CN1196654A - 加热器-传感器复合装置 - Google Patents
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Abstract
本发明涉及一种加热器-传感器复合装置,其中一种铁-铬合金电热材料和一种镍或镍-铬合金组成一个热电偶。采用这种加热器-传感器复合装置,可以方便且精确地检测出钎焊烙铁的尖端温度。
Description
本发明涉及一种双引线型加热器-传感器复合装置,包括集成在一起的一个加热器单元和一个传感器单元。本发明尤其涉及一种适合用于钎焊烙铁的热输入的加热器-传感器复合装置。
参照表示钎焊烙铁的尖端的图11,一个棒形的陶瓷加热元件51被嵌入钎焊烙铁的尖端部分52。这一陶瓷加热元件51包括一个卷绕在一个陶瓷芯棒上的未烧结(green)的陶瓷片53。未烧结的陶瓷片53已被印制出加热器和传感器的图案。这些图案的拓扑关系可以,例如,如图12所示。在这一实例中,传感器图案55采用钨胶印制成宽度为0.2mm的图案,而加热器图案54采用钨胶环绕上述传感器图案55印制成宽度为0.4mm的图案。传感器图案55向后延伸穿过加热器图案54并与传感器电极56相连,而加热器图案54和位于上述传感器电极56前方的加热器电极57相连。
然而,图11和12中表示出的装有传感器的陶瓷加热器也有缺点,由于它带有四根引线,上述芯棒的外径不能减至小于3.5mm。这样,如果钎焊烙铁需要减小尺寸,由于引线在管理上的自由度的限制,管径就不能被更进一步地减小。由于传感器被装在陶瓷芯棒的圆周表面,钎焊烙铁尖端温度不能被精确地检测到,这也是一个缺点。而且,钎焊烙铁尖端温度的检测,与阻抗值随温度的变化有关,所描述的钎焊烙铁也不例外,这种情况下在产品中必须有一个相当的变动量以便每个产品都必须被调整在允许的容差极限内。
然而,也提供一个以这样的方式装配的加热器-传感器:一根电热丝被直接绕在一根陶瓷芯棒上,然后敷上一层陶瓷涂层,以保证必要的绝缘性能从而代替了将未烧结的陶瓷片缠在陶瓷芯棒上。
然而,这样的一个加热器具有如下缺点:当陶瓷涂层含有紧实精细陶瓷微粒时,由于与陶瓷涂层的热膨胀系数相比电热丝具有相对较高的热膨胀系数,所以涂层易于产生裂纹。另一方面,如果将粗糙的陶瓷微粒用于上述陶瓷涂层,绝缘电阻的降低会引起对工作负载,例如一个基片的电流泄漏。
为实现其目标,通过设计来克服现有技术的上述缺点,本发明提供有一种加热器-传感器复合装置,尽管其结构简单,却不仅能精确检测出钎焊烙铁的尖端温度,而且能确保完全绝缘,而不存在绝缘层内产生裂纹的危险。
为实现上述目标所开发的本发明涉及一个加热器-传感器复合装置,包括一个由第一金属材料制成的加热元件、一个由所述第一金属材料制成的非加热元件,和一个由一种第二金属材料制成的非加热元件。由所述第一金属材料制成的所述加热元件,被焊到由所述第二金属材料制成的所述非加热元件的前端,所述第一金属材料是一种电热铁-铬合金,而所述第二金属材料是一种镍或镍-铬合金,由此在其间形成了热电偶。
由所述第一金属材料制成的所述加热元件最好是一根相对较小直径的金属丝,以线圈的形式绕在一个柱状的绝缘管上,并且与由所述第一金属材料制成的所述非加热元件相连接,该元件是直线型的具有相对较大直径的金属丝,并与所述绝缘管的柱形表面紧固;而由所述第二金属材料制成的所述非加热元件,是一个穿过上述绝缘管内腔的直线型元件。
依照本发明,由于采用了一种铁-铬合金电热材料与一种镍或镍-铬合金相结合组成一种热电偶,就能以一种简单的方式精确地检测出钎焊烙铁的尖端温度。
图1是一个示意图,表示出体现本发明原理的一个加热器-传感器复合装置的基本结构。
图2是一个视图,表示出图1中所示的加热器-传感器复合装置,被装在一个绝缘管中以形成一层绝缘层。
图3是一个曲线图,表示出图1中所示的加热器-传感器复合装置的温度分布。
图4是一个曲线图,表示出图1中所示的加热器-传感器复合装置的热电动势的特性。
图5是一个视图,表示出图2中所示的加热器-传感器复合装置与保护管的几何关系。
图6是一个视图,表示出钎焊烙铁的整体形状。
图7是一个剖面图,表示出钎焊烙铁的结构。
图8是一个框图,表示出钎焊烙铁的温度控制电路的一部分。
图9是一个框图,表示出同一温度控制电路的其余部分。
图10是一个时序图,表示出图8中所示的控制电路的各部分的波形。
图11是一个视图,表示出常规钎焊烙铁的结构。
图12是一个视图,表示出加热器图案和传感器图案。
现在将参照附图的几个视图中所示的优选实施例更详细地描述本发明。
如图1和2所示,根据本发明,钎焊烙铁加热器的主要部分包括一个带有一个沿轴向的内腔1a的柱形绝缘管1,以及一个装在其上的加热器-传感器复合装置2。绝缘管1可以,例如,是一个氧化铝管。
参照表示出加热器-传感器复合装置的图1,线圈形加热丝3的尖端3a通过氩弧焊与直线型非加热丝4的尖端4a焊接。加热丝3的端部3b与直线型的非加热丝5焊接。加热丝3由铁-铬合金制成。合金组分的典型实例如表1中所示。
表1
Cr Al Mn C Fe
第1种 23-27 3.5-5.5 ≤1.0 ≤0.15 余额
第2种 17-21 2-4 ≤1.0 ≤0.15 余额
在这些铁-铬合金中,最好采用Kanthal D(由Kanthal公司制造的一种Kanthal丝)。其主要的组成元素的比例为Cr=22.0而Al=4.8。也可以采用可供选择的组分:Cr=22.0,Al=5.8;Cr=22.0,Al=5.3;以及Cr=20.0,Al=4.0。
在这一实施例中,非加热丝4由镍制成,而非加热丝5和加热丝3由相同的Kanthal D合金制成。然而,为了防止在非加热丝5中产生热量,非加热丝5的直径大约为加热丝3的直径的2.5倍。
当上述结构的加热器-传感器复合装置2被供给电流时,加热丝3产生热量,从而在理论上得到图3(b)中所示的温度分布。因此,尽管非加热丝4、5的端部4b、5b的温度大体相同并等于T0,氩弧焊点4a、3a的温度为T1,而加热丝3的中央部分则达到一个很高的温度。Kanthal丝(3、5)和Ni丝(4)组成一个热电偶,这样,假定Ni丝的塞贝克系数为α,而Kanthal丝的塞贝克系数为β,则在非加热丝4的端部4b与非加热丝5(Kanthal丝)的端部5b之间会产生电动势
α(T1-T0)-β(T1-T0)
由于α和β的符号不同,非加热丝4、5的电动势互相迭加。非加热丝5的尖端部分5a的温度随着加热丝3的温度的增益而升高,因此,假定将Ni丝选作非加热丝5,则非加热丝4、5的端部4b、5b之间的电动势会降低。
表2(单位:mV)
温度 0 100 200 300 400
0 0 1.731 3.622 6.332 8.410
10 0.175 1.939 3.830 6.521 8.626
20 0.381 2.079 4.044 6.724 8.849
30 0.587 2.265 4.400 6.929 9.060
40 0.804 2.470 4.691 7.132 9.271
50 1.005 2.676 4.989 7.356 9.531
60 1.007 2.899 5.289 7.561 9.748
70 1.107 3.081 5.583 7.774 10.210
80 1.310 3.186 5.879 7.992 10.219
90 1.522 3.422 6.075 8.200 10.429
100 1.731 3.622 6.332 8.410 10.649
表2表示出加热器-传感器复合装置2的实测特性。这样,氩弧焊点3a、4a的温度从0℃升至500℃,测量出来非加热丝的端部4b、5b的电压值。从表2可以看出,在通常用于钎焊烙铁的温度范围200℃-450℃内可以获得很好的线性,而且传感器的输出也在实际应用的水平。图4是一个曲线图,比较了加热器-传感器复合装置2(B)的输出特性和热电偶K(A)的特性,它表明加热器-传感器复合装置2的电动势大约为热电偶K的电动势的一半。从图中可以看出,采用这一加热器-传感器复合装置2,直至600℃仍可获得稳定的传感器输出,这表明这种加热器-传感器复合装置2不仅可以用作钎焊烙铁的温度传感器,而且可以用于其它应用。
现在描述根据本发明的钎焊烙铁加热器的制造方法。首先,将非加热丝4穿过绝缘管1的内腔1a,并将加热丝3缠在绝缘管1的圆周表面。然后,利用一根包括有一根Kanthal丝的固定丝6,将非加热丝5固定到绝缘管1的外周上(图2)。
其后,采用浸渍涂层技术在氩弧焊点3a、4a、加热丝3以及固定丝6上涂上第一陶瓷涂层7,并且将所敷涂层7干燥并烧结。上述的第一陶瓷涂层7是一种含水的分散体,包括粘结剂和粗级的氧化铝粉,而且当所敷涂层经干燥和烧结后,氩弧焊点3a、4a及加热丝3被紧固到绝缘管1上。由于这一陶瓷涂层7是粗糙颗粒的分散体,所以它有效地吸收了绝缘管1与加热丝3之间热膨胀系数的差异,使得在使用中不会发生裂纹或劈裂。
然后,采用浸渍涂层技术涂上第二陶瓷涂层8,并经干燥和烧结。同时,利用这一陶瓷涂层8,将加热器-传感器复合装置2固定在钎焊烙铁的尖端部分9中形成的凹槽9a中(图5)。当然,钎焊烙铁的尖端9是由具有良好导热性的材料制成的。
第二陶瓷涂层8是一种特定的含水分散体,包括粘结剂和细氧化铝粉,当这一涂层经干燥及烧结后,就得到了一层绝对的绝缘层。此外,通过该第二陶瓷涂层8,加热器-传感器复合装置2被紧固在钎焊烙铁的尖端部分9。
由于在本发明的加热器-传感器复合装置2中,非加热丝4与环绕它的绝缘管1的内腔之间有一段自由的气隙,非加热丝4大体上对加热丝3的温度不敏感。而且,由于非加热丝4是抗氧化腐蚀的Ni丝,所以它能暴露接触空气。
在加热器-传感器复合装置2被紧固安装在钎焊烙铁的尖端部分9的凹槽9a内之后,保护管10被固定到其端部的尖端部分9的圆周上(图5)。此外,一个合成树脂元件(引线部分)11被配合安装在保护管10的基座处,接线端12、13伸出到合成树脂元件之外,结果,总体上形成了一个集成的钎焊烙铁加热器(图6)。通过将上述接线端12、13与相应连接器连接或分离,可将这种钎焊烙铁加热器安装或拆卸。如图7中所示,保护管10的基座侧面被一个夹持元件14紧紧夹住,而且与接线端12、13紧邻,还设置有一个用于温度测量的热敏电阻器TH。
图8和9表示出包含有加热器-传感器复合装置2的温度控制电路。所示的温度电路主要包括用于加热钎焊烙铁的尖端,并检测其尖端温度T1的所述加热器-传感器复合装置2、用于检测加热器-传感器复合装置2的基座端部温度T0的所述热敏电阻TH、一个用于加热器-传感器复合装置2的电源模块15、一个用于放大来自加热器-传感器复合装置2的热电偶输出的放大模块16、一个用于将热电偶输出与热敏电阻输出相迭加的加法器模块17、一个用于对直流电压(图9,该电压加到后续元件上)整流的全波整流器18、一个零交叉脉冲发生器19、一个用于设定钎焊烙铁的尖端温度的温度设定模块20,以及一个用于控制全部操作的微处理器单元21。计算出的尖端温度显示在与微处理器单元21相连接的显示器22上。
在这一实施例中,微处理器单元21具体是一个单片微处理器M37470(Mitsubishi)。这种微处理器单元21提供有输出端、端口1和端口2,而且如此设置:电源模块15根据端口1的输出数据被控制为开或关,而加法器17的输出端的开关SW根据端口2的输出数据被控制为开或关。
此外,微处理器单元21提供有与一个数/模转换器相连的模拟输入端ADIN1和ADIN2。来自加法器模块17的输出值被输入模拟输入端ADIN1,而对应于设定温度的电压值被输入模拟输入端ADIN2。微处理器单元的模拟输入端VREF已经被输入用于数/模转换器的参考电压(例如,2.55V),由此确定了数/模转换器的分辨率。
微处理器单元21还设置有一个中断端口INT,与零交叉脉冲发生器19相连,以便当全波整流脉冲电流值已经达到0V时,向微处理器单元21发出一个中断信号,然后开始中断程序。
如图8中所示,电源模块15包括一个场效应管FET1和一个与场效应管FET1的门端相连的电阻R1。场效应管FET1的漏端与全波整流器18+V的输出端(例如,波峰值=2.4V)相连,而源端与加热器-传感器复合装置2相连。
放大器16包括一个限流电阻R2、二极管D1、D2、一个同相放大器A0、电阻R3、R4,可以实现放大系数大约为250、一个反向放大器A1以及电阻R5、R6。根据这一电路,加热器-传感器2的传感器电压被放大至250倍,而其相位被所述同相放大器A0和反向放大器A1反向。电阻值可以为,例如,R3=1KΩ,R4=250KΩ,而R5=R6=100KΩ。
在这一电路中,由于同相放大器A0的源电压是+VDD和-VDD(例如,±5V),加在同相放大器A0上的电压若超过+VDD~-VDD的范围则会导致特性变坏甚至击穿。因此,设置有限压二极管D1、D2使得只有+VDD+VF~-VDD-VF范围内的电压才可以加到同相放大器A0上。需要指出的是VF是二极管D1、D2的正向电压。
现在,当场效应管FET1为开时,电压V-VDD-VF被加到电阻R2上,但是由于电阻R2的电阻值被设为大约10KΩ,所以最大只有大约2mA的电流。相反,当场效应管FET1为关时,加热器-传感器复合装置2的热电偶的输出被加到电阻R2上,使得电阻R2上的压降会出现问题。然而,在本发明中,由于通过同相放大器A0实现放大,其输入阻抗Rin足够大满足条件Rin>>R2,从而使得可以检测出精确的热电偶输出。如果采用一个反向放大器用于这一放大,条件Rin>>R2可能不会满足。
加法器模块17主要包括一个反向放大器A2和电阻R7、R8、R11,及R13。电阻R10与热敏电阻TH并联,而源电压+VDD通过R9输入。电阻值可以,例如,为:R7=R8=100KΩ,R11=R13=47KΩ,R9=220KΩ,以及R10=50KΩ。在加法器模块17与微处理器单元21之间设置有由输出端PORT2控制的开启-闭合开关SW(图9)。
在加法器模块17中,来自反向放大器A1的输入通过电阻R7被加到反向放大器A2上,而来自热敏电阻TH的输入通过电阻R11被提供给放大器A2。此外,由电阻R12和可变电阻VR1将源电压-VDD分压得到的电压,通过电阻R13被提供给反向放大器A2。
由于反向放大器A2的输出被加到微处理器单元21的数/模转换器上,不管加热器-传感器复合装置2和热敏电阻TH的输出电压随温度如何变化,反向放大器A2的输出都必须稳定保持在正数范围内。因此,在本发明中,调整可变电阻VR1使反向放大器A2的输出始终在0V~2.55V的范围内。
如图9所示,温度设定模块20包括电阻器R14、R15、缓冲器A3,及可变电阻器VR2。当参考电压VREF被加到可变电阻器VR2上时,如此设置可以通过操纵可变电阻器VR2将与所设置的200℃-450℃温度相对应的电压加到微处理器单元的模拟输入端AIN2。
现在参照图10的时序图描述图8和图9中的控制电路的工作。图10表示出全波整流电路的输出(A)、零交叉脉冲发生器的输出(B)、模拟输入端AIN1的输入(C)、输出端口PORT1的输出(D),以及加热器-传感器复合装置2的接线端电压(E)。
当全波整流电路18的输出值变为零,而零交叉脉冲发生器19的输出增加时,微处理器单元21被加在中断端口INT处的脉冲信号中断。在中断程序中,微处理器单元21首先向输出端口PORT1、PORT2输出一个控制信号,将场效应管FET1设为关的状态,并将开启-关闭开关SW1设到开的位置。
当场效应管FET1被设为关的状态时,供给加热器-传感器2的电流被中断,使得在加热器-传感器联合装置2的两端只呈现热电偶输出。这一热电偶输出值对应于尖端温度T1与基部(4b、5b)温度T0的温差T1-T0,并且这一热电偶的输出在放大模块16中被放大250倍,并被加到加法器模块17的电阻R5上。另一方面,将一个对应于热敏电阻TH1的电阻值的电压加到加法器模块17中的电阻R7上,而热敏电阻TH1的电阻值随传感器-加热器复合装置2的基部4b、5b的温度T0变化。因此,加法器模块17输出一个对应于钎焊烙铁尖端温度T1的电压。由于这时开启-关闭开关SW1处于开的状态,所以这一对应于尖端温度T1的电压,被从所述模拟输入端口ADIN1提供给微处理器单元21。
同时,对应于设定温度TS的电压已从模拟输入端ADIN2输入。因此,微处理器单元21将模拟输入端ADIN1的电压与模拟输入端ADIN2的电压相比较,计算出当前的尖端温度TP是否比设定的温度值TS要高。
现在,当中断脉冲(图10(B))不晚于初始的第三个脉冲时,意味着尖端温度TP低于设定温度值TS。在TP<TS的条件下,微处理器单元21通过输出端口PORT2将开启-关闭开关SW1设为关,并通过输出端口PORT1设定场效应管FET1为开以终止中断程序。然后,由于场效应管FET1已被设为开,全波整流模块18的输出就如此提供给传感器-加热器2,以向加热器供给能量,提高钎焊烙铁的尖端温度。
参照图10的脉冲波形图,当中断脉冲不晚于第一个第三脉冲时,重复如上相同操作,以使尖端温度TP升高。响应尖端温度的这一提高,模拟输入端ADIN1的输入被增大。
然而,当中断脉冲为第四个或其后的某一个时,意味着钎焊烙铁的尖端温度TP高于设定温度TS(TP>TS),从而微处理器单元21通过输出端PORT1、PORT2将开启-关闭开关SW1和场效应管FET1置于关的状态,从而终止中断程序。当场效应管FET1被这样设为关时,即便在中断程序完成以后,电源模块15仍继续终止向传感器-加热器复合装置2提供电流,以使钎焊烙铁尖端温度不断下降。然后,当尖端温度TP降至设定值TS以下时(TP<TS),电源模块15恢复向加热器-传感器2提供电流。
Claims (2)
1、一种加热器-传感器复合装置,包括一个由第一金属材料制成的加热元件、由同样的第一金属材料制成的非加热元件,以及由第二金属材料制成的非加热元件,
由所述第一金属材料制成的所述加热元件,与由所述第二金属材料制成的所述非加热元件的前端相连,
所述第一金属材料是一种电热铁-铬合金,而所述第二金属材料是一种镍或镍-铬合金,从而在其间形成一个热电偶。
2、根据权利要求1的加热器-传感器复合装置,其中由所述第一金属材料制成的所述加热元件,包括一根相对较小直径的金属丝,其以线圈的形式缠绕在一个柱形绝缘管上,并与由同样的第一金属材料制成的所述非加热元件相连,该非加热元件是直线型的相对较大直径的金属丝,并与所述绝缘管的园周表面紧固,
由所述第二金属材料制成的所述非加热元件是一个穿入所述绝缘管的内腔的直线型元件。
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- 1998-03-13 ES ES009800551A patent/ES2144947B1/es not_active Expired - Fee Related
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CN101493707B (zh) * | 2008-01-21 | 2011-03-23 | 同方威视技术股份有限公司 | 闭环温度控制加热电路 |
CN102090141A (zh) * | 2008-02-26 | 2011-06-08 | 阿雷瓦核能有限责任公司 | 电加热元件 |
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CN102009243A (zh) * | 2010-10-27 | 2011-04-13 | 华东交通大学 | 一种定热量电烙铁装置及控制方法 |
CN102009243B (zh) * | 2010-10-27 | 2012-09-19 | 华东交通大学 | 一种定热量电烙铁装置及控制方法 |
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CN103207028B (zh) * | 2012-01-17 | 2015-09-02 | 太洋电机产业株式会社 | 烙铁头温度测量装置及用于其的温度传感器 |
CN104577239A (zh) * | 2013-10-17 | 2015-04-29 | 福特全球技术公司 | 电动车辆的电池热电偶 |
CN106687244A (zh) * | 2014-05-28 | 2017-05-17 | 白光株式会社 | 加热器传感器分组件及钎焊卡式件 |
CN106687244B (zh) * | 2014-05-28 | 2019-04-05 | 白光株式会社 | 加热器传感器分组件及钎焊卡式件 |
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CN106914674A (zh) * | 2015-12-28 | 2017-07-04 | 太洋电机产业株式会社 | 烙铁 |
US10232456B2 (en) | 2015-12-28 | 2019-03-19 | Taiyo Electric Ind. Co., Ltd. | Soldering iron |
CN106914674B (zh) * | 2015-12-28 | 2020-05-01 | 太洋电机产业株式会社 | 烙铁 |
CN108770103A (zh) * | 2018-06-08 | 2018-11-06 | 宁波兴慈热动电器有限公司 | 电子调温器用电子加热器 |
CN108770103B (zh) * | 2018-06-08 | 2024-04-26 | 宁波兴慈热动电器有限公司 | 电子调温器用电子加热器 |
WO2021168961A1 (zh) * | 2020-02-27 | 2021-09-02 | 南京科润工业介质股份有限公司 | 一种淬火介质热稳定性的测试装置 |
WO2021168960A1 (zh) * | 2020-02-27 | 2021-09-02 | 南京科润工业介质股份有限公司 | 一种淬火介质冷却性能的在线监测*** |
Also Published As
Publication number | Publication date |
---|---|
FR2760931A1 (fr) | 1998-09-18 |
KR19980080206A (ko) | 1998-11-25 |
FR2760931B1 (fr) | 2001-08-24 |
KR100506023B1 (ko) | 2005-10-28 |
IT1299379B1 (it) | 2000-03-16 |
GB2325840A (en) | 1998-12-02 |
GB9805212D0 (en) | 1998-05-06 |
ITRM980161A1 (it) | 1999-09-13 |
ES2144947A1 (es) | 2000-06-16 |
CA2231924A1 (en) | 1998-09-14 |
CN1133353C (zh) | 2003-12-31 |
DE19810519C2 (de) | 2002-02-21 |
DE19810519A1 (de) | 1998-09-17 |
HK1015115A1 (en) | 1999-10-08 |
ID20052A (id) | 1998-09-17 |
TW441218B (en) | 2001-06-16 |
US6054678A (en) | 2000-04-25 |
JPH10260083A (ja) | 1998-09-29 |
MY121720A (en) | 2006-02-28 |
GB2325840B (en) | 2001-04-11 |
ITRM980161A0 (it) | 1998-03-13 |
ES2144947B1 (es) | 2001-01-16 |
CA2231924C (en) | 2007-05-15 |
JP3124506B2 (ja) | 2001-01-15 |
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