A power surge protection device

Abstract

This invention discloses a power supply lightning protection device, comprising: an intelligent monitoring module including a controller and signal connections to a lightning counter and a leakage current sensor; a backup protection module including multiple backup protection switches, each backup protection switch having an auxiliary contact signal-connected to the controller; a multi-level collaborative protection module including a first-level protection unit, a second-level protection unit, a third-level protection unit, and a fourth-level protection unit; a circuit protection module installed in the multi-level collaborative protection module, the backup protection module, and the power supply circuit; and an alarm module signal-connected to the controller. The multi-level collaborative protection module of this invention weakens lightning strike energy layer by layer, providing a safe and stable power supply for subsequent power modules while avoiding mutual interference between circuits. The intelligent monitoring module monitors the line status in real time, greatly improving the overall safety and stability of the device and effectively preventing damage caused by lightning strikes.

Description

Technical Field

[0001] This invention relates to the field of power supply lightning protection technology for rail transit, and specifically to a power supply lightning protection device. Background Technology

[0002] Lightning is a natural atmospheric phenomenon caused by the discharge of large currents resulting from the separation of charges between clouds and the ground. When lightning strikes a building, the current is conducted through the building's structure because the building is conductive. Therefore, everyday power supply lines are easily subjected to lightning surges, leading to frequent faults such as line aging, short circuits, and leakage, which can easily damage downstream electrical equipment and pose electrical safety hazards. Existing lightning protection devices have only one level of protection, with most circuits using single-stage or simple two-stage protection, lacking proper decoupling. The surge energy at each stage cannot be effectively diverted and buffered, resulting in low discharge efficiency; the residual voltage at the downstream end is too high, easily damaging precision electrical components. Furthermore, circuits are prone to mutual interference, resulting in poor coordination of protection actions and insufficient overall lightning protection reliability, significantly increasing the risk of equipment damage. Therefore, there is an urgent need for a power supply lightning protection device to improve the reliability of lightning protection and protect downstream electrical components. Summary of the Invention

[0003] This invention addresses at least one technical problem in the prior art by disclosing a power supply lightning protection device. The multi-level collaborative protection module progressively weakens lightning strike energy, providing a safe and stable power supply for subsequent power modules. Circuit protection modules are included in the multi-level collaborative protection module, power circuit, and backup protection module to facilitate timely disconnection of faulty circuits without affecting other circuits, thus avoiding mutual interference between circuits. An intelligent monitoring module monitors the line status in real time and is linked with the backup protection module and alarm module to intuitively display operating data and alarm for abnormalities, greatly improving the overall safety and stability of the device and effectively preventing damage caused by lightning strikes.

[0004] This invention is achieved through the following technical solution:

[0005] This invention first provides a power surge protection device, comprising:

[0006] The intelligent monitoring module includes a controller and a lightning counter connected to it by separate signals, as well as a leakage current sensor for identifying line leakage faults.

[0007] The backup protection module includes multiple backup protection switches, each of which has an auxiliary contact. The auxiliary contact signal is connected to the controller.

[0008] The multi-level collaborative protection module includes a first-level protection unit connected to the power input terminal to conduct instantaneous large lightning current to the ground, a second-level protection unit connected to the output terminal of the first-level protection unit to achieve voltage clamping and delay the surge rise slope, a backup protection module connected to the output terminal of the second-level protection unit, a third-level protection unit configured for each backup protection switch to achieve multi-channel synchronous voltage equalization protection, and a fourth-level protection unit set at the output terminal of the backup protection module.

[0009] The circuit protection module is installed in the multi-level collaborative protection module, backup protection module and power circuit to cut off the faulty circuit;

[0010] The alarm module is connected to the controller signal.

[0011] The enclosure is used to house a multi-level collaborative protection module, an alarm module, a circuit protection module, a backup protection module, and an intelligent monitoring module.

[0012] As a further solution, the circuit protection module includes a temperature fuse and an overcurrent fuse. The temperature fuse is fitted into the multi-level collaborative protection module and is used to cut off the protection circuit when the multi-level collaborative protection module overheats. The overcurrent fuse is connected in series in the power supply circuit and is used to cut off the fault circuit when a power frequency short-circuit current occurs.

[0013] As a further solution, the first-level protection unit includes a gas discharge tube and a primary busbar. The primary busbar is connected to the PE terminal of the power input terminal. A temperature fuse is attached to the gas discharge tube. One end of the gas discharge tube is connected to the corresponding phase line and neutral line, and the other end is connected to the grounding busbar to form a longitudinal lightning protection circuit to the ground.

[0014] As a further embodiment, the second-level protection unit includes a varistor and a current-limiting inductor connected in series, with the varistor being attached to a temperature fuse.

[0015] As a further solution, the third-level protection unit includes branch varistor elements and equalizing resistors. The branch varistor elements are varistors connected in parallel between the single phase line and the neutral line to absorb residual surges in the branch. The equalizing resistors are connected to the incoming lines of the corresponding branches and are uniformly connected to the common terminal.

[0016] As a further embodiment, the fourth-level protection unit includes several horizontal lightning protection modules and several vertical lightning protection modules. One end of each vertical lightning protection module is electrically connected to the phase line and the neutral line of each circuit, and the other end is connected to the ground busbar to access the ground. Each horizontal lightning protection module is connected across the phase line and the neutral line.

[0017] As a further option, both the horizontal and vertical surge protection modules are surge protectors used to protect each phase circuit.

[0018] In a three-phase circuit, the fourth-level protection unit includes one 4P surge protector and three 1P surge protectors. In a single-phase circuit, the fourth-level protection unit includes one 2P surge protector and one 1P surge protector.

[0019] As a further provision, each surge protector is equipped with a dedicated backup protector to prevent fires caused by surge protector failure and to ensure that the fourth-level protection unit does not fail after being struck by lightning.

[0020] As a further solution, a filter for suppressing high-frequency noise and electromagnetic interference is connected between the fourth-level protection unit and the alarm module.

[0021] In a three-phase circuit, the filter is a three-phase four-wire filter; in a single-phase circuit, the filter is a single-phase filter.

[0022] As a further solution, the alarm module includes a phase loss sensor, a buzzer, an indicator light, and a display screen, all of which are connected to the controller signal. The phase loss sensor is used to monitor each phase of the circuit. The buzzer, display screen, and indicator light are all mounted on the panel of the enclosure, and the number of indicator lights is the same as the number of phases of the circuit.

[0023] The features and beneficial effects of this invention are as follows:

[0024] (1) The present invention weakens the lightning energy layer by layer through the coordinated cooperation of various modules and the multi-level collaborative protection module, which greatly improves the discharge efficiency of the circuit. The circuit protection module cuts off the fault circuit in time without affecting other circuits, so that the circuit as a whole will not interfere with each other. The intelligent monitoring module monitors the line status in real time and displays the circuit information in time through the alarm module, which facilitates the timely replacement of aging electrical components, greatly improves the safety and reliability of equipment operation, and effectively avoids damage to back-end equipment.

[0025] (2) The multi-level collaborative protection module set up in this invention includes four levels of protection. The first level protection unit is used to directly conduct the instantaneous ultra-large lightning current to the ground and reduce the peak current of the lightning strike. The second level protection unit is used to achieve voltage clamping and delay the rise slope of the surge. The third level protection unit is used to achieve multi-channel synchronous voltage equalization protection of the backup protection module. The fourth level protection unit is used to suppress the differential mode surge between lines and absorb the small amount of surge residual voltage left by the previous protection. Through layer-by-layer protection, this module decomposes the ultra-large lightning current and effectively protects the safety of the downstream electrical equipment.

[0026] (3) The circuit protection module of the present invention is installed in the multi-level collaborative protection module, the backup protection module and the power circuit to cut off the fault circuit and monitor the branch and main circuit at different locations, which greatly improves the safety and stability of the device. When each branch fails, it will not affect other circuits, thus improving the overall stability of the device. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the box body described in an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram showing the distribution of each module in the power surge protection device according to an embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram illustrating the control relationships of the multi-level collaborative protection module, alarm module, backup protection module, and intelligent monitoring module described in an embodiment of the present invention.

[0031] Figure 4 This is a schematic diagram of the electrical control principle described in an embodiment of the present invention;

[0032] Figure 5 This is a schematic diagram of the wiring status of the power surge protection device according to an embodiment of the present invention;

[0033] Figure 6 This is a wiring diagram of two three-phase power supplies in the power surge protection device described in an embodiment of the present invention;

[0034] Figure 7 This is a wiring diagram of the input terminals, parallel terminals, backup protection module, and multi-level collaborative protection module in a three-phase power supply according to an embodiment of the present invention.

[0035] Figure 8 This is a wiring diagram of the multi-level collaborative protection module, phase failure sensor, filter, switching power supply and lightning counter in the three-phase power supply according to an embodiment of the present invention;

[0036] Figure 9 This is a wiring diagram of the multi-level collaborative protection module, indicator light, and buzzer in a three-phase power supply according to an embodiment of the present invention;

[0037] Figure 10 This is a wiring diagram of two single-phase power supplies in the power surge protection device described in an embodiment of the present invention;

[0038] Figure 11 This is a wiring diagram of the input terminal, parallel terminal, backup protection module, multi-level collaborative protection module, and lightning counter in a single-phase power supply according to an embodiment of the present invention.

[0039] Figure 12 This is a wiring diagram of the multi-level collaborative protection module, filter, switching power supply, indicator light and buzzer in a single-phase power supply according to an embodiment of the present invention.

[0040] Explanation of reference numerals in the attached figures:

[0041] 1-Input terminal; 2-Parallel terminal; 3-Backup protection switch; 4-Horizontal surge protection module; 5-Vertical surge protection module; 6-Display screen; 7-Switching power supply; 8-Phase loss sensor; 9-Filter; 10-Lightning counter; 11-Copper busbar; 12-Mounting plate; 13-Elongated hole; 14-Guide rail; 15-Enclosure; 151-Outer shell; 152-Front panel. Detailed Implementation

[0042] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below, and embodiments of the present invention will be provided, but this does not limit the scope of the present invention.

[0043] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0044] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0045] Most current surge protection boxes offer only primary or secondary protection. Primary protection involves safely discharging the lightning current to the ground through a grounding device, while secondary protection involves discharging the lightning current to the ground through a grounding device and installing a surge protector. Some secondary protection uses a two-pole surge protector, but this type of protection only protects against induced lightning and conducted surges, offering limited protection against direct lightning strikes. Furthermore, if the residual voltage (residual voltage after clamping) exceeds the equipment's withstand voltage, it can still damage electronic equipment. In particular, if the arc-extinguishing capability of a switch-type surge protector (SPD) is insufficient after a lightning strike, it may fail to cut off the power frequency follow current, causing the upstream circuit breaker to trip, the line to lose power, and in severe cases, burning out the SPD or causing a fire. This application provides a power supply surge protection device that provides four levels of protection against lightning current through a multi-level collaborative protection module. The first level of protection is used to guide the instantaneous large lightning current to the ground. The second level of protection is used to achieve voltage clamping and delay the surge rise slope. The third level of protection is used to achieve multi-channel synchronous voltage equalization protection of the backup protection module. The fourth level of protection is used to suppress differential mode surges between lines and absorb the trace surge residual voltage left by the first three levels of protection, effectively ensuring the elimination of all residual voltage and protecting the downstream electronic equipment. In addition, this application also achieves intelligent detection through the cooperation of controllers, leakage current sensors, phase loss sensors, and lightning counters. The phase loss sensor monitors each phase circuit in the enclosure and can directly alarm when a phase loss or surge protector failure occurs. The lightning counter records the number of lightning current pulses from the surge protector or grounding down conductor. The leakage current sensor monitors the leakage current to ground from the multi-level collaborative protection module. All of the above data are displayed on the screen by the controller and can also be transmitted to the server. In particular, the lightning counter can display the number of lightning strikes, which makes it convenient for staff to determine whether components need to be replaced based on the number of lightning strikes, thus avoiding the aging of internal electrical components of the lightning protection device and causing lightning protection failure. This application also includes a circuit protection module, which is installed in the multi-level collaborative protection module and the power circuit. When a fault occurs in the circuit it is in, it can quickly cut off the faulty circuit, effectively isolate the faulty components, ensure the stable operation of the multi-level lightning protection structure, significantly improve the overall safety protection level and service life of the device, and effectively protect the downstream equipment.

[0046] A power surge protection device, such as Figures 1 to 12 As shown, it includes:

[0047] The intelligent monitoring module includes a controller and a lightning counter connected to it by separate signals, as well as a leakage current sensor for identifying line leakage faults.

[0048] The backup protection module includes a multi-channel backup protection switch 3, each of which has an auxiliary contact whose signal is connected to the controller.

[0049] The multi-level collaborative protection module includes a first-level protection unit connected to the power input terminal to conduct instantaneous large lightning current to the ground; a second-level protection unit connected to the output terminal of the first-level protection unit to achieve voltage clamping and delay the surge rise slope; the output terminal of the second-level protection unit connected to the backup protection module; a third-level protection unit configured for each backup protection switch to achieve multi-channel synchronous voltage equalization protection; and a fourth-level protection unit set at the output terminal of the backup protection module to absorb the small amount of residual surge voltage left by the first three levels of protection.

[0050] The circuit protection module is installed in the multi-level collaborative protection module, backup protection module and power circuit to cut off the faulty circuit;

[0051] The alarm module, connected to the controller signal, is used to display circuit information and provide alarms for abnormal conditions;

[0052] The enclosure is used to house multi-level collaborative protection modules, alarm modules, circuit protection modules, backup protection modules, and intelligent monitoring modules.

[0053] The multi-level collaborative protection module in this application weakens the energy of lightning strikes layer by layer, providing a safe and stable power supply for subsequent power modules. The backup protection module has multiple channels, and this module relies on auxiliary contacts to transmit operating condition signals. Circuit protection modules are set in the multi-level collaborative protection module, power circuit, and backup protection module to facilitate timely disconnection of faulty circuits without affecting other circuits. The intelligent monitoring module monitors the line status in real time and is linked with the backup protection module and alarm module to intuitively display operating data and alarm for abnormalities. All modules of this device work together to provide multiple protections including lightning protection, circuit breaking, monitoring, and early warning, greatly improving the overall safety and stability.

[0054] In some embodiments, the controller is a microcontroller.

[0055] In some embodiments, the housing 15 includes an outer shell 151 and a panel 152 hinged to one side. A mounting plate 12 is provided on the rear wall of the outer shell 151. The mounting plate 12 is provided with a plurality of guide rails 14 and elongated holes 13. The elongated holes 13 can be used for heat dissipation and as wire channels for wiring, preventing wire harness accumulation from causing heat dissipation and wiring difficulties. At the same time, wiring the wire harness along the nearest elongated hole 13 can save wire harness length and facilitate finding the corresponding wire harness in later maintenance. The guide rails 14 are used to install the above-mentioned modules, and the guide rails 14 are detachably connected to the mounting plate 12, which facilitates the adjustment of the position according to actual needs.

[0056] Panel 152 is equipped with display screen 6, which is used to display the status of all components inside the enclosure.

[0057] The backup protection module includes multiple backup protection switches 3, each with an auxiliary contact. Each backup protection switch 3 is connected to the power input terminal 1, the parallel terminal 2, and the multi-level collaborative protection module. The backup protection switches 3 are connected to the power input terminal and the parallel terminal respectively, ensuring stable power supply and reliable protection action. They also enable parallel current convergence of multiple switches, achieving circuit expansion and collaborative protection. Furthermore, they cut off the power supply in case of power frequency circuit faults or leakage, protecting the circuit and downstream equipment. Each backup protection switch has its own auxiliary contact. The auxiliary contact signal is connected to the controller. When an overcurrent or lightning strike trips in a certain circuit, the auxiliary contact changes position, transmitting a fault signal for accurate alarm.

[0058] When the power surge protection device is three-phase, the number of backup protection switches 3 is 4, namely the three-phase circuits A, B, and C and the N circuit; when the power surge protection device is single-phase, the number of backup protection switches 3 is 2, namely the L circuit and the N circuit.

[0059] The alarm module includes a phase loss sensor 8, a buzzer, and an indicator light. The phase loss sensor 8 is fixed on the mounting plate 12, and the buzzer and indicator light are both mounted on the panel 152. The phase loss sensor 8 monitors each phase circuit in the enclosure. When a phase loss occurs or the surge protector fails, it triggers a red light to stay on and a buzzer to continuously alarm, making it easy to detect problems in time and quickly troubleshoot faults.

[0060] Preferably, when the power supply surge protection device is three-phase, the buzzer includes a surge alarm buzzer and a phase loss alarm buzzer, and the indicator lights include A-phase indicator lights, B-phase indicator lights, and C-phase indicator lights. For easy differentiation, corresponding labels are written near the indicator lights and buzzers. When the power supply surge protection device is single-phase, the buzzer is a surge alarm buzzer, and there is one indicator light.

[0061] In some embodiments, the intelligent monitoring module includes a controller and a lightning counter, a leakage current sensor, and a temperature sensor, each connected to a signal connection thereon. The lightning counter records the number of lightning current pulses from the surge protector or the grounding down conductor. The leakage current sensor is connected in series with the grounding down conductor of the multi-level collaborative protection module or the output side of the device's main switch to monitor the leakage current to ground from the multi-level collaborative protection module. The temperature sensor monitors the temperature inside the enclosure. The lightning counter, leakage current sensor, and temperature sensor send the collected signals to the controller, which displays them on the display screen 6, allowing staff to easily understand the internal operating status of the enclosure. The display screen 6 can also visually display the device's normal, deteriorated, and failed operating states based on set data.

[0062] In some embodiments, since the number of circuits installed inside the enclosure is 2, but only one lightning counter and one temperature sensor are designed to achieve the above functions, in order to ensure the accuracy of the leakage current sensor, in this embodiment, an alarm contact is connected in series on the grounding lead of each surge protector. The alarm contact is a leakage current sensor used to monitor the leakage current generated by the deterioration of the surge protector.

[0063] In other embodiments, a leakage current sensor is installed on the outgoing side of the main switch of the device to detect the remaining leakage current of the power supply line in real time. It can accurately identify leakage current faults in the line and trigger the protection switch to disconnect the circuit when an abnormality occurs. In conjunction with the multi-level collaborative protection module, it can take into account both lightning surge protection and leakage current protection, and comprehensively improve the safety of power supply use.

[0064] Preferably, the controller can transmit all collected and processed data to the server or central control room via a wireless network, facilitating later traceability and serving as reference data for later research and development. At the same time, when the controller determines that the temperature inside the enclosure is too high, it will sound an alarm via a buzzer and send a remote alarm to the staff as needed.

[0065] In some embodiments, the circuit protection module includes a temperature fuse and an overcurrent fuse. The temperature fuse is fitted into the multi-level collaborative protection module and is used to cut off the protection circuit when the multi-level collaborative protection module overheats. The overcurrent fuse is connected in series in the power supply circuit and is used to cut off the faulty circuit when a power frequency short-circuit current occurs. The circuit protection module can achieve dual overheat and overcurrent protection. When the temperature rise of the components in the multi-level collaborative protection module is abnormal, the circuit is quickly cut off to prevent the risk of fire. When the line is subjected to overcurrent impact, the current is promptly interrupted and limited, effectively isolating faulty components, ensuring the stable operation of the multi-level lightning protection structure, and significantly improving the overall safety protection level and service life of the device.

[0066] The multi-level collaborative protection module includes a first-level protection unit, a second-level protection unit, a third-level protection unit, and a fourth-level protection unit arranged sequentially. The first-level protection unit is connected to the output terminal of the power input terminal 1 and is used to directly conduct instantaneous large lightning currents to the ground, reducing the peak lightning current. The output terminal of the first-level protection unit is connected to the second-level protection unit, which is used to achieve voltage clamping and delay the surge rise slope. The output terminal of the second-level protection unit is connected to the backup protection module. Each branch of the backup protection module is equipped with a third-level protection unit, which is used to achieve multi-channel synchronous voltage equalization protection of the backup protection module. The output terminal of the backup protection module is equipped with a fourth-level protection unit, which is used to suppress differential mode surges between lines and absorb the trace surge residual voltage that may remain in the first three levels of protection. This application first coarsely guides the current at the power input terminal, then clamps the voltage, then divides the voltage through multiple branches, and finally sets a fourth level of protection after the backup protection module to absorb the small amount of residual surge voltage that may remain in the first three levels. Through the progressive and coordinated four-level protection units, this application completely eliminates the residual surge voltage and effectively protects the electrical equipment at the downstream end.

[0067] The first-stage protection unit includes a gas discharge tube and a primary busbar. The primary busbar is connected to the PE terminal of the power input terminal. The gas discharge tube is equipped with a contact temperature fuse, with one end connected to the input phase line and neutral line respectively, and the other end connected to the groundbar, forming a longitudinal lightning protection loop to ground. When a lightning surge enters the line, the gas discharge tube quickly breaks down and conducts, directly diverting the instantaneous ultra-large lightning current to the ground, reducing the peak lightning current, completing the first layer of coarse protection, and reducing the impact pressure on the downstream circuit. The first-stage protection unit can reduce the discharge impedance and prevent lightning backflow.

[0068] The second-level protection unit includes a varistor and a current-limiting inductor connected in series. The varistor is attached to a temperature fuse. When the varistor temperature is too high or it short-circuits due to aging, the temperature fuse will automatically blow to prevent fire and explosion, thus improving the safety performance of the equipment. The varistor is used to clamp the voltage of residual surges and limit the maximum voltage of the circuit. The current-limiting inductor slows down the surge rise slope and avoids voltage sudden changes from impacting components.

[0069] The third-level protection unit includes branch varistor elements and equalizing resistors. The branch varistor elements are connected in parallel between the phase line and neutral line of a single circuit to absorb residual surges in the branch. The equalizing resistors are connected to the incoming lines of the corresponding branches and uniformly connected to a common terminal. The varistor elements and equalizing resistors are independently installed. Each backup protection switch 3 of the backup protection module is connected in parallel to a separate third-level protection unit, forcibly equalizing the potential of the branch circuit where each backup protection switch 3 is located, achieving multi-circuit synchronous equalizing protection, and avoiding single-circuit voltage drift and branch uneven voltage interference. This level adopts distributed protection; a single-circuit fault does not affect the remaining circuits.

[0070] The fourth-level protection unit includes several horizontal surge protection modules 4 and several vertical surge protection modules 5. One end of each vertical surge protection module 5 is electrically connected to the phase line and neutral line of each circuit, and the other end is connected to the ground bus and then connected to the earth to eliminate common-mode surges to ground, balance the potential of the casing, and prevent electric shock. Each horizontal surge protection module 4 is connected across the phase line and the neutral line to suppress differential-mode surges (or differential-mode interference) between lines (such as LN) and control the residual voltage of the surge protector at a safe level.

[0071] The fourth-level protection unit, in conjunction with filter 9 (installed between the fourth-level protection unit and the alarm module), filters out high-frequency noise generated by lightning strikes, suppressing the final residual voltage within the safe tolerance range of the electrical equipment, thus achieving refined voltage stabilization and purification. Filter 9 is a high-frequency filter.

[0072] Preferably, in a three-phase single-circuit circuit, filter 9 is a three-phase four-wire filter; in a single-phase circuit, filter 9 is a single-phase filter. The filter works in conjunction with the fourth-level protection unit to suppress high-frequency noise and electromagnetic interference, ensuring stable power quality. The filter is integrated into the front end of the alarm module, effectively suppressing high-frequency interference and ensuring stable operation of downstream equipment.

[0073] Preferably, both the horizontal surge protection module 4 and the vertical surge protection module 5 are surge protectors. The surge protectors are voltage-limiting surge protectors (SPDs) that use high-energy MOV modules, have short response times, a maximum discharge current of 80kA (8 / 20 μs), and a built-in thermal trip device that automatically disconnects when the surge protector deteriorates.

[0074] The three-phase power surge protection box is equipped with one 4P surge protector (vertical surge protection module) and three 1P surge protectors (horizontal surge protection module) for each of the two circuits to protect each phase circuit; the single-phase power surge protection box is equipped with one 2P surge protector (vertical surge protection module) and one 1P surge protector (horizontal surge protection module) for each of the two circuits to protect each phase circuit.

[0075] Preferably, each surge protector is equipped with a dedicated backup protector. Since surge protectors age, if the surge protector overheats, the dedicated backup protector will immediately cut off the circuit to prevent the surge protector from burning. After the dedicated backup protector cuts off the circuit, the branch is completely de-energized, which will not affect other branches and makes it safer to replace equipment. In addition, the dedicated backup protector will not trip during lightning strikes, ensuring that the surge protector can safely discharge the lightning current without affecting the lightning protection function.

[0076] The working principle of the multi-level collaborative protection module is as follows:

[0077] Under normal power supply conditions, all levels of protection units are in a high-resistance cutoff state, backup protection switches remain closed, and the equipment is powered normally. When the line encounters a direct lightning strike, induced lightning strike, or surge overvoltage, the surge first enters the first-level protection unit, diverting most of the large current to the ground. The residual surge enters the second-level protection unit, completing clamping, current limiting, and overheat protection. The current is evenly distributed to multiple backup protection switches, and the third-level protection unit ensures consistent voltage across all circuits. In case of an anomaly, the switch trips and transmits a signal through auxiliary contacts. Finally, the fourth-level protection unit eliminates residual common-mode and differential-mode voltages, purifies the power supply, and outputs stable power to the load. After the fault is cleared, the device automatically recovers or is manually reset, continuously ensuring power distribution safety.

[0078] Example 1

[0079] like Figures 4 to 9 As shown, the power surge protection device is a three-phase power surge protection device, with two three-phase power supplies installed inside the enclosure. Figures 6 to 10 In the diagram, D represents the input power terminal, D1 represents the first input power terminal (the Arabic numerals only represent the number), B represents the parallel terminal, and similarly, B1 represents the first parallel terminal.

[0080] S1. Cut two 500mm guide rails and two 100mm guide rails, place them in appropriate positions on the mounting plate 12, and fix them with rivets. The guide rails are mainly located between two adjacent elongated holes to facilitate heat dissipation and to lay the wire harness in the elongated holes. The actual position is adjusted according to the size of the installed components.

[0081] S2. Use M6×14 combination bolts to fix the insulator to the mounting plate 12. Then use M6×14 combination bolts again to fix the copper busbar 11 (the copper busbar is the ground wire busbar) to the insulator. Fill the remaining holes with M8×12 bolts and tighten them.

[0082] S3. Install other components

[0083] The two circuits are symmetrically mounted on the mounting plate 12. A lightning counter 10 and a temperature sensor are installed between the two circuits. Since the connection methods of the two circuits are the same, only the connection method of one circuit is described at this time.

[0084] The components are arranged according to the principle of minimizing circuit connections. The main components, from top to bottom, are: power input terminal 1, backup protection unit, fourth-level protection unit, and phase failure sensor 8. The column containing phase failure sensor 8 also houses the switching power supply 7 and filter 9. Parallel terminals 2 are installed on one side of the backup protection unit and the fourth-level protection unit.

[0085] S31. Power input terminal 1 includes three phase lines A, B, and C and a neutral line N, for a total of four lines. The output terminal of power input terminal 1 is connected to the first-level protection unit. The first-level protection unit contains three gas discharge tubes, each of which is attached to a temperature fuse. The two poles of each gas discharge tube are electrically connected to the corresponding live wire and neutral wire, respectively. The grounding terminals are connected to the first-level busbar. The first-level busbar is used to directly connect to the building's main grounding grid or equipotential grounding terminal to realize the discharge of lightning energy to the ground.

[0086] S32, a second-level protection unit is connected in series on all four lines;

[0087] S33, the backup protection module includes four parallel backup protection switches 3, used to protect the three phase lines A, B, and C and the neutral line N, respectively. The fourth-level protection unit includes one 4P surge protector and three 1P surge protectors. Each backup protection switch 3 is connected in parallel with a third-level protection unit and then connected to the 4P surge protector. The three 1P surge protectors are connected across the phase line and the neutral line to suppress inter-line differential residual voltage. Each backup protection switch 3 also has an auxiliary contact, which is connected to the power input terminal 1 and the parallel terminal 2.

[0088] Each of the S34, 4P surge protector, and three 1P surge protectors is equipped with a dedicated backup protector.

[0089] A three-phase four-wire filter is also installed between the S35, the fourth-level protection unit, and the alarm unit. The filter works in conjunction with the fourth-level protection unit to suppress high-frequency noise and electromagnetic interference, ensuring stable power quality. The filter is located at the front end of the alarm module, effectively suppressing high-frequency interference and ensuring the stable operation of the back-end equipment.

[0090] S36. The alarm module includes a phase loss sensor 8, a buzzer, and indicator lights. The phase loss sensor 8 is fixed on the mounting plate 12. The buzzer and indicator lights are both mounted on the panel 152. The phase loss sensor 8 monitors each phase of electricity in the enclosure. The buzzer includes a lightning protection alarm buzzer and a phase loss alarm buzzer. The indicator lights include A-phase indicator lights, B-phase indicator lights, and C-phase indicator lights. Corresponding labels are written near the buzzer and indicator lights.

[0091] S37. The intelligent monitoring module includes a controller and its respective signal-connected lightning counter, leakage current sensor, and temperature sensor. The controller is installed on panel 152. The leakage current sensor is connected in series to the output side of the main switch of the device, covering all live conductors, and is located at the rear end of the surge protector (with the power input terminal 1 as the front).

[0092] S4. Wiring principles:

[0093] S41. Wiring installation should be organized and categorized in layers to control the thickness of the mounting plate and ensure that it can be placed in the enclosure.

[0094] S42. Wrap the reserved wires with spiral wound tubing to prevent the wires from getting tangled or crossing.

[0095] S43. When inserting a terminal block into a parallel terminal block, it should be fully inserted.

[0096] S44. Wiring connections must be secure and there should be no looseness. The connection points between the terminals and the equipment should be bent at 90°.

[0097] S5, such as Figure 5 As shown, place the configured mounting plate 12 into the housing 151, adjust the wiring at the rear of the mounting plate 12 until the mounting plate 12 is flush with the housing 151, and tighten the fixing screws with flat washers and spring washers to avoid loosening or uneven pressure. Use cable ties to fix the wiring wrapped in the spiral tube to the housing to ensure that the wiring is neat and secure.

[0098] S6. Install the display screen and controller on panel 152. Connect the controller, display screen, indicator lights, buzzer, leakage current sensor, temperature sensor, and lightning counter via signal cables. Cut off any excess tubing and secure the wrapped control cables to panel 152 with cable ties.

[0099] S7. Quality Inspection.

[0100] The principle of intelligent detection is as follows:

[0101] Under normal power supply conditions, all levels of protection units are in a high-resistance cutoff state, all backup protection switches remain closed, and the equipment is powered normally. When the line encounters direct lightning strikes, induced lightning strikes, or surge overvoltages, the surge first enters the first-level protection unit, diverting most of the large current to the ground; the residual surge enters the second-level protection unit, completing clamping, current limiting, and overheat protection; the current is evenly distributed to multiple backup protection switches, and the third-level protection unit ensures consistent voltage across all circuits. Auxiliary contacts are used to monitor the status of each backup protection switch in real time and transmit the collected signals to the controller in real time. When the backup protection switch in phase A circuit trips, the controller will display it on the screen, and the corresponding indicator light for phase A circuit will turn red to alarm, and the lightning protection alarm buzzer will sound an alarm. When all circuits are not affected... When a problem occurs, the display only shows the current status of the circuit. The fourth-level protection unit includes one 4P surge protector and three 1P surge protectors. Each surge protector is also equipped with an alarm contact (leakage sensor). The alarm contact transmits the collected signal to the controller in real time. When the controller determines that the 4P surge protector is abnormal, it will display the abnormality on the screen and the lightning protection alarm buzzer will sound an alarm. The phase failure sensor is used to monitor each three-phase circuit and the neutral line N in real time and transmits the collected information to the controller in real time. When the controller determines that the A-phase circuit is faulty, the indicator light corresponding to the A-phase circuit will turn red and the phase failure alarm buzzer will sound an alarm. If there are no problems throughout the process, the display only shows the current status of the circuit, the data collected by the lightning counter, and the temperature of the temperature sensor.

[0102] Example 2

[0103] like Figures 10 to 12 As shown, the power surge protection device is a single-phase power surge protection device. Two single-phase power supplies are installed inside the enclosure. D represents the input power terminal, B represents the parallel terminal, and B1 represents parallel terminal number one (Arabic numerals only represent serial numbers).

[0104] T1. Cut two 500mm guide rails and two 100mm guide rails, place them in appropriate positions on the mounting plate 12, and fix them with rivets. The guide rails are mainly located between two adjacent elongated holes to facilitate heat dissipation and to lay the wire harness in the elongated holes. The actual position is adjusted according to the size of the installed components.

[0105] T2. Use M6×14 combination bolts to fix the insulator to the mounting plate 12, and then use M6×14 combination bolts again to fix the copper busbar 11 to the insulator. Fill the remaining holes with M8×12 bolts and tighten them.

[0106] T3, Install other components

[0107] The two circuits are symmetrically mounted on the mounting plate 12. A lightning counter 10 and a temperature sensor are installed between the two circuits. Since the connection methods of the two circuits are the same, only the connection method of one circuit is described at this time.

[0108] The components are arranged according to the principle of minimizing circuit connections. The main components, from top to bottom, are: power input terminal 1, backup protection unit, fourth-level protection unit, and phase failure sensor 8. The column containing phase failure sensor 8 also houses the switching power supply 7 and filter 9. Parallel terminals 2 are installed on one side of the backup protection unit and the fourth-level protection unit.

[0109] T31. Power input terminal 1 includes two lines: live wire L and neutral wire N. The output terminal of power input terminal 1 is connected to the first-level protection unit. The first-level protection unit contains one gas discharge tube. The gas discharge tube is attached to a temperature fuse. The two poles of the gas discharge tube are electrically connected to the corresponding live wire and neutral wire, respectively. The grounding terminals are connected to the first-level busbar. The first-level busbar is used to directly connect to the main grounding grid of the building or the equipotential grounding terminal to realize the discharge of lightning energy to the ground.

[0110] T32, all four lines have a second-level protection unit connected in series;

[0111] The T33 backup protection module includes two parallel backup protection switches 3, used to protect the live wire L and the neutral wire N respectively. The fourth-level protection unit includes one 2P surge protector and one 1P surge protector. Each backup protection switch 3 is connected in parallel with a third-level protection unit and then connected to the 2P surge protector.

[0112] A 1P surge protector is connected between the phase line and the neutral line to suppress inter-line differential residual voltage. Each backup protection switch 3 also has an auxiliary contact, which is connected to the power input terminal 1 and the parallel terminal 2.

[0113] The T34, 2P surge protector, and 1P surge protector are all equipped with a dedicated backup protector.

[0114] A single-phase filter is also installed between the T35, the fourth-level protection unit, and the alarm unit. The filter works in conjunction with the fourth-level protection unit to suppress high-frequency noise and electromagnetic interference, ensuring stable power quality. The filter is located at the front end of the alarm module, effectively suppressing high-frequency interference and ensuring stable operation of the back-end equipment.

[0115] T36, the alarm module includes a surge protection alarm buzzer and indicator lights, both of which are mounted on panel 152.

[0116] T37. The intelligent monitoring module includes a controller and its respective signal-connected lightning counter, leakage current sensor, and temperature sensor. The controller is installed on panel 152. The leakage current sensor is connected in series to the output side of the main switch of the device, covering all live conductors, and is located at the rear end of the surge protector (with the power input terminal 1 as the front).

[0117] T4. Wiring principles:

[0118] T41. Wiring installation should be organized and categorized in layers to control the thickness of the mounting plate and ensure it can be placed in the enclosure.

[0119] T42. Wrap the reserved wires with spiral wound tubing to prevent the wires from getting tangled or crossing.

[0120] T43. When inserting a terminal block into a parallel terminal block, it should be fully inserted.

[0121] T44. Wiring connections must be secure and there should be no looseness. The connection points between the terminals and the equipment should be bent at 90°.

[0122] T5. Place the configured mounting plate 12 into the outer casing 151, adjust the wiring at the rear of the mounting plate 12 until the mounting plate 12 is flush with the outer casing 151, and tighten the fixing screws with flat washers and spring washers to avoid loosening or uneven pressure. Use cable ties to fix the wiring wrapped in the spiral tube to the box to ensure that the wiring is neat and secure.

[0123] T6. Install the display screen and controller on panel 152. Connect the controller, display screen, indicator lights, buzzer, leakage current sensor, temperature sensor, and lightning counter via signal cables. Cut off any excess tubing and secure the wrapped control cables to panel 152 with cable ties.

[0124] T7. Quality Inspection.

[0125] The principle of intelligent detection is as follows:

[0126] Under normal power supply conditions, all levels of protection units are in a high-resistance cutoff state, all backup protection switches 3 remain closed, and the equipment is powered normally. When the line encounters a direct lightning strike, induced lightning strike, or surge overvoltage, the surge first enters the first-level protection unit, diverting most of the large current to the ground; the residual surge enters the second-level protection unit, completing clamping, current limiting, and overheat protection; the current is evenly distributed to multiple backup protection switches, and the third-level protection unit ensures that the voltage of each circuit is consistent. Auxiliary contacts are used to monitor the status of each backup protection switch in real time and transmit the collected signals to the controller in real time. When the backup protection switch in the live wire L circuit trips, the controller will display... The screen displays the current status of the circuit, and the indicator light turns red to indicate an alarm. The surge protection alarm buzzer sounds an alarm. When all circuits are functioning correctly, the display only shows the current status of that circuit. The fourth-level protection unit includes one 2P surge protector and one 1P surge protector. Each surge protector is also equipped with an alarm contact (leakage sensor). The alarm contact transmits the collected signal to the controller in real time. When the controller determines that the 2P surge protector is malfunctioning, it will display the abnormality on the screen and the surge protection alarm buzzer will sound an alarm. If there are no problems throughout the process, the display only shows the current status of the circuit, the data collected by the lightning counter, and the temperature of the temperature sensor.

[0127] Comparative Example 1

[0128] The three-phase power surge protector box purchased from the market has the same application method as Comparative Example 1 and features secondary protection.

[0129] The surge protection effect of the five power surge protection devices assembled according to Example 1 (named S1, S2, S3, S4 and S5 respectively for easy differentiation during testing) and the five products purchased from Comparative Example 1 (named D1, D2, D3, D4 and D5 respectively) will be tested according to GB / T 21431-2023. The test steps include the following:

[0130] A1. Ensure a safe testing environment (mandatory by standard).

[0131] A11. Perform a full power-off test, hang a warning sign, and verify that there is no power.

[0132] A12. Before disconnecting the wire, short-circuit L / N / PE to ground for 3–5 seconds to discharge.

[0133] A13. Ensure reliable grounding, with grounding resistance ≤4Ω (≤1Ω for important computer rooms) and transition resistance ≤0.2Ω.

[0134] A2. Visual and wiring inspection

[0135] A21. No deformation, blackening, odor, or water ingress; door lock intact.

[0136] A22, L / N / PE wire diameter ≥ 6mm², crimped securely, no loosening or oxidation; PE wire must be reliably grounded separately.

[0137] A23, SPD module: No cracks, yellowing, or burning; indicator lights, buzzer, and display screen are normal; trip unit / circuit breaker is normal.

[0138] A3. Test Items

[0139] A31. Residual Pressure Test

[0140] Equipment: An 8 / 20μs surge generator is used, injecting a nominal current of 40kA.

[0141] Test: Measure the residual voltage at L–PE, N–PE, and L–N (voltage protection level U) P ).

[0142] Qualified: Residual voltage ≤ 1.5kV (low voltage); the lower the voltage, the better the protection.

[0143] A32. Current Capacity Test

[0144] Inject a nominal current of 52kA (1.3 times the nominal current) and impact it 10 times.

[0145] Pass: The module does not break down, does not burn, and the residual pressure does not increase significantly.

[0146] A33, Response Time

[0147] The time it takes for a surge voltage to switch from being cut off to conducting and discharging current in the instant a surge voltage strikes.

[0148] Qualified: ≤25ns.

[0149] A34, Power Frequency Withstand Voltage

[0150] Applying 2kV / 1min (L–PE, N–PE) resulted in no flashover or breakdown.

[0151] The results of testing Examples 1, 2, 1 (Comparative Example), and 2 (Comparative Example 2) using the methods described above are shown in Table 1.

[0152] Table 1

[0153] External wiring qualified qualified qualified qualified qualified qualified qualified qualified qualified qualified Insulation resistance qualified qualified qualified qualified qualified qualified qualified qualified qualified qualified DC reference voltage 1% 5% -1% 3% 8% 1% 6% -5% 8% 1% Leakage current (μA) 150 180 100 120 160 150 140 100 170 180 Grounding resistance (standard) (Ω) 2 2 2 2 2 2 2 2 2 2 Power frequency withstand voltage qualified qualified qualified qualified qualified qualified qualified qualified qualified qualified 8 / 20μs residual voltage (kV) 0.1 0.5 0.3 0.1 0.2 1.3 1.5 1.1 1.3 1.2 Nominal flow impact qualified qualified qualified qualified qualified qualified qualified qualified qualified qualified Response time (ns) 10 12 15 8 9 20 25 22 19 18

[0154] As shown in Table 1, all test results of the above 10 products meet the standard requirements, and therefore they are all qualified products.

[0155] The residual voltage of the residual test is considered qualified if it is ≤1.5kV. Since the lower the value, the better the protection effect. As can be seen from the data, the average residual voltage of the products S1-S5 in the example is (0.1+0.5+0.3+0.1+0.2)kV / 5=0.24kV, and the average residual voltage of the comparative products D1-D5 is (1.3+1.5+1.1+1.3+1.2)kV / 5=1.28kV. The data of the comparative products are close to the qualified line of the mandatory standard, while the residual voltage of the protection device of this application is much lower than the qualified line of the national standard. This indicates that the protection effect of this application is much higher than the national standard requirements, and the protection effect is better than that of secondary lightning protection products.

[0156] The response time is the time it takes for a surge voltage to switch from cutoff to conduction to discharge current. It generally cannot exceed 25 ns. A faster response clamps the high voltage earlier, reducing damage to the equipment. Excessive response time results in insufficient voltage suppression and protection failure. Table 1 shows that the average response time of products S1-S5 in the embodiment is (10+12+15+8+9) ns / 5 = 10.8 ns, while the average response time of products D1-D5 in the comparative example is (20+25+22+19+18) ns / 5 = 20.8 ns. From the above data, it can be seen that the average response speed of the protection device in this application is 10 ns faster than that of the comparative product, effectively reducing damage to the equipment.

[0157] This power supply surge protection device is designed for power supply systems. It couples the power cable to allow lightning to flow into the ground, protecting electrical equipment from damage caused by transient surges such as lightning surges and operational overvoltages. It can also monitor and track data of lightning intrusion into the power cable in real time, and realize phase loss alarm function. It is suitable for communication base stations, industrial equipment, data centers and other scenarios.

[0158] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A power supply surge protection device, characterized in that: include: The intelligent monitoring module includes a controller and a lightning counter connected to it, as well as a leakage current sensor for identifying line leakage faults. The backup protection module includes multiple backup protection switches, each of which has an auxiliary contact. The auxiliary contact signal is connected to the controller. The multi-level collaborative protection module includes a first-level protection unit connected to the power input terminal to conduct instantaneous large lightning current to the ground, a second-level protection unit connected to the output terminal of the first-level protection unit to achieve voltage clamping and delay the surge rise slope, a backup protection module connected to the output terminal of the second-level protection unit, a third-level protection unit configured for each backup protection switch to achieve multi-channel synchronous voltage equalization protection, and a fourth-level protection unit set at the output terminal of the backup protection module. The first-level protection unit includes a gas discharge tube and a primary busbar. The primary busbar is connected to the PE terminal of the power input terminal. The gas discharge tube is equipped with a thermal fuse. One end of the gas discharge tube is connected to the input phase line and the neutral line respectively, and the other end is connected to the grounding busbar to form a longitudinal lightning protection circuit to the ground. The second-level protection unit includes a varistor and a current-limiting inductor connected in series, and the varistor is attached to the temperature fuse; The third-level protection unit includes branch varistor elements and equalizing resistors. The branch varistor elements are varistors connected in parallel between the single phase line and the neutral line to absorb residual surges in the branch. The equalizing resistors are connected to the incoming lines of the corresponding branches and are uniformly connected to the common terminal. The fourth-level protection unit includes several horizontal lightning protection modules and several vertical lightning protection modules. One end of each vertical lightning protection module is electrically connected to the phase line and the neutral line of each circuit, and the other end is connected to the ground busbar to the ground. Each horizontal lightning protection module is connected across the phase line and the neutral line. The circuit protection module is installed in the multi-level collaborative protection module, backup protection module and power circuit to cut off the faulty circuit; The alarm module is connected to the controller signal. The enclosure is used to house multi-level collaborative protection modules, alarm modules, circuit protection modules, backup protection modules, and intelligent monitoring modules.

2. The power supply surge protection device according to claim 1, characterized in that: The circuit protection module includes a temperature fuse and an overcurrent fuse. The temperature fuse is fitted into the multi-level collaborative protection module and is used to cut off the faulty circuit when the multi-level collaborative protection module fails. The overcurrent fuse is connected in series in the power supply circuit and is used to cut off the faulty circuit when a power frequency short circuit current occurs.

3. The power supply surge protection device according to claim 1, characterized in that: Both the horizontal and vertical surge protection modules are surge protectors used to protect each phase of the circuit. In a three-phase circuit, the fourth-level protection unit includes one 4P surge protector and three 1P surge protectors. In a single-phase circuit, the fourth-level protection unit includes one 2P surge protector and one 1P surge protector.

4. A power surge protection device according to claim 3, characterized in that: Each surge protector is equipped with a dedicated backup protector to prevent fires caused by surge protector failure and to ensure that the fourth-level protection unit does not fail after being struck by lightning.

5. A power supply surge protection device according to claim 1, characterized in that: A filter is connected between the fourth-level protection unit and the alarm module to suppress high-frequency noise and electromagnetic interference. In a three-phase circuit, the filter is a three-phase four-wire filter; in a single-phase circuit, the filter is a single-phase filter.

6. A power surge protection device according to claim 1, characterized in that: The alarm module includes a phase loss sensor, a buzzer, an indicator light, and a display screen, all of which are connected to the controller signal. The phase loss sensor is used to monitor each phase of the circuit. The buzzer, display screen, and indicator light are all mounted on the panel of the enclosure. The number of indicator lights is the same as the number of phases in the circuit.

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