the aging capacitor after receiving a discharge signal of the control module; the inductor, the diode and the recovery capacitor are connected in series with the aging capacitor; and the recovery capacitor is used for storing electric energy in the aging capacitor.

[0010] In a preferred example of the present application, a communication module is further provided, connected to the control module, and used for data interaction with the upper computer software through EtherCat.

[0011] In a preferred example of the present application, the transformer is a coupled inductor or a common-mode inductor.

[0012] In a preferred example of the present application, a sensitivity adjustment module is further provided, comprising a first switch and a second transformer.

[0013] The sensitivity adjustment module is connected to the first transformer and the control module.

[0014] The control module is further used for controlling the first switch through a PWM wave to adjust the voltage at the output end of the second transformer.

[0015] In a preferred example of the present application, a charging current adjustment module is further provided, connected to the control module and the charging circuit, and used for forming a constant current source.

[0016] The control module is further used for adjusting the voltage of the constant current source through a PWM wave, so that the constant current source outputs a set current.

[0017] In a preferred example of the present application, a charging-off module is further provided, connected to the control module and the charging circuit, and used for shutting off the charging circuit.

[0018] The control module is further used for turning on or off the charging-off module.

[0019] In a preferred example of the present application, a voltage acquisition module is further provided, comprising a voltage dividing resistor and an isolation voltage unit, connected to the control module and the charging circuit, and used for detecting the leakage current of the aging capacitor during the aging process.

[0020] In a preferred example of the present application, a protection circuit is further provided, connected to the implosion detection module, and used for disconnecting the aging switch under a preset condition to protect the aging switch.

[0021] In a preferred example of the present application, further configured to further comprise a unit for expanding the detection channel, for realizing multi-channel detection through a serial logic chip.

[0022] In a preferred example of the present application, further configured to further comprise a host computer software module connected to the communication module, for realizing parameter configuration, data storage, report generation and data interface of the system.

[0023] Compared with the prior art, the technical scheme provided by the embodiments of the present application has at least the following beneficial effects:

[0024] The system provided by the present application utilizes the principle of electromagnetic induction, can detect the change of current in a very short time, realizes the rapid detection of the sudden change of current during implosion, and uses controllable discharge and energy recovery units, so that the energy of the capacitor is recovered to the power system or energy storage system, realizes the regeneration of energy, improves the energy efficiency, and achieves the effect of energy saving and environmental protection. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 A module diagram of a capacitor aging detection and energy recovery system is provided for an embodiment of the present application.

[0026] Figure 2 A circuit diagram of a capacitor aging detection and energy recovery system is provided for an embodiment of the present application. DETAILED DESCRIPTION

[0027] The technical scheme in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0028] In an embodiment of the present application, a capacitor aging detection and energy recovery system is provided, please refer to Figure 1 As shown in the figure, comprising a control module 100, an implosion detection module 200 and an energy recovery module 300;

[0029] The control module is used for communicating with each module and controlling the elements in each module.

[0030] The implosion detection module includes an aging switch, a first transformer, a voltage comparator, and a latch; the transformer is coupled to a charging circuit to be detected, the charging circuit includes at least one aging capacitor, when the transformer detects a sudden magnetic field, a sudden signal is generated; the voltage comparator compares the sudden signal with a set voltage sensitivity after detecting the sudden signal, an implosion signal is obtained, and the implosion signal is output to the latch; the latch is used to store the implosion signal and communicate with an external reading device.

[0031] The energy recovery module includes a switch tube, an inductor, a diode, and a recovery capacitor; the switch tube is connected in parallel with the aging capacitor, and discharges the aging capacitor after receiving a discharge signal of the control module; the inductor, the diode, and the recovery capacitor are connected in series with the aging capacitor; and the recovery capacitor is used to store the electrical energy in the aging capacitor.

[0032] In a specific implementation, the circuit structure of the system can be as follows: Figure 2 The following describes the connection relationship of each element in the circuit, the function of each sub-circuit structure, and the implementation mode thereof. Figure 2

[0033] The control module includes an MCU shown in the figure, which is connected with and communicates with each module, is used to store and process data, and controls the working state of each module.

[0034] The implosion detection module is based on the principle of capacitor implosion micro-short circuit detection and realizes electrical isolation, and the implementation mode is as follows: when the total switch S1 is closed, the aging switch Q1 charges the aging capacitor C1, the current flows through one side of the first transformer T1, when there is an implosion micro-short circuit, the current will be suddenly changed, and the suddenly changed current will generate a suddenly changed magnetic field. The suddenly changed signal is detected by the other side of the T1, a suddenly changed voltage is generated, the voltage comparator U6A compares the suddenly changed voltage with a preset voltage sensitivity, and an implosion signal can be output. The output implosion signal is captured by the flip-flop and latch U7, and is locked in the U7 to wait for reading by the upper computer. The T1 transformer can be a coupled inductor or a common-mode inductor, etc.

[0035] The energy recovery module includes a switch tube Q5, an inductor L1, a diode D1, and a recovery capacitor C5, so that the stored energy of the capacitor can be recycled, to achieve the purpose of efficiency, energy saving, and environmental protection. L1, Q5, and D1 constitute a discharge energy recovery circuit, Q5 is controlled by the PWM wave of the MCU to discharge C1, the discharged energy is fed back to the power supply or the energy storage system through L1 and D1, and the recovery circuit can be a step-up circuit or a step-down circuit to meet the different voltage requirements of the subsequent energy storage.

[0036] ​In the embodiment, the system utilizes the principle of electromagnetic induction, can detect the change of current in a very short time, realizes the rapid detection of the sudden change of current in implosion, and the system uses controllable discharge and energy recovery unit, so that the energy of the capacitor is recovered to the power system or energy storage system, realizes the regeneration of energy, improves the energy efficiency, and achieves the effect of energy saving and environmental protection.

[0037] In some embodiments, further comprising:

[0038] A communication module connected to the control module, used for data interaction with the host computer software through EtherCat.

[0039] A host computer software module connected to the communication module, used for realizing parameter configuration, data storage, report generation and providing data interface of the system.

[0040] In specific implementation, as shown in the figure, Figure 2 The system further comprises an MCU U3 and an EtherCat high-speed communication unit U5A connected to the EtherCat bus through Ethernet, realizing high-speed communication with the host computer. The host computer software module comprises host computer software, used for realizing parameter configuration, data storage, report generation and providing data interface of the system.

[0041] In the embodiment, high-speed EtherCat bus is used for communication, which significantly improves the communication speed, shortens the sampling period of the host computer software, and significantly improves the detection rate of the capacitor relying on the host computer software.

[0042] In some embodiments, further comprising:

[0043] A sensitivity adjustment module comprising a first switch and a second transformer;

[0044] The sensitivity adjustment module is connected to the first transformer and the control module;

[0045] The control module is further used for controlling the first switch through PWM wave, and adjusting the voltage at the output end of the second transformer.

[0046] A charging current adjustment module connected to the control module and the charging circuit, used for constituting a constant current source;

[0047] The control module is further used for adjusting the voltage of the constant current source through PWM wave, so that the constant current source outputs the set current.

[0048] In specific implementation, as shown in the figure, Figure 2As shown, Q4 is controlled by the PWM wave of MCU to adjust the voltage at the output end of the second transformer T3, and the output voltage is connected to the inverting input end of the comparator U6A, so as to adjust the sensitivity of the implosion detection, and the second transformer T3 realizes the isolation of the circuit.

[0049] Q1, U1A and R1 in the charging current adjusting module constitute a constant current source. The third transformer T2 and Q3 are controlled by the PWM wave of MCU to output the adjusting voltage of the constant current source, so that the constant current source outputs the set current, and the third transformer T2 realizes the isolation of the circuit.

[0050] In the embodiment, the electrical isolation of the charging circuit and the detection circuit is realized, and the implosion detection, the sensitivity control, the constant current source control and the voltage and current sampling are all realized in the electrical isolation, so that the stability of the detection circuit is greatly improved, and the board is hardly damaged, and the large-area board burning is hardly caused.

[0051] In some embodiments, the system further comprises:

[0052] A charging-off module connected to the control module and the charging circuit, and used for turning off the charging circuit.

[0053] A voltage sampling module comprising a voltage dividing resistor and an isolated voltage unit, and connected to the control module and the charging circuit, and used for detecting the leakage current of the aging capacitor in the aging process.

[0054] A protection circuit connected to the implosion detection module, and used for disconnecting the aging switch under a preset condition to protect the aging switch.

[0055] In specific implementation, as shown in Figure 2 As shown, the system further comprises a second switch Q2 which can turn off the charging. When the aging capacitor C1 has a poor implosion, multiple implosions may occur in the subsequent aging process, which affects the stability of the system, and it is necessary to turn off the charging. The MCU controls the opening and closing of the second switch Q2 through the optocoupler U2, so as to control the opening and closing of the aging switch Q1, to realize the opening and closing of the charging of the aging capacitor C1, and the optocoupler U2 realizes the isolation of the circuit.

[0056] As shown in Figure 2 As shown, the system further comprises an isolated voltage sampling circuit, the voltage dividing resistors R8 and R9 and the isolated voltage sampling module V1 constitute a voltage sampling unit. The voltage is sent to the MCU through the ADC conversion module U8LNA. In addition, the system further comprises an isolated current sampling circuit composed of the sampling resistor R1 and the isolated current sampling module A1, and the current is sent to the MCU through the ADC conversion module U8LNA, to realize the detection of the leakage current of the aging capacitor C1 in the aging process.

[0057] As shown in Figure 2As shown, the system further comprises an aging switch Q1 protection circuit, and the TVS T1 can absorb the high voltage in the explosion moment of the aging capacitor C1, and the fuse F1 is disconnected in an extreme case to protect the aging switch Q1.

[0058] In the embodiment, the security of the system is improved.

[0059] In some embodiments, the unit for expanding the detection channel is further included, and the multi-channel detection is realized through the serial logic chip. Figure 2 As shown in U7 and U4 serial logic chips, multi-channel detection can be realized.

[0060] The technical features of the above embodiments can be combined arbitrarily. In order to make the description simple, all possible combinations of the technical features in the above embodiments are not described, however, as long as the combination of the technical features does not exist contradictory, it should be considered as the scope of the description. The above described embodiments only express several implementation manners of the present application, the description is more specific and detailed, but it should not be understood as the limitation of the patent scope. It should be pointed out that, for those skilled in the art, without departing from the concept of the present application, several modifications and improvements can be made, which all belong to the protection scope of the present application. Therefore, the patent protection scope of the present application should be subject to the appended claims.

Claims

1. A capacitor aging detection and energy recovery system, characterized in that: including a control module, an implosion detection module, and an energy recovery module; The control module is used to communicate with each module and control the components in each module; The implosion detection module includes an aging switch, a first transformer, a voltage comparator, and a latch. The first transformer is coupled to a charging circuit to be detected, and the charging circuit includes at least one aging capacitor. When the first transformer detects a sudden change in the magnetic field, it generates a sudden change signal. After detecting the sudden change signal, the voltage comparator compares the sudden change signal with a set voltage sensitivity to obtain an implosion signal, and outputs the implosion signal to the latch. The latch is used to store the implosion signal and communicate with an external reading device. The energy recovery module includes a switching tube, an inductor, a diode and a recovery capacitor; the switching tube is connected in parallel to the aging capacitor, and discharges the aging capacitor after receiving the discharge signal from the control module; the inductor, diode, recovery capacitor and the aging capacitor are connected in series; the recovery capacitor is used to store the electrical energy in the aging capacitor.

2. The capacitor aging detection and energy recovery system according to claim 1, characterized in that: It also includes a communication module connected to the control module, which is used to exchange data with the host computer software through EtherCat.

3. The capacitor aging detection and energy recovery system according to claim 1, characterized in that: The transformer is a coupled inductor or a common-mode inductor.

4. The capacitor aging detection and energy recovery system according to claim 3, characterized in that: Also included is a sensitivity adjustment module, including a first switch and a second transformer; The sensitivity adjustment module is connected to the first transformer and the control module; The control module is further configured to control the first switch via a PWM wave to adjust the voltage at the output end of the second transformer.

5. The capacitor aging detection and energy recovery system according to claim 4, characterized in that: It also includes a charging current regulating module, connected to the control module and the charging circuit, for forming a constant current source; The control module is also used to adjust the voltage of the constant current source through the PWM wave so that the constant current source outputs a set current.

6. The capacitor aging detection and energy recovery system according to claim 1, characterized in that: It also includes a charging shutoff module connected to the control module and the charging circuit, and is used to shut down the charging circuit; The control module is further configured to turn on or off the charging shutdown module.

7. The capacitor aging detection and energy recovery system according to claim 6, characterized in that: It also includes a voltage acquisition module, including a voltage dividing resistor and an isolation voltage unit, connected to the control module and the charging circuit, and used to detect the leakage current of the aging capacitor during the aging process.

8. The capacitor aging detection and energy recovery system according to claim 7, characterized in that: It also includes a protection circuit connected to the implosion detection module, which is used to disconnect the aging switch under preset circumstances to protect the aging switch.

9. The capacitor aging detection and energy recovery system according to claim 1, characterized in that: It also includes a unit for expanding the detection channel, which is used to realize multi-channel detection through a serial logic chip.

10. The capacitor aging detection and energy recovery system according to claim 2, characterized in that: It also includes a host computer software module connected to the communication module for implementing system parameter configuration, data storage, report generation and providing a data interface.

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