Abnormal arc control method and device at sub-microsecond speed level

Abstract

The invention provides a sub-microsecond speed level abnormal arc control method and device. The method provided by the invention comprises the steps of detecting a real-time pulse voltage and a real-time voltage in a discharge circuit in real time, and calculating a current change rate and a voltage change rate; determining a plurality of current thresholds and a plurality of current fluctuation thresholds corresponding to different discharge states; calculating voltage thresholds and voltage fluctuation thresholds corresponding to the current thresholds and the current fluctuation thresholds; obtaining a first identification result of the discharge state according to the relationship between the real-time pulse current and the current change rate and the current threshold and the current fluctuation threshold; the first recognition result is corrected according to the relation between the real-time voltage and the voltage change rate and the voltage threshold value and the voltage fluctuation threshold value, and the real-time discharging state is obtained; and matching a corresponding discharge control strategy according to the real-time discharge state. According to the method and the device for controlling the abnormal electric arc at the sub-microsecond speed level, the abnormal electric arc at the sub-microsecond speed level can be identified and controlled.

Description

Technical Field

[0001] This application relates to the field of arc control technology, and in particular to a method and apparatus for controlling abnormal arcs at sub-microsecond speed levels. Background Technology

[0002] In modern industrial manufacturing, many advanced processing techniques rely on stable and efficient discharge processes. Cathodic arc deposition can form high-quality coatings on material surfaces, significantly improving the materials' wear resistance, corrosion resistance, and decorative properties. It is widely used in industries such as aerospace, automotive manufacturing, and electronic equipment. However, the occurrence of abnormal arcs can lead to serious problems such as reduced coating quality and equipment damage. Accurate and timely detection of abnormal arcs is crucial for ensuring smooth production processes, improving product quality, and reducing production costs.

[0003] Currently, various technologies have been developed for detecting abnormal electric arcs. Among these, the most common are methods based on monitoring electrical parameters, such as using simple current and voltage sensors to collect current and voltage values ​​during the arc discharge process. Some technologies also utilize oscilloscopes and other equipment to observe the waveforms of the collected electrical signals, relying on the operator's experience to determine the presence of abnormal arcs. In addition, there are methods that identify anomalies by detecting the optical signals of the arc, using photoelectric sensors to capture changes in the intensity, color, and other characteristics of the arc's emission, thereby inferring the arc's state.

[0004] However, existing abnormal arc detection technologies have many shortcomings. Methods based on electrical parameter monitoring suffer from limited sensor accuracy, resulting in significant errors in current and voltage data acquired in complex discharge environments, making it difficult to accurately reflect the true state of the arc. Furthermore, relying solely on observing electrical signal waveforms and manual judgment is highly subjective and inefficient, prone to misjudgments and omissions. For arc discharge processes with complex internal structures, it is difficult to quickly, comprehensively, and accurately identify and control abnormal arcs. Summary of the Invention

[0005] In view of this, this application provides a sub-microsecond speed-level abnormal arc control method and apparatus to achieve sub-microsecond level abnormal arc identification and control.

[0006] Specifically, this application is implemented through the following technical solution:

[0007] The first aspect of this application provides a method for controlling abnormal electric arcs at the sub-microsecond velocity level, the method comprising:

[0008] The real-time pulse current in the discharge circuit is detected in real time using a Rogowski coil, and the real-time voltage in the discharge circuit is detected in real time using a Hall voltage sensor.

[0009] Calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage;

[0010] Determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states;

[0011] Calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and current fluctuation thresholds based on the circuit structure of the discharge circuit.

[0012] The first identification result of the discharge state is obtained by the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold.

[0013] The first identification result is corrected by the relationship between the real-time voltage and voltage change rate and the voltage threshold and voltage fluctuation threshold, so as to obtain the real-time discharge state of the discharge circuit.

[0014] The corresponding discharge control strategy is matched based on the real-time discharge status.

[0015] A second aspect of this application provides an abnormal electric arc control device at the sub-microsecond speed level, the device comprising a detection module, a calculation module, and a control module;

[0016] The detection module is used to detect the real-time pulse current in the discharge circuit using a Rogowski coil and to detect the real-time voltage in the discharge circuit using a Hall voltage sensor.

[0017] The calculation module is used to calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage.

[0018] The calculation module is also used to determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states;

[0019] The calculation module is also used to calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and each of the current fluctuation thresholds according to the circuit structure of the discharge circuit.

[0020] The control module is used to obtain the first identification result of the discharge state based on the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold.

[0021] The control module is also used to correct the first identification result based on the relationship between the real-time voltage and the voltage change rate and the voltage threshold and the voltage fluctuation threshold, so as to obtain the real-time discharge state of the discharge circuit.

[0022] The control module is also used to match a corresponding discharge control strategy based on the real-time discharge state.

[0023] The sub-microsecond-level abnormal arc control method and apparatus provided in this application use Rogowski coils and Hall voltage sensing elements to detect changes in current and voltage in the discharge circuit, without damaging the discharge circuit structure, and can achieve sub-microsecond-level anomaly detection in the discharge circuit. Based on the detected signal, the anomaly level is accurately determined by using the current signal as the primary signal and the voltage signal as a secondary signal, and graded control is performed. Specifically, since the voltage signal is an auxiliary signal, the voltage threshold and voltage fluctuation threshold are directly calculated from the current threshold and current fluctuation threshold, rather than being directly determined numerical ranges. This avoids repeatedly determining the threshold through noisy or computationally complex methods such as experience or simulation. At the same time, the relationship between real-time pulse current, current change rate and corresponding threshold is used to obtain the first identification result, and then the relationship between real-time voltage, voltage change rate and corresponding threshold is used to correct the first identification result, which improves the accuracy of discharge state identification. This ensures that abnormal arcs can be quickly and accurately identified and effectively controlled in complex discharge circuit environments, guaranteeing the stable operation of related equipment and the smooth progress of the production process. Attached Figure Description

[0024] Figure 1 A flowchart of an embodiment of the sub-microsecond speed-level abnormal arc control method provided in this application;

[0025] Figure 2 This is a schematic diagram of the structure of an embodiment of the sub-microsecond speed-level abnormal arc control device provided in this application. Detailed Implementation

[0026] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application.

[0027] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms “a,” “the,” and “the” used herein are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0028] It should be understood that although the terms first, second, third, etc., may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0029] The following specific embodiments are given to illustrate the technical solution of this application in detail.

[0030] Figure 1 This is a flowchart of an embodiment of the sub-microsecond velocity-level abnormal arc control method provided in this application. Please refer to... Figure 1 The method provided in this embodiment may include:

[0031] S101. Real-time pulse current in the discharge circuit is detected using a Rogowski coil, and real-time voltage in the discharge circuit is detected using a Hall voltage sensor.

[0032] Specifically, Rogowski coils operate based on the principle of electromagnetic induction. When the current in the circuit being detected changes, an induced electromotive force (EMF) is generated in the Rogowski coil. By measuring and processing this induced EMF, the pulse current information in the circuit can be obtained in real time. Hall voltage sensors utilize the Hall effect. When current flows through a semiconductor wafer (Hall element) placed in a magnetic field, a voltage is generated in the direction perpendicular to both the current and the magnetic field. This voltage is proportional to the measured voltage, thus enabling real-time voltage detection of the discharge circuit. Rogowski coils operate based on the principle of electromagnetic induction. Because this electromagnetic induction is based on the direct action of physical laws, there is almost no delay, allowing for real-time capture of current changes and sub-microsecond current detection. Hall voltage sensors utilize the Hall effect; this physical effect-based voltage sensing method has an extremely fast response speed, reflecting voltage changes in the discharge circuit in real time and achieving sub-microsecond voltage detection. Real-time pulse current detection in a discharge circuit using Rogowski coils can include:

[0033] (1) Select the circuit to be tested in the discharge circuit and pass the circuit to be tested through the Rogowski coil;

[0034] Specifically, in some discharge circuits, the tail end directly acts on the processing or reaction area, such as in cathodic arc deposition equipment. The area where a coating is formed on the material surface is the tail end discharge location. The discharge condition here directly determines product quality. Monitoring the current and voltage of the tail end circuit can promptly detect abnormal arcs and avoid coating defects. When abnormalities such as short circuits or overloads occur, the current and voltage parameters of the tail end discharge circuit will change immediately. Monitoring allows for rapid intervention to ensure smooth production.

[0035] (2) Based on the current flowing through the circuit to be tested, an induced electromotive force detection pulse voltage signal is generated in the Rogowski coil;

[0036] Specifically, a Rogowski coil is a hollow toroidal coil. A wire whose current needs to be monitored is selected from the discharge circuit (such as a high-voltage discharge circuit, load line, etc.), and the Rogowski coil is wrapped around the wire. When the current in the circuit passes through the Rogowski coil, the Rogowski coil generates an induced electromotive force that is proportional to the rate of change of current, and a corresponding pulse voltage signal is generated based on the induced electromotive force.

[0037] Furthermore, the pulse voltage signal output by the Rogowski coil can be calculated using the following formula:

[0038]

[0039] Where M is the mutual inductance coefficient;

[0040] This represents the rate of change of current corresponding to the current flowing through the circuit under test.

[0041] (3) The pulse voltage signal is input to a differential amplifier, the differential amplifier amplifies the pulse voltage signal, and outputs the amplified pulse voltage signal;

[0042] Specifically, the differential amplifier receives the pulse voltage signal output from the Rogowski coil, amplifies it to an amplitude suitable for subsequent processing (e.g., 0-5V), and suppresses common-mode interference to obtain the amplified pulse voltage signal.

[0043] (4) The amplified pulse voltage signal is input to a low-pass filter, the low-pass filter smooths the amplified pulse voltage signal, and outputs a smoothed pulse voltage signal;

[0044] Specifically, a low-pass filter can filter out high-frequency components (such as switching noise and electromagnetic spikes) in the amplified pulse voltage signal, while retaining the effective frequency components related to the measured current, making the waveform of the amplified pulse voltage signal smoother and obtaining a smoothed pulse voltage signal.

[0045] (5) The smoothed pulse voltage signal is converted into a digital current signal based on the analog-to-digital converter.

[0046] Specifically, the digital-to-analog converter converts the smoothed pulse voltage signal into a digital voltage signal. Furthermore, the digital voltage signal is substituted into the above pulse voltage signal calculation formula and integrated to restore the digital voltage signal to a digital current signal, which is then used as the real-time pulse current of the circuit under test.

[0047] S102. Calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage.

[0048] Specifically, the rate of change of current reflects how quickly the current changes over time in the discharge circuit, while the rate of change of voltage reflects the state of the circuit components and the stability of the discharge process. When the rate of change of voltage fluctuates drastically or exceeds the normal range, it indicates that the discharge process is unstable. In some high-voltage discharge experimental devices, if unstable arc combustion occurs, the rate of change of voltage will change drastically. This may be due to uneven evaporation of electrode materials, plasma instability, or other reasons. An unstable rate of change of voltage not only affects the normal operating performance of the circuit but may also damage other components in the circuit.

[0049] Furthermore, the steps for calculating the rate of change of current based on the real-time pulse current include:

[0050] (1) Calculate the time difference based on the preset sampling points;

[0051] Specifically, the preset sampling point is a pre-determined time point for sampling the current in the discharge circuit. For example, if the pulse current is sampled every 1 millisecond, then the time interval between two adjacent sampling points is 1 millisecond. By recording the time of each sampling point, the time difference between any two adjacent sampling points can be calculated using the following formula:

[0052] Δt = t1 - t0;

[0053] Where t0 is the current sampling time point;

[0054] t1 is the next sampling time point.

[0055] (2) Calculate the current difference of the pulse current between adjacent sampling points;

[0056] Specifically, the current difference can be calculated using the following formula:

[0057] ΔI = I1 - I0;

[0058] Where I0 is the current value at the current sampling time point;

[0059] I1 is the current value at the next sampling time point.

[0060] (3) Calculate the rate of change of current based on the ratio of the current difference to the time difference.

[0061] Specifically, the rate of change of current can be calculated using the following formula:

[0062]

[0063] Where ΔI is the current difference;

[0064] Δt represents the time difference.

[0065] Furthermore, the steps for calculating the voltage change rate based on the real-time voltage include:

[0066] (1) Calculate the time difference based on the preset sampling points;

[0067] Specifically, the time difference for calculating the rate of change of voltage is the same as the time difference for calculating the rate of change of current. Please refer to the above description for the formula for calculating the time difference, which will not be repeated here.

[0068] (2) Calculate the voltage difference of the pulse current between adjacent sampling points;

[0069] Specifically, the voltage difference can be calculated using the following formula:

[0070] ΔU=U1-U0;

[0071] Where U0 is the voltage value at the current sampling time point;

[0072] U1 is the voltage value at the next sampling time point.

[0073] (3) Calculate the voltage change rate based on the ratio of the voltage difference to the time difference.

[0074] Specifically, the rate of change of voltage can be calculated using the following formula:

[0075]

[0076] Where ΔU is the current difference;

[0077] Δt represents the time difference.

[0078] S103. Determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states.

[0079] Specifically, based on the design requirements of the discharge circuit, the withstand capability of the components, and historical operating data, current thresholds and current fluctuation thresholds are pre-set for different discharge states. For example, during normal discharge, the current should fluctuate within a reasonable range; the upper and lower limits of this range are the current thresholds for normal discharge. Similarly, there are corresponding current thresholds for abnormal discharge states such as overload or short circuit. The current fluctuation threshold is used to measure the severity of current fluctuations; current fluctuations are smaller during normal discharge and may increase during abnormal discharge.

[0080] Optionally, determining multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states may include:

[0081] (1) Determine the current relationship at each location point in the discharge circuit;

[0082] Specifically, based on the circuit diagram of the discharge circuit, the connection methods and positional relationships of each component in the discharge circuit are determined, and all nodes and branches of the discharge circuit are identified. A node is a connection point of three or more branches in the circuit, while a branch is a circuit section connecting two nodes, containing one or more components. By identifying nodes and branches, the path of current in the circuit can be described more clearly.

[0083] Furthermore, for all nodes in the discharge circuit, the current relationship corresponding to each node is determined based on Kirchhoff's Current Law. According to Kirchhoff's Current Law, the sum of the currents flowing into a node is equal to the sum of the currents flowing out of that node. Combining the connection method and positional relationship of each device in the discharge circuit, the current relationship between each position point can be determined. For example, in a series circuit, the current at each position point is equal; in a parallel circuit, the total current is equal to the sum of the currents in each branch. Determining this current relationship is the basis for subsequent calculation of the current threshold.

[0084] (2) Determine the operating current that each device in the discharge circuit can withstand under different operating states;

[0085] Specifically, different devices can withstand different currents under different operating conditions. Resistors have a maximum power limit; using the power calculation formula, the maximum current they can withstand under different operating conditions can be calculated. For capacitors, the current they can withstand depends on the charging and discharging process; the current they can withstand varies at different operating frequencies and voltages. By consulting the device's specifications or through experimental testing, the corresponding operating current that each device can withstand under different operating conditions can be determined.

[0086] (3) Take the minimum operating current that each device can withstand under each operating state as the reference current corresponding to the operating state.

[0087] Specifically, in a given operating state, each component in the circuit has its own withstandable operating current. To ensure the safe operation of the entire circuit in this state, a current value that represents the overall withstand capability of the circuit needs to be selected. Since the safety of the circuit depends on its weakest link, the minimum withstandable operating current of each component is taken as the reference current. This ensures that all components operate within their safe current range in this operating state, preventing damage from excessive current to any single component, thus guaranteeing the stability and reliability of the entire circuit.

[0088] (4) Calculate the current value of the reference current at the real-time pulse current detection position under each working state based on the reference current, the position point corresponding to the reference current, and the current relationship, and use it as the current threshold corresponding to each working state.

[0089] Specifically, given the reference current and its corresponding location, and based on the previously determined current relationships at various locations in the circuit, the current value at the real-time pulse current detection location can be calculated using circuit analysis methods such as Ohm's law and Kirchhoff's laws. This current value is the current threshold used to determine whether the real-time pulse current is normal under this operating condition.

[0090] Furthermore, the steps for determining the current fluctuation threshold may include:

[0091] Based on the changing trend of discharge current under various operating states in the discharge circuit, multiple initial sampling points are determined for each operating state. Starting from the initial sampling points, the current fluctuation rate under different discharge intervals is sampled and calculated as the current fluctuation threshold.

[0092] Specifically, taking a specific operating state as an example, the discharge current waveform of the maximum discharge current in the discharge circuit under that operating state is determined. From this waveform, three intervals are identified: the rising edge, the falling edge, and the top. Within each interval, a preset percentage of the current value reaching the peak current is used as the initial sampling point. This percentage varies for each interval. After determining the initial sampling point for each interval, the discharge current within each interval is sampled starting from the initial sampling point using preset sampling points. The current fluctuation rate within that interval is calculated based on the ratio of the time interval between adjacent sampling points to the current difference. For different operating states, the maximum discharge current is different, and the corresponding discharge current waveforms are also different.

[0093] Specifically, the operating states of the discharge circuit include normal discharge, overload discharge, short-circuit discharge, minimum arc initiation state, and maximum current state. The discharge range of the discharge circuit includes the rising edge, falling edge, and top range. The rising edge range refers to the stage where the current rapidly rises from its initial value to its peak value; the falling edge range refers to the stage where the current decreases from its peak value to a stable value; and the top range refers to the plateau region where the current remains near its peak value. The current signal in the discharge circuit can be acquired in real time using a Rogowski coil. The analog current signal is converted into a digital signal using an analog-to-digital converter. Waveform analysis is performed on the acquired digital current signal, and algorithms are used to identify the rising edge, falling edge, and top range of the current. For example, the rising slope and falling slope of the current signal are calculated. The range where the rising slope is greater than a rising threshold is defined as the rising edge range of the current signal; the range where the falling slope is greater than a falling threshold is defined as the falling edge range of the current signal; and the range where the difference between the slope and zero is less than a difference threshold is defined as the top range of the current signal. It should be noted that the rising threshold, falling threshold, and difference threshold are set according to actual needs, and are not limited in this embodiment.

[0094] Furthermore, the peak discharge current is the maximum value that the current can reach during the discharge process, reflecting the intensity of the discharge. Determining the start time is to provide a benchmark point for the current change within the evaluation interval, which facilitates subsequent analysis of the rate of change of the current. It should be noted that the preset percentage is set according to actual needs. In this embodiment, it is not limited. For example, in one embodiment, the preset percentage is 5%.

[0095] Furthermore, starting from the beginning of the current waveform, the time axis is traced backward. When the current value first reaches a preset percentage of the peak current, this moment is recorded and designated as the initial sampling point for sampling the discharge circuit. It should be noted that the peak current and the location of the initial sampling point differ for different operating states of the discharge circuit.

[0096] Furthermore, for different discharge intervals under a certain operating state, taking the rising edge interval as an example, current sampling is performed within the rising edge interval according to pre-sampled points to obtain the current value corresponding to each sampling point within the rising edge interval. The time interval is then calculated based on the time between two adjacent sampling points, and the current difference is calculated based on the current values ​​of two adjacent sampling points. The current volatility of the rising edge interval is calculated based on the ratio of the current difference to the time interval. The calculation method for the current volatility of the falling edge interval and the top interval is the same as that for the rising edge interval. It is understandable that the current volatility of different discharge intervals may be the same or different.

[0097] The above method is used to calculate the upper limit of the current fluctuation threshold for different discharge intervals under different operating conditions. Each upper limit includes the upper limit of the current fluctuation threshold for the rising edge, falling edge and top intervals, which is essentially a threshold sequence containing three variables.

[0098] Furthermore, taking a certain working state as an example, the discharge current waveform of the minimum discharge current of the discharge circuit in that working state is determined. The steps of determining the rising edge, falling edge and top three intervals are returned. The lower limit of the current fluctuation threshold for different discharge intervals in different working states is calculated in the same way. Each lower limit includes the lower limit of the current fluctuation threshold for the rising edge, falling edge and top three intervals. In essence, it is a threshold sequence containing three variables.

[0099] S104. Calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and current fluctuation thresholds according to the circuit structure of the discharge circuit.

[0100] Specifically, the steps for calculating the voltage threshold and voltage fluctuation threshold may include:

[0101] (1) Calculate the current-voltage relationship at the real-time pulse current detection location in the circuit structure;

[0102] Specifically, first, determine the devices involved at the real-time pulse current detection location and their characteristics. Based on the device characteristics, determine the corresponding calculation formula, and then determine the corresponding current-voltage relationship using the calculation formula. For example, if there is a resistive element at the real-time pulse current detection location, the current-voltage relationship can be determined using Ohm's law; if there is a capacitive element at the real-time pulse current detection location, the current-voltage relationship can be determined using the following formula:

[0103]

[0104] Where C is the capacitance value of the capacitor element;

[0105] I represents the real-time pulse current value;

[0106] It represents the voltage value passing through the capacitor element per unit time;

[0107] Furthermore, for complex circuit structures composed of multiple components, Kirchhoff's voltage law may be needed to determine the current-voltage relationship. In any closed loop, the algebraic sum of the voltages in each segment is equal to zero. By analyzing a closed loop containing a real-time pulse current detection location and combining the current-voltage characteristics of each device, the loop voltage equation is derived, and then the current-voltage relationship at that location is solved.

[0108] (2) Calculate the voltage threshold based on the current-voltage relationship and the current threshold;

[0109] Specifically, after determining the current-voltage relationship, a functional relationship with current as the independent variable and voltage as the dependent variable can be obtained from the current-voltage relationship. By substituting the previously calculated current threshold into the corresponding current-voltage functional relationship, the corresponding voltage threshold can be obtained.

[0110] (3) Calculate the voltage fluctuation threshold based on the current-voltage relationship and the current fluctuation threshold.

[0111] Specifically, based on the above description, the current fluctuation threshold is taken as the independent variable and the voltage fluctuation threshold is taken as the dependent variable according to the current-voltage relationship. The voltage fluctuation threshold is obtained by substituting the current fluctuation threshold into the corresponding current-voltage relationship.

[0112] S105. The first identification result of the discharge state is obtained by the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold.

[0113] Specifically, the discharge state of the discharge circuit includes normal discharge, overload discharge, and short-circuit discharge. The real-time detected pulse current and calculated current change rate are compared with preset current thresholds and current fluctuation thresholds. A first identification result is determined based on the comparison result. Determining the first identification result may include:

[0114] (1) Compare the real-time pulse current with the current threshold, and the current change rate with the current fluctuation threshold;

[0115] (2) When the real-time pulse current is less than or equal to the current threshold and the current change rate is between the upper and lower limits of the current fluctuation threshold, the first identification result is determined to be normal discharge.

[0116] (3) When the real-time pulse current is greater than the current threshold and the current change rate is less than the lower limit of the current fluctuation threshold, the first identification result is determined to be overload discharge.

[0117] (4) When the real-time pulse current is greater than the current threshold and the current change rate is greater than the upper limit of the current fluctuation threshold, the first identification result is determined to be short-circuit discharge.

[0118] Specifically, the current threshold is a reference value determined based on the rated current of circuit components and circuit design requirements, used to measure whether the current exceeds the normal range. The current fluctuation threshold reflects the drastic degree of current change, used to determine whether the current change is abnormal. The lower limit of the current fluctuation threshold represents the minimum rate of change for stable operation of the discharge circuit, and the upper limit represents the maximum rate of change for safe operation of the discharge circuit. By comparing the real-time pulse current with the current threshold and the current change rate with the current fluctuation threshold, it can be determined whether the current state in the circuit is normal.

[0119] Furthermore, when the real-time pulse current is below the current threshold and the rate of change of the current is between the upper and lower limits of the current fluctuation threshold, it indicates that the magnitude and variation of the current in the circuit are within the normal range, and the circuit can be considered to be operating stably. The first identification result is normal discharge. For example, in a discharge circuit, if the real-time detected pulse current is always lower than the current value that the battery and circuit components can withstand, and the current change is relatively stable without drastic fluctuations, then the circuit can be judged to be in normal discharge. When the real-time pulse current exceeds the current threshold, but the rate of change of the current is less than the lower limit of the current fluctuation threshold, it indicates that the current in the circuit has exceeded the normal range, but the current change is relatively stable, which may be due to an increase in load or changes in circuit component parameters. In this case, the first identification result is overload discharge. When the real-time pulse current exceeds the current threshold and the rate of change of the current also exceeds the upper limit of the current fluctuation threshold, it indicates that a short circuit fault may have occurred in the circuit, and the first identification result is short circuit discharge.

[0120] S106. The first identification result is corrected based on the relationship between the real-time voltage and voltage change rate and the voltage threshold and voltage fluctuation threshold to obtain the real-time discharge state of the discharge circuit.

[0121] Specifically, while current information can reflect some of the circuit's operating states, relying solely on current for judgment may have limitations. By combining current with voltage information for analysis, the actual discharge state of the circuit can be identified more accurately, reducing the possibility of misjudgment. In practical applications, circuits may be affected by various interference factors, leading to errors in current detection. Voltage detection can serve as an auxiliary means to verify and supplement the current detection results. When the voltage result is inconsistent with the initial identification result based on current, further analysis and judgment are required to avoid incorrect decisions due to errors in a single detection indicator. This improves the stability and reliability of the entire circuit status monitoring system, ensuring accurate identification of the circuit's discharge state under various complex conditions, enabling timely implementation of appropriate protective measures, and guaranteeing the safe operation of circuits and equipment.

[0122] Furthermore, correcting the first identification result based on the relationship between real-time voltage and voltage change rate with voltage threshold and voltage fluctuation threshold may include:

[0123] (1) When the real-time voltage is less than or equal to the voltage threshold and the voltage change rate is less than or equal to the voltage fluctuation threshold, the judgment result is determined to be normal discharge;

[0124] Specifically, when the voltage detected in real time does not exceed the preset voltage threshold and the voltage change rate is within the normal voltage fluctuation threshold range, it indicates that the voltage magnitude and change in the circuit are in normal discharge mode.

[0125] (2) When the real-time voltage is less than the voltage threshold and the voltage change rate is greater than the voltage fluctuation threshold, the judgment result is determined to be overload discharge;

[0126] Specifically, if the real-time voltage is lower than the voltage threshold, but the rate of change of voltage is greater than the voltage fluctuation threshold, it means that although the voltage has not reached an abnormally high level, the rate of change is relatively fast. In some circuits, when the load increases and causes an overload, the power supply will increase the current to maintain the operation of the load, which may cause a rapid change in voltage (increased rate of change of voltage), while the voltage may drop (below the voltage threshold). For example, when a motor is overloaded, the motor current increases, and the power supply voltage may decrease and the rate of change of voltage may increase, which can be identified as overload discharge.

[0127] (3) When the real-time voltage is greater than the voltage threshold and the voltage change rate is greater than the voltage fluctuation threshold, the judgment result is determined to be short-circuit discharge;

[0128] Specifically, when the real-time voltage exceeds the voltage threshold and the rate of change of voltage also exceeds the voltage fluctuation threshold, it indicates that a short circuit fault may have occurred in the circuit. During a short circuit, the circuit resistance decreases sharply, the current increases rapidly, leading to an abnormal voltage rise (exceeding the voltage threshold) and very drastic changes (the rate of change of voltage exceeds the voltage fluctuation threshold). For example, at the instant a short circuit occurs, the voltage across the power supply may rise instantaneously with a large rate of change of voltage, which can be identified as a short circuit discharge.

[0129] (4) Compare the judgment result with the first identification result. If the judgment result is the same as the first identification result, the first identification result shall be taken as the final identification result.

[0130] (5) If the judgment result is different from the first identification result, the judgment result shall be taken as the final identification result.

[0131] Specifically, the judgment result based on voltage and voltage change rate is compared with the first identification result previously obtained based on current and current change rate. If the two are the same, it means that the judgment from both the current and voltage perspectives is consistent, and the judgment based on the first identification result has high reliability. Therefore, the first identification result is determined as the final identification result. For example, if the circuit is judged to be in a normal discharge state by current and current change rate, and the circuit is also judged to be in a normal discharge state by voltage and voltage change rate, then the circuit is finally determined to be in a normal discharge state.

[0132] Furthermore, if the judgment result based on voltage and voltage change rate is inconsistent with the first identification result based on current and current change rate, considering the relationship between voltage and current in the circuit, the voltage result may provide more accurate information. Therefore, the judgment result based on voltage is taken as the final identification result. For example, if the current-based judgment indicates normal discharge, but the voltage-based judgment indicates short-circuit discharge, the voltage judgment result is taken as the final result because a short-circuit fault may affect the accuracy of current detection, while voltage change can more intuitively reflect the circuit state.

[0133] S107. Match the corresponding discharge control strategy according to the real-time discharge status.

[0134] Specifically, the matching discharge control strategy may include:

[0135] (1) Determine the urgency of the corresponding discharge anomaly based on the real-time discharge status.

[0136] Specifically, based on the real-time discharge status, the urgency of the discharge anomaly is determined as primary urgency, intermediate urgency, and advanced urgency. Normal discharge corresponds to primary urgency, overload discharge corresponds to intermediate urgency, and short-circuit discharge corresponds to advanced urgency.

[0137] (2) Determine the start time and magnitude of voltage reduction based on the urgency of the discharge anomaly, wherein the more urgent the discharge anomaly, the closer the start time of voltage reduction, and the greater the magnitude of voltage reduction.

[0138] Specifically, it can be understood that a higher discharge urgency level indicates a more urgent abnormality in the discharge circuit. When the discharge circuit is at the primary urgency level corresponding to normal discharge, voltage reduction is generally unnecessary. This is because the circuit is operating normally at this time, and voltage reduction might affect the normal operation of the equipment. However, continuous monitoring of the discharge status is required. Once an abnormal trend is detected, the urgency level should be reassessed and the strategy adjusted promptly. For example, if a gradual increase in current or voltage is observed, even if it is still within the normal range, it may indicate an impending overload, requiring advance preparation.

[0139] Optionally, the discharge state of the discharge circuit is monitored in real time. When the discharge state exceeds the normal discharge but does not reach the overload discharge, the number of times the discharge state occurs is calculated. When the number exceeds a preset number, the voltage of the discharge circuit is reduced. It should be noted that the preset number is set based on the historical abnormal data and actual operating conditions of the discharge circuit. In this embodiment, it is not limited.

[0140] Furthermore, when the discharge state is overload discharge, the degree of overload is calculated based on the real-time current and real-time voltage, and the voltage drop level and voltage drop time are determined based on the degree of overload.

[0141] Furthermore, for medium-level emergency situations corresponding to overload discharge, the start time for voltage reduction can be slightly delayed compared to high-level emergency situations, but it should still be initiated within a short time, generally within a few seconds. This is because although the severity of overload discharge is lower than that of short-circuit discharge, prolonged overload can still damage equipment. Regarding the voltage reduction level, it doesn't need to be as drastic as for short-circuit discharge, but it still needs to be adjusted appropriately according to the degree of overload. For example, if the overload is minor, reducing the voltage by 10%-20% may effectively alleviate the overload; if the overload is severe, it may be necessary to reduce the voltage by 20%-50% to ensure the current returns to a safe range.

[0142] Furthermore, for high-emergency situations corresponding to short-circuit discharge, the voltage reduction operation must be initiated as quickly as possible. The start time of the voltage reduction should be as close as possible to the moment the anomaly is detected, ideally within milliseconds or even less. Simultaneously, to quickly suppress excessive short-circuit current, the voltage reduction magnitude must be sufficiently large. For example, if the normal operating voltage is 220V, in a short-circuit situation, it may be necessary to rapidly reduce the voltage to tens of volts or even lower to effectively interrupt the short-circuit current and prevent further damage to the equipment.

[0143] The sub-microsecond-level abnormal arc control method provided in this embodiment utilizes Rogowski coils and Hall voltage sensors to acquire real-time pulse current and voltage in the discharge circuit. This allows for rapid detection of subtle changes in circuit parameters, providing reliable data support for subsequent accurate judgment. Furthermore, by determining current thresholds, current fluctuation thresholds, voltage thresholds, and voltage fluctuation thresholds under different discharge states, and comprehensively comparing the relationships between real-time pulse current, current change rate, real-time voltage, and voltage change rate with these thresholds, different states such as normal discharge, overload discharge, and short-circuit discharge can be accurately identified. By combining multi-parameter and multi-threshold judgment methods, false positives and false negatives are reduced, significantly improving accuracy compared to traditional methods relying solely on a single parameter or human experience. When matching the corresponding discharge control strategy to the real-time discharge state, it can react at extremely fast speeds. For advanced urgency levels corresponding to short-circuit discharge, it can initiate voltage reduction operations in milliseconds or even less, far faster than traditional arc control methods. By rapidly adjusting the voltage, excessive short-circuit current is quickly suppressed, effectively preventing severe damage to equipment due to excessive short-circuit current in a short time, thus improving equipment safety and stability.

[0144] Corresponding to the aforementioned embodiment of an abnormal arc control method at the sub-microsecond speed level, this application also provides an embodiment of an abnormal arc control device at the sub-microsecond speed level.

[0145] Figure 2 This is a schematic diagram of the structure of an embodiment of the sub-microsecond speed-level abnormal arc control device provided in this application. Please refer to... Figure 2 The device provided in this embodiment includes a detection module 210, a calculation module 220, and a control module 230;

[0146] The detection module 210 is used to detect the real-time pulse current in the discharge circuit using a Rogowski coil and to detect the real-time voltage in the discharge circuit using a Hall voltage sensor.

[0147] The calculation module 220 is used to calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage.

[0148] The calculation module 220 is also used to determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states;

[0149] The calculation module 220 is also used to calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and each of the current fluctuation thresholds according to the circuit structure of the discharge circuit.

[0150] The control module 230 is used to obtain the first identification result of the discharge state based on the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold.

[0151] The control module 230 is further configured to correct the first identification result based on the relationship between the real-time voltage and the voltage change rate and the voltage threshold and the voltage fluctuation threshold, so as to obtain the real-time discharge state of the discharge circuit.

[0152] The control module 230 is also used to match a corresponding discharge control strategy according to the real-time discharge state.

[0153] The apparatus of this embodiment can be used to perform... Figure 1 The steps of the method embodiment shown are similar in principle and process, and will not be repeated here.

[0154] The specific implementation process of the functions and roles of each unit in the above device can be found in the implementation process of the corresponding steps in the above method, and will not be repeated here.

[0155] For the device embodiments, since they basically correspond to the method embodiments, the relevant parts can be referred to in the description of the method embodiments. The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this application according to actual needs. Those skilled in the art can understand and implement this without creative effort.

[0156] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for controlling abnormal electric arcs at sub-microsecond speeds, characterized in that, The method includes: The real-time pulse current in the discharge circuit is detected in real time using a Rogowski coil, and the real-time voltage in the discharge circuit is detected in real time using a Hall voltage sensor. Calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage; Determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states; Calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and current fluctuation thresholds based on the circuit structure of the discharge circuit. The first identification result of the discharge state is obtained by the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold. The first identification result is corrected by the relationship between the real-time voltage and voltage change rate and the voltage threshold and voltage fluctuation threshold, so as to obtain the real-time discharge state of the discharge circuit. The corresponding discharge control strategy is matched based on the real-time discharge status.

2. The method according to claim 1, characterized in that, The method of using a Rogowski coil to detect the real-time pulse current in the discharge circuit includes: Select the line to be tested in the discharge circuit and pass the line to be tested through the Rogowski coil; The detection pulse voltage signal is generated in the Rogowski coil based on the induced electromotive force generated by the current flowing through the circuit to be detected. The pulse voltage signal is input to a differential amplifier, which amplifies the pulse voltage signal and outputs the amplified pulse voltage signal. The amplified pulse voltage signal is input to a low-pass filter, which smooths the amplified pulse voltage signal and outputs a smoothed pulse voltage signal. The smoothed pulse voltage signal is converted into a digital current signal using an analog-to-digital converter.

3. The method according to claim 1, characterized in that, The step of calculating the rate of change of current based on the real-time pulse current includes: Calculate the time difference based on the preset sampling points; Calculate the current difference between the pulse currents of adjacent sampling points; The rate of change of current is calculated based on the ratio of the current difference to the time difference.

4. The method according to claim 1, characterized in that, The step of calculating the voltage change rate based on the real-time voltage includes: Calculate the time difference based on the preset sampling points; Calculate the voltage difference of the pulse current between adjacent sampling points; The voltage change rate is calculated based on the ratio of the voltage difference to the time difference.

5. The method according to claim 1, characterized in that, The determination of multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states includes: Determine the current relationship at each location point in the discharge circuit; Determine the operating current that each device in the discharge circuit can withstand under different operating states; The minimum operating current that each device can withstand under each operating state is taken as the reference current for the corresponding operating state. Based on the reference current, the location point corresponding to the reference current, and the current relationship, the current value of the reference current at the real-time pulse current detection location under each working state is calculated, and used as the current threshold corresponding to each working state. Based on the changing trend of discharge current under various operating states in the discharge circuit, multiple initial sampling points are determined for each operating state. Starting from the initial sampling points, the current fluctuation rate under different discharge intervals is sampled and calculated as the current fluctuation threshold.

6. The method according to claim 1, characterized in that, The real-time discharge state is used to describe the operating state of the discharge circuit, and the matching of the corresponding discharge control strategy based on the real-time discharge state includes: The urgency level of the corresponding discharge anomaly is determined based on the real-time discharge status. The start time and magnitude of voltage reduction are determined based on the urgency of the discharge anomaly, wherein the more urgent the discharge anomaly, the closer the start time of voltage reduction, and the greater the magnitude of voltage reduction.

7. The method according to claim 1, characterized in that, The step of calculating the voltage threshold and voltage fluctuation threshold corresponding to each current threshold and each current fluctuation threshold based on the circuit structure of the discharge circuit includes: Calculate the current-voltage relationship at the real-time pulse current detection location in the circuit structure; The voltage threshold is calculated based on the current-voltage relationship and the current threshold. The voltage fluctuation threshold is calculated based on the current-voltage relationship and the current fluctuation threshold.

8. The method according to claim 1, characterized in that, The discharge states include normal discharge, overload discharge, and short-circuit discharge. The first discharge state identification result is obtained by relating the real-time pulse current and current change rate to the current threshold and current fluctuation threshold; including: Compare the real-time pulse current with the current threshold, and the current change rate with the current fluctuation threshold; When the real-time pulse current is less than or equal to the current threshold and the current change rate is between the upper and lower limits of the current fluctuation threshold, the first identification result is determined to be normal discharge. When the real-time pulse current is greater than the current threshold and the current change rate is less than the lower limit of the current fluctuation threshold, the first identification result is determined to be an overload discharge. When the real-time pulse current is greater than the current threshold and the current change rate is greater than the upper limit of the current fluctuation threshold, the first identification result is determined to be a short-circuit discharge.

9. The method according to claim 1, characterized in that, The discharge states include normal discharge, overload discharge, and short-circuit discharge. The step of correcting the first identification result based on the relationship between the real-time voltage and voltage change rate and the voltage threshold and voltage fluctuation threshold includes: When the real-time voltage is less than or equal to the voltage threshold and the voltage change rate is less than or equal to the voltage fluctuation threshold, the judgment result is determined to be normal discharge; When the real-time voltage is less than the voltage threshold and the voltage change rate is greater than the voltage fluctuation threshold, the judgment result is determined to be overload discharge; When the real-time voltage is greater than the voltage threshold and the voltage change rate is greater than the voltage fluctuation threshold, the judgment result is determined to be short-circuit discharge; Compare the judgment result with the first identification result. If the judgment result is the same as the first identification result, the first identification result shall be taken as the final identification result. If the judgment result is different from the first identification result, the judgment result shall be taken as the final identification result.

10. A sub-microsecond speed-level abnormal arc control device, characterized in that, The device includes a detection module, a calculation module, and a control module; wherein, The detection module is used to detect the real-time pulse current in the discharge circuit using a Rogowski coil and to detect the real-time voltage in the discharge circuit using a Hall voltage sensor. The calculation module is used to calculate the rate of change of current and the rate of change of voltage based on the real-time pulse current and the real-time voltage. The calculation module is also used to determine multiple current thresholds and multiple current fluctuation thresholds corresponding to different discharge states; The calculation module is also used to calculate the voltage threshold and voltage fluctuation threshold corresponding to each of the current thresholds and each of the current fluctuation thresholds according to the circuit structure of the discharge circuit. The control module is used to obtain the first identification result of the discharge state based on the relationship between the real-time pulse current and the rate of change of current and the current threshold and the current fluctuation threshold. The control module is also used to correct the first identification result based on the relationship between the real-time voltage and the voltage change rate and the voltage threshold and the voltage fluctuation threshold, so as to obtain the real-time discharge state of the discharge circuit. The control module is also used to match a corresponding discharge control strategy based on the real-time discharge state.

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