A surge-resistant, synergistic, multi-stage electromagnetic compatibility filtering system

Abstract

This invention discloses a surge-resistant, collaborative, multi-stage electromagnetic compatibility (EMC) filtering system in the field of industrial robot control technology. The system includes a protective housing, which integrates a zero-level transient overvoltage protection module, a primary reactor module, and a secondary high-frequency electromagnetic interference (EMI) filtering module. The input of the primary reactor module is connected to the power grid via a three-in-one safety conductor, and its output is connected to the input of the secondary EMI filtering module, used to increase input impedance and suppress low-frequency harmonics. The secondary EMI filtering module is connected to the output of the primary reactor module before being connected to the input power supply of the robot control cabinet. This invention achieves full-spectrum, full-process protection against instantaneous high-energy surge impacts and continuous broadband electromagnetic interference in industrial robot control systems by constructing a three-stage collaborative protection system of "zero-level surge protection – primary low-frequency harmonic mitigation – secondary high-frequency EMI filtering."

Description

Technical Field

[0001] This invention relates to a surge-resistant collaborative multi-stage electromagnetic compatibility filtering system, belonging to the field of industrial robot control technology. Background Technology

[0002] Industrial robot control systems mainly consist of controllers, servo drivers, and servo motors. Among these, the servo driver, as the core power conversion unit, generates abundant high-frequency harmonics and high voltage change rates due to the high-speed switching of its internal power devices. These disturbances, through conduction and radiation, not only pollute the power grid and affect other equipment, but also directly threaten motor insulation and cause encoder signal abnormalities. They are key factors affecting robot accuracy and reliability. Furthermore, surge impacts such as operational overvoltages and lightning strikes in the industrial power grid also pose a continuous threat to expensive robot control systems.

[0003] Currently, the main approach to addressing these issues in industrial settings is to distribute and install independent filters, reactors, surge protectors, and other devices. This distributed approach has significant drawbacks: it easily leads to filtering blind spots, and may cause harmful resonance due to mismatch with power grid parameters, even reducing the stability of the entire robot control system. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a surge-resistant collaborative multi-level electromagnetic compatibility filtering system. By constructing a three-level collaborative protection system of "zero-level surge protection - first-level low-frequency harmonic control - second-level high-frequency EMI filtering", it can achieve full-spectrum and full-process protection against instantaneous high-energy surge impacts and continuous wide-band electromagnetic interference in the industrial robot control system.

[0005] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0006] In a first aspect, the present invention provides a surge-resistant, collaborative, multi-stage electromagnetic compatibility (EMC) filtering system, comprising a protective housing. The protective housing integrates and encapsulates: a zero-stage transient overvoltage protection module, a primary reactor module, and a secondary high-frequency electromagnetic interference (EMI) filtering module. The input terminal of the primary reactor module is connected to the power grid via a three-in-one safety conductor, and its output terminal is connected to the input terminal of the secondary EMI filtering module, used to increase input impedance and suppress low-frequency harmonics. The secondary EMI filtering module is connected in front to the output terminal of the primary reactor module and in the rear to the input power supply of a robot control cabinet, used to suppress high-frequency conducted interference. The zero-stage transient overvoltage protection module is connected between the secondary EMI filtering module and the robot control cabinet, used to discharge surge energy and clamp overvoltage. The parameters of the zero-stage transient overvoltage protection module, the primary reactor module, and the secondary EMI filtering module are collaboratively designed to form a three-stage collaborative protection system against transient surge impacts and continuous broadband interference.

[0007] Furthermore, the collaborative protection effectiveness of the filtering system is evaluated using a collaborative protection effectiveness quantitative model. The formula for calculating the collaborative protection effectiveness index E_cpe of the model is as follows:

[0008] ×SE_case×G_syn

[0009] In the formula: E_cpe is the collaborative protection effectiveness index; η_surge is the surge suppression depth; IL_total is the total insertion loss; ΔTHD_i is the improvement degree of total harmonic distortion of input current; SE_case is the shielding effectiveness of the protective enclosure; G_syn is the multi-level module collaborative gain coefficient; P_loss is the total power consumption of the system; C_inst is the installation and maintenance complexity factor; K_s, K_f, K_h, K_p, and K_c are the weighting coefficients corresponding to each parameter.

[0010] Furthermore, the zero-level transient overvoltage protection module includes at least one varistor, which is set to correspond to the phase line of the power supply, forming a common-mode and differential-mode surge protection circuit for the three-phase power supply.

[0011] Furthermore, the core protection device of the zero-level transient overvoltage protection module is one of a varistor, a transient voltage suppressor diode (TVS), or a gas discharge tube, and its clamping voltage and current capacity parameters are matched with the rated parameters of the components of the subsequent filter module.

[0012] Furthermore, the primary reactor module includes an iron core made of stacked silicon steel sheets or amorphous alloys, and windings made of aluminum conductors or copper conductors.

[0013] Furthermore, the inductance of the reactor is determined based on the target harmonic order to be suppressed and the system rated current, and is used to suppress low-frequency harmonics and avoid resonance with the power grid.

[0014] Furthermore, the secondary high-frequency EMI filter module includes an X safety capacitor, a Y safety capacitor, an inductor coil, and a discharge resistor mounted on the PCB circuit board, which are integrated into a filter circuit by wave soldering.

[0015] Furthermore, the capacitance values ​​of the X safety capacitor and / or Y safety capacitor in the secondary high-frequency EMI filter module, as well as the resistance value of the discharge resistor, can be replaced according to the filtering requirements and safety regulations.

[0016] Furthermore, the protective shell is made of galvanized steel sheet or stainless steel sheet that has undergone anti-corrosion treatment, and its joints are sealed with sealant.

[0017] Furthermore, the protective housing has a protection level of not less than IP54, and is protected by setting waterproof and dustproof gaskets, glands, and internal potting process.

[0018] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0019] I. This solution innovatively constructs a three-level collaborative protection system: "Level 0 surge protection - Level 1 low-frequency harmonic mitigation - Level 2 high-frequency EMI filtering." This achieves full-spectrum, full-process protection against instantaneous high-energy surge impacts and continuous wide-band electromagnetic interference in industrial robot control systems, fundamentally solving the filtering blind spots and protection failure problems of distributed solutions. The parameter coordination design of the Level 0 varistor and the subsequent filtering module avoids damage to the filtering components by surge energy. The filtering module operates on a "clean" power supply basis, significantly improving filtering efficiency. It effectively suppresses high-frequency harmonics of servo drives, delays motor insulation aging, reduces encoder signal abnormality rate, and significantly improves the mean time between failures (MTBF) of the robot control system, extending its lifespan.

[0020] Second, all modules adopt topology integration and global parameter optimization design, eliminating performance conflicts and the influence of wiring parasitic parameters in distributed solutions. The inductance of the input reactor matches the capacitance parameters of the high-frequency EMI filter module, avoiding harmful resonance with the power grid, reducing system voltage fluctuations and significantly improving operational stability. The three-phase symmetrical circuit layout and short wiring design of the secondary EMI filter module reduce wiring parasitic impedance and stray capacitance, increase the high-frequency interference suppression ratio, and can efficiently filter out high-frequency harmonics generated by the servo driver, greatly reducing the robot's motion accuracy deviation and adapting to the operating requirements of high-precision industrial robots.

[0021] 3. All functional modules are integrated and encapsulated in a galvanized steel shell with an IP54+ protection rating. The shell adopts a triple sealing design of waterproof adhesive treatment, polyurethane potting, and IP67-rated gaskets. It can be directly applied to harsh industrial environments with moisture, dust, and splashes, such as welding, spraying, and machining, without the need for additional protective cabinets. The galvanized steel shell provides efficient electromagnetic shielding, preventing external interference intrusion and internal interference radiation. It also has anti-corrosion and shockproof properties, adapting to the complex environment of industrial sites. The equipment installation volume is greatly reduced compared to distributed solutions, further reducing installation costs.

[0022] Fourth, adopting an integrated structure, all modules are pre-wired and pre-fixed internally, and externally only require a 3-in-1 safety-certified wire to achieve a seamless connection between the power grid and the robot control cabinet. This significantly reduces external connection points, avoids parasitic interference from wiring in distributed solutions, and further shortens installation time. The modular design makes troubleshooting more convenient, and faulty individual modules can be directly replaced without checking individual components one by one, significantly improving maintenance efficiency and greatly reducing robot downtime.

[0023] Fifth, the entire filtering system has passed IEC and domestic EMC and safety authoritative certifications, providing direct compliance proof for industrial robot manufacturers. This eliminates the need for repeated testing and certification of distributed components, significantly shortening the product launch cycle and reducing repetitive testing costs. Authoritative certifications enhance the credibility and market competitiveness of robot products, especially facilitating the export of complete robot systems and solving the core pain point of export certification.

[0024] VI. This filtering system can directly replace the distributed filtering and protection devices of industrial robots, reducing equipment size, installation and maintenance costs, while improving the operational reliability and accuracy of robots, reducing downtime losses, and saving industrial manufacturing enterprises a lot of production costs. The collaborative multi-level filtering and protection technology of this invention promotes the localization and upgrading of core supporting equipment for industrial robots, enhances the adaptability and international competitiveness of domestic industrial robots in harsh environments, and helps the development of the intelligent manufacturing industry. Attached Figure Description

[0025] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0026] Figure 1 An overall structural diagram of a surge-resistant collaborative multi-stage electromagnetic compatibility filter system provided in an embodiment of the present invention;

[0027] Figure 2 This is a structural diagram of an EMI filtering module in a surge-resistant collaborative multi-stage electromagnetic compatibility filtering system provided in an embodiment of the present invention.

[0028] In the diagram: 1. Metal casing; 2. Waterproof and dustproof gasket; 3. Gland head waterproof and dustproof gasket; 4. Reactor; 5. EMI filter module; 6. Three-in-one safety wire; 7. Casing base plate; 501. X safety capacitor; 502. Coil assembly; 503. Safety X capacitor; 504. Safety Y capacitor; 505. Varistor; 506. Discharge resistor; 507. PCB circuit board. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0030] The following detailed description is exemplary and intended to provide further detailed explanation of the invention. Unless otherwise specified, all technical terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this invention is for describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention.

[0031] Example:

[0032] Please see Figure 1This embodiment proposes a surge-resistant collaborative multi-stage electromagnetic compatibility (EMC) filtering system. The system comprises a metal casing 1, waterproof and dustproof gaskets 2, gland-type waterproof and dustproof gaskets 3, a reactor 4, an EMI filter module 5, a three-in-one safety conductor 6, and a base plate 7. The metal casing 1 is a galvanized steel sheet metal casing treated with waterproof adhesive, with an open bottom. The top wall of the metal casing 1 has an adhesive injection port, and the two side walls each have openings. It should be noted that the metal casing 1 is made of 1.0mm thick galvanized steel sheet, and after pickling, phosphating, and powder coating, the inner surface is fully coated with a high-temperature resistant waterproof coating. The adhesive enhances corrosion and water resistance while providing electromagnetic shielding to prevent external interference intrusion and internal interference radiation. The waterproof and dustproof gasket 2 is an IP67-rated waterproof and dustproof gasket, installed on the top wall of the metal casing 1 for sealing after the glue is injected. The waterproof and dustproof gasket 2 is made of fluororubber. There are two gland-type waterproof and dustproof gaskets 3, which are installed on the side wall openings of the metal casing 1 respectively. The gland-type waterproof and dustproof gaskets 3 are IP67-rated and are used to seal the holes in the casing. A three-in-one safety wire 6 is inserted through the middle of both gland-type waterproof and dustproof gaskets 3. Reactor 4 is installed inside the metal casing 1 and is used for the first stage of low-frequency harmonic processing. Its inductance is determined based on the target harmonic order to be suppressed and the system's rated current. The reactor 4 structure includes an iron core made of stacked silicon steel sheets, windings made of aluminum conductors, insulating windings soaked in insulating oil, and a support structure composed of a 1.5mm thick galvanized steel plate bracket. The input of reactor 4 is connected to the power grid via a three-in-one safety conductor 6, and the output of reactor 4 is connected to the input of EMI filter module 5. EMI filter module 5 is used for the second stage of high-frequency filtering. Its pre-stage is connected to the output of reactor 4, and its post-stage is connected to the power input of the robot control cabinet, which supplies power to the robot controller, including a servo driver. The bottom plate 7 is installed at the bottom of the metal casing 1, and the inside of the bottom plate 7 is treated with waterproof adhesive. The bottom plate 7 is made of 1.5mm thick galvanized steel plate and is rigidly connected to the metal casing 1 with screws. The joints are sealed with sealant. The final step before the product of this surge-resistant collaborative multi-stage electromagnetic compatibility filter system is to inject adhesive at the injection port of the metal shell 1, so as to waterproof and seal the metal shell 1 with the shell base plate 7.

[0033] In this embodiment, a zero-level transient overvoltage protection module is connected between the EMI filter module 5 and the robot control cabinet. This module is the first line of defense for the system and is connected to the later stage of the entire system. The core component is a K550 type varistor (MOV1~MOV3), a total of 3, which correspond to the phase lines of the three-phase power supply and form the common-mode and differential-mode surge protection circuit of the three-phase power supply. The varistor parameters are: rated voltage 530VAC, maximum clamping voltage 550V RMS value, and current carrying capacity (8 / 20μs) ≥20kA. When the power grid experiences surges such as operational overvoltages or lightning strikes, reaching a voltage of 550V, the varistor rapidly breaks down within milliseconds, quickly dissipating the surge energy. Simultaneously, it triggers the air switch at the robot's front end to trip, providing overvoltage protection for the downstream robot control circuit. The clamping voltage and current capacity of the varistor are precisely matched with the rated voltage, current, and surge withstand capability of the components in reactor 4 and EMI filter module 5, preventing surge energy from damaging the filter components and ensuring the speed and reliability of surge protection.

[0034] In this embodiment, reactor 4 constitutes a first-stage reactor module, which is the low-frequency filtering unit of the system. Its input is connected to the industrial power grid, and its output is connected to the EMI filter module 5. It mainly suppresses low-frequency harmonics (i.e., the 3rd, 5th, and 7th harmonics of the 50 / 60Hz fundamental frequency) in the industrial robot control system and increases the system's input impedance, preventing resonance between the power grid and the robot system. The specific structure of the reactor assembly includes:

[0035] (1) Iron core: It is made of high silicon steel sheets (silicon content 3.5%) stacked together, with a stacking coefficient ≥0.95, which improves the magnetic permeability of the iron core and reduces iron loss;

[0036] (2) Winding: It is made of high conductivity aluminum conductor. The number of turns of the winding matches the rated current of the industrial robot (adjusted according to the robot power). The winding method is layered flat winding to improve the heat dissipation performance of the winding.

[0037] (3) Insulation materials: The windings are insulated with polyimide film, and the entire reactor assembly is immersed in high-temperature insulating oil to achieve full insulation protection and improve insulation withstand voltage performance;

[0038] (4) Support structure (D): The bracket is made of 1.5mm thick galvanized steel plate, which fixes the iron core and winding into an integrated assembly. Rubber anti-vibration pads are set between the bracket and the shell to suppress the vibration and noise of the reactor during operation.

[0039] The inductance of the reactor is precisely designed based on the target harmonic order (3rd, 5th, 7th) and the rated current of the robot system. The preferred inductance in this solution is 0.14mH, which is suitable for the low-frequency harmonic control requirements of 5~20kW industrial robots.

[0040] In this embodiment, the EMI filter module 5 constitutes a two-stage high-frequency electromagnetic interference (EMI) filter module. This module is the core unit of the system's high-frequency filtering. Its input is connected to the output of the reactor 4, and its output is connected to the zero-level transient overvoltage protection module. It mainly achieves efficient suppression of high-frequency conducted interference (10kHz~1GHz) in the industrial robot control system. At the same time, it shapes the PWM waveform output by the servo driver, protects the servo motor, and optimizes its performance. The EMI filter board module integrates components onto the PCB circuit board (⑦) through wave soldering. For specific component configuration and connection relationships, please refer to the relevant documentation. Figure 2 In this embodiment, the EMI filter module 5 comprises X safety capacitors 501, coil assembly 502, X safety capacitors 503, Y safety capacitors 504, varistors 505, and discharge resistors 506, all mounted on the PCB circuit board 507. Specifically: the X safety capacitors 501 are 4.7uF, numbered 7 pieces, with three connected in parallel to the front stage of the EMI filter module 5 to suppress differential-mode signals; the remaining four are located at the rear stage of the EMI filter module 5 to suppress common-mode signals. The coil assembly 502 is a 1.8mH inductance coil assembly, its input connected to the output of the reactor 4, and its output connected to the four X safety capacitors 501. The X safety capacitors 503 are 33nF, numbered three in total, placed between the reactor 4 and the coil assembly 502 and bridging the live wire. The Y safety capacitors 504 are 22... There are six nF components in total. Three are located at the input and three at the output of coil assembly 502, with each phase's live wire connected to ground. Varistors 505 are K550 type varistor with a maximum effective value of 550V and a rated voltage of 530VAC. They are connected after the EMI filter module 5 and provide overvoltage protection for the downstream robot circuit. When the voltage reaches 550V, they can short-circuit within milliseconds, causing the front-end air switch to activate. This part uses varistor 505 as the core component to form the common-mode and differential-mode surge protection circuit for the three-phase power supply. The clamping voltage and current carrying capacity parameters of varistor 505 are designed in conjunction with the rated voltage, current, and surge withstand capability of the components in reactor 4 and EMI filter module 5. Discharge resistor 506 has a resistance of 330KΩ and is connected after the EMI filter module 5, ensuring the entire unit meets the 5-second safe discharge requirement. It should be noted that the above components are assembled into a two-stage filter using wave soldering.

[0041] In this solution, reactor 4 achieves primary input impedance and low-frequency harmonic mitigation, EMI filter module 5 achieves secondary high-frequency conducted interference suppression, and varistor 505 provides transient overvoltage protection. All structures are integrated and packaged in a unified housing with a protection rating of IP54 or higher. This solution clamps and discharges transient overvoltages from the input power supply, and sequentially suppresses low-frequency harmonics and filters out high-frequency conducted interference through a co-designed filter module. It also shapes the PWM waveform output by the servo driver to protect the motor and optimize performance. The well-sealed housing with an IP54 or higher protection rating ensures reliable operation of the system in harsh industrial environments. Based on system performance indicators certified by a third party, the solution ensures that the robot control system meets relevant electromagnetic compatibility and safety regulations.

[0042] This solution constructs a three-tiered collaborative protection system: "Level 0 surge protection - Level 1 low-frequency harmonic mitigation - Level 2 high-frequency EMI filtering," and employs integrated design and global parameter optimization to enhance overall effectiveness. The overall protection effectiveness of this collaborative filtering system is quantified using a collaborative protection effectiveness quantification model. This model is used to calculate the comprehensive protection effectiveness index provided by the filtering system to the industrial robot control system under specific operating conditions. The formula is as follows:

[0043] ×SE_case×G_syn

[0044] In the formula: E_cpe is the collaborative protection effectiveness index, which is a comprehensive score. The higher the value, the better the "full spectrum, full process" protection effectiveness of the filtering system for the robot control system under the set operating conditions, that is, the better the overall performance of the system in terms of reliability, accuracy improvement and life extension. η_surge is the surge suppression depth, which represents the absorption and clamping efficiency of the zero-level transient overvoltage protection module (with varistor as the core) for surge energy. Its value is calculated based on the residual voltage ratio of the module inlet and outlet in the surge generator test. Data source: Surge immunity test data according to IEC61000-4-5 standard. IL_total is the total insertion loss, which represents the overall noise suppression capability of the first-level reactor module and the second-level EMI filter module working together for the entire conducted interference frequency band (such as 10kHz-1GHz), in decibels (dB). Data source: The integral of the insertion loss curve or the weighted value of the characteristic frequency point measured by a network analyzer in a shielded room according to IEC60939 standard. ΔTHD_i represents the improvement in total harmonic distortion (THD) of the input current, indicating the percentage reduction in the content of grid-side current harmonics (especially the 3rd, 5th, and 7th low-frequency harmonics) before and after system connection. Data source: Calculated by measuring the harmonic content of the filter system's input current under rated load using a power analyzer. SE_case represents the shielding effectiveness of the protective enclosure, indicating the shielding capability of the metal enclosure (galvanized steel plate) against electromagnetic interference, expressed in decibels (dB). Data source: Tested in a microwave anechoic chamber according to IEC61000-5-7 or similar standards, measuring the attenuation value of the enclosure against radiated interference in a specific frequency band. G_syn represents the multi-level module synergistic gain coefficient, which is >1 and quantifies the additional performance gains brought about by "parameter global optimization design" and "topology integration." For example, by avoiding filter blind zones and harmful resonances and reducing parasitic parameters, the overall performance exceeds the simple linear summation of the performance of each module. Data source: Obtained by comparing the ratio of "measured integrated system performance" to "theoretical summation of independent module performance." P_loss represents the total system power consumption, referring to the active power loss generated by the filtering system itself (mainly copper losses in the reactor windings, iron losses in the core, and losses in the filtering components), measured in watts (W). Data source: The difference between the total input and total output power measured by the power meter under the system's rated operating conditions. C_inst is the installation and maintenance complexity factor, a normalized coefficient (usually ≤1) used to characterize the ease of installation and maintenance resulting from integrated and modular design. The fewer external connection points and the higher the degree of modularity, the closer this factor is to 1. Data source: Assigned based on a comparative analysis of the number of installation steps, mean time to repair (MTTR), and baseline distributed solutions.K_s, K_f, K_h, K_p, and K_c are the weighting coefficients for each parameter. They are set by the designer according to different application scenarios (such as high-precision assembly and heavy-duty welding) to adjust the emphasis of various performance indicators. They are not core variable parameters.

[0045] System design engineers utilize circuit simulation software (such as SPICE and SIMetrix) and electromagnetic simulation tools, combined with device models and target parameters, to perform pre-calculation and optimization to guide the initial design. During product testing and maintenance, key data is collected in real time or periodically in the embedded monitoring unit of the integrated test platform or high-end filtering system through integrated sensors (such as voltage / current probes and temperature sensors) and processors to calculate the E_cpe index, which is used for product factory performance evaluation or online health status monitoring.

[0046] Compared to traditional distributed filtering schemes that focus only on the design and evaluation of single device parameters (such as the inductance of a single reactor or the insertion loss of a single filter), the supplementary Cooperative Protection Effectiveness Equivalence Model (CPEM) has the following outstanding advantages:

[0047] Traditional methods examine surge protection and filtering in isolation, focusing on single functional indicators. This model innovatively introduces the "synergistic gain coefficient (G_syn)" and the "complexity factor (C_inst)," comprehensively evaluating electrical performance (surge suppression, filtering effect), structural effectiveness (shielding, installation), and the "1+1>2" effect resulting from integrated design within a unified mathematical framework. This more fully reflects the core advantages of this invention: "synergistic" and "integrated."

[0048] Traditional distributed design relies on experience, making it difficult to accurately assess interactions between modules (such as resonance caused by parameter mismatch). This model quantifies synergistic effects through formulas, enabling engineers to perform simulations and optimizations during the design phase by adjusting variables in the formulas (such as changing the inductance of reactors to affect ΔTHD_i and P_loss, and optimizing the layout to improve SE_case and G_syn). This achieves the "global parameter optimization" emphasized in the document, avoiding performance conflicts and shifting from qualitative judgment to quantitative optimization.

[0049] The numerator of the model formula embodies the protection effect against "instantaneous high-energy impact" (η_surge) and "continuous broadband interference" (IL_total, ΔTHD_i), while the denominator considers the system's own power consumption and ease of use. Multiplying this by the additional gain brought by the integrated design (SE_case, G_syn) forms a quantitative indicator for evaluating the protection concept of "full spectrum, full process, high reliability, and easy maintenance." This is a concise mathematical expression of the beneficial effects of the invention and provides a theoretical basis for performance verification and market claims.

[0050] To broaden the scope of patent protection and prevent others from circumventing this technology to achieve the same invention, the core technical solution of this invention can adopt the following equivalent alternative, whose core collaborative filtering protection function and beneficial effects are consistent with the original solution:

[0051] (a) Device replacement for zero-level surge protection module

[0052] Varistor: Replace the K550 varistor with a TVS diode (transient voltage suppressor diode) or a gas discharge tube. TVS diodes are suitable for high-frequency surge protection, while gas discharge tubes are suitable for high-current surge protection. As long as their clamping voltage and current capacity are matched with the parameters of the downstream module, equivalent surge protection can be achieved.

[0053] Quantity configuration: Based on the number of phases required by the robot, the number of varistors can be adjusted from 3 to 2 or 4 to adapt to industrial robots with single-phase or four-phase power supply.

[0054] (II) Material and parameter substitution for primary reactor module

[0055] Winding material: Replacing aluminum conductors with copper conductors improves the conductivity and heat dissipation of the windings, making it suitable for high-power industrial robots (≥30kW).

[0056] Core material: The high silicon steel sheets are replaced with an amorphous alloy core to reduce iron loss and improve the low-frequency harmonic suppression efficiency, making it suitable for scenarios with high energy consumption requirements;

[0057] Inductance: Based on the target harmonic order to be suppressed and the robot's rated current, adjust 1.8mH to 1.5mH / 2.0mH. As long as the requirements for low-frequency harmonic control and anti-resonance are met, the equivalent effect can be achieved.

[0058] (III) Replacement of capacitor parameters and types in the secondary EMI filter module

[0059] Safety X capacitors: Replace the 33nF / 4.7uF safety X capacitors with 22nF / 6.8uF safety X capacitors, or use film capacitors instead of ceramic capacitors. Film capacitors have better temperature resistance and high-frequency performance and are suitable for high-temperature industrial environments.

[0060] Safety Y capacitor: Replace the 22nF safety Y capacitor with a 10nF / 33nF safety Y capacitor. As long as the capacitance and safety requirements for common-mode filtering are met, equivalent common-mode interference suppression can be achieved.

[0061] Discharge resistor: Replace the 330KΩ resistor with a 270KΩ / 470KΩ resistor. As long as the safety standard of safe discharge within 5 seconds is met, the equivalent capacitance can be discharged.

[0062] (iv) Replacement of protective shell material and protection level

[0063] Outer shell material: The galvanized steel sheet is replaced with stainless steel sheet (304 / 316) to improve the chemical corrosion resistance of the outer shell, making it suitable for industrial environments with corrosive gases such as spraying and electroplating.

[0064] Protection rating: Based on environmental requirements, IP54 is upgraded to IP65 / IP67, the number of sealing layers of the housing is increased, and higher-grade glands and gaskets are used, making it suitable for extreme and harsh environments such as humid and dusty conditions.

[0065] (v) Alternative configuration of wiring components

[0066] 3-in-1 Safety Cable: Replaces the integrated safety cable with a combination of waterproof aviation plug and copper busbar, improving the reliability of wiring and current carrying capacity, suitable for industrial robots that require frequent disassembly;

[0067] Conductor material: Ordinary safety conductors are replaced with silver-plated conductors, which reduces high-frequency impedance and improves high-frequency filtering efficiency, making them suitable for industrial scenarios with ultra-high frequency interference.

[0068] In summary, this solution achieves comprehensive electrical stress protection, innovatively integrating surge protection with harmonic and EMI filtering to form "full-spectrum, full-process" protection against instantaneous high-energy impacts and continuous broadband interference, fundamentally improving the reliability and lifespan of the robot control system. The integrated design eliminates performance conflicts and wiring parasitic parameter effects inherent in separate solutions. Global parameter optimization avoids resonance, ensuring system stability. Furthermore, the IP54 protective enclosure allows direct installation in most industrial environments, providing dust and water resistance and strong adaptability. Integration reduces external connection points and failure sources, allowing internal modules to operate in a controlled environment, significantly improving the overall mean time between failures (MTBF). Pre-installed third-party authoritative certifications provide robot manufacturers with direct EMC and safety compliance proof, significantly shortening product launch cycles, reducing repetitive testing costs, and enhancing end-customer trust.

[0069] As is known from common technical knowledge, this invention can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative and not exhaustive. All modifications within the scope of this invention or its equivalents are included in this invention.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. An anti-surge synergistic multi-stage electromagnetic compatibility filter system, characterized in that, The system includes a protective housing, which integrates and encapsulates a zero-level transient overvoltage protection module, a primary reactor module, and a secondary high-frequency electromagnetic interference (EMI) filter module. The input of the primary reactor module is connected to the power grid via a three-in-one safety conductor, and its output is connected to the input of the secondary EMI filter module, used to increase input impedance and suppress low-frequency harmonics. The secondary EMI filter module is connected to the output of the primary reactor module at the front end and to the input power of the robot control cabinet at the rear end, used to suppress high-frequency conducted interference. The zero-level transient overvoltage protection module is connected between the secondary EMI filter module and the robot control cabinet, used to discharge surge energy and clamp overvoltage. The parameters of the zero-level transient overvoltage protection module, the primary reactor module, and the secondary EMI filter module are designed in a coordinated manner to form a three-level coordinated protection system against transient surge impacts and continuous broadband interference.

2. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system according to claim 1, characterized in that, The collaborative protection effectiveness of the filtering system is evaluated using a collaborative protection effectiveness quantitative model. The formula for calculating the collaborative protection effectiveness index E_cpe of the model is as follows: x SE_case x G_syn In the formula: E_cpe is the collaborative protection effectiveness index; η_surge is the surge suppression depth; IL_total is the total insertion loss; ΔTHD_i is the improvement degree of total harmonic distortion of input current; SE_case is the shielding effectiveness of the protective enclosure; G_syn is the multi-level module collaborative gain coefficient; P_loss is the total power consumption of the system; C_inst is the installation and maintenance complexity factor; K_s, K_f, K_h, K_p, and K_c are the weighting coefficients corresponding to each parameter.

3. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 1, wherein, The zero-level transient overvoltage protection module includes at least one varistor, which is set to correspond to the phase line of the power supply, forming a common-mode and differential-mode surge protection circuit for a three-phase power supply.

4. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 3, wherein, The core protection device of the zero-level transient overvoltage protection module is one of a varistor, a transient suppression diode (TVS), or a gas discharge tube. Its clamping voltage and current carrying capacity parameters are matched with the rated parameters of the components in the subsequent filter module.

5. The surge resistant synergistic multi-stage electromagnetic compatibility filtering system of claim 1, wherein, The primary reactor module includes an iron core made of stacked silicon steel sheets or amorphous alloys, and windings made of aluminum or copper conductors.

6. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 5, wherein, The inductance of the reactor is determined based on the target harmonic order to be suppressed and the system rated current, and is used to suppress low-frequency harmonics and avoid resonance with the power grid.

7. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 1, wherein, The secondary high-frequency EMI filter module includes an X safety capacitor, a Y safety capacitor, an inductor coil, and a discharge resistor mounted on a PCB circuit board, which are integrated into a filter circuit by wave soldering.

8. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 7, wherein, The capacitance values ​​of the X safety capacitor and / or Y safety capacitor in the secondary high-frequency EMI filter module, as well as the resistance value of the discharge resistor, are replaced according to the filtering requirements and safety regulations.

9. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 1, wherein, The protective shell is made of galvanized steel or stainless steel that has undergone anti-corrosion treatment, and its joints are sealed with sealant.

10. The anti-surge synergistic multi-stage electromagnetic compatibility filtering system of claim 9, wherein, The protective housing has a protection level of not less than IP54, and is protected by setting waterproof and dustproof gaskets, glands, and internal potting process.

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