摘要：電子節(jié)能燈是一種節(jié)能減排的新型照明設(shè)備。介紹了電子節(jié)能燈在制造過程中的幾項關(guān)鍵技術(shù)，為相關(guān)工程技術(shù)人員提供參考。
Abstract: electronic energy-saving lamp is a new lighting energy saving and emission reduction. Electronic energy-saving lamps are introduced several key techniques in the manufacturing process, provide a reference for relevant engineering technical personnel.
關(guān)鍵詞：電子節(jié)能燈；制造；關(guān)鍵技術(shù)
Keywords: electronic energy-saving lamps; Manufacturing; The key technology
1 引言
1 introduction
節(jié)能減排是當(dāng)前我國十分關(guān)注的問題。隨著社會的發(fā)展和人們生活水平的提高，照明用電量逐年增加，照明在能源消耗和環(huán)境污染上的問題已引起人們的重視。在保證照明質(zhì)量的前提下如何節(jié)約用電、減少污染、實現(xiàn)綠色照明已成為照明行業(yè)的發(fā)展主題。電子型自鎮(zhèn)流熒光燈。即一體化電子節(jié)能燈，已越來越多地代替白熾燈泡而廣泛用于家庭、商場、賓館等各種室內(nèi)照明場合。
Energy conservation and emissions reduction is one of the focuses of the current our country. With the development of the society and people living standard rise, the lighting electricity consumption increases year by year, lighting on the energy consumption and environment pollution problem has aroused people's attention. On the premise of guarantee the quality of lighting to save electricity, reduce pollution, realizing the development of green lighting lighting industry has become a topic. Electrical ballast fluorescent lamps. Integration of electronic energy-saving lamps, have increasingly replace incandescent bulbs and are widely used in family, shopping malls, hotels and other indoor lighting situations.
2 電子節(jié)能燈的制造關(guān)鍵技術(shù)
2 electronic energy-saving lamp manufacturing key technologies
2、1 節(jié)能燈元器件的選擇
2, the selection of energy-saving lamp components
(1)毛管是電子節(jié)能燈的重要部件。技術(shù)指標(biāo)主要有光電參數(shù)，其次有外形尺寸和外觀以及機(jī)械強度等，再次是低溫啟動性能和熱態(tài)參數(shù)穩(wěn)定特性等。光通量是否合格將直接關(guān)系到節(jié)能燈的能效等級能否達(dá)到標(biāo)準(zhǔn)的要求。光通維持率是產(chǎn)品申請“能源之星”認(rèn)證時必須要考核的指標(biāo)，要求節(jié)能燈燃點至有效壽命40％時，其光通量不得小于額定值的80％。此外還有相關(guān)色溫、顯色性、色坐標(biāo)和色容差等指標(biāo)，也是應(yīng)該重視的。尤其是色容差，色容差超標(biāo)往往會給予不合格的判定。至于熒光粉品質(zhì)的分選，可用驗鈔燈作對比檢驗。
(1) capillary is one of the important parts of electronic energy-saving lamps. Technical indicators are photoelectric parameters, the second shape size and appearance as well as mechanical strength, again is a low-temperature startup performance and thermal state parameters stability characteristics. Luminous flux eligibility will be directly related to energy-saving lamps energy efficiency grade can meet the requirements of standard. Optic products maintain rate is apply for energy star certification must be assessment indicators, require 40% energy-saving lamps ignition point to useful life, the luminous flux shall not be less than 80% of rating. In addition to correlated color temperature, color rendering, color coordinates, and poor capacity index of color, also should pay attention to. Especially the color tolerance, color tolerance levels tend to give unqualified judgement. As for the fluorescent powder quality sorting, yanchao lights available comparison test.
(2)整流二極管。
(2) the rectifier diode.
選擇整流二極管時，應(yīng)注意以下參數(shù)。最大正向整流電流該參數(shù)與燈功率有關(guān)，所選二極管的額定電流值至少應(yīng)是交流母線中峰值電流的3倍以上。對大功率燈而言。整流二極管不可直接并聯(lián)使用，因為二極管的熱電阻有差異，會使可靠性降低，最好用一組電流大的二極管。
Choosing a rectifier diode, the following parameters should be paid attention to. Biggest positive the parameters associated with the lamp power rectifier current, the rated current value of the selected diode should be a peak current in ac bus at least more than 3 times. For high power lamps. Rectifier diodes cannot be used directly in parallel, because the diode heat resistance have differences, will reduce the reliability, it is better to a set of current of diode.
峰值反向截止電壓，因工作溫度高，一般要選用1200V的產(chǎn)品。濾波電解電容器，電解電容因會受到高頻脈動電流的沖擊和工作溫度升高，選用高性價比的電解電容器就顯得很重要。電容量及容差、額定電壓、耐紋波電流、串聯(lián)等效電阻(ESR)、允許溫度等都是重要的技術(shù)指標(biāo)，質(zhì)量的好壞直接關(guān)系到使用壽命。電解電容的耐紋波電流值應(yīng)越大越好。如果電解電容的耐紋波電流值達(dá)不到線路要求，則會嚴(yán)重影響其使用壽命，選用時應(yīng)特別注意。紋波電流流經(jīng)ESR，會產(chǎn)生熱量引起電解內(nèi)部溫度升高，目前制造商對電容器在額定工作溫度下工作的紋波電流的確定，一般均遵循5℃原則。電容量的選擇與輸入電流中的諧波含量和燈電流的波峰因數(shù)以及鎮(zhèn)流器的效率有關(guān)。電解電容的標(biāo)記溫度，必須大于實際工作溫度，并留出一定的差值。
Peak reverse cut-off voltage, due to the high operating temperature, generally should choose the 1200 v products. Filtering electrolytic capacitor, electrolytic capacitor will be impacted by the high frequency pulse electric current and working temperature, choose high performance to price ratio of the electrolytic capacitor is very important. And capacitance tolerance, rated voltage, ripple current, equivalent series resistance (ESR), allowed temperature, etc are important technical indicators, quality is directly related to life. Resistance of electrolytic capacitor ripple current value should be the bigger the better. If the resistance of electrolytic capacitor ripple current value can not meet the line requirement, will seriously affect its service life, should pay special attention to when choose. Ripple current flows through the ESR, can produce heat cause the electrolytic temperature, current manufacturer of capacitors work under rated operating temperature of the determination of ripple current general shall follow the principle of 5 ℃. Capacitance of the selection and input current harmonic content and the crest factor of lamp current and efficiency of ballasts. Signs of electrolytic temperature, temperature must be greater than the actual work, and set aside a certain difference.
(3)功率晶體管。
(3) the power transistor.
功率晶體管工作在開關(guān)狀態(tài)，選擇的原則是：開關(guān)速度要快，飽和壓降要小，集電極電流要大，在不增加成本的條件下，功率和二次擊穿耐量越大越好。集電極額定電流應(yīng)依據(jù)陰極導(dǎo)人電流峰值并留存足夠的安全余量。開關(guān)時間要小，應(yīng)重點關(guān)注存貯時間ts，從理論上講ts小則開關(guān)功率損耗也小，但更重要的是上、下兩管ts值的對稱。如果同一電路板上的兩個管子的ts嚴(yán)重偏離，會使正負(fù)兩個波形的面積嚴(yán)重不對稱，導(dǎo)致管子過熱損壞。
Work power transistor in the switch state, in principle is: faster switching speed, saturation voltage drop and collector current, under the condition of without increasing cost, power and secondary breakdown tolerance is bigger, the better. Collector current rating should be based on the cathode lead people current peak and keep enough safety margin. Switching time, should focus on storage time ts, theoretically ts a small switch power loss is little, but more importantly, the two tube ts values of symmetry. If the same PCB two ts gravely deviates from the tube, will make the area of plus or minus two waveform serious asymmetry, lead to damaged tube overheating.
(4)振蕩變壓器。
(4) oscillation transformer.
振蕩變壓器通常是在環(huán)形鐵氧體磁芯上繞線制成，實際上是一個電流互感器。對磁環(huán)的要求是：首先，磁導(dǎo)率應(yīng)有負(fù)溫度特性，轉(zhuǎn)折溫度在95'C左右；其次，磁滯回線左右要對稱并且近似為矩形；再次，磁導(dǎo)率參數(shù)的離散性要小。要與供應(yīng)商預(yù)約電感系數(shù)，并做到分檔包裝，否則，成燈功率的偏差不易把握。
Oscillation transformer are usually made on the ring ferrite core coil winding, is actually a current transformer. Demand for copper is: first, the permeability should be negative temperature characteristic, turning the temperature in the 95 'C or so; Second, hysteresis loop around to symmetry and approximate rectangle; Again, the discreteness of permeability parameters. To make an appointment to inductance coefficient with the supplier and do step packaging, otherwise, the lamp power deviation is not easy to grasp.
(5)濾波電感。
(5) filtering inductance.
燈功率在25w或以下時，通常在直流電路中插入L與C，組成簡單的濾波回路。對于串模濾波電感，因其中流過直流電流，故要求磁芯應(yīng)在不飽和狀態(tài)下工作。又因燈內(nèi)溫度高，因此又要求電感量隨溫度變化要盡可能小。另外，電感量不能隨頻率的升高而下降。
Under 25 w or lamp power, usually inserted in the dc with C L, form a simple filter circuit. In series mode filtering inductance, because of which flows through the dc current, the magnetic core is therefore required work under unsaturated condition. And because of the high temperature in the lamp, so asked for inductance varies with temperature changes as small as possible. In addition, the inductance can't along with the rise of frequency decline.
燈功率大于25w時，一般要在交流電路中插入共模電感。共模電感是在同一磁芯上繞有兩個相同匝數(shù)的線圈，往復(fù)的負(fù)載電流在磁芯內(nèi)部產(chǎn)生的磁場相互抵消，因此磁芯不會飽和。燈功率大于45w時，產(chǎn)生的傳導(dǎo)干擾會更大，當(dāng)單純使用共模濾波仍然不能解決問題時，還要加入差模電感。
Lights when the power is greater than 25 w, generally want to insert the common-mode inductors in the circuit. Common-mode inductance is wound on the same core has two the same number of turns of the coil, the reciprocating load current in the magnetic core of internal magnetic field offset each other, so that no magnetic core is saturated. Lights when the power is greater than 45 w, the conducted interference will be bigger, when pure use of common mode filter still cannot solve the problem, but also in differential mode inductance.
2、2 EMC濾波電路調(diào)試
2, 2, EMC filter circuit debugging
分析傳導(dǎo)干擾噪聲源，可以發(fā)現(xiàn)共模噪聲與差模噪聲是相互獨立的。輻射干擾起源于傳導(dǎo)干擾。抓住傳導(dǎo)噪聲的抑制，產(chǎn)品就容易符合EMC要求。為滿足標(biāo)準(zhǔn)要求，必要時可對兩個噪聲分量單獨設(shè)計合適的濾波器。
Analysis conducted interference noise, we can find common mode and differential mode noise were independent of each other. Radiated interference originated in the conducted interference. Seize the transmission noise suppression, the product is easy to meet EMC requirements. To meet the requirements of the standard, if necessary, for the two noise component separate design a suitable filter.
共模干擾信號主要是通過燈內(nèi)元器件和線路的分布電容構(gòu)成回路傳輸?shù)��？梢�。共模干擾信號基本上都是屬于高頻信號。共模電感參數(shù)的選擇，取決于開關(guān)頻率以及所要求的衰減量。選用不同的電感參數(shù)，對應(yīng)衰減共模干擾信號的頻率也不一樣。在輸入功率較大的電路中，僅用一個共模電感不能達(dá)到標(biāo)準(zhǔn)要求時就要用兩個共模電感了，其中一個可用環(huán)形磁芯電感。
Common-mode interference signals mainly through the light of internal components and wiring capacitance circuit transmission. Visible. Common-mode interference signals are basically belongs to the high frequency signal. The choice of common-mode inductance parameters, depends on the switching frequency and the attenuation. Choose different inductance parameters, the attenuation common-mode interference signals of corresponding frequency is different also. Circuits in the input power is larger, with only a common-mode inductance can't meet the requirements of standard with two common mode inductor, one of the available circular magnetic core inductance.
事實上共模電感的兩個線圈的電感量不可能完全對稱，從而形成差模電感，同時用來抑制電源線上存在的差模干擾信號。必要時再設(shè)專用的差模電感。差模干擾信號是通過電源輸電線路進(jìn)行傳輸?shù)�，并繼發(fā)輻射干擾。對于差模電感和X2電容，從理論上講電感量和電容量越大，其插入損耗也越大，但要更多的關(guān)注它們的頻率諧振點。一般說來，L、c濾波器的諧振頻率應(yīng)小于或等于點燈頻率。
In fact two of common-mode inductance coil inductance can't completely symmetrical, forming a differential mode inductance, at the same time to restrain the power cord of differential mode interference signal. When it is necessary to set up a dedicated differential mode inductance. Differential mode interference signals are transmitted through the power transmission lines, and secondary radiated interference. For differential mode inductance and X2 capacitors, theoretically the inductance and capacitance, the greater the its insertion loss is bigger, but they should pay more attention to the frequency of the resonant point. Generally speaking, L, c filter resonant frequency should be less than or equal to the frequency of light.
對于串模電感的電感量，當(dāng)前趨向是取小一些，C取大一些。這不但可使L的自身溫升減低，還能改善濾波效果。這是因為c值大，使低頻段噪聲的插入損耗也大；L小，其分布電容也小，從而降低高頻段噪聲的傳導(dǎo)量。
For string mode choke inductance, current trends is smaller, C get bigger. This not only can make the temperature decrease of L, can also improve the filtering effect. This is because the c value is big, the insertion loss for low frequency noise; L is small, the distributed capacitance is small, so as to reduce the amount of conduction, the high frequency noise.
2、3 開關(guān)晶體管的設(shè)計
2, 3, the design of the switching transistor
開關(guān)晶體管的驅(qū)動信號有一個最佳值。基極電流Ib最理想的數(shù)值是集電極電流Ic的1／10左右，不過該電流的最優(yōu)化值也是隨晶體管不同而不同的。采用電流互感器驅(qū)動時，Ib應(yīng)始終保持為Ic的1／10左右，無論Ic大小如何，均保持這個關(guān)系，就不會出現(xiàn)Ic小時，驅(qū)動功率過大；而Ic大時，驅(qū)動功率不足的現(xiàn)象。按hfe合理設(shè)計驅(qū)動電流及其匝數(shù)比•使開關(guān)晶體管在導(dǎo)通時始終處于淺飽和狀態(tài)。這樣可以提高開關(guān)管的響應(yīng)速度，并可最大限度地減少驅(qū)動功率的浪費和損耗。驅(qū)動信號不僅有幅度的要求，還有波形的要求，即晶體管的開關(guān)渡越時間要短。開關(guān)渡越時間既與開關(guān)晶體管的開關(guān)時間有關(guān)，又與磁滯回線的角形比有關(guān)，此外，還與電路參數(shù)的調(diào)試有關(guān)。取存貯時間ts相同的開關(guān)管制作鎮(zhèn)流器，用半導(dǎo)體點溫度計檢測兩開關(guān)管的表面溫度，如果兩管的溫度差別較大，就可適當(dāng)或加或減磁環(huán)的初級匝數(shù)，使之趨于平衡。開關(guān)晶體管的功率容限，即安全工作區(qū)SOA。有時燈電路中會有同時出現(xiàn)大電流和高電壓的情況，尤其是燈在熱態(tài)做開關(guān)試驗時。用SOA值高的管子就不容易損壞。在無條件直接測試管子的SOA值時，可選用BVceo高的晶體管，BVceo高的管子一般SOA也高。
Switch transistor driver signal has an optimum value. Base current Ib is the most ideal numerical collector current Ic around 1/10, but the current optimization values is also varies with the transistor. Driven by current transformer, the Ib should be kept for about 1/10 of the Ic, whatever Ic size, all keep the relationship, you won't get Ic hours, driving power is too large; Big and Ic, as driving power, insufficient phenomenon. According to hfe reasonable design drive current and the number of turns, the switch transistor is always in a state of shallow saturated. When conducting So that we can improve the response speed of the switch tube, and can minimize driving power waste and loss. Drive signal not only has a range of requirements, and waveform of requirements, namely the transistor switch shorter transit time. Switch to transit time is related to the switching time of the switch transistor, and associated with the Angle ratio of hysteresis loop, in addition, also associated with the commissioning of circuit parameters. Take storage time ts the same switch control for ballast, with semiconductor thermometer testing two switch tube surface temperature, if the temperature difference of two tube is bigger, can be appropriate, or add or subtract the circular on the number of primary turns, bring it into balance. Switch transistor power tolerance that SOA security work area. Sometimes lamp circuit has a large current and high voltage that appears at the same time, especially when lamp switch in hot state test. With SOA value high tube is not easy to damage. In unconditional test tube SOA value directly, can choose high BVceo transistors, BVceo high tube general SOA is high also.
3 結(jié)論
3 conclusion
節(jié)能燈的制造技術(shù)貫通于產(chǎn)品的設(shè)計與檢驗過程，與生產(chǎn)實踐緊密相連。需要工程技術(shù)人員合理設(shè)計，編制出好的工藝文件，指導(dǎo)工人做好每個工序的生產(chǎn)，把握好每個工序的生產(chǎn)質(zhì)量，這樣才能為社會和家庭提供光效高、壽命長的新一代照明工具。
Energy-saving lamp manufacturing technology breakthrough in the design of the products and the inspection process, closely combined with production practice. Need reasonable design engineering and technical personnel, prepare a good process documents, guide the workers to do every working procedure of production, good grasp every process of production quality, so as to provide high photosynthetic efficiency, long life for social and family to a new generation of lighting tools.
