High-voltage capacitor safety discharge device and method

Abstract

This invention discloses a high-voltage capacitor safety discharge device and method, relating to the field of safety discharge technology. The device includes a discharge box, a resistor box, and a control box. The top of the discharge box is equipped with a test electrode for connection to the component to be discharged. Inside the discharge box are at least two robotic arm modules and a voltage divider for monitoring the voltage of the component to be discharged. A conductive electrode is located at the end of each robotic arm module facing the test electrode. The resistor box contains at least two sets of discharge resistors with different resistance values ​​and a temperature sensor. The input terminal of each discharge resistor is connected to a corresponding conductive electrode, and the output terminals of each discharge resistor are connected in series with a current sensor and then grounded. The control box is configured to control at least one robotic arm module to move towards or away from the test electrode based on signals output from the voltage divider, current sensor, and temperature sensor, thereby controlling at least one conductive electrode to contact or disconnect from the test electrode. This invention can improve safety during the discharge process.

Description

Technical Field

[0001] This application relates to the field of safe discharge technology, specifically to a high-voltage capacitor safe discharge device and method. Background Technology

[0002] After a DC withstand voltage test is completed, large capacitor equipment needs to be discharged. Current technology typically involves a technician manually discharging the test sample using a discharge rod after the test. This discharge process usually relies on the technician's experience. For samples with particularly large capacitance, a segmented discharge method is required. First, resistive discharge is performed using the discharge rod's built-in resistor. To ensure that the discharge process doesn't generate excessively large arcs or cause the discharge rod to explode due to excessively violent discharge in a short period, the operator needs extensive experience. After a period of time, direct grounding discharge is performed via a grounding wire. When using a discharge rod to discharge equipment, the entire process lacks sufficient monitoring indicators, heavily relies on the operator's experience, and carries inherent risks. Summary of the Invention

[0003] This application provides a high-voltage capacitor safety discharge device and method, which can solve the technical problem of low safety during the discharge process of large capacitor equipment in the prior art.

[0004] In a first aspect, embodiments of this application provide a high-voltage capacitor safety discharge device for discharging a component having a high-voltage capacitor, the high-voltage capacitor safety discharge device comprising: A discharge chamber, the top of which is provided with a test electrode for connecting to the device to be discharged, and the discharge chamber is provided with at least two robotic arm modules and a voltage divider for monitoring the voltage of the device to be discharged, and the end of the robotic arm module facing the test electrode is provided with a conductive electrode; A resistance box is provided, which contains at least two sets of discharge resistors with different resistance values ​​and a temperature sensor for monitoring the internal temperature of the resistance box. The input terminal of each discharge resistor is connected to a conductive electrode, and the output terminals of each discharge resistor are connected in series with a current sensor and then grounded. A control box is configured to control at least one robotic arm module to move toward or away from the test electrode according to the signals output by the voltage divider, current sensor and temperature sensor, so as to control at least one conductive electrode to contact or disconnect from the test electrode.

[0005] In conjunction with the first aspect, in one embodiment, the robotic arm module includes: A lifting mechanism located inside the discharge box has an insulating rod extending out of the discharge box at one end, and the extended end of the insulating rod is connected to the conductive electrode through an elastic connector. The lifting mechanism is electrically connected to the control box to receive control signals from the control box. In response to the control signals, the lifting mechanism moves toward the test electrode and, under the elastic force of the elastic connector, makes the conductive electrode reliably contact the test electrode.

[0006] In conjunction with the first aspect, in one embodiment, the end of the insulating rod facing the lifting mechanism is provided with a position detection element for outputting a position signal to the control box. The position detection element is triggered to output a position signal when the conductive electrode and the test electrode reach a reliable contact state.

[0007] In conjunction with the first aspect, in one embodiment, the control box includes: The signal input interface includes a first connector for connecting the voltage divider and a second connector for connecting the current sensor and the temperature sensor. A communication module is provided, which is connected to each of the robotic arm modules and the temperature sensor via a communication interface. The main control module is connected to the first and second aviation connectors respectively through signal processing and protection circuits; The display module is connected to the signal processing and protection circuit and is used to display voltage, current, temperature and discharge status information.

[0008] In conjunction with the first aspect, in one embodiment, the input terminal of the voltage divider is connected to the test electrode via a conductive rod extending from the discharge box, and the conductive rod extending from the outer surface of the discharge box is covered with an insulating rod; the output terminal of the voltage divider is connected to the control box via the first connector.

[0009] Secondly, embodiments of this application provide a high-voltage capacitor safe discharge method, used by the high-voltage capacitor safe discharge device described in any of the above embodiments to discharge a component having a high-voltage capacitor, the high-voltage capacitor safe discharge method comprising: Based on the capacitance and initial voltage of the device to be discharged, determine the first discharge resistor, the second discharge resistor, the first voltage threshold, and the second voltage threshold. Discharge is performed using the first discharge resistor. It is determined whether the current discharge state meets the preset protection conditions. If it does, the discharge is interrupted and the discharge is restarted after waiting. If it does not meet the conditions, the discharge continues until the discharge time reaches the first discharge time and the voltage of the device to be discharged drops below the first voltage threshold. Discharge is performed using a second discharge resistor. It is determined whether the current discharge state meets the preset protection conditions. If it does, the discharge is interrupted and the discharge is restarted after waiting. If it does not meet the conditions, the discharge continues until the discharge time reaches the second discharge time and the voltage of the device to be discharged drops below the second voltage threshold. The discharge is then complete. Wherein, the first discharge resistor is greater than the second discharge resistor.

[0010] In conjunction with the second aspect, in one embodiment, determining the first discharge resistor, the second discharge resistor, the first voltage threshold, and the second voltage threshold based on the capacitance and initial voltage of the device to be discharged includes: Based on the capacitance and initial voltage of the device to be discharged, the first discharge resistor and the second discharge resistor are determined from multiple preset candidate resistor combinations. Based on the first discharge resistor, the first voltage threshold is calculated as follows:

[0011] in, Indicates the first voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the first discharge time. Represents the first time constant. , Indicates the first discharge resistor. Indicates capacitance; Based on the second discharge resistor, the second voltage threshold is calculated as follows:

[0012] in, Indicates the second voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the second discharge time. Indicates the second time constant. , Indicates the second discharge resistor. Indicates electrical capacity.

[0013] In conjunction with the second aspect, in one embodiment, the preset protection conditions include overcurrent protection conditions and overheat protection conditions. The overcurrent protection condition is that the discharge current exceeds a preset current threshold and the duration exceeds a preset time range. The overheat protection condition is that the temperature of the discharge resistor exceeds a preset temperature threshold. When either preset protection condition is met, the discharge is interrupted and the discharge is restarted after waiting.

[0014] In conjunction with the second aspect, in one implementation, the preset current threshold is a preset multiple of the maximum discharge current in the current discharge state, wherein the calculation of the maximum discharge current is specifically as follows:

[0015] in, Indicates the maximum discharge current. Indicates the current voltage. This indicates the current discharge resistance.

[0016] In conjunction with the second aspect, in one implementation, the method of restarting the discharge after waiting includes: Conditions for determining whether an interrupt discharge is triggered: If the condition for triggering the discharge interruption is that the overcurrent protection condition is met, then wait until the discharge current drops below the preset current threshold before restarting the discharge. If the condition for triggering the discharge interruption is that the overheat protection condition is met, then wait until the temperature of the discharge resistor drops below the preset temperature threshold before restarting the discharge.

[0017] The beneficial effects of the technical solutions provided in this application include: This embodiment of the application uses a control box to automatically control the movement of the robotic arm module based on sensor signals to complete the connection and disconnection of the discharge circuit. Operators do not need to approach the high-voltage discharge point, fundamentally avoiding the risk of personal injury. This embodiment of the application sets multiple sets of combinable discharge resistors in the resistor box, and controls different robotic arm modules to connect to the first and second discharge resistors respectively through the control box. This achieves a staged discharge strategy of first high resistance and then low resistance. This allows for pre-calculation and selection of matching resistors based on the sample capacitance and voltage, thereby actively limiting the initial discharge power and current, effectively suppressing the arc size, and avoiding the risk of equipment damage or explosion due to instantaneous energy release. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the high-voltage capacitor safety discharge device provided in the embodiments of this application; Figure 2 A schematic diagram of the control box provided in an embodiment of this application; Figure 3 A schematic diagram of a resistor box provided in an embodiment of this application; Figure 4 A schematic diagram of a voltage divider provided in an embodiment of this application; Figure 5 This is a schematic flowchart of a high-voltage capacitor safe discharge method provided in an embodiment of this application.

[0019] In the diagram: 1. Component to be discharged; 2. Discharge box; 211. Lifting mechanism; 212. Insulating rod; 22. Voltage divider; 23. Conductive electrode; 3. Resistance box; 31. Discharge resistor; 32. Temperature sensor; 33. Current sensor; 4. Control box; 41. First connector; 42. Second connector; 43. Communication module; 44. Varistor; 45. Magnetic ring; 46. EMI filter; 47. OP07 operational amplifier; 48. Analog-to-digital converter; 49. Control CPU; 410. High voltage indicator; 411. Discharge current indicator; 412. LCD display; 413. Position feedback detection module; 5. Test electrode; 6. Conductive rod; 7. Insulating rod; 8. DC withstand voltage power supply. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0021] This application provides a high-voltage capacitor safety discharge device and method, which can solve the technical problem of low safety during the discharge process of large capacitor equipment in the prior art.

[0022] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0023] In a first aspect, embodiments of this application provide a high-voltage capacitor safety discharge device.

[0024] In one embodiment, reference is made to Figure 1 , Figure 1 This is a schematic diagram of the structure of the high-voltage capacitor safety discharge device provided in an embodiment of this application. Figure 1 As shown, the high-voltage capacitor safety discharge device includes: The discharge box 2 has a test electrode 5 on its top for connection with the component 1 to be discharged. Inside the discharge box 2 are at least two robotic arm modules and a voltage divider 22 for monitoring the voltage of the component 1. A conductive electrode 23 is provided at the end of each robotic arm module facing the test electrode 5. A resistance box 3 has at least two sets of discharge resistors 31 with different resistance values ​​and a temperature sensor 32 for monitoring the internal temperature of the resistance box 3. The input terminal of each discharge resistor 31 is connected to a conductive electrode 23, and the output terminals of each discharge resistor 31 are connected in series with a current sensor 33 and then grounded. A control box 4 is configured to control at least one robotic arm module to move towards or away from the test electrode 5 according to the signals output by the voltage divider 22, the current sensor 33, and the temperature sensor 32, so as to control at least one conductive electrode 23 to contact or disconnect from the test electrode 5.

[0025] Specifically, the test electrode 5 is composed of a copper busbar with a thickness of not less than 5mm, a width of not less than 50mm, and a length of not less than 490mm, ensuring a reliable electrical connection with the device to be discharged 1 and meeting the current-carrying requirements of high-current discharge. The test electrode 5 is fixed to the discharge chamber 2 via two sets of PP material insulating supports. The insulating supports are 40cm high and 35mm in diameter. The top panel of the discharge chamber 2 is an epoxy resin insulating panel to achieve high-voltage isolation between the test electrode 5 and the discharge chamber 2, avoiding the risk of leakage.

[0026] Figure 3 This is a schematic diagram of the resistor box 3 provided in an embodiment of this application. See also... Figure 3 The resistor box 3 contains at least two sets of discharge resistors 31 with different resistance values. Each set is formed by combining multiple high-voltage, high-power resistors in series and parallel. In a specific embodiment, four basic resistors can be set, with resistance values ​​of 10MΩ, 10MΩ, 5MΩ, and 1MΩ, respectively. Each basic resistor has a withstand voltage of not less than 60kV and a rated power of not less than 500W. By combining them in series and parallel, they can adapt to the discharge requirements of components 1 with different capacitances. A temperature sensor 32 is installed inside the resistor box 3 to monitor the temperature changes of the box and resistors in real time. It is connected to the control box 4 via an RS485 communication interface to provide a basis for overheat protection. A current sensor 33 is a Hall sensor, connected in series between the output terminal of the discharge resistor 31 and the ground terminal. It is used to collect the current signal in the discharge circuit in real time and transmit the signal to the control box 4 to provide a basis for overcurrent protection and discharge status judgment.

[0027] In this embodiment, the robotic arm module includes a lifting mechanism 211 located inside the discharge box 2. One end of the lifting mechanism 211 is provided with an insulating rod 212 extending out of the discharge box 2. The extended end of the insulating rod 212 is connected to the conductive electrode 23 through an elastic connector. The lifting mechanism 211 is electrically connected to the control box 4 to receive control signals from the control box 4. In response to the control signals, the lifting mechanism 211 moves toward the test electrode 5 and, under the elastic force of the elastic connector, makes the conductive electrode 23 reliably contact the test electrode 5.

[0028] Specifically, the lifting mechanism 211, as the power source and transmission component of the robotic arm module, is usually composed of a motor, a reducer, and a mechanism that converts rotary motion into linear motion. The lifting mechanism 211 can output linear thrust or pull along the vertical direction.

[0029] The insulating rod 212, serving as both a support and insulation component for the robotic arm module, is integrally molded from PP material. The diameter of the insulating rod 212 is no less than 25mm, and its length is no less than 500mm, ensuring reliable insulation performance under high-voltage conditions and preventing leakage risks during discharge. One end of the insulating rod 212 is connected to the linear motion output end of the lifting mechanism 211, while the other end (the protruding end of the insulating rod 212) passes through the insulating panel on the top of the discharge box 2 and extends into the high-voltage area, thereby achieving electrical isolation and ensuring sufficient insulation strength between the conductive electrode 23 on the high-voltage side and the discharge box 2.

[0030] The elastic connector can be a compression spring, which connects the extended end of the insulating rod 212 to the conductive electrode 23. The conductive electrode 23 uses a columnar or spherical contact made of copper or copper alloy, possessing good conductivity and current-carrying capacity to meet the current transmission requirements during the discharge of large capacitor equipment. The lifting mechanism 211 drives the insulating rod 212 to move vertically up and down, and the insulating rod 212 drives the conductive electrode 23 to move together through the elastic connector. When the conductive electrode 23 makes physical contact with the test electrode 5, the lifting mechanism 211 continues to push the insulating rod 212 upward, and the elastic connector generates a reverse contact pressure. This contact pressure ensures that even if there are microscopic unevenness or slight dirt between the surfaces of the conductive electrode 23 and the test electrode 5, a tight metallic contact can be maintained, and the discharge current flows from the test electrode 5 through this contact point to the conductive electrode 23.

[0031] Furthermore, the end of the insulating rod 212 facing the lifting mechanism 211 is provided with a position detection element for outputting a position signal to the control box 4. The position detection element is triggered to output a position signal when the conductive electrode 23 and the test electrode 5 reach a reliable contact state.

[0032] Specifically, the position detection element can be a limit switch, a device that triggers the closing or opening of its internal electrical contacts through physical displacement. When the control box 4 commands the lifting mechanism 211 to operate, and the motor drives the insulating rod 212 to lift upward, the triggering component fixed on the insulating rod 212 is driven to move upward synchronously. When the conductive electrode 23 and the test electrode 5 reach a reliable contact state, the contact state inside the position detection element switches, generating a positioning signal. The control box 4 determines that the robotic arm module has been lifted into position based on the positioning signal.

[0033] Figure 2 A schematic diagram of the control box 4 provided in an embodiment of this application. See also... Figure 2 In this embodiment, the control box 4 includes: a signal input interface, which includes a first connector 41 for connecting the voltage divider 22 and a second connector 42 for connecting the current sensor 33 and the temperature sensor 32; a communication module 43, which is connected to each robotic arm module and the temperature sensor 32 respectively through the communication interface; a main control module, which is connected to the first connector 41 and the second connector 42 respectively through the signal processing and protection circuit; and a display module, which is connected to the signal processing and protection circuit and is used to display voltage, current, temperature and discharge status information.

[0034] Specifically, the first connector 41 is dedicated to connecting the high-voltage divider 22 inside the discharge box 2. Its interface specifications are matched with the low-voltage arm output cable of the divider 22, transmitting the residual voltage signal of the device to be discharged 1 collected by the divider 22 to the control box 4, providing voltage signals for the discharge stage and voltage threshold monitoring. The second connector 42 is a multi-functional signal input interface, connecting the current sensor 33 and the temperature sensor 32 inside the resistor box 3, respectively.

[0035] The communication module 43 is an RS485 communication interface, which is connected to each robotic arm module and the temperature sensor 32 via shielded cables. The communication module 43 sends lifting and reset control signals to the robotic arm module to realize the on / off control of the discharge circuit. At the same time, the communication module 43 receives the position signal of the robotic arm module to confirm the contact status between the conductive electrode 23 and the test electrode 5, and also receives the real-time temperature signal from the temperature sensor 32 to provide a temperature signal for overheat protection.

[0036] The signal processing and protection circuit receives voltage signals from voltage divider 22 in discharge box 2, current sensor 33 from resistor box 3, and temperature sensor 32. The signal processing and protection circuit includes: a varistor 44 connected in parallel to the signal input terminals of the first connector 41 and the second connector 42; when an abnormal overvoltage occurs in the input signal, its resistance drops rapidly, keeping the signal voltage within a safe range; a magnetic ring 45 and an EMI filter 46 connected in series; the magnetic ring 45 improves signal transmission stability by absorbing electromagnetic interference signals, and the EMI filter 46 further filters out common-mode and differential-mode interference in the signal, ensuring the purity of the input signal and avoiding control misjudgments caused by interference; an OP07 operational amplifier 47, used to receive the signal after anti-interference processing, buffer and adjust the signal amplitude to match it to the optimal input range of the back-end analog-to-digital converter 48 (ADC); and the ADC 48, connected to the output of the OP07 operational amplifier 47, used to convert the buffered signal into a digital signal and transmit it to the main control module for processing.

[0037] The main control module includes a control CPU 49, which continuously reads the digital value after ADC conversion to obtain the real-time values ​​of residual voltage and discharge current. At the same time, it obtains the temperature and position status of the robotic arm module through the position feedback detection module 413. Based on the parameters obtained above and the preset high-voltage capacitor safe discharge method, control commands are generated.

[0038] The display module includes a high-voltage indicator 410 and a discharge current indicator 411, both of which are directly connected in parallel to their respective measurement channels to provide operators with real-time voltage and current readings. The display module also includes an LCD display screen 412 connected to the control CPU 49, used to receive digital information output by the control CPU. In addition to displaying precise values ​​of voltage, current, and temperature, it can also display information such as discharge stage, protection status, and remaining discharge time, achieving multi-dimensional status feedback.

[0039] In this embodiment, the input end of the voltage divider 22 is connected to the test electrode 5 via a conductive rod 6 extending out of the discharge box 2, and the conductive rod 6 is covered with an insulating rod 7 on the outer surface of the discharge box 2. The output end of the voltage divider 22 is connected to the control box 4 via a first connector 41.

[0040] Figure 4 A schematic diagram of the voltage divider 22 provided in an embodiment of this application. See also... Figure 1 and Figure 4Specifically, the conductive rod 6 can be a copper rod, passing through the central hole of the insulating rod 7. Its top end is electrically connected to the test electrode 5 on the top of the discharge box 2. Therefore, all the voltage applied to the test electrode 5 is led to the high-voltage input terminal of the voltage divider 22 through the conductive rod 6. The voltage divider 22 is a purely resistive voltage divider. In one specific embodiment, the rated voltage of the voltage divider is DC 60kV. The high-voltage arm consists of four high-precision 30kV high-voltage resistors (R1, R2, R3, R4), each with a rated voltage of 30kV, an accuracy of 0.1%, and a power of 10W. The total resistance of the high-voltage arm is 200MΩ, the total rated power is not less than 40W, and the withstand voltage is not less than 120kV. The low-voltage arm resistor (R5) of the voltage divider is 16.7kΩ with an accuracy of 0.1%. A varistor (R6) and a gas discharge tube (R7) are connected in parallel on the low-voltage arm. The varistor has an operating voltage of 10V, and the gas discharge tube has an operating voltage of 50V. The rated transformation ratio of the voltage divider is 11976, and the output range of the low-voltage arm is controlled within the DC 0~5V range. The high-voltage arm uses a configuration of four resistors connected in series, which makes the total rated withstand voltage higher than the operating voltage, improving the breakdown capability of the voltage divider in a 60kV DC environment.

[0041] In this embodiment, the control box 4 automatically controls the movement of the robotic arm module based on sensor signals to connect and disconnect the discharge circuit. Operators do not need to approach the high-voltage discharge point, fundamentally avoiding the risk of personal injury. This embodiment also incorporates multiple combinable discharge resistors in the resistor box, and the control box controls different robotic arm modules to connect to the first and second discharge resistors respectively. This achieves a phased discharge strategy of first high resistance and then low resistance. This allows for pre-calculation and selection of matching resistors based on the sample capacitance and voltage, thereby actively limiting the initial discharge power and current, effectively suppressing the arc size, and avoiding the risk of equipment damage or explosion due to instantaneous energy release.

[0042] Secondly, embodiments of this application provide a high-voltage capacitor safe discharge method, used by the high-voltage capacitor safe discharge device described in any of the above embodiments to discharge a component with a high-voltage capacitor.

[0043] In one embodiment, reference is made to Figure 5 , Figure 5 This is a schematic flowchart illustrating the safe discharge method for a high-voltage capacitor provided in an embodiment of this application. Figure 5 As shown, the safe discharge methods for high-voltage capacitors include: Step S1: Determine the first discharge resistor, the second discharge resistor, the first voltage threshold, and the second voltage threshold based on the capacitance and initial voltage of the device to be discharged 1.

[0044] In this embodiment of the application, step S1 specifically includes the following steps: Step S11: Based on the capacitance and initial voltage of the component 1 to be discharged, determine the first discharge resistor and the second discharge resistor from multiple preset candidate resistor combinations.

[0045] Specifically, the user inputs or selects the capacitance and initial voltage of the component to be discharged through the human-machine interface of the control box. The main control module selects from multiple preset candidate resistor combinations based on the capacitance and initial voltage of the component to be discharged 1. The selection principle is to ensure that the maximum discharge power at the start of discharge does not exceed the rated power of the selected resistor, and to comprehensively consider the total discharge time, select a first discharge resistor with a larger resistance value and a second discharge resistor with a smaller resistance value than the first discharge resistor.

[0046] In a specific embodiment, the discharge process of a test sample with a capacitance of 4.5 μF and a withstand voltage test voltage of 44 kV is taken as an example. The total electrostatic energy stored in the test sample under the test voltage is:

[0047] in, Represents the total electrostatic energy. Indicates capacitance, This represents the initial voltage.

[0048] Therefore, the total electrostatic energy is very large. If the 4356 joules of energy were released instantaneously, it would be sufficient to generate a powerful explosive arc, melt metal, and cause serious harm to personnel and equipment. If a 1MΩ resistor is used for discharge, the maximum discharge power at the start of the discharge is:

[0049] in, This indicates the maximum discharge power. This indicates the resistance value.

[0050] Therefore, if a 1M resistor is used for discharge, the maximum discharge power at the start of discharge reaches 1936W. This power exceeds the rated power of the 1M high-voltage high-power resistor built into the resistor box by many times. As a result, the 1M power resistor will heat up severely at the beginning of the discharge, which may cause the resistor to be damaged.

[0051] Therefore, the embodiments of this application adopt a two-stage discharge process. First, a 5M resistor is used for discharge, and then a 1M small resistor is connected for discharge. The overall discharge time is not long, and the discharge power is greatly reduced. The requirements for the resistor and the safety of the test are guaranteed.

[0052] Step S12: Calculate the first voltage threshold based on the first discharge resistor, specifically as follows:

[0053] in, Indicates the first voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the first discharge time. Represents the first time constant. , Indicates the first discharge resistor. This indicates the capacitance. The first voltage threshold means, theoretically, the expected voltage value to be reached after the first discharge time using the first discharge resistor to discharge the device to be discharged. The first voltage threshold is used as the basis for determining whether the first discharge stage can end and safely switch to the second discharge stage.

[0054] In a specific embodiment, based on the RC discharge exponential law, it is generally considered that 5 time constants are sufficient for the capacitor to be fully discharged. The first discharge resistance is 5MΩ, therefore:

[0055] At this time, the maximum discharge power during discharge is:

[0056] Therefore, it can be seen that in the first discharge stage, the discharge power is controlled within 400W, which can ensure the safety and reliability of the entire discharge process.

[0057] Step S13: Calculate the second voltage threshold based on the second discharge resistor. The specific calculation is as follows:

[0058] in, Indicates the second voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the second discharge time. Indicates the second time constant. , Indicates the second discharge resistor. This indicates the capacitance. The first voltage threshold means the extremely low voltage value expected to be reached after two discharge stages, starting from the initial voltage. The first voltage threshold is used as the basis for determining whether the first discharge stage can end and safely switch to the second discharge stage.

[0059] In one specific embodiment, the second discharge resistor is 5MΩ||1MΩ = 833kΩ, therefore:

[0060] At this time, the maximum discharge power during discharge is:

[0061] Therefore, it can be seen that in the second discharge stage, the discharge power is controlled within 400W, which can ensure the safety and reliability of the entire discharge process.

[0062] In one specific embodiment, before the DC withstand voltage test begins, the DC withstand voltage power supply 8, the high-voltage capacitor safety discharge device and the component to be discharged 1 are connected, wherein the test electrode 5 is directly connected to the component to be discharged 1. The capacitance and initial voltage of the component to be discharged 1 are input through the control box 4. The main control module calculates and determines the combination scheme of the two sets of discharge resistors 31, the first voltage threshold, the second voltage threshold and the discharge time of each stage based on the parameters.

[0063] Step S2: Discharge using the first discharge resistor, determine whether the current discharge state meets the preset protection conditions. If it does, interrupt the discharge and wait before restarting the discharge. If it does not meet the conditions, continue discharging until the discharge time reaches the first discharge time and the voltage of the device to be discharged drops below the first voltage threshold.

[0064] Specifically, the main control module of the control box 4 sends a lifting control signal to the robotic arm module connected to the first discharge resistor through the communication module 43. The robotic arm module responds to the signal and drives the insulating rod 212 to move the conductive electrode 23 toward the test electrode 5 until the conductive electrode 23 makes reliable contact with the test electrode 5. The first discharge resistor is then connected to the discharge circuit, and the component to be discharged 1 forms a discharge circuit through the first discharge resistor, thus starting the first stage of discharge.

[0065] The voltage divider 22 in the discharge box 2 collects the real-time residual voltage signal of the component 1 to be discharged. The current sensor 33 in the resistor box 3 collects the real-time current signal of the discharge circuit. The temperature sensor 32 in the resistor box 3 collects the real-time temperature signal of the resistor box 3. After signal processing, the voltage and current signals are transmitted to the ADC sampling module of the control box 4, converted into digital signals and sent to the control CPU 49. The temperature signal is transmitted to the control CPU 49 of the control box 4 through the RS485 communication module 43.

[0066] In this embodiment, the preset protection conditions include overcurrent protection conditions and overheat protection conditions. The overcurrent protection condition is that the discharge current exceeds a preset current threshold and the duration exceeds a preset time range. The overheat protection condition is that the temperature of the discharge resistor 31 exceeds a preset temperature threshold. When either preset protection condition is met, the discharge is interrupted and the discharge is restarted after waiting.

[0067] Specifically, the control CPU 49 compares the real-time acquired digital value of the discharge current with a preset current threshold for the current stage, and compares the real-time acquired temperature value of the temperature sensor 32 with a preset temperature threshold. If either protection condition is met, the discharge is interrupted; if neither is met, the discharge continues.

[0068] In this embodiment, the preset current threshold is a preset multiple of the maximum discharge current in the current discharge state, wherein the calculation of the maximum discharge current is as follows:

[0069] in, Indicates the maximum discharge current. Indicates the current voltage. This indicates the current discharge resistance.

[0070] Specifically, the preset multiplier can be 1.2 times, the preset time range can be 0.5 seconds, and the preset temperature threshold can be 80℃.

[0071] In this embodiment of the application, restarting the discharge after waiting includes: Determine the conditions for triggering discharge interruption: If the condition for triggering discharge interruption is that the overcurrent protection condition is met, wait until the discharge current drops below the preset current threshold and then restart the discharge; if the condition for triggering discharge interruption is that the overheat protection condition is met, wait until the temperature of the discharge resistor drops below the preset temperature threshold and then restart the discharge.

[0072] Specifically, when the control CPU 49 determines that any protection condition is met, it sends an emergency descent command to the robotic arm module via the RS485 communication module 43. Upon receiving the command, the lifting mechanism 211 of the robotic arm module drives the insulating rod 212 to descend, separating the conductive electrode 23 from the test electrode 5 and cutting off the discharge circuit. The control CPU 49 continuously monitors the current and temperature signals until the current drops below a preset current threshold or the temperature drops below a preset temperature threshold, at which point the preset protection condition is eliminated. The control CPU 49 then sends a lifting signal to the robotic arm module again, reconnecting the first discharge resistor and restarting the first stage of discharge.

[0073] The CPU49 continuously monitors the discharge time and the voltage of the device to be discharged 1. When the discharge time reaches the first discharge time and the voltage of the device to be discharged 1 drops below the first voltage threshold, the first discharge stage is completed. This embodiment employs a dual overcurrent and overheat protection mechanism to monitor abnormal states during the discharge process in real time, avoiding safety hazards caused by resistor overload, overheating damage, or arcing. Simultaneously, in case of a fault, the discharge is interrupted and automatically restarted without manual intervention, further improving safety during the discharge process.

[0074] Step S3: Discharge using the second discharge resistor, determine whether the current discharge state meets the preset protection conditions. If it does, interrupt the discharge and wait before restarting the discharge. If it does not meet the conditions, continue discharging until the discharge time reaches the second discharge time and the voltage of the device to be discharged 1 drops below the second voltage threshold, and the discharge is complete.

[0075] Specifically, the main control module of the control box 4 sends a lifting control signal to the robotic arm module connected to the second discharge resistor through the communication module 43. The robotic arm module responds to the signal and drives the insulating rod 212 to move the conductive electrode 23 toward the test electrode 5 until the conductive electrode 23 makes reliable contact with the test electrode 5. The second discharge resistor is then connected to the discharge circuit in parallel with the first stage resistor, and the second stage discharge begins.

[0076] The control CPU 49 continuously monitors the discharge status and performs preset protection condition judgments and abnormal handling. When the discharge time reaches the second discharge time and the voltage of the component to be discharged 1 drops below the second voltage threshold, the second discharge stage is completed. The control CPU 49 sends a reset signal to the two robotic arm modules through the communication module 43, driving them to reset and disconnect the discharge circuit. At the same time, the control CPU 49 sends a discharge completion signal to the display module. The LCD display 412 displays a discharge completion prompt, and the high voltage indicator 410 and the discharge current indicator 411 return to zero, informing the operator that there is no residual high voltage on the component to be discharged 1 and that subsequent grounding or maintenance operations can be performed.

[0077] For any technical features and effects not mentioned in the embodiments of this application, please refer to the previous embodiment and they will not be repeated here.

[0078] Thirdly, embodiments of this application provide a high-voltage capacitor safe discharge device, which can be a device with data processing capabilities such as a personal computer (PC), a laptop computer, or a server.

[0079] In this embodiment, the high-voltage capacitor safe discharge device may include a processor, a memory, a communication interface, and a communication bus. The communication bus can be of any type and is used to interconnect the processor, memory, and communication interface.

[0080] Communication interfaces include input / output (I / O) interfaces, physical interfaces, and logical interfaces used for interconnecting internal components of the high-voltage capacitor safety discharge equipment, as well as interfaces used for interconnecting the high-voltage capacitor safety discharge equipment with other devices (such as other computing devices or user equipment). Physical interfaces can be Ethernet interfaces, fiber optic interfaces, ATM interfaces, etc.; user equipment can be displays, keyboards, etc.

[0081] Memory can be various types of storage media, such as random access memory (RAM), read-only memory (ROM), non-volatile RAM (NVRAM), flash memory, optical storage, hard disk, programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), etc.

[0082] The processor can be a general-purpose processor, which can call the high-voltage capacitor safety discharge program stored in the memory and execute the high-voltage capacitor safety discharge method provided in the embodiments of this application. For example, the general-purpose processor can be a central processing unit (CPU). The method executed when the high-voltage capacitor safety discharge program is called can be referred to in the various embodiments of the high-voltage capacitor safety discharge method of this application, and will not be repeated here.

[0083] Those skilled in the art will understand that the hardware structure shown in Figure m does not constitute a limitation of this application and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0084] Fourthly, embodiments of this application also provide a computer-readable storage medium.

[0085] The present application has a computer-readable storage medium storing a high-voltage capacitor safe discharge program, wherein when the high-voltage capacitor safe discharge program is executed by a processor, it implements the steps of the high-voltage capacitor safe discharge method as described above.

[0086] The method implemented when the high-voltage capacitor safety discharge procedure is executed can be referred to in various embodiments of the high-voltage capacitor safety discharge method of this application, and will not be repeated here.

[0087] It should be noted that the sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0088] The terms "comprising" and "having," and any variations thereof, in the specification, claims, and accompanying drawings of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such process, method, product, or apparatus. The terms "first," "second," and "third," etc., are used to distinguish different objects, etc., and do not indicate a sequence, nor do they limit "first," "second," and "third" to different types.

[0089] In the description of the embodiments of this application, terms such as "exemplary," "for example," or "for instance" are used to indicate examples, illustrations, or explanations. Any embodiment or design described as "exemplary," "for example," or "for instance" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of terms such as "exemplary," "for example," or "for instance" is intended to present the relevant concepts in a concrete manner.

[0090] In the description of the embodiments of this application, unless otherwise stated, " / " means "or". For example, A / B can mean A or B. The "and / or" in the text is merely a description of the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, A and B exist simultaneously, and B exists alone. In addition, in the description of the embodiments of this application, "multiple" means two or more.

[0091] In some processes described in the embodiments of this application, multiple operations or steps are included in a specific order. However, it should be understood that these operations or steps may not be executed in the order they appear in the embodiments of this application, or they may be executed in parallel. The sequence number of the operation is only used to distinguish different operations, and the sequence number itself does not represent any execution order. In addition, these processes may include more or fewer operations, and these operations or steps may be executed sequentially or in parallel, and these operations or steps may be combined.

[0092] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) as described above, and includes several instructions to cause a terminal device to execute the methods described in the various embodiments of this application.

[0093] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A high-voltage capacitor safety discharge device for discharging a component with a high-voltage capacitor, characterized in that, The high-voltage capacitor safety discharge device includes: A discharge chamber, the top of which is provided with a test electrode for connecting to the device to be discharged, and the discharge chamber is provided with at least two robotic arm modules and a voltage divider for monitoring the voltage of the device to be discharged, and the end of the robotic arm module facing the test electrode is provided with a conductive electrode; A resistance box is provided, which contains at least two sets of discharge resistors with different resistance values ​​and a temperature sensor for monitoring the internal temperature of the resistance box. The input terminal of each discharge resistor is connected to a conductive electrode, and the output terminals of each discharge resistor are connected in series with a current sensor and then grounded. A control box is configured to control at least one robotic arm module to move toward or away from the test electrode according to the signals output by the voltage divider, current sensor and temperature sensor, so as to control at least one conductive electrode to contact or disconnect from the test electrode.

2. The high-voltage capacitor safety discharge device according to claim 1, characterized in that, The robotic arm module includes: A lifting mechanism located inside the discharge box has an insulating rod extending out of the discharge box at one end, and the extended end of the insulating rod is connected to the conductive electrode through an elastic connector. The lifting mechanism is electrically connected to the control box to receive control signals from the control box. In response to the control signals, the lifting mechanism moves toward the test electrode and, under the elastic force of the elastic connector, makes the conductive electrode reliably contact the test electrode.

3. The high-voltage capacitor safety discharge device according to claim 2, characterized in that, The insulating rod is provided with a position detection element at one end facing the lifting mechanism for outputting a position signal to the control box. The position detection element is triggered to output a position signal when the conductive electrode and the test electrode reach a reliable contact state.

4. The high-voltage capacitor safety discharge device according to claim 1, characterized in that, The control box includes: The signal input interface includes a first connector for connecting the voltage divider and a second connector for connecting the current sensor and the temperature sensor. A communication module is provided, which is connected to each of the robotic arm modules and the temperature sensor via a communication interface. The main control module is connected to the first and second aviation connectors respectively through signal processing and protection circuits; The display module is connected to the signal processing and protection circuit and is used to display voltage, current, temperature and discharge status information.

5. The high-voltage capacitor safety discharge device according to claim 4, characterized in that, The input terminal of the voltage divider is connected to the test electrode via a conductive rod extending out of the discharge box, and the conductive rod extending out of the outer surface of the discharge box is covered with an insulating rod. The output terminal of the voltage divider is connected to the control box via the first connector.

6. A method for safe discharge of a high-voltage capacitor, used by the high-voltage capacitor safe discharge device according to any one of claims 1 to 5 to discharge a component containing a high-voltage capacitor, characterized in that, The high-voltage capacitor safe discharge method includes: Based on the capacitance and initial voltage of the device to be discharged, determine the first discharge resistor, the second discharge resistor, the first voltage threshold, and the second voltage threshold. Discharge is performed using the first discharge resistor. It is determined whether the current discharge state meets the preset protection conditions. If it does, the discharge is interrupted and the discharge is restarted after waiting. If it does not meet the conditions, the discharge continues until the discharge time reaches the first discharge time and the voltage of the device to be discharged drops below the first voltage threshold. Discharge is performed using a second discharge resistor. It is determined whether the current discharge state meets the preset protection conditions. If it does, the discharge is interrupted and the discharge is restarted after waiting. If it does not meet the conditions, the discharge continues until the discharge time reaches the second discharge time and the voltage of the device to be discharged drops below the second voltage threshold, at which point the discharge is complete. Wherein, the first discharge resistor is greater than the second discharge resistor.

7. The high-voltage capacitor safe discharge method according to claim 1, characterized in that, The step of determining the first discharge resistor, the second discharge resistor, the first voltage threshold, and the second voltage threshold based on the capacitance and initial voltage of the device to be discharged includes: Based on the capacitance and initial voltage of the device to be discharged, the first discharge resistor and the second discharge resistor are determined from multiple preset candidate resistor combinations. Based on the first discharge resistor, the first voltage threshold is calculated as follows: in, Indicates the first voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the first discharge time. Represents the first time constant. , Indicates the first discharge resistor. Indicates capacitance; Based on the second discharge resistor, the second voltage threshold is calculated as follows: in, Indicates the second voltage threshold. Indicates the initial voltage. Represents the natural constant. Indicates the second discharge time. Indicates the second time constant. , Indicates the second discharge resistor. Indicates electrical capacity.

8. The high-voltage capacitor safe discharge method according to claim 7, characterized in that, The preset protection conditions include overcurrent protection conditions and overheat protection conditions. The overcurrent protection condition is that the discharge current exceeds a preset current threshold and the duration exceeds a preset time range. The overheat protection condition is that the temperature of the discharge resistor exceeds a preset temperature threshold. When either preset protection condition is met, the discharge is interrupted and the discharge is restarted after waiting.

9. The high-voltage capacitor safe discharge method according to claim 8, characterized in that, The preset current threshold is a preset multiple of the maximum discharge current in the current discharge state, wherein the calculation of the maximum discharge current is as follows: in, Indicates the maximum discharge current. Indicates the current voltage. This indicates the current discharge resistance.

10. The high-voltage capacitor safe discharge method according to claim 8, characterized in that, The process of restarting the discharge after waiting includes: Conditions for determining whether an interrupt discharge is triggered: If the condition for triggering the discharge interruption is that the overcurrent protection condition is met, then wait until the discharge current drops below the preset current threshold before restarting the discharge. If the condition for triggering the discharge interruption is that the overheat protection condition is met, then wait until the temperature of the discharge resistor drops below the preset temperature threshold before restarting the discharge.

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